Brake System PDF

206-03-1 Front Disc Brake 206-03-1
REMOVAL AND INSTALLATION

Disc Brake System — Exploded View
4.0L SOHC and 4.6L (3V)
NOTE: LH shown, RH similar.
Item Part Number Description Item Part Number Description

1 — Brake caliper guide pin bolts 3 2001 Brake pads kit
(2 required) (part of 2B134, 4 — Spring clips (4 required) (part
also part of 2001) of 2001)
2 2C357 RH/ Brake caliper 5 W710233 Brake caliper anchor plate
2C358 LH bolts (2 required)
(Continued) (Continued)
Copyright  2006, Ford Motor Company

Last updated: 6/19/2006 2007 Mustang, Mustang GT 8/2006
REMOVAL AND INSTALLATION (Continued)
6 2B134 Brake caliper anchor plate 13 — Brake tube fittings
7 — Guide pins (part of 2B134) 14 N802191 Brake flexible hose bracket
8 1125 Brake disc bolts
9 W500020 Brake disc shield bolts (3 15 2078 RH/ Brake flexible hose
required) 2B557 LH
10 2K004 Brake disc shield 16 — Bleeder screw cap (part of
2208)
11 W712275 Brake caliper flow bolt
17 2208 Bleeder screw
12 W712362 Copper washers (2 required)
(Continued)
2007 Mustang, Mustang GT 8/2006

5.4L
NOTE: RH shown, LH similar

1 383609 Retaining nut 7 — Brake pad mounting pin (2
2 1125 Brake disc required) (part of 2B164)
3 2B220 RH/ Brake caliper 8 — Spring retainer clip (part of
2B221 LH 2K583)
4 W500020 Brake disc shield bolt (3 9 N802191 Brake hose-to-strut bolt
required) 10 W710233 Brake caliper bolt (2
5 2K004 Brake disc shield required)
6 2001 Brake pad (2 required) 11 — Brake tube fitting
(Continued)
(Continued)

Item Part Number Description 1. NOTE: A revised part, with the same base part
12 N802191 Brake hose bracket-to-body number, has been released for the RH brake
bolt hose. When installing a new RH brake hose,
13 2078 RH/ Brake flexible hose position the anti-rotation tab on the mounting
2B557 LH bracket toward the front of the vehicle and
14 W712362 Copper washer (2 required) install the bolt with the head toward the rear of
the vehicle.
15 W712275 Brake caliper flow bolt
For additional information, refer to the
procedures in this section.

206-09-1 Vehicle Dynamic Systems 206-09-1

Anti-Lock Brake System (ABS)
Module
Item Part Number Description

1 — Anti-lock brake system (ABS)
module electrical connector
(part of 14A005)
2 ZD061 ABS module screws (4
required)
3 2C219 ABS module

Removal and Installation 4. Remove the 4 screws and the ABS module.
• To install, tighten to 3 Nm (27 lb-in) in the
CAUTION: Electronic modules are sequence shown.
sensitive to electrical charges. The anti-lock
brake system (ABS) module can be damaged if
exposed to these charges.
1. Disconnect the battery ground cable. For

additional information, refer to Section 414-01.
2. Remove the air cleaner assembly. For additional

information, refer to Section 303-12.
3. Disconnect the ABS module electrical

connector.
5. To install, reverse the removal procedure.

DIAGNOSIS AND TESTING

Anti-Lock Control The ABS module is self-monitoring. When the
ignition switch is turned to the run position, the
Special Tool(s) ABS module does a preliminary electrical check
Vehicle Communication Module and, at approximately 12 km/h (8 mph), the pump
(VCM) and Integrated motor is turned on for approximately one
Diagnostic System (IDS) half-second. Any malfunction of the ABS causes
software with appropriate the ABS to shut OFF and the yellow ABS warning
hardware, or equivalent scan
indicator to illuminate, however normal power
tool
assisted braking remains.
The traction control system controls wheelspin by
73III Digital Multi-meter modulating engine torque and by applying and
105-R0057 or equivalent releasing the appropriate rear brake to restore
traction when driving on slippery or loose surfaces.
The traction control system can be disabled by
pressing the traction control switch and is indicated
by an indicator lamp in the traction control switch.
The traction control will reset and return to normal
Flex Probe Kit traction assist when the ignition switch is cycled or
418-F090 (105-R025B) or
equivalent when the traction control switch is pressed and
released a second time.
Inspection and Verification
1. Verify the customer concern.
2. Verify the stoplamps operate correctly by
Principles of Operation applying and releasing the brake pedal with the
The anti-lock brake system (ABS) module receives ignition switch in the OFF position. If the
wheel speed readings from each wheel speed sensor stoplamps do not operate correctly, refer to
and processes this information to determine if an Section 417-01. If the stoplamps operate
ABS event is necessary. The wheel speed sensor correctly, proceed to the next step.
electrically senses each tooth of the wheel speed 3. Visually inspect for obvious signs of
sensor indicators as it passes through the wheel mechanical or electrical damage:
speed sensor’s magnetic field.
Visual Inspection Chart
The ABS module continuously monitors and
compares the rotational speed of each wheel and, Mechanical Electrical
when it detects an impending wheel lock, modulates • Brake fluid level • Bussed electrical center
hydraulic brake pressure to the appropriate brake • Tire inflation (BEC) fuse(s):
caliper. This is accomplished by the ABS module • Wheel and tire sizes — 8 (40A)
triggering the hydraulic control unit (HCU) to open • Steering components — 65 (30A)
and suspension • Smart junction box
and close the appropriate solenoid valves. Once the
components (SJB) fuse 18 (10A)
affected wheel returns to normal speed, the ABS • Base brake system • Circuitry
module returns the solenoid valves to their normal • Wheel speed sensor ring • Brake fluid level switch
position and normal (base) braking resumes. • HCU • Stoplamp switch
• Wheel speed sensor
• Anti-lock brake system
(ABS) module
• Traction control switch
4. If an obvious cause for an observed or reported

concern is found, correct the cause (if possible)
before proceeding to the next step.
DIAGNOSIS AND TESTING (Continued)
5. NOTE: Make sure to use the latest scan tool • refer to Section 418-00 to diagnose no
software release. response from the powertrain control module
If the cause is not visually evident, connect the (PCM).
scan tool to the data link connector (DLC). 8. Carry out the network test.
6. NOTE: The vehicle communication module • If the scan tool responds with no
(VCM) LED prove out confirms power and communication for one or more modules,
ground from the DLC are provided to the refer to Section 418-00.
VCM. • If the network test passes, retrieve and
If the scan tool does not communicate with the record continuous memory diagnostic
VCM: trouble codes (DTCs).
• check the VCM connection to the vehicle. 9. Clear the continuous DTCs and carry out the
• check the scan tool connection to the VCM. self-test diagnostics for the anti-lock brake
system (ABS) module.
• refer to Section 418-00, No Power To The
Scan Tool, to diagnose no communication 10. If the DTCs retrieved are related to the concern,
with the scan tool. go to the Anti-Lock Brake System (ABS)
Module Diagnostic Trouble Code (DTC) Chart.
7. If the scan tool does not communicate with the For all other DTCs, refer to Section 419-10.
vehicle:
11. If no DTCs related to the concern are retrieved,
• verify the ignition key is in the ON position. GO to Symptom Chart.
• verify the scan tool operation with a known
good vehicle.
Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Chart
DTC Description Source Action
B1317 Battery Voltage High ABS Module GO to Pinpoint Test A.
B1318 Battery Voltage Low ABS Module GO to Pinpoint Test A.
B1342 ECU is Faulted ABS Module NOTE: If other DTCs are present, repair
them before installing a new module.
CLEAR the DTCs. RETRIEVE the
DTCs. If DTC B1342 is retrieved again,
INSTALL a new ABS module. REFER
to Anti-Lock Brake System (ABS)
Module in this section. REPEAT the
self-test.
C1093 Traction Control Disable Switch Circuit Instrument GO to Pinpoint Test H.
Failure Cluster
C1095 ABS Hydraulic Pump Motor Circuit ABS Module GO to Pinpoint Test B.
Failure
C1096 ABS Hydraulic Pump Motor Circuit ABS Module GO to Pinpoint Test B.
Open
C1115 ABS Power Relay Output Short Circuit ABS Module CLEAR all DTCs. DRIVE the vehicle. If
to Battery DTC C1115 is retrieved again, INSTALL
a new ABS module. REFER to
Anti-Lock Brake System (ABS) Module
in this section. CARRY OUT the
self-test with the brake pedal not
applied.
C1145 Wheel Speed Sensor RF Input Circuit ABS Module GO to Pinpoint Test C.
Failure

Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Chart (Continued)
C1155 Wheel Speed Sensor LF Input Circuit ABS Module GO to Pinpoint Test C.
Failure
C1165 Wheel Speed Sensor RR Input Circuit ABS Module GO to Pinpoint Test C.
Failure
C1175 Wheel Speed Sensor LR Input Circuit ABS Module GO to Pinpoint Test C.
Failure
C1185 ABS Power Relay Output Circuit Failure ABS Module CLEAR all DTCs. If DTC C1185 is
retrieved again, INSTALL a new ABS
module. REFER to Anti-Lock Brake
System (ABS) Module in this section.
CARRY OUT the self-test with the brake
pedal not applied.
C1194 ABS Outlet Valve Coil LF Circuit ABS Module CLEAR all DTCs. DRIVE the vehicle. If
Failure DTC C1194 is retrieved again, INSTALL
applied.
C1198 ABS Inlet Valve Coil LF Circuit Failure ABS Module CLEAR all DTCs. DRIVE the vehicle. If
DTC C1198 is retrieved again, INSTALL
a new ABS module. INSTALL a new
ABS module. REFER to Anti-Lock
Brake System (ABS) Module in this
section. CARRY OUT the self-test with
the brake pedal not applied.
C1210 ABS Outlet Valve Coil RF Circuit ABS Module CLEAR all DTCs. DRIVE the vehicle. If
C1214 ABS Inlet Valve Coil RF Circuit Failure ABS Module CLEAR all DTCs. DRIVE the vehicle. If
C1222 Wheel Speed Mismatch ABS Module GO to Pinpoint Test D.
C1233 Wheel Speed LF Input Signal Missing ABS Module GO to Pinpoint Test D.
C1234 Wheel Speed RF Input Signal Missing ABS Module GO to Pinpoint Test D.
C1235 Wheel Speed RR Input Signal Missing ABS Module GO to Pinpoint Test D.
C1236 Wheel Speed LR Input Signal Missing ABS Module GO to Pinpoint Test D.

C1242 ABS Outlet Valve Coil LR Circuit ABS Module CLEAR all DTCs. DRIVE the vehicle. If
C1246 ABS Outlet Valve Coil RR Circuit ABS Module CLEAR all DTCs. DRIVE the vehicle. If
C1250 ABS Inlet Valve Coil LR Circuit Failure ABS Module CLEAR all DTCs. DRIVE the vehicle. If
C1254 ABS Inlet Valve Coil RR Circuit Failure ABS Module CLEAR all DTCs. DRIVE the vehicle. If
C1329 ABS Valve Outlet Coil Over RF ABS Module CLEAR all DTCs. DRIVE the vehicle. If
Temperature DTC C1329 is retrieved again, INSTALL
applied.
C1330 ABS Valve Outlet Coil Over LR ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1331 ABS Valve Outlet Coil Over RR ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.

C1332 ABS Valve Outlet Coil Over LF ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1333 ABS Valve Inlet Coil Over RF ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1334 ABS Valve Inlet Coil Over LR ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1335 ABS Valve Inlet Coil Over RR ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1336 ABS Valve Inlet Coil Over LF ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1404 Traction Control Valve Rear Circuit ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1446 Brake Switch Circuit Failure ABS Module GO to Pinpoint Test F.
C1527 ABS TC Valve Inlet Coil Over ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.

C1531 ABS TC Valve Outlet Coil Over ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
C1730 Reference Voltage Out of Range (+5 V) ABS Module If any other DTC(s) are present,
DIAGNOSE those DTC(s) first. CLEAR
all DTCs. DRIVE the vehicle. If the
DTC is still present, INSTALL a new
C1958 ABS TC Valve Outlet Coil Failure ABS Module CLEAR all DTCs. DRIVE the vehicle. If
applied.
U0073 CAN Bus Off — Transmit Error ABS Module REFER to Section 418-00.
U1900 CAN Communication Bus Fault — ABS Module REFER to Section 418-00.
Receive Error
U2011 Module Transmitted Invalid Data ABS Module VERIFY powertrain control module
(PCM) configuration. If PCM is not
correctly configured, CONFIGURE the
PCM. If the PCM is correctly configured,
REFER to Section 418-00.
Symptom Chart
Symptom Chart
Condition Possible Sources Action
• No communication with the • Circuitry • Refer to Section 418-00 to
anti-lock brake system (ABS) • ABS module diagnose the no
module communications problem.
• No communication with the • Circuitry • Refer to Section 418-00 to
instrument cluster • Instrument cluster diagnose the no
communication problem.
• The red brake warning • Circuitry • Refer to Section 413-01 to
indicator does not self-check • Instrument cluster continue diagnosis of the red
brake warning indicator.
• The red brake warning • Base brake system • Refer to Section 413-01 to
indicator stays on when the • Circuitry continue diagnosis of the red
ignition is in RUN • Low brake fluid warning brake warning indicator.
switch
• Parking brake switch
• Anti-lock brake system (ABS)
module
• Instrument cluster

Symptom Chart (Continued)
• The yellow anti-lock brake • Circuitry • Refer to Section 413-01 to
system (ABS) warning • Instrument cluster continue diagnosis of the
indicator does not self-check yellow brake warning
indicator.
• Spongy/soft/low brake pedal • Air in brake hydraulic system • GO to Pinpoint Test F.
with no warning indicator • Base brake system
• Hydraulic control unit (HCU)
• Poor vehicle tracking during • Tire pressure • Refer to Section 206-00 to
anti-lock function • Air in the brake system continue diagnosis of the
• Base brake system brake system.
• Hydraulic control unit (HCU) • GO to Pinpoint Test G.
• The traction control is • Circuitry • Install a new ABS module.
inoperative • Traction control switch Refer to Anti-Lock Brake
• Anti-lock brake system (ABS) System (ABS) Module in this
module section.
• The traction control system • Circuitry • GO to Pinpoint Test H.
cannot be disabled • Traction control switch
module
• The traction control switch • Circuitry • GO to Pinpoint Test I.
indicator is never/always on • Traction control switch
module
Pinpoint Tests Possible Causes
Pinpoint Test A: DTCs B1317 and B1318 — • Fuse(s)

Battery Voltage High/Low • Circuit open
Refer to Wiring Diagrams Cell 42, Vehicle • Charging system
Dynamic Systems for schematic and connector • Anti-lock brake system (ABS) module
information.
Normal Operation
The vehicle electrical system voltage supplied is
within the range of 10-16 volts. Above or below
that voltage range, the DTC B1317 (Battery Voltage
High) or the DTC B1318 (Battery Voltage Low)
will be set.
Fused ignition voltage is supplied to the anti-lock
brake system (ABS) module from smart junction
box (SJB) fuse 18 (10A) along circuit 1844
(LG/RD), bussed electrical center (BEC) fuse 65
(30A) along circuit 601 (LB/BK) and BEC fuse 8
(40A) along circuit 534 (YE/LG). Ground is
provided along circuit 1205 (BK). There are 2
ground circuits, both share the same circuit number
and wire color.

