Brake System - General Information Ford Explorer Sport Trac II

Material

Material

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The brake system consists of the following components

1. ABS
2. Brake pedal and bracket assembly
3. Drum-in-hat cable-actuated parking brake system
4. Front and rear disc brakes
5. Master cylinder and fluid reservoir
6. Red brake light indicator
7. Vacuum-assisted power brake booster

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 doubled-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.

The vehicle has an optional adjustable brake pedal to increase driver comfort. The brake pedal position is changed in phase with the accelerator pedal. The system is adjusted by pressing the dash-mounted switch that powers the adjustable pedal motor mounted on the accelerator pedal assembly. On systems equipped with the optional memory feature, the pedals can also be adjusted using the memory SET switch and the remote transmitter. The 2-way motor operates backward (toward the driver) or forward (away from the driver) to adjust the accelerator pedal directly and the brake pedal through the drive cable attached to the brake pedal assembly.

For information on

1. hydraulic brake actuation, refer to «HYDRAULIC BRAKE ACTUATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) article.
2. ABS, refer to «VEHICLE DYNAMIC SYSTEMS»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system) article.
3. the vacuum assisted power brake booster, refer to «POWER BRAKE ACTUATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#power-brake-actuation-brake-booster) article.
4. the front disc brakes, refer to «FRONT DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#front-disc-brake-system) article.
5. the rear disc brakes, refer to «REAR DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#rear-disc-brake-system) article.
6. parking brake actuation, refer to «PARKING BRAKE AND ACTUATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/parking-brake-system/#parking-brake-system-and-actuation) article.

Special Tools Illustration Tool Name Tool Number 73III Automotive Meter 105-R0057 or equivalent Flex Probe Kit 418-F090 (105-R025B) or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 1

Material

Hydraulic Brake System

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 into the master cylinder. This produces hydraulic pressure in the master cylinder. On vehicles not equipped with ABS, the hydraulic pressure is transmitted by brake fluid through the brake lines to the individual brake calipers. On vehicles equipped with ABS, the hydraulic pressure is transmitted by brake fluid through the brake lines to the 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.

Red Brake Warning Indicator

The red brake warning indicator alerts the driver to certain conditions that exist in the brake system. The instrument cluster 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).

Adjustable Pedals

The brake and accelerator pedals can be adjusted for a more comfortable driving position. The adjustable pedal feature is operational with the ignition switch in the RUN, ACC or OFF position. Adjustable pedal may be connected to the driver memory system, if equipped, or they may be a stand alone system.

Non-Memory Adjustable Pedals

For non-memory adjustable pedals, the pedals are controlled directly by the adjustable pedal switch and motor. The motor is attached to the accelerator pedal and the brake pedal is connected to the motor via a cable. The motor is connected to the brake pedal and accelerator pedal and both move together as an assembly. The pedals are adjusted by pressing the adjustable pedal switch in either the forward or rearward position. Pressing the switch powers the adjustable pedal motor which then causes the pedals to move either toward the driver or away from the driver.

Memory Adjustable Pedals

For memory adjustable pedals, the pedals can be adjusted in 1 of 3 ways

1. By pressing the adjustable pedal switch.
2. By pressing the memory position 1 or memory position 2 switch.
3. By using the remote transmitter.

For memory adjustable pedals, the pedals are controlled by the driver seat module (DSM). The DSM receives input from 1 of the 3 sources and then powers the adjustable pedal motor in the desired direction. The DSM will also control the driver seat position and the side-view mirror positions.

For information on the DSM and Memory Position Programming, refer to SEATING article.

Inspection and Verification - Hydraulic Brake System

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

Note. Prior to carrying out any diagnosis, make sure the red brake warning indicator is functional. Refer to INSTRUMENT CLUSTER (IC), MESSAGE CENTER, AND WARNING CHIMES article.

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 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. This bleeding operation may release the brakes but will not correct the cause of the concern. If this does not relieve the locked wheel condition, repair the locked components before proceeding.

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

1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Mechanical Electrical Brake master cylinder Brake master cylinder reservoir Brake booster Brake booster check valve Brake booster vacuum hose Brake hoses and tubes Brake caliper Brake caliper piston seals Brake caliper guide pins Brake disc Brake pads Brake pedal linkage Wheel bearings Tires Parking brake switch Brake fluid level switch Wiring, terminals or connectors
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the cause is not visually evident, go to «Symptom Chart - Brake System»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information) or Go to «Symptom Chart - Noise, Vibration and Harshness (NVH)»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information) . For low or spongy brake pedal concerns: check for fluid leaks. Repair as necessary. check and, if necessary, refill the brake master cylinder reservoir with clean, specified brake fluid. bleed the brake system and retest the brake pedal feel. if the brake pedal is still low or feels spongy, check the brake pedal mounting for looseness and correct installation. Check the power brake booster and the master cylinder for loose mounting. Correct as necessary and retest the system for normal operation. For a slow or incomplete brake pedal return concern: inspect for binding, damage, correct installation or interference at the brake pedal. check the power brake booster for binding, damage and correct installation.

Road Test

The technician should have a thorough knowledge of the brake system operation and accepted general braking guidelines in order to detect any problems.

Select a road that is reasonably smooth and level. Gravel or bumpy roads are not suitable because the surface does not allow the tires to grip the road equally. Avoid crowned roads.

A key factor in evaluating brake concerns is the deceleration rate. This varies from vehicle to vehicle and with changes in operating conditions. It is evident how well the brakes are working after just a few applications.

