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Hydraulic Brake System Actuation Ford Five Hundred I

Mechanical - Hydraulic 2 illustrations ~885 words

GENERAL SPECIFICATIONS

ItemSpecification
Lubricant
High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 (Canada CPM-1)ESA-M6C25-A

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

DescriptionNm
Brake booster nuts25
Brake line fittings17
Brake master cylinder nuts17
Brake pedal bracket bolt25

TORQUE SPECIFICATIONS

Hydraulic Brake Actuation

CAUTIONBlistering or swelling of rubber brake components may indicate contamination of the brake fluid by a petroleum based substance. If contaminated rubber components in the hydraulic brake system are found, new components must be installed, and the entire hydraulic brake system must be flushed with clean brake fluid to prevent recontamination.

The hydraulic brake actuation system consists of the following

  1. adjustable pedals (optional)
  2. fixed brake pedal
  3. brake vacuum booster
  4. brake master cylinder
  5. brake tubes
  6. anti-lock brake system (ABS) components

Brake Fluid

WARNINGUse of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.
WARNINGBrake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.
CAUTIONBrake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

Use clean, new DOT 3 motor vehicle brake fluid.

  1. Do not reuse brake fluid drained or bled from the system.
  2. Do not use brake fluid that has been stored in an open container.
  3. Do not use contaminated brake fluid.

Brake Master Cylinder

The brake master cylinder is a dual piston type. The brake master cylinder operates as follows

  1. When the brake pedal is pressed, pressure is applied by mechanical linkage to the primary and secondary piston.
  2. Brake master cylinder pistons apply hydraulic pressure to the 2 diagonal hydraulic circuits.
  3. The anti-lock brake system (ABS) brake master cylinder cannot be overhauled, due to internal adjustments which require extensive special tools and fixtures. The repair is made by installing a new master cylinder only.

The brake master cylinder consists of

  1. brake master cylinder fluid reservoir
  2. brake master cylinder body

Brake Master Cylinder Reservoir

Note. The brake master cylinder and brake master cylinder reservoir are replaced as an assembly. The reservoir cannot be replaced separately form the brake master cylinder.

The brake master cylinder reservoir

  1. is mounted to the brake master cylinder.
  2. holds fluid supply for each brake master cylinder hydraulic piston.
  3. provides visual maximum and minimum fluid level markings.
  4. contains the brake master cylinder fluid level indicator switch.

The brake master cylinder fluid level indicator switch can be checked by putting a magnetic probe against the inside of the reservoir to activate the indicator switch.

Brake Tubes and Hoses

CAUTIONNever use copper tubing. It is subject to fatigue, cracking and corrosion, which could result in brake tube failure.

Double wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly 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.

If a section of brake tube is damaged, an entire new section must be installed with a tube of the same type, size, shape and length.

When installing new hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After installation, bleed the brake system. For additional information, refer to BRAKE SYSTEM-GENERAL INFORMATION .

The wet appearance on the outer cover of rubber brake hoses is called "sweating." This is a normal condition for neoprene rayon braid hose and is not a sign of leakage or cause for the installation of a new hose.

Adjustable Pedal Indexing

CAUTIONThe adjustable pedal system must be indexed whenever the brake pedal assembly or accelerator pedal assembly is repaired.
  1. Disconnect the adjustable pedal motor drive cable from the brake pedal drive.
  2. Operate the accelerator pedal to the full rearward position.
  3. Connect the adjustable pedal motor drive cable to the adjustable brake pedal drive.
  4. Operate the adjustable pedals to the full forward position.
  5. Disconnect the adjustable pedal motor drive cable form the adjustable brake pedal assembly.
  6. Operate the adjustable accelerator pedal to the full forward position.
  7. Connect the adjustable pedal motor drive cable to the adjustable brake pedal drive.
  8. Check that the brake and accelerator pedals can be fully adjusted forward and rearward.

Brake Pedal and Bracket - Adjustable

Note. The adjustable pedal assembly is shown, the fixed pedal assembly is similar.

Scheme 3

Scheme 3: Brake Pedal and Bracket - Adjustable
Scheme 3: Brake Pedal and Bracket - Adjustable
  1. If equipped with adjustable pedals, make sure they are in the full forward position.
  2. Remove the steering column. For additional information, refer to «STEERING COLUMN»(/ford/five-hundred/i-2004-2007/remont/steering-column/#steering-column) .
  3. Disconnect the electrical connectors from the brake pedal assembly.
  4. Remove the stoplamp switch.
  5. If equipped, remove the speed control deactivator switch.
  6. Remove the redundant self-locking clip cover and the self-locking clip.
  7. Remove the booster rod and washer from the brake pedal.
  8. Remove the 4 brake booster nuts. To install, tighten to 25 Nm (18 lb-ft).
  9. Position the brake booster forward enough to allow the brake booster studs to clear the brake pedal assembly.
  10. Remove the lower brake pedal bracket bolt, under the accelerator pedal, from the brake pedal bracket assembly. To install, tighten to 25 Nm (18 lb-ft).
  11. Remove the upper 2 brake pedal bracket bolts from the brake pedal bracket assembly. To install, tighten to 25 Nm (18 lb-ft).
  12. Disconnect the vehicle electrical harness locators and remove the brake pedal bracket assembly from the vehicle.
  13. To install, reverse the removal procedure.

Material

ItemSpecification
High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 (Canada CPM-1)ESA-M6C25-A

MATERIAL SPECIFICATION - BRAKE MASTER CYLINDER

Scheme 4

Scheme 4
Scheme 4

Removal and Installation

WARNINGUse of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.
WARNINGBrake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.
CAUTIONBrake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
  1. With the engine off, press the brake pedal several times to deplete the brake booster vacuum.
  2. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  3. Remove the air cleaner assembly. For additional information, refer to «FUEL CHARGING & CONTROLS»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-engine-control-system) .
  4. Use a suitable suction device to drain the brake master cylinder reservoir.
  5. Disconnect the master cylinder brake fluid level indicator switch electrical connector.
  6. Disconnect the brake lines from the master cylinder. To install, tighten to 17 Nm (13 lb-ft). Cap the brake lines and plug the master cylinder ports.
  7. Remove and discard the 2 brake master cylinder-to-brake booster nuts and remove the brake master cylinder. To install, tighten 17 Nm (13 lb-ft).
  8. To install, reverse the removal procedure. Bleed the brake system. For additional information, refer to «BRAKE SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information) . Test the brake system for proper operation.

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