Master Cylinder: Disassembly

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.

NOTE: ABS master cylinder shown, non-ABS similar.

Remove the brake master cylinder (2140); refer to MASTER CYLINDER .
Clean the outside of the brake master cylinder.
Support the brake master cylinder body in a vice.

Fig 1: Supporting Brake Master Cylinder Body In Vice
Courtesy of FORD MOTOR CO.
Remove the reservoir cap.

Fig 2: Removing Reservoir Cap
Courtesy of FORD MOTOR CO.
Use a suitable suction device to drain the brake master cylinder reservoir (2K478).
Carefully pry up on the brake master cylinder reservoir to remove.

Fig 3: Removing Brake Master Cylinder Reservoir
Courtesy of FORD MOTOR CO.
If equipped, remove the two brake pressure control valves (2B091).

Fig 4: Removing Two Brake Pressure Control Valves
Courtesy of FORD MOTOR CO.
Remove the primary piston assembly.
1. Depress the (A) primary piston and remove the (B) snap ring.
2. Remove and discard the primary piston assembly.
Fig 5: Removing Primary Piston Assembly
Courtesy of FORD MOTOR CO.
Remove the secondary piston assembly.
1. Plug the rear outlet port.
2. Apply compressed air into the front outlet port and remove and discard the secondary piston assembly.
Fig 6: 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 7: Inspecting Brake Master Cylinder Bore For Damage

Courtesy of FORD MOTOR CO.

Inspect the brake master cylinder bore for damage.
- Use isopropyl alcohol to clean the bore.