PINPOINT TEST A: DTCs B1317 AND B1318 — BATTERY VOLTAGE HIGH/LOW
CAUTION: Use the Flex Probe Kit for all test connections to prevent damage to the
wiring terminals. Do not use standard multi-meter probes.
Test Step Result / Action to Take
A1 CHECK THE BATTERY VOLTAGE
• Measure the battery voltage between the positive and negative
battery terminals with: Yes
— the key ON and the engine OFF (KOEO). GO to A2.
— the engine running. No
• Is the battery voltage between 10 and 13 volts with KOEO, REFER to Section 414-00 to continue
and between 13 and 17 volts with the engine running? diagnosis of the charging system.
A2 CHECK VOLTAGE TO THE ABS MODULE
• Key in OFF position.
• Disconnect: ABS Module C135.
• Key in ON position.
• Measure the voltage between ground and:
— ABS module C135-2, circuit 601 (LB/PK), harness side.
— ABS module C135-32, circuit 1844 (LG/RD), harness side.
Yes
GO to A3.
No
VERIFY SJB fuse 18 (10A) is OK. If OK,
REPAIR circuit 1844 (LG/RD).
VERIFY BEC fuse 65 (30A) is OK. If OK,
REPAIR circuit 601 (LB/PK).
CLEAR the DTCs. CARRY OUT the
• Are the voltages greater than 10 volts? self-test with the brake pedal not applied.
A3 CHECK THE ABS MODULE GROUND
• Measure the resistance between ground and:
— ABS module C135-45, circuit 1205 (BK), harness side.
Yes
GO to A4.
No
REPAIR the affected circuit(s). REPEAT
• Are the resistances less than 5 ohms? the self-test.
(Continued)

PINPOINT TEST A: DTCs B1317 AND B1318 — BATTERY VOLTAGE HIGH/LOW (Continued)
A4 CHECK FOR CORRECT ABS MODULE OPERATION
• Disconnect: ABS Module C135. Yes
• Check for: INSTALL a new ABS module. REFER to
— corrosion. Anti-Lock Brake System (ABS) Module in
— spread terminals. this section. CLEAR the DTCs. REPEAT
— pushed-out pins. the self-test.
• Connect the ABS module connector and make sure it seats No
correctly. The system is operating correctly at this
• Operate the system and verify the concern is still present. time. The concern may have been caused
• Is the concern still present? by a loose or corroded connector. CLEAR
the DTCs. CARRY OUT the self-test with
Pinpoint Test B: DTCs C1095 and C1096 — Fused battery voltage is supplied from the bussed
ABS Hydraulic Pump Motor Circuit electrical center (BEC) fuse 8 (40A) along circuit
Failure/Open 534 (YE/LG). Ground is provided along circuit
Refer to Wiring Diagrams Cell 42, Vehicle 1205 (BK).
Dynamic Systems for schematic and connector Possible Causes
information.
• Fuse
Normal Operation
• Circuit open
Anti-lock brake system (ABS) diagnostic trouble
code (DTC) C1095 sets only when the motor is • Hydraulic pump motor
initially commanded on for 100 ms (+/-6 ms) and • Anti-lock brake system (ABS) module
the ABS hydraulic pump motor is then commanded
off and the voltage back is read after 6 ms. If the
voltage indicates the motor is spinning at less than
500 rpm, there may be a locked motor. If this
condition is detected 4 times, then a locked motor
DTC C1095 is set. The pump motor is checked for
an open circuit 2 seconds after the most recent
successful pump motor off command. If the pump
motor feedback remains greater than 0.75 volt for
more than 50 ms (+/-6 ms) after these conditions
have been met, then DTC C1096 is set.
PINPOINT TEST B: DTCs C1095 AND C1096 — ABS HYDRAULIC PUMP MOTOR CIRCUIT
FAILURE/OPEN
B1 CHECK THE ABS PUMP MOTOR
• Key in ON position. Yes
• Is the ABS pump motor running all the time? INSTALL a new ABS module and
hydraulic control unit (HCU). REFER to
and Hydraulic Control Unit (HCU) in this
section. CLEAR the DTCs. REPEAT the
ABS self-test.
No
GO to B2.
(Continued)

FAILURE/OPEN (Continued)
B2 CHECK THE PUMP MOTOR OPERATION
• Trigger the ABS module pump motor ON active command. Yes
• Does the ABS pump motor run for approximately 2 CLEAR the DTCs. CHECK the yellow ABS
seconds? warning indicator while driving the vehicle
(brakes must not be applied) above 32
km/h (20 mph). If the yellow ABS warning
indicator illuminates, RETRIEVE the
DTCs. If DTC C1096 is retrieved, GO to
B5.
If DTC C1095 is retrieved, INSTALL a new
HCU. REFER to Hydraulic Control Unit
(HCU) in this section. CLEAR the DTCs.
REPEAT the self-test.
No
TRIGGER the ABS module pump motor
OFF active command. GO to B3.
B3 CHECK CIRCUIT 534 (YE/LG) FOR AN OPEN
• Measure the voltage between ABS module C135-31, circuit 534
(YE/LG), harness side and ground.
Yes
GO to B4.
No
VERIFY BEC fuse 8 (40A) is OK. If OK,
REPAIR circuit 534 (YE/LG). CLEAR the
• Is the voltage greater than 10 volts? DTCs. REPEAT the self-test.
B4 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
• Measure the resistance between ground and:
Yes
REPAIR the affected circuit(s). CLEAR the
DTCs. REPEAT the self-test.
No
INSTALL a new HCU. REFER to Hydraulic
Control Unit (HCU) in this section. CLEAR
• Are the resistances greater than 10,000 ohms? the DTCs. REPEAT the self-test.
(Continued)

FAILURE/OPEN (Continued)
B5 CHECK FOR CORRECT ABS MODULE OPERATION
the DTCs. REPEAT the self-test.
Pinpoint Test C: DTCs C1145, C1155, C1165 Voltage and ground signals are supplied to the
and C1175 — Wheel Speed Sensor Input wheel speed sensors from the ABS module.
Circuit Failure
Possible Causes
Refer to Wiring Diagrams Cell 42, Vehicle
Dynamic Systems for schematic and connector • Circuit open
information. • Circuit shorted
Normal Operation • Wheel speed sensor
The active wheel speed sensors generate a square • Anti-lock brake system (ABS) module
wave signal that is sent to the anti-lock brake
system (ABS) module. The wheel speed sensor
circuitry connects to the ABS module through 2
wires and a connector at each wheel speed sensor.
When the ignition is turned to the run position, the
ABS module carries out a self-test by sending a
reference voltage to all of the wheel speed sensors
and their circuitry to determine if they are
functional.
PINPOINT TEST C: DTCs C1145, C1155, C1165 AND C1175 — WHEEL SPEED SENSOR INPUT CIRCUIT
FAILURE
C1 CHECK THE WHEEL SPEED SENSOR CIRCUITS FOR A SHORT
TO VOLTAGE
NOTE: Both circuits must be checked for each DTC.
• Disconnect: Suspect Wheel Speed Sensor.
• For DTC C1145, measure the voltage between:
— ABS module C135-26, circuit 514 (YE/RD), harness side
and ground.
— ABS module C135-27, circuit 516 (YE/BK), harness side
and ground.
— ABS module C135-13, circuit 522 (TN/BK), harness side
and ground.
— ABS module C135-12, circuit 521 (TN/OG), harness side
and ground.
— ABS module C135-44, circuit 524 (PK/BK), harness side
and ground.
— ABS module C135-43, circuit 523 (RD/PK), harness side
and ground.
(Continued)

FAILURE (Continued)
TO VOLTAGE (Continued)
— ABS module C135-42, circuit 518 (LG/RD), harness side Yes
and ground. REPAIR the affected circuit(s). CLEAR the
— ABS module C135-41, circuit 519 (LG/BK), harness side DTCs. REPEAT the self-test.
and ground. No
• Is voltage present? GO to C2.
TO GROUND
• For DTC C1145, measure the resistance between:
and ground.
and ground.
and ground.
and ground.
and ground.
and ground.
— ABS module C135-42, circuit 518 (LG/RD), harness side Yes
and ground. GO to C3.
— ABS module C135-41, circuit 519 (LG/BK), harness side No
and ground. REPAIR the affected circuit(s). CLEAR the
• Are the resistances greater than 10,000 ohms? DTCs. REPEAT the self-test.
C3 CHECK THE WHEEL SPEED SENSOR CIRCUITS FOR AN OPEN
and RH front wheel speed sensor C160-1, circuit 514
(YE/RD), harness side.
and RH front wheel speed sensor C160-2, circuit 516
(YE/BK), harness side.
and LH front wheel speed sensor C150-2, circuit 522
(TN/BK), harness side.
and LH front wheel speed sensor C150-1, circuit 521
(TN/OG), harness side.
and RH rear wheel speed sensor C3117-2, circuit 524
(PK/BK), harness side.
and RH rear wheel speed sensor C3117-1, circuit 523
(RD/PK), harness side.
— ABS module C135-42, circuit 518 (LG/RD), harness side
and LH rear wheel speed sensor C3116-1, circuit 518
(LG/RD), harness side. Yes
— ABS module C135-41, circuit 519 (LG/BK), harness side GO to C4.
and LH rear wheel speed sensor C3116-2, circuit 519 No
(LG/BK), harness side. REPAIR the affected circuit(s). CLEAR the
• Are the resistances less than 5 ohms? DTCs. REPEAT the self-test.
(Continued)

FAILURE (Continued)
C4 CHECK FOR SHORTED WHEEL SPEED SENSOR CIRCUITS
• Measure the resistance between the suspect wheel speed
sensor pins, harness side with the meter in the 10 mega ohm
range.
Yes
REPAIR the affected circuit(s). CLEAR the
No
• Is there any continuity? GO to C5.
C5 CHECK THE ABS MODULE OUTPUT
• Connect: ABS Module C135.
• Measure the voltage between the suspect wheel speed sensor
pins, harness side.
Yes
INSTALL a new wheel speed sensor.
REFER to Wheel Speed Sensor — Front
or Wheel Speed Sensor — Rear in this
self-test.
No
• Is the voltage greater than 10 volts? GO to C6.
C6 CHECK FOR CORRECT ABS MODULE OPERATION
Pinpoint Test D: DTCs C1222, C1233, C1234, Normal Operation

C1235 and C1236 — Wheel Speed Sensor The wheel speed sensor and sensor ring generate a
Input Signal Missing/Mismatch square wave signal to the anti-lock brake system
Refer to Wiring Diagrams Cell 42, Vehicle (ABS) module that is proportional to wheel speed.
Dynamic Systems for schematic and connector The ABS module compares wheel speed inputs
information. from all wheel speed sensors to determine an
impending wheel lockup. Incorrect tire size can set
these DTCs as well.
Possible Causes
• Wheel speed sensor
• ABS module
PINPOINT TEST D: DTCs C1222, C1233, C1234, C1235 AND C1236 — WHEEL SPEED SENSOR INPUT
SIGNAL MISSING/MISMATCH
D1 CHECK THE DTCs FROM THE SELF-TEST
• Retrieve the recorded results from the anti-lock brake system Yes
(ABS) module continuous and on-demand self tests. GO to Pinpoint Test C.
• Are DTCs C1145, C1155, C1165 or C1175 present? No
If DTC C1222 is present, GO to D3. All
others, GO to D2.
D2 CHECK THE WHEEL SPEED SENSOR OUTPUT
NOTE: The ignition switch must be in the OFF position until the
connections are made or a DTC will set and the ABS warning
indicator will illuminate, cutting voltage to the wheel speed sensors.
If this happens, turn the ignition switch to the OFF position and
make sure that no jumper connections are shorted to ground or
shorted together. Turn the ignition switch to the ON position and
wait for the ABS warning indicator to prove out.
• Disconnect: Suspect Wheel Speed Sensor.
• Connect a fused (5A) jumper wire between the suspect wheel
speed sensor, component side, and the wheel speed sensor,
harness side, as follows:
— For DTC C1233: LH front wheel speed sensor C150-1,
circuit 521 (TN/OG), harness side and LH front wheel speed
sensor C150 pin 1, circuit 521 (TN/OG), component side.
— For DTC C1234: RH front wheel speed sensor C160-1,
circuit 514 (YE/RD), harness side and RH front wheel speed
sensor C160 pin 1, circuit 514 (YE/RD), component side.
— For DTC C1235: RH rear wheel speed sensor C3117-1,
circuit 523 (RD/PK), harness side and RH rear wheel speed
sensor C3117 pin 1, circuit 523 (RD/PK), component side.
— For DTC C1236: LH rear wheel speed sensor C3116-1,
circuit 518 (LG/RD), harness side and LH rear wheel speed
sensor C3116 pin 1, circuit 518 (LG/RD), component side.
(Continued)

PINPOINT TEST D: DTCs C1222, C1233, C1234, C1235 AND C1236 — WHEEL SPEED SENSOR INPUT
SIGNAL MISSING/MISMATCH (Continued)
D2 CHECK THE WHEEL SPEED SENSOR OUTPUT (Continued)
• Connect a digital multi-meter between the suspect wheel speed
sensor, component side, and the wheel speed sensor, harness
side, as follows:
— For DTC C1233: LH front wheel speed sensor C150-2,
circuit 522 (TN/BK), harness side and LH front wheel speed
sensor C150 pin 2, circuit 522 (TN/BK), component side.
— For DTC C1234: RH front wheel speed sensor C160-2,
circuit 516 (YE/BK), harness side and RH front wheel speed
sensor C160 pin 2, circuit 516 (YE/BK), component side.
— For DTC C1235: RH rear wheel speed sensor C3117-2,
circuit 524 (PK/BK), harness side and RH rear wheel speed
sensor C3117 pin 2, circuit 524 (PK/BK), component side.
— For DTC C1236: LH rear wheel speed sensor C3116-2,
circuit 519 (LG/BK), harness side and LH rear wheel speed
sensor C3116 pin 2, circuit 519 (LG/BK), component side. Yes
• Key in ACCESSORY position. GO to D4.
• NOTE: The wheel must be moved very slowly to allow the meter No
to read the high and low current as the sensor tone ring INSTALL a new wheel speed sensor.
openings pass the sensor. REFER to Wheel Speed Sensor — Front
Measure the current while rotating the wheel slightly. or Wheel Speed Sensor — Rear in this
• Does the digital multi-meter switch between the low state section. CLEAR the DTC(s). REPEAT the
(5-8 mA) and the high state (11-18 mA)? self-test.
D3 CHECK FOR CORRECT ABS MODULE CONFIGURATION
OPERATION
NOTE: DTC C1222 indicates there is a problem with the Yes
configuration in the ABS module. GO to D4.
• Carry out the ABS module configuration. Verify the vehicle data No
matches the vehicle options. Refer to Section 418-01. The system is operating correctly at this
• Clear the DTCs and carry out the self-test. time. CLEAR the DTCs. REPEAT the
• Is DTC C1222 still present? self-test.
D4 CHECK FOR CORRECT ABS MODULE OPERATION
Pinpoint Test E: DTC C1446 — Brake Switch Possible Causes

Circuit Failure • Circuit shorted
Refer to Wiring Diagrams Cell 42, Vehicle • Brake pedal switch
Dynamic Systems for schematic and connector
information. • Brake fluid level sensor (master cylinder)
• Anti-lock brake system (ABS) module
Normal Operation
The anti-lock brake system (ABS) module receives
a voltage signal from the smart junction box (SJB)
along circuit 535 (LB/RD) through the brake pedal
switch. When the brake pedal is applied the voltage
signal is no longer referenced by the ABS module.
The SJB provides 5 volts to the brake fluid level
switch along circuit 547 (LG/YE). When the brake
fluid reaches a certain level, the switch closes and
the 5 volts are sent back to the SJB along circuit
512 (TN/LG).

PINPOINT TEST E: DTC C1446 — BRAKE SWITCH CIRCUIT FAILURE
E1 MONITOR THE SMART JUNCTION BOX (SJB) STOPLAMP
SWITCH PID
• Connect the scan tool. Yes
• Key in ON position. GO to E2.
• Press and release the brake pedal while monitoring the SJB No
stoplamp switch PID. For further diagnosis of the stoplamps,
• Do the stoplamps illuminate and does the PID agree? REFER to Section 417-01.
E2 MONITOR THE ANTI-LOCK BRAKE SYSTEM (ABS) MODULE
STOPLAMP SWITCH PID
• Press and release the brake pedal while monitoring the ABS Yes
module stoplamp switch PID and observing the stoplamps. GO to E3.
• Does the PID agree with the brake pedal position? No
REPAIR circuit 535 (LB/RD). CLEAR the
E3 CHECK THE BRAKE FLUID LEVEL SWITCH FOR A SHORT
• Key in OFF position. Yes
• Disconnect: Brake Fluid Level Switch C124. GO to E4.
• Clear the DTCs. No
• Perform the smart junction box (SJB) self test. Retrieve and INSTALL a new brake fluid reservoir.
record any DTCs. REFER to section Section 206-06.
• Did DTC C1446 return? CLEAR the DTCs. REPEAT the self-test.
E4 CHECK CIRCUIT 512 (TN/LG) FOR A SHORT TO VOLTAGE
• Disconnect: Smart Junction Box (SJB) C2280c. Yes
• Key in ON position. REPAIR circuit 512 (TN/LG). CLEAR the
• Measure the voltage between brake fluid level switch C124-2, DTCs. REPEAT the self-test.
circuit 512 (TN/LG), harness side and ground. No
• Is any voltage present? GO to E5.
E5 CHECK THE ABS MODULE CONNECTOR
• Key in OFF position. Yes
• Disconnect: ABS Module C135. INSTALL a new ABS module. REFER to
• Check the ABS module connector for: Anti-Lock Brake System (ABS) Module in
— corrosion. this section. CLEAR the DTCs. REPEAT
— spread terminals. No
• Connect: ABS Module C135. The system is operating correctly at this
• Make sure the ABS module connector seats correctly, then time. The concern may have been caused
operate the system and verify if the concern is still present. by a loose or corroded connector. CLEAR
• Is the concern still present? the DTCs. REPEAT the self-test with the
brake pedal not applied.
Pinpoint Test F: Spongy/Soft/Low Brake Possible Causes

Pedal with No Warning Indicator • Base brake system
Normal Operation • Hydraulic control unit (HCU)
The brake pedal should be firm when applied.
PINPOINT TEST F: SPONGY/SOFT/LOW BRAKE PEDAL WITH NO WARNING INDICATOR
F1 CHECK THE BASE BRAKE COMPONENTS
• Visually inspect the brake hoses and tubes from the hydraulic Yes
control unit (HCU) to the brake calipers. REPAIR or INSTALL new components as
• Visually inspect the calipers and brake components. necessary. TEST the system for normal
• Are any of these components damaged? operation.
No
GO to F2.
(Continued)

PINPOINT TEST F: SPONGY/SOFT/LOW BRAKE PEDAL WITH NO WARNING INDICATOR (Continued)
F2 CHECK FOR A LEAKING DUMP VALVE
• Remove the rubber boots from the 2 HCU low pressure
accumulators (LPA) and insert a clean steel implement (e.g.
paper clip or a small screwdriver) into each LPA.
• NOTE: A leaking dump valve is similar to the master cylinder Yes
bypass condition. It is important that the pedal be quickly and INSTALL a new HCU. REFER to Hydraulic
forcefully applied to rule out master cylinder bypass as a Control Unit (HCU) in this section.
condition. No
Have an assistant press hard on the brake pedal while REMOVE the steel implements. INSTALL
observing the steel implements. the rubber boots on each LPA. REFER to
• Do either of the implements move out 6.35 mm (0.25 in) or Section 206-00 to continue diagnosis of
more? the base brake system.
Pinpoint Test G: Poor Vehicle Tracking Fused ignition voltage is supplied by the smart
During Anti-lock Function junction box (SJB) through circuit 1844 (LG/RD)
Normal Operation and fused battery voltage is supplied by the bussed
The operating voltage required to supply the electrical center (BEC) through circuit 601 (LB/PK)
anti-lock brake system (ABS) module, hydraulic and circuit 534 (YE/LG). Ground is provided
pump and isolation valves is in a range between 10 through circuit 1205 (BK).
and 16 volts. Possible Causes
• Base brake system
• Hydraulic control unit (HCU)
PINPOINT TEST G: POOR VEHICLE TRACKING DURING ANTI-LOCK FUNCTION
G1 BLEED THE BRAKE SYSTEM
• Bleed the brake system using the scan tool. Refer to Section Yes
206-00. The brake system is operating correctly.
• Test drive the vehicle. The concern may have been caused by
• Does the vehicle track correctly? air in the hydraulic system or a sticky
valve.
No
GO to G2.
G2 CHECK THE ABS INLET VALVE (CLOSED POSITION)
• Rotate all the wheels to make sure they rotate freely (the TRIGGER the LF INLET OFF active
transmission must be in NEUTRAL). command. GO to G3.
• Trigger the ABS module LF INLET ON active command. No
• Apply moderate brake pedal effort. INSTALL a new HCU. REFER to Hydraulic
• Have an assistant attempt to rotate the LF wheel. Control Unit (HCU) in this section. TEST
• Does the LF wheel rotate? the system for normal operation.
(Continued)

