Mercury F5AZ-2140-D Cylinder Assy - Master

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The brake master cylinders on the vehicles covered are rebuildable, but if assembled incorrectly or with the wrong rebuild kit seals, they may continue to leak after overhaul. Avoid honing the brake master cylinder bore as it may lead to improper fit with the rebuild kit. If the bore is seriously pitted or corroded, consider replacing it with a new or professionally rebuilt unit or consult an automotive machine shop. During removal, cover brake line fittings with rags and plug the ends of the lines to prevent contamination. Unplug the brake warning light connector, remove the brake master cylinder mounting nuts, and detach it from the brake booster or Hydro-Boost unit. Before overhauling, inspect and clean the brake master cylinder and components. If any corrosion or damage is found, replace the brake master cylinder body with a new one. Lubricate and install new reservoir grommets and diaphragm if applicable. Bench bleed the brake master cylinder before installation and carefully install it by following the reverse of the removal steps. Be sure to bleed the brakes after installation.

For the overhaul, mount the master cylinder in a vise, remove the pressure control valve, and extract the primary piston snap-ring and the primary and secondary piston assemblies. Clean the master cylinder body and components with brake system cleaner, avoiding petroleum-based solvents. Inspect the cylinder bore for corrosion and damage, replacing the body if needed. Lubricate new reservoir grommets with silicone grease and press them into the master cylinder body. Lay the reservoir on a hard surface and press the master cylinder body onto it. Lubricate the cylinder bore and piston assemblies with clean brake fluid, then insert the secondary piston assembly followed by the primary piston assembly. Install the snap-ring and, if equipped, the stop bolt with a new sealing washer. Inspect the reservoir cap and diaphragm, replacing damaged parts.

For the overhaul, mount the master cylinder in a vise, remove the pressure control valve, and extract the primary piston snap-ring and the primary and secondary piston assemblies. Clean the master cylinder body and components with brake system cleaner, avoiding petroleum-based solvents. Inspect the cylinder bore for corrosion and damage, replacing the body if needed. Lubricate new reservoir grommets with silicone grease and press them into the master cylinder body. Lay the reservoir on a hard surface and press the master cylinder body onto it. Lubricate the cylinder bore and piston assemblies with clean brake fluid, then insert the secondary piston assembly followed by the primary piston assembly. Install the snap-ring and, if equipped, the stop bolt with a new sealing washer. Inspect the reservoir cap and diaphragm, replacing damaged parts.