Brake System-General Information: Other Ford Econoline E150

Brake Pads

Note. It is not required to install new brake pads if friction material properties are within guidelines. It is also not required to install new brake pads when the brake discs are machined.

1. Remove the brake pads. For additional information, refer to «DISC & DRUM»(ref-161514) for front or rear disc brakes.
2. Inspect and measure the thickness of the brake pad friction material. Install new brake pads if the thickness of the friction material is less than 3.0 mm (0.118 inch). For additional information, refer to «DISC & DRUM»(ref-161514) for front or rear disc brakes. Compare all 4 front or rear pads for uneven wear. Install new brake pads if the thickness of the friction material varies from pad to pad by more than 2.0 mm (0.079 inch). For additional information, refer to «DISC & DRUM»(ref-161514) for front or rear disc brakes. Install new brake pads if there are missing chunks or cracks in the lining through to the backing plate. For additional information, refer to «DISC & DRUM»(ref-161514) for front or rear disc brakes. If the friction material shows taper wear, i.e. the thickness varies by more than 3.0 mm (0.118 inch) in any direction, verify the caliper guide pins are functioning correctly. For additional information, refer to «BRAKE CALIPER GUIDE PINS»(ref-210119-S42698548112005121300000) .

Brake Discs

Note. It is generally not required to install new brake discs to address noise issues.

1. Remove the brake disc. For additional information, refer to «DISC & DRUM»(ref-161514) for front or rear disc brakes.
2. Inspect the brake discs and measure the brake disc thickness in a minimum of 4 places around the circumference of the brake disc. Record the measurements. Install new brake discs if any thickness measurement is less than the minimum specification. For additional information, refer to «DISC & DRUM»(ref-161514) for front or rear disc brakes. Install new brake discs if cracked. For additional information, refer to «DISC & DRUM»(ref-161514) for front or rear disc brakes. Machine the brake discs if the diagnosis has revealed vibration in the steering wheel, seat, or pedal while braking. Heavily scored brake discs, similar to that caused by pads worn down to the backing plate, should also be machined. In order to machine, discs must be above the minimum thickness to machine specification. For additional information, refer to «SPECIFICATIONS»(ref-210119-S42099566722005121300000) and «BRAKE DISC MACHINING»(ref-210119-S06247157132005121300000) .

Brake Caliper

Inspect the brake calipers for the following

1. Brake fluid leaks. For additional information, refer to «BRAKE SYSTEM LEAK CHECK»(ref-210119-S14088252982005121300000) .
2. Boots and seals for tears or cracks.
3. Caliper piston for binding and corrosion.
4. Guide pins for correct operation. For additional information, refer to «BRAKE CALIPER GUIDE PINS»(ref-210119-S42698548112005121300000) .

Brake Caliper Guide Pins

The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper wear or the guide pins are difficult to move, then carry out the following steps.

Note. If a guide pin kit is not available, install a new caliper assembly.

1. Disassemble the guide pins. For additional information, refer to «DISC & DRUM»(ref-161514) for front or rear disc brakes.
2. Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material from the caliper guide pin bores. Clean remaining debris from the bores with brake parts cleaner and compressed air.
3. Install new brake pads if the lining is not within specifications. For additional information, refer to «DISC & DRUM»(ref-161514) for front or rear disc brakes.
4. Assemble the caliper guide pins using new caliper seals, boots and guide pins. Use an ample amount of grease to lubricate the bores and guide pins.

Brake Lines and Tubes

1. Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly double flared to provide strong, leakproof connections. When bending tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube.
2. If a section of the brake tube is damaged, the entire section must be installed new with a tube of the same type, size, shape and length.
3. When installing the hydraulic brake tubing, hoses, or connectors, tighten all connections to specifications. After installation, bleed the brake system. For additional information, refer to «BRAKE SYSTEM BLEEDING»(ref-210119-S20869138792005121300000) .
4. The wet appearance on the outer cover of rubber brake hoses is called sweating. This is a normal condition for rayon-braid neoprene hose and is not a sign of leakage or cause to install a new hose.

