Brake System - General Information Ford Five Hundred I

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The brake system has the following components

1. a fixed brake pedal
2. an optional power adjustable brake pedal with memory function
3. vacuum-assisted power brake booster
4. digital split hydraulic system
5. front disc brakes uses a dual piston brake caliper and disc system
6. rear disc brakes with an integral parking brake, uses a single piston brake caliper and disc system
7. 4-wheel anti-lock brake system (4WABS). For additional information, refer to «ANTI-LOCK CONTROL»(/ford/five-hundred/i-2004-2007/remont/anti-locktraction-control/#anti-lock-brake-system) .

Adjustable Pedals

Using the adjustable pedal switch, located on the instrument panel, the driver can adjust the brake and accelerator pedals for a more comfortable driving position.

Adjustable Pedals Operation

The adjustable pedals feature is operational with the key in the ON or OFF position. The pedals can be adjusted forward or rearward using the adjustable pedal switch.

Memory Adjustable Pedal Operation

The power adjustable pedal memory feature stores the current accelerator and brake pedal positions and recalls the previously stored pedal positions for a specified driver as requested by the personality feature. The adjustable pedals with memory feature

1. retains 2 separate driver pedal positions.
2. updates the retained pedal position when the driver personality is stored.
3. moves the pedal to the retained pedal position when the driver personality is recalled.
4. stops pedal movement when any manual actuation of the adjustable pedal switch occurs while memory recall is moving the pedal.

Refer to ANTI-LOCK BRAKES (Montego), ANTI-LOCK BRAKES (Five Hundred), ANTI-LOCK BRAKES (Freestyle) for schematic and connector information.

Special Tool(s)

SPECIAL TOOL 73III Automotive Meter 105-R0057 or equivalent Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool On-Vehicle Brake Lathe 201-00002 or equivalent

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Material

MATERIAL SPECIFICATION - BRAKE SYSTEM

Power Brakes

Pressing the brake pedal pushes a rod into the brake booster which, through the use of vacuum, boosts the force of the rod, transmitting the force into the master cylinder. This action produces hydraulic pressure in the master cylinder. Hydraulic pressure is transmitted through the master cylinder by brake fluid, through the brake lines, to the individual brake calipers. The brake calipers use hydraulic pressure to apply the pads. The application of the brake pads against the friction surfaces of the brake discs causes the rotation of the wheels to slow or stop depending on how much brake pressure is applied. The parking brakes perform the same function except that they are mechanically actuated by a cable that connects only to the rear brake calipers.

Programming Adjustable Pedal Positions

An adjustable pedal position can be stored at any time.

Programming adjustable pedal positions can be accomplished by the following

1. To store the adjustable pedal position to memory, move the pedals to the preferred position using the adjustable pedal switch. Press the memory SET switch, activating the memory SET switch light emitting diode (LED). Within 5 seconds (before the LED goes out) select memory position 1 or 2.
2. If no memory switch input is received within the 5-second time limit, the operation is aborted and the memory SET switch LED is turned OFF. If one of the following inputs is received during the 5-second programming limit, the operation is aborted and the memory SET switch LED is turned OFF: adjustable pedal switch power driver seat switch exterior mirror control switch memory SET switch.

To program the remote keyless entry (RKE) transmitter, refer to HANDLES, LOCKS, LATCHES AND ENTRY SYSTEMS .

Recalling a Stored Adjustable Pedal Position

Once a preferred adjustable pedal position is stored, it is recalled by pressing the corresponding memory switch, or by using a programmed RKE transmitter.

1. The driver can recall a preferred adjustable pedal position by pressing one of the memory recall switches. Pressing memory switch 1 initiates a recall of the adjustable pedal position stored in memory No. 1. Pressing memory switch 2 initiates a recall of the adjustable pedal position stored in memory No. 2.
2. A remote transmitter can be used to recall previously set memory positions. The remote transmitters are manufactured with an assigned personality number (1 or 2) and are so designated on the back of the remote transmitter case. The remote transmitter assigned with personality 1 is capable of only recalling memory position 1. Similarly, the remote transmitter assigned with personality 2 can recall memory positions 2.
3. Memory recall occurs when the UNLOCK switch is pressed on the remote transmitters. A second press of the UNLOCK switch, which unlocks the passenger doors, does not initiate a memory recall.
4. A memory recall in progress does not prohibit the initiation of another memory recall; the most recently requested memory recall is executed.

Inspection and Verification

Note. Always check the fluid level in the brake master cylinder reservoir before carrying out the test procedures. If the fluid level is not between the MIN and MAX level mark, clean the reservoir cap before removing, then add DOT 3 brake fluid.

Note. Prior to carrying out any diagnosis, make sure the red brake warning indicator is functional. For additional information, refer to INSTRUMENT CLUSTER .

