Ford AE9Z-2005-A Booster Assembly - Brake

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To check the brake system, depress the brake pedal multiple times with the engine off to check pedal reserve distance. Then, depress the pedal and start the engine. If the pedal goes down slightly, it's normal. For an air tightness check, start the engine, turn it off after a minute, and depress the brake pedal several times. If the pedal goes down farther initially but rises after the second or third depression, the booster is airtight. If there's no change in pedal reserve travel after 30 seconds with the engine off and pedal depressed, the booster is airtight. If there's a problem, install a new or factory rebuilt unit. Before disconnecting the brake pedal, brake booster, or booster pushrod, remove the brake light switch and speed control deactivator switch. In the driver's footwell, remove the pin cover on the brake pedal arm and the retaining pin. Remove the washer and brake booster pushrod. On 2010 and later models, use a 12-point, 11 mm wrench to release the tabs on the clevis locking pin. Remove the brake booster mounting nuts, then lift the booster unit out. Installation is the reverse of removal, using new booster mounting nuts, and test the brakes before normal use. On 2010 and later models, install the brake booster pushrod before the brake light switch and speed control deactivator switch, being careful not to move the brake pedal.