Ford 5L1Z-2005-AA Booster Assembly - Brake

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In the engine compartment, remove the nuts attaching the master cylinder to the booster and carefully pull the master cylinder, along with the RWAL control module and isolation/dump valve, forward until it clears the mounting studs. Be careful not to bend or kink the brake lines. On 2005 and later Expedition/Navigator models, remove the air filter housing and unbolt and set aside the degas bottle. Disconnect the vacuum hose where it attaches to the power brake booster. Before removing the power brake booster, detach the intake manifold vacuum hose from the booster housing. In the passenger compartment, remove the cotter pin and the brake light switch and disconnect the power brake pushrod from the top of the brake pedal. Remove the nuts attaching the booster to the firewall. Carefully lift the booster unit away from the firewall and out of the engine compartment.

Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal. Start the engine and turn it off after one or two minutes. Depress the brake pedal several times slowly. If the pedal goes down farther the first time but gradually rises after the second or third depression, the booster is airtight. Depress the brake pedal while the engine is running, then stop the engine with the pedal depressed. If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is airtight.