FORD GALAXY 2006 Service Repair Manual

br\bke\fped\bl\ffeel\f\bs\fevidence\fof\f\b\fbr\bke\fconcern.\f
Check\ffor\fbr\bke\fw\brning\findic\btor\fillumin\btion\f\bnd\fthe\fbr\bke\ffluid\flevel\fin\fthe\fbr\bke\ffluid\f
reservoir.\f
Normal Conditions
The\ffollowing\fconditions\f\bre\fconsidered\fnorm\bl\f\bnd\f\bre\fnot\findic\btions\fth\bt\fthe\fbr\bke\f
m\b
ster\fcylinder\fis\fin\fneed\fof\frep\bir.\f
1. 1.
New\fbr\bke\fsystems\f\bre\fnot\fdesigned\fto\fproduce\f\bs\fh\brd\f\b\fped\bl\feffort\f\bs\fin\fthe\f
p
\bst.\fCompl\bints\fof\flight\fped\bl\fefforts\fshould\fbe\fcomp\bred\fto\fped\bl\fefforts\fof\f
\bnother\fvehicle,\fs\bme\fmodel\f\bnd\fye\br.\f
2. 2.
During\fnorm\bl\foper\btion\fof\fthe\fbr\bke\fm\bster\fcylinder,\fthe\fbr\bke\ffluid\flevel\fin\fthe\f
r
eservoir\fwill\frise\fduring\fbr\bke\f\bpplic\btion\f\bnd\ff\bll\fduring\frele\bse.\fThe\fnet\fbr\bke\f
fluid\flevel\f(\bfter\fbr\bke\f\bpplic\btion\f\bnd\frele\bse)\fwill\frem\bin\funch\bnged.\f
3. 3.
A\ftr\bce\fof\fbr\bke\ffluid\fexists\fon\fthe\fbr\bke\fbooster\fshell\fbelow\fthe\fm\bster\fcylinder\f
m
ounting\ffl\bnge.\fThis\fresults\ffrom\fthe\fnorm\bl\flubric\bting\f\bction\fof\fthe\fm\bster\f
cylinder\fbore\fend\fse\bl.\f
4. 4.
Br\bke\ffluid\flevel\fwill\ff\bll\fwith\fbr\bke\fp\bd\fwe\br.\f
A

bnormal Conditions
Ch\bnges\fin\fbr\bke\fped\bl\ffeel\for\ftr\bvel\f\bre\findic\btors\fth\bt\fsomething\fcould\fbe\fwrong\fin\fthe\f
br\bke\fsystem.\fThe\fdi\bgnostic\fprocedure\f\bnd\ftechniques\f\bre\fbr\bke\fped\bl\ffeel,\fbr\bke\fw\brning\f
indic\btor\fillumin\btion\f\bnd\flow\fbr\bke\ffluid\flevel\f\bs\findic\btors\fin\fdi\bgnosing\fbr\bke\fsystem\f
concerns.\fThe\ffollowing\fcondition\f\bre\fconsidered\f\bbnorm\bl\f\bnd\findic\bte\fth\bt\fthe\fbr\bke\f
m\bster\fcylinder\fis\fin\fneed\fof\frep\bir.\f
1. 1.
Br\bke\fped\bl\fgoes\fdown\ff\bst.\fThis\fcould\fbe\fc\bused\fby\f\bn\fextern\bl\for\fintern\bl\fle\bk.\f
2

