FORD FIESTA 2007 Workshop Manual

206-00-9 Brake System - General Information 206-00-9
DIAGNOSIS AND TESTING
Symptom
Brakedrag
Excessive brake pedal effort
Brake noise
I
i
i
Slow or incomplete brake pedal
return Possible Sources
Action
Brake discs.
Brake booster.
Incorrectly adjusted brake light
switch. Brake pressure control valve.
Seized brake caliper or wheel
cylinder. Parking brake applied or
malfunction.
Seized parking brake cables.
Seized brake caliper slide pins.
Brake booster inoperative.
Worn or contaminated brake
shoes or brake pads.
Worn brake shoes or brake
pads.
Brake booster.
Brake booster.
Brake master cylinder.
GO to Pinpoint Test H.
GO to Pinpoint Test I.
ADJUST the brake light switch.
PERFORM a brake booster
functional test REFER to the
component tests.
INSTALL new brake shoes or
brake pads. REFER to:
Brake Shoes (206-02 Drum Brake, Removal and Installa-
tion),
Brake Pads (206-03 Front Disc
Brake, Removal and Installa-
tion),
Brake Pads (206-04 Rear Disc Brake, Removal and Installa-
tion).
GO to Pinpoint Test J.
INSTALL new brake shoes or
brake pads. REFER to:
Brake Shoes (206-02 Drum Brake, Removal and Installa-
tion),
Brake Pads (206-03 Front Disc
Brake, Removal and Installa-
tion),
Brake Pads (206-04 Rear Disc
Brake, Removal and Installa-
tion).
GO to Pinpoint Test K.
GO to Pinpoint Test L.
2006.0 Fiesta 1212006 G28494en
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206-00-1 0 Brake System - General Information 206-00-1 0
DIAGNOSIS AND TESTING
Pinpoint Tests
PINPOINT TEST A : BRAKES PULL OR DRIFT
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS
A1 : ROAD TEST THE VEHICLE
Road test the vehicle and apply the brake pedal.
Does the vehicle pull or drift?
+ Yes
GO to A2.
+ No
Vehicle OK.
A2: TIRE INSPECTION
Check for excessive wear or incorrect tire pres-
sures.
Are the tires in good condition?
-, Yes
GO to A3.
+ No
INFLATE the tires to the correct pressure.
INSTALL new tires if excessively worn. TEST
the system for normal operation.
A3: BRAKE SHOE OR BRAKE PADS AND LINING INSPECTION
Inspect the brake shoes or brake pads for
grease or fluid on the linings and or wear
concerns.
Are any concerns present?
+ Yes
INSTALL new brake shoes or brake pads.
REFER to:
Brake Shoes (206-02 Drum Brake, Removal and
Installation),
Brake Pads (206-03 Front Disc Brake, Removal
and Installation),
Brake Pads (206-04 Rear Disc Brake, Removal
and Installation).
TEST the system for normal operation.
+ No
GO to A4.
2006.0 Fiesta 1212006 G28494en
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206-00-1 1 Brake System - General Information 206-00-1 1
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESULTSIACTIONS
1 A4: CHECK PRESSURE CONTROL VALVE-RIGHT-HAND REAR --
Install pressure gauges in the left-hand front
and right-hand rear bleed nipples. Apply the
brake to read 6895
kPa (1000 psi) at the left-
hand front wheel.
- Read the pressure at right-hand rear wheel.
Does the pressure gauge read between 4692-
5164
kPa (680-750 psi) at the right-hand rear
wheel?
-+ Yes
INSPECT the brake calipers and INSTALL
new components as required. GO to A5.
-+ No
INSTALL a new right-hand rear brake pres-
sure control valve. BLEED the brake system.
REFER to: (206-00 Brake System
- General
Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures). TEST the system for normal operation.
2006.0 Fiesta 1212006 G28494en
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206=00-I 2 Brake System - General Information 206-00-1 2
DIAGNOSIS AND TESTING
TEST CONDITIONS
I A5: CHECK PRESSURE CONTROL VALVE-LEI T-HAND REAR I
Install pressure gauges in the right-hand front
and left-hand rear bleed nipples. Apply the brake
to read 6895
kPa (1000 psi) at the right-hand
front wheel.
- Read the pressure at left-hand rear wheel.
