Brake System - General Information Ford Taurus X I

Material

Material

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The brake system consists of the following components

1. Front and rear disc brakes
2. Cable/caliper actuated parking brake
3. Brake master cylinder and fluid reservoir
4. Vacuum-assisted power brake booster
5. Four-wheel ABS
6. Red brake light indicator

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

For additional information on the following

1. Front disc brakes, refer to «FRONT DISC BRAKE»(/ford/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#front-disc-brake-system) article.
2. Rear disc brakes, refer to «REAR DISC BRAKE»(/ford/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#rear-disc-brake-system) article.
3. Parking brake actuation, refer to «PARKING BRAKE AND ACTUATION»(/ford/taurus-x/i-2007-2009/remont/parking-brake-system/#parking-brake-system-and-actuation) article.
4. Hydraulic brake actuation, refer to «HYDRAULIC BRAKE ACTUATION»(/ford/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) article.
5. Vacuum-assisted power brake booster, refer to «POWER BRAKE ACTUATION»(/ford/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#power-brake-actuation-brake-booster) article.
6. ABS, refer to «VEHICLE DYNAMIC SYSTEMS»(/ford/taurus-x/i-2007-2009/remont/anti-locktraction-control/#anti-lock-brake-system) article.

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

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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 tubes to the individual brake calipers. On vehicles equipped with ABS, the hydraulic pressure is transmitted by brake fluid through the brake tubes to the ABS hydraulic control unit (HCU), which then distributes that pressure to the individual brake calipers. The brake calipers use hydraulic pressure to apply the pads. The application of the brake pads will cause the rotation of the wheels to slow or stop depending on how much brake pressure is applied. The parking brakes carry out the same function except that they are mechanically actuated by a cable that connects only to the rear brakes.

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 pedals feature is operational with the ignition switch in the RUN, ACC or OFF position. Adjustable pedals 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. Do not spill brake fluid onto painted or plastic surfaces. If spilled, wipe up immediately before damage to the painted or plastic surface occurs.

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 red 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 trouble. 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.

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 and 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 - Hydraulic Brake System»(/ford/taurus-x/i-2007-2009/remont/anti-locktraction-control/#brake-system-general-information) or Go to «Symptom Chart - Noise, Vibration and Harshness (NVH)»(/ford/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#front-disc-brake-system) article for front disc brakes or «REAR DISC BRAKE»(/ford/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#front-disc-brake-system) article for front disc brakes or «REAR DISC BRAKE»(/ford/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#front-disc-brake-system) article for front disc brakes or «REAR DISC BRAKE»(/ford/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/remont/anti-locktraction-control/#brake-system-general-information__brake-caliper-guide-pins) .

Brake Discs

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

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

1. Remove the brake disc. Refer to «FRONT DISC BRAKE»(/ford/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#front-disc-brake-system) article for front disc brakes or «REAR DISC BRAKE»(/ford/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#front-disc-brake-system) article for front disc brakes or «REAR DISC BRAKE»(/ford/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#front-disc-brake-system) article for front disc brakes or «REAR DISC BRAKE»(/ford/taurus-x/i-2007-2009/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 and «Brake Disc Machining»(/ford/taurus-x/i-2007-2009/remont/anti-locktraction-control/#brake-system-general-information__brake-disc-machining) .

Brake Calipers

Inspect the brake calipers for the following

1. Brake fluid leaks. Refer to «Brake System Leak Check»(/ford/taurus-x/i-2007-2009/remont/anti-locktraction-control/#brake-system-general-information__brake-system-leak-check) and «Non-Pressure Leaks»(/ford/taurus-x/i-2007-2009/remont/anti-locktraction-control/#brake-system-general-information__non-pressure-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/taurus-x/i-2007-2009/remont/anti-locktraction-control/#brake-system-general-information__brake-caliper-guide-pins) .

Brake Caliper Guide Pins

Note. Do not use power tools for caliper guide pin bore cleaning. Damage to the bore may result.

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

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

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/taurus-x/i-2007-2009/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 reservoir assembly. Refer to Brake Fluid Reservoir 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 - Hydraulic Brake System for abnormal condition diagnosis.

Brake Booster

Inspect the brake booster

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

Parking Brake

Check the operation of the parking brake system with the vehicle on a hoist and the parking brake control fully released. Check for any damaged cables and install new components as necessary. Check the rear brake adjustment or carry out the brake system diagnosis. Refer to PARKING BRAKE AND ACTUATION article.