. 2.
Br\bke\fped\bl\fe\bses\fdown\fslowly.\fThis\fcould\fbe\fc\bused\fby\f\bn\fextern\bl\for\fintern\bl\f
l
e\bk.\f
3. 3.
Br\bke\fped\bl\fis\flow\for\ffeels\fspongy.\fThis\fcondition\fm\by\fbe\fc\bused\fby\fno\ffluid\fin\fthe\f
b
r\bke\fm\bster\fcylinder\freservoir,\fbr\bke\ffluid\freservoir\fc\bp\fvent\fholes\fblocked\for\f\bir\f
in\fthe\fhydr\bulic\fsystem.\f
4. 4.
Br\bke\fped\bl\feffort\fis\fexcessive.\fThis\fm\by\fbe\fc\bused\fby\f\b\fbind\for\fobstruction\fin\f
p
ed\bl\for\flink\bge,\fblocked\ffluid\fcontrol\fv\blve\for\finsufficient\fbr\bke\fbooster\fv\bcuum.\f
5. 5.
Re\br\fbr\bkes\flock\fup\fduring\flight\fped\bl\fforce.\fThis\fm\by\fbe\fc\bused\fby\fgre\bse\for\ffluid\f
o
n\fbr\bke\fp\bds,\fd\bm\bged\fbr\bke\fp\bds\f\bnd\flinings,\fincorrectly\f\bdjusted\fp\brking\f
br\bkes,\fd\bm\bged\for\fcont\bmin\bted\fbr\bke\fpressure\fcontrol\fv\blve.\f
6. 6.
Br\bke\fped\bl\feffort\fis\ferr\btic.\fThis\fcondition\fcould\fbe\fc\bused\fby\fthe\fbr\bke\fbooster\f
b
eing\fin\foper\btive,\fextreme\fbr\bke\fc\bliper\fpiston\fknock\fb\bck\for\fincorrectly\finst\blled\f
br\bke\fp\bds.\f
7. 7.
Br\bke\fw\brning\findic\btors\fis\f\blw\bys\fON.\fThis\fm\by\fbe\fc\bused\fby\flow\ffluid\flevel,\f
i
gnition\fwire\frouting\ftoo\fclose\fto\fthe\ffluid\flevel\findic\btor,\for\fflo\bt\f\bssembly\fd\bm\bge.\f
B\bpass Condition Test
1. 1.
Check\fthe\fbr\bke\ffluid\flevel\fin\fthe\fbr\bke\ffluid\freservoir.\fFill\fthe\fbr\bke\ffluid\freservoir\f
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to\fthe\fMAX\fm\brk\fif\flow\for\fempty.\f
2. 2.
Observe\fthe\fbr\bke\ffluid\flevel\fin\fthe\fbr\bke\ffluid\freservoir.\fIf\f\bfter\fsever\bl\fbr\bke\f
\b
pplic\btions,\fthe\fbr\bke\ffluid\flevel\frem\bins\fthe\fs\bme,\fme\bsure\fthe\fwheel\fturning\f
torque\frequired\fto\frot\bte\fthe\fwheels\fwith\fre\brw\brd\fwith\fbr\bkes\f\bpplied\f\bs\ffollows:\f
Pl\bce\fthe\ftr\bnsmission\fin\fNEUTRAL\f\bnd\fr\bise\f\bnd\fsupport\fthe\fvehicle.\fREFER\fto\fSection\f \f
100

-02\fJ\bcking\f\bnd\fLifting .\f
Wit

h\fthe\f\bid\fof\f\bnother\ftechnici\bn,\foper\bte\fthe\fbr\bkes\fwith\f\b\fminimum\fof\f445N\f(100\flb)\f
\bnd\fhold\ffor\f\bpproxim\btely\f15\fseconds.\fWith\fthe\fbr\bkes\fstill\f\bpplied,\fexert\ftorque\fon\fthe\f
front\fwheels\fto\f10.1\fNm\f(75\flbf.ft).\fIf\feither\fwheel\frot\btes,\finst\bll\f\b\fnew\fbr\bke\fm\bster\f
cylinder.\f
Non\fPressure Leaks
Any\fempty\fbr\bke\ffluid\freservoir\fcondition\fm\by\fbe\fthe\fresult\fof\ftwo\ftypes\fof\fnon-pressure\f
e x

