Brake Master Cylinder - Removal and Installation

Removal

NOTICE: If fluid spills on the painted surface, the affected area must be washed immediately with cold water.

All vehicles

1. 1
   Remove the battery tray.
   Refer to: Battery Compartment - 1.6 L Duratec-16V Ti-VCT (88 kW/120 L hp) - Sigma (414-01 Battery, Mounting and Cables, Removal and Installation).
   Refer to: Battery Compartment - 1.6 L EcoBoost (132 kW/180 L hp) - Sigma (414-01 Battery, Mounting and Cables, Removal and Installation).
2. 2
   Disconnect the vacuum hose from the brake booster and disconnect the guide bracket.

   

3. 3
   Disconnect the electrical connector, remove the screws and the headlamp assembly.

   

4. 4
   Remove the bolt and rotate the cowl vent panel upward.
   Torque: 19 lb-in (2.2 N·m)

   

5. 5
   Using a suitable suction device, remove the brake fluid from the remote reservoir, then remove the nuts.
   Torque: 62 lb-in (7 N·m)

   

6. 6
   Disconnect the clip and remove the brake fluid remote reservoir.

   

Vehicles with manual transmission

7. Release the clip and disconnect the clutch master cylinder tube.

All vehicles

1. 1
   Disconnect the brake fluid level sensor electrical connector and the brake tube fittings.
   Torque: 150 lb-in (17 N·m)

   

2. 2
   Remove the nuts and the brake master cylinder. Discard the nuts.
   Torque: 177 lb-in (20 N·m)

   

3. 3

   NOTICE: Use extra care when handling the component.

   Do not remove the brake master cylinder piston extension.

   

Installation

All vehicles

1. 1
   Remove the plastic ties and the protective cap.

   

2. 2
   To install, reverse the removal procedure.
3. 3
   • If a new brake master cylinder was installed, bleed the master cylinder.
     Refer to: Component Bleeding (206-00 Brake System - General Information, General Procedures).

   • If the brake master cylinder was removed to access other components, bleed the brake system.
     Refer to: Depressurizing the Brake System (206-00 Brake System - General Information, General Procedures).

Vehicles with manual transmission

4. Bleed the clutch system.
   Refer to: Clutch System Bleeding (308-02 Clutch Controls - 5-Speed Manual Transmission; Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, General Procedures).