Remove brake tubes from primary and secondary outlet ports of brake master cylinder (2140).
Disconnect brake fluid level warning switch connector.
Remove nut retaining cowl top inner panel tube (02206) to brake master cylinder
Disconnect cowl top inner panel tube from cowl and remove.
Remove two nuts retaining brake master cylinder to power brake booster assembly.
Slide brake master cylinder forward and upward from vehicle.
Position brake master cylinder on studs on power brake booster assembly.
Install retaining nuts. Tighten to 26-39 Nm (20-28 lb-ft).
Connect cowl top inner panel tube to cowl.
Install nut retaining cowl top inner panel tube to brake master cylinder and tighten to 21-29 Nm (16-21 lb-ft).
Install primary and secondary brake tubes to brake master cylinder outlet ports. Tighten to 16-20 Nm (12-14 lb-ft).
Connect brake fluid level warning switch connector.
Fill brake master cylinder reservoir (2K478) with specified brake fluid to MAX line to 4.0 mm (0.16 inch) below with High Performance DOT-3 Motor Vehicle Fluid C6AZ-19542-AB or DOT-3 equivalent meeting Ford specification ESA-M6C25-A, DOT-3.
Bleed brake system as described.
When any part of the hydraulic system has been disconnected for service, air may enter system and cause spongy pedal action. Bleed hydraulic system after it has been opened to make sure all air is expelled.
Brake Master Cylinder Bleeding
When a new brake master cylinder (2140) has been installed or the brake system emptied or partially emptied, fluid may not flow from the bleeder screws during normal bleeding. It may be necessary to prime system using the following procedure.
Use tubing wrench to remove the brake lines from brake master cylinder.
Install short brake lines in brake master cylinder and position them so they point back into reservoir and ends of pipes are submerged in brake fluid.
Fill reservoir with new High Performance DOT-3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT-3.
Cover reservoir with clean shop towel.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
Pump brakes until clear, bubble-free fluid comes out of both brake tubes.
Remove short brake tubes and reinstall brake tubes from vehicle.
Bleed each brake line at brake master cylinder using the following procedure:
If any brake lines or calipers have been removed, it may be helpful to prime system by gravity bleeding it. This should be done after brake master cylinder is primed and bled. To prime brake system:
After brake master cylinder and brake system have been primed and lines bled at brake master cylinder, normal brake system bleeding can resume at each wheel.
The primary and secondary (diagonal split) hydraulic brake systems are individual systems and are bled separately. Bleed longest line first on individual system being serviced. During complete bleeding operation, do not allow brake master cylinder reservoir to run dry. Keep master cylinder reservoir filled with High Performance DOT-3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25-A, DOT-3. Never reuse brake fluid that has been drained from hydraulic system or has been allowed to stand in open container for an extended period of time. \
To bleed brake system, position suitable box wrench on bleeder fitting on brake wheel cylinder. Attach rubber drain tube to bleeder fitting. The end of tube should fit snugly around bleeder fitting.
Submerge free end of the tube in container partially filled with clean brake fluid and loosen bleeder fitting approximately three-quarters of a turn.
Have assistant push brake pedal down slowly through its full travel. Close bleeder fitting and return the brake pedal to full release position. Repeat this operation until air bubbles cease to appear at submerged end of bleeder tube.
When fluid is completely free of air bubbles, secure bleeder fitting and remove bleeder tube.
Repeat this procedure for the opposite diagonal system. Refill brake master cylinder reservoir after each system is bled and install master cylinder reservoir cap and gasket. Make sure diaphragm-type gasket is properly positioned in master cylinder reservoir cap. When bleeding operation is completed, fluid level should be at MAX line to 4.0 mm (0.16 inch) below.
After disc brake service, make sure disc brake pistons are returned to their normal positions and shoe and lining assemblies are properly seated. This is accomplished by applying brake pedal several times until normal pedal travel is established.
