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Removal and Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 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. Failure to follow these instructions may result in personal injury.

    All Vehicles 

  1. Disconnect the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Use a suitable suction device to remove the brake fluid from the brake master cylinder reservoir.
  3. Remove the coolant reservoir bolts and position the reservoir aside.
    Fig 1: Removing Coolant Reservoir Bolts
    G03891530Courtesy of FORD MOTOR CO.
  4. Disconnect the speed control deactivator switch connector.
    Fig 2: Disconnecting Speed Control Deactivator Switch Connector
    G03891531Courtesy of FORD MOTOR CO.
  5. Disconnect the brake fluid level switch electrical connector.
    Fig 3: Disconnecting Brake Fluid Level Switch Electrical Connector
    G03891532Courtesy of FORD MOTOR CO.
  6. Disconnect the brake master cylinder lines.
    Fig 4: Disconnecting Brake Master Cylinder Lines
    G03891533Courtesy of FORD MOTOR CO.

    7. Diesel engines 

  7. Disconnect the coolant hoses from the air cleaner outlet tube.
    Fig 5: Locating Coolant Hoses & Air Cleaner Outlet Pipe
    G03887859Courtesy of FORD MOTOR CO.
  8. Loosen the clamp and disconnect the air cleaner outlet tube.
    Fig 6: Disconnecting Air Cleaner Outlet Tube
    G03888320Courtesy of FORD MOTOR CO.
  9. Disconnect the mass air flow (MAF) sensor electrical connector.
    • Slide out the red lock.
    • Press the tab and remove the electrical connector.
      Fig 7: MAF Sensor Electrical Connector
      G03888312Courtesy of FORD MOTOR CO.
  10. Disconnect the 3 latches and remove the air cleaner cover.
    Fig 8: Locating Latches & Air Cleaner Cover
    G03888313Courtesy of FORD MOTOR CO.

    11. Gasoline engines 

  11. Remove the 2 powertrain control module (PCM) bracket nuts and position the PCM and bracket aside.
    Fig 9: Removing Powertrain Control Module (PCM) Bracket Nuts
    G03891538Courtesy of FORD MOTOR CO.

    12. All vehicles 

    NOTE: Discard the brake master cylinder nuts. They are a torque-prevailing type and cannot be reused.
    Fig 10: Removing Brake Master Cylinder Nuts
    G03891539Courtesy of FORD MOTOR CO.
  12. Remove the brake master cylinder nuts.
  13. Remove the brake master cylinder.
  14. To install, reverse the removal procedure.
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