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 concern. If this does not relieve the locked wheel condition, repair the locked components before proceeding.

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

Road Test

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 guidelines. It is also 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. Install new brake pads if the thickness of the friction material is less than 3.0mm (0.118 inch). For additional information, refer to «FRONT DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#front-disc-brake-system) for front disc brakes or «REAR DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#rear-disc-brake-system) for rear disc brakes. Compare all 4 front or rear pads for uneven wear. Install new brake pads if the thickness of the friction material varies from pad to pad by more than 2.0mm (0.079 inch). For additional information, refer to «FRONT DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#front-disc-brake-system) for front disc brakes or «REAR DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#rear-disc-brake-system) for rear disc brakes. Install new brake pads if there are missing chunks or cracks in the lining through to the backing plate. For additional information, refer to «FRONT DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#front-disc-brake-system) or «REAR DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#rear-disc-brake-system) . If the friction material shows taper wear (i.e. the thickness varies by more than 3.0mm [0.118 inch] in any direction) verify the caliper guide pins are functioning correctly. For additional information, refer to «BRAKE CALIPER GUIDE PINS»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#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. For additional information, refer to «FRONT DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#front-disc-brake-system) or «REAR DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#rear-disc-brake-system) .
2. Inspect the brake discs and measure the brake disc thickness in a minimum of 4 places around the circumference of the brake disc. Record the measurements. Install new brake discs if any thickness measurement is less than the minimum specification. For additional information, refer to «FRONT DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#front-disc-brake-system) or «REAR DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#rear-disc-brake-system) . Install new brake discs if cracked. For additional information, refer to «FRONT DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#front-disc-brake-system) or «REAR DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#rear-disc-brake-system) . Machine the brake discs if the diagnosis has revealed vibration in the steering wheel, seat, or pedal while braking. Heavily scored brake discs, similar to that caused by pads worn down to the backing plate, should also be machined. In order to machine, discs must be above the minimum thickness to machine specification. For additional information, refer to «SPECIFICATIONS»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information) and «BRAKE DISC MACHINING»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information) .

Brake Calipers

Inspect the brake calipers for the following

1. Brake fluid leaks. For additional information, refer to «BRAKE SYSTEM LEAK CHECK»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information__brake-system-leak-check) .
2. Boots and seals for tears or cracks.
3. Caliper pistons for binding and corrosion.
4. Guide pins for correct operation. For additional information, refer to «BRAKE CALIPER GUIDE PINS»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information__brake-caliper-guide-pins) .

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. For additional information, refer to FRONT DISC BRAKE for the front brake caliper anchor plate or REAR DISC BRAKE for the rear brake caliper anchor plate.

Install new brake pads if the lining is not within specifications. For additional information, refer to FRONT DISC BRAKE for front disc brakes or REAR DISC BRAKE for rear disc brakes.

Brake Lines and Tubes

1. Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly double flared to provide strong, leakproof connections. When bending tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube.
2. If a section of the brake tube is damaged, the entire section must be installed 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. For additional information, refer to «BRAKE SYSTEM BLEEDING»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information) .
4. The wet appearance on the outer cover of rubber brake hoses is called "sweating." This is a normal condition for rayon-braided neoprene hose and is not a sign of leakage or cause to install a new hose.

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

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

Non-Pressure Leaks

Note. The wet appearance on the outer cover of rubber brake hoses is called "sweating." This is a normal condition for rayon-braided neoprene hose. The sweating condition is not evidence of a brake fluid leak and will not result in a loss of pressure in the system.

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

1. missing or poorly-fitted brake master cylinder filler cap
2. punctured or otherwise damaged brake master cylinder reservoir
3. missing or damaged brake master cylinder filler cap gasket
4. missing, damaged or poorly-fitted sealing grommets between the brake master cylinder and the brake master cylinder reservoir

The brake master cylinder reservoir grommets are not repairable and must be installed new as part of a new brake master cylinder reservoir.

Brake Master Cylinder - Normal Conditions

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

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

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

Condition 3: Fluid level will decrease with pad wear.

Brake Master Cylinder - Abnormal Conditions

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

Brake Booster

Inspect the brake booster for the following

1. excessive corrosion or damage
2. vacuum connections for leakage
3. vacuum hoses for kinks or leakage
4. brake booster check valve for correct operation

For low or spongy brake pedal concerns

1. check and, if necessary, refill the brake master cylinder reservoir.
2. bleed the brake system and retest the brake pedal feel.

For a slow or incomplete brake pedal return concern

1. inspect for binding, damage, correct installation or interference at the brake pedal.
2. check the brake booster for binding, damage and correct installation.

