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Home >> Merkur >> 1985 >> XR4Ti Standard >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Disc & Drum >> Removal & Installation >> Power Brake Unit >> Removal

Power Brake Unit: Removal

  1. With engine off. Depress brake pedal several times to deplete vacuum reserve in power booster. De-pressurize EFT fuel system using a hand operated vacuum pump. Connect pump hose to fuel system pressure regulator. Apply at least 25 in. Hg of vacuum.
    NOTE: Fuel supply lines will remain pressurized for some period of time after engine is shut off. System pressure must be relieved before disconnecting any fuel lines.
  2. Disconnect fuel inlet hose at pulse damper. Disconnect fuel return line using Quick Connect Remover (T82L 9500 AH). See Fig 1 . Disconnect low oil level sensor connector and remove engine oil level dipstick.
    Fig 1: Removing Fuel Return Line
    G50692
  3. Remove screw attaching engine oil dipstick tube to pulse damper bracket. Remove stud nuts attaching pulse damper bracket to intake manifold. Disconnect pulse damper from fuel manifold and remove damper/bracket assembly.
  4. Disconnect source hose from vacuum "tree" and remove vacuum "tree". Disconnect low brake fluid warning connector from master cylinder reservoir cap. Pull vacuum check valve out of power booster. See Fig 2 .
    Fig 2: Location of Vacuum Check Valve
    G50693
  5. Disconnect and plug brake lines at master cylinder. Inside vehicle, remove sound deadening panel located under instrument panel. Remove booster push rod to brake pedal retaining clip.
  6. Remove booster attaching nuts. Remove power booster. Use care to prevent damage to any underhood painted surfaces (such as suspension strut tower). If necessary, tape shop cloths over these areas to prevent damage.