Brake System - General Information Ford Econoline E250

SPECIFICATIONS

MATERIAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

The brake system consists of the following components

1. ABS
2. Cable drum-in-hat actuated parking brake system
3. Front and rear disc brakes
4. Hydro-Boost® or vacuum-assisted power brake booster
5. Brake master cylinder and fluid reservoir
6. Red brake warning indicator

The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. When the brake pedal is pressed, brake fluid is pushed through the double-walled steel tubes and flexible hoses to the front and rear disc brake calipers. The brake fluid enters the disc brake calipers, forcing the caliper pistons and brake pads outward against the brake disc friction surface, slowing or stopping rotation. When the brake pedal is released, brake fluid pressure is relieved, returning the front and rear disc brake caliper pistons and brake pads to the unapplied position.

For information on the following components

1. Front disc brakes, refer to «FRONT DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#front-disc-brake-system) .
2. Rear disc brakes, refer to «REAR DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#rear-disc-brake-system) .
3. Parking brake actuation, refer to «PARKING BRAKE AND ACTUATION»(/ford/econoline-e250/2012-2013/remont/parking-brake-system/#parking-brake-system-parking-brake-actuation) .
4. Hydraulic brake actuation, refer to «HYDRAULIC BRAKE ACTUATION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) .
5. Power brake booster, refer to «POWER BRAKE ACTUATION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#power-brake-actuation-brake-booster) .
6. ABS, refer to «ANTI-LOCK BRAKE SYSTEM (ABS) AND STABILITY CONTROL»(/ford/econoline-e250/2012-2013/remont/anti-locktraction-control/#anti-lock-brake-system-and-stability-control) .

Applying the brake pedal uses lever action to push a rod into the brake booster, which through the use of vacuum, boosts the force of the rod and then transmits this force to the primary piston in the master cylinder. This produces hydraulic pressure in the master cylinder. This pressure builds in the master cylinder and brake tubes as the brake pedal is depressed further. The pressure between the primary and secondary piston forces the secondary piston to compress building pressure in its circuit. The hydraulic pressure is transmitted by brake fluid through the brake tubes to the ABS Hydraulic Control Unit (HCU), which then distributes that pressure to the individual brake calipers. The brake calipers use hydraulic pressure to apply the pads. The application of the brake pads will cause the rotation of the wheels to slow or stop, depending on how much brake pressure is applied. The parking brakes carry out the same function except that they are mechanically actuated by a cable that connects only to the rear brakes.

Depending on application, some vehicles will be equipped with a Hydro-Boost® brake booster and some will be equipped with a standard vacuum brake booster. The Hydro-Boost® system uses the power steering system to boost brake pedal pressure while the vacuum system uses engine manifold vacuum to boost brake pedal pressure. For a complete description on the operation of both systems, refer to POWER BRAKE ACTUATION .

Brake Master Cylinder Compensator Ports

The purpose of the compensator ports in the brake master cylinder is to supply additional brake fluid from the master cylinder reservoir when needed by the brake system due to brake lining wear and allow brake fluid to return to the master cylinder reservoir when the brakes are released. The returning brake fluid creates a slight turbulence in the master cylinder reservoir. This is a normal condition and indicates that the compensator ports are not clogged. Clogged compensator ports may cause the brakes to hang up or not fully release.

Red Brake Warning Indicator

The red brake warning indicator alerts the driver to certain conditions that exist in the brake system. The Instrument Cluster (IC) performs a bulb check when the ignition key is turned to the RUN position. The conditions that cause the indicator to illuminate are low brake fluid level, the parking brake is applied or there is a fault in the ABS (if the yellow ABS warning indicator is also illuminated). To diagnose red brake warning indicator concerns, refer to INSTRUMENTATION, MESSAGE CENTER, AND WARNING CHIMES .

Inspection And Verification

MATERIAL SPECIFICATIONS

Note. Blistering or swelling of rubber brake components can indicate contamination of the brake fluid by a petroleum-based substance. The entire hydraulic brake system must be flushed with clean, specified brake fluid and contaminated rubber components must be replaced to prevent recontamination.

