Brake Booster: Removal

WARNING: This page is about a different car, the 2015 Lincoln MKZ. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

NOTE: Removal steps in this procedure may contain installation details.

1.

WARNING: Before beginning any service procedure, refer to Health and Safety Precautions . Failure to follow this instruction may result in serious personal injury.

Refer to: Health and Safety Precautions .

2.

Remove the battery tray. Refer to: Battery Tray .

3.

Remove the nut, bolt and the battery tray support bracket.
Torque: 18 lb.ft (24 Nm)

GFD101405

Courtesy of FORD MOTOR COMPANY

4.

Detach the brake tube retainer, disconnect the brake fluid level sensor electrical connector and if equipped, disconnect the clutch master cylinder supply tube.

GFD101406

Courtesy of FORD MOTOR COMPANY

5.

NOTE: Before removing the master cylinder, relieve the vacuum in the brake booster or the master cylinder O-ring seal may be drawn into the brake booster, causing brake booster failure and increased brake pedal effort.

Fully apply and release the brake pedal 5 times.

GFD101399

Courtesy of FORD MOTOR COMPANY

6.
- 1.
  
  Disconnect the brake tube fittings.
  Torque: 18 lb.ft (25 Nm)
- 2.
  
  Remove the nuts and remove the brake master cylinder and brake tubes as an assembly. Discard the nuts.
  Torque: 159 lb.in (18 Nm)

GFD101407

Courtesy of FORD MOTOR COMPANY

7.
- NOTE: Make sure that the master cylinder-to-booster seal is removed with the master cylinder.
  
  Discard the O-ring seal.

GFD101408

Courtesy of FORD MOTOR COMPANY

8.
- Disconnect the brake booster vacuum sensor electrical connector.
- Detach the vacuum check valve from the booster and position aside.

GFD101409

Courtesy of FORD MOTOR COMPANY

9.

Remove the stud bolt and position the tube aside.
Torque: 133 lb.in (15 Nm)

GFD101410

Courtesy of FORD MOTOR COMPANY

10.

NOTE: Do not service the brake pedal or brake booster without first removing the stoplamp switch. This switch must be removed with the brake pedal in the at-rest position. The switch plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch.

Remove the stoplamp switch. Refer to: Stoplamp Switch .

11.

Compress the tabs and remove the clevis pin. Discard the pin.

GFD101396

Courtesy of FORD MOTOR COMPANY

12.

Remove the screws and the lower steering column shroud.

GFD101393

Courtesy of FORD MOTOR COMPANY

13.

Remove and discard the nuts.
Torque: 17 lb.ft (23 Nm)

GFD101411

Courtesy of FORD MOTOR COMPANY

14.

Remove the bolt and position the HCU off of the stud.
Torque: 177 lb.in (20 Nm)

GFD101412

Courtesy of FORD MOTOR COMPANY

15.

Remove the brake booster.

GFD101413

Courtesy of FORD MOTOR COMPANY