FORD MUSTANG 2003 Workshop Manual

Four Wheel Anti-
Lock Brake System (4WABS) Hydraulic Control Unit (HCU)
NOTE: This procedure only needs to be performed if the 4- wheel anti-lock brake (4WABS) hydraulic
control unit (HCU) has been installed new or if the HCU lines have been opened.
1. Clean all dirt from and remove the brake master cylinder filler cap (2162), and fill the brake master cylinder reservoir (2K478) with the specified brake fluid.
2. Connect a clear waste line to the RH rear bleeder screw (2208) and the other end in a container partially filled with recommended brake fluid.
3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal (2455), tighten the RH rear bleeder screw.
zRepeat until clear, bubble- free fluid comes out.
z Refill the brake master cylinder reservoir as necessary.
4. Tighten the RH rear bleeder screw, and disconnect the waste line. Klj . 4 ba
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5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper (2B120)
bleeder screw, and the LH front disc brake caliper bleeder screw, in that order.
6. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the scan tool instructions.
7. Repeat the system bleed procedure as outlined in Steps 1 through 5.
Caliper 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper
(2B120) was disconnected.
Place a box end wrench on the disc brake caliper bleeder screw (2208). Attach a rubber drain
tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. Klj . 5 ba
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2. Have an assistant pump the brake pedal (BP) (2455) and then hold firm pressure on the brake
pedal.
3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw.
zRepeat until clear, bubble- free fluid comes out.
z Refill the brake master cylinder reservoir (2K478) as necessary.
4. Tighten the disc brake caliper bleeder screw. Refer to Specifications. Klj . 6 ba
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GENERAL PROCEDURES
Bleeding —
System
Manual
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.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never
reuse the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled
onto a painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new
components, air can get into the system and cause spongy brake pedal action. This requires bleeding
of the hydraulic system after it has been correctly connected. The hydraulic system can be bled
manually or with pressure bleeding equipment.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid.
2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with
clean brake fluid.
SECTION 206-
00: Brake System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the RH rear bleeder screw.
zRepeat until clear, bubble- free fluid comes out.
z Refill the brake master cylinder reservoir as necessary.
5. Tighten the RH rear bleeder screw.
6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw.
7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in
a container partially filled with clean brake fluid.
8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake
caliper bleeder screw.
zRepeat until clear, bubble- free fluid comes out.
z Refill the brake master cylinder reservoir as necessary.
10. Tighten the RH front disc brake caliper bleeder screw. For additional information, refer to Specifications in this section. Klj . 2 ba
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11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw.
Pressure 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the
adapter.
Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank
hose to the fitting on the adapter.
3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH
rear bleeder screw, and submerge the free end of the tube in a container partially filled with
clean brake fluid. 4. Open the valve on the bleeder tank. Klj . 3 ba
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5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-
free brake fluid flows, then
tighten the RH rear bleeder screw and remove the rubber hose.
6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder
screw.
7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Klj . 4 ba
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GENERAL PROCEDURES
Hydraulic Leak Check
1. NOTE: Brake fluid is water soluble and it is possible that all evidence of fluid leakage has been
washed off if the vehicle has been operated in the rain or snow.
Make sure the brake master cylinder reservoir (2K478) is full.
2. Apply the brakes several times and make sure the brake pedal (2455) feel is not spongy. If necessary, bleed the system. For additional information, refer to Bleeding — System in this
section.
3. If the reservoir level is dropping, inspect the brake components, fittings and lines to locate the source of the leak.
SECTION 206-
00: Brake System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
Runout Check —
Brake Disc and Hub
CAUTION: The brake disc (1126) runout specification must be met to ensure correct brake
performance without roughness complaints.
CAUTION: Do not install brake discs that are less than the minimum thickness specified.
Do not machine a brake disc below the minimum thickness specification.
NOTE: When installing brake discs, always align the painted match marks on the brake discs with
those on the front hub or rear axle.
NOTE: When installing brake discs, always apply anti- seize lubricant to the brake disc-to-front hub or
to the brake disc- to-rear axle mating surfaces.
1. Do not remove the tire and wheel assembly. Tighten the wheel nuts to specification with a torque stick or torque wrench.
2. Raise and support the vehicle.
3. Assemble the Brake Measurement Kit, using the spherical tip extension.
4. Locate an opening on the inboard side of the dust shield that will allow the dial indicator tip to be positioned at least 5 mm (0.2 inch) from the outer edge of the brake disc.
5. NOTE: Do not clamp the gauge set to a vehicle component separated from the brake disc by a
flexible joint, such as a ball joint or body mount.
Clamp the Brake Measurement Kit on the vehicle, making sure the flexible indicator arm and
probe tip do not touch the dust shield or tire while rotating.
6. NOTE: For rear wheel measurement only, have an assistant push in on the wheel cover or axle
shaft center while rotating the wheel.
Rotate the wheel for six revolutions, and record the total indicated runout.
SECTION 206-
00: Brake System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Brake Measurement Kit
134-R0199 or equivalent
Material Item Specification
High Temperature Nickel Anti-
Seize Lubricant
F6AZ-
9L494- AA ESE-
M12A4-
A Klj . 1 ba
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7. If the total indicated runout exceeds the maximum specification, remove the brake disc. For
additional information, refer to Section 206 - 03 for front or to
Section 206 - 04 for rear.
8. Clean the brake disc mounting face of dirt, rust and foreign material.
9. For front wheels, measure and record the total indicated runout of the hub face outside the stud circle.
10. Install a new front hub if the total indicated runout exceeds the maximum specification. For additional information, refer to Section 204 - 01 .
z Repeat the hub runout measurement.
11. NOTE: Clean the axle flange surface before measuring.
NOTE: For rear wheels, press inward on the axle shaft while measuring the rear axle runout.
For rear wheels, measure and record the total indicated runout at a point on the axle shaft
outside the stud circle.
12. If the total indicated runout exceeds the maximum specification, inspect the rear axle. For additional information, refer to Section 205 - 00 . Repair as necessary.
z Repeat the rear brake disc runout measurement. Klj . 2 ba
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