All about Ford Mondeo

Master cylinder - removal and refitting
Braking system / Master cylinder - removal and refitting

1 Disconnect the low fluid level warning light multi-plug from the fluid reservoir filler cap (see illustration). Unscrew and remove the cap (note that the filler cap should not be inverted). Draw off the hydraulic fluid from the reservoir, using an old battery hydrometer or a poultry baster. Do not syphon the fluid by mouth; it is poisonous. Any brake fluid spilt on paintwork should be washed off with clean water, without delay - brake fluid is also a highly-effective paint-stripper!

11.1 Brake fluid reservoir and low level warning light multi-plug
11.1 Brake fluid reservoir and low level warning light multi-plug

2 Identify the locations of each brake pipe on the master cylinder. On non-ABS models, there are four pipes; the two rear brake pipes are attached to PCR (pressure-conscious relief) valves on the master cylinder. On ABS models, there are only two pipes, which lead to the ABS hydraulic unit (see illustration).

11.2 Master cylinder connections
11.2 Master cylinder connections

A Non-ABS models
B ABS models
1 Brake fluid reservoir
2 Master cylinder
3 PCR valves for rear brakes 4 Primary brake hydraulic circuit (front right/rear left) 5 Secondary brake hydraulic circuit (front left/rear right)

3 Place rags beneath the master cylinder to catch spilt hydraulic fluid.

4 Clean around the hydraulic union nuts.

Unscrew the nuts, and disconnect the hydraulic lines from the master cylinder.

5 Unscrew the mounting nuts, and withdraw the master cylinder from the studs on the front of the servo unit. If the nuts are tight, a split ring spanner should be used in preference to an open-ended spanner. Plug or cap open unions, to keep dust and dirt out.

6 Recover the gasket from the master cylinder.

7 If the master cylinder is faulty, it must be renewed. At the time of writing, no overhaul kits were available.

8 Clean the contact surfaces of the master cylinder and servo.

9 Locate a new gasket on the master cylinder.

10 Position the master cylinder on the studs on the servo unit. Refit and tighten the nuts to the specified torque.

11 Carefully insert the hydraulic lines in the apertures in the master cylinder, then tighten the union nuts. Make sure that the nuts enter their threads correctly.

12 Fill the reservoir with fresh brake fluid.

13 Bleed the hydraulic system as described in Section 15.

14 Refit the reservoir filler cap, and reconnect the multi-plug for the low fluid level warning light.

15 Test the brakes carefully before returning the vehicle to normal service.

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