Brake Pads

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

1. Remove the brake pads. Refer to «FRONT DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#front-disc-brake-system) article for front disc brakes or «REAR DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#rear-disc-brake-system) article for rear disc brakes.
2. Inspect and measure the thickness of the brake pad friction material. Refer to «SPECIFICATIONS»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information) . If there are missing chunks or cracks in the lining through to the backing plate, install new brake pads. Refer to «FRONT DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#front-disc-brake-system) article for front disc brakes or «REAR DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#rear-disc-brake-system) article for rear disc brakes. If the thickness of the friction material is less than the specified thickness, install new brake pads, Refer to «FRONT DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#front-disc-brake-system) article for front disc brakes or «REAR DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#rear-disc-brake-system) article for rear disc brakes. If the friction material shows taper wear that is not within specifications, verify the caliper guide pins are functioning correctly. Refer to «Brake Caliper Guide Pins»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information__brake-caliper-guide-pins) .

Brake Discs

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

1. Remove the brake disc. Refer to «FRONT DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#front-disc-brake-system) article for front disc brakes or «REAR DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#rear-disc-brake-system) article for 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, refer to «SPECIFICATIONS»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information) . If the brake disc is cracked or otherwise damaged, install new a brake disc. Refer to «FRONT DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#front-disc-brake-system) article for front disc brakes or «REAR DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#rear-disc-brake-system) article for rear disc brakes. If any thickness measurement is less than the minimum specification, install a new brake disc. Refer to «FRONT DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#front-disc-brake-system) article for front disc brakes or «REAR DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#rear-disc-brake-system) article for rear disc 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. Refer to «SPECIFICATIONS»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information) and «Brake Disc Machining»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information__brake-disc-machining) .

Brake Calipers

Inspect the brake calipers for the following

1. Brake fluid leaks.
2. Boots and seals for tears or cracks.
3. Caliper pistons for binding and corrosion.
4. Guide pins for correct operation. Refer to «Brake Caliper Guide Pins»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information__brake-caliper-guide-pins) e.

Brake Caliper Guide Pins

Note. The guide pins are part of the anchor plate.

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, install a new brake caliper anchor plate. Refer to FRONT DISC BRAKE article for the front brake caliper anchor plate or REAR DISC BRAKE article for the rear brake caliper anchor plate.

If the lining is not within specifications, install new brake pads. Refer to FRONT DISC BRAKE article for front disc brakes or REAR DISC BRAKE article for rear disc brakes.

Brake Hoses 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 with a new 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. Refer to «Brake System Bleeding»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information__brake-system-bleeding) .

Install a new brake flexible 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

Two parts of the brake system that may have a brake fluid loss that does not appear when the system is under pressure are the brake master cylinder reservoir and the brake caliper under the following conditions

Reservoir

1. Missing or poorly-fitted brake master cylinder filler cap
2. Missing or damaged brake master cylinder filler cap gasket
3. Punctured or otherwise damaged brake master cylinder reservoir
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 serviceable and must be installed new as part of a new brake master cylinder and reservoir assembly. Refer to brake master cylinder in HYDRAULIC BRAKE ACTUATION article.

Caliper

1. Foreign material in the caliper piston seal groove
2. Punctured or otherwise damaged caliper piston seal

The brake caliper piston seals are not serviceable and must be installed new as part of a new brake caliper. Refer to FRONT DISC BRAKE article for front disc brakes or REAR DISC BRAKE article for rear disc brakes.

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 fall during brake application and rise 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 may be wrong in the brake system. Go to Symptom Chart - Brake System for abnormal condition diagnosis.

Brake Booster

Inspect the brake booster for the following

1. Excessive corrosion or damage.
2. Leaks at vacuum connections.
3. Leaks or kinks in vacuum hoses.
4. Correct operation of the check valve.

Parking Brake

Check the operation of the parking brake system with the vehicle on a hoist and the parking brake control fully released. Check the rear brake adjustment or carry out the brake system diagnosis. Refer to PARKING BRAKE AND ACTUATION article.

Symptom Chart - Brake System

Symptom Chart - Brake System

Symptom Chart - Noise, Vibration and Harshness (NVH)

Note. Noise, vibration and harshness (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 AND HARSHNESS article. 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 AND HARSHNESS article for the next likely system and continue diagnosis.

Symptom Chart - Noise, Vibration and Harshness (NVH)

Inspection and Verification - Adjustable Pedals Without Memory Feature

1. Verify the customer concern by operating the adjustable pedals.
2. Visually inspect for obvious signs of mechanical or electrical damage. Refer to the following chart: VISUAL INSPECTION CHART Mechanical Electrical Adjustable pedals Adjustable pedal cable Adjustable pedal motor Foreign material Adjustable pedal switch Smart junction box (SJB) fuse 1 (20A) Wiring, terminals or connectors
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the cause is not visually evident, go to «Symptom Chart - Adjustable Pedals Without Memory Feature»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information) .

