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Home >> Ford >> 2006 >> Focus ZX3 SE, Automatic >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Hydraulic Brake System Actuation >> Removal And Installation >> Brake Master Cylinder >> Removal and Installation

Removal and Installation

All vehicles 

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: 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.
  1. Remove the battery. For additional information, refer to BATTERY MOUNTING AND CABLES .
  2. Disconnect the electrical connector from the brake fluid reservoir filler cap.
    • Pull back the tab.
    • Press the clips.
    • Disconnect the electrical connector.
    3. CAUTION: Make sure the filler cap does not become contaminated.
  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 1: Locating Battery Junction Box (BJB) Electrical Connectors
    G04651667Courtesy of FORD MOTOR CO.
  7. Remove the BJB screw.
  8. Position the BJB aside.
    9. CAUTION: Cap the hose connections to prevent fluid loss or dirt contamination.
    Fig 2: Locating Brake Fluid Reservoir-To-Master Cylinder Tube
    G04651668Courtesy of FORD MOTOR CO.
  9. Disconnect the brake fluid reservoir-to-master cylinder tube.

    10. Vehicles with manual transaxle 

    CAUTION: Cap the hose connections to prevent fluid loss or dirt contamination.
    Fig 3: Locating Clutch Master Cylinder Tube
    G04651669Courtesy of FORD MOTOR CO.
  10. Disconnect the clutch master cylinder tube.

    11. Vehicles without anti-lock brakes 

    CAUTION: Cap the brake tube connections to prevent fluid loss or dirt contamination.
  11. Disconnect the brake tube fittings.
    • To install, tighten to 20 Nm (15 lb-ft).

    12. Vehicles with anti-lock brakes 

    CAUTION: Cap the brake tube connections to prevent fluid loss or dirt contamination.
  12. Disconnect the brake tube fittings.
    • To install, tighten to 17 Nm (13 lb-ft).

    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.
  13. Disconnect the brake booster vacuum hose.
  14. Remove the 2 brake master cylinder nuts and the brake master cylinder.
    • To install, tighten to 20 Nm (15 lb-ft).
    15. CAUTION: Before installing the master cylinder make sure that the vacuum seal is in place and that the mating faces are clean.
  15. To install, reverse the removal procedure.
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