Removal Procedure
- Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
- Remove the cruise control module. Refer to Cruise Control Module Replacement in Cruise control.
- Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.6L.
- Remove the accelerator cable. Refer to Accelerator Control Cable Replacement in Engine Controls - 4.6L.
- Remove the master cylinder attaching nuts (6).
- Remove the master cylinder from the booster (7).
- Disconnect the vacuum hose from the vacuum check valve (1).
- in Cautions and Notices
- Disconnect the shift control cable from the shaft lever pin. Refer to Shift Cable Replacement in Axle Transaxle 4T80E.
- Remove the shift control cable from the shift cable bracket and move out of the way. Refer to Shift Cable Replacement in Axle Transaxle 4T80E.
- Remove the EGR inlet pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls - 4.6L.
- Remove the left closeout insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gauges, and Console.
- Remove the left knee bolster. Refer to Driver Knee Bolster Panel Replacement in Instrument Panel, Gauges, and Console.
- Remove the booster attaching nuts.
- Remove the retaining clip (2 ) from the brake pedal. .
- Remove the washer (1) from the brake pedal.
- Tilt the entire booster slightly to work pushrod off the pedal clevis pin without putting undue side pressure on the pushrod
- Remove the booster pushrod from the brake pedal.
- Remove the booster from the vehicle.
Important: It is not necessary to remove or disconnect the master cylinder from the vehicle in order to remove the vacuum booster. However, if both the vacuum booster and master cylinder are to be removed, remove the master cylinder first as described in Master Cylinder Replacement .
Move the master cylinder forward just enough to clear the studs on the vacuum booster. This will flex the brake pipes slightly. Do not bend or distort the brake pipes.
Caution: Chock the wheels to prevent the vehicle from moving. Failure to chock the wheels can cause personal injury when the electrical system is repaired.
To allow access for the removal of the vacuum brake booster, position the gearshift lever into the lowest gear.
Installation Procedure
- Install the gasket to booster.
- Install the vacuum brake booster to the vehicle.
- Install the booster pushrod to the brake pedal. Tilt the entire booster slightly to work pushrod on the pedal clevis pin without putting undue side pressure on the pushrod.
- Install the washer (1) to the brake pedal.
- Install the retainer clip (2) to the brake pedal.
- Install the booster attaching nuts.
- Install the left knee bolster. Refer to Driver Knee Bolster Panel Replacement in Instrument Panel, Gauges, and Console.
- Install the left closeout insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gauges, and Console.
- Install the EGR inlet pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Mechanical- 4.6L.
- Install the shift control cable to the shift cable bracket. Refer to Shift Cable Replacement in Axle Transaxle 4T80E.
- Connect the shift control cable to the shaft lever pin. Refer to Shift Cable Replacement in Axle Transaxle 4T80E.
- Install the booster vacuum hose to the vacuum check valve.
- Install the master cylinder to the booster.
- Install the master cylinder attaching nuts.
- Install the accelerator cable. Refer to Accelerator Control Cable Replacement in Engine Controls - 4.6L.
- Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.6L.
- Install the cruise control module. Refer to Cruise Control Module Replacement in Cruise control.
- Install the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Tighten
Tighten the nuts to 28 N·m (21 lb ft).
Tighten
Tighten the master cylinder attaching nuts to 28 N·m (21 lb ft).
