Lincoln Nautilus: Power Brake Actuation / Brake Booster. Removal and Installation

Removal

NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

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

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

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

1. Detach the check valve from the brake booster.
   

1. Disconnect the brake fluid level sensor and detach the wiring retainer.
   

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

   Disconnect the brake tube fittings, remove the nuts and remove the brake master cylinder and brake tubes as an assembly. Discard the nuts and O-ring seal.
   Torque:
      1.:   21 lb.ft (28 Nm)
      2.:   18 lb.ft (25 Nm)

1. Remove the nuts, disconnect the electrical connector and remove the LH insulator panel.
   

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

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

1. Disconnect the brake booster vacuum sensor electrical connector.
   

1. Remove the brake booster.
   

Installation

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

   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).