Install a new flexible brake hose if the hose shows signs of softening, cracking or other damage.

When installing a new brake hose, position the hose to avoid contact with other vehicle components.

Non-Pressure Leaks

The only part of the brake system that could have a brake fluid loss that does not appear when the system is under pressure is the brake master cylinder reservoir under the following conditions

1. Missing or poorly-fitted brake master cylinder filler cap
2. Punctured or otherwise damaged brake master cylinder reservoir
3. Missing or damaged brake master cylinder filler cap gasket
4. 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

The following conditions are considered normal and are not indications that the brake master cylinder is in need of service.

Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir will rise during brake application and fall during release. The net fluid level (such as after brake application and release) will remain unchanged.

Condition 2: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This results from the normal lubricating action of the master cylinder bore and seal.

Condition 3: Fluid level will decrease with pad wear.

Brake Master Cylinder - Abnormal Conditions

Changes in brake pedal feel or travel are indicators that something could be wrong in the brake system. GO to SYMPTOM CHART for abnormal condition diagnosis.

Brake Booster

Inspect the brake booster for the following

1. Excessive corrosion or damage
2. Vacuum connections for leakage
3. Vacuum hoses for kinks or leakage
4. Brake booster check valve for correct operation

Changes in the brake pedal feel or travel are indicators that something could be wrong in the brake system. GO to SYMPTOM CHART for abnormal condition diagnosis.

Parking Brake

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. Check the rear brake adjustment or carry out the brake system diagnosis. For additional information, refer to DISC & DRUM .

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COMPONENT TESTS

Note. If a vehicle with a locked wheel must be moved, loosen the bleeder screw to relieve pressure.

Always check brake fluid level and, if necessary, fill with clean DOT 3 brake fluid.

Check Valve

The function of the power brake booster check valve is to allow manifold vacuum to enter the power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation.

To test the function of the power brake booster check valve

1. Start and run the engine for at least 10 seconds.
2. Operate the brake pedal to check for power assist.
3. Disconnect the vacuum booster hose from the power brake booster. Do not remove the power brake booster check valve from the power brake booster.
4. There should be enough vacuum retained in the power brake booster for at least one more power-assisted brake operation.

Brake Master Cylinder

1. Disconnect the brake lines at the brake master cylinder.
2. Plug the outlet ports of the brake master cylinder.
3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and a new one must be installed. For additional information, refer to «DISC & DRUM»(ref-161514) .

Compensator Port Check

The purpose of the compensator ports in the brake master cylinder is to supply any additional brake fluid required by the system due to brake pad wear, and to allow brake fluid returning from the brake lines to the brake master cylinder to enter the brake master cylinder reservoir.

The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir. Turbulence seen in the brake master cylinder reservoir upon release of the brake pedal is normal and shows that the compensating ports are not plugged.

Brake Disc Machining

SPECIAL TOOL(S)

Scheme 104

MATERIAL

MATERIAL SPECIFICATIONS

Note. Read the entire operating manual and view the video shipped with the lathe before installing, operating, or repairing the lathe.

Note. If the thickness of the brake disc is less than the minimum thickness to machine specification, install a new brake disc. This will make sure that the brake disc will be above minimum thickness after machining.

Note. Do not machine new brake discs.

