Removal And Installation

All vehicles 

1. Remove the brake master cylinder. For additional information, refer to HYDRAULIC BRAKE ACTUATION article.
2. Remove the PCM. For additional information, refer to ELECTRONIC ENGINE CONTROLS - 2.3L article or ELECTRONIC ENGINE CONTROLS - 3.0L (4V) article.
3. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
4. Remove the bolt and disconnect the ground cable.
   • To install, tighten to 12 Nm (106 lb-in).
5. Disconnect the harness fastener and remove the 3 nuts and the PCM bracket.
NOTE: Make sure that the aspirator tube is routed correctly and that the clamps are positioned so they do not make contact with surrounding components or damage to the tube may occur.
6. Disconnect the vacuum hose/check valve assembly from the brake booster.

Automatic transmission vehicles 

NOTE: It is not necessary to remove the fluid level indicator tube from the transmission. The tube can be positioned aside with only the bolt removed.
7. Remove the transmission fluid level indicator tube bolt and position the tube aside.
   • To install, tighten to 8 Nm (71 lb-in).

All vehicles 

8. Remove the brake booster push rod pin and clip and disconnect the push rod from the brake pedal.
9. Remove the 4 nuts and the brake booster.
   • To install, tighten the nuts in a criss-cross pattern to 23 Nm (17 lb-ft).
NOTE: Prior to installation, make sure that the distance between the booster mating surface and the push rod center point is as shown or reduced brake assist may occur.
10. To install, reverse the removal procedure.
    • Check for correct booster push rod distance and adjust as necessary.
      • Tighten the booster push rod jam nut to 17 Nm (150 lb-in).
Fig 1: Identifying Booster Push Rod Distance
Courtesy of FORD MOTOR CO.