Ford Freestar, Monterey 2004-2006

Master Cylinder


  1. This procedure requires the use of the following special tools or their equivalents: Worldwide Diagnostic System (WDS) and Vehicle Communication Module (VCM) with proper adapters or equivalent diagnostic scan tool.
    Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.

    Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.

    Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

    When any part of the hydraulic system has been disconnected for repair or installation of new components, air can enter the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment.

    When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from entering the system.

  3. For in-vehicle priming, disconnect the brake lines.
  5. For bench priming, mount the brake master cylinder in a vise.
  7. Install short brake tubes onto the primary and secondary ports with the ends submerged in the brake master cylinder reservoir.
  9. Fill the brake master cylinder reservoir with DOT 3 motor vehicle brake fluid.
  11. Have an assistant pump the brake pedal, or slowly press the primary piston until clear fluid flows from the brake tubes, without air bubbles.
  13. If the brake master cylinder has been primed at the bench, install it in the vehicle.
  15. Remove the short brake tubes, and install the master cylinder brake tubes. Tighten to 13 ft. lbs. (17 Nm).
  17. Bleed each brake tube at the brake master cylinder as follows:
    1. Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal.
    3. Loosen the rear-most brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting.
    5. Repeat this operation until clear, bubble-free fluid comes out.
    7. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube.