Maverick and Comet Repair
BRAKES - MASTER CYLINDER REMOVAL AND INSTALLATION
- Working from inside the car below the instrument panel, disconnect the master cylinder pushrod from the brake pedal assembly. The pushrod cannot be removed from the master cylinder.
- Disconnect the stoplight switch wires at the connector. Remove the spring retainer. Slide the stoplight switch off the brake pedal pin just far enough to clear the end of the pin, then lift and remove the switch from the pin. Take care not to damage the switch during removal.
- Loosen the master cylinder attaching nuts from inside the engine compartment. Slide the master cylinder pushrod, nylon washers and bushings off the brake pedal pin.
- Remove the brake tubes from the primary and secondary outlet ports of the master cylinder, and mark them for reassembly.
- Remove the locknuts and lockwashers securing the master cylinder to the dash and lift the cylinder forward and upward from the car.
- To install, position the rubber boot on the pushrod and secure the boot to the master cylinder. Carefully insert the boot through the dash panel opening and position the master cylinder and master cylinder mounting gasket (if so equipped) on the dash panel studs.
- Install the attaching nuts and leave them loose.
- Coat the nylon bushings with light (10W) engine oil. Install the nylon washer and bushing on the brake pedal pin.
- Position the spotlight switch and pushrod on the brake pedal pin. Install the nylon bushing and washer and secure them in position with the spring retainer.
- Connect the wires at the stoplight switch connector.
- Tighten the master cylinder attaching nuts and connect the brake lines at the master cylinder.
- Fill the master cylinder with fluid meeting SAE 70R3 or DOT 3 specifications to within 1/4 in. of the top of the dual reservoirs.
- Bleed the master cylinder and both the primary and secondary brake hydraulic systems as outlined under "Hydraulic System Bleeding."
- Centralize the pressure differential valve as outlined under "Differential Valve Centering."
- Operate the brakes several times and check for any leakage.