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

Adjustable Pedal 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 Memory set switch Circuitry Smart junction box (SJB) fuse 4 (15 A)
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 (only for adjustable pedal with memory, all others GO to «SYMPTOM CHART»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information__symptom-chart) connect the diagnostic tool to the data link connector (DLC) and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: check that the program card is correctly installed. check the connections to the vehicle. check the ignition switch position.
5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual.
6. Carry out the diagnostic tool data link test. If the diagnostic tool responds with: CAN, UBP or ISO circuit fault; all electronic control units no response/not equipped, refer to «MODULE COMMUNICATIONS NETWORK»(/ford/five-hundred/i-2004-2007/remont/communication-devices/#module-communications-network-system) . No response/not equipped for the driver seat module (DSM), refer to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/five-hundred/i-2004-2007/remont/communication-devices/#multifunction-electronic-modules-system) . System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), and carry out the self-test diagnostics for the DSM.
7. If the DTCs retrieved are related to the concern, go to the «DRIVER SEAT MODULE (DSM) DIAGNOSTIC TROUBLE CODE (DTC) INDEX»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information__driver-seat-module-dsm-diagnostic-trouble) .
8. If no DTCs related to the concern are retrieved, GO to «SYMPTOM CHART»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information__symptom-chart) .

Driver Seat Module (DSM) Diagnostic Trouble Code (DTC) Index

DRIVER SEAT MODULE (DSM) DIAGNOSTIC TROUBLE CODE (DTC) INDEX

For a complete list of DSM DTCs, refer to MULTIFUNCTION ELECTRONIC MODULES .

Symptom Chart

SYMPTOM CHART

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Normal Operation

The red brake warning indicator is located in the instrument cluster and illuminates when the brake fluid in the brake master cylinder reservoir is below a specific level, when the parking brake is engaged, or when there is a failure with the anti-lock brake system (ABS) electronic brake force distribution (EBD) system (the yellow ABS warning indicator will also illuminate). The instrument cluster receives a ground input on circuit 1309 (RD/YE) when the parking brake has been applied through circuit 1205 (BK), turning on the brake warning indicator. The smart junction box (SJB) provides a voltage reference signal to the brake fluid level switch through circuit 1305 (DB) and back to the SJB on circuit 128 (VT/YE). When the brake fluid level is low, the brake fluid level switch closes to circuit 128 (VT/YE). If the voltage reference signal the SJB is sending to the brake fluid level switch drops to zero, then the SJB sends a standard corporate protocol (SCP) message to the instrument cluster to turn on the brake warning indicator.

Possible Causes

1. low brake fluid level
2. brake fluid level switch
3. parking brake engaged
4. parking brake switch
5. circuit 128 (VT/YE) short to ground
6. circuit 1305 (DB) short to ground
7. circuit 1309 (RD/YE) short to ground
8. instrument cluster
9. SJB

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1. A1 CHECK FOR A SHORTED PARKING BRAKE SWITCH Key in OFF position. Disconnect: Parking Brake Switch C306. Key in ON position. Is the red brake warning indicator off? Yes : The parking brake switch is closed. REPAIR as necessary. TEST the system for normal operation. No : GO to A2.
2. A2 CHECK THE PARKING BRAKE CIRCUIT FOR A SHORT TO GROUND Key in OFF position. Disconnect: Smart Junction Box (SJB) C2280c. Measure the resistance between the SJB connector C2280c-23, circuit 1309 (RD/YE) harness side and ground. Is the resistance greater than 10,000 ohms? Yes : GO to A3. No : REPAIR the circuit. TEST the system for normal operation.
3. A3 CHECK THE BRAKE FLUID LEVEL SWITCH Disconnect: Brake Fluid Level Switch C124. Connect: SJB C2280c. Key in ON position. Is the red brake warning indicator off? Yes : INSTALL a new brake fluid level switch. TEST the system for normal operation. No : GO to A4.
4. A4 CHECK CIRCUITS 128 (VT/YE) AND 1305 (DB) FOR A SHORT TO GROUND Key in OFF position. Disconnect: SJB C2280a. Measure the resistance between the brake fluid level switch connector C124-2, circuit 128 (VT/YE), harness side and ground; and between C124-3, circuit 1305 (DB), harness side and ground. Are the resistances greater than 10,000 ohms? Yes : GO to A5. No : REPAIR the circuit. TEST the system for normal operation.
5. A5 ISOLATE THE INSTRUMENT CLUSTER Key in ON position. Enter the following diagnostic mode on the diagnostic tool: Active Commands. Using Active Commands, turn the red brake warning indicator on and off in the instrument cluster. Does the red brake warning indicator operate correctly? Yes : GO to A6. No : GO to A7 .
6. A6 CHECK FOR CORRECT SJB OPERATION Disconnect all the SJB connectors. Check for: corrosion pushed-out pins Connect all the SJB connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new SJB. REFER to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/five-hundred/i-2004-2007/remont/communication-devices/#multifunction-electronic-modules-system) . TEST the system for normal operation. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
7. A7 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all the instrument cluster connectors. Check for: corrosion pushed-out pins Connect all the instrument cluster connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new instrument cluster. REFER to «INSTRUMENT CLUSTER»(/ford/five-hundred/i-2004-2007/remont/gauges-instrument-panels/#instrument-cluster-system) . TEST the system for normal operation. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. TEST the system for normal operation.

