Ford Fusion: Hydraulic Brake Actuation / Brake Master Cylinder. Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

All vehicles

1. NOTICE: Before removing the master cylinder, relieve the vacuum in the brake booster or the master cylinder O-ring seal may be drawn into the brake booster, causing brake booster failure and increased brake pedal effort.

   Fully apply and release the brake pedal 5 times.
   

1. Disconnect the battery.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1.5L EcoBoost (118kW/160PS)/2.5L Duratec (125kW/170PS)

1. Disconnect the brake fluid level sensor electrical connector and detach the brake tube retainer.
   

2.0L EcoBoost (184kW/250PS) - MI4/2.7L EcoBoost (238kW/324PS)

1. Disconnect the brake fluid level sensor electrical connector and detach the wiring retainers.
   Torque: 18 lb.ft (25 Nm)

All vehicles

NOTE: 2.0L EcoBoost engine shown

1. NOTICE: If the brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.

   NOTICE: Make sure that all openings are sealed.

   Disconnect the brake tube fittings.
   Torque: 18 lb.ft (25 Nm)

1. NOTE: Make sure that the master cylinder-to-booster seal is removed with the master cylinder.

   Remove the nuts and the brake master cylinder. Discard the nuts.
   Torque: 18 lb.ft (25 Nm)

Installation

1. To install, reverse the removal procedure.
   

1. • If a new brake master cylinder has been 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: Brake System Pressure Bleeding (206-00 Brake System - General Information, General Procedures).