Check pedal feel. If brake pedal feels spongy repeat bleed procedure.
For pressure bleeding, use bladder-type bleeder tank only, such as Rotunda Brake Bleeder 104-00064 or equivalent.
WARNING: NEVER EXCEED 344 KPA (50 PSI) PRESSURE IN THE BRAKE BLEEDER TO PREVENT INJURY.
Bleed longest lines first. The bleeder tank should contain enough new brake fluid to complete bleeding operation. Use High Performance DOT-3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent fluid meeting Ford specification ESA-M6C25-A, DOT-3. Never reuse brake fluid that has been drained from hydraulic system. The tank should be charged with approximately 69-206 kPa (10-30 psi) of air pressure.
Clean all dirt from master cylinder reservoir cap.
Remove brake master cylinder filler cap (2162). Fill the brake master cylinder reservoir with specified brake fluid. Install pressure bleeder adapter tool to brake master cylinder and attach bleeder tank hose to fitting on adapter. Master cylinder pressure bleeder adapter tools can be obtained from various manufacturers. Follow instructions of the manufacturer to install adapter.
If the rear disc brake calipers are to be bled, use a suitable box wrench on bleeder fitting at the RH rear disc brake caliper. Attach bleeder tube snugly around bleeder fitting.
Open valve on bleeder tank to admit pressurized brake fluid into brake mastercylinder reservoir.
Submerge free end of tube in container partially filled with clean brake fluid and loosen bleeder fitting.
When air bubbles cease to appear in fluid at submerged end of bleeder tube, close bleeder fitting. Remove tube. Replace rubber dust cap on bleeder screw.
Attach bleeder tube and repeat Steps 4, 5 and 6 at LH rear disc brake caliper.
On front brakes, repeat Steps 4, 5 and 6 starting at RH rear disc brake caliper and ending at LH disc brake caliper.
When bleeding operation is completed, close bleeder tank valve and remove tank hose from adapter fitting.
Remove pressure bleeder adapter tool from brake master cylinder. Fill the brakemaster cylinder reservoir to the MAX line to 4 mm (0.16 inch) below. Install brake master cylinder filler cap.
Anti-Lock Brake System Bleeding
The service ABS hydraulic control unit is supplied filled with brake fluid. Therefore, a conventional bleed procedure should be adequate to remove all air from the brake system. However, if a spongy pedal is present and air in hydraulic control unit is suspected, use the following procedure.
Using Rotunda New Generation Star (NGS) Tester 007-00500 or equivalent:
Bleed entire system conventionally using a manual or pressure bleed procedure as described.
Attach pressure bleeder as described. Connect Rotunda New Generation Star (NGS) Tester 007-00500 or equivalent to serial data link connector (DLC) below instrument panel as though retrieving codes.
Make sure ignition switch is in RUN position.
Follow instructions on NGS screen. Choose correct vehicle and model year, go to Diagnostic Data Link menu item, choose ABS Module, choose Function Tests and choose Service Bleed.
RF Caliper Bleed
Open RF caliper bleed screw.
Start bleed program on NGS tester.
Bleed at RF caliper for at least 2 minutes.
Close RF bleed screw and press the red trigger button on the NGS tester.
LF Caliper Bleed
Open LF caliper bleed screw.
Bleed at LF caliper for at least 2 minutes.
Close LF bleed screw and press the red Trigger button on the NGS tester.
LR Caliper Bleed
Open LR caliper bleed screw.
Bleed at LR caliper for at least 2 minutes.
Close LR bleed screw and press the red Trigger button on the NGS tester.
RR Caliper Bleed
Open RR caliper bleed screw.
Bleed at RR caliper for at least 2 minutes.
Close RR bleed screw and press the red Trigger button on the NGS tester.
Remove pressure supply, adjust brake fluid level in brake master cylinder reservoir and replace brake master cylinder filler cap.
Hi you will need a special scanner to bled the ABS system if you need more help please let me know thanks