Removal And Installation
WARNING: This page is about a different car, the 2007 Mercury Mariner and 2007 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
The traction battery and charging system contains high voltage components and wiring. High voltage insulated safety gloves and a face shield must be worn when carrying out any diagnostics on this vehicle. Failure to follow these instructions may result in severe personal injury or death.
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.
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:
Brake fluid reservoir shown removed for clarity.
- Disconnect the battery. For additional information refer to BATTERY, MOUNTING AND CABLES article.
- Depower the high-voltage battery. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.
- Remove the stop lamp switch. For additional information, refer to EXTERIOR LIGHTING article.
- If equipped, remove the speed control deactivator switch. For additional information, refer to SPEED CONTROL article.
- Using a suitable suction device, remove the brake fluid from the master cylinder reservoir.
- Disconnect the brake fluid level switch electrical connector.
- Disconnect the brake travel sensor electrical connector.
- Disconnect and cap the 2 brake tube fitting nuts.
- To install, tighten to 14 Nm (10 lb-ft).
- Remove the return hose clamp and the return hose.
- To install, tighten to 3 Nm (27 lb-in).
- Remove the feed hose clamp and the feed hose.
- To install, tighten to 3 Nm (27 lb-in).
- Remove the brake push rod pin redundant clip.
- Remove the brake push rod self-locking pin.
- Remove the brake push rod outer bushing.
- Slide the brake push rod off the brake pedal pin.
- Remove the 4 master cylinder nuts.
- To install, tighten to 23 Nm (17 lb-ft).
- Remove the master cylinder.
- To install, reverse the removal procedure.
- Repower the high-voltage battery. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.
- Bleed the brake system. For additional information, refer to BRAKE SYSTEM - GENERAL INFORMATION article.
CAUTION:
Always remove the stop lamp switch before removing the speed control deactivator switch. Always remove both switches with the brake pedal secured to the brake booster push rod and with the brake pedal in the at-rest position. Do not press or pull on the brake pedal when removing the switches or damage to switches can occur.
CAUTION:
The stop lamp switch and the speed control deactivator switch must be removed prior to removing the brake pedal and bracket, brake booster and associated mounting fasteners or damage to the switches can occur.
CAUTION:
Do not install the stop lamp switch and the speed control deactivator switch until installation of the brake booster, brake pedal and bracket are complete. The brake pedal arm must be secured to the brake booster push rod and in the at-rest position prior to switch installation. Failure to follow these instructions can result in incorrect adjustment or damage to the switches.
CAUTION:
Do not press, pull or otherwise move the brake pedal while installing the stop lamp switch or the speed control deactivator switch. Failure to follow these instructions can result in incorrect adjustment or damage to the switches.