Ford 7L1Z-2140-D Cylinder Assembly - Master

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To remove and overhaul the Brake Master Cylinder, begin by considering the availability and cost of a new or factory rebuilt unit, as well as the availability of a rebuild kit. Place rags under the brake line fittings and prepare caps or plastic bags to cover the ends of the lines when disconnecting them, taking care to avoid spilling brake fluid on painted surfaces. If the vehicle is equipped with cruise control, unplug the electrical connector from the brake pressure switch, and in 2005 and later Expedition/Navigator models, remove the air filter housing and degas bottle. Loosen the tube nuts at the ends of the brake lines where they enter the Brake Master Cylinder, using a flare-nut wrench to avoid rounding off the nuts. Pull the brake lines slightly away from the Brake Master Cylinder and plug the ends. Remove the two Brake Master Cylinder mounting nuts, turn the Brake Master Cylinder on its side, and unplug the electrical connector for the low fluid level warning switch. Remove the Brake Master Cylinder and discard any remaining fluid in the reservoir. To start the overhaul and installation process, pry the reservoir off the Brake Master Cylinder and remove the old reservoir grommets, replacing them if cracked or torn. Depress the primary piston, remove the snap-ring, and take out the fluid control valve and brake pressure switch if present. Remove the primary and secondary piston assemblies from the cylinder bore, potentially tapping the Brake Master Cylinder against a block of wood to expel the secondary piston. Thoroughly wash and inspect all parts, including the cylinder bore, pistons, and seals. Install new secondary piston seals with the lips facing away from each other, and lubricate the cylinder bore and piston assemblies with brake assembly lube or clean brake fluid before installing the pistons. Depress the primary piston, install the snap ring, and lubricate new reservoir grommets with brake fluid before pressing them into the Brake Master Cylinder body. Attach the diaphragm to the reservoir cover and ensure it's in good condition. If the Brake Master Cylinder is removed, the entire hydraulic system must be bled, and bench bleeding before installation can reduce bleeding time. Fill the reservoirs with brake fluid, support the Brake Master Cylinder to prevent spills, and hold fingers tightly over the holes where the brake lines connect to prevent air from entering as you stroke the piston to expel air. Carefully install the Brake Master Cylinder by reversing the removal steps and bleed the brake system to complete the process.

To remove and overhaul the Brake Master Cylinder, begin by considering the availability and cost of a new or factory rebuilt unit, as well as the availability of a rebuild kit. Place rags under the brake line fittings and prepare caps or plastic bags to cover the ends of the lines when disconnecting them, taking care to avoid spilling brake fluid on painted surfaces. If the vehicle is equipped with cruise control, unplug the electrical connector from the brake pressure switch, and in 2005 and later Expedition/Navigator models, remove the air filter housing and degas bottle. Loosen the tube nuts at the ends of the brake lines where they enter the Brake Master Cylinder, using a flare-nut wrench to avoid rounding off the nuts. Pull the brake lines slightly away from the Brake Master Cylinder and plug the ends. Remove the two Brake Master Cylinder mounting nuts, turn the Brake Master Cylinder on its side, and unplug the electrical connector for the low fluid level warning switch. Remove the Brake Master Cylinder and discard any remaining fluid in the reservoir. To start the overhaul and installation process, pry the reservoir off the Brake Master Cylinder and remove the old reservoir grommets, replacing them if cracked or torn. Depress the primary piston, remove the snap-ring, and take out the fluid control valve and brake pressure switch if present. Remove the primary and secondary piston assemblies from the cylinder bore, potentially tapping the Brake Master Cylinder against a block of wood to expel the secondary piston. Thoroughly wash and inspect all parts, including the cylinder bore, pistons, and seals. Install new secondary piston seals with the lips facing away from each other, and lubricate the cylinder bore and piston assemblies with brake assembly lube or clean brake fluid before installing the pistons. Depress the primary piston, install the snap ring, and lubricate new reservoir grommets with brake fluid before pressing them into the Brake Master Cylinder body. Attach the diaphragm to the reservoir cover and ensure it's in good condition. If the Brake Master Cylinder is removed, the entire hydraulic system must be bled, and bench bleeding before installation can reduce bleeding time. Fill the reservoirs with brake fluid, support the Brake Master Cylinder to prevent spills, and hold fingers tightly over the holes where the brake lines connect to prevent air from entering as you stroke the piston to expel air. Carefully install the Brake Master Cylinder by reversing the removal steps and bleed the brake system to complete the process.