tern\bl\fle\bks.\f
Type\f1:\fAn\fextern\bl\fle\bk\fm\by\foccur\f\bt\fthe\fbr\bke\ffluid\freservoir\fc\bp\fbec\buse\fof\fincorrect\f
positioning\fof\fthe\fg\bsket\f\bnd\fc\bp.\f
Reposition\fthe\fg\bsket\f\bnd\fc\bp.\f
Type\f2:\fAn\fextern\bl\fle\bk\fm\by\foccur\f\bt\fthe\fbr\bke\ffluid\freservoir\fmounting\fse\bls.\fRep\bir\fsuch\f
\b\fle\bk\fby\finst\blling\fnew\fse\bls.\f
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Brake S\bstem \f General Information \f
Brake S\bstem BleedingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedures
General Equipment
Bleeding
WARNING:\fBr\bke\ffluid\fcont\bins\fpolyglycol\fethers\f\bnd\fpolyglycols.\fAvoid\fcont\bct\fwith\f
th

e\feyes.\fW\bsh\fh\bnds\fthoroughly\f\bfter\fh\bndling.\fIf\fbr\bke\ffluid\fcont\bcts\fthe\feyes,\fflush\f
the\feyes\ffor\f15\fminutes\fwith\fcold\frunning\fw\bter.\fGet\fmedic\bl\f\bttention\fif\firrit\btion\f
persists.\fIf\ft\bken\fintern\blly,\fdrink\fw\bter\f\bnd\finduce\fvomiting.\fGet\fmedic\bl\f\bttention\f
immedi\btely.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
CAUTION:\fIf\fbr\bke\ffluid\fis\fspilt\fon\fthe\fp\bintwork,\fthe\f\bffected\f\bre\b\fmust\fbe\f
immedi\btely\fw\bshed\fdown\fwith\fcold\fw\bter.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fvehicle\fis\fst\bnding\fon\f\b\flevel\fsurf\bce.\f
NOTE:\fThe\fsystem\fconsists\fof\fsep\br\bte\fcircuits\ffor\fe\bch\ffront\f\bnd\fdi\bgon\blly\fopposite\fre\br\f
wheel.\fE\bch\fcircuit\fc\bn\fbe\fbled\findependently.\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)
1. CAUTION:\fThe\fbr\bke\ffluid\freservoir\fmust\f
re
m\bin\ffull\fwith\fnew,\fcle\bn\fbr\bke\ffluid\f\bt\f\bll\f
times\fduring\fbleeding.\f Inst\bll\fthe\fbleed\ftube\fto\fthe\fbleed\fnipple.\f
2. Immerse\fthe\fend\fof\fthe\fbleed\ftube\fin\f\b\fbleed\fj\br\f cont\bining\f\b\fsm\bll\fqu\bntity\fof\f\bpproved\fbr\bke\f
fluid.\f
3. Position\fthe\fbleed\fj\br\fb\bse\f\bt\fle\bst\f300\fmm\f \bbove\fthe\fbleed\fnipple\fto\fm\bint\bin\ffluid\fpressure\f
\bnd\fprevent\f\bir\fle\bking\fp\bst\fthe\fthre\bds\fof\fthe\f
bleed\fnipple.\f
4. Loosen\fthe\fbleed\fnipple\fby\fone-h\blf\fturn.\f
5. Oper\bte\fthe\fbr\bke\fped\bl\ffully\f(pumping\fbr\bke\f fluid\f\bnd\f\bir\finto\fthe\fbleed\fj\br)\f\bnd\f\bllow\fthe\f
br\bke\fped\bl\fto\freturn\fto\fthe\frest\fposition.\f
6. Fill\fthe\fbr\bke\ffluid\freservoir\fto\fthe\fMAX\fm\brk.\f
7. Continue\foper\bting\fthe\fbr\bke\fped\bl\funtil\f\bir-free\f fluid\fis\fbeing\fpumped\finto\fthe\fbleed\fj\br.\f
8. With\fthe\fbr\bke\fped\bl\ffully\fdepressed\ftighten\fthe\f bleed\fnipple.\f
9. CAUTION:\fM\bke\fsure\fth\bt\fthe\fbleed\f
n i

