Ford Fusion Manuals

Ford Fusion: Power Brake Actuation / Brake Booster. Removal and Installation

Ford Fusion 2013–2020 Service Manual / Chassis / Brake System / Power Brake Actuation / Brake Booster. Removal and Installation

Materials

Name Specification
Motorcraft® MERCON® LV Automatic Transmission Fluid
XT-10-QLVC
WSS-M2C938-A
MERCON® LV,
 

Removal

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

All vehicles

  1. Remove the battery tray.
    Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. If equipped, remove the nut, bolt and the battery tray support bracket
    Torque: 18 lb.ft (24 Nm)
Ford Fusion. Brake Booster. Removal and Installation

1.6L EcoBoost (118kW/160PS) – Sigma/2.5L Duratec (125kW/170PS)

    1. Disconnect the brake fluid level sensor electrical connector.
    1. Detach the brake tube retainer.
    1. Disconnect the vacuum sensor electrical connector and position the wiring aside.
Ford Fusion. Brake Booster. Removal and Installation

2.0L EcoBoost (184kW/250PS) – MI4/2.7L EcoBoost (238kW/324PS)

    1. Disconnect the brake fluid level sensor electrical connector.
    1. Detach the wiring harness retainers.
    1. Disconnect the vacuum sensor electrical connector and position the wiring aside.
Ford Fusion. Brake Booster. Removal and Installation

All vehicles

  1. NOTE: 2.0L EcoBoost engine shown.

    NOTE: Make sure that the brake booster vacuum is released.

    Disconnect the vacuum tube.
Ford Fusion. Brake Booster. Removal and Installation
  1. NOTICE: If the brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.

    NOTE: Make sure that all openings are sealed.

    1. Disconnect the brake tube fittings.
      Torque: 18 lb.ft (25 Nm)
    1. NOTE: Make sure that the master cylinder-to-booster seal is removed with the master cylinder.

      Remove the nuts and then remove the brake master cylinder and brake tubes as an assembly. Discard the nuts.
      Torque: 18 lb.ft (25 Nm)
Ford Fusion. Brake Booster. Removal and Installation
  1. Remove the nut and position the transmission selector lever cable aside.
    Torque: 80 lb.in (9 Nm)
Ford Fusion. Brake Booster. Removal and Installation
    1. Detach the brake tube and position aside from brake booster.
    1. Remove the stud bolt and the brake tube retainer.
      Torque: 133 lb.in (15 Nm)
Ford Fusion. Brake Booster. Removal and Installation

1.5L EcoBoost (118kW/160PS) – I4

  1. NOTICE: Make sure that all openings are sealed.

    NOTICE: If the fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.

    Disconnect the brake tube fittings and position the brake tubes aside.
    Torque: 159 lb.in (18 Nm)
Ford Fusion. Brake Booster. Removal and Installation

All vehicles

  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.

    Refer to: Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).
  1. Compress the tabs and remove the clevis pin. Discard the pin.
Ford Fusion. Brake Booster. Removal and Installation
  1. Remove and discard the nuts.
    Torque: 17 lb.ft (23 Nm)
Ford Fusion. Brake Booster. Removal and Installation

2.7L EcoBoost (238kW/324PS)

    1. Remove the stud bolt.
      Torque: 80 lb.in (9 Nm)
    1. Disconnect the fitting and remove the transmission fluid cooler tube.
      Torque: 22 lb.ft (30 Nm)
    1. Inspect the O-rings and instal new as necessary.
    1. Before installation, lubricate the O-rings with clean specified transmission fluid.
      Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV, )
Ford Fusion. Brake Booster. Removal and Installation

All vehicles

  1. Remove the brake booster.
Ford Fusion. Brake Booster. Removal and Installation

Installation

All vehicles

  1. 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).

2.7L EcoBoost (238kW/324PS)

  1. Check the transmission fluid and fill as necessary.
    Material: Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC (WSS-M2C938-A) (MERCON® LV, )

    Power Brake Actuation

    ..

    Brake Vacuum Pump - 1.5L EcoBoost (118kW/160PS) – I4. Removal and Installation

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    Ford Fusion 2013–2020 Service Manual: Rear Door Alignment. General Procedures


    Adjustment NOTE: Removal steps in this procedure may contain installation details. NOTE: LH shown, RH similar. All alignments Check the body to rear door dimensions. Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation)...

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