brake FORD MUSTANG 2003 Workshop Manual

6. Remove the brake pedal and bracket.
Installation 1. To install, reverse the removal procedure. Klj . 2 ba
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REMOVAL AND INSTALLATION
Master Cylinder
Removal
1. Disconnect the fluid level sensor connector.
2. Disconnect the brake tubes.
3. Remove the brake master cylinder nuts.
4. Remove the brake master cylinder (2140).
Installation
1. To install, reverse the removal procedure. zBleed the brake system. For additional information, refer to Section 206 - 00 .
SECTION 206-
06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Master Cylinder —
Hydro-Boost
Removal 1. Disconnect the fluid level sensor connector.
2. Disconnect the brake tubes.
3. Remove the brake master cylinder nuts. 4. Remove the brake master cylinder (2140). SECTION 206-
06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
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Installation
1. To install, reverse the removal procedure. zBleed the brake system. For additional information, refer to Section 206 - 00 . Klj . 2 ba
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REMOVAL AND INSTALLATION
Reservoir
Removal
WARNING: Brake 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.
1. Disconnect the brake master cylinder fluid level switch.
2. Use a suitable suction device to drain the brake master cylinder reservoir (2K478).
3. Carefully pry up on the brake master cylinder reservoir and remove.
Installation 1. NOTE: Whenever installing a new brake master cylinder reservoir, install new grommets.
Install the brake master cylinder reservoir. 1. Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542- AB
or equivalent fluid meeting Ford specification ESA- M6C25-A and insert the grommets
into the brake master cylinder (2140).
2. Press the brake master cylinder reservoir into the grommets until it is fully seated.
3. Connect the brake master cylinder fluid level switch.
4. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ- 19542- AB or equivalent fluid meeting Ford specification ESA- M6C25-A.
5. Bleed the brake master cylinder. For additional information, refer to Section 206 - 00 .
SECTION 206-
06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Control Valve
Removal
1. Disconnect the brake tubes.
2. Remove the brake fluid control valve bracket nut.
Installation 1. To install, reverse the removal procedure.
SECTION 206-
06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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SPECIFICATIONS
SECTION 206-
07: Power Brake Actuation 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft Power brake booster nuts 25 19
Brake master cylinder nuts 25 19
Hydraulic tube connections 17 13
Power steering pressure lines 19 14 Klj . 1 ba
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DESCRIPTION AND OPERATION
Brake Booster —
Vacuum
Power Brake Booster
The vacuum type power brake booster (2005):
zis a dual diaphragm, vacuum assisted power brake booster
z reduces brake pedal force and travel distance.
z is located on the LH side of the bulkhead in the engine compartment, between the brake pedal
(2455) and the brake master cylinder (2140).
z is divided into separate chambers by the diaphragms.
z will not operate if vacuum is restricted or if any of the vacuum related power brake components
fail.
z is installed as an assembly.
If the power assist fails, the brake system will continue to operate with increased brake pedal effort.
Hose and Check Valve
The power brake booster check valve (2365): SECTION 206-
07: Power Brake Actuation 2003 Mustang Workshop Manual Item Part Number Description
1 2140 Master cylinder
2 2B560 Hydro-Boost
3 2005 Power brake booster Klj . 1 ba
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z
is located on the front of the power brake booster.
z is installed separately; (install a new grommet when installing a new check valve).
z is positioned between the power brake booster and the power brake booster hose.
z closes when the engine is turned off.
z in the closed position, traps engine vacuum in the power brake booster
z retains vacuum to provide several power assisted brake applications with the engine off. Item Part Number Description
1 2140 Master cylinder
2 2005 Power brake booster Klj . 2 ba
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DESCRIPTION AND OPERATION
Brake Booster —
Hydro-Boost
The Hydro- Boost brake booster is a hydraulically operated brake booster powered by the power
steering pump (3A674). The power steering pump provides the fluid pressure to operate both the
power brake booster and the power steering gear (3504).
A Hydro- Boost reserve system (accumulator) stores sufficient fluid under pressure to provide at least
two power- assisted brake applications in the event the power steering pump fluid flow is interrupted.
For low assist concerns on vehicles equipped with the Hydro- Boost system, refer to Section 211 - 00 to
check the power steering pump pressure and flow.
The brakes can also be applied manually if the reserve system is depleted.
Any leakage goes directly back to the power steering pump reservoir (3E764). SECTION 206-
07: Power Brake Actuation 2003 Mustang Workshop Manual Item Part Number Description
1 2140 Master cylinder
2 2B559 Hydro-Boost Klj . 1 ba
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