Mark VIII V8-4.6L DOHC (1996)
Vacuum Brake Booster: Service and Repair
Removal and Installation
1. Disconnect battery ground cable and remove air cleaner. Pump brake pedal several times to exhaust any vacuum in the booster.
2. Disconnect manifold vacuum hose from booster check valve.
3. Disconnect brake lines from primary and secondary outlet ports of master cylinder.
4. Remove master cylinder to booster attaching nuts and the master cylinder.
5. Remove windshield wiper motor.
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. Slide booster pushrod, bushing and inner nylon washer off brake pedal pin.
10. Move booster forward in engine compartment until booster studs clear dash panel, then rotate front of booster toward engine and remove booster.
11. Reverse procedure to install, noting the following:
a. Ensure proper clearance between pushrod and master cylinder exists.
b. Bleed brake hydraulic system. Refer to Brake Bleeding.
c. Torque booster-to-dash panel retaining nuts to 19-25 ft lb.
d. Torque master cylinder-to-booster locking nuts to 16-25 ft lb.
