brake FORD FIESTA 2007 Service Manual

206-00-3 Brake System - General Information 206-00-3
DIAGNOSIS AND TESTING
Brake System
The brakes system operates by transferring effort
applied to the brake pedal by the driver to the
brakes at each wheel.
The braking effort is distributed to each wheel,
using a hydraulic system. The system is assisted
using a vacuum brake booster that reduces pedal
effort and increases hydraulic pressure.
The parking brake operates on the rear wheels
and is applied using a hand operated control.
lnspection and Verification
N0TE:Before carrying out any diagnosis, make
sure that the brake system warning indicator is
functional.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
damage.
3. If an obvious cause for an observed or reported
concern is found, correct the case (if possible)
before proceeding to the next step.
4. If the cause if not visually evident, verify the
symptom and refer to the Symptom Chart.
Visual lnspection Chart
Road Test
1.
Perform a road test to compare actual vehicle
braking performance with the performance
standards expected by the driver. The ability of the
test driver to make valid comparisons and detect
performance deficiencies will depend on
experience.
Mechanical
- Tire pressure
- Wheels and tires
- Fluid leak from brake line(s)
The driver should have a thorough knowledge of
the brake system operation and accepted general
performance guidelines to make good comparisons
, and detect performance concerns.
An experienced technician will always establish a
route that will be used for all brake diagnosis road
tests. The road selected will be reasonably smooth and level. Gravel
or bumpy roads are not suitable
because the surface does not allow the tires to grip
the road equally. Crowned roads should be avoided
because of the large amount of weight shifted to
the low set of wheels on this type of road. Once
the route is established and consistently used, the
road surface variable can be eliminated from the
test results.
Before a road test, get a complete description of
the customer concerns or suspected condition.
From the description, the technician will be able to
match possible causes with symptoms. Certain
components will be identified as possible sources
while others will be eliminated by the evidence.
More importantly, the customer description can
reveal unsafe conditions which should be checked
or corrected before a road test. The description will
also help form the basic approach to the road test
by narrowing the concern to specific components,
vehicle speed or conditions.
Begin the road test with a general brake
performance check. Using the description of the
concern, test the brakes at different vehicle speeds
using both light and heavy pedal pressure.
Determine if the concern is in the front or rear
braking system. First use the foot brake and then
the parking brake. If the condition
(i.e. pull,
vibration, pulsation) occurs only on operation of
the parking brake, the concern is in the rear brake
system.
If the condition occurs when the foot brake
is depressed, the concern is in the front brake
system.
Avoid locking the brakes and sliding the tires. This
condition will not indicate brake efficiency. A heavily
braked but turning wheel will stop the vehicle in a
shorter distance than locked wheels.
If the concern becomes evident during this check,
make sure it fits the description given before the
road test. If the concern is not evident, attempt to
duplicate the condition using the information from
the description.
If a concern exists, use the Brake System Symptom
Chart in order to isolate it to a specific sub-system
and condition description. From this description, a
list of possible sources can be used to further
narrow the cause to a specific component or
condition.
- -
2006.0 Fiesta 1212006 G28494en
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206-004 Brake System - General Information 206-00-4
DIAGNOSIS AND TESTING
Symptom Chart - -
Symptom
Brakes pull or drift
Possible Sources Action
Worn or damaged brake shoes
or brake pads and linings. 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).
Abnormal wear or distortion of
brake discs.
INSTALL a new brake discs.
REFER to: Brake Disc (206-04
Rear Disc Brake, Removal
and Installation).
lncorrect rear brake adjust-
ment. PERFORM
a parking brake
cable adjustment. REFER to:
(206-05 Parking Brake and
Actuation)
Parking Brake Cable Adjust-
ment
- Vehicles With: Rear
Drum Brakes (General
Procedures),
Parking Brake Cable Adjust-
ment
- Vehicles With: Rear
Disc Brakes (General
Procedures).
lncorrect wheel alignment
adjustment. PERFORM a
wheel alignment
adjustment.
REFER to: Front Toe Adjust-
ment (204-00 Suspension
System
- General Informa-
tion, General Procedures).
l ncorrect wheel bearing preload
adjustment. ADJUST or INSTALL a new
wheel bearing. REFER to:
Front Wheel Bearing (204-01 Front Suspension, Removal
and Installation),
Rear Wheel Bearing (204-02 Rear Suspension, Removal
and Installation).
2006.0 Fiesta 1212006 G28494en
Unequal air pressure in the
tires. INFLATE the tires to the correct
pressure.