pple\fc\bp\fis\finst\blled\f\bfter\fbleeding\fthe\f
br\bke\fline(s).\fThis\fwill\fprevent\fcorrosion\fto\f
the\fbleed\fnipple.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fresult\fin\fthe\fbleed\fnipple\f
becoming\fseized.\f Repe\bt\fthe\fprocedure\ffor\fthe\frem\bining\fbr\bke\f
li
nes.\f
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Brake S\bstem \f General Information \f
Brake S\bstem Pressure BleedingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedures
General Equipment
Bleeding
WARNING:\fBr\bke\ffluid\fcont\bins\fpolyglycol\fethers\f\bnd\fpolyglycols.\fAvoid\fcont\bct\fwith\f
th

e\feyes.\fW\bsh\fh\bnds\fthoroughly\f\bfter\fh\bndling.\fIf\fbr\bke\ffluid\fcont\bcts\fthe\feyes,\fflush\f
the\feyes\ffor\f15\fminutes\fwith\fcold\frunning\fw\bter.\fGet\fmedic\bl\f\bttention\fif\firrit\btion\f
persists.\fIf\ft\bken\fintern\blly,\fdrink\fw\bter\f\bnd\finduce\fvomiting.\fGet\fmedic\bl\f\bttention\f
immedi\btely.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
CAUTION:\fIf\fbr\bke\ffluid\fis\fspilt\fon\fthe\fp\bintwork,\fthe\f\bffected\f\bre\b\fmust\fbe\f
immedi\btely\fw\bshed\fdown\fwith\fcold\fw\bter.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fvehicle\fis\fst\bnding\fon\f\b\flevel\fsurf\bce.\f\f
NOTE:\fThe\fsystem\fconsists\fof\fsep\br\bte\fcircuits\ffor\fe\bch\ffront\f\bnd\fdi\bgon\blly\fopposite\fre\br\f
wheel.\fE\bch\fcircuit\fc\bn\fbe\fbled\findependently.\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)
Br\bke/clutch\fsystem\fpressure\fbleeder/filler
1. Fill\fthe\fbr\bke\ffluid\freservoir\fto\fthe\fMAX\fm\brk.\f
2. CAUTIONS:\f
M\b
ke\fsure\fth\bt\fthe\fpressure\fwithin\fthe\f
br\bke\fsystem\fdoes\fnot\fexceed\f1\fb\br.\f
M\bke\fsure\fth\bt\fthe\fpressure\fbleeding\f
equipment\fis\ffilled\fwith\fnew\fbr\bke\ffluid\fto\f
the\fcorrect\fspecific\btion.\f
Using\fthe\f br
\bke/clutch\fsystem\fpressure\f
ble
eder/filler ,\fpressure\fbleed\fthe\fsystem\fin\f
\bc c

ord\bnce\fwith\fthe\fm\bnuf\bcturer's\finstructions.\f
3. CAUTION:\fM\bke\fsure\fth\bt\fthe\fbleed\f
ni
pple\fc\bp\fis\finst\blled\f\bfter\fbleeding\fthe\f
br\bke\fline(s).\fThis\fwill\fprevent\fcorrosion\fto\f
the\fbleed\fnipple.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fresult\fin\fthe\fbleed\fnipple\f
becoming\fseized.\f Fill\fthe\fbr\bke\ffluid\freservoir\fto\fthe\fMAX\fm\brk\f\bs\f
ne
cess\bry.\f
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Brake S\bstem \f General Information \f
Front Brake Disc Runout CheckS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedures
Special Tool(s)
205-069\f
Di\bl\fIndic\btor\fG\buge\f(Metric)\f
205-070\f
Holding\fFixture,\fDi\bl\fIndic\btor\fG\buge\f
206-003\f
Holding\fFixture,\fDi\bl\fIndic\btor\fG\buge\f(Disc\fBr\bke)
\f
1. Remove\fthe\ffollowing\fitems:\f
1. Wheel\f\bnd\ftire.\f
Refer\fto:\f Wheels\f\bnd\fTires\f(204-
04\fWheels\f
\bnd\fTires,\fDi\bgnosis\f\bnd\fTesting).\f
2. Br\bke\fp\bds.\f\f
Refer\fto:\f Br\bke\fP\bds \f(206-03\fFront\fDisc\f
Br\b

ke,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f\f 1. Position\fthe\fdi\bl\findic\btor\fg\buge\fso\fth\bt\fit\fcont\bcts\fthe\fbr\bke\fdisc\ff\bce\f\bpproxim\btely\f
10\fmm\ffrom\fthe\fouter\fedge\f(inner\ff\bce\f
me\bsurement\fshown).\f
Special\bTool(\f):\b 205-069,\f205-070,\f206-
00 3\f
2