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

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

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

1. Verify the customer concern. For parking brake concerns, refer to «PARKING BRAKE AND ACTUATION»(/ford/econoline-e250/2012-2013/remont/parking-brake-system/#parking-brake-system-parking-brake-actuation) . For ABS concerns, refer to «ANTI-LOCK BRAKE SYSTEM (ABS) AND STABILITY CONTROL»(/ford/econoline-e250/2012-2013/remont/anti-locktraction-control/#anti-lock-brake-system-and-stability-control) . For all other concerns, continue with next step.
2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Mechanical Electrical Brake fluid level and condition Brake master cylinder Brake master cylinder reservoir Brake booster Brake booster check valve Brake booster vacuum hoses and tubes Brake hoses and tubes Brake caliper, guide pins and anchor plate Brake disc Brake pads Brake pedal, bracket and booster linkage Hydro-Boost® power steering fluid hoses and connections Vacuum pump and drive belt (vacuum booster equipped diesel vehicles) Aftermarket modifications Parking brake switch Brake fluid level switch Wiring, terminals or connectors
3. Visually inspect the suspension system and tires for obvious signs of wear or damage. For suspension system concerns, refer to «SUSPENSION SYSTEM - GENERAL INFORMATION»(/ford/econoline-e250/2012-2013/remont/suspension-front/#suspension-system-general-information) . For tire concerns, refer to «WHEELS AND TIRES»(/ford/econoline-e250/2012-2013/remont/wheel-tire-system/#wheels-tires) .
4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
5. If the cause is not visually evident, GO to «SYMPTOM CHART - BRAKE SYSTEM»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__symptom-chart-brake-system) or «SYMPTOM CHART - NVH»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__symptom-chart-nvh) .

Symptom Chart - Brake System

SYMPTOM CHART - BRAKE SYSTEM

Symptom Chart - NVH

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

SYMPTOM CHART - NVH

Normal Operation

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. Pedal pulsation or steering wheel nibble when the brakes are applied (frequency is proportioned to the vehicle speed) indicates a concern with a brake or suspension component.

PINPOINT TEST A: VIBRATION WHEN THE BRAKES ARE APPLIED

1. A1 ROAD TEST THE VEHICLE - LIGHT BRAKING Road test the vehicle. Warm the brakes by slowing the vehicle from 80 to 32 km/h (50 to 20 mph) using light brake force. At highway speeds of 89-97 km/h (55-60 mph), apply the brake using light pedal force. Is there a vibration/shudder felt in the steering wheel, seat or brake pedal? Yes : GO to A4 . No : GO to A2.
2. A2 ROAD TEST THE VEHICLE - MODERATE TO HEAVY BRAKING Road test the vehicle. At highway speeds of 89-97 km/h (55-60 mph), apply the brake using a moderate to heavy pedal force. Is there a vibration/shudder? Yes : GO to A3. No : The concern is not present at this time.
3. A3 CHECK ABS OPERATION NOTE: During moderate to heavy braking, noise from the 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 operation of the ABS. Pedal pulsation or steering wheel nibble with the frequency proportional to vehicle speed indicates a concern with a brake or suspension component. Road test the vehicle and apply the brakes on a dry, firm surface, then apply the brakes on a wet, snowy or loose surface (such as gravel). Is the vibration/shudder only present on a wet, snowy or loose surface? Yes : This is a normal operating condition of the ABS. No : GO to A5 .
4. A4 ISOLATE BRAKE VIBRATION NOTE: This test is not applicable to vehicles with drum-in-hat type parking brakes. For vehicles with drum-in-hat parking brakes, proceed to the next test step. For all other vehicles, apply the parking brake to identify if the problem is in the front or rear brake. Apply the parking brake to identify if the problem is in the front or rear brake. At highway speeds of 89-97 km/h (55-60 mph), lightly apply the parking brake until the vehicle slows down. Release the parking brake immediately after the test. Is there a vibration/shudder? Yes : GO to A7 . No : GO to A5.
5. A5 CHECK THE FRONT SUSPENSION Check the front suspension. Refer to «SUSPENSION SYSTEM - GENERAL INFORMATION»(/ford/econoline-e250/2012-2013/remont/suspension-front/#suspension-system-general-information) . Are all the suspension components in satisfactory condition? Yes : GO to A6. No : REPAIR or INSTALL new components as necessary. TEST the system for normal operation.
6. A6 CHECK THE FRONT BRAKE DISCS Inspect the front brake discs. Refer to «BRAKE SYSTEM INSPECTION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__brake-system-inspection) . Road test the vehicle. Is the vibration/shudder present? Yes : GO to A7. No : The concern has been repaired.
7. A7 CHECK THE REAR SUSPENSION Check the rear suspension. Refer to «SUSPENSION SYSTEM - GENERAL INFORMATION»(/ford/econoline-e250/2012-2013/remont/suspension-front/#suspension-system-general-information) . Are all the suspension components in satisfactory condition? Yes : INSPECT the rear brake discs. REFER to «BRAKE SYSTEM INSPECTION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__brake-system-inspection) . No : REPAIR or INSTALL new components as necessary. TEST the system for normal operation.