Symptom Chart - Hydraulic Brake System

Symptom Chart - Hydraulic 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 27 (20A) Wiring, terminals and 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/taurus-x/i-2007-2009/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 cable Adjustable pedal motor Adjustable pedals Foreign material Adjustable pedal switch Driver seat module (DSM) Memory SET switch Remote transmitter Smart junction box (SJB) fuse 27 (20A) Wiring, terminals and 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/taurus-x/i-2007-2009/remont/communication-devices/#module-communications-network-system) 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/taurus-x/i-2007-2009/remont/communication-devices/#module-communications-network-system) 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/taurus-x/i-2007-2009/remont/communication-devices/#module-communications-network-system) 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 TABLE»(/ford/taurus-x/i-2007-2009/remont/anti-locktraction-control/#brake-system-general-information) . For all other DTCs, refer to the Master DTC Table in «MULTIFUNCTION ELECTRONIC MODULES»(/ford/taurus-x/i-2007-2009/remont/communication-devices/#multifunction-electronic-modules-system) article.
10. If no DTCs related to the concern are retrieved, go to «Symptom Chart - Adjustable Pedals With Memory Feature»(/ford/taurus-x/i-2007-2009/remont/anti-locktraction-control/#brake-system-general-information) .

Driver Seat Module (DSM) DTC Table

DRIVER SEAT MODULE (DSM) DTC TABLE

Symptom Chart - Adjustable Pedals With Memory Feature

Symptom Chart - Adjustable Pedals With Memory Feature

Pinpoint Test A: 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 27 (20A) along circuit SBP27 (BU/RD).

When the adjustable pedal switch is placed in the forward position, voltage is sent to the adjustable pedal motor along circuit CPP09 (VT/OG), passes through the motor and returns to the switch along circuit CPP10 (BN/BU) where it is grounded along circuit GD111 (BK/BU). This causes the pedal to move forward (away from the driver).

When the adjustable pedal switch is placed in the forward position, voltage is sent to the adjustable pedal motor along circuit CPP10 (BN/BU), passes through the motor and returns to the switch along circuit CPP09 (VT/OG) where it is grounded along circuit GD111 (BK/BU). This causes the pedal to move rearward (toward the driver).

This pinpoint test is intended to diagnose the following

1. Foreign material
2. Fuse
3. Wiring, terminals or connectors
4. Adjustable pedal cable
5. Adjustable pedal switch
6. Adjustable pedal motor

Note. Use the Flex Probe Kit for all test connections to prevent damage to the wiring terminals. Do not use standard multi-meter probes.

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1. A1 INSPECT THE SYSTEM FOR FOREIGN MATERIAL Inspect the adjustable brake pedal assembly for foreign material causing a binding condition. Was any foreign material found? YES : REMOVE the foreign material. TEST the system for normal operation. NO : Go to A2 .
2. A2 ISOLATE THE ADJUSTABLE BRAKE PEDAL Disconnect the adjustable brake pedal cable from the adjustable brake pedal. Operate the adjustable pedal control switch. Does the adjustable accelerator pedal move according to switch position? YES : Go to A3 . NO : Go to A5 .
3. A3 CHECK THE ADJUSTABLE BRAKE PEDAL CABLE OPERATION Operate the adjustable pedal control switch. Does the adjustable brake pedal cable spin in the conduit when the switch is operated? YES : Go to A4 . NO : INSTALL a new adjustable brake pedal motor cable. TEST the system for normal operation.
4. A4 CHECK THE CABLE Disconnect the adjustable brake pedal cable from the adjustable pedal motor. Inspect the ends of the brake pedal motor cable for wear or damage. Are the cable ends OK? YES : INSTALL a new adjustable brake pedal and bracket. REFER to «HYDRAULIC BRAKE ACTUATION»(/ford/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) article. TEST the system for normal operation. NO : INSTALL a new brake pedal motor cable. TEST the system for normal operation.
5. A5 TEST THE ADJUSTABLE PEDAL SWITCH Key in OFF position. Disconnect: Adjustable Pedal Switch C2235 Measure the resistance between adjustable pedal switch C2235 pins, component side, while activating the adjustable pedal switch to the indicated positions. Adjustable Pedal Switch Position Adjustable Pedal Switch Pin Resistance Value Rest 2 and 1 Open Rest 2 and 7 Open Rest 1 and 3 0 Ohms Rest 7 and 6 0 Ohms Rearward (Bottom Arrow) 2 and 1 0 Ohms Rearward (Bottom Arrow) 2 and 7 Open Rearward (Bottom Arrow) 1 and 3 Open Rearward (Bottom Arrow) 7 and 6 0 Ohms Forward (Top Arrow) 2 and 1 Open Forward (Top Arrow) 2 and 7 0 Ohms Forward (Top Arrow) 1 and 3 0 Ohms Forward (Top Arrow) 7 and 6 Open Does the adjustable pedal switch pass the 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 Measure the voltage between adjustable pedal switch C2235-2, circuit SBP27 (BU/RD), harness side and ground. Is the voltage greater than 10 volts? YES : Go to A7 . NO : VERIFY SJB fuse 27 (20A) is OK. If OK, REPAIR circuit SBP27 (BU/RD). TEST the system for normal operation.
7. A7 CHECK CIRCUIT GD111 (BK/BU) FOR AN OPEN Measure the resistance between ground and: adjustable pedal switch C2235-3, circuit GD111 (BK/BU), harness side. adjustable pedal switch C2235-6, circuit GD111 (BK/BU), harness side. Are the resistances less than 5 ohms? YES : Go to A8 . NO : REPAIR circuit GD111 (BK/BU). TEST the system for normal operation.
8. A8 CHECK CIRCUITS CPP09 (VT/OG) AND CPP10 (BN/BU) FOR AN OPEN Disconnect: Adjustable Pedal Motor C2159 Measure the resistance between adjustable pedal switch C2235-1, circuit CPP10 (BN/BU), harness side and adjustable pedal motor C2159-1, circuit CPP10 (BN/BU), harness side. Measure the resistance between adjustable pedal switch C2235-7, circuit CPP09 (VT/OG), harness side and adjustable pedal motor C2159-2, circuit CPP09 (VT/OG), harness side. Is the resistance less than 5 ohms? YES : Go to A9 . NO : REPAIR the affected circuit(s). TEST the system for normal operation.
9. A9 CHECK CIRCUITS CPP09 (VT/OG) AND CPP10 (BN/BU) FOR A SHORT TO GROUND Measure the resistance between ground and: adjustable pedal switch C2235-7, circuit CPP09 (VT/OG), harness side. adjustable pedal switch C2235-1, circuit CPP10 (BN/BU), harness side. Are the resistances greater than 10,000 ohms? YES : INSTALL a new adjustable brake pedal and bracket assembly. REFER to «HYDRAULIC BRAKE ACTUATION»(/ford/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) article. TEST the system for normal operation. NO : REPAIR the affected circuit(s). TEST the system for normal operation.

