Brake Booster

Brake Booster

Removal

Vehicles equipped with 2.3L PZEV
1. Remove the battery tray.

Vehicle equipped with 2.0L ZETEC or 2.0L SPI
2. Disconnect the battery.
3. Remove the air cleaner.
4. Remove the air cleaner outlet tube.





All vehicles
5. Disconnect the speed control unit electrical connector.





6. Detach the speed control unit.
^ Lower the speed control unit.





Vehicles equipped with 2.3L PZEV
7. Remove the two bolts and position aside the fuel canister assembly.





8. Remove the Vapor Management Valve (VMV).
1 Disconnect the VMV electrical connector.
2 Remove the upper fuel line.
3 Remove the lower fuel line.
4 Remove the two VMV bolts and the VMV.





9. Disconnect the heat shield from the bulkhead, then remove the heat shield.





All vehicles
10. Detach the heater hose bracket from the bulkhead.





11. Detach the brake tubes from the bulkhead.
12. Remove the hydraulic control unit (HCU).

13. CAUTION: If brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.

Remove the master cylinder.





14. Detach the brake booster actuating rod from the brake pedal.
1 Press the brake pedal.
2 Press the clip.
3 Remove the pin.





15. Remove the brake booster retaining nuts.
16. Remove the brake booster.

Installation





1. CAUTION: Make sure that the brake booster actuator rod is correctly positioned through the bulkhead rubber boot.

CAUTION: Make sure the brake booster gasket is correctly positioned on the brake booster before installation.

To install, reverse the removal procedure.
2. Bleed the brake system.