SECTION 206-00: Brake System - General Information

SPECIFICATIONS

Material

Item Specification Fill

Capacity
Motorcraft® DOT 4 LV WSS-M6C65-A2 and -
High Performance Motor ISO 4925 Class 6
Vehicle Brake Fluid
PM-20

General Specifications

Item Specification
Front Brakes

cardiagn.com
Brake disc minimum thickness 23 mm (0.905 in)
Brake pad maximum taper wear (in any direction) 3.0 mm (0.118 in)
Brake pad minimum thickness 3.0 mm (0.118 in)
Rear Brakes
Brake disc minimum thickness 9354 in)
Brake pad minimum thickness 3.0 mm (0.118 in)

Torque Specifications

Description Nm lb-ft lb-in

Brake caliper bleeder screw (front) 8 - 71
Brake caliper bleeder screw (rear) 14 - 124
Master cylinder brake tube fittings 25 18 -
SECTION 206-00: Brake System - General Information
DIAGNOSIS AND TESTING

Brake System

Material

Item Specification
Motorcraft® DOT 4 LV WSS-M6C65-A2 and
High Performance Motor ISO 4925 Class 6
Vehicle Brake Fluid
PM-20

Preliminary Inspection

WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in
Section 100-00 . Failure to follow this instruction may result in serious personal injury.

cardiagn.com
NOTICE: Do not spiake fluid onto painted or plastic surfaces. If spilled, wipe up immediately before
damage to the painted or plastic surface occurs.

NOTE: Always check the fluid level in the brake master cylinder reservoir before carrying out the test
procedures. If the fluid level is not at the correct level, clean the reservoir cap before removing, then add
clean, specified brake fluid.

NOTE: Prior to carrying out any diagnosis, make sure the red brake warning indicator is functional. Refer to
Section 413-01 .

The first indication that something may be wrong in the brake system is a change in the feeling through the
brake pedal. The brake warning indicator in the Instrument Cluster (IC) and the brake fluid level in the brake
master cylinder reservoir are also indicators of system concerns.

If a wheel is locked and the vehicle must be moved, open a bleeder screw at the locked wheel to let out
enough fluid to relieve the pressure. Close the bleeder screw. If multiple wheels are locked, check the brake
pedal free play to verify brake pedal is not partially applied. These operations may release the brakes, but will
not correct the concern. If this does not relieve the locked wheel condition, repair the locked components
before proceeding.

Inspect all hoses and connections. All unused vacuum connectors should be capped. Make sure hoses and
their connections are correctly secured and in good condition with no holes, soft or collapsed areas.

1. Verify the customer concern.

• For parking brake concerns, refer to Section 206-05 .

• For ABS concerns, refer to Section 206-09 .
• For all other concerns, continue with the next step.

2. Visually inspect for obvious signs of mechanical or electrical damage.

 Visual Inspection Chart

Mechanical Electrical

• Brake master cylinder • Parking brake switch

• Brake master cylinder • Brake fluid level switch
reservoir • Wiring, terminals and
• Brake booster connectors
• Brake booster check
valve
• Brake booster vacuum
hose
• Brake hoses and tubes
• Brake caliper
• Brake caliper piston
seals
• Brake caliper guide
pins
• Brake disc
• Brake pads

cardiagn.com
• Brake pedal linkage
• Wheel bearings
• Tires

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.

4. If the cause is not visually evident, GO to Symptom Chart - Hydraulic Brake System or GO to
Symptom Chart - Noise, Vibration and Harshness (NVH) .

Symptom Chart - Brake System

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
Refer to Diagnostic Methods in Section 100-00 for information about these practices.

Symptom Chart - Brake System

Symptom Chart - NVH

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
Refer to Diagnostic Methods in Section 100-00 for information about these practices.

Symptom Chart - NVH

NOTE: NVH symptoms should be identified using the diagnostic tools that are available. For a list of these
tools, an explanation of their uses and a glossary of common terms, refer to Section 100-04 . Since it is
possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of
elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for
the symptom, refer back to Section 100-04 for the next likely system and continue diagnosis.
 ConditionPossible SourcesAction

• Vibration when the brakes are applied

• Brake disc(s)
• Suspension component(s)

• GO to Pinpoint Test A .

• Brake vibration/shudder - occurs when the brake pedal is released

• Brake drag

• GO to Symptom Chart - Brake System .

• Rattling noise

• Caliper guide pins or guide pin bolts

• CHECK the caliper guide pins and guide pin bolts. REFER to Brake System Inspection in this

cardiagn.com
section.