Pinpoint Test B: Adjustable Brake Pedal is Inoperative/Does Not Operate Correctly - Using the Adjustable Pedal Switch (System With Memory Feature)

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

The adjustable pedal switch receives fused battery voltage from smart junction box (SJB) fuse 27 (20A) along circuit SBP27 (BN/RD).

When the adjustable pedal switch is placed in the forward position, voltage is sent to the driver seat module (DSM) along circuit CPP09 (VT/OG), the DSM then sends the voltage to the adjustable pedal motor along circuit CPP09 (VT/OG), the voltage passes through the motor and returns to the DSM along circuit CPP10 (BN/BU). The DSM then sends the voltage back to the switch along circuit CPP10 (BN/BU) where it is grounded along circuit GD111 (BK/BU). This causes the pedal to move forward (away from the driver).

When the adjustable pedal switch is placed in the forward position, voltage is sent to the DSM along circuit CPP10 (BN/BU), the DSM then sends the voltage to the adjustable pedal motor along circuit CPP10 (BN/BU), the voltage passes through the motor and returns to the DSM along circuit CPP09 (VT/OG). The DSM then sends the voltage back to the switch along circuit CPP09 (VT/OG) where it is grounded along circuit GD111 (BK/BU). This causes the pedal to move rearward (toward the driver).

1. B1988 Pedal Position Forward Switch Circuit Short to Battery - If during normal operation, the DSM detects battery voltage on the adjustable pedal switch forward input circuit for more than 2 minutes DTC B1988 will be set. If during the DSM on-demand self test, the DSM detects voltage on the adjustable pedal switch forward input circuit at all, DTC B1988 will be set.
2. B1989 Pedal Position Rearward Switch Circuit Short to Battery - If during normal operation, the DSM detects battery voltage on the adjustable pedal switch rearward input circuit for more than 2 minutes DTC B1989 will be set. If during the DSM on-demand self test, the DSM detects voltage on the adjustable pedal switch rearward input circuit at all, DTC B1989 will be set.

This pinpoint test is intended to diagnose the following

1. Foreign material
2. Fuse
3. Wiring, terminals or connectors
4. Adjustable pedal switch
5. Adjustable pedal potentiometer
6. Adjustable pedal motor

Note. Use the Flex Probe Kit for all test connections to prevent damage to the wiring terminals. Do not use standard multi-meter probes.