Testing

1. B1 CHECK FOR TSBs Check the Technical Service Bulletins (TSBs) for applicable brake concerns. Is there applicable information available in a TSB? Yes : REFER to the TSB. CARRY OUT any necessary repairs that are indicated by the TSB. If the concern is still present, GO to B2. No : GO to B2.
2. B2 ROAD TEST THE VEHICLE - LIGHT BRAKING Inspect the wheels and tires. Refer to «SUSPENSION SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/suspension-front/#suspension-system-general-information) . 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 B5 . No : GO to B3.
3. B3 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 B4. No : The concern is not present at this time.
4. B4 NORMAL ACTUATION OF THE ABS SYSTEM DIAGNOSIS During moderate to heavy braking, noise from the hydraulic control unit (HCU) and pulsation in the brake pedal can be observed. Pedal pulsation coupled with noise during heavy braking or on loose gravel, bumps, wet or snowy surfaces is acceptable and indicates correct functioning of the ABS system. Pedal pulsation or steering wheel nibble (frequency is proportioned to the vehicle speed) indicates a concern with a brake or suspension component. Is the vibration/shudder vehicle speed sensitive? Yes : GO to B6 . No : The concern is not present at this time.
5. B5 APPLICATION OF THE PARKING BRAKE 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. 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 B8 . No : GO to B6.
6. B6 CHECK THE FRONT SUSPENSION Check the front suspension. Refer to «SUSPENSION SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/suspension-front/#suspension-system-general-information) . Are all the suspension components in satisfactory condition? Yes : GO to B7. No : REPAIR or INSTALL new components as necessary. TEST the system for normal operation.
7. B7 RESURFACE THE FRONT BRAKE DISCS CAUTION: Do not use a bench lathe to machine the brake discs. NOTE: Follow the manufacturer's instructions to machine the brake discs. After machining, make sure the brake disc meets the thickness specification. Resurface the front brake discs. Refer to «BRAKE DISC MACHINING»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information) . Road test the vehicle. Is the vibration/shudder present? Yes : GO to B8. No : The concern is not present at this time.
8. B8 CHECK THE REAR SUSPENSION Check the rear suspension. Refer to «SUSPENSION SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/suspension-front/#suspension-system-general-information) . Are all the suspension components in satisfactory condition? Yes : GO to B9. No : REPAIR or INSTALL new components as necessary. TEST the system for normal operation.
9. B9 RESURFACE THE REAR BRAKE DISCS OR REAR DRUMS CAUTION: Do not use a bench lathe to machine brake discs. NOTE: Follow the manufacturer's instructions to machine the brake discs or drums. After machining, make sure they are within the specifications. Resurface the rear brake discs or brake drums. Refer to «BRAKE DISC MACHINING»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information) . Road test the vehicle. Is the vibration/shudder present? Yes : Refer to «NOISE, VIBRATION & HARSHNESS»(/ford/five-hundred/i-2004-2007/remont/oem-general-information/#noise-vibration-harshness) to continue diagnosis of the vibration. No : The concern is not present at this time.

The adjustable pedal memory function uses an adjustable pedal potentiometer located in the adjustable pedal motor. The driver seat module (DSM) supplies a reference voltage to the potentiometer and a signal return. The signal voltage from the adjustable pedal potentiometer to the DSM provides an indication to the DSM of whether or not the adjustable pedal motor is stalled. When the driver sets a pedal position in the DSM, it stores the value of where the adjustable pedals are located using a time frame of motor operation. When the driver requests a return to a pedal position in memory, the DSM will operate the adjustable pedal motor until the adjustable pedal potentiometer output matches the time frame stored in memory. If the memory function is not used, the adjustable pedal switch can also be used for normal operation of the adjustable pedal system. The DSM sends out a voltage reference on circuits 1495 (WH) (rearward) and 1494 (RD) (forward) to the adjustable pedal switch. When the switch is operated to the forward/rearward position, the voltage reference from the DSM is grounded on circuit 1205 (BK). Depending on which circuit is grounded, the DSM interprets this and powers one of the circuits 1490 (LB/OG) or 1489 (LB/BK) and grounds the opposite circuit. The adjustable pedals will then operate in the commanded direction.

