Ford 6W1Z-2140-AA Cylinder Assembly - Master

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To overhaul the brake master cylinder, first consider the availability and cost of a new or factory-rebuilt unit, as well as the availability of a rebuild kit. To begin removal, place rags under the brake line fittings and prepare to cover the line ends after disconnecting them to prevent brake fluid spillage. Unscrew the tube nuts at the ends of the brake lines using a flare-nut wrench, pull the lines slightly away from the brake master cylinder, and plug the ends. Disconnect the brake warning light electrical connector, remove the two mounting nuts, and detach the brake master cylinder from the vehicle. Remove the reservoir cap and discard any remaining fluid. For the overhaul process, mount the brake master cylinder in a vise, remove the pressure control valve, and extract the primary piston snap-ring and the primary and secondary piston assemblies. Clean the brake master cylinder body and components with brake system cleaner, avoiding petroleum-based solvents. Inspect the cylinder bore for corrosion and damage, replacing the body if needed. Lubricate new reservoir grommets with silicone grease and press them into the brake master cylinder body. Lay the reservoir on a hard surface and press the brake master cylinder body onto it. Lubricate the cylinder bore and piston assemblies with clean brake fluid, then insert the secondary piston assembly followed by the primary piston assembly. Install the snap-ring and, if equipped, the stop bolt with a new sealing washer. Inspect the reservoir cap and diaphragm, replacing damaged parts. To bleed the system efficiently, bench bleed the brake master cylinder by filling the reservoirs with brake fluid and using threaded plugs in the outlet holes to force air from the cylinder. Stroke the piston assemblies several times for each outlet, ensuring all air is expelled. Refill the reservoirs, install the diaphragm and cap assembly, and proceed with the brake master cylinder installation in reverse order, followed by brake bleeding.

To efficiently bleed the system, bench bleed the master cylinder by filling the reservoirs with brake fluid and using threaded plugs in the outlet holes to force air from the cylinder. Stroke the piston assemblies several times for each outlet, ensuring all air is expelled. Refill the reservoirs, install the diaphragm and cap assembly, and proceed with the master cylinder installation in reverse order, followed by brake bleeding.