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.
NOTE: ABS master cylinder shown, non-ABS similar.
Remove the brake master cylinder
Clean the outside of the brake master cylinder.
Support the brake master cylinder body in a vice.
Remove the reservoir cap.
Use a suitable suction device to drain the brake master cylinder reservoir.
Carefully pry up on the brake master cylinder reservoir to remove.
If equipped, remove the two brake pressure control valves.
Remove the primary piston assembly.
1
Depress the (A) primary piston and remove the (B) snap ring.
2
Remove and discard the primary piston assembly.
Remove the secondary piston assembly.
1
Plug the rear outlet port.
2
Apply compressed air into the front outlet port and remove and discard the secondary piston assembly.
NOTE: If the brake master cylinder bore is damaged, the brake master cylinder must be replaced.
Inspect the brake master cylinder bore for damage.
Use isopropyl alcohol to clean the bore.
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.
Use clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3 to lubricate the new piston assembly seals and the brake master cylinder bore.
Carefully install the secondary piston assembly.
Carefully install the primary piston assembly.
Install the snap ring.
1
Depress the primary piston.
2
Install the snap ring.
If equipped, install the two brake pressure control valves.
Install the brake master cylinder reservoir.
1
Lubricate the grommets with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3 and insert the grommets into the brake master cylinder.
2
Press the brake master cylinder reservoir into the grommets until it snaps in securely.
3
Fill the brake master cylinder with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3.