1. circuit 267 (BN/LG) open or short to ground
2. circuit 268 (BK/OG) open or short to ground
3. circuit 270 (BN/LG) open or short to ground
4. circuit 1205 (BK) open
5. circuit 1489 (LB/BK) open or short to ground
6. circuit 1490 (LB/OG) open or short to ground
7. circuit 1491 (LB/WH) open or short to ground
8. circuit 1494 (RD) open or short to ground
9. circuit 1495 (WH) open or short to ground
10. circuit 1899 (WH) open or short to ground
11. memory set switch
12. adjustable pedal switch
13. adjustable pedal potentiometer
14. adjustable pedal motor

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1. C1 CHECK FOR DTCS Use the recorded Driver Seat Module (DSM) DTCs from the continuous and on-demand self-tests. Are any DSM DTCs recorded? Yes : If DTC(s) B1530, B1534, B1538 was retrieved, GO to C14 . If DTC B1987 was retrieved, GO to C2. If DTC(s) B1988, B1989 was retrieved, GO to C3 . If DTC B2971 or B2972 was retrieved GO to C11 . No : GO to C2.
2. C2 CHECK THE MANUAL OPERATION 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. Pinch the locking collar and give a firm tug on the cable allowing 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 improperly 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. Manually operate the adjustable pedal using the adjustable pedal switch on the instrument panel in both directions. Does the adjustable pedal operate in BOTH directions? Yes : GO to C11 . No : GO to C3.
3. C3 CHECK THE ADJUSTABLE PEDAL SWITCH Key in OFF position. Disconnect: Adjustable Pedal Switch C2089. For vehicles built before 1/2005, measure the resistance between the adjustable pedal switch pins C2089, component side, while activating the adjustable pedal switch to the indicated positions. ADJUSTABLE PEDAL SWITCH RESISTANCE VALUE Adjustable Pedal Switch Pin Adjustable Pedal Switch Position Resistance Value 1 and 2 Bottom Arrow 0 Ohms 1 and 7 Bottom Arrow Open 2 and 7 Bottom Arrow Open 2 and 7 Top Arrow 0 Ohms 2 and 1 Top Arrow Open 1 and 7 Top Arrow Open For vehicles built after 1/2005, measure the resistance between the adjustable pedal switch pins C2089, component side, while activating the adjustable pedal switch to the indicated positions. ADJUSTABLE PEDAL SWITCH RESISTANCE VALUE Adjustable Pedal Switch Pin Adjustable Pedal Switch Position Resistance Value 3 and 4 Bottom Arrow 0 Ohms 3 and 7 Bottom Arrow Open 4 and 7 Bottom Arrow Open 4 and 7 Top Arrow 0 Ohms 4 and 3 Top Arrow Open 3 and 7 Top Arrow Open Does the adjustable pedal switch pass the component test? Yes : GO to C4. No : INSTALL a new adjustable pedal switch. TEST the system for normal operation.
4. C4 CHECK CIRCUIT 1567 (RD/LB) FOR VOLTAGE Key in ON position. For vehicles built before 1/2005, measure the voltage between the adjustable pedal switch C2089-2, circuit 1567 (RD/LB), harness side and ground. For vehicles built after 1/2005, measure the voltage between the adjustable pedal switch C2089-4, circuit 1567 (RD/LB), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to C5. No : REPAIR the circuit. TEST the system for normal operation.
5. C5 CHECK CIRCUIT 1205 (BK) FOR AN OPEN Key in OFF position. For vehicles built before 1/2005, measure the resistance between the adjustable pedal switch C2089-3, circuit 1205 (BK), harness side and ground; and between the adjustable pedal switch C2089-6, circuit 1205 (BK), harness side and ground. For vehicles built after 1/2005, measure the resistance between the adjustable pedal switch C2089-1, circuit 1205 (BK), harness side and ground. Are the resistances less than 5 ohms? Yes : GO to C6. No : REPAIR the circuit. TEST the system for normal operation.
6. C6 CHECK CIRCUIT 1494 (RD) FOR AN OPEN AND A SHORT TO GROUND Disconnect: DSM C341c. Measure the resistance between the adjustable pedal switch C2089-7, circuit 1494 (RD), harness side and the DSM C341c-14, circuit 1494 (RD), harness side; and between the adjustable pedal switch C2089-7, circuit 1494 (RD), harness side and ground. Measure the resistance between the adjustable pedal switch C2089-7, circuit 1494 (RD), harness side and the DSM C341c-14, circuit 1494 (RD), harness side; and between the adjustable pedal switch C2089-7, circuit 1494 (RD), harness side and ground. Are the resistances less than 5 ohms between the adjustable pedal switch and the DSM, and greater than 10,000 ohms between the adjustable pedal switch and ground? Yes : GO to C7. No : REPAIR the circuit. TEST the system for normal operation.
7. C7 CHECK CIRCUIT 1495 (WH) FOR AN OPEN AND A SHORT TO GROUND For vehicles built before 1/2005, measure the resistance between the adjustable pedal switch C2089-1, circuit 1495 (WH), harness side and the DSM C341c-2, circuit 1495 (WH), harness side; and between the adjustable pedal switch C2089-1, circuit 1495 (WH), harness side and ground. For vehicles built after 1/2005, measure the resistance between the adjustable pedal switch C2089-3, circuit 1495 (WH), harness side and the DSM C341c-2, circuit 1495 (WH), harness side; and between the adjustable pedal switch C2089-3, circuit 1495 (WH), harness side and ground. Are the resistances less than 5 ohms between the adjustable pedal switch and the DSM, and greater than 10,000 ohms between the adjustable pedal switch and ground? Yes : GO to C8. No : REPAIR the circuit. TEST the system for normal operation.
8. C8 CHECK CIRCUIT 1490 (LB/OG) FOR AN OPEN AND A SHORT TO GROUND Disconnect: Adjustable Pedal Motor C2003. Measure the resistance between the DSM C341c-21, circuit 1490 (LB/OG), harness side and the adjustable pedal motor C2003-1, circuit 1490 (LB/OG), harness side; and between the DSM C341c-21, circuit 1490 (LB/OG), harness side and ground. Is the resistance less than 5 ohms between the DSM and the adjustable pedal motor, and greater than 10,000 ohms between the DSM and ground? Yes : GO to C9. No : REPAIR the circuit. TEST the system for normal operation.
