Aerostar 2WD V6-245 4.0L (1990)
Brake Master Cylinder: Service and Repair
Master Cylinder Removal and Installation
Removal
1. Disconnect wiring harness from fluid level indicator switch in the cartridge master cylinder reservoir.
2. Disconnect brake lines from master cylinder.
3. Remove the two nuts that attach the cartridge master cylinder to the booster. Care should be employed when removing the cartridge master
cylinder to not scratch the exposed primary piston.
4. Discard fluid from cartridge master cylinder by turning over cartridge master cylinder and allowing fluid to pour through the filter opening of the
reservoir.
Caution: Never reuse any fluid removed from the brake system during any repair operation. Always discard old brake fluid and replenish system with
fresh brake fluid.
Installation
1. Make sure the interface seal is located ion the annular groove in the cartridge master cylinder body where the cartridge master cylinder seals with
the booster. DO NOT assemble cartridge master cylinder to booster without this square section interface seal.
2. Install cartridge master cylinder to booster. Use care to prevent scratching or other damage to exposed primary piston during handling. Make sure
the primary piston socket engages the booster push rod before tightening. Tighten retaining nuts to 17 - 27 Nm ( 12 - 20 ft lbs ).
3. Connect wiring harness to fluid level indicator switch.
4. Attach brake lines to master cylinder. Fill unit with clean brake fluid and bleed entire brake system to remove all entrapped air.