Symptom Chart - Adjustable Pedals Without Memory Feature

Symptom Chart - Adjustable Pedals Without Memory Feature

Inspection and Verification - Adjustable Pedals With Memory Feature

1. Verify the customer concern by operating the adjustable pedal.
2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Mechanical Electrical Adjustable pedal assembly Adjustable pedal switch Brake pedal linkage Foreign material Adjustable pedal switch Battery junction box (BJB) fuses: 1 (50A) 14 (30A) Driver seat module Electrical connector(s) Memory SET switch Parking brake switch Smart junction box (SJB) fuse 1 (20A) Wiring, terminals or connectors
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the cause is not visually evident, connect the scan tool to the data link connector (DLC).
5. If the scan tool does not communicate with the VCM: check the VCM connection to the vehicle. check the scan tool connection to the VCM. refer to «MODULE COMMUNICATIONS NETWORK»(/ford/explorer-sport-trac/ii-2006-2010/remont/communication-devices/#module-communications-network) article, No Power To The Scan Tool, to diagnose no communication with the scan tool.
6. If the scan tool does not communicate with the vehicle: verify the ignition key is in the ON position. verify the scan tool operation with a known good vehicle. refer to «MODULE COMMUNICATIONS NETWORK»(/ford/explorer-sport-trac/ii-2006-2010/remont/communication-devices/#module-communications-network) article to diagnose no response from the PCM.
7. Carry out the network test. If the scan tool responds with no communication for one or more modules, refer to «MODULE COMMUNICATIONS NETWORK»(/ford/explorer-sport-trac/ii-2006-2010/remont/communication-devices/#module-communications-network) article. If the network test passes, retrieve and record continuous memory DTCs.
8. Clear the continuous DTCs and carry out the self-test diagnostics for the driver seat module (DSM).
9. If the DTCs retrieved are related to the concern, go to Driver Seat Module (DSM) DTC Chart. For all other DTCs, refer to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/explorer-sport-trac/ii-2006-2010/remont/communication-devices/#multifunction-electronic-modules) article.
10. If no DTCs related to the concern are retrieved, go to «Symptom Chart - Adjustable Pedals With Memory Feature»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information) .

DRIVER SEAT MODULE (DSM) DTC CHART

Symptom Chart - Adjustable Pedals With Memory Feature

Symptom Chart - Adjustable Pedals With Memory Feature

Pinpoint Test A: The Adjustable Brake Pedal is Inoperative/Does Not Operate Correctly (System Without Memory Feature)

Refer to appropriate SYSTEM WIRING DIAGRAMS article, Adjustable Pedals for schematic and connector information.

Normal Operation

The adjustable pedal switch receives fused battery voltage from smart junction box (SJB) fuse 1 (20A) along circuit SBP01 (RD) at all times. The switch is grounded through circuit GD138 (BK/WH).

When the adjustable pedal switch is pressed in the forward position (away from the driver), the switch connects circuit SBP01 (RD) with circuit CPP09 (VT/OG) and the voltage is sent to the adjustable pedal motor along circuit CPP09 (VT/OG). The voltage returns to the switch along circuit CPP10 (BN/BU) and is grounded through the switch along circuit GD138 (BK/WH). The adjustable pedal motor rotates cables that are attached to the brake and accelerator pedals which are then moved away from the driver.

When the adjustable pedal switch is pressed in the rearward position (toward the driver), the switch connects circuit SBP01 (RD) with circuit CPP10 (BN/BU) and the voltage is sent to the adjustable pedal motor along circuit CPP10 (BN/BU). The voltage returns to the switch along circuit CPP09 (VT/OG) and is grounded through the switch along circuit GD138 (BK/WH). The adjustable pedal motor rotates cables that are attached to the brake and accelerator pedals which are then moved toward the driver.

This pinpoint test is intended to diagnose the following

1. Fuse
2. Wiring, terminals or connectors
3. Adjustable pedal switch
4. Adjustable pedal obstruction
5. Adjustable pedal cable(s)
6. Adjustable pedal motor assembly

PINPOINT TEST A: THE ADJUSTABLE PEDAL IS INOPERATIVE/DOES NOT OPERATE CORRECTLY (SYSTEM WITHOUT MEMORY FEATURE)

Note. The integrity of the adjustable pedals and their associated transmission integrity can be verified by removing the drive cables from the individual adjustable pedal transmission. A firm tug on the cable allows the cable to be released from the adjustable pedal transmission. At this time, the adjustable pedal motor can be operated to determine if the concern may be due to a jammed adjustable pedal transmission or incorrectly timed adjustable pedal. Timing the pedal involves installing one cable into the respective transmission and operating the adjustable pedal switch until the particular pedal involved is bottomed out to the same position as the other pedal.

