Ford Taurus Service Manual: Power Brake Actuation

SPECIFICATIONS

Torque Specifications

Ford Taurus. Brake System

DESCRIPTION AND OPERATION

Brake Booster

The power brake actuation system includes a vacuum sorce (engine manifold or vacuum pump), vacuum assisted brake booster, vacuum check valve and a vacuum supply tube. Vehicles equipped with 3.5L and 3.7L engines utilize engine manifold vacuum and vehicles equipped with 2.0L GTDI engines utilize an engine-mounted/cam-driven vacuum pump and engine manifold vacuum to supply vacuum.

Vacuum is delivered through the vacuum supply tube to the vacuum check valve. The vacuum check valve is a one-way valve that allows supplied vacuum to the booster then closes when the vacuum supply is removed. The vacuum is applied to a rubber diaphragm on the vacuum side of the brake booster chamber which then pulls the piston rod in when the brakes are applied to provide power assist, reducing the amount of effort required at the brake pedal to actuate the foundation brakes.

REMOVAL AND INSTALLATION

Brake Booster

Removal

WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in Section 100-00. Failure to follow this instruction may result in serious personal injury.

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

All vehicles

    • To install, tighten to 63 Nm (46 lb-ft).

    Ford Taurus. Brake System

Vehicles equipped with 3.5 L Ti-VCT, 3.7L Ti-VCT or 2.0L Gasoline Turbocharged Direct Injection (GTDI) engines

  1. Remove the Air Cleaner (ACL) outlet pipe. Refer to Section 303-12.
  1. Remove the Hydraulic Control Unit (HCU). Refer to Section 206-09.

Vehicles equipped with 3.5L GTDI engine

    • To install, tighten the nut to 6 Nm (53 lb-in).
    • To install, tighten the clamps to 5 Nm (44 lb-in)

    Ford Taurus. Brake System

  1. Disconnect the ABS module electrical connector.

    Ford Taurus. Brake System

All vehicles

  1. Remove the brake master cylinder. Refer to Section 206-06.

    Ford Taurus. Brake System

    Ford Taurus. Brake System

  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 Section 417-01.

  1. NOTE: The booster push rod clevis-locking pin is a one-time use only part. Any time the booster push rod clevis-locking pin is removed, a new booster push rod clevis-locking pin should be used. Remove the clevis-locking pin by squeezing the locking tabs and pulling outward on the opposite end.

    Ford Taurus. Brake System

    • To install, tighten the new nuts to 25 Nm (18 lb-ft).

    Ford Taurus. Brake System

Installation

  1. To install, reverse the removal procedure.

Brake Vacuum Pump

Removal and Installation

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

  1. Remove the air cleaner outlet pipe. For additional information, refer to Intake Air System Components-Exploded View in Section 303-12.

    Ford Taurus. Brake System

    • To install, tighten to 10 Nm (89 lb-in).

    Ford Taurus. Brake System

  1. Inspect and, if necessary, install a new brake vacuum pump gasket.

    Ford Taurus. Brake System

  1. To install, reverse the removal procedure.

Brake Booster Vacuum Sensor

Ford Taurus. Brake System

Ford Taurus. Brake System

Removal

WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in Section 100-00. Failure to follow this instruction may result in serious personal injury.

  1. Disconnect the brake booster vacuum sensor electrical connector.
  1. Remove the brake booster vacuum sensor.

Installation

  1. NOTE: Please note the correct installation position in the exploded view. It is critical that the sensor be installed in the exact position that it was removed.

    To install, reverse the removal procedure.

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    Other materials:

    Cabin air filter
    Note: Make sure you have a cabin air filter installed at all times. This prevents foreign objects from entering the system. Running the system without a filter in place could result in degradation or damage to the system. Your vehicle is equipped with a cabin air filter, which is located just ...

    Child Safety
    • You are required by law to properly use safety seats for infants and toddlers in the United States and Canada. • Many states and provinces require that small children use approved booster seats until they reach age eight, a height of 4 feet 9 inches (1.45 meters) tall, or 80 pounds (36 ...

    Safety precautions
    WARNING: Do not overfill the fuel tank. The pressure in an overfilled tank may cause leakage and lead to fuel spray and fire. WARNING: The fuel system may be under pressure. If you hear a hissing sound near the fuel filler inlet, do not refuel until the sound stops. Otherwise, fuel may spray out ...