Brake Master Cylinder: Removal

NOTE: If the fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.

NOTE: Removal steps in this procedure may contain installation details.

All vehicles

Remove the battery tray. Refer to: Battery Tray - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma . Refer to: Battery Tray - 1.6L EcoBoost (132kW/180PS) - Sigma .
Disconnect the vacuum tube from the brake booster and detach the routing clip.

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Disconnect the electrical connector, remove the screws and the headlamp assembly.

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Remove the bolt and position the cowl vent panel upward.
Torque: 19 lb.in (2.2 Nm)

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Using a suitable suction device, remove the brake fluid from the remote reservoir and then remove the nuts.
Torque: 62 lb.in (7 Nm)

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Release the coupling and remove the remote brake fluid reservoir.

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Vehicles with manual transmission
Release the coupling and disconnect the clutch master cylinder tube.

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All vehicles
Disconnect the brake fluid level sensor electrical connector and the brake tube fittings.
Torque: 150 lb.in (17 Nm)

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NOTE: Before installing the master cylinder make sure a new brake booster-to-master cylinder O-ring is in place and the mating faces are clean.

Remove the nuts and the brake master cylinder. Discard the nuts.

Torque: 177 lb.in (20 Nm)

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NOTE: Take extra care when handling the component.

Do not remove the brake master cylinder piston extension.

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