Ford F150 Pickup. Instruction — part 408

Fig. 96: Identifying Master Cylinder Ports
Courtesy of FORD MOTOR CO.

Inspection

Clean all parts with isopropyl alcohol and blow dry with compressed air. Ensure all ports and vents are open
and free of foreign matter. Inspect master cylinder bore and all parts for excessive wear or damage. If bore is
damaged, replace master cylinder.

Reassembly

1. Use clean High-Performance DOT 3 Brake Fluid (C6AZ-19542-AB), or equivalent DOT 3 fluid meeting

Ford specification ESA-M6C25-A, to lubricate the new piston assembly seals.

2. Carefully install the secondary piston assembly. See Fig. 97 .

3. Carefully install the primary piston assembly. See Fig. 98 .

4. Depress the primary piston. Install the snap ring. See Fig. 95 .

5. Install the brake master cylinder fluid control valve.

NOTE:

Manufacturer does not recommend honing cylinder bore.

2003 Ford Pickup F150

2002-04 BRAKES Disc & Drum - Blackwood, F150 Heritage Pickup & F150 Pickup

6. If equipped, install the brake pressure switch. See Fig. 93 .

7. Install the brake master cylinder.

8. Fill the brake master cylinder reservoir with High-Performance DOT 3 Brake Fluid (C6AZ-19542-AB),

or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A and install the brake master
cylinder filler cap.

9. Bleed the brake master cylinder and system as necessary. See COMPONENT BLEEDING or

BLEEDING BRAKE SYSTEM .

Fig. 97: Installing Secondary Piston Assembly
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

2002-04 BRAKES Disc & Drum - Blackwood, F150 Heritage Pickup & F150 Pickup

Fig. 98: Installing Primary Piston Assembly
Courtesy of FORD MOTOR CO.

WHEEL CYLINDERS

Disassembly

With wheel cylinder removed from vehicle, remove rubber boots from ends of cylinders. Remove pistons,
piston cups and return spring from cylinder. Remove bleeder screw. See Fig. 99 . Inspect cylinder bore for
damage.

2003 Ford Pickup F150

2002-04 BRAKES Disc & Drum - Blackwood, F150 Heritage Pickup & F150 Pickup

Fig. 99: Exploded View Of Rear Wheel Cylinder
Courtesy of FORD MOTOR CO.

Reassembly

If cylinder bore is lightly pitted or scratched, hone or replace as necessary. DO NOT hone cylinders more
than .003" (.08 mm). Coat all parts with clean brake fluid. To assemble, reverse disassembly procedure. Clamp
brake cylinder pistons against ends of cylinder.

TORQUE SPECIFICATIONS

BLACKWOOD

TORQUE SPECIFICATIONS (BLACKWOOD)

Application

Ft. Lbs. (N.m)

Adjustable Pedal Motor Cable

18 (24)

Brake Booster Nut

18 (24)

Brake Master Cylinder Nut

18 (24)

Brake Pedal Bracket Bolts & Nuts

18 (24)

2003 Ford Pickup F150

2002-04 BRAKES Disc & Drum - Blackwood, F150 Heritage Pickup & F150 Pickup