Ford XW7Z-2005-AA Booster Assembly - Brake

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The power brake booster unit typically requires no special maintenance aside from periodic inspections of the vacuum hose and the case, and it's not typically disassembled by home mechanics. If issues arise, it's recommended to install a new or factory rebuilt unit. To check the power booster, start by depressing the brake pedal multiple times with the engine off and ensuring no change in the pedal reserve distance. Then, depress the pedal and start the engine; if the pedal goes down slightly, it's normal. If it remains airtight when the engine is turned off and the pedal is held down for about 30 seconds, it's considered airtight. A "hard" pedal feel with the engine running suggests booster problems or vacuum hose leaks. For removal, detach the master cylinder from the booster, disconnect the manifold vacuum hose, unplug the electrical connector from the brake light switch, and remove the pushrod retaining clip and nylon washer from the brake pedal pin. Remove the nuts attaching the booster to the firewall, detach the booster from the firewall, and lift it out of the engine compartment. To install, place the booster on the firewall, tighten the mounting nuts, reconnect the pushrod and brake light switch to the brake pedal, install the retaining clip, and attach the master cylinder to the booster, tightening the nuts. Adjustment may be necessary for some boosters with adjustable pushrods. Symptoms of a misadjusted pushrod include dragging brakes or excessive pedal travel with a groaning sound. To check the pushrod length, unbolt the master cylinder, place a pushrod gauge against the end of the pushrod, exerting a force of around five pounds, and adjust as needed. After adjustment, reinstall the master cylinder and check for proper brake operation before driving the vehicle in traffic.

The power brake booster unit typically requires no special maintenance aside from periodic inspections of the vacuum hose and the case, and it's not typically disassembled by home mechanics. If issues arise, it's recommended to install a new or factory rebuilt unit. To check the power booster, start by depressing the brake pedal multiple times with the engine off and ensuring no change in the pedal reserve distance. Then, depress the pedal and start the engine; if the pedal goes down slightly, it's normal. If it remains airtight when the engine is turned off and the pedal is held down for about 30 seconds, it's considered airtight. A "hard" pedal feel with the engine running suggests booster problems or vacuum hose leaks. For removal, detach the master cylinder from the booster, disconnect the manifold vacuum hose, unplug the electrical connector from the brake light switch, and remove the pushrod retaining clip and nylon washer from the brake pedal pin. Remove the nuts attaching the booster to the firewall, detach the booster from the firewall, and lift it out of the engine compartment. To install, place the booster on the firewall, tighten the mounting nuts, reconnect the pushrod and brake light switch to the brake pedal, install the retaining clip, and attach the master cylinder to the booster, tightening the nuts. Adjustment may be necessary for some boosters with adjustable pushrods. Symptoms of a misadjusted pushrod include dragging brakes or excessive pedal travel with a groaning sound. To check the pushrod length, unbolt the master cylinder, place a pushrod gauge against the end of the pushrod, exerting a force of around five pounds, and adjust as needed. After adjustment, reinstall the master cylinder and check for proper brake operation before driving the vehicle in traffic.

To remove the booster, detach the master cylinder, vacuum hose, brake light switch, and nuts attaching it to the firewall. Installation involves placing the booster on the firewall, connecting the pushrod and brake light switch, and tightening the mounting nuts. Adjustment may be necessary if the pushrod is misadjusted, and a gauge can be used to check the pushrod length.