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1. B1 CHECK THE ADJUSTABLE PEDAL SWITCH (PEDPOSSW) PID Connect the diagnostic tool. Key in ON position. Enter the following diagnostic mode on the diagnostic tool: DSM DataLogger Monitor the PEDPOSSW PID while activating the adjustable pedal switch. Does the PID display REARWARD and then FORWARD within one second of pressing the switch in that direction, and then OFF when the switch is released? YES : Go to B2 . NO : Go to B10 .
2. B2 CHECK THE ADJUSTABLE PEDAL MOTOR OUTPUT COMMANDS NOTE: Toggling the active command ON will cause the pedal to move in the commanded direction until it reaches a soft or hard stop. Enter the following diagnostic mode on the diagnostic tool: DSM DataLogger NOTE: If the pedal is in the full forward position it will not move when commanded forward. If the pedal is in the full rearward position it will not move when commanded rearward. Toggle the pedal forwrd (PED_FWD) or pedal rearward (PED_RWD) output control ON for 2 seconds and then OFF. Toggle the opposite output control ON for 2 seconds and then OFF. Does the pedal move in the direction commanded? YES : Go to B3 . NO : Go to B13 .
3. B3 CHECK FOR DTCs Carry out the DSM on-demand self test. Retrieve and record any DSM DTCs. Are any DSM DTCs retrieved? YES : For DTCs B1988 and B1989, go to B17 . For DTCs B1987, B1991 and B2275, go to «DRIVER SEAT MODULE (DSM) DTC TABLE»(/ford/taurus-x/i-2007-2009/remont/anti-locktraction-control/#brake-system-general-information) . For all other DSM DTCs, REFER to the Master DTC Table in «MULTIFUNCTION ELECTRONIC MODULES»(/ford/taurus-x/i-2007-2009/remont/communication-devices/#multifunction-electronic-modules-system) article. NO : Go to B4 .
4. B4 INSPECT THE SYSTEM FOR FOREIGN MATERIAL Inspect the adjustable brake pedal assembly for foreign material causing a binding condition. Was any foreign material found? YES : REMOVE the foreign material. TEST the system for normal operation. NO : Go to B5 .
5. B5 ISOLATE THE ADJUSTABLE BRAKE PEDAL Disconnect the adjustable brake pedal cable from the adjustable brake pedal. Operate the adjustable pedal control switch. Does the adjustable accelerator pedal move according to switch position? YES : Go to B6 . NO : Go to B8 .
6. B6 CHECK THE ADJUSTABLE BRAKE PEDAL CABLE OPERATION Operate the adjustable pedal control switch. Does the adjustable brake pedal cable spin in the conduit when the switch is operated? YES : Go to B7 . NO : INSTALL a new adjustable brake pedal motor cable. TEST the system for normal operation.
7. B7 INSPECT THE ADJUSTABLE BRAKE PEDAL CABLE FOR DAMAGE Disconnect the adjustable brake pedal cable from the adjustable pedal motor. Inspect the ends of the brake pedal motor cable for wear or damage. Are the cable ends OK? YES : INSTALL a new adjustable brake pedal and bracket. REFER to «HYDRAULIC BRAKE ACTUATION»(/ford/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) article. TEST the system for normal operation. NO : INSTALL a new brake pedal motor cable. TEST the system for normal operation.
8. B8 CHECK FOR VOLTAGE TO THE ADJUSTABLE PEDAL SWITCH Measure the voltage between adjustable pedal switch C2235-2, circuit SBP27 (BU/RD), harness side and ground. Is the voltage greater than 10 volts? YES : Go to B9 . NO : VERIFY SJB fuse 27 (20A) is OK. If OK, REPAIR circuit SBP27 (BU/RD). TEST the system for normal operation.
9. B9 CHECK CIRCUIT GD111 (BK/BU) FOR AN OPEN Measure the resistance between ground and: adjustable pedal switch C2235-3, circuit GD111 (BK/BU), harness side. adjustable pedal switch C2235-6, circuit GD111 (BK/BU), harness side. Are the resistances less than 5 ohms? YES : Go to B10 . NO : REPAIR circuit GD111 (BK/BU). TEST the system for normal operation.
10. B10 CHECK CIRCUIT CPP09 (VT/OG) FOR AN OPEN Disconnect: DSM C341c Measure the resistance between adjustable pedal switch C2235-7, circuit CPP09 (VT/OG), harness side and DSM C341c-21, circuit CPP09 (VT/OG), harness side. Is the resistances less than 5 ohms? YES : Go to B11 . NO : REPAIR circuit CPP09 (VT/OG). TEST the system for normal operation.
