AC system FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Cable and Conduit —
Front
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.
Release the cable tension. For additional information, refer to Parking Brake Cable Tension Release in this section.
2. Disconnect the parking brake rear cables and conduits.
3. Remove the parking brake control nuts.
4. Disconnect the parking brake cable.
SECTION 206-
05: Parking Brake and Actuation 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Cable and Conduit
Removal
NOTE:
The RH rear is shown, the LH is similar.
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.
Release the cable tension. For additional information, refer to Parking Brake Cable Tension Release in this section.
2. Disconnect the parking brake rear cable and conduit.
3. Using a 13 mm (0.52 in) box- end wrench, depress the conduit retaining prongs and remove the
parking brake rear cable and conduit.
SECTION 206-
05: Parking Brake and Actuation 2003 Mustang Workshop Manual Klj . 1 ba
42003 Mustang Workshop Manual
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DESCRIPTION AND OPERATION
Hydraulic Brake Actuation
CAUTION: Blistering or swelling of rubber brake components may indicate contamination
of the brake fluid by a petroleum based substance. New rubber components must be installed
in the hydraulic brake system if contaminated and the entire hydraulic brake system must be
flushed with clean brake fluid to prevent recontamination.
This vehicle is equipped with a brake pedal actuated dual brake system. The system consists of the
following:
zpower brake booster (2005)
z brake master cylinder (2140)
z brake pressure control valve (2B091)
z disc brake calipers (2B120)
z rear disc brake calipers (2553)
z brake tubes and hoses
z anti- lock brake system (ABS) components
SECTION 206-
06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual Item Part Number Description
1 2K478 Master cylinder reservoir
2 2140 Master cylinder
3 — Pedal support bracket (part of 2455)
4 2455 Brake pedal Klj . 1 ba
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The dual brake system is split front and rear with the front wheel brakes comprising of one circuit and
the rear wheel brakes, the other circuit.
Brake Fluid
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with
eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running
water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water
and induce vomiting. Get medical attention immediately.
Clean, fresh Ford High Performance DOT 3 Brake Fluid C6AZ-19542- AB or equivalent DOT 3 fluid
meeting Ford specification ESA- M6C25-A is the only brake fluid that should be used in Ford vehicles.
z Do not reuse brake fluid drained or bled from the system.
z Do not use brake fluid that has been stored in an open container.
z Do not mix different types of brake fluid.
Brake Master Cylinder
The brake master cylinder is a dual piston type. The brake master cylinder operates as follows: zWhen the brake pedal (2455) is depressed, pressure is applied by mechanical linkage to the
primary and secondary piston.
z Brake master cylinder pistons apply hydraulic pressure to the two hydraulic circuits.
z Brake master cylinder will not be overhauled, a new master cylinder is installed only.
The brake master cylinder consists of:
zbrake master cylinder reservoir (2K478)
z brake master cylinder body
Brake Master Cylinder Reservoir
NOTE: Whenever the brake master cylinder reservoir is removed from the brake master cylinder, new
grommets must be installed.
The brake master cylinder reservoir :
zis mounted to the brake master cylinder.
z holds fluid supply for each brake master cylinder hydraulic piston.
z provides visual fluid level markings.
z contains the brake master cylinder fluid level sensor. Klj . 2 ba
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Brake Pressure Control Valve
The brake pressure control valve proportions the pressure to the rear brakes.
zWhen the brake pedal is applied, brake fluid pressure passes through the proportioning valves
to the rear brake system until the valve split point is reached.
z Above its split point, the proportioning valve begins to reduce the hydraulic pressure to the rear
brakes, creating a balanced braking condition between the front and rear brakes.
Brake Tubes and Hoses CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion which
could result in brake tube failure.
Steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly
double flared to provide strong leakproof connections. When bending the tubing to fit the underbody or
rear axle contours, be careful not to kink or crack the tube.
If a section of brake tube is damaged, the entire section must be removed and a new tube of the same
type, size, shape and length installed.
When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After
installation, bleed the brake system. For additional information, refer to Section 206 - 00 . Klj . 3 ba
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REMOVAL AND INSTALLATION
Master Cylinder
Removal
1. Disconnect the fluid level sensor connector.
2. Disconnect the brake tubes.
3. Remove the brake master cylinder nuts.
4. Remove the brake master cylinder (2140).
Installation
1. To install, reverse the removal procedure. zBleed the brake system. For additional information, refer to Section 206 - 00 .
SECTION 206-
06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual Klj . 1 ba
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Installation
1. To install, reverse the removal procedure. zBleed the brake system. For additional information, refer to Section 206 - 00 . Klj . 2 ba
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DESCRIPTION AND OPERATION
Brake Booster —
Vacuum
Power Brake Booster
The vacuum type power brake booster (2005):
zis a dual diaphragm, vacuum assisted power brake booster
z reduces brake pedal force and travel distance.
z is located on the LH side of the bulkhead in the engine compartment, between the brake pedal
(2455) and the brake master cylinder (2140).
z is divided into separate chambers by the diaphragms.
z will not operate if vacuum is restricted or if any of the vacuum related power brake components
fail.
z is installed as an assembly.
If the power assist fails, the brake system will continue to operate with increased brake pedal effort.
Hose and Check Valve
The power brake booster check valve (2365): SECTION 206-
07: Power Brake Actuation 2003 Mustang Workshop Manual Item Part Number Description
1 2140 Master cylinder
2 2B560 Hydro-Boost
3 2005 Power brake booster Klj . 1 ba
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DESCRIPTION AND OPERATION
Brake Booster —
Hydro-Boost
The Hydro- Boost brake booster is a hydraulically operated brake booster powered by the power
steering pump (3A674). The power steering pump provides the fluid pressure to operate both the
power brake booster and the power steering gear (3504).
A Hydro- Boost reserve system (accumulator) stores sufficient fluid under pressure to provide at least
two power- assisted brake applications in the event the power steering pump fluid flow is interrupted.
For low assist concerns on vehicles equipped with the Hydro- Boost system, refer to Section 211 - 00 to
check the power steering pump pressure and flow.
The brakes can also be applied manually if the reserve system is depleted.
Any leakage goes directly back to the power steering pump reservoir (3E764). SECTION 206-
07: Power Brake Actuation 2003 Mustang Workshop Manual Item Part Number Description
1 2140 Master cylinder
2 2B559 Hydro-Boost Klj . 1 ba
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GENERAL PROCEDURES
Hydro-
Boost Bleeding
1. NOTE: The Hydro- Boost power brake booster (2B560) is generally self- bleeding, and the
following procedure will normally bleed the air from the power brake booster. Normal operation
of the vehicle will further remove any additional trapped air.
Fill the power steering oil reservoir (3A697) with MERCON® Multi- Purpose ATF XT-2-QDX or
MERCON® equivalent.
2. Remove the powertrain control module (PCM) fuse to prevent the engine from starting.
3. Crank the engine for several seconds.
4. Check the fluid level in the power steering oil reservoir and add if necessary. Install the powertrain control module (PCM) fuse.
5. Start the engine.
6. With the engine running, turn the steering wheel (3600) from stop- to-stop twice. Turn the engine
off.
7. Depress the brake pedal (2455) several times to discharge the accumulator.
8. Repeat Steps 5 and 6.
9. If foaming occurs, stop the engine and allow the foam to dissipate.
10. Repeat Steps 5 and 6 as required, until all the air is removed from the system (when the foaming stops).
SECTION 206-
07: Power Brake Actuation 2003 Mustang Workshop Manual Klj . 1 ba
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