Brake Master Cylinder: Service and Repair

Brake Master Cylinder













Removal and Installation

WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury.

WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.

NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

1. With the engine OFF, press the brake pedal several times to deplete the brake booster vacuum.

2. Remove the battery tray.

3. Remove the battery ground cable bolt and position the cable aside.
- To install, tighten 10 Nm (89 lb-in).






4. Loosen the Battery Junction Box (BJB) mounting screw.





5. Press the locking tab, disconnect the BJB (Battery Junction Box) from the bracket and position the BJB (Battery Junction Box) aside.





6. NOTE: Cap the hose connections to prevent fluid loss.
Disconnect the brake fluid reservoir-to-master cylinder tube.






7. NOTE: Cap the brake tube connections to prevent fluid loss.

NOTE: To aid in correct installation, make a note of the position of the brake tubes.

Disconnect the brake tube fittings at the master cylinder. Loosen the master cylinder brake tube fittings at the Hydraulic Control Unit (HCU) to allow the brake tubes to move without being damaged.
- To install, tighten to 23 Nm (17 lb-ft).


8. NOTE: Make sure that the master cylinder-to-booster seal is removed with the master cylinder.
Remove and discard the 2 brake master cylinder nuts and remove the brake master cylinder.

- Discard the master cylinder-to-booster seal.

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


9. NOTE: Before installing the master cylinder, make sure that the new master cylinder-to-booster seal is in place and that the mating faces are clean.

To install, reverse the removal procedure.
- Bleed the master cylinder.