Scheme 2

Scheme 3

1. A1 CHECK THE ADJUSTABLE PEDAL MOTOR INSTALLATION Check the adjustable pedal motor for correct installation. Is the motor installation correctly? YES : Go to A2 . NO : REINSTALL the adjustable pedal motor. REFER to «HYDRAULIC BRAKE ACTUATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) article. TEST the system for normal operation.
2. A2 INSPECT FOR FOREIGN MATERIAL Inspect the adjustable brake pedal and accelerator pedal for foreign material that could cause a binding condition. Was any foreign material found? YES : REMOVE the foreign material. TEST for normal operation. NO : Go to A3 .
3. A3 CHECK THE ADJUSTABLE PEDAL CABLE OPERATION Disconnect the cable from the brake pedal and the accelerator pedal assemblies. Operate the adjustable pedal control switch. Does the adjustable brake pedal cable turn in the conduit? YES : INSTALL a new adjustable pedal assembly. REFER to «HYDRAULIC BRAKE ACTUATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) article. TEST the system for normal operation. NO : Go to A4 .
4. A4 ISOLATE THE ADJUSTABLE PEDAL CABLE Disconnect the adjustable pedal cable from the adjustable pedal motor. Operate the adjustable pedal control switch. Does the adjustable pedal motor run? YES : INSTALL a new adjustable pedal cable. TEST the system for normal operation. NO : Go to A5 .
5. A5 TEST THE ADJUSTABLE PEDAL SWITCH Disconnect: Adjustable Pedal Switch C2089 Measure the resistance between the adjustable pedal switch pins, component side, as indicated while activating the adjustable pedal switch to the indicated positions. Adjustable Pedal Switch Pin Adjustable Pedal Switch Position Resistance Value 1 and 2 Forward 0 Ohm 1 and 7 Forward Open 2 and 7 Forward Open 2 and 7 Rearward 0 Ohm 2 and 1 Rearward Open 1 and 7 Rearward Open Did the adjustable pedal switch pass the component test? YES : Go to A6 . NO : INSTALL a new adjustable pedal switch. TEST the system for normal operation.
6. A6 CHECK FOR VOLTAGE TO THE ADJUSTABLE PEDAL SWITCH Disconnect: Adjustable Pedal Switch C2089 Measure the voltage between adjustable pedal switch C2089-2, circuit SBP01 (RD), harness side and ground. Is the voltage greater than 10 volts? YES : Go to A7 . NO : VERIFY SJB fuse 1 (20A) is OK. If OK, REPAIR circuit SBP01 (RD). TEST the system for normal operation.
7. A7 CHECK CIRCUIT GD138 (BK/WH) FOR AN OPEN Measure the resistance between ground and: adjustable pedal switch C2089-3, circuit GD138 (BK/WH), harness side. adjustable pedal switch C2089-6, circuit GD138 (BK/WH), harness side. Are the resistances less than 5 ohms? YES : Go to A8 . NO : REPAIR circuit GD138 (BK/WH). TEST the system for normal operation.
8. A8 CHECK CIRCUITS CPP09 (VT/OG) AND CPP10 (BN/BU) FOR AN OPEN Disconnect: Adjustable Pedal Motor C2003 Measure the resistance between: adjustable pedal motor C2003-1, circuit CPP09 (VT/OG), harness side and adjustable pedal switch C2089-1, circuit CPP09 (VT/OG), harness side. adjustable pedal motor C2003-2, circuit CPP10 (BN/BU), harness side and adjustable pedal switch C2089-7, circuit CPP10 (BN/BU), harness side. Are the resistances less than 5 ohms? YES : INSTALL a new adjustable pedal motor. REFER to «HYDRAULIC BRAKE ACTUATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) article. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. NO : REPAIR the affected circuit(s). TEST the system for normal operation.

Pinpoint Test B: The Adjustable Brake Pedal is Inoperative/Does Not Operate Correctly - Using the Adjustable Pedal Switch, Memory Position Switch and/or the Remote Transmitter (System With Memory Feature)

Refer to appropriate SYSTEM WIRING DIAGRAMS article, Adjustable Pedals for schematic and connector information.

The adjustable pedal switch and the adjustable pedal motor are connected to the driver seat module (DSM). When the DSM receives a signal from the adjustable pedal switch, memory position switch or the remote transmitter, it operates the motor in the appropriate direction. The adjustable pedal motor rotates and turns cables that are attached to the brake and accelerator pedals which are then moved toward or away from the driver.

The adjustable pedal switch receives fused battery voltage from smart junction box (SJB) fuse 1 (20A) along circuit SBP01 (RD) at all times. When the adjustable pedal switch is pressed in the forward position (away from the driver), the switch connects circuit SBP01 (RD) with circuit CPP09 (VT/OG) and the voltage is sent to the DSM along circuit CPP09 (VT/OG). The DSM then sends voltage to the adjustable pedal motor along circuit CPP01 (WH/OG), the voltage passes through the motor and returns to the DSM along circuit CPP02 (BN).

The adjustable pedal switch receives fused battery voltage from SJB fuse 1 (20A) along circuit SBP01 (RD) at all times. When the adjustable pedal switch is pressed in the rearward position (toward the driver), the switch connects circuit SBP01 (RD) with circuit CPP10 (BN/BU) and the voltage is sent to the DSM along circuit CPP10 (BN/BU). The DSM then sends voltage to the adjustable pedal motor along circuit CPP02 (BN), the voltage passes through the motor and returns to the DSM along circuit CPP01 (WH/OG).

1. DTC B1988 Pedal Position Forward Switch Circuit Short to Battery - If the DSM detects voltage on circuit CPP09 (VT/OG) for more than 2 minutes during normal operation or if the DSM detects voltage on the circuit during the on-demand self test, DTC B1988 will be set.
2. DTC B1989 Pedal Position Rearward Switch Circuit Short to Battery - If the DSM detects voltage on circuit CPP10 (BN/BU) for more than 2 minutes during normal operation or if the DSM detects voltage on the circuit during the on-demand self test, DTC B1988 will be set.

This pinpoint test is intended to diagnose the following

1. Fuse
2. Wiring, terminals or connectors
3. Adjustable pedal switch
4. Adjustable pedal motor
5. DSM

PINPOINT TEST B: THE ADJUSTABLE PEDAL IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - USING THE ADJUSTABLE PEDAL SWITCH, MEMORY POSITION SWITCH AND/OR THE REMOTE TRANSMITTER (SYSTEM WITH MEMORY FEATURE)

Note. The integrity of the adjustable pedals and their associated transmission integrity can be verified by removing the drive cables from the individual adjustable pedal transmission. A firm tug on the cable allows the cable to be released from the adjustable pedal transmission. At this time, the adjustable pedal motor can be operated to determine if the concern may be due to a jammed adjustable pedal transmission or incorrectly timed adjustable pedal. Timing the pedal involves installing one cable into the respective transmission and operating the adjustable pedal switch until the particular pedal involved is bottomed out to the same position as the other pedal.

