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

Brake Master Cylinder Reservoir

Removal

 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.

  1. Disconnect the battery ground cable (14301).

  1. Disconnect the brake warning lamp indicator wire from the plastic reservoir fluid level indicator socket. Using a suitable suction device, drain the brake fluid from the brake master cylinder (2140).





  1. Using a large screwdriver, pry between the brake master cylinder reservoir and the brake master cylinder and remove the brake master cylinder reservoir.

Installation

  1. NOTE: Whenever replacing the brake master cylinder reservoir, replace the grommets.

    Lubricate the two grommets included in Service Kit 2K478 with High-Performance DOT 3 Brake Fluid C6AZ-19542-AA or -BA or equivalent DOT 3 brake fluid meeting Ford specification ESA-M6C25-A. Insert the grommets into the brake master cylinder.

  1. Press the brake master cylinder reservoir into the grommets with the fluid level indicator socket facing outboard. The brake master cylinder reservoir should snap in place.

  1. Connect the brake warning lamp indicator wire to the fluid level indicator socket.

  1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

    Connect the battery ground cable.

  1. Fill the brake master cylinder reservoir with High-Performance DOT 3 Brake Fluid C6AZ-19542-AA or -BA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Bleed the system. Refer to Service Procedures in this section.

  1. After bleeding, fill brake master cylinder reservoir to 3.17mm (1/8 inch) from the top with Ford High-Performance DOT 3 Brake Fluid C6AZ-19542-AA or -BA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.