Disassembly and Assembly
DisassemblyWARNING: 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.
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. CAUTION: Do not damage the body of the brake master cylinder when mounting it in the vise.
Mount the brake master cylinder in a soft-jawed vise.
5. On cruise control equipped vehicles, remove the brake pressure switch.
6. Remove the brake master cylinder reservoir.
7. Remove the primary piston assembly.
1. Depress the primary piston and remove the snap ring.
2. Remove and discard the primary piston assembly.
8. Remove the secondary piston assembly.
1. Plug the rear brake outlet port and, if necessary, plug the brake pressure switch port.
2. Apply compressed air into the front brake outlet port, and remove the secondary piston assembly and discard.
9. NOTE: If the brake master cylinder bore is damaged, install a new brake master cylinder.
Use isopropyl alcohol to clean the break master cylinder bore; inspect for damage.
Assembly
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.
1. Use clean High-Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or an equivalent DOT 3 brake fluid meeting Ford specification ESA-M6C25-A. 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. NOTE: Use clean High-Performance DOT 3 Motor Vehicle Brake Fluid C6AZ- 19542 or an equivalent DOT 3 brake fluid meeting Ford specification ESA-M6C25-A. Fill brake pressure switch.
On cruise control equipped vehicles, install the brake pressure switch.
6. Install the brake master cylinder reservoir.
7. NOTE: Bleed the brake master cylinder prior to installation.
Install the brake master cylinder.
8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap.
9. Bleed the brake system.