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

1. B1 CHECK FOR ADJUSTABLE PEDAL DTCs Connect the diagnostic tool. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: DSM On-Demand and Continuous DTCs Use the recorded DSM DTCs from the continuous and on-demand self tests. Are any adjustable pedal DTCs present in the DSM? YES : If DTC B1988 is present, go to B2 . If DTC B1989 is present, go to B3 . For all other DTCs, go to the «DRIVER SEAT MODULE (DSM) DTC CHART»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information) . NO : If the pedals do not operate using the adjustable pedal switch, go to B4 . If the pedals do not operate using the memory position switch or remote transmitter, go to B9 .
2. B2 CHECK CIRCUIT CPP09 (VT/OG) FOR A SHORT TO VOLTAGE Key in OFF position. Disconnect: DSM C341c Disconnect: Adjustable Pedal C2089 Key in ON position. Measure the voltage between DSM C341c-14, circuit CPP09 (VT/OG), harness side and ground. Is the voltage less than 0.2 volt? YES : REPAIR the affected circuit(s). TEST the system for normal operation. NO : Go to B8 .
3. B3 CHECK CIRCUIT CPP10 (BN/BU) FOR A SHORT TO VOLTAGE Key in OFF position. Disconnect: DSM C341c Disconnect: Adjustable Pedal C2089 Key in ON position. Measure the voltage between DSM C341c-2, circuit CPP10 (BN/BU), harness side and ground. Is the voltage less than 0.2 volt? YES : REPAIR the affected circuit(s). TEST the system for normal operation. NO : Go to B8 .
4. B4 CHECK THE DSM ADJUSTABLE PEDAL SWITCH POSITION (PEDPOSSW) PID Enter the following diagnostic mode on the diagnostic tool: DSM DataLogger Monitor the PEDPOSSW PID while pressing the adjustable pedal switch in both directions. Does the PID agree with the switch position? YES : Go to B9 . NO : Go to B5 .
5. B5 CHECK FOR VOLTAGE TO THE ADJUSTABLE PEDAL SWITCH Disconnect: Adjustable Pedal Switch C2089 Measure the voltage between adjustable pedal switch C2089-2, circuit SBP01 (RD), harness side and ground. Is the voltage greater than 10 volts? YES : Go to B6 . NO : VERIFY SJB fuse 1 (20A) is OK. If OK, REPAIR circuit SBP01 (RD). TEST the system for normal operation.
6. B6 CHECK CIRCUIT CPP09 (VT/OG) FOR AN OPEN OR A SHORT TO GROUND Key in OFF position. Disconnect: DSM C341c Measure the resistance between: adjustable pedal switch C2089-1, circuit CPP09 (VT/OG), harness side and DSM C341c-14, circuit CPP09 (VT/OG), harness side. adjustable pedal switch C2089-1, circuit CPP09 (VT/OG), harness side and ground. Is the resistance less than 5 ohms between the switch and DSM, and greater than 10,000 ohms between the switch and ground? YES : Go to B7 . NO : REPAIR the affected circuit(s). TEST the system for normal operation.
7. B7 CHECK CIRCUIT CPP10 (BN/BU) FOR AND OPEN OR A SHORT TO GROUND Measure the resistance between: adjustable pedal switch C2089-7, circuit CPP10 (BN/BU), harness side and DSM C341c-2, circuit CPP10 (BN/BU), harness side. adjustable pedal switch C2089-7, circuit CPP10 (BN/BU), harness side and ground. Is the resistance less than 5 ohms between the switch and DSM, and greater than 10,000 ohms between the switch and ground? YES : Go to B8 . NO : REPAIR the affected circuit(s). TEST the system for normal operation.
8. B8 CHECK THE ADJUSTABLE PEDAL SWITCH Check the adjustable pedal switch. Remove the switch and measure the resistance between the adjustable pedal switch pins while activating the adjustable pedal switch to the indicated positions. Adjustable Pedal Switch Pin Adjustable Pedal Switch Position Resistance Value 1 and 2 Forward 0 Ohm 1 and 7 Forward Open 2 and 7 Forward Open 2 and 7 Rearward 0 Ohm 2 and 1 Rearward Open 1 and 7 Rearward Open Did the adjustable pedal switch pass the component test? YES : INSTALL a new DSM. REFER to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/explorer-sport-trac/ii-2006-2010/remont/communication-devices/#multifunction-electronic-modules) article. CONFIGURE the DSM. REFER to Programmable Module Installation in «MODULE CONFIGURATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/communication-devices/#module-configuration) article. NO : INSTALL a new adjustable pedal switch. TEST the system for normal operation.
9. B9 CHECK THE ADJUSTABLE PEDAL MOTOR OUTPUT COMMANDS NOTE: Toggling the output command will cause the pedal to move in the commanded direction for 2 seconds and then the pedal will stop. Select PARK. Enter the following diagnostic mode on the diagnostic tool: DSM DataLogger Using the scan tool, toggle the following output commands ON and then OFF (depending on current pedal position): Adjustable pedals forward (PEDAL_FWD). Adjustable pedals rearward (PEDAL_RWD). Do the pedals move in the commanded direction? YES : System operating correctly at this time. INSPECT the adjustable pedal connector and the DSM connectors for corrosion, pushed-out pins and spread terminals. REPAIR as necessary. NO : Go to B10 .
10. B10 CHECK CIRCUITS CPP01 (WH/OG) AND CPP02 (BN) FOR A SHORT TO GROUND Key in OFF position. Disconnect: DSM C341c Disconnect: Adjustable Pedal Motor C2159 Measure the resistance between ground and: DSM C341c-21, circuit CPP02 (BN), harness side. DSM C341c-22, circuit CPP01 (WH/OG), harness side. Are the resistances greater than 10,000 ohms? YES : Go to B11 . NO : REPAIR the affected circuit(s). REPEAT the self-test. CLEAR the DTCs.
11. B11 CHECK CIRCUITS CPP01 (WH/OG) AND CPP02 (BN) FOR AN OPEN Measure the resistance between ground and: DSM C341c-21, circuit CPP02 (BN), harness side and adjustable pedal motor C2159-3, circuit CPP02 (BN), harness side. DSM C341c-22, circuit CPP01 (WH/OG), harness side and adjustable pedal motor C2159-1, circuit CPP01 (WH/OG), harness side. Are the resistances less than 5 ohms? YES : Go to B12 . NO : REPAIR the affected circuit(s). REPEAT the self-test. CLEAR the DTCs.
12. B12 ISOLATE THE ADJUSTABLE PEDALS Connect: DSM C341c Connect: Adjustable Pedal Motor C2159 Disconnect the cables from the adjustable pedals. Select PARK. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: DSM DataLogger Using the scan tool, toggle the following DSM output commands ON: Adjustable pedals forward (PEDAL_FWD). Adjustable pedals rearward (PEDAL_RWD). Does the adjustable pedal motor operate in BOTH directions? YES : INSTALL a new adjustable pedal assembly. REFER to «HYDRAULIC BRAKE ACTUATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) article. TEST the system for normal operation. NO : Go to B13 .
13. B13 ISOLATE THE ADJUSTABLE PEDAL CABLE Disconnect the cables from the adjustable pedal motor. Enter the following diagnostic mode on the diagnostic tool: DSM DataLogger Using the scan tool, toggle the following DSM output commands ON: Adjustable pedals forward (PEDAL_FWD). Adjustable pedals rearward (PEDAL_RWD). Does the adjustable pedal motor operate in BOTH directions? YES : INSTALL a new adjustable pedal cable. TEST the system for normal operation. NO : INSTALL a new adjustable pedal motor. REFER to «HYDRAULIC BRAKE ACTUATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) article. TEST the system for normal operation.