9. C9 CHECK CIRCUIT 1489 (LB/BK) FOR AN OPEN AND A SHORT TO GROUND Measure the resistance between the DSM C341c-22, circuit 1489 (LB/BK), harness side and the adjustable pedal motor C2003-2, circuit 1489 (LB/BK), harness side; and between the DSM C341c-22, circuit 1489 (LB/BK), harness side and ground. Is the resistance less than 5 ohms between the DSM and the adjustable pedal motor, and greater than 10,000 ohms between the DSM and ground? Yes : GO to C10. No : REPAIR the circuit. TEST the system for normal operation.
10. C10 CHECK THE ADJUSTABLE PEDAL MOTOR Connect a fused (10A) jumper wire between the B+ and the adjustable pedal motor C2003 pin 1, component side; and between ground the adjustable pedal motor C2003 pin 2, component side. Reverse the connections to verify the motor operates in both directions. Does the adjustable pedal motor operate in BOTH directions? Yes : GO to C19 . No : INSTALL a new adjustable pedal motor assembly. REFER to «HYDRAULIC BRAKE ACTUATION»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) . TEST the system for normal operation.
11. C11 CHECK CIRCUIT 1491 (LB/YE) FOR AN OPEN AND A SHORT TO GROUND Key in OFF position. Disconnect: DSM C341c. Disconnect: Adjustable Pedal Motor C2003. Measure the resistance between the DSM C341c-16, circuit 1491 (LB/YE), harness side and the adjustable pedal motor C2003-4, circuit 1491 (LB/YE), harness side; and between the DSM C341c-16, circuit 1491 (LB/YE), harness side and ground. Is the resistance less than 5 ohms between the DSM and the adjustable pedal motor, and greater than 10,000 ohms between the DSM and ground? Yes : GO to C12. No : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
12. C12 CHECK CIRCUIT 1899 (WH) FOR AN OPEN AND A SHORT TO GROUND Measure the resistance between the DSM C341c-24, circuit 1899 (WH), harness side and the adjustable pedal motor C2003-3, circuit 1899 (WH), harness side; and between the DSM C341c-24, circuit 1899 (WH), harness side and ground. Is the resistance less than 5 ohms between the DSM and the adjustable pedal motor, and greater than 10,000 ohms between the DSM and ground? Yes : GO to C13. No : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
13. C13 MONITOR THE ADJUSTABLE PEDAL PID Connect: DSM C341c. Connect: Adjustable Pedal Motor C2003. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: PID/DATA Monitor and Record. Monitor the DSM Driver Seat Pedal Position PID while operating the adjustable pedal (using the manual switch) in both directions. Does the PID read approximately the same as the adjustable pedal position? Yes : GO to C14. No : INSTALL a new adjustable pedal motor assembly. REFER to «HYDRAULIC BRAKE ACTUATION»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) . CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
14. C14 CHECK THE MEMORY SET SWITCH Key in OFF position. Disconnect: Memory Set Switch C503. Measure the resistance between the memory set switch pins C503, component side, while activating the memory set switch to the indicated positions. MEMORY SET SWITCH RESISTANCE VALUE Memory Set Switch Pin Memory Set Switch Position Resistance Value 2 and 7 Memory Switch #1 0 Ohms 2 and 3 Memory Switch #1 Open 2 and 4 Memory Switch #1 Open 3 and 2 Memory Switch #2 0 Ohms 4 and 2 Memory Switch #2 Open 7 and 2 Memory Switch #2 0 Ohms 2 and 4 Memory Set Switch 0 Ohms 3 and 2 Memory Set Switch Open 7 and 2 Memory Set Switch Open Does the memory set switch pass the component test? Yes : GO to C15. No : INSTALL a new memory set switch. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
15. C15 CHECK CIRCUIT 1205 (BK) FOR AN OPEN Measure the resistance between the memory set switch C503-2, circuit 1205 (BK), harness side and ground. Is the resistance less than 5 ohms? Yes : GO to C16. No : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
16. C16 CHECK CIRCUIT 270 (BN/OG) FOR AN OPEN AND A SHORT TO GROUND Disconnect: DSM C341c. Measure the resistance between the memory set switch C503-4, circuit 270 (BN/OG), harness side and the DSM C341c-3, circuit 270 (BN/OG), harness side; and between the memory set switch C503-4, circuit 270 (BN/OG), harness side and ground. Is the resistance less than 5 ohms between the memory set switch and the DSM, and greater than 10,000 ohms between the memory set switch and ground? Yes : GO to C17. No : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
17. C17 CHECK CIRCUIT 267 (BN/LG) FOR AN OPEN AND A SHORT TO GROUND Measure the resistance between the memory set switch C503-7, circuit 267 (BN/LG), harness side and the DSM C341c-15, circuit 267 (BN/LG), harness side; and between the memory set switch C503-7, circuit 267 (BN/LG), harness side and ground. Is the resistance less than 5 ohms between the memory set switch and the DSM, and greater than 10,000 ohms between the memory set switch and ground? Yes : GO to C18. No : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
18. C18 CHECK CIRCUIT 268 (BK/OG) FOR AN OPEN AND A SHORT TO GROUND Measure the resistance between the memory set switch C503-3, circuit 268 (BK/OG), harness side and the DSM C341c-4, circuit 268 (BK/OG), harness side; and between the memory set switch C503-3, circuit 268 (BK/OG), harness side and ground. Is the resistance less than 5 ohms between the memory set switch and the DSM, and greater than 10,000 ohms between the memory set switch and ground? Yes : GO to C19. No : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.
19. C19 CHECK FOR CORRECT DSM OPERATION Disconnect all the DSM connectors. Check for: corrosion pushed-out pins Connect all the DSM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new DSM. REFER to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/five-hundred/i-2004-2007/remont/communication-devices/#multifunction-electronic-modules-system) for the removal and installation procedure. TEST the system for normal operation. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation.