PINPOINT TEST G: POOR VEHICLE TRACKING DURING ANTI-LOCK FUNCTION (Continued)
G3 CHECK THE ABS INLET VALVE (OPEN POSITION)
• Apply moderate brake pedal effort. Yes
• Have an assistant attempt to rotate the LF wheel. INSTALL a new HCU. REFER to Hydraulic
• Does the LF wheel rotate? Control Unit (HCU) in this section. TEST
the system for normal operation.
No
GO to G4.
G4 CHECK THE ABS OUTPUT VALVE (OPEN POSITION)
• Apply moderate brake pedal effort.
• Trigger ABS module LF INLET ON active command.
• Trigger ABS module ABS POWER ON active command (turns
on the pump motor) for 6 seconds. (The trigger must be pressed Yes
3 times. Each press runs the pump for 2 seconds.) TRIGGER all active commands OFF. GO
• Trigger the ABS module LF OUTLET ON active command, then to G5.
trigger the ABS module LF OUTLET OFF active command. No
Repeat 3 times. INSTALL a new HCU. REFER to Hydraulic
• Have an assistant attempt to rotate the LF wheel. Control Unit (HCU) in this section. TEST
• Does the LF wheel rotate? the system for normal operation.
G5 CHECK THE ABS INLET AND OUTLET VALVES (CLOSED
POSITION)
• Apply moderate brake pedal effort. Yes
• Have an assistant attempt to rotate the LF wheel. INSTALL a new HCU. REFER to Hydraulic
• Does the LF wheel rotate? Control Unit (HCU) in this section. TEST
the system for normal operation.
No
REPEAT this procedure (beginning with
Step H2) for the RF, LR and RR wheels
using the appropriate active commands. If
no failure occurs, the system is operating
normally.
Pinpoint Test H: DTC C1093 — Traction Possible Causes

Control Disable Switch Circuit Failure and/or • Circuit open
the Traction Control System Cannot be
Disabled • Circuit shorted
Refer to Wiring Diagrams Cell 60, Instrument • Traction control switch
Cluster for schematic and connector information. • Anti-lock brake system (ABS) module
Normal Operation • Instrument cluster
Engine torque modulation is achieved by regulating
fuel and spark to the cylinders. The traction control
system operates using the anti-lock brake system
(ABS) module to interact with the powertrain
control module (PCM) to reduce engine torque and
apply the brakes if the wheels lose traction and
begin to spin during acceleration.
The instrument cluster circuit 1412 (WH/PK)
monitors for a ground (change of state). When the
traction control switch is pressed, a momentary
ground occurs through circuit 1205 (BK). The
instrument cluster then sends a voltage to the
traction control switch through circuit 939 (VT)
illuminating the traction control switch and
disabling the system.

PINPOINT TEST H: DTC C1093 — TRACTION CONTROL DISABLE SWITCH CIRCUIT FAILURE AND/OR
THE TRACTION CONTROL SYSTEM CANNOT BE DISABLED
H1 MONITOR THE INSTRUMENT CLUSTER PID
• Monitor the instrument cluster traction control switch status PID GO to H6.
while pressing the traction control disable switch repeatedly. No
• Does the PID agree with the switch position? GO to H2.
H2 CHECK THE TRACTION CONTROL SWITCH INPUT
• Disconnect: Instrument Cluster C220.
• Measure the resistance between instrument cluster C220-20,
circuit 1412 (WH/PK), harness side and ground while pressing
and releasing the traction control switch.
Yes
GO to H3.
No
INSTALL a new traction control switch.
REFER to Traction Control Switch in this
• Is the resistance less than 5 ohms with the switch pressed section. CLEAR the DTCs. REPEAT the
and greater than 10,000 ohms with the switch released? self-test.
H3 CHECK CIRCUIT 1412 (WH/PK) FOR A SHORT TO GROUND
• Disconnect: Traction Control Switch C2039.
• Measure the resistance between traction control switch C2039-7,
circuit 1412 (WH/PK), harness side and ground.
Yes
REPAIR circuit 1412 (WH/PK). CLEAR the
No
• Is the resistance less than 5 ohms? GO to H4.
(Continued)

PINPOINT TEST H: DTC C1093 — TRACTION CONTROL DISABLE SWITCH CIRCUIT FAILURE AND/OR
THE TRACTION CONTROL SYSTEM CANNOT BE DISABLED (Continued)
H4 CHECK CIRCUIT 1412 (WH/PK) FOR AN OPEN
circuit 1412 (WH/PK), harness side and traction control switch
C2039-7, circuit 1412 (WH/PK), harness side.
Yes
REPAIR circuit 1412 (WH/PK). CLEAR the
No
• Is the resistance greater than 10,000 ohms? GO to H5.
H5 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
• Measure the resistance between traction control switch C2039-1,
circuit 1205 (BK), harness side and ground.
Yes
REPAIR circuit 1205 (BK). CLEAR the
No
INSTALL a new traction control switch.
REFER toTraction Control Switch in this
• Is the resistance greater than 10,000 ohms? self-test.
H6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
• Disconnect: Instrument Cluster C220. Yes
• Check for: INSTALL a new instrument cluster.
— corrosion. REFER to Section 413-01. CLEAR the
— spread terminals. DTCs. REPEAT the self-test.
— pushed-out pins. No
• Connect the instrument cluster connector and make sure it seats The system is operating correctly at this
correctly. time. The concern may have been caused
• Operate the system and verify the concern is still present. by a loose or corroded connector. CLEAR
• Is the concern still present? the DTCs. REPEAT the self-test.
Pinpoint Test I: The Traction Control Switch Normal Operation

Indicator is Never/Always On The instrument cluster circuit 1412 (WH/PK)
Refer to Wiring Diagrams Cell 42, Vehicle monitors for a ground (change of state). When the
Dynamic Systems for schematic and connector traction control switch is pressed momentary ground
information. occurs through circuit 1205 (BK). The instrument
cluster then sends a voltage to the traction control
switch through circuit 939 (VT) illuminating the
traction control switch and disabling the system.

Possible Causes
• Circuit open
• Circuit shorted
• Traction control switch
PINPOINT TEST I: THE TRACTION CONTROL SWITCH INDICATOR IS NEVER/ALWAYS ON
I1 VERIFY THE TRACTION CONTROL SYSTEM OPERATION
• Operate the system and verify the traction control system can be Yes
enabled and disabled. GO to I2.
• Does the traction control system operate correctly? No
REFER to symptom chart to continue
diagnosis.
I2 CHECK CIRCUIT 939 (VT) FOR VOLTAGE
• Disconnect: Traction Control Switch C2039.
• Measure the voltage between traction control switch C2039-4,
circuit 939 (VT), harness side and ground.
Yes
GO to I3.
No
• Is voltage present? GO to I4.
I3 CHECK CIRCUIT 939 (VT) FOR A SHORT TO VOLTAGE
• Measure the voltage between traction control switch C2039-4,
circuit 939 (VT), harness side and ground.
Yes
REPAIR circuit 939 (VT). TEST the
system for normal operation.
No
• Is voltage present? GO to I6.
(Continued)

PINPOINT TEST I: THE TRACTION CONTROL SWITCH INDICATOR IS NEVER/ALWAYS ON (Continued)
I4 CHECK CIRCUIT 939 (VT) FOR AN OPEN OR SHORT TO
GROUND
circuit 939 (VT), harness side and:
— traction control switch C2039-4, circuit 939 (VT), harness
side.
— ground.
Yes
REPAIR circuit 939 (VT). TEST the
• Is the resistance greater than 10,000 ohms between the system for normal operation.
instrument cluster and the traction control switch, and less No
than 5 ohms between the instrument cluster and ground? GO to I5.
I5 CHECK THE INSTRUMENT CLUSTER OPERATION
• Connect: Traction Control Switch C2039.
• Connect a fused (10A) jumper wire between instrument cluster
C220-21, circuit 939 (VT), harness side and instrument cluster
C220-3, circuit 1001 (WH/YE), harness side.
Yes
Remove the jumper wire. GO to I6.
No
Remove the jumper wire. INSTALL a new
traction control switch. REFER to Traction
Control Switch in this section. CLEAR the
• Does the traction control switch indicator illuminate? DTCs. REPEAT the self-test.
I6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
• Disconnect: Instrument Cluster C220. Yes
— spread terminals. DTCs. REPEAT the self-test.
— pushed-out pins. No
• Connect the instrument cluster connector and make sure it seats The system is operating correctly at this
• Operate the system and verify the concern is still present. by a loose or corroded connector. CLEAR

DESCRIPTION AND OPERATION

Anti-Lock Control • Rear wheel speed sensors
• Rear wheel speed sensor rings
Anti-Lock Brake System (ABS) with
Traction Control • Traction control switch
The anti-lock brake system (ABS) consists of the • Traction control switch indicator
following components: • Trac off indicator
• Hydraulic control unit (HCU) • Yellow ABS warning indicator
• ABS module
• Front wheel speed sensors
• Front wheel speed sensors rings

206-07-1 Power Brake Actuation 206-07-1

Brake Booster

1 9C482 Brake booster vacuum hose 5 2N513 Brake booster rod pin
2 — Brake booster vacuum check 6 13480 Stop lamp switch
valve (part of 2B195) 7 9C872 Speed deactivation switch
3 2475 Redundant self-locking clip 8 W520112-S440 Brake booster nuts (4
cover required)
4 380699-S100 Self-locking clip 9 2B195 Brake booster
(Continued)

Removal and Installation 4. NOTE: Do not apply the brake pedal during
the removal or installation of the speed
1. Remove the brake master cylinder. For deactivation switch.
additional information, refer to Section 206-06. Disconnect the electrical connector and remove
the speed deactivation switch.
2. Disconnect the brake booster vacuum hose from
the brake booster vacuum check valve. 5. Remove the redundant self-locking pin cover,
self-locking pin and the booster rod pin.
3. NOTE: Do not apply the brake pedal during
the removal or installation of the stop lamp 6. Remove the 4 brake booster nuts.
switch.
• To install, tighten to 25 Nm (18 lb-ft).
Disconnect the electrical connector and remove
the stop lamp switch. 7. Remove the brake booster assembly from the
vehicle.


Brake Booster • is divided into separate chambers by the
diaphragms.
The vacuum type power brake booster:
• will not operate if vacuum fails.
• is a dual diaphragm, vacuum assisted power brake
booster. • is installed as an assembly.
• reduces brake pedal force and travel distance. If the power assist fails, the brake system continues
to operate with increased brake pedal effort.
• is located on the LH side of the cowl in the
engine compartment, between the brake pedal and
the brake master cylinder.


Brake Caliper — 4.0L SOHC and 4.6L 1. With the vehicle in NEUTRAL, position it on a
(3V) hoist. For additional information, refer to
Section 100-02.
Material
2. Remove the brake caliper flow bolt and discard
Item Specification the 2 copper washers.
High Performance DOT 3 ESA-M6C25-A or
Motor Vehicle Brake Fluid WSS-M6C62-A 3. CAUTION: Do not use the caliper
PM-1 or PM-1-C (US); sight hole to retract pistons as this can
CPM-1 or CPM-1-C
(Canada) damage the pistons and boots.
Remove and discard the 2 brake caliper guide
Removal pin bolts and remove the brake caliper.
WARNING: Use of any other than 4. Inspect the brake caliper.

approved DOT 3 motor vehicle brake fluid will • If leaks or damaged boots are found, install
cause permanent damage to brake components a new brake caliper.
and will render the brakes inoperative. Failure to
follow these instructions may result in personal Installation
injury.
1. Position the brake caliper and install 2 new
WARNING: Carefully read cautionary guide pin bolts.
information on product label. For EMERGENCY • Tighten to 34 Nm (25 lb-ft).
MEDICAL INFORMATION seek medical advice.
In the USA or Canada on Ford/Motorcraft 2. Using 2 new copper washers, position the brake
products call: 1-800-959-3673. For additional flexible hose on the brake caliper and install the
information, consult the product Material Safety brake caliper flow bolt.
Data Sheet (MSDS) if available. Failure to follow
these instructions may result in personal injury. • Tighten to 40 Nm (30 lb-ft).
3. Bleed the brakes. For additional information,

CAUTION: Brake fluid is harmful to
refer to Section 206-00.
painted and plastic surfaces. If brake fluid is
spilled onto a painted or plastic surface,
4. Test the brakes for normal operation.
immediately wash it with water.


Brake Caliper — 5.4L 1. With the vehicle in NEUTRAL, position it on a
hoist. For additional information, refer to
Material Section 100-02.
Item Specification 2. Remove the brake pads. For additional
High Performance DOT 3 ESA-M6C25-A or information, refer to Brake Pads — 5.4L in this
Motor Vehicle Brake Fluid WSS-M6C62-A section.
PM-1 or PM-1-C (US);
CPM-1 or CPM-1-C 3. Remove the brake caliper flow bolt and discard
(Canada)
the 2 copper washers.
Removal and Installation • To install, tighten to 48 Nm (35 lb-ft).
WARNING: Use of any other than 4. CAUTION: Do not remove the bolts
approved DOT 3 motor vehicle brake fluid will securing the 2 caliper halves together. Do not
cause permanent damage to brake components attempt to separate the 2 caliper halves.
and will render the brakes inoperative. Failure to Remove the 2 brake caliper anchor plate bolts
follow these instructions may result in personal and the brake caliper.
injury.
WARNING: Carefully read cautionary
information on product label. For EMERGENCY
MEDICAL INFORMATION seek medical advice. • Bleed the brakes. For additional information,
In the USA or Canada on Ford/Motorcraft refer to Section 206-00.
products call: 1-800-959-3673. For additional • Test the brakes for normal operation.
information, consult the product Material Safety
these instructions may result in personal injury.



Brake Caliper Anchor Plate — 4.0L 2. NOTE: Clean any residual thread lock
SOHC and 4.6L (3V) compound from the anchor plate threads before
installing the bolts.
Material Remove and discard the 2 anchor plate bolts
and remove the brake caliper anchor plate.
Item Specification
Silicone Brake Caliper ESE-M1C171-A
Grease and Dielectric
Compound 3. Inspect the brake caliper anchor plate assembly.
XG-3-A • Check the guide pins and boots for binding
and damage.
Removal and Installation
• Replace worn or damaged pins. Lubricate
1. Remove the brake pads. For additional the pins with the specified grease.
information, refer to Brake Pads — 4.0L SOHC • Install a new brake caliper anchor plate if it
and 4.6L (3V) in this section. is worn or damaged.

206-04-1 Rear Disc Brake 206-04-1

Brake Caliper Anchor Plate Installation
Material 1. CAUTION: In order for the brake

Item Specification caliper anchor plate bolts to attain the
proper clamp load when installed, the
Metal Brake Parts Cleaner —
PM-4-A or PM-4-B (US); residual thread lock compound must be
CPM-4 (Canada) cleaned out of the bolt threads of the anchor
plate.
Removal Clean any residual thread lock compound, and
any other foreign material, from the threads of
1. Remove the brake pads. For additional the brake caliper anchor plate.
information, refer to Brake Pads in this section.
2. Position the brake caliper anchor plate and
2. Remove the 2 brake caliper anchor plate bolts install 2 new anchor plate bolts.
and the brake caliper.
• Tighten to 103 Nm (76 lb-ft).
• Discard the bolts.
3. Install the brake pads. For additional
information, refer to Brake Pads in this section.

206-04-1 Rear Disc Brake 206-04-1

Brake Caliper Support Bracket 3. NOTE: Make sure the anti-moan bracket holes,
the brake caliper support bracket and the brake
Removal and Installation caliper anchor plate holes line up during
installation.
1. Remove the rear axle shaft. For additional Remove the anti-moan bracket.
information, refer to Section 205-02A or • To install, tighten to 35 Nm (26 lb-ft).
Section 205-02B.
4. Remove the 4 brake caliper support bracket
2. Remove the 3 bolts and the brake disc shield. nuts, bolts and the bracket.
• To install, tighten to 20 Nm (15 lb-ft). • To install, tighten to 68 Nm (50 lb-ft).

