Disassembly and Assembly

Master Cylinder

Disassembly

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. 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 so equipped, remove the brake pressure switch.





5. Remove the primary piston assembly.
1. Depress the primary piston and remove the snap ring.
2. Remove and discard the primary piston assembly.





6. 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.





7. NOTE: If the brake master cylinder bore is damaged, the brake master cylinder must be replaced.

Clean the brake master cylinder bore using isopropyl alcohol and inspect for damage.

Assembly
1. Use clean High Performance DOT 3 Motor Vehicle 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. If so equipped, install the brake pressure switch.
6. Install the brake master cylinder.