1. Check the hydraulic brake system for leaks or insufficient fluid.
2. With the transmission in NEUTRAL, stop the engine and apply the parking brake control. Apply the brake pedal several times to exhaust all vacuum in the system.
3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no motion is felt, the brake booster system is not functioning. Continue with the following steps.
4. Remove the vacuum booster hose from the check valve connection. Manifold vacuum must be available at the check valve end of the vacuum booster hose with the engine at idle speed and the transmission in NEUTRAL. If the manifold vacuum is available to the brake booster, connect the vacuum booster hose to the brake booster check valve and repeat Steps 2 and 3 .
5. If no downward movement of the brake pedal is felt, install a new brake booster. For additional information, refer to «POWER BRAKE ACTUATION»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#power-brake-actuation-brake-booster) .
6. 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/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information) .

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.

To test the function of the brake booster check valve

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

Brake Master Cylinder

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

Compensator Port Check

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

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

SPECIAL TOOL On-Car Brake Lathe 201-00002 or equivalent

MATERIAL SPECIFICATION - BRAKE DISC MACHINING

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

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

Note. Do not machine new brake discs.

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

1. Position the brake caliper and brake caliper anchor bracket aside. For additional information, refer to «FRONT DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#front-disc-brake-system) for front disc brakes or «REAR DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#rear-disc-brake-system) for rear disc brakes.
2. For vehicles with a 2-piece brake disc and hub assembly: Mark the brake disc and the wheel stud for correct indexing during re-assembly. Remove the brake disc from the hub. CAUTION: Do not use an abrasive sanding disc since it will remove paint or other protective finishes from the wheel or metal from the mounting surfaces, adversely affecting corrosion protection and brake disc lateral runout. Remove corrosion from the wheel mounting surface, both disc mounting surfaces, and hub mounting surface. Align the match marks and install the brake disc on the hub.
3. Machine the brake disc using an on-car brake lathe. Install the hub adapter and silencer belt, if necessary. Install the cutting lathe. If lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. Total indicated reading (TIR) target is 0.000 mm (0.000 in), maximum is 0.08 mm (0.003 in). Center the cutting head, adjust the cutting bits, and install the chip deflector. NOTE: The depth of cut should be between 0.10 and 0.20 mm (0.004 and 0.008 in). Lighter cuts will cause the bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface finish. Machine the brake disc. Remove the lathe and, if installed, the silencer belt. Remove the hub adapter.
4. Remove metal shavings.
5. For vehicles with a 2-piece brake disc and hub assembly: Remove the brake disc from the hub. Remove metal shavings from the hub, the brake disc mounting surfaces and from the ABS sensors. Apply anti-seize lubricant to hub mounting surface to prevent corrosion. Align the match marks and install the brake disc on the hub.
6. Install the brake caliper and brake caliper anchor bracket. For additional information, refer to «FRONT DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#front-disc-brake-system) for front disc brakes or «REAR DISC BRAKE»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#rear-disc-brake-system) for rear disc brakes.