Pinpoint Test C: DTCs B1987, B2871 and B2972 - Pedal Forward/Rearward Motor Stalled and Pedal Position Input Circuit Failure

Refer to appropriate SYSTEM WIRING DIAGRAMS article, Adjustable Pedals for schematic and connector information.

The driver seat module (DSM) uses a Hall-effect position sensor attached to the adjustable pedal motor to identify the current pedal position. The DSM sends a reference voltage to the sensor along circuit LPP06 (YE/BU), the reference voltage passes through the sensor and returns to the DSM along circuit RPP06 (GN). A sensor circuit fault will cause the motor to activate for one second then stop regardless of how long the switch is pressed.

1. DTC B1987 Pedal Forward/Rearward Motor Stalled - This DTC is only set during a DSM on-demand self test. During the self-test, the adjustable pedal motor will be commanded to move forward and then rearward. If the motor encounters a hard stop while moving, the DSM will attempt to move the pedals in the same direction again. If the DSM does not see any pedal movement via the Hall-effect position sensor during this attempt, DTC B1987 will be set.
2. DTC B2971 Pedal Position Input Short to Ground - If during normal operation or an on-demand self test, the DSM detects a short to ground on circuit LPP06 (YE/BU) or RPP06 (GN), DTC B2971 will be set.
3. DTC B2972 Pedal Position Input Short to Battery - If during normal operation or an on-demand self test, the DSM detects a short to battery voltage or an open circuit on circuit LPP06 (YE/BU) or RPP06 (GN), DTC B2972 will be set.

This pinpoint test is intended to diagnose the following

1. Wiring, terminals or connectors
2. Adjustable pedal motor
3. DSM

Scheme 10

Scheme 11

Scheme 12

Scheme 13

1. C1 CHECK THE ADJUSTABLE PEDAL OPERATION FROM THE ADJUSTABLE PEDAL SWITCH Press the adjustable pedal switch to the FORWARD or REARWARD position (depending on the current pedal position). Do the pedals move in the desired direction for more than one second? YES : The condition is not present. CLEAR the DTCs. REPEAT the self-test. NO : If the pedals only move in one second intervals, go to C2 . If the pedals do not move at all, go to «Pinpoint Test B»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information__pinpoint-test-b-the-adjustable-brake) .
2. C2 CHECK CIRCUITS LPP06 (YE/BU) AND RPP06 (GN) FOR AN OPEN Key in OFF position. Disconnect: Adjustable Pedal Motor C2159 Disconnect: DSM C341c Measure the resistance between: DSM C341c-16, circuit LPP06 (YE/BU), harness side and adjustable pedal motor C2159-4, circuit LPP06 (YE/BU), harness side. DSM C341c-24, circuit RPP06 (GN), harness side and adjustable pedal motor C2159-6, circuit RPP06 (GN), harness side. Are the resistances less than 5 ohms? YES : Go to C3 . NO : REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test.
3. C3 CHECK CIRCUITS LPP06 (YE/BU) AND RPP06 (GN) FOR A SHORT TO GROUND Measure the resistance between ground and: DSM C341c-16, circuit LPP06 (YE/BU), harness side. DSM C341c-24, circuit RPP06 (GN), harness side. Is the resistance greater than 10,000 ohms? YES : Go to C4 . NO : REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test.
4. C4 CHECK CIRCUITS LPP06 (YE/BU) AND RPP06 (GN) FOR A SHORT TOGETHER Measure the resistance between DSM C341c-16, circuit LPP06 (YE/BU), harness side and DSM C341c-24, circuit RPP06 (GN), harness side. Is the resistance greater than 10,000 ohms? YES : Go to C5 . NO : REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test.
5. C5 CHECK CIRCUITS LPP06 (YE/BU) AND RPP06 (GN) FOR A SHORT TO VOLTAGE Key in ON position. Measure the voltage between ground and: DSM C341c-16, circuit LPP06 (YE/BU), harness side. DSM C341c-24, circuit RPP06 (GN), harness side. Is voltage present? YES : REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test. NO : INSTALL a new adjustable pedal motor. REFER to «HYDRAULIC BRAKE ACTUATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) article. CLEAR the DTCs. REPEAT the self-test.