• Missing or damaged anti-rattle clips or springs

• CHECK the brake pads for missing clips or broken springs. INSTALL new components as necessary.
REFER to Section 206-03 for front disc brakes or Section 206-04 for rear disc brakes.

• Loose brake disc shield

• TIGHTEN the brake disc shield bolts to specification. REFER to Section 206-03 for front disc brakes
or Section 206-04 for rear disc brakes.

• Squealing noise - occurs on first (morng) brake application

• Brake pads

• Acceptable condition. Caused by humidity and low brake pad temperature.

• Squealing noise - a continuous squeal

• Brake pads

• INSPECT the brake pads. REFER to Brake System Inspection in this section.

• Squealing noise - an intermittent squeal

• Brake pads

• Acceptable condition. Caused by cold, heat, water, mud or snow.

• Groaning noise - occurs at low speeds with brake lightly applied (creeping)

• Brake pads
• Acceptable condition.

• Grinding/moaning noise - continuous

• Brake pads
• Brake disc

• INSPECT the brake pads, brake discs and attaching hardware for damage. VERIFY brake
components are within specifications. REFER to Brake System Inspection in this section.

cardiagn.com
SECTION 206-00: Brake System - General Information
GENERAL PROCEDURES

Brake System Inspection

Material

Item Specification
Metal Brake Parts Cleaner -
PM-4-A or PM-4-B (US); CPM-4
(Canada)
Silicone Brakeer Grease and ESE-M1C171-A
Dielectric Compound
XG-3-A

Brake Pads

cardiagn.com
NOTE: It is not required to install new brake pads when the brake discs are machined.

1. Inspect the brake pad friction material for contamination.

• If the friction material shows evidence of contamination, install new brake pads. For
additional information, refer to Section 206-03 for front brake pads or Section 206-04 for rear
brake pads.

2. Inspect and measure the thickness of the brake pad friction material. For additional information, refer
to Specifications in this section.
• Minor surface cracks do not require pad replacement, however, if there are missing chunks or
cracks in the lining through to the backing plate, install new brake pads. For additional
information, refer to Section 206-03 for front brake pads or Section 206-04 for rear brake
pads.
• If the thickness of the friction material is less than the specified thickness, install new brake
pads. For additional information, refer to Section 206-03 for front brake pads or Section
206-04 for rear brake pads.
• If the friction material shows taper wear that is not within specifications, install new brake
pads and verify the caliper guide pins are functioning correctly. For additional information,
refer to Brake Caliper Guide Pins inspection in this section.

Brake Discs

NOTICE: Using an impact tool without a torque socket will lead to unevenly tightened wheel nuts. This
causes brake disc on-vehicle lateral runout and brake roughness.

1. Inspect the brake discs and measure the brake disc thickness. Record the measurement, refer to
Specifications in this section.
• If the brake disc is cracked or otherwise damaged, install a new brake disc. For additional
information, refer to Section 206-03 for front brakes or Section 206-04 for rear brakes.
• If the measurement is below the minimum thickness specification, install a new brake disc.
For additional information, refer to Section 206-03 for front brakes or Section 206-04 for rear
brakes.
• If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that
 varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that
caused by pads worn down to the backing plate, should also be machined. In order to
machine, discs must be above the minimum thickness specification. For additional
information, refer to Specifications and Brake Disc Machining in this section.

Brake Calipers

1. Inspect the brake calipers for leaks, damage to seals and piston corrosion or binding.
• If the brake caliper is leaking or otherwise damaged, install a new brake caliper. For
additional information, refer to Section 206-03 for front brake calipers or Section 206-04 for
rear brake calipers.

Brake Caliper Guide Pins

1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper
wear or the guide pins are difficult to move, carry out the following steps.
• Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for
wear, damage and corrosion. If bore is worn or damaged, replace the damaged component.

cardiagn.com
• Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign
material from the caliper guide pin bores. Clean any remaining foreign material from the
bores with brake parts cleaner and compressed air.
• Assemble the caliper seals, boots and guide pins. Use an ample amount of the specified
grease to lubricate the bores and guide pins.
• Inspect the brake pads. For additional information, refer to Brake Pads inspection in this
section.

Brake Flexible Hoses and Tubes

NOTICE: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which may result in
brake tube failure.

NOTE: Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must
be correctly double flared to provide strong, leakproof connections. When bending tubing to fit the underbody
or rear axle contours, be careful not to kink or crack the tube.

1. Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage.
• If a section of the brake tube is damaged, the entire section must be installed with a new tube
of the same type, size, shape and length.
• When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to
specifications. After installation, bleed the brake system. For additional information, refer to
Brake System Bleeding in this section.

2. Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any other
signs of damage.
• Install a new brake flexible hose if the hose shows signs of softening, cracking or other
damage. For additional information, refer to Section 206-03 for the front brake flexible hose
or Section 206-04 for the rear brake flexible hose.

Brake Master Cylinder

NOTE: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder
reservoir will fall during brake application and rise during release. The returning brake fluid creates a slight
turbulence in the master cylinder reservoir. This is a normal condition and indicates that the compensator
ports are not clogged. Clogged compensator ports may cause the brakes to hang up or not fully release. The
net fluid level (such as after brake application and release) will remain unchanged. Fluid level will decrease
with pad wear.

NOTE: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This
results from the normal lubricating action of the master cylinder bore and seal.

1. Inspect the brake master cylinder for fluid leaks.

• Install a new master cylinder or brake fluid reservoir if signs of excessive leaking are present.
For additional information, refer to Section 206-06 .
• To check for correct brake master cylinder operation, refer to Component Tests in this
section.

Brake Booster

1. Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for leaks and

cardiagn.com
kinks.
• Install a new brake booster if signs of excessive corrosion or damage is found. For additional
information, refer to Section 206-07 .
• Repair or replace vacuum hoses as necessary.
• To check for correct brake booster operation, refer to Component Tests in this section.
SECTION 206-00: Brake System - General Information
GENERAL PROCEDURES

Brake Disc Machining

NOTE: Do not use a bench lathe to machine the brake discs. Use an on-vehicle brake lathe only. Read the
entire operating manual and/or view the video shipped with the lathe before installing, operating or repairing
the lathe.

NOTE: An on-vehicle brake lathe with an automatic runout adjustment feature is preferred. However, if the
lathe is not self adjusting, the lathe oscillation must be adjusted using a dial indicator. The total indicated
runout target is 0.000 mm (0.000 in). The maximum indicated runout should be no more than 0.050 mm
(0.002 in). If the runout adjustment (automatic or manual) is carried out correctly prior to machining, then the
final brake disc runout will be within specification, and a runout measurement is not necessary after
machining.

NOTE: Do not machine new brake discs.

NOTE: Lateral runout and disc thickness variation measurements are not required because correct adjustment
of the on-vehicle brake lathe will make sure that these dimensions are within specifications.

cardiagn.com
1. Remove the wheel and tire. For additional information, refer to Section 204-04A .

2. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose may
occur.

NOTE: It is not necessary to disconnect the brake tube from the brake caliper.

Remove the bolts and position the brake caliper or brake caliper and anchor plate assembly aside, as
required.

• Support the brake caliper using mechanic's wire.

3. Install the hub adapter using:

• four wheel nuts on a 4-stud wheel hub.
• five wheel nuts on a 5-stud wheel hub.
• six wheel nuts on a 6-stud wheel hub.
• four wheel nuts on a 7- or 8-stud wheel hub.
• five wheel nuts on a 10-stud wheel hub.

4. Install the cutting lathe.

5. If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. The total indicated
runout target is 0.000 mm (0.000 in). The maximum indicated runout should be no more than 0.050
mm (0.002 in).

6. Center the cutting head, adjust the cutting bits and install the chip deflector/silencer.

7. NOTE: The depth of the cut should be between 0.10 and 0.40 mm (0.004 and 0.015 in). Lighter cuts
will cause the bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface finish.

Machine the brake disc.

8. Remove the lathe and the silencer.

 9. Remove the wheel nuts and hub adapter.

10. Remove the metal shavings.

11. Measure the brake disc thickness.

• If the measurement is below the minimum specification, install a new brake disc. For
additional information, refer to Section 206-03 .

12. NOTE: It is not required to install new brake pads if friction material is within specifications. For
additional information, refer to Specifications in this section.

Position the brake caliper or brake caliper and anchor plate assembly.

• Install the bolts.

• For fastener torque specifications, refer to Section 206-03 .

13. Install the wheel and tire. For additional information, refer to Section 204-04A .

cardiagn.com
SECTION 206-00: Brake System - General Information
GENERAL PROCEDURES

Brake System Bleeding

Material

Item Specification
Motorcraft® DOT 4 LV WSS-M6C65-A2 and
High Performance Motor ISO 4925 Class 6
Vehicle Brake Fluid
PM-20

Pressure

WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in
Section 100-00 . Failure to follow this instruction may result in serious personal injury.

cardiagn.com
NOTICE: Do not sprake fluid on painted or plastic surfaces or damage to the surface may occur. If
brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

NOTE: Pressure bleeding the brake system is preferred to manual bleeding.

1. Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master
cylinder reservoir with clean, specified brake fluid.

2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of
pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter.

Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to
the fitting on the adapter.