11. B11 CHECK CIRCUIT CPP10 (BN/BU) FOR AN OPEN Measure the resistance between adjustable pedal switch C2235-1, circuit CPP10 (BN/BU), harness side and DSM C341c-9, circuit CPP10 (BN/BU), harness side. Is the resistances less than 5 ohms? YES : Go to B12 . NO : REPAIR circuit CPP10 (BN/BU). TEST the system for normal operation.
12. B12 CHECK CIRCUITS CPP09 (VT/OG) AND CPP10 (BN/BU) FOR A SHORT TO GROUND Measure the resistance between ground and: adjustable pedal switch C2235-7, circuit CPP09 (VT/OG), harness side. adjustable pedal switch C2235-1, circuit CPP10 (BN/BU), harness side. Are the resistances greater than 10,000 ohms? YES : Go to B13 . NO : REPAIR the affected circuit(s). TEST the system for normal operation.
13. B13 CHECK THE DSM PEDAL MOTOR REARWARD OUTPUT CIRCUIT FOR AN OPEN Disconnect: Adjustable Pedal Motor C2159 Measure the resistance between DSM C341c-24, circuit CPP10 (BN/BU), harness side and adjustable pedal motor C2159-1, circuit CPP10 (BN/BU), harness side. Is the resistance less than 5 ohms? YES : Go to B14 . NO : REPAIR circuit CPP10 (BN/BU). TEST the system for normal operation.
14. B14 CHECK THE DSM PEDAL MOTOR FORWARD OUTPUT CIRCUIT FOR AN OPEN Measure the resistance between DSM C341c-12, circuit CPP09 (VT/OG), harness side and adjustable pedal motor C2159-2, circuit CPP09 (VT/OG), harness side. Is the resistance less than 5 ohms? YES : Go to B15 . NO : REPAIR circuit CPP09 (VT/OG). TEST the system for normal operation.
15. B15 CHECK THE DSM PEDAL MOTOR FORWARD AND REARWARD OUTPUT CIRCUIT FOR A SHORT TO GROUND Measure the resistance between: adjustable pedal motor C2159-1, circuit CPP10 (BN/BU), harness side. adjustable pedal motor C2159-2, circuit CPP09 (VT/OG), harness side. Are the resistances greater than 10,000 ohms? YES : Go to B16 . NO : REPAIR the affected circuit(s). TEST the system for normal operation.
16. B16 CHECK THE ADJUSTABLE PEDAL MOTOR Connect a fused (10A) jumper wire between the battery positive post and adjustable pedal motor C2159 pin-1, component side. Connect a jumper wire between the battery negative post and adjustable pedal motor C2159 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 B17 . NO : INSTALL a new adjustable brake pedal and bracket. REFER to «HYDRAULIC BRAKE ACTUATION»(/ford/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#hydraulic-brake-system-actuation) article. TEST the system for normal operation.
17. B17 TEST THE ADJUSTABLE PEDAL SWITCH Disconnect: Adjustable Pedal Switch C2235 Measure the resistance between adjustable pedal switch C2235 pins, component side, while activating the adjustable pedal switch to the indicated positions. Adjustable Pedal Switch Position Adjustable Pedal Switch Pin Resistance Value Rest 2 and 1 Open Rest 2 and 7 Open Rest 1 and 3 0 Ohms Rest 7 and 6 0 Ohms Rearward (Bottom Arrow) 2 and 1 0 Ohms Rearward (Bottom Arrow) 2 and 7 Open Rearward (Bottom Arrow) 1 and 3 Open Rearward (Bottom Arrow) 7 and 6 0 Ohms Forward (Top Arrow) 2 and 1 Open Forward (Top Arrow) 2 and 7 0 Ohms Forward (Top Arrow) 1 and 3 0 Ohms Forward (Top Arrow) 7 and 6 Open Does the adjustable pedal switch pass the test? YES : Go to B18 . NO : INSTALL a new adjustable pedal switch. TEST the system for normal operation.
18. B18 CHECK CIRCUITS CPP09 (VT/OG) AND CPP10 (BN/BU) FOR A SHORT TO VOLTAGE Measure the voltage between ground and: adjustable pedal switch C2235-7, circuit CPP09 (VT/OG), harness side. adjustable pedal switch C2235-1, circuit CPP10 (BN/BU), harness side. Is any voltage present? YES : REPAIR the affected circuit(s). TEST the system for normal operation. NO : Go to B19 .
19. B19 CHECK FOR CORRECT DSM OPERATION Disconnect all the DSM connectors. Check the connectors for: corrosion. pushed-out pins. spread terminals. 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/taurus-x/i-2007-2009/remont/communication-devices/#multifunction-electronic-modules-system) article 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.