Accumulator - Hydro-Boost®

1. Start the engine and turn the steering wheel to the left and right stops 1 time.
2. Stop the engine.
3. Apply the brakes. The accumulator in the Hydro-Boost® power brake booster should retain enough pressure for at least 2 power assisted brake operations. If no power assist is felt, install a new Hydro-Boost® power brake booster, refer to «POWER BRAKE ACTUATION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#power-brake-actuation-brake-booster) . If power assist is felt, the accumulator is operating correctly at this time.

Brake Booster - Vacuum Boost

1. Disconnect the vacuum hose from the brake booster and connect a suitable vacuum/pressure tester to the vacuum hose.
2. Apply the parking brake, start the engine and place the transmission in NEUTRAL. Allow the engine to reach normal operating temperature.
3. Verify that vacuum is available at the check valve with engine running at normal idle speed. The vacuum gauge should read between 51-74 kPa (15-22 in-Hg) on vehicles not equipped with a vacuum pump and 70-85 kPa (20-25 in-Hg) on vacuum pump-equipped vehicles. If specified vacuum is available, stop the engine, connect the vacuum hose and continue with Step 5 . If specified vacuum is not available, continue with Step 4.
4. Disconnect the engine side vacuum hose from the check valve and verify that the specified vacuum is available at the hose with the engine at idle speed and the transmission in NEUTRAL. If specified vacuum is available, stop the engine, install a new check valve and continue with Step 5. If specified vacuum is not available, stop the engine, connect the vacuum hose to the check valve and refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/econoline-e250/2012-2013/remont/mechanical/#engine-system-general-information-e-series) to diagnose the no/low vacuum condition.
5. Apply the brake pedal several times to exhaust all vacuum from the system.
6. Apply the brake pedal and hold it in the applied position. Start the engine and verify that the brake pedal moves downward after the engine starts. If the brake pedal moves, the brake booster is operating correctly. If the brake pedal does not move, install a new brake booster. Refer to «POWER BRAKE ACTUATION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#power-brake-actuation-brake-booster) .
7. Operate the engine a minimum of 20 seconds at idle. Stop the engine and let the vehicle stand for 10 minutes, then apply the brake pedal. The brake pedal feel should be the same as that noted with the engine operating. If the brake pedal feels hard (no power assist), install a new brake booster check valve and retest. If condition still exists, install a new brake booster. Refer to «POWER BRAKE ACTUATION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#power-brake-actuation-brake-booster) . If the brake pedal feels the same as noted with the engine operating, the check valve is functioning properly.