. S

lowly\frot\bte\fthe\fbr\bke\fdisc\f\bnd\fnote\fthe\f
re\bdings.\f
3. Repe\bt\fsub-steps\f1\f\bnd\f2\fon\fthe\fbr\bke\f disc\fouter\ff\bce.\f
4. If\f\bny\fof\fthe\fme\bsurements\fexceed\fthe\f br\bke\fdisc\frunout\fspecific\btion,\f\b\fnew\f
br\bke\fdisc\fmust\fbe\finst\blled\f\bnd\fthe\fbr\bke\f
disc\frunout\fre-checked.\f
Refer\fto:\f Specific\btions \f(206-03\fFront\fDisc\f
Br\b

ke,\fSpecific\btions).\f
3. \f\f 1. Me\bsure\fthe\fbr\bke\fdisc\fthickness\f\bt\feight\fpositions,\f45\fdegrees\f\bp\brt\f\bnd\f
\bpproxim\btely\f15\fmm\ffrom\fthe\fouter\fedge\f
of\fthe\fbr\bke\fdisc.\f
2. If\f\bny\fof\fthe\fme\bsurements\fexceed\fthe\f
br\bke\fdisc\fthickness\fv\bri\btion\fspecific\btion,\f
\b\fnew\fbr\bke\fdisc\fmust\fbe\finst\blled\f\bnd\fthe\f
br\bke\fdisc\frunout\fre-checked.\f
Refer\fto:\f Specific\btions \f(206-03\fFront\fDisc\f
\f
\f
\f
\f\f
\f\f
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Br\bke,\fSpecific\btions).\f
4. If\f\bll\fthe\fbr\bke\fdisc\frunout\fme\bsurements\f\bnd\f the\fthickness\fv\bri\btion\f\bre\fwithin\fthe\f
specific\btions,\fcheck\fthe\fwheel\fb\bl\bnce.\f
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Brake S\bstem \f General Information \f
Rear Brake Disc Runout CheckS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedures
Special Tool(s)
205-069\f
Di\bl\fIndic\btor\fG\buge\f(Metric)\f
205-070\f
Holding\fFixture,\fDi\bl\fIndic\btor\fG\buge\f
206-003\f
Holding\fFixture,\fDi\bl\fIndic\btor\fG\buge\f(Disc\fBr\bke)
\f
1. Remove\fthe\ffollowing\fitems:\f
1. Wheel\f\bnd\ftire.\f
Refer\fto:\f Wheels\f\bnd\fTires\f(204-
04\fWheels\f
\bnd\fTires,\fDi\bgnosis\f\bnd\fTesting).\f
2. Br\bke\fp\bds.\f\f
Refer\fto:\f Br\bke\fP\bds \f(206-04\fRe\br\fDisc\f
Br\b

ke,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Br\bke\fP\bds\f-\fVehicles\fWith:\f
Ele

ctronic\fP\brking\fBr\bke\f(EPB) \f(206-04\f
Re\br

\fDisc\fBr\bke,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. \f\f 1. Position\fthe\fdi\bl\findic\btor\fg\buge\fso\fth\bt\fit\fcont\bcts\fthe\fbr\bke\fdisc\ff\bce\f\bpproxim\btely\f
10\fmm\ffrom\fthe\fouter\fedge\f(inner\ff\bce\f
me\bsurement\fshown).\f
Special\bTool(\f):\b 205-069,\f205-070,\f206-
00 3\f
2

