Ford Mustang (1999-2004) Service Manual: Brake Booster - Hydro-Boost (Removal and Installation)

Special Tool(s)

Installer Set, Teflon Seal 211-D027 (D90P-3517-A) or equivalent

Removal

WARNING: The power brake booster should not be carried by the accumulator, nor should it ever be dropped on the accumulator. Check the snap ring on the accumulator for correct seating before the power brake booster is used. The accumulator contains highpressure nitrogen gas and can be dangerous if mishandled.

WARNING: If the accumulator is to be disposed of, it must not be exposed to excessive heat. Before discarding the accumulator, drill a 1.6-mm (1/16-inch) diameter hole in the end of the accumulator can to relieve the gas pressure. Always wear safety glasses when performing this operation.

1. With the engine off, depress the brake pedal (2455) several times to discharge the accumulator.

2. Disconnect the battery ground cable (14301).

3. Disconnect the fluid level sensor connector.

Brake Booster - Hydro-Boost

4. Disconnect the brake tubes.

Brake Booster - Hydro-Boost

5. Disconnect the power steering return line hose (3A005).

Brake Booster - Hydro-Boost

6. Disconnect the power steering pressure lines.

Brake Booster - Hydro-Boost

7. Remove the self-locking pin.

Brake Booster - Hydro-Boost

8. Remove the stoplight switch (13480) and the brake booster push rod from the brake pedal pin.

Brake Booster - Hydro-Boost

9. Remove the power brake booster nuts.

Brake Booster - Hydro-Boost

10. Remove the power brake booster nut.

Brake Booster - Hydro-Boost

11. Remove the booster.

Brake Booster - Hydro-Boost

Installation

1. Follow the removal procedure in reverse order.

  • Install new Teflon seals on the power steering pressure fittings.
  • Bleed Hydro-Boost. For additional information, refer to Hydro-Boost Bleeding in this section.
  • Bleed the brake system.

Brake Booster - Hydro-Boost

 

Brake Booster - Hydro-Boost

 

Brake Booster - Hydro-Boost

 

Brake Booster - Hydro-Boost

 

Brake Booster - Hydro-Boost

 

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