Brake Master Cylinder - Bypass Condition

1. Inspect the master cylinder. Refer to «BRAKE SYSTEM INSPECTION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__brake-system-inspection) .
2. Disconnect the brake tubes from the master cylinder.
3. Plug the outlet ports of the master cylinder.
4. Lightly apply the brakes and hold for 10 seconds. Release the brakes and then reapply with heavy force. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and a new brake master cylinder must be installed. If brake pedal height is maintained, reinstall brake tubes and tighten to specifications. Refer to «SPECIFICATIONS»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__specifications) . After installation, bleed the brake system. Refer to «BRAKE SYSTEM BLEEDING»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__brake-system-bleeding) .

Brake Master Cylinder - Compensator Port

1. Inspect the master cylinder. Refer to «BRAKE SYSTEM INSPECTION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__brake-system-inspection) .
2. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(/ford/econoline-e250/2012-2013/remont/hoistjack/#jacking-lifting) .
3. Apply and release the brakes.
4. With the brakes released, attempt to rotate each wheel and check for any brake drag. If an excessive amount of brake drag exists at multiple wheels, continue to Step 5. If an excessive amount of brake drag exists at only one wheel, it indicates a possible seized brake caliper, brake wheel cylinder or parking brake component. Repair or install new components as necessary.
5. Check the brake stoplamp switch and the brake pedal free play to verify that the brake pedal is not partially applied.
6. Loosen the brake master cylinder nuts and position the brake master cylinder away from the brake booster.
7. With the brakes released, attempt to rotate each wheel and check for any brake drag. If the brake drag is no longer present, install a new brake booster. Refer to «POWER BRAKE ACTUATION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#power-brake-actuation-brake-booster) . If the brake drag is still present, install a new master cylinder. Refer to «HYDRAULIC BRAKE ACTUATION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) .

Brake System Inspection

MATERIAL SPECIFICATIONS

Brake Pads

Note. It is not required to install new brake pads when the brake discs are machined.

1. Inspect and measure the thickness of the brake pad friction material. For additional information, refer to «SPECIFICATIONS»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__specifications) . Minor surface cracks do not require pad replacement, however, if there are missing chunks or cracks in the lining through to the backing plate, install new brake pads. For additional information, refer to «FRONT DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#front-disc-brake-system) for front brake pads or «REAR DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#rear-disc-brake-system) for rear brake pads. If the thickness of the friction material is less than the specified thickness, install new brake pads. For additional information, refer to «FRONT DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#front-disc-brake-system) for front disc brakes or «REAR DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#rear-disc-brake-system) for rear disc brakes. If the friction material shows taper wear that is not within specifications, install new brake pads and verify the caliper guide pins are functioning correctly. For additional information, refer to «BRAKE CALIPER GUIDE PINS»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__brake-caliper-guide-pins) .

Brake Discs

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

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

1. Inspect the brake discs and measure the brake disc thickness. Record the measurement, refer to «SPECIFICATIONS»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__specifications) . If the brake disc is cracked or otherwise damaged, install a new brake disc. For additional information, refer to «FRONT DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#front-disc-brake-system) for front brakes or «REAR DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#rear-disc-brake-system) for rear brakes. If the measurement is below the minimum thickness specification, install a new brake disc. For additional information, refer to «FRONT DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#front-disc-brake-system) for front brakes or «REAR DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#rear-disc-brake-system) for rear brakes. If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that caused by pads worn down to the backing plate, should also be machined. In order to machine, discs must be above the minimum thickness specification. For additional information, refer to «SPECIFICATIONS»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__specifications) and «BRAKE DISC MACHINING»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__brake-disc-machining) .

Brake Calipers and Anchor Plates

1. Inspect the brake calipers for leaks, damage to seals, and piston corrosion or binding. If the brake caliper is leaking or otherwise damaged, install a new brake caliper. For additional information, refer to «FRONT DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#front-disc-brake-system) for front brake calipers or «REAR DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#rear-disc-brake-system) for rear brake calipers.
2. Inspect brake caliper anchor plate for corrosion build up. Clean or install new anchor plates as necessary.

