Section 06-06: Brake System, Hydraulic
1994 Mustang Workshop Manual
DISASSEMBLY AND ASSEMBLY

Brake Master Cylinder

 

Disassembly

  1. Clean the outside of the brake master cylinder (2140) thoroughly. Remove the brake master cylinder filler cap (2162) . Drain all brake fluid from brake master cylinder . Always discard used brake fluid.

    NOTE: If brake master cylinder is to be put into vise to aid in disassembly, mount into vise by flange only to avoid damage to bore or brake master cylinder reservoir (2K478) areas.

  1. Depress the primary piston and remove snap ring from retaining groove at the open end of the bore.



  1. Remove primary and secondary piston assemblies from brake master cylinder . Tap open end of brake master cylinder on bench to remove pistons. If secondary piston does not readily come out, apply air pressure to secondary outlet port to assist removal.
  1. Remove brake master cylinder fluid control valve (2C161) as outlined.


Brake Master Cylinder and Reservoir Assembly





Item Part Number Description
1 2162 Brake Master Cylinder Filler Cap
2 2K478 Brake Master Cylinder Reservoir
3 — Brake Fluid Level Indicator Switch (Part of 2K478)
4 — Primary Piston Assy (Part of 2004)
5 — Snap Ring (Part of 2A032)
6 — Secondary Piston Assy (Part of 2A032)
7 2140 Brake Master Cylinder
8 2L074 Master Cylinder Reservoir Seal
9 2C161 Brake Master Cylinder Fluid Control Valve
 

Assembly

  1. Dip replacement piston assemblies in clean Heavy-Duty Brake Fluid C6AZ-19542-AA (ESA-M6C25-A) or DOT-3 equivalent, for lubrication prior to assembly into brake master cylinder .
  1. Install secondary (smaller) piston assembly into bore, spring end first.
  1. Install primary piston assembly, spring end first.
  1. Depress primary piston, and install snap ring.
  1. Fill and bleed brake master cylinder , and install plugs into outlet ports. Refer to Pressure Bleeding under Service Procedures.
  1. Install brake master cylinder filler cap on brake master cylinder reservoir , and secure.