Brake Booster: Removal

For information on Ford Color Coded Illustrations refer to OEM Color Coding .

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.

Remove the battery tray. Refer to: Battery Tray .
1. Using compressed air, clean around the remote brake fluid reservoir cap.
2. Remove the remote brake fluid reservoir cap.
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Using a suitable suction device, remove the brake fluid from the remote brake fluid reservoir.

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Disconnect the brake fluid level sensor electrical connector.

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If equipped. Disconnect the brake vacuum sensor.

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NOTE: Make sure that all openings are sealed.
1. Remove the remote brake fluid reservoir screws.
  Torque:
  
  22 lb.in (2.5 Nm)
2. Disconnect the brake tube fittings.
  Torque:
  
  18 lb.ft (25 Nm)
3. Remove the nuts and the brake master cylinder, remote brake fluid reservoir and brake tubes as an assembly.
  Torque:
  
  19 lb.ft (26 Nm)
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1. Remove the pin-type retainer.
2. Remove the screws.
  Torque:
  
  38 lb.in (4.3 Nm)
3. Disconnect the ambient lighting electrical connector and remove the insulation panel.
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Remove the instrument panel lower trim panel. Refer to: Instrument Panel Lower Trim Panel .
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 .
1. Press inward on the tabs and remove the clevis pin. Discard the pin.
2. Remove the brake booster nuts.
  Torque:
  
  17 lb.ft (23 Nm)
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Release the coupling and disconnect the fuel vapor line.

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Detach the check valve, position the vacuum tube aside and remove the brake booster.

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