206-04-1 Rear Disc Brake 206-04-1

Brake Caliper
Material
Item Specification
Motor Vehicle Brake Fluid WSS-M6C62-A
CPM-1 or CPM-1-C
(Canada)
Removal
WARNING: Use of any other than

approved DOT 3 motor vehicle brake fluid will 3. Remove the brake caliper flow bolt and discard
cause permanent damage to brake components the 2 copper washers.
4. Remove the 2 brake caliper guide pin bolts and
follow these instructions may result in personal
the brake caliper.
injury.
5. Inspect the brake caliper.
information on product label. For EMERGENCY • If leaks or a damaged piston boot are found,
MEDICAL INFORMATION seek medical advice. install a new brake caliper.
In the USA or Canada on Ford/Motorcraft
Installation
products call: 1-800-959-3673. For additional
Data Sheet (MSDS) if available. Failure to follow 1. Position the brake caliper and install the 2
these instructions may result in personal injury. brake caliper guide pin bolts until snug.
• Tighten the RH caliper guide pin bolts in
CAUTION: Brake fluid is harmful to the following sequence:
painted and plastic surfaces. If brake fluid is X Tighten the top bolt to 33 Nm (24 lb-ft).
immediately wash it with water. X Tighten the bottom bolt to 33 Nm (24
lb-ft).
1. With the vehicle in NEUTRAL, position it on a • Tighten the LH caliper guide pin bolts in
hoist. For additional information, refer to the following sequence:
Section 100-02. X Tighten the bottom bolt to 33 Nm (24
lb-ft).
2. Remove the retaining clip and the parking brake
cable and conduit from the brake caliper. X Tighten the top bolt to 33 Nm (24 lb-ft).
2. Using 2 new copper washers, position the front

brake hose on the brake caliper and install the
flow bolt.
3. Connect the parking brake cable and conduit to

the brake caliper.
• Install the retaining clip.

206-04-2 Rear Disc Brake 206-04-2
4. Bleed the caliper. For additional information,
refer to Section 206-00.

206-00-1 Brake System — General Information 206-00-1
GENERAL PROCEDURES
Brake Disc Machining 2. For vehicles with a 2-piece brake disc and hub
assembly:
Material 1 Mark the brake disc and the wheel stud for
Item Specification correct indexing during re-assembly.
High Temperature Nickel ESE-M12A4-A 2 Remove the brake disc from the hub.
Anti-Seize Lubricant 3 CAUTION: Do not use an abrasive
XL-2 (US); CXG-2-B
(Canada) sanding disc since it will remove paint or
other protective finishes from the wheel
PM-4-A or PM-4-B (US); or metal from the mounting surfaces,
CPM-4 (Canada) adversely affecting corrosion protection
and brake disc lateral runout.
CAUTION: Do not use a bench lathe to Remove corrosion from the wheel mounting
machine the brake discs. surface, both disc mounting surfaces and
hub mounting surface.
NOTE: Read the entire operating manual and view
the video shipped with the lathe before installing, 4 Align the match marks and install the brake
operating or repairing the lathe. disc on the hub.
NOTE: If the thickness of the brake disc is less 3. Machine the brake disc using an on-vehicle
than the minimum thickness to machine brake lathe.
specification, install a new brake disc. This will 1 Install the hub adapter and silencer belt if
make sure that the brake disc will be above necessary.
minimum thickness after machining.
2 Install the cutting lathe.
NOTE: Do not machine new brake discs. 3 If the lathe is not self adjusting, adjust the
lathe oscillation using a dial indicator. Total
NOTE: Lateral runout and disc thickness variation indicated reading (TIR) target is 0.000 mm
measurements are not required because correct (0.000 in), maximum is 0.08 mm (0.003 in).
adjustment of the on-vehicle brake lathe will make
4 Center the cutting head, adjust the cutting
sure that these dimensions are within specifications.
bits and install the chip deflector.
1. NOTE: It is not necessary to disconnect the 5 NOTE: The depth of cut should be between
brake line from the brake caliper. 0.10 and 0.20 mm (0.004 and 0.008 in).
Position the brake caliper and brake caliper Lighter cuts will cause the bit to heat up
anchor bracket aside. For additional and wear faster. Heavier cuts will cause
information, refer to Section 206-03 for front poor brake disc surface finish.
brake discs or Section 206-04 for rear brake Machine the brake disc.
discs. 6 Remove the lathe and, if installed, the
silencer belt.
7 Remove the hub adapter.
4. Remove the metal shavings.

GENERAL PROCEDURES (Continued)
5. For vehicles with a 2-piece brake disc and hub 6. NOTE: It is not required to install new brake
assembly: pads if friction material properties are within
1 Remove the brake disc from the hub. guidelines. For additional information, refer to
Brake Pads in this section.
2 Remove metal shavings from the hub, the
brake disc mounting surfaces and from the Install the brake caliper and brake caliper
ABS sensors. anchor bracket. For additional information, refer
to Section 206-03 for front brake discs or
3 Apply anti-seize lubricant to the hub Section 206-04 for rear brake discs.
mounting surface to prevent corrosion.
4 Align the match marks and install the brake
disc on the hub.

206-04-1 Rear Disc Brake 206-04-1

Brake Disc Shield
1. Remove the brake disc. For additional

information, refer to Brake Disc in this section.
2. Remove the 3 bolts and the brake disc shield.



Brake Disc Shield
1. Remove the brake disc. For additional

information, refer to Brake Disc in this section.
2. Remove the 3 bolts and the brake disc shield.


206-04-1 Rear Disc Brake 206-04-1

Brake Disc 3. Remove the brake disc.
Installation
Material
Item Specification 1. Clean any rust or foreign material from the
High Temperature Nickel ESE-M12A4-A brake disc and the wheel hub.
Anti-Seize Lubricant
XL-2 (US); CXG-2-B • Use brake parts cleaner to clean the brake
(Canada) disc and hub surfaces.
PM-4-A or PM-4-B (US); 2. CAUTION: In order for the brake
CPM-4 (Canada) caliper anchor plate bolts to attain the
proper clamp load when installed, the
Removal residual thread lock compound must be
cleaned out of the bolt threads of the anchor
1. With the vehicle in NEUTRAL, position it on a plate.
Clean any residual thread lock compound, and
Section 100-02.
any other foreign material, from the threads of
the brake caliper anchor plate.
2. CAUTION: Care must be used when
servicing rear brake components without
3. CAUTION: Do not allow the lubricant
disconnecting the parking brake cable from
to make contact with the wheel studs, brake
the brake caliper lever. Carefully position the
pads or brake disc.
caliper aside using a suitable support or
damage to the parking brake cable end Apply a thin coat of anti-seize lubricant to the
fittings can occur. hub flange.
CAUTION: Do not allow the brake 4. Position the brake disc onto the wheel hub.
caliper and anchor plate assembly to hang
from the brake hose or damage to the hose 5. Position the brake caliper anchor plate and
can occur. install 2 new anchor plate bolts.
Remove and discard the 2 anchor plate bolts • Tighten to 103 Nm (76 lb-ft).
and position the brake caliper anchor plate and
brake caliper assembly aside. 6. Test the brakes for normal operation.
• Support the caliper using mechanic’s wire.


Brake Disc
Material
Item Specification
High Temperature Nickel ESE-M12A4-A
Anti-Seize Lubricant
XL-2 (US); CXG-2-B
(Canada)
PM-4-A or PM-4-B (US);
CPM-4 (Canada)
Removal
4. Remove the brake disc.
4.0L SOHC and 4.6L (3V) equipped vehicles
Installation
1. CAUTION: Do not allow the brake All vehicles

caliper, brake pads and anchor plate
assembly to hang from the brake hose or
damage to the hose can occur. 1. CAUTION: Do not use an abrasive
sanding disc since it will remove paint or
Remove and discard the 2 brake caliper anchor other protective finishes from the wheel or
plate bolts and position the brake caliper, brake metal from the mounting surfaces, adversely
pads and anchor plate aside as an assembly. affecting corrosion protection and brake disc
• Support the brake caliper, brake pads and lateral runout.
anchor plate assembly using mechanic’s Remove corrosion from the wheel mounting
wire. surfaces, both disc mounting surfaces and hub
mounting surfaces.
5.4L equipped vehicles
• Use brake parts cleaner to clean the brake
disc and hub surfaces.
2. CAUTION: Do not allow the brake
caliper assembly to hang from the brake • Apply anti-seize lubricant to the hub
hose or damage to the hose can occur. mounting surfaces to prevent future
corrosion.
Remove and discard the 2 brake caliper bolts
and position the caliper assembly aside. 2. Install the brake disc.
• Support the caliper assembly using
mechanic’s wire. 4.0L SOHC and 4.6L (3V) equipped vehicles
All vehicles 3. NOTE: Clean any residual thread lock

compound from the anchor plate threads before
3. If equipped, remove and discard the retainer installing the bolts.
nuts. Position the brake caliper, brake pads and
anchor plate assembly.
• Install 2 new brake caliper anchor plate
bolts and tighten to 115 Nm (85 lb-ft).

5.4L equipped vehicles
4. Position the brake caliper assembly and install 2

new caliper bolts.
• Tighten the bolts to 115 Nm (85 lb-ft).

206-04-1 Rear Disc Brake 206-04-1

Brake Flexible Hose 1. Remove the brake caliper flow bolt and discard
Material • To install, tighten to 40 Nm (30 lb-ft).
Item Specification
2. Disconnect the brake tube fitting from the brake
High Performance DOT 3 ESA-M6C25-A or flexible hose.
Motor Vehicle Brake Fluid WSS-M6C62-A)
PM-1 or PM-1-C (US); • To install, tighten to 17 Nm (13 lb-ft).
CPM-1 or CPM-1-C
(Canada) 3. Remove the bracket bolt and the brake hose.

approved DOT 3 motor vehicle brake fluid will • Bleed the brake caliper. For additional
cause permanent damage to brake components information, refer to Section 206-00.
injury.




Brake Flexible Hose 1. Remove the brake caliper flow bolt and discard
Material • To install, tighten to 40 Nm (30 lb-ft).
Item Specification
2. Disconnect the brake tube fitting from the brake
High Performance DOT 3 ESA-M6C25-A or flexible hose.
PM-1 or PM-1-C (US); • To install, tighten to 17 Nm (13 lb-ft).
CPM-1 or CPM-1-C
(Canada) 3. Remove the 2 bracket bolts and the brake
flexible hose.
WARNING: Use of any other than 4. To install, reverse the removal procedure.
approved DOT 3 motor vehicle brake fluid will
cause permanent damage to brake components • Bleed the brake system. For additional
and will render the brakes inoperative. Failure to information, refer to Section 206-00.
injury.

these instructions may result in personal injury


206-06-1 Hydraulic Brake Actuation 206-06-1

Brake Fluid Reservoir
Material
Item Specification
CPM-1 or CPM-1-C
(Canada)
NOTE: Automatic transmission shown, all others similar.

1 2462 Brake fluid reservoir pin
2 — Brake fluid reservoir seals (2
required) (part of 2422)
3 2422 Brake fluid reservoir

Removal and Installation CAUTION: Brake fluid is harmful to
WARNING: Use of any other than spilled onto a painted or plastic surface,
approved DOT 3 brake fluid will cause immediately wash it with water.
permanent damage to brake components and will
render the brakes inoperative. Failure to follow 1. Using a suitable tool, remove the brake fluid
these instructions may result in personal injury. from the brake fluid reservoir.
WARNING: Carefully read cautionary 2. Remove the brake fluid reservoir pin.
information on product label. For additional • To install, tighten to 8 Nm (71 lb-in).
information, see product Material Safety Data
Sheet (MSDS). For 24-hour MEDICAL 3. NOTE: Use new seals provided with a new
EMERGENCY INFORMATION on brake fluid reservoir.
Ford/Motorcraft products call: 1-800-959-3673 Remove the brake fluid reservoir and discard
(FORD). Failure to follow these instructions may the seals.
result in personal injury.
• When installing the brake fluid reservoir,
lubricate the new seals with brake fluid.


Brake Master Cylinder
Material
Item Specification
CPM-1 or CPM-1-C
(Canada)
NOTE: Automatic transmission and ABS shown, all others similar.

1 — Brake tube fittings 3 N808159 Brake master cylinder nut (2
2 — Brake fluid level sensor required)
electrical connector 4 2A032 Brake master cylinder
(Continued)

Removal and Installation 5.4L equipped vehicles
WARNING: Use of any other than 2. If equipped, remove the suction accumulator.
approved DOT 3 motor vehicle brake fluid will For additional information, refer to Section
cause permanent damage to brake components 412-01.
follow these instructions may result in personal All vehicles
injury.
3. Disconnect the brake fluid sensor electrical
WARNING: Carefully read cautionary connector.
information on product label. For additional
information, see product Material Safety Data 4. If equipped with a manual transmission, remove
Sheet (MSDS). For 24-hour MEDICAL the clutch hose clamp and disconnect the clutch
EMERGENCY INFORMATION on hose from the brake fluid reservoir.
Ford/Motorcraft products call: 1-800-959-3673
(FORD). Failure to follow these instructions may 5. NOTE: Cap the brake lines and plug the master
result in personal injury. cylinder ports.
Disconnect the 2 brake tubes from the master
CAUTION: Brake fluid is harmful to cylinder.
6. Remove and discard the 2 nuts and remove the
All vehicles brake master cylinder.
• To install, tighten 25 Nm (18 lb-ft).
additional information, refer to Section 414-01. 7. To install, reverse the removal procedure.
• Bleed the master cylinder. For additional
information, refer to Section 206-00 in this
section.


Brake Pads — 4.0L SOHC and 4.6L 3. CAUTION: Do not use the caliper
(3V) sight hole to retract pistons as this can
damage the pistons and boots.
Material CAUTION: Do not allow the brake
Item Specification caliper, brake pads and anchor plate
High Performance DOT 3 ESA-M6C25-A or assembly to hang from the brake hose or
Motor Vehicle Brake Fluid WSS-M6C62-A damage to the hose can occur.
PM-1 or PM-1-C (US); Remove and discard the 2 brake caliper guide
CPM-1 or CPM-1-C
(Canada) pin bolts and position the brake caliper aside.
Metal Brake Parts Cleaner — • Support the brake caliper using mechanic’s
PM-4-A or PM-4-B (US); wire.
CPM-4 (Canada)
Silicone Brake Caliper ESE-M1C171-A 4. CAUTION: Install new brake pads if
Grease and Dielectric worn past the specified thickness above the
Compound metal backing plate or rivets. Install brake
XG-3-A
pads in complete axle sets.
Removal Remove the brake pads and discard the 4 spring
clips.
approved DOT 3 motor vehicle brake fluid will 5. Inspect the brake caliper.
cause permanent damage to brake components • If leaks or damaged boots are found, install
and will render the brakes inoperative. Failure to a new brake caliper. For additional
follow these instructions may result in personal information, refer to Brake Caliper — 4.0L
injury. SOHC and 4.6L (3V) in this section.
WARNING: Carefully read cautionary 6. Inspect the brake caliper anchor plate assembly.
information on product label. For EMERGENCY • Check the guide pins and boots for binding
MEDICAL INFORMATION seek medical advice. or damage.
products call: 1-800-959-3673. For additional • Lubricate the guide pins with the specified
information, consult the product Material Safety grease.
Data Sheet (MSDS) if available. Failure to follow • Install a new brake caliper anchor plate if it
these instructions may result in personal injury. is worn or damaged. For additional
information, refer to Brake Caliper — 4.0L
CAUTION: Brake fluid is harmful to SOHC and 4.6L (3V) in this section.
1. Check the brake fluid level in the brake fluid

reservoir.
• If required, remove fluid until the brake
master cylinder reservoir is half full.
2. With the vehicle in NEUTRAL, position it on a

Section 100-02.

Installation 2. CAUTION: Do not allow grease, oil,
brake fluid or other contaminants to contact
1. NOTE: Protect the pistons and the boots when the pad lining material. Do not install
compressing the brake caliper piston into the contaminated pads.
caliper bore. NOTE: Install all the hardware supplied with
Using a suitable tool, compress the caliper the brake pad kits.
pistons into the brake caliper bore. Install 4 new spring clips and the 2 brake pads.
3. Position the brake caliper on the anchor plate

and install 2 new guide pin bolts.
4. If necessary, fill the brake fluid reservoir with

clean, specified brake fluid.


Brake Pads — 5.4L 3. CAUTION: Do not allow the brake
caliper to hang from the brake hose or
Removal and Installation damage to the hose can occur.
Remove and discard the 2 brake caliper bolts
CAUTION: Install new brake pads in and position the brake caliper aside.
complete axle sets. • Support the brake caliper using mechanic’s
wire.
hoist. For additional information, refer to • To install, tighten to 115 Nm (85 lb-ft).
Section 100-02.
4. NOTE: Use a wood block or old brake pad to
2. NOTE: Inspect and install new brake pad protect the caliper piston and dust boots. Use a
mounting hardware as necessary. soft cloth to protect the painted surface of the
brake caliper.
Remove the brake pad mounting pins and
spring retainer clip. Using a C-clamp or similar tool, compress the
caliper pistons.
• Remove the brake pads from the caliper
assembly. 5. To install, reverse the removal procedure.
6. Apply the brake pedal several times before

driving the vehicle.

206-04-1 Rear Disc Brake 206-04-1

Brake Pads 2. CAUTION: Care must be used when
servicing rear brake components without
Special Tool(s) disconnecting the parking brake cable from
the brake caliper lever. Carefully position the
Adapter, Rear Brake Caliper
Piston Adjuster caliper aside using a suitable support or
206-026 (T87P-2588-A) or damage to the parking brake cable end
equivalent fittings can occur.
CAUTION: Do not use caliper sight
hole to retract pistons as this can damage the
pistons and boots.
Material CAUTION: Do not allow the caliper to
hang from the brake hose or damage to the
Item Specification
hose can occur.
Grease and Dielectric Remove the 2 brake caliper guide pin bolts and
Compound position the brake caliper aside.
XG-3-A • Support the caliper using mechanic’s wire.
PM-1 or PM-1-C (US); 3. CAUTION: Install new pads if worn to
CPM-1 or CPM-1-C or past the specified thickness above the
(Canada) metal backing plate or rivets. Install pads in
complete axle sets.
Removal
Remove the brake pads and discard the spring
clips.
approved DOT 3 motor vehicle brake fluid will 4. Measure the brake disc thickness.
cause permanent damage to brake components
• Install a new brake disc if not within
specification. For additional information,
refer to Brake Disc in this section.
injury.
5. Inspect the brake caliper.
information on product label. For EMERGENCY • If leaks or damaged boots are found, install
MEDICAL INFORMATION seek medical advice. a new brake caliper. For additional
In the USA or Canada on Ford/Motorcraft information, refer to Brake Caliper in this
products call: 1-800-959-3673. For additional section.
Data Sheet (MSDS) if available. Failure to follow 6. Inspect the brake caliper anchor plate assembly.
these instructions may result in personal injury. • Check the guide pins and boots for binding
and damage.
CAUTION: Brake fluid is harmful to • Replace worn or damaged pins. Lubricate
painted and plastic surfaces. If brake fluid is the pins with the specified grease.
immediately wash it with water. • Install a new brake caliper anchor plate if it
is worn or damaged.
Section 100-02.