SPECIAL TOOL - COMPONENT BLEEDING Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

MATERIAL SPECIFICATION - COMPONENT BLEEDING

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.

Scheme 30

Scheme 31

Scheme 32

1. For in-vehicle priming, disconnect the brake lines.
2. For bench priming, mount the brake master cylinder in a vise.
3. Install short brake tubes onto the primary and secondary ports with the ends submerged in the brake master cylinder reservoir.
4. Fill the brake master cylinder reservoir with DOT 3 motor vehicle brake fluid.
5. Have an assistant pump the brake pedal, or slowly press the primary piston until clear fluid flows from the brake tubes, without air bubbles.
6. If the brake master cylinder has been primed at the bench, install it in the vehicle. For additional information, refer to «HYDRAULIC BRAKE ACTUATION»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) .
7. Remove the short brake tubes, and install the master cylinder brake tubes. Tighten to 18 Nm (13 lb-ft).
8. Bleed each brake tube at the brake master cylinder as follows: Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal. Loosen the rear-most brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting. Repeat this operation until clear, bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube.

SPECIAL TOOL - BRAKE SYSTEM BLEEDING Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

MATERIAL SPECIFICATION - BRAKE SYSTEM BLEEDING

Manual

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

Note. If the hydraulic control unit (HCU), or any component upstream of the HCU are installed new, carry out the Brake System Pressure Bleeding procedure first without the diagnostic tool, followed by the Brake System Bleed procedure using the diagnostic tool. The Component Bleeding - Rear Brake Caliper procedure is not required as the rear calipers were not replaced.

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

Scheme 33

Scheme 34

Scheme 35

Scheme 36

1. Connect the diagnostic tool cable adapter into the vehicle data link connector (DLC) under the dash and follow the diagnostic tool instructions.
2. Clean all the dirt from the area, remove the brake master cylinder reservoir cap and fill the brake master cylinder reservoir with the specified brake fluid.
3. Remove the rear bleeder cap and place a box end wrench on the RH rear 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 brake fluid.
4. Have an assistant hold firm pressure on the brake pedal.
5. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Press and release the parking brake 5 times. Repeat until clear, bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary.
6. Tighten the RH rear bleeder screw and install the bleeder cap. Tighten to 10 Nm (89 lb-in).
7. Repeat Steps 3 - 6 for the LH rear bleeder screw.
8. Remove the rear bleeder cap and place a box end wrench on the RH front brake caliper bleeder screw. Attach a rubber drain tube to the RH front brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid.
9. Have an assistant hold firm pressure on the brake pedal.
10. Loosen the RH front brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary.
11. Tighten the RH front brake caliper bleeder screw and install the bleeder cap. Tighten to 12 Nm (9 lb-ft).
12. Repeat Steps 8 - 11 for the LH front brake caliper bleeder screw.

Pressure

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

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

Brake System Leak Check

1. Make sure the brake master cylinder reservoir is full.
2. Apply the brakes several times and make sure the brake pedal feel is not spongy. If necessary, bleed the system. For additional information, refer to «BRAKE SYSTEM BLEEDING»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information) .
3. Hold pressure on the brake pedal for 30 seconds.
4. Verify that the reservoir level is not dropping.
5. If the reservoir level is dropping, inspect the brake components, fittings and lines to locate the source of the leak.

See also:
• ANTI-LOCK CONTROL
• HANDLES, LOCKS, LATCHES AND ENTRY SYSTEMS
• INSTRUMENT CLUSTER
• FRONT DISC BRAKE
• REAR DISC BRAKE
• MODULE COMMUNICATIONS NETWORK
• MULTIFUNCTION ELECTRONIC MODULES
• MODULE CONFIGURATION
• SUSPENSION SYSTEM-GENERAL INFORMATION
• PARKING BRAKE & ACTUATION
• NOISE, VIBRATION & HARSHNESS
• HYDRAULIC BRAKE ACTUATION
• POWER BRAKE ACTUATION
• BRAKE CALIPER GUIDE PINS
• SPECIFICATIONS
• BRAKE SYSTEM LEAK CHECK
• SYMPTOM CHART
• DRIVER SEAT MODULE (DSM) DIAGNOSTIC TROUBLE CODE (DTC) INDEX
• Brake Master Cylinder
• Check Valve
• BRAKE PADS