Does the pressure gauge read between 4692-
5164
kPa (680-750 psi) at the left-hand rear
wheel?
+ Yes
INSPECT the brake calipers and INSTALL
new components as required. REFER to:
Brake Shoes (206-02 Drum Brake, Removal and Installation),
Brake Pads (206-03 Front Disc Brake, Removal
and Installation),
Brake Pads (206-04 Rear Disc Brake, Removal
and Installation).
TEST the system for normal operation.
+ No
INSTALL a new left-hand rear brake pressure
control valve. BLEED the brake system.
REFER to: (206-00 Brake System
- General
Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Procedures).
TEST the system for normal operation.
PINPOINT TEST B
: BRAKE WARNING INDICATOR ALWAYS ON
TEST CONDITIONS
DETAILS/RESULTS/ACTIONS
I B1: CHECK BRAKE WARNING INDICATOR I
N0TE:The brake warning indicator should only illuminate when the ignition switch is in the START or
RUN position and the parking brake is applied.
I Ignition switch in position II.
Release the parking brake.
- Check the fluid level in the reservoir is at the
MAX mark.
Does the brake warning indicator illuminate?
+ Yes
REFER to: lnstrument Cluster
- Vehicles Built
Up To: 1 012005 (41 3-01 lnstrument Cluster,
Diagnosis and Testing).
2006.0 Fiesta 12/2006 G28494en
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206-00-1 3 Brake System - General Information 206-00-1 3
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESU LTSIACTIONS
I B2: CHECK BRAKE SYSTEM FOR LEAKAGE 1
rn Check the brake master cylinder reservoir
sealing points and external brake and clutch
system for leaks. Refer to the brake master
cylinder component tests in this section.
Does the system leak?
-+ Yes
REPAIR as necessary. ADD fluid and BLEED
the brake system. REFER to: (206-00 Brake
System
- General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Procedures).
TEST the system for normal operation.
183: CHECK BRAKE WARNING SWITCH OR WIRING I
I rn Ignition switch in position II. I
Remove the brake master cylinder reservoir
filler cap or switch. Allow the float to rest at its
lowest point.
Does the brake warning indicator illuminate?
-+ Yes
The switch or wiring is OK. TEST the system
for normal operation.
-+ No
REFER to: lnstrument Cluster - Vehicles Built I Up To: 1012005 (41 3-01 Instrument Cluster,
I Diagnosis and Testing).
PINPOINT TEST C : VIBRATION WHEN BRAKES ARE APPLIED
TEST CONDITIONS
DETAl LSIRESU LTSIACTIONS
Cl : ROAD TEST THE VEHICLE
Road test the vehicle without applying the
brakes at 40-80 kmlh (25-50 mph).
Is a vibration present?
-+ Yes
REFER to: Noise, Vibration and Harshness
(NVH) (1 00-04 Noise, Vibration and Harsh-
ness, Diagnosis and Testing).
After servicing, TEST the system for normal operation.
-+ No
GO to C2.
2006.0 Fiesta 1212006 G28494en
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206-00-1 4 Brake System - General Information 206-00-1 4
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESU LTSIACTIONS
C2: CHECK FOR REAR BRAKE VIBRATION
N0TE:With a manual release parking brake control, hold the parking brake control release button in
the release position during parking brake control application.
Road test the vehicle at 40-80 kmlh (25-50 mph)
with a medium application on the parking brake
control.
Is a vibration present?
-+ Yes
CHECK the rear brake drums or discs for
excessive wear. INSTALL new components
as necessary. REFER to:
Brake Drum (206-02 Drum Brake, Removal and
Installation),
Brake Shoes (206-02 Drum Brake, Removal and
Installation),
Brake Pads (206-04 Rear Disc Brake, Removal
and lnstallation),
Brake Disc (206-04 Rear Disc Brake, Removal
and Installation). TEST the system for normal operation.
I C3: CHECK FOR FRONT BRAKE VIBRATION I
Road test the vehicle at 40-80 kmlh (25-50 mph)
with light and medium application of the foot
brake.
Is a vibration present?
+ Yes
CHECK the front brake discs for excessive
wear or cracks. INSTALL new components as
necessary. REFER to: (206-03 Front Disc
Brake)
Brake Pads (Removal and lnstallation),
Brake Caliper (Removal and lnstallation).
TEST the system for normal operation.
+ No
Vehicle OK.
