Brake Booster - Removal and Installation

Materials

Removal

All vehicles

1. 1
   Remove the battery tray.
   Refer to: Battery Compartment (414-01 Battery, Mounting and Cables, Removal and Installation).
2. 2
   If equipped, remove the nut, bolt and battery tray support bracket.
   Torque: 18 lb-ft (24 N·m)

   

1.6 L EcoBoost (118 kW/160 L PS) – Sigma/2.5 L Duratec (125 kW/170 L PS)

3. 1. Disconnect the brake fluid level sensor electrical connector.
   2. Disconnect the brake tube retainer.
   3. Disconnect the vacuum sensor electrical connector and position the wiring aside.

2 L EcoBoost (184 kW/250 L PS) – MI4/2.7 L EcoBoost (238 kW/324 L PS)

4. 1. Disconnect the brake fluid level sensor electrical connector.
   2. Disconnect the wiring harness clips.
   3. Disconnect the vacuum sensor electrical connector and position the wiring aside.

All vehicles

1. 1
   Disconnect the vacuum hose.

   

2. 2

   NOTICE: If brake fluid contacts painted surfaces, rinse the affected area immediately with cold water.

   1. Disconnect the brake tube fittings.
      Torque: 18 lb-ft (25 N·m)

   2. Remove the nuts, then remove the brake master cylinder and brake tube assembly. Discard the nuts.
      Torque: 18 lb-ft (25 N·m)

   

3. 3
   Remove the nut and position the shift cable bracket aside.
   Torque: 80 lb-in (9 N·m)

   

4. 4
   1. Disconnect the brake tube and position it away from the brake booster.

   2. Remove the stud and brake tube retainer.
      Torque: 133 lb-in (15 N·m)

   

1.5 L EcoBoost (118 kW/160 L PS) — I4

9. NOTICE: Make sure all openings are covered.

   NOTICE: If fluid spills on the painted surface, the affected area must be washed immediately with cold water.

   Disconnect the brake tube fittings and position the brake tubes aside.
   Torque: 159 lb-in (18 N·m)

All vehicles

1. 1

   NOTICE: Do not service the brake pedal or brake booster without first removing the brake light switch. This switch must be removed with the brake pedal in the rest position. The switch plunger must be compressed so the switch can rotate out of the bracket. Attempting to remove the switch when the plunger is extended (while the pedal is depressed) will damage the switch.

   REFER TO: Brake Pedal Position Switch (417-01 Exterior Lighting, Removal and Installation).
2. 2
   Compress the tangs and remove the cotter pin. Discard the cotter pin.

   

3. 3
   Remove and discard the nuts.
   Torque: 17 lb-ft (23 N·m)

   

2.7 L EcoBoost (238 kW/324 L PS)

13. 1. Remove the stud.
       Torque: 80 lb-in (9 N·m)
    2. Disconnect the fitting and remove the transmission fluid cooler tube.
       Torque: 22 lb-ft (30 N·m)
    3. Inspect the O-rings and install new ones as necessary.
    4. Before installation, lubricate the O-rings with clean, specified transmission fluid.
       Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A)

All vehicles

14. Remove the brake booster.

Installation

All vehicles

1. 1
   To install, reverse the removal procedure.
2. 2
   Bleed the brake system.
   REFER TO: Brake System Pressure Release (206-00 Brake System General Information, General Procedures).

2.7 L EcoBoost (238 kW/324 L PS)

3. Check the transmission fluid level and add as necessary.
   Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A)