Disassembly and Assembly
DisassemblyWARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
1. Remove the brake master cylinder.
2. Clean the outside of the brake master cylinder.
3. Remove the brake master cylinder filler cap and drain the remaining brake fluid.
4. If equipped, remove the brake pressure switch.
5. Remove the brake master cylinder fluid control valve.
6. Remove the primary piston assembly.
1. Depress the primary piston and remove the snap ring.
2. Remove and discard the primary piston assembly.
7. Remove the secondary piston assembly.
1. Plug the rear outlet port and, if necessary, plug the brake pressure switch port.
2. Apply compressed air into the front outlet port and remove the secondary piston assembly and discard.
8. Note: If the brake master cylinder bore is damaged, the brake master cylinder must be installed new.
Use isopropyl alcohol to clean and inspect the brake master cylinder bore for damage.
Assembly
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycol. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
1. Use clean High-Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A, to lubricate the new piston assembly seals.
2. Carefully install the secondary piston assembly.
3. Carefully install the primary piston assembly.
4. Install the snap ring.
1. Depress the primary piston.
2. Install the snap ring.
5. Install the brake master cylinder fluid control valve.
6. If equipped, install the brake pressure switch.
7. Install the brake master cylinder.
8. Fill the brake master cylinder reservoir with High-Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A and install the brake master cylinder filler cap.
9. Bleed the brake master cylinder.