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Brake Booster - 2.0L Duratec-RS (Zetec) RHD > < Power Brake System

Focus RS 2003 (09.2002-)

Power Brake Actuation - Brake Booster—2.0L Duratec-RS (Zetec) LHD Focus RS 2003 (09/2002-)
Removal and Installation

Removal

  1. Remove the master cylinder. For additional information, refer to Section  206-06 Hydraulic Brake Actuation.

  1. Disconnect the anti-lock brake system (ABS) module electrical connector.
    1. Release the retainer.
    1. Disconnect the electrical connector.

  1. CAUTION:
    CAUTION:Cap the brake tube to prevent fluid loss and dirt ingress.
    Detach the brake tubes from the hydraulic control unit (HCU).

  1. Remove the HCU.

  1. Detach the brake tubes from the bulkhead.

  1. Detach the brake booster actuating rod from the brake pedal.
    1. Depress the brake pedal.
    1. Depress the clip.
    1. Remove the brake booster actuating rod pin.

  1. Remove the brake booster retaining nuts.
  1. Remove the brake booster.

Installation

  1. CAUTION:
    CAUTION:Make sure that the brake booster actuator rod is correctly positioned through the bulkhead rubber boot.
    CAUTION:
    CAUTION:Make sure the brake booster gasket is correctly positioned on the brake booster before installation.
    Install the brake booster.

  1. NOTE:
    NOTE:Do not fully tighten at this stage.
    Install the brake booster retaining nuts.

  1. CAUTION:
    CAUTION:Install a new brake booster actuating rod pin to the brake pedal.
    Install the brake booster activator rod pin.
    1. Depress the brake pedal.
    1. Install the brake booster actuator rod pin.

  1. Detach the instrument panel lower panel.
    1. Remove the screws.
    1. Release the fastener.

  1. Detach the data link connector and remove the instrument panel lower panel.

  1. Remove the air duct.
    1. Remove the fastener.
    1. Remove the air duct.

  1. Loosen the brake pedal retractor retaining bolt.

  1. CAUTION:
    CAUTION:Make sure there is clearance between the brake pedal and the brake pedal retractor to allow free movement.
    Align the brake pedal retractor arm to the brake pedal bracket.

  1. Tighten the brake booster retaining nuts.
  1. With the engine running depress the brake pedal three times to make sure the brake pedal moves freely and returns to the full brake off piston.

  1. Tighten the brake peal retractor retaining bolt.

  1. Install the air duct.
    1. Install the air duct.
    1. Secure the fastener.

  1. Attach the data link connector to the instrument panel lower panel.

  1. Install the instrument panel lower panel.
    1. Secure the fastener.
    1. Install the screw.

  1. Attach the brake tubes to the bulkhead.

  1. Install the HCU.

  1. Connect the brake tubes to the HCU.

  1. Connect the ABS module electrical connector.
    1. Connect the electrical connector.
    1. Close the retainer.
  1. Install the master cylinder. For additional information, refer to Section  206-06 Hydraulic Brake Actuation.

Brake Booster - 2.0L Duratec-RS (Zetec) RHD > < Power Brake System