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206-00-5 Brake System - General Information 206-00-5
DIAGNOSIS AND TESTING
Symptom Possible Sources
Action
Grease or fluid on the brake
shoes or brake pads; glazed
linings. 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).
I Stuck or seized calipers. I GO to Pinpoint Test A. I
Brake warning indicator always
on Low
brake fluid level. FILL the reservoir. CHECK the
brake and clutch system for
leaks including brake fluid in
the brake booster.
--
Leaking brake master cylinder
primary piston cup. 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).
Parking brake control not fully
released. FREE UP and
ADJUST the
parking brake cable. REFER
to: (206-05 Parking Brake and
Actuation)
Parking Brake (Diagnosis and Testing),
Parking Brake Cable Adjust-
ment
- Vehicles With: Rear
Drum Brakes (General
Procedures),
Parking Brake Cable Adjust-
ment
- Vehicles With: Rear
Disc Brakes (General
Procedures).
INSTALL new components as
necessary.
I Shorted indicator circuit. I GO to Pinpoint Test B. I
2006.0 Fiesta 12/2006 G28494en
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206-00-6 Brake System - General Information 206-00-6
DIAGNOSIS AND TESTING
Symptom
Vibration when the brakes are
applied Possible
Sources Action
Grease or fluid on the brake
shoes or brake pads; glazed
linings. INSTALL
new brake shoes or
brake pads. REFER to:
i
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).
Worn or damaged brake shoes
or brake pads. 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).
Loose caliper mounting
bolt(s). TIGHTEN the caliper mounting
bolt(s). REFER to:
Specifications (206-03 Front Disc Brake, Specifications),
Specifications (206-04 Rear Disc Brake, Specifications).
Insufficient grease on sliding grease
where neces-
parts.
Damaged brake drum contact
surface. REFER to: Brake Drum (206-
02 Drum Brake, Removal and
Installation).
Loose or missing rear wheel
spindle bolts. TIGHTEN or
INSTALL new rear
wheel spindle bolts.
REFER to: Specifications (204-
02 Rear Suspension, Specifications).
Go to Pinpoint Test
C.
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206-00-7 Brake System - General Information 206-00-7
DIAGNOSIS AND TESTING
1 Pedal goes down fast
Possible Sources Action
Leak in the hydraulic system. REPAIR the leak. CHECK the
entire hydraulic system. FILL
and BLEED the brake system.
REFER to: (206-00 Brake
System
- General Information)
Brake System Bleeding
(General Procedures),
Brake System Pressure
Bleeding (General Proced-
ures).
Air in the system.
CHECK for leaks. BLEED the
brake system. REFER to: (206-
00 Brake System
- General
Information)
Brake System Bleeding
(General Procedures),
Brake System Pressure
Bleeding (General Proced-
u res).
Worn brake master cylinder piston cups or scored cylinder
bore. INSTALL
a new brake master
cylinder. REFER to: (206-06
Hydraulic Brake Actuation)
Brake Master Cylinder
- RHD
(Removal and lnstallation),
Brake Master Cylinder
- LHD
(Removal and lnstallation).
I Brake disc brake 'knock back' I Install a new brake disc. I
I loose wheel bearings.) I I
(Brake pads push the brake
caliper piston back into brake
caliper. Caused by excessive
brake disc lateral
runout or
Worn brake shoes or brake
pads. REFER to:
Brake Disc (206-04
Rear Disc Brake, Removal
and Installation). 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 D.
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206-00-8 Brake System - General Information 206-00-8
DIAGNOSIS AND TESTING
Svm~tom Possible Sources Action
Pedal eases down slowly Air in the system.
Malfunctioning brake master
cylinder.
BLEED the brake system.
REFER to: (206-00 Brake
System
- General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Proced-
ures).
GO to Pinpoint Test E.
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-
Pedal is low or feels spongy
I tion). I
Brake lockup during light brake I
Worn brake shoes or brake
pads.
pedal force INSTALL new brake shoes or
brake pads. REFER to:
Hydraulic system.
Incorrect tire pressures.
Tires worn.
Glazed or worn brake shoes or
brake pads.
Brake booster.
GO to Pinpoint Test F. I
INFLATE the tires to the correct
pressure.
INSTALL new tires. I
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 G.
Excessive or erratic pedal
travel Worn brake shoes or brake
pads. 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),
I
Brake Pads (206-04 Rear Disc
Brake, Removal and Installa-
tion).
2006.0 Fiesta 1212006 G28494en
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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.
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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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