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Master Cylinder Priming - In-Vehicle or Bench

WARNING: This page is about a different car, the 2002 Ford RV Cutaway, 2002 Ford Econoline, 2002 Ford E550 Super Duty, 2002 Ford E450 Super Duty, and 2002 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
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.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can enter the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment.
NOTE: When the brake master cylinder has been installed new or the system has been emptied, or partially emptied, it should be primed to prevent air from entering the system.
  1. For in-vehicle priming, disconnect the brake lines.
    2. Fig 1: Disconnecting Brake Lines
    G03404644Courtesy of FORD MOTOR CO.
  2. For bench priming, mount the brake master cylinder in a vise.
    Fig 2: Mounting Brake Master Cylinder In Vise
    G03404645Courtesy of FORD MOTOR CO.
  3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. Fill the brake master cylinder reservoir with clean DOT 3 brake fluid.
    Fig 3: Installing Short Brake Tubes With Ends Submerged In Brake Master Cylinder Reservoir
    G03404646Courtesy of FORD MOTOR CO.
  4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles.
  5. If the brake master cylinder has been primed at the bench, install it in the vehicle. For additional information, refer to DISC & DRUM .
  6. Remove the short brake tubes, and install the brake outlet tubes.
    Fig 4: Removing Short Brake Tubes (1 Of 2)
    G03404647Courtesy of FORD MOTOR CO.
    7. Fig 5: Removing Short Brake Tubes (2 Of 2)
    G03404648Courtesy of FORD MOTOR CO.
  7. Bleed each brake tube at the brake master cylinder as follows:
    1. Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal.
    2. Loosen the rearmost brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting.
    3. Repeat this operation until clear, bubble-free fluid comes out.
    4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube.
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