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

Removal

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

1. Remove the brake master cylinder.
   Refer to: Brake Master Cylinder (206-06 Hydraulic Brake Actuation, Removal and Installation).
   

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.

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

1. NOTICE: Do not service the brake pedal or brake booster without first removing the cruise control deactivator 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.

   Remove the cruise control deactivator switch.
   Refer to: Cruise Control Deactivator Switch (419-03 Cruise Control, Removal and Installation).
   

1. NOTE: The booster push rod clevis-locking pin is a one-time use only part. Any time the booster push rod clevis-locking pin is removed, a new booster push rod clevis-locking pin should be used.

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

1. Remove the nuts and brake booster. Discard the nuts.
   Torque: 18 lb.ft (25 Nm)

Installation

1. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch and cruise control deactivator switch. Install these switches with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing these switches with the brake pedal in any other position will result in incorrect adjustment and may damage the switches.

   To install, reverse the removal procedure.