Removal And Installation

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.

WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury.

NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

All vehicles

Use a suitable suction device to remove the brake fluid from the brake master cylinder reservoir.
Remove the coolant reservoir bolts and position the reservoir aside.
- To install, tighten to 10 Nm (89 lb-in).

Fig 1: Locating Coolant Reservoir Bolts

Courtesy of FORD MOTOR CO.

Diesel engine equipped vehicles

Disconnect the coolant hoses from the air cleaner outlet tube.

Fig 2: Locating Coolant Hoses & Air Cleaner Outlet Pipe

Courtesy of FORD MOTOR CO.

Loosen the clamp and disconnect the air cleaner outlet tube.
- To install, tighten to 4 Nm (35 lb-in).
Disconnect the Mass Air Flow (MAF) sensor electrical connector.

Fig 3: MAF Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the 3 latches and remove the air cleaner cover.

Fig 4: Locating Latches & Air Cleaner Cover

Courtesy of FORD MOTOR CO.

Gasoline engines equipped vehicles

Disconnect the power cable at the Power Distribution Box (PDB) and position the box aside.

All vehicles

Disconnect the brake fluid level switch electrical connector.
Disconnect the speed control deactivator switch electrical connector.
Disconnect the master cylinder brake tubes.
- To install, tighten to 18 Nm (159 lb-in).
- For vehicles equipped with Roll Stability Control (RSC®), tighten to 28 Nm (21 lb-ft).
Remove the nuts and the outer power steering tube bracket.
- To install, tighten to 9 Nm (80 lb-in).

NOTE: The brake master cylinder nuts are a torque-prevailing type and cannot be reused.

Remove and discard the brake master cylinder nuts.
- To install, tighten the new nuts to 26 Nm (19 lb-ft).
Remove the inner power steering tube bracket.

Fig 5: Identifying Power Steering Tube Bracket

Courtesy of FORD MOTOR CO.

Remove the brake master cylinder.
To install, reverse the removal procedure.
- Bleed the brake system. For additional information, refer to BRAKE SYSTEM - GENERAL INFORMATION article.