Ford Fusion: Power Brake Actuation / Brake Booster. Removal and Installation

Materials

Removal

NOTE: Removal steps in this procedure may contain installation details.

All vehicles

1. Remove the battery tray.
   Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
   

1. If equipped, remove the nut, bolt and the battery tray support bracket
   Torque: 18 lb.ft (24 Nm)

1.6L EcoBoost (118kW/160PS) – Sigma/2.5L Duratec (125kW/170PS)

1. 1. Disconnect the brake fluid level sensor electrical connector.
      
   2. Detach the brake tube retainer.
      
   3. Disconnect the vacuum sensor electrical connector and position the wiring aside.
      

2.0L EcoBoost (184kW/250PS) – MI4/2.7L EcoBoost (238kW/324PS)

1. 1. Disconnect the brake fluid level sensor electrical connector.
      
   2. Detach the wiring harness retainers.
      
   3. Disconnect the vacuum sensor electrical connector and position the wiring aside.
      

All vehicles

1. NOTE: 2.0L EcoBoost engine shown.

   NOTE: Make sure that the brake booster vacuum is released.

   Disconnect the vacuum tube.
   

1. NOTICE: If the brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.

   NOTE: Make sure that all openings are sealed.

   1. Disconnect the brake tube fittings.
      Torque: 18 lb.ft (25 Nm)

   2. NOTE: Make sure that the master cylinder-to-booster seal is removed with the master cylinder.

      Remove the nuts and then remove the brake master cylinder and brake tubes as an assembly. Discard the nuts.
      Torque: 18 lb.ft (25 Nm)

1. Remove the nut and position the transmission selector lever cable aside.
   Torque: 80 lb.in (9 Nm)

1. 1. Detach the brake tube and position aside from brake booster.
      
   2. Remove the stud bolt and the brake tube retainer.
      Torque: 133 lb.in (15 Nm)

1.5L EcoBoost (118kW/160PS) – I4

1. NOTICE: Make sure that all openings are sealed.

   NOTICE: If the fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.

   Disconnect the brake tube fittings and position the brake tubes aside.
   Torque: 159 lb.in (18 Nm)

All vehicles

1. NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp switch. This switch must be removed with the brake pedal in the at-rest position. The switch plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch.

   Refer to: Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).
   

1. Compress the tabs and remove the clevis pin. Discard the pin.
   

1. Remove and discard the nuts.
   Torque: 17 lb.ft (23 Nm)

2.7L EcoBoost (238kW/324PS)

1. 1. Remove the stud bolt.
      Torque: 80 lb.in (9 Nm)
   2. Disconnect the fitting and remove the transmission fluid cooler tube.
      Torque: 22 lb.ft (30 Nm)
   3. Inspect the O-rings and instal new as necessary.
      
   4. Before installation, lubricate the O-rings with clean specified transmission fluid.
      Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV, )

All vehicles

1. Remove the brake booster.
   

Installation

All vehicles

1. To install, reverse the removal procedure.
   

1. Bleed the brake system.
   Refer to: Brake System Pressure Bleeding (206-00 Brake System - General Information, General Procedures).
   

2.7L EcoBoost (238kW/324PS)

1. Check the transmission fluid and fill as necessary.
   Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV, )