206-04-2 Rear Disc Brake 206-04-2
Installation 4. Position the brake caliper on the anchor plate
and install the 2 brake caliper guide pin bolts
1. Using the special tool, compress the brake until snug.
caliper piston into the brake caliper bore. • Tighten the RH caliper guide pin bolts in
the following sequence:
X Tighten the top bolt to 33 Nm (24 lb-ft).
X Tighten the bottom bolt to 33 Nm (24
lb-ft).
• Tighten the LH caliper guide pin bolts in
the following sequence:
X Tighten the bottom bolt to 33 Nm (24
lb-ft).
X Tighten the top bolt to 33 Nm (24 lb-ft).
2. Position the notch in the caliper piston up and

down to align with the alignment pin on the
brake pad.
3. CAUTION: Do not allow grease, oil,

brake fluid or other contaminants to contact
the pad lining material. Do not install
contaminated pads.
NOTE: Install all hardware supplied with the
pad kit.
Install the 2 new spring clips and the brake
pads.


Brake Pedal and Bracket
NOTE: Manual transmission pedal assembly shown, automatic transmission pedal assembly similar.

1 — Speed control deactivator 4 2475 Redundant self-locking clip
switch (brake) cover
2 — Stoplamp switch 5 380699-S100 Self-locking clip
3 — Speed control deactivator 6 2A309 Brake booster rod bushing
switch (clutch) 7 2N513 Brake booster rod pin
(Continued) (Continued)

8 W520112-S440 Brake booster nuts (4
required)
9 W701834-S439 Brake pedal bracket bolts (2
required)
10 2450 Brake pedal bracket
All vehicles
1. CAUTION: The brake pedal must be

connected to the booster rod and in the at 7. NOTE: The clutch master cylinder is
rest position before removing or installing self-bleeding. Pump the clutch pedal until all
the speed control deactivator switch. Failure the air is forced back into the brake master
to follow this instruction will damage the cylinder reservoir.
switch. Remove the hairpin clip and disconnect the
Remove the stoplamp switch and, if equipped, clutch pedal high pressure hydraulic hose from
the speed control deactivator switch (brake). the clutch master cylinder.
• Install the hairpin clip into the clutch master
2. Remove the redundant self-locking pin cover cylinder.
and the self-locking pin.
3. Remove the booster rod pin and bushing from

the brake pedal.
Manual transmission vehicles
4. CAUTION: The clutch pedal must be

connected to the clutch master cylinder
actuation rod and in the at rest position
before removing or installing the speed
control deactivator switch. Failure to follow
this instruction will damage the switch.
Remove the speed control deactivator switch
All vehicles
(clutch) and position it aside.
5. Disconnect the clutch pedal interlock switch 8. Remove the 4 brake booster nuts
electrical connector. • To install, tighten to 25 Nm (18 lb-ft).
6. Disconnect the clutch pedal low pressure 9. Remove the top 2 bolts from the brake pedal
hydraulic hose from the master cylinder bracket assembly.
reservoir.
10. Remove the brake pedal bracket assembly from

the vehicle.

GENERAL PROCEDURES
Brake System Bleeding CAUTION: After the installation of a
hydraulic control unit replacement, conduct the
Special Tool(s) Brake System Pressure Bleeding procedure
before the scan tool based bleed procedure. A
Vehicle Communication Module
(VCM) and Integrated scan tool based bleed procedure is then required
Diagnostic System (IDS) to completely bleed the system. Follow the
software with appropriate instructions from the scan tool.
hardware, or equivalent scan
tool NOTE: If the hydraulic control unit (HCU), or any
component upstream of the HCU are installed new,
carry out the Brake System Pressure Bleeding
Material procedure first without the scan tool, followed by
the Brake System Bleed procedure using the scan
Item Specification tool. The Component Bleeding — Rear Brake
High Performance DOT 3 ESA-M6C25-A or Caliper procedure is not required as new rear
Motor Vehicle Brake Fluid WSS-M6C62-A calipers were not installed.
CPM-1 or CPM-1-C NOTE: When any part of the hydraulic system is
(Canada) disconnected for repair or installation of new
Manual components, air can get into the system and cause
spongy brake pedal action. This requires bleeding of
the hydraulic system after it is correctly connected.
WARNING: Use of any other than The hydraulic system can be bled manually or with
approved DOT 3 motor vehicle brake fluid will pressure bleeding equipment.
and will render the brakes inoperative. Failure to All vehicles
injury.
1. Connect the scan tool cable adapter into the
vehicle data link connector (DLC) under the
dash and follow the scan tool instructions.
information on product label. For additional
information, see product Material Safety Data 2. Clean all the dirt from the area, remove the
Sheet (MSDS). For 24-hour MEDICAL brake master cylinder reservoir cap and fill the
EMERGENCY INFORMATION on brake master cylinder reservoir with clean,
Ford/Motorcraft products call: 1-800-959-3673 specified brake fluid.
(FORD). Failure to follow these instructions may
result in personal injury.

CAUTION: Do not allow the brake master

cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder
reservoir filled with clean, specified brake fluid.
Never reuse the brake fluid that has been
drained from the hydraulic system.

3. Remove the RH rear bleeder cap and place a
box-end wrench on the RH rear bleeder screw.
Attach a rubber drain hose to the RH rear
bleeder screw and submerge the free end of the
hose in a container partially filled with clean,
specified brake fluid.
9. Have an assistant hold firm pressure on the

brake pedal.
10. Loosen the RH front brake caliper bleeder

screw until a stream of brake fluid comes out.
While the assistant maintains pressure on the
brake pedal, tighten the RH front brake caliper
4. Have an assistant hold firm pressure on the bleeder screw.
brake pedal. • Repeat until clear, bubble-free fluid comes
out.
5. Loosen the RH rear bleeder screw until a
stream of brake fluid comes out. While the • Refill the brake master cylinder reservoir as
assistant maintains pressure on the brake pedal, necessary.
tighten the RH rear bleeder screw.
11. Tighten the RH front brake caliper bleeder
• Repeat until clear, bubble-free fluid comes screw and install the bleeder cap.
out.
• Tighten to 10 Nm (89 lb-in).
• Refill the brake master cylinder reservoir as
necessary. 12. Repeat Steps 8 through 11 for the LH front
brake caliper bleeder screw.
6. Tighten the RH rear brake caliper bleeder screw
and install the bleeder cap.
• Tighten to 10 Nm (89 lb-in).
7. Repeat Steps 3 through 6 for the LH rear brake

caliper bleeder screw.
Vehicles equipped with a 4.0L SOHC or 4.6L

(3V) engine
8. Remove the RH front bleeder cap and place a

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

Vehicles equipped with a 5.4L engine 21. Repeat Steps 13-16 for the LH front inner brake
13. Remove the RH front inner bleeder cap and
Pressure
place a box-end wrench on the RH front inner
brake caliper bleeder screw. Attach a rubber
drain hose to the RH front inner bleeder screw WARNING: Use of any other than
and submerge the free end of the hose in a approved DOT 3 motor vehicle brake fluid will
container partially filled with clean, specified cause permanent damage to brake components
brake fluid. and will render the brakes inoperative. Failure to
injury.


14. Have an assistant hold firm pressure on the spilled onto a painted or plastic surface,
brake pedal. immediately wash it with water.
15. Loosen the RH front inner brake caliper bleeder CAUTION: Do not allow the brake master
screw until a stream of brake fluid comes out. cylinder reservoir to run dry during the bleeding
While the assistant maintains pressure on the operation. Keep the brake master cylinder
brake pedal, tighten the RH front brake caliper reservoir filled with clean, specified brake fluid.
bleeder screw. Never reuse the brake fluid that has been
• Repeat until clear, bubble-free fluid comes drained from the hydraulic system.
out.
CAUTION: After the installation of a
• Refill the brake master cylinder reservoir as hydraulic control unit replacement, conduct the
necessary. Brake System Pressure Bleeding procedure
before the scan tool based bleed procedure. A
16. Tighten the RH front inner brake caliper
scan tool based bleed procedure is then required
bleeder screw and install the bleeder cap.
to completely bleed the system. Follow the
• Tighten to 18 Nm (13 lb-ft). instructions from the scan tool.
17. Repeat Steps 13-16 for the RH front outer NOTE: If the hydraulic control unit (HCU), or any
brake caliper bleeder screw. component upstream of the HCU are installed new,
carry out the Brake System Pressure Bleeding
18. Repeat Steps 13-16 for the RH front inner procedure first without the scan tool, followed by
brake caliper bleeder screw. the Brake System Bleed procedure using the scan
tool. The Component Bleeding — Rear Brake
19. Repeat Steps 13-16 for the LH front inner brake Caliper procedure is not required as new rear
caliper bleeder screw. calipers were not installed.
20. Repeat Steps 13-16 for the LH front outer brake


NOTE: When any part of the hydraulic system is
disconnected for repair or installation of new
components, air can get into the system and cause
spongy brake pedal action. This requires bleeding of
The hydraulic system can be bled manually or with
pressure bleeding equipment.
All vehicles
1. Clean all the dirt from the area and remove the
brake master cylinder filler cap. Fill the brake
master cylinder reservoir with clean, specified
brake fluid. 4. Open the valve on the bleeder tank.
Vehicles equipped with a 4.0L SOHC or 4.6L

(3V) engine
5. Loosen the RH rear brake caliper bleeder

screw. Leave open until clear, bubble-free brake
fluid flows, then tighten the RH rear brake
caliper bleeder screw and remove the rubber
hose and install the RH rear bleeder cap.
• To install, tighten to 10 Nm (89 lb-in).
6. Continue bleeding the system, going in order

from the LH rear brake caliper bleeder screw to
the RH front brake caliper bleeder screw ending
2. NOTE: Master cylinder pressure bleeder with the LH front brake caliper bleeder screw.
adapter tools are available from various
manufacturers of pressure bleeding equipment. 7. Close the bleeder tank valve. Remove the tank
Follow the instructions of the manufacturer hose from the adapter, and remove the adapter.
when installing the adapter.
Vehicles equipped with a 5.4L engine
Install the bleeder adapter to the brake master
cylinder reservoir and attach the bleeder tank
hose to the fitting on the adapter. 8. Loosen the RH rear brake caliper bleeder
screw. Leave open until clear, bubble-free brake
3. NOTE: Bleed the longest line first. Make sure fluid flows, then tighten the RH rear brake
the bleeder tank contains enough clean, caliper bleeder screw and remove the rubber
specified brake fluid to complete the bleeding hose and install the RH rear bleeder cap.
operation. • To install, tighten to 18 Nm (13 lb-ft).
Remove the RH rear bleeder cap and place a
box-end wrench on the RH rear bleeder screw.
Attach a rubber drain hose to the RH rear
bleeder screw and submerge the free end of the
hose in a container partially filled with clean,
specified brake fluid.

9. Continue bleeding the system in the following 10. Close the bleeder tank valve. Remove the tank
order: hose from the adapter, and remove the adapter.
1 LH rear brake caliper bleeder screw
2 RH front inner brake caliper bleeder screw
3 RH front outer brake caliper bleeder screw
4 RH front inner brake caliper bleeder screw
5 LH front inner brake caliper bleeder screw
6 LH front outer brake caliper bleeder screw
7 LH front inner brake caliper bleeder screw


Brake System Inspection and Verification
Special Tool(s) WARNING: Use of any brake fluid other

than the approved DOT 3 will cause permanent
Vehicle Communication Module damage to brake components and will render the
(VCM) and Integrated brakes inoperative. Failure to follow these
Diagnostic System (IDS)
software with appropriate instructions may result in personal injury.
hardware, or equivalent scan WARNING: Carefully read cautionary
tool
73III Automotive Meter In the USA or Canada on Ford/Motorcraft
105-R0057 or equivalent products call: 1-800-959-3673. For additional
Flex Probe Kit spilled onto a painted or plastic surface,
105-R025B or equivalent immediately wash it with water.
NOTE: Always check the fluid level in the brake
master cylinder reservoir before carrying out the test
procedures. If the fluid level is below the MIN level
mark, clean the reservoir cap before removing, then
add clean, specified brake fluid.
Material NOTE: Prior to carrying out any diagnosis, make
Item Specification sure the red brake warning indicator is functional.
Refer to Section 413-01.
Motor Vehicle Brake Fluid WSS-M6C62-A The first indication that something may be wrong in
PM-1 or PM-1-C (US); the brake system is a change in the feeling through
CPM-1 or CPM-1-C the brake pedal. The brake warning indicator in the
(Canada) instrument cluster and the brake fluid level in the
Silicone Brake Caliper ESE-M1C171-A brake master cylinder reservoir are also indicators
Grease and Dielectric of system concerns.
Compound
XG-3-A If a wheel is locked and the vehicle must be moved,
Metal Brake Parts Cleaner — open a bleeder screw at the locked wheel to let out
PM-4-A or PM-4-B (US); enough fluid to relieve the pressure. Close the
CPM-4 (Canada) bleeder screw. This bleeding operation may release
the brakes but does 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.

Road Test • Inspect and measure the thickness of the brake
The technician should have a thorough knowledge pad friction material.
of the brake system operation and accepted general — Install new brake pads if the thickness of the
braking guidelines in order to detect any problems. friction material is less than 3.0 mm (0.118
Select a road that is reasonably smooth and level. inch). Refer to Section 206-03 for front disc
Gravel or bumpy roads are not suitable because the brakes or Section 206-04 for rear disc brakes.
surface does not allow the tires to grip the road — Compare all 4 front or rear pads for uneven
equally. Avoid crowned roads. wear. Install new brake pads if the thickness
A key factor in evaluating brake concerns is the of the friction material varies from pad to pad
deceleration rate. This varies from vehicle to vehicle by more than 2.0 mm (0.079 inch). Refer to
and with changes in operating conditions. It is Section 206-03 for front disc brakes or Section
evident how well the brakes are working after just a 206-04 for rear disc brakes.
few applications. — Install new brake pads if there are missing
For low or spongy brake pedal concerns: chunks or cracks in the lining through to the
backing plate. Refer to Section 206-03 for
• bleed the brake system and retest the brake pedal front disc brakes or Section 206-04 for rear
feel. disc brakes.
• if the brake pedal is still low or feels spongy, — If the friction material shows taper wear and
check the brake pedal mounting for looseness and the thickness varies by more than (3.0 mm
correct installation. Check the brake booster and [0.118 inch] in any direction), or if the pads
the brake master cylinder for loose mounting. show uneven wear (2.0 mm [0.079 inch]
Correct as necessary and retest the system for difference between the inboard and the
normal operation. outboard pad), verify the caliper guide pins
• check the fluid level. The fluid level must be at or are functioning correctly. Refer to Section
above the minimum mark. If the fluid level is 206-03 for front disc brakes or Section 206-04
below the minimum mark, check the system for for rear disc brakes.
leaks.
Brake Discs
For a slow or incomplete brake pedal return
concern: CAUTION: Using an impact tool without a
torque socket leads to unevenly tightened wheel
• inspect for binding, damage, correct installation or nuts. This causes brake disc on-vehicle lateral
interference at the brake pedal. runout and brake roughness.
• check the brake booster for binding, damage and NOTE: It is generally not required to install new
correct installation. brake discs to address noise issues.
Brake Pads • Remove the brake disc. Refer to Section 206-03
NOTE: New brake pads are not required if friction for front disc brakes or Section 206-04 for rear
material properties are within guidelines. New brake disc brakes.
pads are not required when the brake discs are
machined.
• Remove the brake pads. Refer to Section 206-03
for front disc brakes or Section 206-04 for rear
disc brakes.

• Inspect the brake discs and measure the brake disc Brake Hoses and Tubes
thickness in a minimum of 4 places around the
CAUTION: Never use copper tubing. It is
circumference of the brake disc. Record the
subject to fatigue, cracking and corrosion, which
measurements.
could result in brake tube failure.
— Install new brake discs if any thickness
measurement is less than the minimum • Double-wall steel tubing is used throughout the
specification. Refer to Section 206-03 for front brake hydraulic system. All brake tube fittings
disc brakes or Section 206-04 for rear disc must be correctly flared to provide strong,
brakes. leakproof connections. When bending tubing to fit
the underbody or rear axle contours, be careful
— Install new brake discs if cracked. Refer to not to kink or crack the tube.
Section 206-03 for front disc brakes or Section
206-04 for rear disc brakes. • If a section of the brake tube is damaged, the
entire section must be installed new with a tube
— Machine the brake discs if the diagnosis has of the same type, size, shape and length.
revealed vibration in the steering wheel, seat
or pedal while braking. Heavily scored brake • When installing the hydraulic brake tubing, hoses,
discs, similar to that caused by pads worn or connectors, tighten all connections to
down to the backing plate, should also be specifications. After installation, bleed the brake
machined. In order to machine, discs must be system. Refer to Brake System Bleeding in this
above the minimum thickness to machine section.
specification. Refer to Specifications and • The wet appearance on the outer cover of rubber
Brake Disc Machining in this section. brake hoses is called sweating. This is a normal
condition for neoprene rayon-braided hose and is
Brake Caliper not a sign of leakage or cause to install a new
Inspect the brake calipers for the following: hose.
• Brake fluid leaks. Install a new flexible brake hose if the hose shows
signs of softening, cracking or other damage.
• Boots and seals for tears or cracks.
When installing a new brake hose, position the hose
• Caliper piston for binding and corrosion.
to avoid contact with other vehicle components.
• Guide pins for correct operation. Refer to Section
206-03 for front disc brakes or Section 206-04 for Non-Pressure Leaks
rear disc brakes. The only part of the brake system that could have a
brake fluid loss that does not appear when the
Brake Caliper Guide Pins
system is under pressure is the brake master
CAUTION: Do not use power tools for cylinder reservoir under the following conditions:
caliper guide pin bore cleaning.
• Missing or poorly-fitted brake master cylinder
NOTE: Guide pin kits are not available. filler cap.
The guide pins should slide with a reasonable • Punctured or otherwise damaged brake master
amount of hand force. If the brake pads show taper cylinder reservoir.
wear or the guide pins are difficult to move, install
• Missing or damaged brake master cylinder filler
a new caliper assembly. For additional information,
cap gasket.
refer to Section 206-03 or Section 206-04.
• Missing, damaged or poorly-fitted sealing
grommets between the brake master cylinder and
the brake master cylinder reservoir.
The brake master cylinder reservoir grommets are
not repairable and must be installed new as part of
a new brake master cylinder reservoir.

