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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 54 (Disc Brakes & Drum Brakes) >> Adjustments >> Master Cylinder Push Rod

Master Cylinder Push Rod

WARNING: This page is about a different car, the 2002 Mercury Villager. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.
  1. Disconnect the battery ground cable.
  2. Disconnect the Mass Air Flow (MAF) sensor harness connector. See Fig 1 .
  3. Disconnect the vacuum hose to outlet tube. See Fig 2 .
  4. Loosen the band clamps. Disconnect the breather tube inlet hose and the bypass air inlet hose. See Fig 3 .
  5. Unclip the four air cleaner housing retaining clips. See Fig 4 .
  6. Disconnect the transaxle vent tube from retainer clip. See Fig 5 .
  7. Remove the air cleaner assembly.
  8. Remove the brake master cylinder. See MASTER CYLINDER & RESERVOIR  under REMOVAL & INSTALLATION.
  9. Disconnect the Electronic Hydraulic Control Unit (EHCU) harness connector. EHCU is part of ABS control module and is located on left side of engine compartment, below master cylinder.
    • Pull the electrical connector lock forward. See Fig 6 .
    • Lift the electrical connector to disconnect it from the EHCU.
  10. Disconnect and cap the brake lines from the EHCU. See Fig 7 .
  11. Disconnect the transaxle shift cable from the EHCU bracket.
  12. Remove the EHCU bracket nut and bolts. Remove the EHCU assembly. See Fig 8 .
  13. Using Rotunda Vacuum Tester (014-R1054), apply a vacuum of 19.69 In. Hg to power booster. See Fig 9 .
  14. Measure push rod length. Push rod length should be 0.4045-0.4144" (10.275-10.525 mm).
  15. Measure the push rod with the push rod pivot bracket. See Fig 10 . Adjust clevis to approximately 4.75" (121 mm).
  16. Adjust push rod nut until push rod length is within specification. See Fig 11 .
  17. Install the brake master cylinder.
  18. Install the EHCU.
  19. Install the air cleaner assembly.
  20. Bleed brakes. See BLEEDING BRAKE SYSTEM  .
Fig 1: Identifying MAP Sensor Harness Connector
G00310800Courtesy of FORD MOTOR CO.
Fig 2: Identifying Vacuum Hose-To-Outlet Tube
G00310801Courtesy of FORD MOTOR CO.
Fig 3: Identifying Band Clamps, Bypass Air Inlet Hose & Breather Tube Inlet Hose
G00310802Courtesy of FORD MOTOR CO.
Fig 4: Identifying Air Cleaner Housing Retaining Clips
G00310804Courtesy of FORD MOTOR CO.
Fig 5: Identifying Transaxle Vent Tube
G00310803Courtesy of FORD MOTOR CO.
Fig 6: Disconnecting EHCU Harness Connector
G00310805Courtesy of FORD MOTOR CO.
Fig 7: Identifying EHCU Brake Lines
G00310806Courtesy of FORD MOTOR CO.
Fig 8: Identifying EHCU Bracket Nut & Bolts
G00310807Courtesy of FORD MOTOR CO.
Fig 9: Measuring Length of Output Rod Extending From Booster
G91I02376Courtesy of NISSAN MOTOR CO., U.S.A.
Fig 10: Adjusting Brake Booster Clevis
G93C76473Courtesy of FORD MOTOR CO.
Fig 11: Adjusting Master Cylinder Push Rod
G93B76472Courtesy of FORD MOTOR CO.
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