Pinpoint Test C: Adjustable Brake Pedal Does Not Operate Correctly - Using the Memory SET Switch or the Remote Transmitter

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

When the desired memory position is selected using the memory switch or the remote transmitter, the driver seat module (DSM) sends voltage to the adjustable pedal motor along circuit CPP09 (VT/OG) to move the pedal forward and along CPP10 (BN/BU) to move the pedal rearward. When voltage is sent to the motor along circuit CPP09 (VT/OG), it returns to the DSM along CPP10 (BN/BU). Likewise, when the voltage is sent to the motor along circuit CPP10 (BN/BU), it returns to the DSM along circuit CPP09 (VT/OG).

The DSM uses a Hall-effect switch attached to the pedal motor to identify the current pedal position. The DSM sends a reference voltage along circuit RPP06 (GN), through the Hall-effect switch and back to the DSM along the signal return circuit, LPP06 (YE/BU).

1. 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 switch during this attempt, DTC B1987 will be set.
2. B1991 Pedal Forward/Rearward Potentiometer Feedback Circuit Short to Battery - If the DSM detects battery voltage on the Hall-effect feedback circuit during normal operation or during the DSM on-demand self test, DTC B1991 will be set.
3. B2275 Pedal Forward/Rearward Potentiometer Feedback Circuit Short to Ground - If the DSM detects a short to ground on the Hall-effect feedback circuit during normal operation or during the DSM on-demand self test, DTC B2275 will be set.

When DTC B1991 or B2275 are set, the adjustable pedal motor will operate in a "jog mode". While in jog mode, the DSM will ignore any memory switch or remote transmitter inputs. The DSM will still accept input from the adjustable pedal switch, but the motor will only move in the desired direction for one second and then stop, regardless of how long the switch is held in the desired direction.

This pinpoint test is intended to diagnose the following

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

PINPOINT TEST C: ADJUSTABLE BRAKE PEDAL DOES NOT OPERATE CORRECTLY - USING THE MEMORY SET SWITCH OR THE USING THE REMOTE TRANSMITTER

Note. Use the Flex Probe Kit for all test connections to prevent damage to the wiring terminals. Do not use standard multi-meter probes.