Brake Master Cylinder — Normal Conditions Brake Booster
The following conditions are considered normal and Inspect the brake booster for the following:
are not indications that the brake master cylinder is
• Excessive corrosion or damage.
in need of service.
• Vacuum connections for leakage.
Condition 1: During normal operation of the brake
master cylinder, the fluid level in the brake master • Vacuum hoses for kinks or leakage.
cylinder reservoir rises during brake application and • Brake booster check valve for correct operation.
falls during release. The net fluid level (such as
Changes in the brake pedal feel or travel are
after brake application and release) remains
indicators that something could be wrong in the
unchanged.
brake system. GO to Symptom Chart for abnormal
Condition 2: A trace of brake fluid exists on the condition diagnosis.
booster shell below the master cylinder mounting
flange. This results from the normal lubricating Parking Brake
action of the master cylinder bore and seal. Check the operation of the parking brake system
Condition 3: Fluid level decreases with pad wear. with the vehicle on a hoist and the parking brake
control fully released. Check for any damaged
Brake Master Cylinder — Abnormal cables and install new components as necessary.
Conditions Check the rear brake adjustment or carry out the
Changes in brake pedal feel or travel are indicators brake system diagnosis. Refer to Section 206-05.
that something could be wrong in the brake system.
GO to Symptom Chart for abnormal condition
diagnosis.
Symptom Chart
Symptom Chart
• The red brake warning • Brake fluid level • If the fluid level is below the
indicator is always on • Brake fluid leak minimum level, CHECK the
system for leaks. REPAIR as
necessary.
• Parking brake switch • GO to Pinpoint Test A.
• Brake fluid level switch
• Circuitry
• Smart junction box (SJB)
• The red brake warning • Circuitry • REFER to Section 413-01.
indicator is inoperative • Instrument cluster
• The brakes pull or drift • Tire air pressure • CHECK the tires for uneven
or excessive wear and
CORRECT the inflation.
• Brake pads • CHECK the brake pads for
• Brake components uneven taper or excessive
wear. REPAIR as necessary.
• Suspension components • CHECK the suspension
• Wheel alignment components and the wheel
alignment. REFER to Section
204-00.

• The brake pedal goes down • Brake fluid level • INSPECT the system for
fast leaks, REPAIR as necessary.
FILL the brake master
cylinder reservoir. BLEED
the system. REFER to Brake
System Bleeding in this
section.
• Air in the system • INSPECT the system for
leaks, REPAIR as necessary.
BLEED the system. REFER
to Brake System Bleeding in
this section.
• Brake master cylinder • CARRY OUT the brake
master cylinder component
test in this section.
• The brake pedal eases down • Air in the system • INSPECT the system for
slowly leaks, REPAIR as necessary.
BLEED the system. REFER
this section.
• Brake lockup under light • Brake pads • CHECK the brake pads for
brake pedal force uneven taper or excessive
wear. REPAIR as necessary.
• Brake component • CHECK the brake
components for correct
operation. REPAIR as
necessary.
• Parking brake component • REPAIR or INSTALL new
components as necessary.
• Anti-lock brake control • CHECK the anti-lock brake
system control system. REFER to
Section 206-09.
• Excessive/erratic brake pedal • Leak in the hydraulic system • INSPECT the system for
travel • Air in the system leaks, REPAIR as necessary.
• Brake caliper BLEED the system. REFER
this section.
• Brake pads • CHECK the brake pads for
excessive wear. REPAIR as
necessary.
• Brake pedal • CHECK the brake pedal for
binding or obstructions.
REPAIR as necessary.

• Brakes drag • Parking brake component • REPAIR or INSTALL new
• Brake caliper guide pins • REPAIR or INSTALL new
brake calipers as necessary.
REFER to Section 206-03 for
front disc brakes or Section
206-04 for rear disc brakes.
• Brake caliper • REPAIR or INSTALL new
• Brake switches • REMOVE and REINSTALL
the stoplamp switch and the
speed deactivation switch.
• Brake booster • CARRY OUT the brake
booster component test in this
section.
• Excessive brake pedal effort • Brake booster • CARRY OUT the brake
booster component test in this
section.
• Brake booster check valve • CARRY OUT the check
valve component test in this
section.
• Brake booster manifold • REROUTE, REPAIR or
vacuum hose INSTALL new components
as necessary.
• Rattling noise • Caliper mounting bolts loose • CHECK the caliper bolts.
TIGHTEN to specifications.
• Damaged or worn caliper • CHECK the caliper guide
guide pins or retainers pins and retainers for
lubrication and correct
operation. LUBRICATE or
INSTALL new components
as necessary. REFER to
Section 206-03 for front disc
brakes or Section 206-04 for
rear disc brakes.
• Missing or damaged • CHECK the brake pads for
anti-rattle clips or springs missing clips or broken
springs. INSTALL new
• Loose brake disc shield • TIGHTEN the brake disc
shield bolts to specification.
206-04 for rear disc brakes

• Clicking noise — with brakes • ABS hydraulic control unit • Acceptable condition.
applied with anti-lock brake (HCU)
system (ABS)
• Squealing noise — occurs on • Brake pads • Acceptable condition. Caused
first brake application by humidity and low brake
pad temperature.
• Squealing noise — a • Brake pads or linings worn • INSPECT the brake pads for
continuous squeal below minimum thickness excessive wear, taper wear or
uneven wear. VERIFY the
brake pads are within
minimum specifications.
REFER to Brake Pads in this
section.
• Squealing noise — an • Brake pads • Acceptable condition.
intermittent squeal brought on
by cold, heat, water, mud or
snow
• Groaning noise — occurs at • Brake pads • Acceptable condition.
low speeds with brake lightly
applied (creeping)
• Grinding noise — continuous • Brake pads or linings worn • INSPECT the brake pads,
below minimum thickness brake discs and attaching
hardware for damage.
VERIFY brake pads are
within minimum
specifications. REFER to
Brake Pads in this section.
• Moaning noise • Brake linings contaminated • INSPECT the brake pads for
with grease or oil contamination. REPAIR or
INSTALL new components
as necessary. REFER to
Section 206-03 for front disc
brakes or Section 206-04 for
rear disc brakes.
• Vibration when the brakes are • Uneven brake pad wear • COMPLETE the brake
applied • Brake disc pad transfer system inspection described
• Brake disc in Inspection and Verification
• Suspension components in this section.
• GO to Pinpoint Test B.
• Brake vibration/shudder — • Brake caliper guide pins • INSPECT the brake caliper
occurs when the brake pedal guide pins for correct
is released operation. REFER to Section
206-03 for front disc brakes
or Section 206-04 for rear
disc brakes.
• Brake drag • INSPECT the brake pads for
premature wear. REPAIR or
INSTALL a new caliper as
necessary. REFER to Section
206-03 for front disc brakes
or Section 206-04 for rear
disc brakes.

Pinpoint Test A: The Red Brake Warning • Circuit shorted

Indicator is Always On • Low brake fluid level
Refer to Wiring Diagrams Cell 60, Instrument • Brake fluid level switch
Cluster for schematic and connector information. • Parking brake engaged
Normal Operation • Parking brake switch
The red brake warning indicator is located in the • Instrument cluster
instrument cluster and illuminates when the brake
fluid in the brake master cylinder reservoir is below • SJB
a specific level or when the parking brake is
engaged. When the parking brake is applied, the
instrument cluster receives a ground input on circuit
1309 (RD/YE) through the parking brake switch and
circuit 1205 (BK), turning on the brake warning
indicator. The smart junction box (SJB) provides a
voltage to the brake fluid level switch through
circuit 547 (LG/YE) and back through the SJB
return circuit 512 (TN/LG). When the brake fluid
level is low, the brake fluid level switch closes and
connects circuit 547 (LG/YE) to circuit 512
(TN/LG). The voltage reference signal the SJB is
sending to the brake fluid level switch drops to
zero, then the SJB sends a message over the
medium speed communication area network
(MS-CAN) to the instrument cluster to turn on the
brake warning indicator.
PINPOINT TEST A: THE RED BRAKE WARNING INDICATOR IS ALWAYS ON
A1 CHECK THE PARKING BRAKE SWITCH
• Verify the parking brake is fully released. Yes
• Key in OFF position. GO to A2.
• Disconnect: Parking Brake Switch C306. No
• Key in ON position. INSTALL a new parking brake switch.
• Is the red brake warning indicator illuminated? CLEAR the DTCs. REPEAT the self-test.
A2 CHECK THE BRAKE FLUID LEVEL SWITCH
• Disconnect: Brake Fluid Level Switch C124. Yes
• Is the red brake warning indicator illuminated? GO to A3.
No
INSTALL a new brake fluid reservoir.
REFER to Section 206-06. CLEAR the
A3 CHECK CIRCUIT 1309 (RD/YE) FOR A SHORT TO GROUND
• Disconnect: SJB C2280c.
(Continued)

PINPOINT TEST A: THE RED BRAKE WARNING INDICATOR IS ALWAYS ON (Continued)
A3 CHECK CIRCUIT 1309 (RD/YE) FOR A SHORT TO GROUND
(Continued)
• Measure the resistance between parking brake switch C306-1,
circuit 1309 (RD/YE), harness side and ground.
Yes
REPAIR circuit 1309 (RD/YE). CLEAR the
No
• Is the resistance less than 5 ohms? GO to A4.
A4 CHECK CIRCUIT 547 (LG/YE) FOR A SHORT TO GROUND
• Measure the resistance between brake fluid level switch C124-1,
circuit 547 (LG/YE), harness side and ground.
Yes
REPAIR circuit 547 (LG/YE). CLEAR the
No
• Is the resistance less than 5 ohms? GO to A5.
A5 CHECK FOR A SHORT BETWEEN CIRCUIT 512 (TN/LG) AND
CIRCUIT 547 (LG/YE)
• Measure the resistance between brake fluid level switch C124-1,
circuit 547 (LG/YE), harness side and between brake fluid level
switch C124-2, circuit 512 (TN/LG), harness side.
Yes
GO to A6.
No
INSTALL a new brake fluid reservoir.
REFER to Section 206-06. CLEAR the
• Is the resistance less than 5 ohms? DTCs. REPEAT the self-test.
(Continued)

PINPOINT TEST A: THE RED BRAKE WARNING INDICATOR IS ALWAYS ON (Continued)
A6 CHECK THE SMART JUNCTION BOX (SJB) OUTPUT
• Connect: SJB C2280c. Yes
• Disconnect: SJB C2280b. GO to A7.
• Observe the red brake warning indicator. No
• Is the red brake warning indicator illuminated? GO to A8.
A7 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION
• Connect: SJB C2280b.
• Disconnect all the instrument cluster connectors. Yes
— pushed-out pins. DTCs. REPEAT the self-test.
• Connect all the instrument cluster connectors and make sure The system is operating correctly at this
they seat correctly. time. The concern may have been caused
• Operate the system and verify if the concern is still present. by a loose or corroded connector. CLEAR
A8 CHECK FOR CORRECT SJB OPERATION
• Disconnect all the SJB connectors. Yes
• Check for: INSTALL a new SJB. REFER to Section
— corrosion. 419-10. CLEAR the DTCs. REPEAT the
— pushed-out pins. self-test.
• Connect all the SJB connectors and make sure they seat The system is operating correctly at this
• Operate the system and verify if the concern is still present. by a loose or corroded connector. CLEAR
Pinpoint Test B: Vibration When the Brakes

are Applied
Possible Causes
• Uneven brake pad wear
• Brake disc pad transfer
• Brake disc
• Suspension components
PINPOINT TEST B: VIBRATION WHEN THE BRAKES ARE APPLIED
B1 CHECK OASIS AND FOR TSBs
• Check the On-Line Automotive Service Information System Yes
(OASIS) and Technical Service Bulletins (TSBs) for applicable REFER to OASIS or the TSB. CARRY
brake concerns. OUT any necessary repairs that are
• Is there applicable information available on OASIS or in a indicated by OASIS or the TSB. If the
TSB? concern is still present, GO to B2.
No
GO to B2.
B2 ROAD TEST THE VEHICLE — LIGHT BRAKING
• Inspect the wheels and tires. Refer to Section 204-00.
• Road test the vehicle. Warm the brakes by slowing the vehicle
from 80-32 km/h (50-20 mph) using light brake force. At highway
speeds of 89-97 km/h (55-60 mph), apply the brake using light Yes
pedal force. GO to B5.
• Is there a vibration/shudder felt in the steering wheel, seat No
or brake pedal? GO to B3.
(Continued)

PINPOINT TEST B: VIBRATION WHEN THE BRAKES ARE APPLIED (Continued)
B3 ROAD TEST THE VEHICLE — MODERATE TO HEAVY
BRAKING
• Road test the vehicle. At highway speeds of 89-97 km/h (55-60 Yes
mph), apply the brake using a moderate to heavy pedal force. GO to B4.
• Is there a vibration/shudder? No
The concern is not present at this time.
B4 NORMAL ACTUATION OF THE ANTI-LOCK BRAKE SYSTEM
(ABS) SYSTEM DIAGNOSIS
• During moderate to heavy braking, noise from the hydraulic
control unit (HCU) and pulsation in the brake pedal can be
observed. Pedal pulsation coupled with noise during heavy
braking or on loose gravel, bumps, wet or snowy surfaces is
acceptable and indicates correct functioning of the ABS system.
Pedal pulsation or steering wheel nibble (frequency is Yes
proportioned to the vehicle speed) indicates a concern with a GO to B5.
brake or suspension component. No
• Is the vibration/shudder vehicle speed sensitive? The concern is not present at this time.
B5 CHECK THE FRONT SUSPENSION
• Check the front suspension. Refer to Section 204-00. Yes
• Are all the suspension components in satisfactory GO to B6.
condition? No
REPAIR or INSTALL new components as
necessary. REFER to Section 204-01.
TEST the system for normal operation.
B6 RESURFACE THE FRONT BRAKE DISCS
• CAUTION: Do not use a bench lathe to machine the

brake discs.
NOTE: Follow the manufacturer’s instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification.
Resurface the front brake discs. Refer to Brake Disc Machining Yes
in this section. GO to B7.
• Road test the vehicle. No
• Is the vibration/shudder present? The concern is not present at this time.
B7 CHECK THE REAR SUSPENSION
• Check the rear suspension. Refer to Section 204-00. Yes
• Are all the suspension components in satisfactory GO to B8.
condition? No
REPAIR or INSTALL new components as
necessary. REFER to Section 204-02.
B8 RESURFACE THE REAR BRAKE DISC
• CAUTION: Do not use a bench lathe to machine the

brake discs.
NOTE: Follow the manufacturer’s instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification. Yes
Resurface the rear brake discs. Refer to Brake Disc Machining REFER to Section 100-04 to continue
in this section. diagnosis of the vibration.
• Road test the vehicle. No
• Is the vibration/shudder present? The concern is not present at this time.
Component Tests 2. With the transmission in NEUTRAL, stop the

engine and apply the parking brake control.
Brake Booster Apply the brake pedal several times to exhaust
1. Check the hydraulic brake system for leaks or all vacuum in the system.
insufficient fluid.

3. Apply the brake pedal and hold it in the applied To test the function of the brake booster check
position. Start the engine. If the vacuum system valve:
is operating, the brake pedal tends to move
• start and run the engine for at least 10 seconds.
downward under constant foot pressure. If no
motion is felt, the brake booster system is not • operate the brake pedal to check for power assist.
functioning. Continue with the following steps. • disconnect the vacuum booster hose from the
4. Remove the vacuum booster hose from the brake booster check valve. Do not remove the
check valve connection. Manifold vacuum must brake booster check valve from the brake booster.
be available at the check valve end of the • there should be enough vacuum retained in the
vacuum booster hose with the engine at idle brake booster for at least one more power-assisted
speed and the transmission in NEUTRAL. If brake operation.
the manifold vacuum is available to the brake
booster, connect the vacuum booster hose to the Brake Master Cylinder — Bypass Condition
brake booster check valve and repeat Steps 2 1. Disconnect the brake tubes at the brake master
and 3. cylinder.
5. If no downward movement of the brake pedal is 2. Plug the outlet ports of the brake master
felt, install a new brake booster. For additional cylinder.
information, refer to Section 206-07. 3. Apply the brakes. If brake pedal height cannot
6. Operate the engine a minimum of 10 seconds at be maintained, the brake master cylinder has an
fast idle. Stop the engine, and let the vehicle internal leak and a new brake master cylinder
stand for 10 minutes. Then apply the brake must be installed.
pedal with approximately 89 N (20 lb) of force.
Brake Master Cylinder — Compensator Port
The brake pedal feel should be the same as that
Check
noted with the engine operating. If the brake
pedal feels hard (no power assist), install a new The purpose of the compensator ports in the brake
brake booster check valve and retest. If the master cylinder is to supply any additional brake
brake pedal feels spongy, bleed the hydraulic fluid required by the system due to brake pad wear
system to remove air. Refer to Brake System and to allow brake fluid returning from the brake
Bleeding in this section. hoses and tubes to the brake master cylinder to
enter the brake master cylinder reservoir.
Check Valve The returning brake fluid causes a slight turbulence
The function of the brake booster check valve is to in the brake master cylinder reservoir. Turbulence
allow manifold vacuum to enter the brake booster seen in the brake master cylinder reservoir upon
and prevent the escape of vacuum in case manifold application or release of the brake pedal is normal
vacuum is lost during sustained full throttle and shows that the compensating ports are not
operation. plugged.


