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Removal and Installation

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury.
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.
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.
  1. With the engine off, apply the brake pedal several times to deplete the brake booster accumulator reserve.
  2. Remove the master cylinder, refer to HYDRAULIC BRAKE ACTUATION .
  3. Disconnect the 2 power steering jumper line fittings.
    • Remove and discard the 2 Teflon® O-rings.
    • To install, tighten to 28 Nm (21 lb-ft).
  4. Disconnect the power steering fluid return hose.
  5. Remove the brake pedal cotter pin cover and the cotter pin.
  6. Remove the Brake Pedal Position (BPP) switch and the booster push rod from the brake pedal arm.
  7. Remove the 4 brake booster-to-pedal bracket nuts and the brake booster.
    • To install, tighten to 25 Nm (18 lb-ft).
  8. To install, reverse the removal procedure.
    • Using the Teflon® Seal Installer Set, install new Teflon® O-rings on the power steering line fittings.
    • Fill the power steering system. For additional information, refer to STEERING SYSTEM .
    • Bleed the brake system. For additional information, refer to BRAKE SYSTEM - GENERAL INFORMATION .
      Fig 1: Identifying Installer Set, Teflon® Seal (211-D027)
      G06063976Courtesy of FORD MOTOR CO.
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