Brake Caliper Guide Pins

1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper wear or the guide pins are difficult to move, carry out the following steps. Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for wear, damage and corrosion. If bore is worn or damaged, replace the damaged component. Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material from the caliper guide pin bores. Clean any remaining foreign material from the bores with brake parts cleaner and compressed air. Assemble the caliper guide pins using new caliper seals, boots and guide pins. Use an ample amount of the specified grease to lubricate the bores and guide pins. Inspect the brake pads. For additional information, refer to «BRAKE PADS INSPECTION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__brake-pads) .

Brake Flexible Hoses and Tubes

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

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

1. Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage. If a section of the brake tube is damaged, the entire section must be installed with a new tube of the same type, size, shape and length. When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to specifications. After installation, bleed the brake system. For additional information, refer to «BRAKE SYSTEM BLEEDING»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__brake-system-bleeding) .
2. Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any other signs of damage. Install a new brake flexible hose if the hose shows signs of softening, cracking or other damage. For additional information, refer to «FRONT DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#front-disc-brake-system) for the front brake flexible hose or «REAR DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#rear-disc-brake-system) for the rear brake flexible hose.

Brake Master Cylinder

Note. During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir will fall during brake application and rise during release. The net fluid level (such as after brake application and release) will remain unchanged. Fluid level will decrease with pad wear.

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

1. Inspect the brake master cylinder for fluid leaks. Install a new master cylinder or brake fluid reservoir if signs of excessive leaking are present. For additional information, refer to «HYDRAULIC BRAKE ACTUATION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) . To check for correct brake master cylinder operation, refer to «COMPONENT TESTS»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information) .

Brake Booster

1. Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for leaks and kinks. Install a new brake booster if signs of excessive corrosion or damage is found. For additional information, refer to «POWER BRAKE ACTUATION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#power-brake-actuation-brake-booster) . Repair or replace vacuum hoses as necessary. To check for correct brake booster operation, refer to «COMPONENT TESTS»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information) .
2. Inspect the Hydro-Boost® brake booster excessive corrosion or damage. Inspect the fluid hoses for leaks and kinks. Install a new Hydro-Boost® brake booster if signs of excessive corrosion or damage is found. For additional information, refer to «POWER BRAKE ACTUATION»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#power-brake-actuation-brake-booster) . Repair or replace fluid hoses or connections as necessary. To check for correct Hydro-Boost® brake booster accumulator operation, refer to «COMPONENT TESTS»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information) .

Brake Disc Machining

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

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

Note. 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 specification.

1. Remove the wheel and tire. For additional information, refer to «WHEELS AND TIRES»(/ford/econoline-e250/2012-2013/remont/wheel-tire-system/#wheels-tires) .
2. Remove the bolts and position the brake caliper or brake caliper and anchor plate assembly aside, as required. Support the brake caliper using mechanic's wire.
3. Install the hub adapter using: four wheel nuts on a 4-stud wheel hub. five wheel nuts on a 5-stud wheel hub. six wheel nuts on a 6-stud wheel hub. four wheel nuts on a 7- or 8-stud wheel hub. five wheel nuts on a 10-stud wheel hub.
4. Install the cutting lathe.
5. If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. The total indicated runout target is 0.000 mm (0.000 in). The maximum indicated runout should be no more than 0.050 mm (0.002 in).
6. Center the cutting head, adjust the cutting bits and install the chip deflector/silencer.
7. Machine the brake disc.
8. Remove the lathe and the silencer.
9. Remove the wheel nuts and hub adapter.
10. Remove the metal shavings.
11. Measure the brake disc thickness. If the measurement is below the minimum specification, install a new brake disc. For additional information, refer to «FRONT DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#front-disc-brake-system) for front disc brakes or «REAR DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#rear-disc-brake-system) for rear disc brakes.
12. Position the brake caliper or brake caliper and anchor plate assembly. Install the bolts. For fastener torque specifications, refer to «FRONT DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#front-disc-brake-system) for front disc brakes or «REAR DISC BRAKE»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#rear-disc-brake-system) for rear disc brakes.
13. Install the wheel and tire. For additional information, refer to «WHEELS AND TIRES»(/ford/econoline-e250/2012-2013/remont/wheel-tire-system/#wheels-tires) .