Brake System • rear disc brakes with an integral parking brake,
using a single piston brake caliper and disc
The brake system consists of the following
system
components:
• a 4-wheel anti-lock brake system (ABS). Refer to
• a vacuum-assisted power brake booster Section 206-09.
• a front-to-rear split hydraulic system
• front disc brakes using a dual piston brake caliper
and disc system

GENERAL PROCEDURES
Component Bleeding CAUTION: Brake fluid is harmful to
Special Tool(s) spilled onto a painted or plastic surface,
Vehicle Communication Module
(VCM) and Integrated NOTE: When any part of the hydraulic system is
Diagnostic System (IDS)
software with appropriate disconnected for repair or installation of new
hardware, or equivalent scan components, air can enter the system and cause
tool spongy brake pedal action. This requires bleeding of
The hydraulic system can be bled manually or with
Adapter for Adjuster, Rear pressure bleeding equipment.
Brake Caliper Piston
206-026 (T87P-2588-A) NOTE: When a new brake master cylinder is
installed, or the system is emptied or partially
emptied, it should be primed to prevent air from
entering the system.
1. For in-vehicle priming, disconnect the brake

Material tubes.
Item Specification
CPM-1 or CPM-1-C
(Canada)
Master Cylinder
WARNING: Use of any brake fluid other

than approved DOT 3 will cause permanent
damage to brake components and will render the
brakes inoperative. Failure to follow these
instructions may result in personal injury.
2. For bench priming, mount the brake master
WARNING: Carefully read cautionary cylinder in a vise.

Never reuse the brake fluid that has been
drained from the hydraulic system.

3. Install short brake tubes onto the primary and Rear Brake Caliper
secondary ports with the ends submerged in the
brake master cylinder reservoir. WARNING: Use of any other than
approved DOT 3 motor vehicle brake fluid will
injury.

4. Fill the brake master cylinder reservoir with
clean, specified brake fluid. CAUTION: Brake fluid is harmful to
5. Have an assistant pump the brake pedal, or
slowly press the primary piston until clear fluid
flows from the brake tubes, without air bubbles.
6. If the brake master cylinder has been primed at
the bench, install it in the vehicle. For
7. Remove the short brake tubes and install the Never reuse the brake fluid that has been
master cylinder brake tubes. drained from the hydraulic system.
• Tighten to 17 Nm (13 lb-ft). NOTE: When any part of the hydraulic system is
disconnected for repair or installation of new
8. Bleed each brake tube at the brake master components, air can get into the system and cause
cylinder as follows: spongy brake pedal action. This requires bleeding of
1 Have an assistant pump the brake pedal, the hydraulic system after it is correctly connected.
and then hold firm pressure on the brake The hydraulic system can be bled manually or with
pedal. pressure bleeding equipment.
2 Loosen the rear-most brake tube fittings NOTE: Due to the complexity of the fluid path
until a stream of brake fluid comes out. within the rear integral parking brake calipers, it
While the assistant maintains pressure on may be necessary to follow this procedure when
the brake pedal, tighten the brake tube new calipers are installed.
fitting.
3 Repeat this operation until clear, bubble-free 1. NOTE: This procedure is necessary only when
fluid comes out. installing a new rear brake caliper. To bleed the
4 Refill the brake master cylinder reservoir as brake system, refer to Brake System Bleeding
necessary. Repeat the bleeding operation at in this section.
the front brake tube. With the vehicle in NEUTRAL, position it on a
Section 100-02.

2. Remove the 2 brake caliper bolts and position 5. Slowly apply the brake pedal to extend the
the brake caliper aside. brake caliper piston outward.
6. Remove the 2 brake caliper bolts and position

the brake caliper aside.
3. Remove the outer brake pad.
7. Bleed the brake caliper.

• Remove the bleeder screw cap and place a
box end wrench on the brake caliper bleeder
screw. Attach a rubber drain hose to the
brake caliper bleeder screw and submerge
the free end of the hose in a container
partially filled with clean, specified brake
fluid.
4. NOTE: Place a shop towel between the caliper

and the brake disc.
Install the brake caliper using the 2 brake
caliper bolts.
8. Loosen the brake caliper bleeder screw.

9. Using the special tool, fully retract the brake 13. Position the brake caliper and install the 2
caliper piston and tighten the bleeder screw. brake caliper bolts.
• Tighten to 10 Nm (89 lb-in). • Tighten to 33 Nm (24 lb-ft).
• Refill the brake master cylinder reservoir as
necessary.
Hydraulic Control Unit (HCU)
NOTE: This procedure is only required when a new

10. Repeat Steps 5 through 9 until clear, bubble
HCU is installed.
free fluid comes out.
• Install the bleeder screw cap. NOTE: When any part of the hydraulic system has
been disconnected for repair or new installation, air
11. Remove the 2 brake caliper bolts and the shop may get into the system and cause spongy brake
towel. pedal action. This requires bleeding of the hydraulic
system after it has been correctly connected. The
12. Install the outer brake pad. hydraulic system can be gravity bled, manually bled
or bled with pressure bleeding equipment.
1. Connect the scan tool and follow the anti-lock

brake system (ABS) bleed instructions.
2. Use the pressure or manual bleed procedure(s)

to bleed the system. Begin at the RH rear brake
caliper.

206-04-1 Rear Disc Brake 206-04-1

Disc Brake System — Exploded View
NOTE: 4.0L SOHC and 4.6L (3L) shown, 5.4L similar.

1 2N386 Brake caliper guide pin bolts 5 — Guide pin and boot (part of
2 2552 RH/ 2553 Brake caliper kit 2B296)
LH 6 W705821 Brake caliper anchor plate
3 2218 Brake pads (kit) bolt kits (2 bolts each side)
4 — Spring clips (part of kit 2200) 7 2B511 Brake caliper anchor plate
(Continued) 8 2C026 Brake disc
(Continued)

206-04-2 Rear Disc Brake 206-04-2
9 W500020 Brake disc shield bolts (3 19 — Anti-moan bracket U-bolt and
required) (part of 2C029) clamp (part of 2C371)
10 2C029 Brake disc shield 20 2C371 Anti-moan bracket (4.0L
11 — Brake tube fitting SOHC and 4.6L [3V] only)
12 W712275 Brake caliper flow bolt 21 — Brake caliper support bracket
bolts (4 required) (part of
13 W712362 Copper washers (2 required) 4001)
14 2A442 RH/ Brake hose 22 — Brake caliper support bracket
2A478 LH flag nuts (4 required) (part of
15 N802191 Brake hose bracket bolt 4001)
16 — Bleeder screw cap (part of 23 — Brake caliper support bracket
2N033) (part of 4001)
17 2N033 Bleeder screw
18 W520112 Anti-moan bracket U-bolt 1. For additional information, refer to the
nuts (2 required) procedures in this section.
(Continued)


Front Disc Brake
The front disc brake system includes the brake
caliper, the disc brake pads, the anchor plate and the
brake disc. The brake caliper on 4.0L SOHC and
4.6L (3V) equipped vehicles is a dual piston
floating design. The brake caliper is mounted to the
anchor plate by the caliper guide bolts. The brake
caliper slides, or floats, on the caliper guide bolts.
The brake caliper on 5.4L equipped vehicles is a
quad piston, non-floating design. The brake caliper
is mounted directly to the wheel knuckle and does
not have an anchor plate. The brake disc is a cast,
ventilated type rotor. When mechanical force is
applied by the driver to the brake pedal, the force is
converted into hydraulic pressure by the master
cylinder. The hydraulic force is directed to the
brake calipers. The brake pads are then forced
against the brake disc friction surfaces by the brake
caliper pistons. The friction of the brake pads on the
brake disc causes the slowing of wheel rotation and
the vehicle. The brake disc shield, mounted to the
wheel knuckle, protects the inner surface of the
brake disc from foreign material.


Front Disc Brake


Hydraulic Brake Actuation Brake Pedal and Bracket
The brake pedal is connected to the power brake
Brake Master Cylinder booster, which is connected to the brake master
The dual brake system is split front and rear with cylinder. When the brake pedal is pressed, brake
the front wheel brakes comprising one circuit and fluid is forced from the brake master cylinder
the rear wheel brakes the other circuit. through the steel tubing and flexible hoses to the
The brake master cylinder is a dual piston type. front and rear brake calipers.
When the brake pedal is pressed, pressure is applied The brake pedal bracket provides a mounting
by mechanical linkage to the primary and secondary location for the clutch pedal and clutch pedal master
piston. The pistons then apply hydraulic pressure to cylinder for vehicles with manual transmissions. The
the two hydraulic circuits. The brake master bracket also provides a mounting location for the
cylinder can not be repaired. Install a new master speed control deactivator switches, stoplamp
cylinder if replacement is necessary. switch, and on vehicles with manual transmissions,
The brake master cylinder consists of: the starter interlock switch, mounted just below the
clutch.
• brake master cylinder reservoir
• brake master cylinder body Brake Tubes and Hoses
CAUTION: Never use copper tubing. It is
Brake Master Cylinder Reservoir subject to fatigue, cracking and corrosion which
The brake master cylinder reservoir: could result in brake tube failure.
• is mounted to the brake master cylinder. Steel tubing is used throughout the brake hydraulic
• holds fluid supply for each brake master cylinder system. All brake tube fittings must be correctly
hydraulic piston. flared to provide strong leakproof connections.
When bending the tubing to fit the underbody or
• provides visual fluid level markings. rear axle contours, be careful not to kink or crack
• contains the brake master cylinder fluid level the tube.
sensor. If a section of brake tube is damaged, the entire
section must be removed and a new tube of the
same type, size, shape and length installed.
When replacing hydraulic brake tubing, hoses, or
connectors, tighten all connections securely. After
installation, bleed the brake system. For additional
information, refer to Section 206-00.


Hydraulic Brake Actuation


Hydraulic Control Unit (HCU)
Material
Item Specification
CPM-1 or CPM-1-C
(Canada)

Item Part Number Description 1. Disconnect the battery ground cable. For
1 — Anti-lock brake system (ABS) additional information, refer to Section 414-01.
module electrical connector
(part of 14A005) 2. Remove the air cleaner assembly. For additional
2 — Brake tube-to-hydraulic information, refer to Section 303-12.
control unit (HCU) fittings
(part of 2C296) (6 required) 3. Disconnect the anti-lock brake system (ABS)
3 13083701 HCU bracket-to-frame bolts module electrical connector.
(3 required)
4 2C215 HCU 4. NOTE: Brake tubes must be installed in the
same location as removed.
5 3B676 Bracket-to-HCU bolt
6 2C304 HCU bracket Loosen the 6 brake tube-to-hydraulic control
unit (HCU) fittings, disconnect and position the
Removal and Installation brake tubes aside.
approved DOT 3 brake fluid will cause 5. Remove the 3 HCU bracket-to-frame bolts.
permanent damage to brake components and will • To install, tighten to 25 Nm (18 lb-ft).
render the brakes inoperative. Failure to follow
these instructions may result in personal injury. 6. Remove the HCU assembly.
WARNING: Carefully read cautionary 7. If necessary, remove the HCU bracket bolt and
information on product label. For EMERGENCY bracket.
MEDICAL INFORMATION seek medical advice. • To install, tighten to 11 Nm (8 lb-ft).
products call: 1-800-959-3673. For additional 8. To install, reverse the removal procedure.
information, consult the product Material Safety • Bleed the brake system. For additional
Data Sheet (MSDS) if available. Failure to follow information, refer to Section 206-00.


206-05-1 Parking Brake and Actuation 206-05-1

Parking Brake — Exploded View

1 N804796 Parking brake control nuts (2 7 2A635 Rear parking brake cable
required) (RH)
2 W704911 Parking brake control bolt (2 8 2A823 Rear parking brake cable
required) (LH)
3 2780 Parking brake control 9 — Front parking brake cable
4 2860 Parking brake cable retaining (part of 2780)
clips (2 required)
5 W505263 Parking brake cable bracket 1. For additional information, refer to the
bolts procedures in this section.
6 W704911 Parking brake cable
crossmember bracket bolt
(Continued)


Parking Brake Cable — Rear 5. Remove and discard the appropriate support
brace front bolts.
All vehicles

Section 100-02.
2. Release the tension on the parking brake cable.

For additional information, refer to Parking
Brake Cable Tension Release in this section.
Convertible vehicles
3. Remove and discard the appropriate support All vehicles

brace rear bolts.
• To install, tighten to 63 Nm (46 lb-ft). 6. Disconnect the appropriate rear parking brake
cable from the front parking brake cable at the
equalizer, and release the cable from the body
bracket.
4. Remove and discard the appropriate support

brace upper bolts.

7. CAUTION: Verify that the boot is 8. Remove the parking brake cable bracket bolt.
attached to the conduit end fitting and the • To install, tighten to 27 Nm (20 lb-ft).
strand end fitting. A clamp must be secured
on the strand end fitting (t-end). There 9. If removing the RH cable, remove the parking
should be no exposed strand at the wheel end brake cable crossmember bracket bolt.
of the parking brake cable. • To install, tighten to 20 Nm (15 lb-ft).
Remove the parking brake cable retaining clip
from the parking brake cable and disconnect the 10. To install, reverse the removal procedure.
rear parking brake cable from the brake caliper. • Adjust the parking brake cable tension. For
additional information, refer to the Parking
Brake Cable Adjustment in this section.

GENERAL PROCEDURES
Parking Brake Cable Adjustment
CAUTION: Do not overtighten the parking

brake cable adjustment nut. Overtightening will
cause the brakes to drag or lock up.
1. Remove the access cover inside the floor

console bin.
4. Apply the tension by tightening the parking

brake cable adjustment nut until there is no lash
in the system with the handle in the lowered
position.
5. Cycle the parking brake control 4 times and

adjust as necessary.
6. Lower the parking brake handle and install the

access cover.
2. Position the parking brake handle up at the
fourth notch to access the adjuster nut. 7. Test the parking brake system for proper
operation.
3. NOTE: The rod is staked to prevent the
removal of the nut.
Loosen, but do not remove, the parking brake
cable adjuster nut.

GENERAL PROCEDURES
Parking Brake Cable Tension Release 2. Position the parking brake control handle at the
fourth notch to access the parking brake cable
adjuster nut.
CAUTION: Do not overtighten the parking
brake cable adjustment nut. Overtightening will 3. NOTE: The rod is staked to prevent the
cause the brakes to drag or lock up. removal of the nut.
1. Remove the access cover inside the floor Loosen, but do not remove, the parking brake
console bin. cable adjuster nut.
4. Lower the parking brake control handle.
5. To adjust the parking brake cable tension, refer

to Parking Brake Cable Adjustment in this
section.


Parking Brake Control 5. Disconnect the parking brake switch electrical
connector.
6. Remove the 2 nuts from the parking brake
control.
hoist. For additional information, refer to • To install, tighten to 17 Nm (13 lb-ft).
Section 100-02.
7. Remove the 2 bolts from the parking brake
2. Remove the floor console. For additional control.
information, refer to Section 501-12. • To install, tighten to 30 Nm (22 lb-ft).
3. Release the tension on the parking brake cable. 8. Remove the parking brake control.
For additional information, refer to Parking • Position the cable and equalizer through the
Brake Cable Tension Release in this section. floorpan.
4. Disconnect the front parking brake cable from 9. To install, reverse the removal procedure.
the 2 rear parking brake cables at the equalizer
and release the front cable from the body • Adjust the parking brake cable tension. For
bracket. additional information, refer to Parking
Brake Cable Adjustment in this section.


Parking Brake The parking brake cable tension is not
self-adjusting. Refer to Parking Brake Cable
Parking Brake Adjustment in this section.
The parking brake system is a mechanical system
that activates a self-adjusting brake system within
the rear brake caliper.
The parking brake system is cable-actuated and
controlled by an independent hand-operated parking
brake control. The parking brake system is actuated
when the parking brake control is pulled up and
released by pressing the release button on the end
of the parking brake control handle. The parking
brake control applies tension to rear brake pads
through the front parking brake cable and conduit
and the LH and RH rear parking brake cables. The
respective rear parking brake assemblies are then
applied.


Parking Brake 2. Visually inspect for obvious signs of
mechanical damage.
Principles of Operation
Visual Inspection Chart
Parking Brake System
The parking brake system is cable-actuated and Mechanical
controlled by an independent hand-operated parking • Parking brake control
brake control that is not self adjusting, The parking • Parking brake cables
brake system is actuated when the parking brake • Parking brake release handle
control is pulled up. The parking brake control
applies tension to the brake pads through the front 3. If an obvious cause for an observed or reported
parking brake cable and conduit and the LH and RH concern is found, correct the cause (if possible)
rear parking brake cables. before proceeding to the next step.
Inspection and Verification 4. If the cause is not visually evident, verify the
symptom and GO to Symptom Chart.
NOTE: Prior to carrying out any diagnosis, make
sure the red brake warning indicator is functional.
The first indication that something may be wrong in
the brake system is a change in the feeling through
the parking brake control. The parking brake not
holding on an incline or dragging after being
released are also indicators of system concerns.
Check the operation of the parking brake system
with the vehicle on a hoist and the parking brake
control fully released. Check for any damaged
cables and install new components as necessary.
Carry out the brake system diagnosis.
1. Verify the customer concern.
Symptom Chart
Symptom Chart
• Rear brakes drag • Parking brake component • REPAIR or INSTALL new
parking brake components as
necessary. REFER to Parking
Brake Control or Parking
Brake Cable — Rear in this
section.
• Brake caliper guide pins • REPAIR or INSTALL new
brake caliper guide pins.
• Brake caliper • REPAIR or INSTALL new
• Brake booster • CARRY OUT the Brake
Booster Component Test.
• Brake master cylinder • CARRY OUT the Brake
Master Cylinder Component
Test. REFER to Section
206-00.

