2009 Expedition remove brake booster

[CooterExpedition]

Hi there, I have a replacement brake booster in hand, I have removed the 4 bolts that hold the booster to the firewall, but I can't disconnect the booster from the brake pedal. The retainer is round and surrounded by Pale blue plastic. It is not a clip like on older fords.
Anybody know how to disconnect it? See attached photo from under the dashboard.

 

[Bedrck47]

Copied from the 09 Ford service manual

Removal and Installation

All vehicles


Remove the air cleaner element. For additional information, refer to Section 303-12 for Intake Air Distribution and Filtering.
Remove the 2 bolts and position the degas bottle/lower air cleaner housing assembly aside.
To install, tighten bolts to 15 Nm (133 lb-in).

Relieve the vacuum in the brake booster by pressing and releasing the brake pedal a minimum of 5 times with the engine not running.
Disconnect the brake fluid level switch.
NOTE: Support the master cylinder with mechanic's wire.

Remove the 2 brake master cylinder nuts and position the master cylinder aside.
To install, tighten the nuts to 25 Nm (18 lb-ft).
Vehicles equipped with Roll Stability Control (RSC®)


Disconnect the brake pedal travel solenoid electrical connector.
All vehicles


Disconnect the brake pedal travel sensor electrical connector.
Disconnect the manifold vacuum outlet assembly from the brake booster.
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. For additional information, refer to Section 417-01 .
Remove the brake pedal arm pin and disconnect the booster push rod from the brake pedal arm.
Remove the 4 brake booster-to-pedal bracket nuts and remove the brake booster.
To access the retaining nuts, fold back the sound insulation.
To install, tighten to 27 Nm (20 lb-ft).
NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch. This 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 this 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.
For vehicles equipped with Roll Stability Control (RSC®), calibrate the ABS module. Follow the directions on the scan tool for the calibration procedure.


From the manual it appears the pin is just pushed into place I would carefully pry it out

 

[CooterExpedition]

OK well the round retainer holding the booster rod isn't budging. Anybody with actual hands on experience here?

 

[stamp11127]

With such an important pin there should be some kind of clip to secure the pin. Can you get a pic of the other side of the brake pedal arm?

http://www.f150forum.com/f12/removing-brake-booster-283291/

 

[Bedrck47]

There isn't a clip The pin has barbs on it that hold t in place

Stamp I'll send you a pic from the service manual

 

[Bedrck47]

print

 

[CooterExpedition]

Will do, thanks. I'm actually back to square one because i got the wrong booster. I got the one without the electric connector for the stability control. It will take 3 or 4 days to get the proper part.
Will update this thread when I make some progress. Thank you in advance.

 

[CooterExpedition]

Well it looks like I'm going to leave the booster alone and replace the master cylinder. The symptoms that I was experiencing was pedal blowing through to the floor with minimal stopage.you ready had to stand on the brakes hard to stop the truck.
I understand that the booster only needs replacing if you loose vacuum and the pedal gets hard similar to when the engine is off. That's not my case. I think the master cylinder is just pushing fluid back to the reservoir instead of the calipers.

 

[CooterExpedition]

Has anybody removed the brake pedal retaining pin? I replaced the master cylinder with new, bled system, no leaks and the brakes are still way soft. Gotta stand on it to stop. Mush all the way through. I have a new booster but I gota move the his barbed pin.
Anyone? The picture is the reverse side of the very first picture of this thread.

 

[CooterExpedition]

With such an important pin there should be some kind of clip to secure the pin. Can you get a pic of the other side of the brake pedal arm?

http://www.f150forum.com/f12/removing-brake-booster-283291/

I took a photo today, see bottom of post, ya it's barbed, but now I need to remove it to replace the booster. I really don't want to break it.