AC system FORD MUSTANG 2003 Workshop Manual

4. Bleed the caliper. For additional information, refer to
Section 206 - 00 .
5. Install the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
6. Fill the brake master cylinder reservoir (2K478) with clean High Performance DOT 3 Brake Fluid C6AZ- 19542- AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25- A. Install
brake master cylinder filler cap (2162).
7. Check the brake system operation. Klj . 4 ba
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2.
CAUTION: Never reuse piston seals and dust boots.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Lubricate the caliper piston, piston seal and caliper bores with clean High Performance DOT 3
Brake Fluid C6AZ-19542- AB or equivalent DOT 3 fluid meeting Ford specification ESA- M6C25-
A.
3. Install the caliper piston. Klj . 3 ba
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DESCRIPTION AND OPERATION
Rear Disc Brake
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.
The rear disc brake system consists of:
zsolid, full- cast brake disc (2C026).
z hydraulically activated rear disc brake caliper (2552).
z integral mechanically (cable) operated parking brake mechanism that is self- adjusting.
Rear Disc Brake System Components SECTION 206-
04: Rear Disc Brake 2003 Mustang Workshop Manual Item Part Number Description
1 2552 Rear disc brake caliper
2 2C028 Brake disc shield
3 N606675-
S2 Bolt (3 req'd each side)
4 1104 Wheel hub
5 2C026 Brake disc
6 4B423 Rear wheel hub retainer
7 W623485-S2 Nut (2 req'd each side)
8 N805163-S100 Bolt (4 req'd) Klj . 1 ba
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6. Remove the rear disc brake caliper brake hose bolt.
7. Remove the rear brake pin retainers (2N386) and remove the caliper.
Installation 1. NOTE: Use new copper washers.
Follow the removal procedure in reverse order. zBleed the brake system. For additional information, refer to Section 206 - 00 . Klj . 2 ba
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NOTE:
Use new brake fluid when assembling and bleeding the brake system.
NOTE: Lightly lubricate the parking brake lever bore, limiting bolt, parking brake lever shaft and
parking brake shaft recess with Silicone Dielectric Compound D7AZ-19A331- A or equivalent
meeting Ford specification ESE- M1C171-A.
Follow the disassembly procedure in reverse order. Klj . 4 ba
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DESCRIPTION AND OPERATION
Parking Brake
The parking brake system is cable-
actuated and controlled by an independent hand- operated parking
brake control (2780). To apply parking brake, pull parking brake control upward as far as possible.
The parking brake system is an AUTO- ADJUST system. The spring in the parking brake control
continuously adjusts the cable tension in the system.
Brake Warning System
A parking brake warning indicator:
zis located in the instrument panel.
z illuminates to signal the driver the parking brake is applied or to signal a low fluid condition.
z remains lit when a brake malfunction has occurred.
SECTION 206-
05: Parking Brake and Actuation 2003 Mustang Workshop Manual Item Part Number Description
1 2780 Parking brake control
2 2552 Rear disc brake caliper Klj . 1 ba
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DIAGNOSIS AND TESTING
Parking Brake
Inspection and Verification
1. Verify the customer's concern by operating the parking brake system to duplicate the condition.
2. Inspect to determine if one of the following mechanical or electrical concerns apply:
3. If the inspection reveals obvious concern(s) that can be readily identified, service as necessary.
4. If concern(s) remains after the inspection, determine the symptoms. GO to Symptom Chart .
Symptom Chart
Pinpoint Tests
PINPOINT TEST A: PARKING BRAKE WILL NOT APPLY SECTION 206-
05: Parking Brake and Actuation 2003 Mustang Workshop Manual Visual Inspection Chart
Mechanical Electrical
z
Damaged parking brake control
z Binding/damaged parking brake cables z
Parking brake signal switch
Symptom Chart Condition
Possible Sources Action
z Parking Brake Will Not
Apply z
Parking brake
control.
z Parking brake
cable. z
Go To Pinpoint Test A .
z Parking Brake Will Not
Release z
Parking brake
cable.
z Parking brake
control. z
Go To Pinpoint Test B .
Test Step Result / Action to Take
A1 CHECK THE PARKING BRAKE
CABLES z
Raise and support the vehicle. Refer Yes Klj . 1 ba
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PINPOINT TEST B: PARKING BRAKE WILL NOT RELEASE to Section 100 - 02 .
z Inspect for broken or binding parking
brake cables or broken guide clips.
z Is there a parking brake cable
concern? INSTALL a new parking brake cable as
necessary. TEST the system for normal
operation.
No
GO to
A2 .
A2 CHECK THE PARKING BRAKE
CONTROL z
Operate the parking brake control.
z Does the parking brake control
operate smoothly? Yes
INSTALL a new parking brake lever. RESTORE
vehicle and TEST the system for normal
operation.
No
REPAIR the binding condition in the parking brake
control. TEST the system for normal operation.
Test Step Result / Action to Take
B1 CHECK PARKING BRAKE CONTROL
z
Raise and support the vehicle. Refer to
Section 100 - 02 .
z Release parking brake by pulling
upward on hand lever and pushing
release button.
z Did parking brake release? Yes
GO to
B2 .
No
INSTALL a new parking brake control.
RESTORE the vehicle and TEST the system for
normal operation. B2 CHECK PARKING BRAKE CABLES
z
Loosen tensioner. Refer to Parking Brake Cable Tension Release in this
section.
z Move the gearshift lever to NEUTRAL
position.
z Rotate rear wheels by hand.
z Did rear wheels turn freely? Yes
GO to
B3 .
No
INSTALL new parking brake cables. RESTORE
the vehicle and TEST the system for normal
operation. B3 CHECK REAR PARKING BRAKE
LEVERS z
Disconnect parking brake levers one at
a time.
z Rotate wheel affected by disconnected
parking brake lever.
z Did wheel turn freely? Yes
INSTALL a new parking brake lever. RESTORE
vehicle and TEST the system for normal
operation.
No
REPAIR or INSTALL a new rear brake
component if worn or damaged. TEST the
system for normal operation. Klj . 2 ba
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GENERAL PROCEDURES
Parking Brake Cable Tension Release
1. CAUTION: If any component in the parking brake system requires repair or if the
rear axle housing (4010) is removed, the cable tension must be released.
Place the parking brake control (2780) in the released position.
2. Remove the console. For additional information, refer to Section 501 - 12 .
3. With an assistant inside the vehicle, raise and support the vehicle. For additional information, refer to Section 100 - 02 .
4. Pull the parking brake cable and equalizer rearward.
5. CAUTION: Do not remove the steel pin until the parking brake cable and
equalizer/rear cable and conduits are connected to the parking brake control. Pin
removal releases the tension in the ratchet wheel causing the spring to unwind and
release tension. Insert a steel pin through holes in the lever to the ratchet wheel. SECTION 206-
05: Parking Brake and Actuation 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Parking Brake Control
Removal
1. CAUTION: If any component in the parking brake system requires repair or if the
rear axle housing (4010) is removed, the cable tension must be released.
Place the parking brake control (2780) in the released position.
2. Remove the console. For additional information, refer to Section 501 - 12 .
3. Remove the parking brake control studs.
4. NOTE: Self adjust pawl must be off to allow wind up.
Place the control handle in the fully downward position, then pull the control handle forward to
wind- up the self- adjusting mechanism.
5. Insert a steel pin through hole in the lever to the ratchet wheel, then carefully release the spring tension onto the pin.
SECTION 206-
05: Parking Brake and Actuation 2003 Mustang Workshop Manual Klj . 1 ba
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