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

1. C1 CHECK FOR DTCs Connect the diagnostic tool. Key in ON position. Carry out the DSM on-demand self test. Retrieve and record any DSM DTCs. Are any DSM DTCs retrieved? YES : For DTC B1987, go to C9 . For DTC B1991, go to C11 . For DTC B2275, go to C10 . For DTCs B1988 and B1989, go to «DRIVER SEAT MODULE (DSM) DTC TABLE»(/ford/taurus-x/i-2007-2009/remont/anti-locktraction-control/#brake-system-general-information) . For all other DSM DTCs, REFER to the Master DTC Table in «MULTIFUNCTION ELECTRONIC MODULES»(/ford/taurus-x/i-2007-2009/remont/communication-devices/#multifunction-electronic-modules-system) article. NO : Go to C2 .
2. C2 CHECK THE MEMORY SWITCH PIDs Enter the following diagnostic mode on the diagnostic tool: DSM DataLogger Monitor the following PIDs while activating the memory 1 and 2 switches: Memory switch position 1 (MEM_1) Memory switch position 2 (MEM_2) Do the PIDs display ON within one second of pressing the switch and OFF when the switch is released? YES : Go to C3 . NO : REFER to «SEATING»(/ford/taurus-x/i-2007-2009/remont/seats/#seat-system) article to diagnose the memory seats.
3. C3 CHECK THE ADJUSTABLE PEDAL OUTPUT ACTIVE COMMANDS NOTE: Toggling the active command ON will cause the pedal to move in the commanded direction until it reaches a soft or hard stop. NOTE: If the pedal is in the full forward position it will not move when commanded forward. If the pedal is in the full rearward position it will not move when commanded rearward. Toggle the pedal forward (PED_FWD) or pedal rearward (PED_RWD) output command ON for 2 seconds and then OFF. Toggle the opposite output command ON for 2 seconds and then OFF. Does the pedal move in the direction commanded? YES : Go to C4 . NO : Go to C5 .
4. C4 CHECK THE ADJUSTABLE PEDAL MOTOR SENSOR (PDLFWD) PID Monitor the DSM PDLFWD PID while pressing the adjustable pedal switch either forward or rearward. Does the PID display SENSED when the pedals move and NOT SENSED when the pedals are not moving? YES : Go to C13 . NO : Go to C9 .
5. C5 CHECK CIRCUITS CPP10 (BN/BU) AND CPP09 (VT/OG) FOR AN OPEN Key in OFF position. Disconnect: Adjustable Pedal Motor C2159 Disconnect: DSM C341c Measure the resistance between DSM C341c-24, circuit CPP10 (BN/BU), harness side and adjustable pedal motor C2159-1, circuit CPP10 (BN/BU), harness side. Measure the resistance between DSM C341c-12, circuit CPP09 (VT/OG), harness side and adjustable pedal motor C2159-2, circuit CPP09 (VT/OG), harness side. Is the resistance less than 5 ohms? YES : Go to C6 . NO : REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test.
6. C6 CHECK CIRCUITS CPP10 (BN/BU) AND CPP09 (VT/OG) FOR A SHORT TO GROUND Measure the resistance between: adjustable pedal motor C2159-1, circuit CPP10 (BN/BU), harness side. adjustable pedal motor C2159-2, circuit CPP09 (VT/OG), harness side. Are the resistances greater than 10,000 ohms? YES : Go to C7 . NO : REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test.
7. C7 CHECK CIRCUITS CPP10 (BN/BU) AND CPP09 (VT/OG) FOR A SHORT TO VOLTAGE Key in ON position. Measure the voltage between: adjustable pedal motor C2159-1, circuit CPP10 (BN/BU), harness side. adjustable pedal motor C2159-2, circuit CPP09 (VT/OG), harness side. Is any voltage present? YES : REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test. NO : Go to C8 .
8. C8 CHECK THE ADJUSTABLE PEDAL MOTOR OPERATION Key in OFF position. Connect a fused (10A) jumper wire between the battery positive post and adjustable pedal motor C2159 pin-1, component side. Connect a jumper wire between the battery negative post and adjustable pedal motor C2159 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 C13 . NO : INSTALL a new adjustable pedal motor. CLEAR the DTCs. REPEAT the self-test.
9. C9 CHECK CIRCUITS RPP06 (GN) AND LPP06 (YE/BU) FOR AN OPEN Key in OFF position. Disconnect: Adjustable Pedal Motor C2159 Disconnect: DSM C341c Measure the resistance between DSM C341c-3, circuit RPP06 (GN), harness side and adjustable pedal motor C2159-4, circuit RPP06 (GN), harness side. Measure the resistance between DSM C341c-15, circuit LPP06 (YE/BU), harness side and adjustable pedal motor C2159-3, circuit LPP06 (YE/BU), harness side. Are the resistances less than 5 ohms? YES : Go to C10 . NO : REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test.
10. C10 CHECK CIRCUITS RPP06 (GN) AND LPP06 (YE/BU) FOR A SHORT TO GROUND Key in OFF position. Disconnect: Adjustable Pedal Motor C2159 Disconnect: DSM C341c Measure the resistance between ground and: adjustable pedal motor C2159-4, circuit RPP06 (GN), harness side. adjustable pedal motor C2159-3, circuit LPP06 (YE/BU), harness side. Is the resistance greater than 10,000 ohms? YES : Go to C11 . NO : REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test.
11. C11 CHECK CIRCUITS RPP06 (GN) AND LPP06 (YE/BU) FOR A SHORT TOGETHER Key in OFF position. Disconnect: Adjustable Pedal Motor C2159 Disconnect: DSM C341c Measure the resistance between adjustable pedal motor C2159-4, circuit RPP06 (GN), harness side and adjustable pedal motor C2159-3, circuit LPP06 (YE/BU), harness side. Is the resistance greater than 10,000 ohms? YES : Go to C12 . NO : REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test.
12. C12 CHECK CIRCUITS RPP06 (GN) AND LPP06 (YE/BU) FOR A SHORT TO VOLTAGE Key in ON position. Measure the voltage between ground and: adjustable pedal motor C2159-4, circuit RPP06 (GN), harness side. adjustable pedal motor C2159-3, circuit LPP06 (YE/BU), harness side. Is any voltage present? YES : REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test. NO : Go to C13 .
13. C13 CHECK THE DSM CONNECTORS Key in OFF position. Disconnect: DSM C341c Check the connector for: corrosion. pushed-out pins. spread terminals. Connect: DSM C341c Make sure the connector seats 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/taurus-x/i-2007-2009/remont/communication-devices/#multifunction-electronic-modules-system) article. CLEAR the DTCs. REPEAT the self-test. 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.

During moderate to heavy braking, noise from the hydraulic control unit (HCU) and pulsation in the brake pedal can be observed. Pedal pulsation coupled with noise during heavy braking or on loose gravel, bumps, wet or snowy surfaces is acceptable and indicates correct functioning of the ABS. Pedal pulsation or steering wheel nibble when the brakes are applied (frequency is proportioned to the vehicle speed) indicates a concern with a brake or suspension component.

