Brake Booster: Removal

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

All vehicles

Remove the battery tray.Refer to: Battery Tray .
1. Disconnect the brake fluid level sensor electrical connector.
2. Detach the wiring harness retainers.
3. Disconnect the vacuum sensor electrical connector and position the wiring aside.
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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.

Disconnect the vacuum tube.

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Remove the nut and position the transmission selector lever cable aside.
Torque: 80 lb.in (9 Nm)

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1. Detach the brake tube.
2. Remove the stud bolt and the brake tube retainer.
  Torque: 133 lb.in (15 Nm)
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1. NOTE: If the brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.
  
  NOTE: Make sure that all openings are sealed.
  
  Disconnect the brake tube fittings.
  
  Torque: 18 lb.ft (25 Nm)
2. NOTE: Make sure that the master cylinder-to-booster seal is removed with the master cylinder.
  
  Remove the nuts and then remove the brake master cylinder and brake tubes as an assembly. Discard the nuts.
  
  Torque: 18 lb.ft (25 Nm)
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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 .
Compress the tabs and remove the clevis pin. Discard the pin.

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

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3.0L EcoBoost
1. Remove the stud bolt.
  Torque: 80 lb.in (9 Nm)
2. Disconnect the fitting and remove the transmission fluid cooler tube.
  Torque: 22 lb.ft (30 Nm)
3. Inspect the O-rings and instal new as necessary.
4. Before installation, lubricate the O-rings with clean specified transmission fluid.
  Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON® LV) (WSS-M2C938-A)
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All vehicles
Remove the brake booster.

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