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.

This pinpoint test is intended to diagnose the following

1. Uneven brake pad wear
2. Brake disc pad transfer
3. Brake disc
4. Suspension components

PINPOINT TEST D: VIBRATION WHEN THE BRAKES ARE APPLIED

1. D1 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 D3 . NO : Go to D2 .
2. D2 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 D3 . NO : The concern is not present at this time.
3. D3 CHECK ABS OPERATION 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 D4 .
4. D4 CHECK THE FRONT SUSPENSION Check the front suspension. Refer to «SUSPENSION SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/suspension-front/#suspension-system-general-information) article. Are all the suspension components in satisfactory condition? YES : Go to D5 . NO : REPAIR or INSTALL new components as necessary. TEST the system for normal operation.
5. D5 RESURFACE THE FRONT BRAKE DISCS CAUTION: Do not use a bench lathe to machine the brake discs. A bench lathe may cause brake disc on-vehicle lateral runout and brake roughness. NOTE: Follow the brake lathe 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»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information__brake-disc-machining) . Road test the vehicle. Is the vibration/shudder present? YES : Go to D6 . NO : The concern has been repaired.
6. D6 CHECK THE REAR SUSPENSION Check the rear suspension. Refer to «SUSPENSION SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/suspension-front/#suspension-system-general-information) article. Are all the suspension components in satisfactory condition? YES : RESURFACE the rear brake discs. REFER to «Brake Disc Machining»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information__brake-disc-machining) . NO : REPAIR or INSTALL new components as necessary. TEST the system for normal operation.

1. Disconnect the check valve from the brake booster.
2. Apply the parking brake, start the engine and place the transmission in NEUTRAL.
3. Verify that manifold vacuum is available at the check valve with the engine at idle speed and the transmission in NEUTRAL. If manifold vacuum is available, stop the engine, connect the check valve and continue with Step 5. If manifold vacuum is not available, continue with Step 4.
4. Disconnect the check valve from the vacuum hose and verify that manifold vacuum is available at the hose with the engine at idle speed and the transmission in NEUTRAL. If manifold vacuum is available, stop the engine, install a new check valve and continue with Step 5. If manifold vacuum is not available, stop the engine, connect the vacuum hose to the check valve and refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article to diagnose the no 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/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#power-brake-actuation-brake-booster) article.
7. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lb) of force. 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 the brake pedal feels spongy, bleed the hydraulic system to remove air. Refer to «Brake System Bleeding»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information__brake-system-bleeding) .

Check Valve

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

1. Disconnect the vacuum booster hose from the check valve.
2. Apply the parking brake, start the engine and place the transmission in NEUTRAL.
3. Verify that manifold vacuum is available at the check valve end of the vacuum hose with the engine at idle speed and the transmission in NEUTRAL. If manifold vacuum is available, stop the engine, connect the vacuum hose to the check valve and continue this test. If manifold vacuum is not available, stop the engine, connect the vacuum hose to the check valve and refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical/#engine-system-general-information) article to diagnose the no vacuum condition.
4. Connect the vacuum hose to the check valve and run the engine for at least 10 seconds.
5. Operate the brake pedal to check for power assist. If power assist is present, continue with this test. If power assist is not present, refer to Brake Booster Component Test in this article.
6. Stop the engine and disconnect the vacuum booster hose from the brake booster check valve.
7. Apply the brake and verify that there is enough vacuum retained in the brake booster for at least one power-assisted brake application. If there is enough vacuum for at least one power-asssisted brake application, the check valve is functioning correctly. If there is not enough vacuum for at least one power-asssisted brake application, continue with this test.
8. Inspect the brake booster for any signs of damage that could cause a leak. If any damage is found, install a new brake booster and repeat this test. If no damage is found, install a new check valve.

Brake Master Cylinder - Bypass Condition

1. Disconnect the brake tubes from the master cylinder.
2. Plug the outlet ports of the master cylinder.
3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and a new brake master cylinder must be installed.

Brake Master Cylinder - Compensator Port

The purpose of the compensator ports in the brake master cylinder is to

1. supply additional brake fluid from the brake master cylinder reservoir needed by the brake system due to brake lining wear.
2. allow brake fluid to return to the brake master cylinder reservoir when the brakes are released. The returning brake fluid creates a slight turbulence in the brake 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. If clogged compensator ports are suspected, proceed as follows

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. With the brakes released, attempt to rotate each wheel and check for any brake drag. If an excessive amount of brake drag exists at all 4 wheels, continue with the test. 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.
3. Check the brake stoplamp switch and the brake pedal free play to verify that the brake pedal is not partially applied.
4. Loosen the brake master cylinder nuts and position the brake master cylinder away from the brake booster.
5. 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/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#power-brake-actuation-brake-booster) article. If the brake drag is still present, install a new master cylinder. Refer to «HYDRAULIC BRAKE ACTUATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) article.

Brake Disc Machining

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

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

Note. Do not machine new brake discs.

