Section 06-07C: Brake, Power, Hydro-Boost Booster
1996 F-Super Duty Chassis Cab and Motorhome Chassis Workshop Manual
REMOVAL AND INSTALLATION

Hydro-Boost Booster

 WARNING: THE POWER BRAKE BOOSTER (2005) SHOULD NOT BE CARRIED BY THE ACCUMULATOR, NOR SHOULD IT EVER BE DROPPED ON THE ACCUMULATOR. THE SNAP RING ON THE ACCUMULATOR SHOULD BE CHECKED FOR PROPER SEATING BEFORE THE POWER BRAKE BOOSTER IS USED. THE ACCUMULATOR CONTAINS HIGH-PRESSURE NITROGEN GAS AND CAN BE DANGEROUS IF MISHANDLED.

 WARNING: IF THE ACCUMULATOR IS TO BE DISPOSED OF, IT MUST NOT BE EXPOSED TO EXCESSIVE HEAT, FIRE OR INCINERATION. BEFORE DISCARDING THE ACCUMULATOR, DRILL A 1.6MM (1/16-INCH) DIAMETER HOLE IN THE END OF THE ACCUMULATOR CAN TO RELIEVE THE GAS PRESSURE. ALWAYS WEAR SAFETY GLASSES WHEN PERFORMING THIS OPERATION.

Removal

  1.  CAUTION: Do not activate the power brake booster with the brake master cylinder (2140) removed.

    With the engine (6007) off, depress the brake pedal (2455) several times to discharge the accumulator.

  1. Remove the brake master cylinder from the Hydro-Boost power brake booster. Support the brake master cylinder and position out of the way.

  1. Disconnect power steering right turn pressure hose (3A717), power steering left turn pressure hose (3A714) and power steering return line hose (3A005) from the power brake booster.

  1. Disconnect the brake pedal push rod from the brake pedal.

  1. Remove the power brake booster nuts, and remove the power brake booster from the vehicle.

Installation

  1. Install the power brake booster in the vehicle and tighten the power brake booster nuts to 21-28 Nm (16-21 lb-ft).

  1. Connect the brake pedal push rod to the brake pedal.

  1. Position the brake master cylinder on the power brake booster and tighten the brake master cylinder-to-power brake booster nuts to 21-28 Nm (16-21 lb-ft).

  1. Connect the power steering right turn pressure hose, power steering left turn pressure hose and power steering return line hose to the Hydro-Boost power brake booster. Refill the system and bleed as required.



    Hydro-Boost Booster, F-Super Duty Chassis Cab





    ItemPart NumberDescription
    13504Steering Gear
    23A697Power Steering Oil Reservoir
    33A717Power Steering Right Turn Pressure Hose
    43A714Power Steering Left Turn Pressure Hose
    52344Power Steering Return Line Clamp
    63A005Power Steering Return Line Hose
    72005Power Brake Booster
    895873-SBundling Strap
    93A713Power Steering Return Hose (Steering Gear-to-Pump)
    1040949-S2Screw, Power Steering Line Clamp
    112140Brake Master Cylinder
    12—Power Steering Right Turn Pressure Hose Fitting
    (Part of 3A717)
    133A674Power Steering Pump
    A—Tighten to 15-20 Nm
    (11-15 Lb-Ft)
    B—Tighten to 30-40 Nm
    (22-29 Lb-Ft)


    Hydro-Boost Booster, F-Super Duty Motorhome Chassis





    ItemPart NumberDescription
    12455Brake Pedal
    2380699Self-Locking Pin
    32N060Boot
    444880-S2Washer
    52474Brake Master Cylinder Push Rod Bushing
    62005Power Brake Booster
    72140Brake Master Cylinder
    82C022Heat Shield
    92031Booster Front Mounting Bracket
    10N630088Washer
    112A248Master Cylinder and Booster Bracket Holder
    12N601790Bolt
    132474Brake Master Cylinder Push Rod Bushing
    14N802114-S2Bolt
    15N800937-S2Nut
    16389564-S190Bolt
    172B353Bellcrank Bracket
    1844878-S2Washer
    19382400-S2Nut
    2044880-S2Washer
    212B362Bellcrank Spacer
    222B327Bellcrank
    232A525Bellcrank Rod
    242B129Brake Master Cylinder Push Rod Spacer
    252462Brake Pedal Pin
    2613480Stoplight Switch
    27382400-S2Nut
    2844878-S2Washer
    29389863-S2Bolt
    302461Brake and Clutch Pedal Bushing
    317506Clutch and Brake Pedal Pivot Shaft
    A—Tighten to 86-104 Nm
    (65-88 Lb-Ft)
    B—Tighten to 50-68 Nm
    (37-50 Lb-Ft)