brake pads FORD FIESTA 2007 User Guide

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-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 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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206-00-21 Brake System - General Information 206-00-21
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESU LTSIACTIONS
162: TIRE INSPECTION
rn Check for excessive tire wear or incorrect tire
pressures.
Are the tires in good order?
-+ Yes
GO to G3. GO to Pinpoint Test G.
-+ No
SUBSTITUTE known good tires. INFLATE to
the correct pressure. TEST the system for
normal operation.
163: BRAKE SHOES OR BRAKE PADS INSPECTION I
rn Inspect the brake shoes or brake pads are
correctly fitted and for grease or fluid contamin-
ation or wear concerns.
Are there any concerns?
-+ Yes
REPAIR or INSTALL new components as
necessary. TEST the system for normal
operation.
-+ No
GO to G4. GO to Pinpoint Test G.
1 64: CHECK PRESSURE CONSCIOUS REDUCING VALVE-RIGHT-HAND REAR I
rn Install pressure gauges in the left-hand front
and right-hand rear bleed nipples. Apply the brake to read 6895
kPa (1 000 psi) at the left-
hand front wheel.
- Read the pressure at the right-hand rear
wheel.
Does the pressure gauge read between 4692-
5164
kPa (680-750 psi) at the right-hand rear
wheel?
-+ Yes
TEST the brake booster. Go to Pinpoint Test
I.
-+ 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 normal operation.
2006.0 Fiesta 12/2006 G28494en
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206-00-27 Brake System - General Information 206-00-27
DIAGNOSIS AND TESTING
PINPOINT TEST K : BRAKE NOISE
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS
K1: CHECK FOR PEDAL NOISE
Inspect the brake pads and brake shoes for
excessive wear.
- Run the engine at idle for 10 seconds or
longer. Apply the brake pedal and listen for
noise. Compare results with a known good
system.
Was a noise present?
-+ Yes
GO to K2.
-+ No
Vehicle OK.
K2: CHECK PUSH ROD ALIGNMENT
Check the brake booster push rod alignment
and travel.
Is the push rod OK?
-+ Yes
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
INSTALL a new brake booster. REFER to:
(206-07 Power Brake Actuation)
Brake Booster
- LHD (Removal and lnstallation),
Brake Booster
- RHD (Removal and Installation).
TEST the system for normal operation.
2006.0 Fiesta 1212006 G28494en
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206-03-1 Front Disc Brake 206-03-1
SECTION 206-03' Front Disc Brake
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications ........................................................................\
............................................. 206-03-2
Front Disc Brake Specification
........................................................................\
................ 206-03-2
DESCRIPTION AND OPERATION
Front Disc Brake ............................. ......................................................... ...................... 206-03-3
Overview
........................................................................\
............................. - ...................... 206-03-3
DIAGNOSIS AND TESTING
Front Disc Brake ........................................................................\
.........................................
REMOVAL AND INSTALLATION
Brake Pads ........................................................................\
........................... (122340)
Brake Caliper
........................................................................\
.......................... (12 243 0)
(
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206-03-2 Front Disc Brake 206-03-2
SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives
Specification
Brake Fluid - Super DOT 4 ESD-M6C57-A
Front Disc Brake Specification
I Brake disc diameter - Vehicles with 2.OL Duratec-HE I 278 I
Description
Brake disc diameter
I New brake disc nominal thickness I 22 I
mm
258
New brake disc nominal thickness
- Vehicles with 2.OL Duratec-HE
Worn brake disc discard thickness
*
I Worn brake pad discard thickness ** I 1.5 I
25
20
Worn brake disc discard thickness
- Vehicles with 2.OL Duratec-HE *
Maximum brake disc thickness variation
I Worn brake pad discard thickness - Vehicles with 2.OL Duratec-HE ** I 2.0 I
23
0.025
I * When the discard thickness has been reached, install a new brake disc and new brake pads.
I ** When the discard thickness has been reached, install new brake pads.
Torque Specifications
Description
Nm Ib-ft lb-in I(
I Brake caliper anchor plate retaining bolts I 70 I 52 I - I
Brake caliper anchor plate retaining bolts - Vehicles
L2.OLuratec-H E
I Brake caliper retaining bolts I 30 I 22 I - I
me hose to brake caliper union I 17 I 13 I - I
2006.0 Fiesta 1212006 GI 7354en
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206-03-3 Front Disc Brake 206-03-3
DESCRIPTION AND OPERATION
Front Disc Brake
Overview
Item Description
i
The front brake system has internally ventilated
brake discs and a single-piston floating caliper.
3
4
5
The front disc brakes are the same on all vehicles,
irrespective of the vehicle specifications.
1
2
Retaining spring clip
Brake pads
Brake caliper
Please refer to the "General Specifications" section
for the dimensions of the brake discs.
Brakedisc
Brake back plate assembly
The piston of the brake caliper has a diameter of
54 mm.
2006.0 Fiesta 1212006 G250945en
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206-03-5 Front Disc Brake 206-03-5 - - --- -- -
REMOVAL AND INSTALLATION
Brake Pads(l2 234 0)
i Special Tool(s) Remove the brake hose retaining clip.
Retractor, Brake Caliper
Piston
206-005
Materials
Name Specification
I Silicone Grease I ESE-MlC171-A I
Removal
Brake Fluid - Super
I DOT4 4m &AUTION:S~~~~~~ the brake caliper to
prevent load being placed on the brake hose.
ESD-M6C57-A
Detach the brake caliper from the brake
caliper anchor plate.
A CAUTI0N:If brake fluid is spilt on the
paintwork, the affected area must be 1. Remove the brake caliper retaining bolt
immediately washed down with cold water. covers (if equipped).
2. Remove the brake caliper retaining bolts.
I. Remove the wheel and tire. I i For additional information, refer to: Wheel
and Tire
(204-04 Wheels and Tires, Removal
and Installation).
2. Remove the brake caliper retaining clip.
3. N0TE:Make a note of the position of the
brake hose to aid installation.
Detach the brake hose from the brake hose
support bracket.
5. Remove the brake pads.
2006.0 Fiesta 1212006 G149890en
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206-03-7 Front Disc Brake 206-03-7
REMOVAL AND INSTALLATION
Brake Caliper(l2 243 0) /
' General Equipment 2. Disconnect the brake hose.
Brake hose
clamp
Materials
Name Specification
I Silicone Grease I ESE-MlC171-A I
Removal
A CAUTI0N:If brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
1. Remove the wheel and tire.
4. Remove the brake caliper.
For additional information, refer to: Wheel
and Tire
(204-04 Wheels and Tires, Removal I. Remove the brake caliper retaining bolt
and Installation). covers (if equipped).
2. Remove the brake caliper retaining clip. 2. Remove the brake caliper retaining bolts.
5. Remove the brake pads.
3' ACAUTION:C~~ the brake hose to prevent
fluid loss or dirt ingress.
N0TE:Use a wrench to prevent the brake hose
from rotating.
Disconnect the brake hose from the brake
caliper.
I. Using a brake hose clamp, clamp the brake
hose.
Installation
ACAUTION:D~ not twist the brake hose
when connecting the brake hose to the brake
caliper to prevent damage to the brake hose.
- -
2006.0 Fiesta 1212006 G149891en
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