Section 06-09: Brake System, Anti-Lock
1994 Mustang Workshop Manual
REMOVAL AND INSTALLATION

Brake Booster, Vacuum

 

3.8L Engine

Removal

Refer to illustration following Brake Booster, Power 5.0L Engine.

  1. Disconnect battery ground cable.
  1. Disconnect accelerator cable (9A758) from throttle body (9E926) .
  1. Remove screw that secures accelerator cable to accelerator shaft bracket, and remove accelerator cable from bracket.
  1. Remove two screws that secure accelerator shaft bracket to manifold, and rotate bracket toward engine.
  1. Remove horn (13832) .

     CAUTION: The fuel system is under pressure and must be bled prior to disconnecting the quick connect fittings. Refer to Section 10-00.

  1. Disconnect two manifold injector connectors located near oil level indicator retaining bracket.
  1. Disconnect two fuel hoses to fuel injection supply manifold assembly.
  1. Remove three bolts holding the oil level indicator bracket to upper intake manifold. Remove oil level indicator and bracket.
  1. Remove windshield wiper motor.
  1. Remove vacuum line hoses directly over power brake booster at dash panel vacuum tee.
  1. Remove bolt holding clutch cable stand (if equipped); move bracket to side rail at fender inner panel.
  1. Move speed control cable aside to clear power brake booster (if equipped).
  1. Disconnect manifold vacuum hose from power brake booster check valve.
  1. Remove brake tubes from the primary and secondary outlet ports of brake master cylinder.
  1. Remove two nuts retaining brake master cylinder to power brake booster assembly, and remove brake master cylinder.
  1. Working inside vehicle below dash panel (01610) , remove stoplight switch wiring connector from stoplight switch (13480) . Remove hairpin retainer and outer brake master cylinder push rod spacer (2B129) from pedal pin. Slide stoplight switch off brake pedal pin just far enough for outer arm to clear pin. Remove stoplight switch . Be careful not to damage stoplight switch during removal. Remove booster-to-dash pedal retaining nuts.
  1. Remove and set aside the speed control amplifier (if equipped) which is mounted to the lower outboard booster stud. Slide the booster push rod, brake master cylinder push rod bushing (2474) , and the inner brake master cylinder push rod bushing off the brake pedal pin.
  1. Inside the engine compartment, move power brake booster (2005) forward until the power brake booster studs clear the dash panel, then rotate front of power brake booster inboard (toward engine), and remove power brake booster by raising up until clear.
 

Installation

  1. Place power brake booster in position on dash panel .
  1. Working inside vehicle, install inner brake master cylinder push rod bushing , booster push rod and brake master cylinder push rod spacers on brake pedal pin.
  1. Place speed control amplifier bracket (if equipped) over lower outboard booster stud and position bracket locating tab in hole provided in pedal support bracket (01508) .
  1. Secure the booster-to-dash panel retaining nuts, and tighten to 21-29 Nm (16-21 lb-ft). Position stoplight switch , so that it straddles booster push rod with switch slot toward pedal blade and hole just clearing pin. Slide stoplight switch completely onto pin. Be careful not to bend or deform stoplight switch . Install brake master cylinder push rod bushing on pin, and secure all parts to pin with hairpin retainer. Make sure retainer is fully installed and locked over pedal pin. Install stoplight switch wiring connector on stoplight switch .
  1. Connect manifold vacuum hose to power brake booster check valve (2365) .
  1. Install brake master cylinder (2140) assembly to booster studs. Tighten to 21-29 Nm (16-21 lb-ft).
  1. Install brake tube fittings into ports. Tighten to 14-24 Nm (11-17 lb-ft).
  1. Place accelerator shaft bracket in position on engine, and secure two screws.
  1. Route accelerator cable bracket to shaft bracket with a screw.
  1. Connect accelerator cable to throttle body .
  1. Install horn .
  1. Connect battery ground cable.
  1. Install the oil level indicator tube bracket assembly to upper intake manifold. Connect two wiring connectors.
  1. Install windshield wiper motor.
  1. Connect fuel line supply and return hoses to fuel injection supply manifold assembly.
  1. Connect clutch cable stand off bracket to side rail.
  1. Connect vacuum line hoses to vacuum tee over power brake booster .
  1. If equipped, reroute speed control cable.
  1. Bleed brake system as outlined in Section 06-06.
  1. Start engine and check power brake function.
 