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

1. Position the brake caliper and brake caliper anchor bracket aside. For additional information, refer to «DISC & DRUM»(ref-161514) for front or rear disc brakes.
2. For vehicles with a two-piece brake disc and hub assembly: Mark the brake disc and the wheel stud for correct indexing during re-assembly. Remove the brake disc from the hub. CAUTION: Do not use an abrasive sanding disc since it will remove paint or other protective finishes from the wheel or metal from the mounting surfaces, adversely affecting corrosion protection and brake disc lateral runout. Remove corrosion from the wheel mounting surface, both disc mounting surfaces, and hub mounting surface. Align the match marks and install the brake disc on the hub.
3. Machine the brake disc using an on-car brake lathe. Install the hub adapter and silencer belt, if necessary. Install the cutting lathe. If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. Total indicated reading (TIR) target is 0.000 mm (0.000 in), maximum is 0.08 mm (0.003 in). Center the cutting head, adjust the cutting bits, and install the chip deflector. NOTE: The depth of cut should be between 0.10 and 0.20 mm (0.004 and 0.008 in). Lighter cuts will cause the bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface finish. Machine the brake disc. Remove the lathe and, if installed, the silencer belt. Remove the hub adapter.
4. Remove the metal shavings.
5. For vehicles with a two-piece brake disc and hub assembly: Remove the brake disc from the hub. Remove metal shavings from the hub, the brake disc mounting surfaces and from the ABS sensors. Apply anti-seize lubricant to the hub mounting surface to prevent corrosion. Align the match marks and install the brake disc on the hub.
6. Install the brake caliper and brake caliper anchor bracket. For additional information, refer to «DISC & DRUM»(ref-161514) for front disc brakes or rear disc brakes.

Component Bleeding

SPECIAL TOOL(S)

Scheme 105

MATERIAL

MATERIAL SPECIFICATIONS

Master Cylinder Priming - In-Vehicle or Bench

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

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

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1. For in-vehicle priming, disconnect the brake lines.
2. For bench priming, mount the brake master cylinder in a vise.
3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. Fill the brake master cylinder reservoir with clean DOT 3 brake fluid.
4. Have an assistant pump the brake pedal, or slowly press the primary piston until clear fluid flows from both brake tubes, without air bubbles.
5. If the brake master cylinder has been primed at the bench, install it in the vehicle. For additional information, refer to «DISC & DRUM»(ref-161514) .
6. Remove the short brake tubes.
7. Install the brake outlet tubes.
8. Bleed each brake tube at the brake master cylinder as follows: Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal. Loosen the rearmost brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting. Repeat this operation until clear, bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube.

Four Wheel Anti-Lock Brake System (4WABS) Hydraulic Control Unit (HCU)

Note. This procedure only needs to be carried out if a new 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been installed or if the HCU lines have been opened.

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1. Clean all dirt from and remove the brake master cylinder filler cap. Fill the brake master cylinder reservoir with the specified brake fluid.
2. Connect a clear waste line to the RH rear bleeder screw and submerge the other end in a container partially filled with the recommended brake fluid.
3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary.
4. Tighten the rear bleeder screw, and disconnect the waste line.
5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw, in that order.
6. Connect the diagnostic tool to the data link connector (DLC) and follow the diagnostic tool instructions.
7. Repeat the system bleed procedure as described in Steps 1 through 5.

Scheme 113

1. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary.
4. Tighten the front and rear bleeder screw.

Brake System Bleeding

SPECIAL TOOL(S)

Scheme 114

MATERIAL

MATERIAL SPECIFICATIONS

Manual

Note. When any part of the hydraulic system has been 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 after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment.

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1. Connect the diagnostic tool to the vehicle data link connector (DLC) and follow the diagnostic tool instructions.
2. Clean all dirt from and remove the brake master cylinder filler cap. Fill the brake master cylinder reservoir with the specified brake fluid.
3. Attach a rubber drain tube to the bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid.
4. Have an assistant hold firm pressure on the brake pedal.
5. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary.
6. Tighten the bleeder screw.
7. Repeat Steps 3, 4, 5 and 6 for the remaining bleeder screws in the system.

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Scheme 118

1. Clean all dirt from and remove the brake master cylinder filler cap. Fill the brake master cylinder reservoir with the specified brake fluid.
2. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter.
3. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid.
4. Open the valve on the bleeder tank.
5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose.
6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw and ending with the LH front disc brake caliper bleeder screw.
7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter.

Brake System Leak Check

1. Make sure the brake master cylinder reservoir is full.
2. Apply the brakes several times and make sure the brake pedal feel is not spongy. If necessary, bleed the system. For additional information, refer to «BRAKE SYSTEM BLEEDING»(ref-210119-S20869138792005121300000) .
3. If the brake reservoir level is going down, inspect the brake components, fittings and lines to locate the source of the leak.