Master Cylinder: Disassembly

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, and 2003 Ford Excursion. 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.

Remove the brake master cylinder (2140). Refer to Brake Master Cylinder .
Clean the outside of the brake master cylinder.
Remove the brake master cylinder filler cap and drain the remaining brake fluid.

Fig 1: Removing Brake Master Cylinder Filler Cap And Draining Remaining Brake Fluid
Courtesy of FORD MOTOR CO.
If so equipped, remove the brake pressure switch.

Fig 2: Removing Brake Pressure Switch
Courtesy of FORD MOTOR CO.
Remove the primary piston assembly.
1. Depress the primary piston and remove the snap ring.
2. Remove and discard the primary piston assembly.
  
  Fig 3: Removing And Discarding Primary Piston Assembly
  Courtesy of FORD MOTOR CO.
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.
  
  Fig 4: Applying Compressed Air Into Front Outlet Port And Removing Secondary Piston Assembly
  Courtesy of FORD MOTOR CO.

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

Fig 5: Cleaning Brake Master Cylinder Bore And Inspecting For Damage

Courtesy of FORD MOTOR CO.

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