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

1. Remove the wheel and tire. For additional information, refer to «WHEELS AND TIRES»(/ford/explorer-sport-trac/ii-2006-2010/remont/wheel-tire-system/#tires-and-wheels) article.
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. Position the brake caliper or brake caliper and anchor plate assembly. Install the bolts. For fastener torque specifications, refer to «FRONT DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#front-disc-brake-system) article for front disc brakes or «REAR DISC BRAKE»(/ford/explorer-sport-trac/ii-2006-2010/remont/mechanical-hydraulic/#rear-disc-brake-system) article for rear disc brakes.
12. Install the wheel and tire. For additional information, refer to «WHEELS AND TIRES»(/ford/explorer-sport-trac/ii-2006-2010/remont/wheel-tire-system/#tires-and-wheels) article.

Brake System Bleeding

Special Tools Illustration Tool Name Tool Number Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Material

Pressure Bleed

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.

Note. Pressure bleed the brake system at 207-345 kPa (30-50 psi).

1. Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master cylinder reservoir with clean, specified brake fluid.
2. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter.
3. Remove the RH rear brake caliper 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.
4. Open the valve on the bleeder tank.
5. Loosen the RH rear brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw. Press and release the parking brake 5 times. Repeat until clear, bubble-free fluid comes out.
6. Tighten the RH rear brake caliper bleeder screw to 22 Nm (16 lb-ft), remove the rubber hose and install the bleeder screw cap.
7. Repeat Steps 5 and 6 for the LH rear brake caliper. Tighten the LH rear brake caliper bleeder screw to 22 Nm (16 lb-ft).
8. Continue bleeding the front of the system, going in order from the RH front brake caliper and then to the LH front brake caliper. Tighten the front brake caliper bleeder screws to 10 Nm (89 lb-in).
9. Close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter. Fill the reservoir with clean, specified brake fluid and install the reservoir cap.

Manual Bleeding

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 after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment.

1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with clean, specified brake fluid.
2. Remove the RH rear brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid.
3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
4. Loosen the RH rear brake caliper 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.
5. Tighten the RH rear brake caliper bleeder screw to 22 Nm (16 lb-ft), remove the rubber hose and install the bleeder screw cap.
6. Repeat Steps 2 through 5 for the LH rear brake caliper bleeder screw. Tighten the LH rear brake caliper bleeder screw to 22 Nm (16 lb-ft).
7. Remove the RH front brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid.
8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
9. 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 bleeder screw. Repeat until clear, bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary.
10. Tighten the RH front brake caliper bleeder screw to 10 Nm (89 lb-in), remove the rubber hose and install the bleeder screw cap.
11. Repeat Steps 7 through 10 for the LH front brake caliper bleeder screw. Tighten the LH front brake caliper bleeder screw to 10 Nm (89 lb-in).

ABS Hydraulic Control Unit (HCU) Bleeding

Note. This procedure is only required when a new hydraulic control unit (HCU) is installed.

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 after it is correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment.

1. Connect the scan tool to the vehicle.
2. Access the ABS HCU bleed function and follow the directions on the scan tool.
3. Manually bleed the brake hydraulic system. For additional information, refer to «Manual Bleeding»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information__manual-bleeding) .
4. Repeat the procedure carrying out a total of 2 scan tool cycles and 2 manual bleed cycles.

Component Bleeding

Material

Master Cylinder

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

1. Disconnect the brake tubes from the master cylinder.
2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with clean, specified brake fluid.
3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air bubbles.
4. Remove the short brake tubes and install the brake outlet tubes.
5. Bleed each brake tube at the brake master cylinder as follows: Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. Loosen the rearmost brake tube fitting 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. Tighten the master cylinder brake tube fittings to 18 Nm (13 lb-ft).
6. Bleed the brake system, refer to «Brake System Bleeding»(/ford/explorer-sport-trac/ii-2006-2010/remont/anti-locktraction-control/#brake-system-general-information__brake-system-bleeding) .

Brake Caliper

Note. It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or installed new.

1. Remove the brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
3. 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. Tighten the brake caliper bleeder screw, remove the rubber hose and install the bleeder screw cap. Tighten the front brake caliper bleeder screw to 10 Nm (89 lb-in). Tighten the rear brake caliper bleeder screw to 22 Nm (16 lb-ft).

See also:
• HYDRAULIC BRAKE ACTUATION
• VEHICLE DYNAMIC SYSTEMS
• POWER BRAKE ACTUATION
• FRONT DISC BRAKE
• REAR DISC BRAKE
• PARKING BRAKE AND ACTUATION
• SEATING
• INSTRUMENT CLUSTER (IC), MESSAGE CENTER, AND WARNING CHIMES
• WHEELS AND TIRES
• FRONT SUSPENSION - REAR WHEEL DRIVE (RWD)
• FRONT SUSPENSION - FOUR WHEEL DRIVE (4WD)
• REAR SUSPENSION
• SUSPENSION SYSTEM - GENERAL INFORMATION
• ENGINE SYSTEM - GENERAL INFORMATION
• NOISE, VIBRATION AND HARSHNESS
• MODULE COMMUNICATIONS NETWORK
• MULTIFUNCTION ELECTRONIC MODULES
• MODULE CONFIGURATION
• REAR VIEW MIRRORS
• HANDLES, LOCKS, LATCHES AND ENTRY SYSTEMS
• JACKING AND LIFTING
• Symptom Chart - Brake System
• Brake Caliper Guide Pins
• Brake Disc Machining
• Brake System Bleeding
• Brake Pads
• Brake Calipers
• Pinpoint Test D
• Pinpoint Test A
• Pinpoint Test C
• Pinpoint Test B
• Manual Bleeding