Component Bleeding

MATERIAL SPECIFICATIONS

Master Cylinder

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

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

Scheme 1

Scheme 2

1. Disconnect the brake tubes from the master cylinder.
2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir.
3. Fill the brake master cylinder reservoir with clean, specified brake fluid.
4. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air bubbles.
5. Remove the short brake tubes and install the brake outlet tubes.
6. Bleed the brake system. For additional information, refer to «BRAKE SYSTEM BLEEDING»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__brake-system-bleeding) .

Brake Caliper

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

Scheme 3

1. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid.
2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal.
3. 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.
4. Remove the rubber hose and tighten the bleeder screw to specifications. For additional information, refer to «SPECIFICATIONS»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__specifications) . Install the bleeder screw cap.

Brake System Bleeding

SPECIAL TOOLS CHART Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 4

MATERIAL SPECIFICATIONS

Pressure

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

Note. The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new.

Note. Pressure bleeding the brake system is preferred to manual bleeding.

Scheme 5

Scheme 6

1. Clean all dirt from the brake master cylinder filler cap and remove the filler cap. Fill the brake master cylinder with clean 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. Open the valve on the bleeder tank. Apply 207-345 kPa (30-50 psi) to the brake system.
4. Remove the RH rear bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid.
5. 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. Tighten to specifications. For additional information, refer to «SPECIFICATIONS»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__specifications) . Install the bleeder screw cap.
6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front bleeder screw ending with the LH front bleeder screw.
7. Release the bleeder tank pressure and close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter from the brake fluid reservoir.

Manual

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

Note. The HCU bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new.

Note. Pressure bleeding the brake system is preferred to manual bleeding.

1. Clean all dirt from the brake master cylinder filler cap and remove the filler cap. Fill the brake master cylinder with clean specified brake fluid.
2. Remove the bleeder screw 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.
3. Have an assistant pump the brake pedal at least 3 times and then hold firm pressure on the brake pedal.
4. 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.
5. Remove the rubber hose and tighten the bleeder screw to specifications. For additional information, refer to «SPECIFICATIONS»(/ford/econoline-e250/2012-2013/remont/mechanical-hydraulic/#brake-system-general-information__specifications) . Install the bleeder screw cap.
6. Repeat Steps 2 through 5 for the LH rear, RH front and LH front bleeder screws in this order.

Hydraulic Control Unit (HCU)

Note. The HCU bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new.

Note. Pressure bleeding the brake system is preferred to manual bleeding.

1. Follow the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system.
2. Connect the scan tool and follow the ABS Service Bleed instructions.
3. Repeat the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system.

See also:
• FRONT DISC BRAKE
• REAR DISC BRAKE
• PARKING BRAKE AND ACTUATION
• HYDRAULIC BRAKE ACTUATION
• POWER BRAKE ACTUATION
• ANTI-LOCK BRAKE SYSTEM (ABS) AND STABILITY CONTROL
• INSTRUMENTATION, MESSAGE CENTER, AND WARNING CHIMES
• SUSPENSION SYSTEM - GENERAL INFORMATION
• WHEELS AND TIRES
• STEERING SYSTEM
• EXTERIOR LIGHTING
• POWER STEERING
• NOISE, VIBRATION & HARSHNESS
• ENGINE SYSTEM - GENERAL INFORMATION
• JACKING & LIFTING
• SYMPTOM CHART - BRAKE SYSTEM
• SYMPTOM CHART - NVH
• BRAKE SYSTEM INSPECTION
• BRAKE SYSTEM BLEEDING
• BRAKE MASTER CYLINDER - BYPASS CONDITION
• BRAKE MASTER CYLINDER - COMPENSATOR PORT
• BRAKE BOOSTER
• PINPOINT TEST A
• SPECIFICATIONS
• BRAKE CALIPER GUIDE PINS
• BRAKE DISC MACHINING
• BRAKE PADS INSPECTION
• COMPONENT TESTS