Mustang V8-4.6L DOHC (1996)
Hydraulic Brake Booster: Service and Repair
Removal and Installation
WARNING: The booster should not be carried by the accumulator, nor should it be dropped on this portion. The accumulator contains high
pressure nitrogen gas and can be dangerous if mishandled. If the accumulator is ready for disposal, it must be kept clear of excessive heat, fire
or incineration. Before disposal, drill a 1/16 inch diameter hole in the accumulator can's end to relieve the gas pressure. Be sure to use wear
safety glasses while performing this operation.
CAUTION: Do not activate the booster when the master cylinder has been removed.
1. Disconnect battery ground cable.
2. Apply brake pedal several times to discharge accumulator.
3. Remove brake lines from proportioning valve's primary and secondary ports.
4. Disconnect fluid level sensor.
5. Disconnect clutch cable from master cylinder routing bracket.
6. Remove hose routing bracket from master cylinder.
7. Disconnect power steering pressure hoses and return line from Hydro-Boost unit. Move hoses out of the way.
8. Remove electrical connector from brake lamp switch.
9. Loosen four booster retaining nuts and brake pedal support bracket to cowl bolt.
10. Remove hairpin type retainer. Slide stop lamp switch off brake pedal pin just far enough for switch outer arm to clear pin, then remove switch.
11. Slide brake master cylinder pushrod bushing off brake pedal pin.
12. Remove booster to firewall attaching nuts.
13. Move booster and master cylinder forward and upward until booster's studs clear firewall. Remove unit from vehicle.
14. Reverse procedure to install, noting the following:
a. Torque booster to firewall nuts to 16-21 ft lb.
b. Torque brake pedal support bracket to cowl bolt to 14-19 ft lb.
c. Torque brake line fittings in ports to 11-17 ft lb.
d. Torque power steering pressure hoses and return line to booster tubes to 10-15 ft lb.
e. Perform system brake bleeding procedures. Check power brake operation and bleed booster of air if necessary.
