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

Removal

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

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

All vehicles

1. Remove the battery tray.
   Refer to: Battery Tray - 1.6L Duratec-16V Ti-VCT (88kW/120PS) – Sigma (414-01 Battery, Mounting and Cables, Removal and Installation).
   Refer to: Battery Tray - 1.6L EcoBoost (132kW/180PS) – Sigma (414-01 Battery, Mounting and Cables, Removal and Installation).
   

1. Disconnect the vacuum tube from the brake booster and detach the routing clip.
   

1. Disconnect the electrical connector, remove the screws and the headlamp assembly.
   

1. Remove the bolt and position the cowl vent panel upward.
   Torque: 19 lb.in (2.2 Nm)

1. Using a suitable suction device, remove the brake fluid from the remote reservoir and then remove the nuts.
   Torque: 62 lb.in (7 Nm)

1. Release the coupling and remove the remote brake fluid reservoir.
   

Vehicles with manual transmission

1. Release the coupling and disconnect the clutch master cylinder tube.
   

All vehicles

1. Disconnect the brake fluid level sensor electrical connector and the brake tube fittings.
   Torque: 150 lb.in (17 Nm)

1. NOTE: Before installing the master cylinder make sure a new brake booster-to-master cylinder O-ring is in place and the mating faces are clean.

   Remove the nuts and the brake master cylinder. Discard the nuts.
   Torque: 177 lb.in (20 Nm)

1. NOTICE: Take extra care when handling the component.

   Do not remove the brake master cylinder piston extension.
   

Installation

All vehicles

1. NOTE: This step is only necessary when installing a new component.

   Remove the plastic ties and the protective cap.
   

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).
     

Vehicles with manual transmission

1. Bleed the clutch system.
   Refer to: Clutch System Bleeding (308-02 Clutch Controls - 5-Speed Manual Transmission – B5/IB5/6-Speed Manual Transmission – B6, General Procedures).