5.0L Engine

Removal

  1. Remove engine air cleaner (ACL) (9600) , and disconnect the battery.
  1. Disconnect manifold vacuum hose from power brake booster check valve .
  1. Remove the brake tubes from the primary and secondary outlet ports of the brake master cylinder .
  1. Remove two nuts attaching brake master cylinder to power brake booster assembly, and remove brake master cylinder .
  1. Working inside vehicle below dash panel , remove stoplight switch wiring connector from stoplight switch . Remove hairpin retainer and outer nylon brake master cylinder push rod spacer from pedal pin. Slide the stoplight switch off brake pedal pin just far enough for outer arm to clear pin. Remove stoplight switch . Be careful not to damage stoplight switch during removal. Remove booster-to-dash panel retaining nuts.
  1. Remove and set aside the speed control amplifier (9D843) (if equipped) which is mounted to the lower outboard power brake booster stud. Slide the booster push rod brake master cylinder push rod bushing off the brake pedal pin.
  1. Inside the engine compartment, move power brake booster forward until the booster studs clear the dash panel . Rotate front of power brake booster inboard (toward engine), and remove power brake booster by raising up until clear.
 

Installation

  1. Place power brake booster in position on dash panel .
  1. Working inside vehicle, install booster push rod and brake master cylinder push rod bushings on brake pedal pin.
  1. Place speed control amplifier bracket over lower outboard booster stud and position bracket locating tab in hole provided in pedal support bracket .
  1. Install booster-to-dash panel retaining nuts. Tighten to 21-29 Nm (16-21 lb-ft). Position stoplight switch so that it straddles booster push rod with stoplight switch slot toward pedal blade and hole just clearing pin. Slide stoplight switch completely onto pin. Be careful not to bend or deform stoplight switch . Install brake master cylinder push rod spacer on pin, and secure all parts to pin with hairpin retainer. Make sure retainer is fully installed and locked over pedal pin. Install stoplight switch wiring connector on stoplight switch .
  1. Connect manifold vacuum hose to power brake booster check valve .
  1. Install brake master cylinder assembly to booster studs. Tighten to 21-29 Nm (16-21 lb-ft).
  1. Install brake tube fittings into ports. Tighten to 14-24 Nm (11-17 lb-ft).
  1. Bleed brake system as outlined in Section 06-06.


Hydraulic Brake System





Item Part Number Description
1 2140 Brake Master Cylinder
2 2B450 Spacer
3 01508 Pedal Support Bracket
4 45265-S2 J-Nut
5A 57048-S2 Screw
6A 385759-S2 Nut (4 Req'd)
7 2005 Power Brake Booster
8A 382802-S100 Nut (2 Req'd)
9B N610957-S2 Screw
10 9C961 Speed Control Vacuum Dump Valve Mounting Bracket
11 — Vacuum Tube
12 9C727 Speed Control Dump Valve
13 — Clip
14 — Mounting Hole
15 9C962 Speed Control Vacuum Valve Actuator Adapter
16 2455 Brake Pedal
17 N800197-S2 Bushing
18C N620481-S2 Nut
19 N800661-S2 Bolt
20 13480 Stoplight Switch
21 2B129 Brake Master Cylinder Push Rod Spacer (2 Req'd)
22 2457 Brake Pedal Pad
23 2A309 Brake Master Cylinder Push Rod Bushing
24 — Push Rod Assy (Part of 2005)
25 N800196 Spacer (2 Req'd)
26 380699-S100 Pin
A Tighten to 18-34 Nm (13-24 Lb-Ft)
B Tighten to 8-13.6 Nm (6-10 Lb-Ft)
C Tighten to 14-27 Nm (10-20 Lb-Ft)