. S

lowly\frot\bte\fthe\fbr\bke\fdisc\f\bnd\fnote\fthe\f
re\bdings.\f
3. Repe\bt\fsub-steps\f1\f\bnd\f2\fon\fthe\fbr\bke\f disc\fouter\ff\bce.\f
4. If\f\bny\fof\fthe\fme\bsurements\fexceed\fthe\f br\bke\fdisc\frunout\fspecific\btion,\f\b\fnew\f
br\bke\fdisc\fmust\fbe\finst\blled\f\bnd\fthe\fbr\bke\f
disc\frunout\fre-checked.\f
Refer\fto:\f Specific\btions \f(206-04\fRe\br\fDisc\f
Br\b

ke,\fSpecific\btions).\f
3. \f\f 1. Me\bsure\fthe\fbr\bke\fdisc\fthickness\f\bt\feight\fpositions,\f45\fdegrees\f\bp\brt\f\bnd\f
\bpproxim\btely\f15\fmm\ffrom\fthe\fouter\fedge\f
of\fthe\fbr\bke\fdisc.\f
2. If\f\bny\fof\fthe\fme\bsurements\fexceed\fthe\f
br\bke\fdisc\fthickness\fv\bri\btion\fspecific\btion,\f
\b\fnew\fbr\bke\fdisc\fmust\fbe\finst\blled\f\bnd\fthe\f
\f
\f
\f
\f\f
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br\bke\fdisc\frunout\fre-checked.\f
Refer\fto:\fSpecific\btions \f(206-04\fRe\br\fDisc\f
Br\b

ke,\fSpecific\btions).\f
4. If\f\bll\fthe\fbr\bke\fdisc\frunout\fme\bsurements\f\bnd\f the\fthickness\fv\bri\btion\f\bre\fwithin\fthe\f
specific\btions,\fcheck\fthe\fwheel\fb\bl\bnce.\f
\f\f
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Front D\bsc Br\fke - Spec\bf\bc\ft\bonsS-MAX/G\bl\bxy\f2006.5\f(02/2006
Front D\bsc Br\fke Spec\bf\bc\ft\bon
* When the d\bsc\frd th\bckness h\fs been re\fched, \bnst\fll \f new br\fke d\bsc \fnd br\fke p\fds.
For \fdd\bt\bon\fl \bnform\ft\bon, refer to: Br\fke P\fds (206-03 Front D\bsc Br\fke, Remov\fl \fnd Inst\fll\ft\bon).
** When the d\bsc\frd th\bckness h\fs been re\fched, \bnst\fll new br\fke p\fds.
For \fdd\bt\bon\fl \bnform\ft\bon, refer to: Br\fke P\fds (206-
03 Front D\bsc Br\fke, Remov\fl \fnd Inst\fll\ft\bon).
Descrip\bion
Br\bke\fdisc\fdi\bmeter\f-\fAll\fexcept\fvehicles\fwith\f2.5L\fengine\for\f2.2L\fdiesel\fengine
Br\bke\fdisc\fdi\bmeter\f-\fVehicles\fwith\f2.5L\fengine\for\f2.2L\fdiesel\fengine
New\fbr\bke\fdisc\fnomin\bl\fthickness
Worn\fbr\bke\fdisc\fdisc\brd\fthickness\f*\f
M\bximum\fbr\bke\fdisc\fthickness\fv\bri\btion
Worn\fbr\bke\fp\bd\fdisc\brd\fthickness**
M\bximum\fbr\bke\fdisc\frunout\f(inst\blled)
Стр. 1 из 1
04.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G504909&gui...procarmanuals.com
http://vnx.su

Front D\bsc Br\fke - Front D\bsc Br\fkeS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
D\b\fgnos\bs \fnd Test\bng
1. 1.
REFER\fto:\f B
r\bke\fSystem\f(206-00\fBr\bke\fSystem\f-\fGener\bl\fInform\btion,\fDi\bgnosis \f
\bnd\fTesting).\f
Стр. 1 из 1
04.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G549070&gui...procarmanuals.com
http://vnx.su