• The parking brake will not • Parking brake control • GO to Pinpoint Test A.
apply • Parking brake cables
• Parking brake rear wheel
components
• The parking brake will not • Parking brake cables • GO to Pinpoint Test B.
release • Parking brake control
• Parking brake rear wheel
components
Pinpoint Test A: The Parking Brake Will Not • Parking brake control
Apply • Parking brake cables
Normal Operation • Parking brake rear wheel components
brake control that is not self adjusting, The parking
brake system is actuated when the parking brake
applies tension to the brake pads through the front
parking brake cable and conduit and the LH and RH
rear parking brake cables.
PINPOINT TEST A: THE PARKING BRAKE WILL NOT APPLY
A1 CHECK THE PARKING BRAKE CABLES
• With the vehicle in NEUTRAL, position it on a hoist. Refer to Yes
Section 100-02. INSTALL a new parking brake cable as
• Inspect for broken or binding parking brake cables. necessary. REFER to Parking Brake
• Is there a parking brake cable concern? Cable — Rear in this section. TEST the
No
GO to A2.
A2 CHECK THE PARKING BRAKE CONTROL
• Operate the parking brake control. Yes
• Does the parking brake control operate smoothly? GO to A3.
No
INSTALL a new parking brake control.
REFER to Parking Brake Control in this
section. TEST the system for normal
operation.
A3 CHECK THE PARKING BRAKE COMPONENTS
• Operate the parking brake control and observe the parking brake Yes
components. CHECK the brake pad installation. REFER
• Do the parking brake components operate correctly? to Section 206-04.
No
INSTALL new components. TEST the

Pinpoint Test B: The Parking Brake Will Not Possible Causes
Release • Parking brake cables
Normal Operation • Parking brake control
• Parking brake rear wheel components
brake control that is not self adjusting. The parking
brake system is actuated when the parking brake
applies tension to the brake pads through the front
parking brake cable and conduit and the LH and RH
rear parking brake cables.
PINPOINT TEST B: THE PARKING BRAKE WILL NOT RELEASE
B1 CHECK THE FRONT PARKING BRAKE CABLE
• Release the parking brake control. Yes
• If the vehicle cannot be moved, raise and support it. INSPECT the front parking brake cable for
• Release the parking brake cable tension. Refer to Parking Brake binding. INSPECT the parking brake
Cable Tension Release in this section. control for wear or damage. INSTALL new
• Disconnect the parking brake cable at the parking brake lever. components as necessary. Refer to
• Does the parking brake release? Parking Brake Control in this section.
No
GO to B2.
B2 CHECK THE PARKING BRAKE REAR CABLES
• Disconnect the RH parking brake rear cable and conduit and the Yes
LH parking brake rear cable and conduit from the parking brake INSPECT the parking brake rear cable
lever at each wheel. and conduits for wear or damage.
• Does the parking brake release? INSTALL new components as necessary.
Refer to Parking Brake Cable — Rear in
this section. TEST the system for normal
operation.
No
REPAIR the worn or damaged rear wheel
parking brake components as necessary.


Power Brake System

206-04-1 Rear Disc Brake 206-04-1

Rear Disc Brake
The braking system includes the brake caliper, the
brake pads and the brake disc. The brake caliper is
a single piston, floating design. The brake caliper is
mounted to the brake caliper anchor plate by the
caliper guide bolts. The brake caliper slides, or
floats, on the caliper guide pins. The brake disc is a
cast, non-ventilated type rotor. When mechanical
force is applied by the driver to the brake pedal, the
force is converted into hydraulic pressure by the
master cylinder. The hydraulic force is directed to
the disc brake calipers and transferred to the brake
pads. The brake pads are then forced against the
brake disc friction surfaces by the brake caliper
pistons slowing the vehicle.
The brake caliper is also used for the parking brakes
and is activated by the rear parking brake cable.
When the cable is actuated, a lever on the caliper
engages a self-adjusting ratchet assembly inside the
brake caliper piston. This applies pressure to the
brake pads, preventing the brake disc from moving.

206-04-1 Rear Disc Brake 206-04-1

Rear Disc Brake

SPECIFICATIONS
General Specifications (Continued)
Item Specification
General Specifications
Item Specification Motor Vehicle Brake WSS-M6C62-A
Brake Pads — 4.0L SOHC and 4.6L (3V) Fluid PM-1 or PM-1-C
(US); CPM-1 or CPM-1-C
Minimum brake pad 3.0 mm (0.118 in) (Canada)
thickness
Maximum brake pad 2.0 mm (0.079 in) Anti-Seize Lubricant XL-2
thickness variation (US); CXG-2-B (Canada)
(pad-to-pad)
Maximum brake pad taper 3.0 mm (0.118 in) Grease and Dielectric
wear (in any direction) Compound XG-3-A
Brake Disc — 4.0L SOHC and 4.6L (3V) Metal Brake Parts Cleaner —
Minimum front brake disc 28.4 mm (1.11 in) PM-4-A or PM-4-B (US);
thickness CPM-4 (Canada)
Minimum rear brake disc 17.4 mm (0.68 in)
thickness Torque Specifications
Minimum thickness to 29 mm (1.14 in)
machine front brake disc Description Nm lb-ft lb-in
Minimum thickness to 18 mm (0.71 in) Bleeder screw 10 — 89

machine rear brake disc Brake caliper anchor 115 85 —
Brake Pads — 5.4L plate bolts
Minimum front brake pad 1.8 mm (0.071 in) Brake caliper guide pin 34 25 —
thickness bolts
Minimum rear brake pad 3.0 mm (0.118 in) Brake caliper flow bolt 40 30 —
thickness Brake disc shield bolts 20 15 —
Brake Disc — 5.4L Brake flexible 20 15 —
Minimum front brake disc 3.0 mm (1.18 in) hose-to-body bolt
thickness Brake flexible 20 15 —
Minimum thickness to 30.6 mm (1.20 in) hose-to-strut bolt
machine front brake disc Brake tube fittings 17 13 —
Lubricant Brake caliper bolt — 115 85 —
5.4L

SPECIFICATIONS
Item Specification
Item Specification Motor Vehicle Brake WSS-M6C62-A
Brake Pads — 4.0L SOHC and 4.6L (3V) Fluid PM-1 or PM-1-C
(US); CPM-1 or CPM-1-C
Minimum brake pad 3.0 mm (0.118 inch) (Canada)
thickness
Maximum brake pad 2.0 mm (0.079 inch) Anti-Seize Lubricant XL-2
thickness variation (US); CXG-2-B (Canada)
(pad-to-pad)
Maximum brake pad taper 3.0 mm (0.118 inch) Grease and Dielectric
wear (in any direction) Compound XG-3-A
Brake Disc — 4.0L SOHC and 4.6L (3V) Metal Brake Parts Cleaner —
Minimum front brake disc 28.4 mm (1.11 in) PM-4-A or PM-4-B (US);
thickness CPM-4 (Canada)
Minimum rear brake disc 17.4 mm (0.68 in)
thickness Torque Specifications
Minimum thickness to 29 mm (1.14 in)
machine front brake disc Description Nm lb-ft lb-in
Minimum thickness to 18 mm (0.71 in) Brake caliper boltsa 33 24 —

machine rear brake disc Front brake caliper 10 — 89
Brake Pads — 5.4L bleeder screw — 4.0L
SOHC and 4.6L (3V)
Minimum front brake pad 1.8 mm (0.071 in)
thickness Front brake caliper 18 13 —
bleeder screws — 5.4L
Minimum rear brake pad 3.0 mm (0.118 in)
thickness Master cylinder brake 17 13 —
tube fittings
Brake Disc — 5.4L
Rear brake caliper 10 — 89
Minimum front brake disc 3.0 mm (1.18 in) bleeder screw — all
thickness vehicles
Minimum thickness to 30.6 mm (1.20 in) a The bolts retaining the front caliper halves together
machine front brake disc on 5.4L equipped vehicles are not serviceable.
Lubricant

206-04-1 Rear Disc Brake 206-04-1
SPECIFICATIONS
Item Specification
Item Specification Grease and Dielectric
Brake Pads Compound XG-3-A
Minimum brake pad 3.0 mm (0.118 in) Metal Brake Parts Cleaner —
thickness PM-4 or PM-4-B (US);
CPM-4 (Canada)
Maximum brake pad 2.0 mm (0.079 in)
thickness variation
(pad-to-pad) Torque Specifications
Maximum brake pad taper 3.0 mm (0.118 in) Description Nm lb-ft lb-in
wear (in any direction)
Anti-moan bracket 35 26 —
Brake Disc U-bolt nuts
Minimum brake disc 17.4 mm (0.68 in) Bleeder screw 10 — 89
thickness
Brake caliper flow bolt 40 30 —
Minimum thickness to 18.0 mm (0.7 in)
machine brake disc Brake disc shield bolts 20 15 —
Lubricant Brake caliper anchor 103 76 —
plate bolts
Motor Vehicle Brake WSS-M6C62-A Brake hose bracket 15 11 —
Fluid PM-1 or PM-1-C bolts
(US); CPM-1 or CPM-1-C Brake caliper guide pin — — —
(Canada) boltsa
High Temperature Nickel ESE-M12A4-A Brake tube fitting 17 13 —
Anti-Seize Lubricant XL-2
(US); CXG-2-B (Canada) Brake caliper support 68 50 —
bracket bolts
a Refer to the procedure for the proper tightening
sequence and torque specifications.

SPECIFICATIONS
Torque Specifications (Continued)
Description Nm lb-ft
Torque Specifications
Parking brake control bolts 30 22
Description Nm lb-ft
Parking brake control nuts 17 13
Parking brake cable 20 15
crossmember bracket bolt Support brace bolts 63 46
Parking brake cable bracket 27 20

bolts

SPECIFICATIONS
Description Nm lb-ft lb-in
Brake booster nuts 25 18 —

SPECIFICATIONS
Brake booster nuts 25 18 —
Item Specification
Brake fluid 25 18 —
Lubricant proportioning valve
High Performance DOT 3 ESA-M6C25-A or Brake fluid reservoir 8 — 71
Motor Vehicle Brake WSS-M6C62-A pin
Fluid
PM-1 or PM-1-C (US); Brake tube fittings 17 13 —
CPM-1 or CPM-1-C Brake master cylinder 25 18 —
(Canada) nuts
Brake pedal bracket 25 18 —
bolt

SPECIFICATIONS
Anti-lock brake system 3 — 27
Item Specification (ABS) module screws
Lubricant Bracket-to-HCU bolt 11 8 —
High Performance DOT 3 ESA-M6C25-A or Brake tube-to-HCU 17 13 —
Motor Vehicle Brake WSS-M6C62-A fittings
Fluid PM-1 or PM-1-C
(US); CPM-1 or CPM-1-C Hydraulic control unit 25 18 —
(Canada) (HCU) bracket-to-frame
bolts
Wheel speed sensor 15 11 —
bolt


Traction Control Switch
1. Remove the instrument panel center finish

panel. For additional information, refer to
Section 501-12.
2. Press the retaining tabs and remove the

switchblock.


Wheel Speed Sensor — Front

1 — Wheel speed sensor electrical 3 — Wheel speed sensor grommet
connector (part of 14406) retainers (part of 2C204) (2
2 — Wheel speed sensor harness required)
pin-type retainers (part of 4 S997960825 Wheel speed sensor bolt
2C204) (3 required) 5 2C204 Wheel speed sensor
(Continued)

Removal and Installation 5. Disconnect the 2 wheel speed sensor grommet
retainers from the brake hose clips.
additional information, refer to Section 414-01. 6. Remove the wheel speed sensor bolt.
hoist. For additional information, refer to 7. Remove the wheel speed sensor and harness
Section 100-02. assembly.
3. Disconnect the wheel speed sensor electrical 8. To install, reverse the removal procedure.
connector.
4. Disconnect the 3 wheel speed sensor harness

pin-type retainers.


Wheel Speed Sensor — Rear

1 14406 Wheel speed sensor electrical 4 S997960825 Wheel speed sensor bolt
connector 5 2C190 Wheel speed sensor
2 — Wheel speed sensor harness
pin-type retainers (part of Removal and Installation
2C190) (2 required)
3 — Wheel speed sensor grommet
retainer (part of 2C190) 1. Disconnect the battery ground cable. For
(Continued)

2. With the vehicle in NEUTRAL, position it on a 5. Disconnect the wheel speed sensor grommet
hoist. For additional information, refer to retainer from the brake hose clip.
Section 100-02.
6. Remove the wheel speed sensor bolt.
3. Disconnect the wheel speed sensor electrical • To install, tighten to 15 Nm (11 lb-ft).
connector.
7. Remove the wheel speed sensor.
4. Disconnect the 2 wheel speed sensor harness
pin-type retainers. 8. To install, reverse the removal procedure.


Wheel Speed Sensor Ring — Front
Special Tool(s)
Pinion Bearing Cone Remover
205-D002 (D79P-4621A)
Axle Bearing/Seal Plate
205-090 (T75L-1165-B)
Installer, Wheel Speed Sensor

Ring
206-041 (T89P-20202-A) Installation
1. Using the special tool, install the front wheel

speed sensor ring to the front hub.
Remover/Installer, Wheel Speed

Sensor
206-033 (T88P-20202-A)
Removal
1. Remove the front hub and bearing assembly.

For additional information, refer to Section
204-01.
2. Install the front hub and bearing assembly. For
2. Using the special tools, remove the front wheel additional information, refer to Section 204-01.
speed sensor ring from the front hub.


Wheel Speed Sensor Ring — Rear
Special Tool(s)
Pinion Bearing Cone Remover
205-D002 (D79P-4621A) or
equivalent
Axle Bearing/Seal Plate

205-090 (T75L-1165-B)
Installer, Wheel Speed Sensor

Ring
206-041 (T89P-20202-A)
Removal
1. Remove the rear axle shaft. For additional

information, refer to Section 205-02A or
Section 205-02B.
2. Using the special tool, remove the anti-lock

brake sensor indicator from the axle shaft.

Installation 2. Using the special tools, press the rear anti-lock
brake sensor on the rear axle shaft to
1. Using the special tools, align the rear anti-lock specification.
brake sensor indicator to the rear axle shaft.
3. Install the rear axle shaft. For additional

information, refer to Section 205-02A.

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206-03-1 Front Disc Brake 206-03-1

REMOVAL AND INSTALLATION

Item Part Number Description Item Part Number Description

Copyright  2006, Ford Motor Company

2007 Mustang, Mustang GT 8/2006

Item Part Number Description Item Part Number Description

2007 Mustang, Mustang GT 8/2006

2007 Mustang, Mustang GT 8/2006

REMOVAL AND INSTALLATION

Item Part Number Description

Copyright  2006, Ford Motor Company

1. Disconnect the battery ground cable. For

2. Remove the air cleaner assembly. For additional

3. Disconnect the ABS module electrical

5. To install, reverse the removal procedure.

2007 Mustang, Mustang GT 8/2006

DIAGNOSIS AND TESTING

4. If an obvious cause for an observed or reported

2007 Mustang, Mustang GT 8/2006

2007 Mustang, Mustang GT 8/2006

2007 Mustang, Mustang GT 8/2006

2007 Mustang, Mustang GT 8/2006

2007 Mustang, Mustang GT 8/2006

Pinpoint Tests Possible Causes

Pinpoint Test A: DTCs B1317 and B1318 — • Fuse(s)

2007 Mustang, Mustang GT 8/2006

2007 Mustang, Mustang GT 8/2006

2007 Mustang, Mustang GT 8/2006

2007 Mustang, Mustang GT 8/2006

2007 Mustang, Mustang GT 8/2006

2007 Mustang, Mustang GT 8/2006

Pinpoint Test D: DTCs C1222, C1233, C1234, Normal Operation

2007 Mustang, Mustang GT 8/2006

Pinpoint Test E: DTC C1446 — Brake Switch Possible Causes

2007 Mustang, Mustang GT 8/2006

Pinpoint Test F: Spongy/Soft/Low Brake Possible Causes

2007 Mustang, Mustang GT 8/2006

2007 Mustang, Mustang GT 8/2006

Pinpoint Test H: DTC C1093 — Traction Possible Causes

2007 Mustang, Mustang GT 8/2006

2007 Mustang, Mustang GT 8/2006

Pinpoint Test I: The Traction Control Switch Normal Operation

2007 Mustang, Mustang GT 8/2006

2007 Mustang, Mustang GT 8/2006

2007 Mustang, Mustang GT 8/2006

DESCRIPTION AND OPERATION

Copyright  2006, Ford Motor Company

REMOVAL AND INSTALLATION

Item Part Number Description Item Part Number Description

Copyright  2006, Ford Motor Company

8. To install, reverse the removal procedure.

2007 Mustang, Mustang GT 8/2006

DESCRIPTION AND OPERATION

Copyright  2006, Ford Motor Company

REMOVAL AND INSTALLATION

WARNING: Use of any other than 4. Inspect the brake caliper.

3. Bleed the brakes. For additional information,

Copyright  2006, Ford Motor Company