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Home >> Ford >> 2005 >> Focus ZX5 S, Automatic >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Hydraulic Brake System Actuation >> Removal And Installation >> Brake Master Cylinder >> Removal and Installation

Removal and Installation

WARNING: Use of any other than approved DOT 3 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: 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.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

    All vehicles 

  1. Remove the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Disconnect the electrical connector from the filler cap.
    1. Pull back the tab.
    2. Press the clips.
    3. Disconnect the electrical connector.
    Fig 1: Disconnecting Electrical Connector From Filler Cap
    G03950107Courtesy of FORD MOTOR CO.
    3. CAUTION: Make sure the filler cap does not become contaminated.
    Fig 2: Removing Brake Fluid Reservoir Filler Cap
    G03950108Courtesy of FORD MOTOR CO.
  3. Remove the brake fluid reservoir filler cap.
  4. Using a suitable clean suction device, drain the reservoir.
  5. Install the brake fluid reservoir filler cap.
  6. Disconnect the battery junction box (BJB) electrical connectors.
    Fig 3: Disconnecting Battery Junction Box (BJB) Electrical Connectors
    G03950109Courtesy of FORD MOTOR CO.
  7. Remove the BJB screw.
    Fig 4: Removing BJB Screw
    G03950110Courtesy of FORD MOTOR CO.
  8. Position the BJB aside.
    Fig 5: Positioning BJB
    G03950111Courtesy of FORD MOTOR CO.
    9. CAUTION: Cap the hose connections to prevent fluid loss or dirt contamination.
    Fig 6: Disconnecting Brake Master Cylinder Feed Hose
    G03950112Courtesy of FORD MOTOR CO.
  9. Disconnect the brake master cylinder feed hose.

    10. Vehicles with manual transaxle 

    CAUTION: Cap the hose connections to prevent fluid loss or dirt contamination.
    Fig 7: Disconnecting Clutch Master Cylinder Feed Hose
    G03950113Courtesy of FORD MOTOR CO.
  10. Disconnect the clutch master cylinder feed hose.

    11. Vehicles without anti-lock brakes 

    CAUTION: Cap the brake tube connections to prevent fluid loss or dirt contamination.
    Fig 8: Disconnecting Brake Lines
    G03950114Courtesy of FORD MOTOR CO.
  11. Disconnect the brake lines.

    12. Vehicles with anti-lock brakes 

    CAUTION: Cap the brake tube connections to prevent fluid loss or dirt contamination.
    Fig 9: Disconnecting Brake Lines
    G03950115Courtesy of FORD MOTOR CO.
  12. Disconnect the brake lines.

    13. All vehicles 

    CAUTION: Before removing the master cylinder make sure that the booster vacuum is exhausted. This may be done by removing the vacuum pipe from the brake booster.
    Fig 10: Removing Brake Booster Vacuum Hose
    G03950116Courtesy of FORD MOTOR CO.
  13. Remove the brake booster vacuum hose.
  14. Remove the brake master cylinder retaining nuts.
    • Remove the master cylinder.
    Fig 11: Removing Brake Master Cylinder Retaining Nuts
    G03950117Courtesy of FORD MOTOR CO.
    15. CAUTION: Before installing the master cylinder make sure that the vacuum seal is in place and that the mating faces are clean.
    NOTE: After installation, bleed the brake system. For additional information, refer to BRAKE SYSTEM-GENERAL INFORMATION .
  15. To install, reverse the removal procedure.
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