Thunderbird V6-232 3.8L (1982)
Hydraulic Brake Booster: Service and Repair
Removal and Installation
EXC. HYDRO-BOOST
Exc. 1985-87 4-140
1.
Disconnect battery ground cable and remove air cleaner.
2.
On 1982-84 models equipped with 4-140 engine, disconnect accelerator cable from carburetor, then remove screw that secures accelerator cable to
to shaft bracket and remove cable bracket. Remove two screws that secure accelerator shaft bracket to manifold and rotate bracket toward engine.
Remove RPO horn, if equipped.
3.
On all models, disconnect manifold vacuum hose from booster check valve.
4.
Disconnect brake lines from primary and secondary outlet ports of master cylinder.
5.
Remove master cylinder-to-booster attaching nuts and the master cylinder.
6.
Working under instrument panel, disconnect electrical connector from stop lamp switch.
7.
Remove hairpin type retainer. Slide stop lamp switch off brake pedal pin just far enough for the switch outer hole to clear the pin, then lower
switch away from pin.
8.
Remove booster-to-dash panel attaching nuts.
9.
On models equipped with speed control, unfasten control amplifier from lower outboard booster stud and position aside.
10.
On all models, slide booster pushrod, bushing and inner nylon washer off brake pedal pin.
11.
Move booster forward in engine compartment until booster studs clear dash panel, then rotate front of booster toward engine and remove booster.
12.
Reverse procedure to install.
HYDRO-BOOST
1.
Disconnect stoplight switch wires at connector and remove hairpin retainer, then slide stoplight switch off brake pedal pin far enough for switch
outer hole to clear pin and remove pin from switch.
2.
Slide hydro-boost pushrod and nylon washers and bushing off brake pedal pin.
3.
Remove master cylinder and position to one side without disturbing hydraulic lines. It is not necessary to disconnect brake lines, but care
should be taken not to deform lines.
4.
Disconnect pressure, steering gear and return lines from booster, then plug lines and ports in hydro-boost to prevent entry of dirt.
5.
Remove hydro-boost retaining nuts, and remove assembly sliding pushrod link from engine side of dash panel.
6.
Reverse procedure to install. To purge system, disconnect coil wire so that engine will not start. Fill power steering pump reservoir, then while
engaging starter, pump brake pedal. Do not cycle steering wheel until all residual air has been purged from the hydro boost unit. Check fluid level,
then connect coil wire and start engine. Apply brakes with a pumping action and cycle steering wheel, then check system for leaks.