2006.0 Fiesta 12/2006 G28494en
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206-00-1 5 Brake System - General Information 206-00-1 5
DIAGNOSIS AND TESTING
PINPOINT TEST D : PEDAL GOES DOWN FAST
Dl : ROAD TEST THE VEHICLE
rn Road test the vehicle and apply the foot brake.
Was the brake pedal effort normal?
+ Yes
Vehicle OK.
+ No
GO to
D2.
D2: CHECK BRAKE FLUID LEVEL
Check the brake master cylinder reservoir fluid
level.
Is the fluid level acceptable?
+ Yes
GO to D3.
+ NO
CHECK the brake master cylinder reservoir
sealing points for leaks. REFER to the brake
master cylinder component tests in this
section. ADD fluid and BLEED the brake
system. REFER to: (206-00 Brake System
-
General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures).
TEST the system for normal operation.
/
2006.0 Fiesta 12/2006 G28494en
TEST CONDITIONS
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206-00-1 6 Brake System - General Information 206mOO-16
DIAGNOSIS AND TESTING
TEST CONDITIONS
2006.0 Fiesta 12/2006 G28494en
D3: PRESSURIZE THE SYSTEM
D4: CHECK FOR BRAKE SYSTEM LEAKS
Pump the foot brake rapidly five times.
Does the brake pedal height build up and then
hold?
+ Yes
CHECK parking brake adjustment and
ADJUST as necessary. REFER to: (206-05
Parking Brake and Actuation)
Parking Brake Cable Adjustment
- Vehicles With:
Rear Drum Brakes (General Procedures),
Parking Brake Cable Adjustment
- Vehicles With:
Rear Disc Brakes (General Procedures).
If the condition still exists. BLEED the brake
system. REFER to: (206-00 Brake System
-
General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures). TEST the system for normal operation.
+ No
GO to D4.
Check for external brake and clutch system
leaks. REFER to the component tests.
Are any leaks found?
+ Yes
REPAIR as necessary. ADD fluid and BLEED
the brake system. REFER to: (206-00 Brake
System
- General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures). TEST the system for normal operation.
+ No
GO to D5.
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206-00-1 7 Brake System - General Information 206-00-1 7
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESU LTSIACTIONS
I D5: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION CHECK
Test for a brake master cylinder bypass. REFER
to the component tests.
Was a concern found?
+ Yes
INSTALL a new brake master cylinder.
REFER to: (206-06 Hydraulic Brake Actuation)
Brake Master Cylinder
- RHD (Removal and
Installation),
Brake Master Cylinder
- LHD (Removal and
Installation). ADD fluid and BLEED the brake system.
REFER to: (206-00 Brake System
- General
Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Procedures). TEST the system for normal operation.
+ No
System OK.
( 1 PINPOINT TEST E : PEDAL EASES DOWN SLOWLY
TEST CONDITIONS
DETAILSIRESULTSIACTIONS 1
I El: CHECK BRAKE PEDAL OPERATION 1
Check if the condition occurs when applying the
brake pedal while the vehicle is moving.
Does the condition occur with the vehicle
stationary?
+ Yes GO to E2.
-, No
REFER to the component tests.
2006.0 Fiesta 1212006 G28494en
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206-00-18 Brake System - General Information 206-00-1 8
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESU LTSIACTIONS
E2: CHECK FOR BRAKE SYSTEM LEAKS
Check for external brake system leaks. Refer
to the component tests.
Are any leaks found?
+ Yes
REPAIR as necessary. ADD fluid and BLEED
the brake system. REFER to: (206-00 Brake
System
- General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Procedures). TEST the system for normal operation.
+ No
GO to E3.
E3: PERFORM A BRAKE MASTER CYLINDER BYPASS TEST
Test for a brake master cylinder bypass. Refer
to the component tests.
Was a concern found?
+ Yes
INSTALL a new brake master cylinder.
REFER to: (206-06 Hydraulic Brake Actuation)
Brake Master Cylinder
- RHD (Removal and
Installation),
Brake Master Cylinder
- LHD (Removal and
Installation).
ADD fluid and BLEED the bake system.
REFER to: (206-00 Brake System
- General
Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Procedures). TEST the system for normal operation.
-+ No
System
OK. TEST the system for normal
operation.
2006.0 Fiesta 12/2006 G28494en
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