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Brake Master Cylinder - 2.0L Duratec-RS (Zetec) RHD > < Hydraulic Brake Actuation

Focus RS 2003 (09.2002-)

Hydraulic Brake Actuation - Brake Pedal—2.0L Duratec-RS (Zetec) Focus RS 2003 (09/2002-)
Removal and Installation

Removal

All vehicles
  1. Detach the instrument panel lower panel from the instrument panel.
    1. Remove the retaining screws.
    1. Release the clip.

  1. Disconnect the data link (DLC) and footwell light (if equiped) electrical connectors.
    • Remove the instrument panel lower panel.

  1. Detach the pedal switches from the pedal bracket.
    1. Unlock the switches.
    1. Detach the switches.

  1. Remove the air duct (left-hand drive shown, right-hand drive similar).
    1. Remove the fastener.
    1. Remove the air duct.

  1. Remove the brake booster retaining nuts.

  1. Detach the brake booster actuating rod from the pedal.
    1. Depress the brake pedal.
    1. Depress the clip.
    1. Remove the brake booster actuator rod pin.
Right-hand drive vehicles
  1. Center the steering wheel.
    • Remove the ignition key and lock the steering wheel.

  1. Disconnect the steering column shaft from the steering gear pinion extension.
    • Discard the bolt.
All vehicles
  1. Detach the clutch master cylinder from the pedal bracket.
    1. Remove the retaining clip.
    1. Remove the retaining bolts.

  1. Detach the clutch master cylinder actuator rod from the clutch pedal.

  1. Remove the brake pedal retractor retaining bolt.
  1. Remove the brake pedal bracket from the vehicle.

  1. Detach the brake pedal bracket from the brake pedal retractor.
    1. Remove the retaining clips.
    1. Release the brake pedal.

Installation

All vehicles
  1. Attach the brake pedal, pedal bracket to the brake pedal retractor arm.
    1. Locate the brake pedal bracket fin under the brake pedal retractor arm rear pin.
    1. Locate the brake pedal over the brake pedal retractor arm front pin.

  1. Install the retaining clips.
  1. NOTE:
    NOTE:Make sure the brake pedal locates into the brake booster actuator rod clevis.
    Install the brake pedal bracket.

  1. NOTE:
    NOTE:Do not fully tighten at this stage.
    Install the brake booster retaining nuts.

  1. NOTE:
    NOTE:Do not fully tighten at this stage.
    Install the brake pedal retractor arm bolt.

  1. Attach the clutch master cylinder to the clutch pedal.

  1. NOTE:
    NOTE:Locate the clutch master cylinder into the pedal bracket holes.
    Attach the clutch master cylinder to the clutch pedal.
    1. Install the retaining bolts.
    1. Install the retaining clip.

  1. CAUTION:
    CAUTION:Install a new brake booster actuator rod pin.
    Install the brake booster actuator rod pin.
    1. Depress the brake pedal.
    1. Install the brake booster actuator rod pin.

  1. CAUTION:
    CAUTION:Make sure there is clearance between the brake pedal and the brake pedal retractor to allow free movement.
    Align the brake pedal and the brake pedal retractor to allow free movement.
    • Align the brake pedal retractor arm to the brake pedal bracket.

  1. Tighten the brake pedal bracket nuts.

  1. Tighten the brake pedal retractor arm bolt.
  1. With the engine running depress the brake pedal three times to make sure the brake pedal moves freely and returns to the full brake off position.

  1. Install the air duct (left-hand drive shown, right-hand drive similar).
    1. Install the air duct.
    1. Secure the fastener.
Right-hand drive vehicles
  1. WARNING:
    WARNING:Install a new pinch bolt. Failure to follow this instruction may result in personal injury.
    Connect the steering column to the steering gear pinion extension.
All vehicles
  1. Set the stoplight switch.
    • Pull the switch plunger out to its full extent.
  1. Depress the brake pedal.

  1. Attach the pedal switches to the pedal bracket.
    1. Attach the switches.
    1. Lock the switches in position.
  1. Slowly release the brake pedal.

  1. Connect the data link (DLC) and footwell light (if equiped) electrical connectors.

  1. Install the instrument panel lower panel.
    1. Secure the clip.
    1. Install the retaining screws.

Brake Master Cylinder - 2.0L Duratec-RS (Zetec) RHD > < Hydraulic Brake Actuation