PINPOINT TEST 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/taurus-x/i-2007-2009/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 NOTE: 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/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/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»(/ford/taurus-x/i-2007-2009/remont/anti-locktraction-control/#brake-system-general-information) Component Test.
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 on one power-asssisted brake application, continue with this test.
8. Inspect the brake booster for any signs of damage that may 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/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/remont/wheel-tire-system/#wheels-tires) 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/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#front-disc-brake-system) article for front disc brakes or «REAR DISC BRAKE»(/ford/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/remont/wheel-tire-system/#wheels-tires) article.

Component Bleeding

Material

Master Cylinder

Note. Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

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 onto the primary and secondary ports with the ends submerged in the brake master cylinder reservoir.
3. Fill the brake master cylinder reservoir with clean, specified brake fluid.
4. Have an assistant pump the brake pedal until clear fluid flows from the brake tubes without air bubbles.
5. Remove the short brake tubes, and install the master cylinder brake tubes. Tighten to 18 Nm (13 lb-ft).
6. 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.

Brake Caliper

Note. Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately before damage to the painted or plastic surface occurs.

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 screws to 12 Nm (9 lb-ft). Tighten the rear brake caliper bleeder screws to 10 Nm (89 lb-in).

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

Note. Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

Note. Pressure bleeding the brake system at 207-345 kPa (30-50 psi) is preferred to manual bleeding.

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. If the hydraulic control unit (HCU) or any component upstream of the HCU are installed new, carry out the brake system bleed procedure first without the scan tool, followed by the brake system bleed procedure using the scan tool.

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

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 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 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 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 bleeder screw to 10 Nm (89 lb-in), remove the rubber hose and install the bleeder screw cap.
7. Repeat Steps 5 and 6 for the LH rear brake caliper.
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 12 Nm (9 lb-ft).
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

Note. Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

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, including the hydraulic control unit (HCU) after it has been correctly connected.

Note. If the HCU or any component upstream of the HCU are installed new, carry out the brake system bleed procedure first without the scan tool, followed by the brake system bleed procedure using the scan tool.

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 around the brake fluid reservoir cap and remove the cap. Fill the brake master cylinder reservoir with clean, specified brake fluid.
2. Remove the RH rear bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid.
3. Have an assistant hold firm pressure on the brake pedal.
4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Press and release the parking brake 5 times. Repeat until clear, bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary.
5. Tighten the RH rear bleeder screw to 10 Nm (89 lb-in), remove the rubber hose and install the bleeder screw cap.
6. Repeat Steps 2 through 5 for the LH rear brake caliper.
7. Remove the RH front bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain tube to the RH front bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid.
8. Have an assistant hold firm pressure on the brake pedal.
9. Loosen the RH front bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front bleeder screw. Repeat until clear, bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary.
10. Tighten the RH front bleeder screw to 12 Nm (9 lb-ft), remove the rubber hose and install the bleeder screw cap.
11. Repeat Steps 7 through 10 for the LH front brake caliper bleeder screw.

ABS Hydraulic Control Unit (HCU) Bleeding

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, including the hydraulic control unit (HCU) after it has been correctly connected.

Note. If the HCU or any component upstream of the HCU are installed new, carry out the brake system bleed procedure first without the scan tool, followed by the brake system bleed procedure using the scan tool.

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

1. Connect the scan tool and follow the ABS HCU bleed instructions.
2. Follow the pressure bleeding or manual bleeding procedure steps to bleed the system.

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/taurus-x/i-2007-2009/remont/anti-locktraction-control/#brake-system-general-information__brake-system-bleeding) .
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, hoses and tubes to locate the source of the leak.

See also:
• FRONT DISC BRAKE
• REAR DISC BRAKE
• PARKING BRAKE AND ACTUATION
• HYDRAULIC BRAKE ACTUATION
• POWER BRAKE ACTUATION
• VEHICLE DYNAMIC SYSTEMS
• SEATING
• INSTRUMENT CLUSTER (IC), MESSAGE CENTER, AND WARNING CHIMES
• WHEELS AND TIRES
• FRONT SUSPENSION
• REAR DRIVE AXLE/DIFFERENTIAL
• SUSPENSION SYSTEM - GENERAL INFORMATION
• ENGINE SYSTEM - GENERAL INFORMATION
• NOISE, VIBRATION AND HARSHNESS
• MODULE COMMUNICATIONS NETWORK
• MULTIFUNCTION ELECTRONIC MODULES
• MODULE CONFIGURATION
• REAR VIEW MIRRORS
• JACKING AND LIFTING
• Symptom Chart - Hydraulic Brake System
• Brake Caliper Guide Pins
• Brake Disc Machining
• Brake System Leak Check
• Non-Pressure Leaks
• Brake System Bleeding
• Brake Pads
• Brake Calipers
• Pinpoint Test D
• Pinpoint Test A
• Pinpoint Test C
• Pinpoint Test B