3. NOTE: Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding
operation.

Open the valve on the bleeder tank.

• Apply 207-345 kPa (30-50 psi) to the brake system.

4. Remove the RH rear bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber
drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially
filled with clean, specified brake fluid.

5. NOTE: Due to the complexity of the fluid path within the rear integral parking brake calipers, it is
necessary to press and release the parking brake during the bleed procedure.

Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten
the RH rear bleeder screw.

• Press and release the parking brake 5 times.

• Repeat until clear, bubble-free fluid comes out.
 6. Tighten the RH rear bleeder screw to specification. Refer to Specifications in this section.
• Remove the rubber hose and install the bleeder screw cap.

7. Repeat Steps 5 and 6 for the LH rear brake caliper.

8. Continue bleeding the front of the system, going in order from the RH front brake caliper and then to
the LH front brake caliper.
• Tighten the front brake caliper bleeder screws to specification. Refer to Specifications in this
section.

9. Close the bleeder tank valve and release the pressure. Remove the tank hose from the adapter and
remove the adapter. Fill the reservoir with clean, specified brake fluid and install the reservoir cap.

Manual

WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in
Section 100-00 . Failure to follow this instruction may result in serious personal injury.

NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If

cardiagn.com
brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

NOTE: Pressure bleeding the brake system is preferred to manual bleeding.

1. Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master
cylinder reservoir with clean, specified brake fluid.

2. Have an assistant hold firm pressure on the brake pedal.

3. NOTE: Due to the complexity of the fluid path within the rear integral parking brake calipers, it is
necessary to press and release the parking brake during the bleed procedure.

Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the RH rear bleeder screw.

• Press and release the parking brake 5 times.

• Repeat until clear, bubble-free fluid comes out.
• Refill the brake master cylinder reservoir as necessary.

4. Tighten the RH rear bleeder screw to specification. Refer to Specifications in this section.
• Remove the rubber hose and install the bleeder screw cap.

5. Repeat Steps 2 through 5 for the LH rear brake caliper.

6. Remove the RH front bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber
drain tube to the RH front bleeder screw and submerge the free end of the tube in a container partially
filled with clean, specified brake fluid.

7. Have an assistant hold firm pressure on the brake pedal.

8. Loosen the RH front bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the RH front bleeder screw.
• Repeat until clear, bubble-free fluid comes out.
• Refill the brake master cylinder reservoir as necessary.
 9. Tighten the RH front bleeder screw to specification. Refer to Specifications in this section.
• Remove the rubber hose and install the bleeder screw cap.

10. Repeat Steps 7 through 10 for the LH front brake caliper bleeder screw.

cardiagn.com
SECTION 206-00: Brake System - General Information
GENERAL PROCEDURES

Component Bleeding

Material

Item Specification
Motorcraft® DOT 4 LV WSS-M6C65-A2 and
High Performance Motor ISO 4925 Class 6
Vehicle Brake Fluid
PM-20

Master Cylinder

WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in
Section 100-00 . Failure to follow this instruction may result in serious personal injury.

cardiagn.com
NOTICE: Do not sbrake fluid on painted or plastic surfaces or damage to the surface may occur. If
brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

NOTE: 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.

1. Disconnect the brake tubes from the master cylinder.

2. Install short brake tubes onto the primary and secondary ports with the ends submerged in the remote
brake fluid reservoir.

3. Fill the brake master cylinder reservoir with clean, specified brake fluid.

4. Have an assistant pump the brake pedal until clear fluid flows from the brake tubes without air
bubbles.

5. Remove the short brake tubes, and install the master cylinder brake tubes. Refer to Specifications in
this section.

6. Bleed the brake system. For additional information, refer to Brake System Bleeding in this section.

Brake Caliper

WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in
Section 100-00 . Failure to follow this instruction may result in serious personal injury.

NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If
brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was
disconnected.
 Remove the brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach
a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially
filled with clean, specified brake fluid.

2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.

3. NOTE: Due to the complexity of the fluid path within the rear integral parking brake calipers, it is
necessary to press and release the parking brake during the bleed procedure.

Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains
pressure on the brake pedal, tighten the bleeder screw.

• If bleeding a rear brake caliper, press and release the parking brake 5 times.
• Repeat until clear, bubble-free fluid comes out.
• Refill the brake master cylinder reservoir as necessary.

4. Tighten the brake caliper bleeder screw, remove the rubber hose and install the bleeder screw cap.
• Tighten the front brake caliper bleeder screws to specification. Refer to Specifications in this
section.
• Tighten the rear brake caliper bleeder screws to specification. Refer to Specifications in this

cardiagn.com
section.