Section 06-06: Brake System, Hydraulic | 1996 F-150, F-250, F-350, Bronco and F-Super Duty Workshop Manual |
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.
CAUTION: F-Super Duty vehicles are equipped with a hydraulic brake booster.Refer to Section 06-07C for hydraulic brake booster removal and installation procedures.
Removal
Disconnect the battery ground cable (14301).
With the engine turned off, push the brake pedal (2455) down to expel vacuum from the power brake booster (2005).
Disconnect fluid level indicator switch connector from the brake master cylinder (2140).
Disconnect the front brake tube (2264) and brake master cylinder connector tube from the brake master cylinder.
Remove the nuts retaining power brake booster to brake master cylinder. Remove the brake master cylinder from the power brake booster.
Installation
Before installing the brake master cylinder, check the distance from the outer end of the booster assembly push rod, to the front face of the power brake booster.
Using a shop fabricated gauge, adjust the power brake booster push rod so that the end is 24.89-25.27mm (0.980-0.995 inch) from the face of the power brake booster.
| Item | Part Number | Description |
|---|---|---|
| 1 | — | Shop Fabricated Gauge |
| 2 | — | Adjustment Screw (Part of 2005) |
| A | — | 24.89-25.27mm (0.980-0.995 Inch) |
| B | — | 25.27mm (0.995 Inch) |
| C | — | 19.05mm (0.75 Inch) |
| D | — | 74.61mm (2.94 Inch) |
Position the brake master cylinder assembly over the booster push rod and onto the two studs on the power brake booster.
Install the attaching nuts and tighten to 24-34 Nm (18-25 lb-ft).
Loosely connect the brake master cylinder outlet rear tube (2B253) and brake master cylinder connector tube (2A040) to the brake master cylinder.
Tighten the front master cylinder brake tube fitting to 22-28 Nm (16-21 lb-ft) and the rear master cylinder brake tube fitting to 15-20 Nm (11-15 lb-ft).
NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
Connect the battery ground cable.
Connect fluid level indicator switch.
Bleed the brake master cylinder. Refer to Service Procedures in this section.