Section 06-06: Brake System, Hydraulic
1996 F-150, F-250, F-350, Bronco and F-Super Duty Workshop Manual
DISASSEMBLY AND ASSEMBLY

Brake Master Cylinder

 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.

Disassembly

  1. Remove the brake master cylinder (2140) from the vehicle.

  1. Clean the outside of the brake master cylinder. Remove the brake master cylinder filler cap (2162) and gasket. Drain and discard any brake fluid that remains in the brake master cylinder.

  1. If equipped, remove the brake master cylinder fluid control valve from the brake master cylinder.

  1. Remove stop-bolt from the bottom of the brake master cylinder.



    Brake Master Cylinder





    ItemPart NumberDescription
    12162Brake Master Cylinder Filler Cap
    2—Float (Part of 2L454)
    32L454Brake Master Cylinder Reservoir
    4—Brake Master Cylinder Grommets (Part of 2L454)
    52140Brake Master Cylinder
    6—Stop Bolt (Part of 2140)
    7—Primary Piston (Part of 2004)
    8—Snap Ring (Part of 2004)
    9—Secondary Piston
    (Part of 2004)
    102C161Brake Master Cylinder Fluid Control Valve

  1. Depress the primary piston and remove snap ring from retaining groove at the rear of the brake master cylinder bore.





  1. Remove primary piston assembly from the brake master cylinder bore. Discard assembly.

  1. Remove the secondary piston assembly by directing compressed air into the outlet port at the blind end of the bore while plugging the other outlet port. Discard assembly.

  1. Inspect the brake master cylinder bore for signs of etching, pitting, scoring or other damage.

    1. If bore is damaged, discard and replace with new brake master cylinder. Do not attempt to hone bore.
    1. If bore is not damaged, rebuild brake master cylinder using the proper repair kit and the procedure below.

Assembly

  1. Clean the brake master cylinder body with clean isopropyl alcohol to remove any contamination.

  1. Dip the repair kit piston assemblies in clean High-Performance DOT 3 Brake Fluid C6AZ-19542-AA or -BA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A to lubricate seals.

  1. Carefully insert the complete secondary piston assembly in the brake master cylinder bore.

  1. Carefully insert the primary piston assembly in the brake master cylinder bore.

  1. Depress the primary piston and install the snap ring in the groove in the brake master cylinder bore.

  1. Install the stop bolt into the bottom of the brake master cylinder.

  1. If equipped, install the brake master cylinder fluid control valve into the brake master cylinder.

  1. Install the brake master cylinder filler cap on the brake master cylinder reservoir.

  1. Install the brake master cylinder on vehicle.

  1. Bleed the brakes. Refer to Service Procedures in this section. Check for proper brake operation.