brake fluid FORD MUSTANG 2003 Repair Manual

REMOVAL AND INSTALLATION
Master Cylinder —
Hydro-Boost
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). SECTION 206-
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REMOVAL AND INSTALLATION
Reservoir
Removal
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.
1. Disconnect the brake master cylinder fluid level switch.
2. Use a suitable suction device to drain the brake master cylinder reservoir (2K478).
3. Carefully pry up on the brake master cylinder reservoir and remove.
Installation 1. NOTE: Whenever installing a new brake master cylinder reservoir, install new grommets.
Install the brake master cylinder reservoir. 1. Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542- AB
or equivalent fluid meeting Ford specification ESA- M6C25-A and insert the grommets
into the brake master cylinder (2140).
2. Press the brake master cylinder reservoir into the grommets until it is fully seated.
3. Connect the brake master cylinder fluid level switch.
4. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ- 19542- AB or equivalent fluid meeting Ford specification ESA- M6C25-A.
5. Bleed the brake master cylinder. For additional information, refer to Section 206 - 00 .
SECTION 206-
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REMOVAL AND INSTALLATION
Control Valve
Removal
1. Disconnect the brake tubes.
2. Remove the brake fluid control valve bracket nut.
Installation 1. To install, reverse the removal procedure.
SECTION 206-
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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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REMOVAL AND INSTALLATION
Brake Booster —
Hydro-Boost
Removal WARNING: The power brake booster should not be carried by the accumulator, nor
should it ever be dropped on the accumulator. Check the snap ring on the accumulator for
correct seating before the power brake booster is used. The accumulator contains high-
pressure nitrogen gas and can be dangerous if mishandled.
WARNING: If the accumulator is to be disposed of, it must not be exposed to excessive
heat. Before discarding the accumulator, drill a 1.6- mm (1/16-inch) diameter hole in the end of
the accumulator can to relieve the gas pressure. Always wear safety glasses when performing
this operation.
1. With the engine off, depress the brake pedal (2455) several times to discharge the accumulator.
2. Disconnect the battery ground cable (14301). For additional information, refer to Section 414 -
01 .
3. Disconnect the fluid level sensor connector.
4. Disconnect the brake tubes.
SECTION 206-
07: Power Brake Actuation 2003 Mustang Workshop Manual Special Tool(s)
Installer Set, Teflon Seal
211-
D027 (D90P-3517- A) or
equivalent Klj . 1 ba
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3. If the concern remains after the inspection, connect the scan tool to the data link connector
(DLC) located beneath the instrument panel and select the vehicle to be tested from the scan
tool menu. If the scan tool does not communicate with the vehicle: 1. Check that the program card is correctly installed.
2. Check the connections to the vehicle.
3. Check the ignition switch position.
4. If the scan tool still does not communicate with the vehicle, refer to the scan tool Manual.
5. Carry out the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: 1. CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418-00.
2. NO RESP/NOT EQUIP for the anti- lock brake control module, Go To Pinpoint Test A .
3. SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self- test diagnostics for the anti-lock brake
control module.
6. If the DTCs retrieved are related to the concern, go to the Anti- Lock Brake Control Module
Diagnostic Trouble Code (DTC) Reference Chart to continue diagnostics.
7. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnostics.
Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index
NOTE: If a wheel speed signal fault or a pump motor fault is detected, the yellow ABS warning
indicator cannot be reset with the key OFF and key ON method. The vehicle must be driven over 12
km/h (8 mph) for the anti- lock brake control module to carry out a re- check of the system before the
yellow ABS warning indicator is turned OFF. Visual Inspection Chart Mechanical Electrical
z
Low brake fluid
z Anti- lock brake sensor
z Anti- lock brake sensor indicator
z Base brake system z
Central junction box (CJB)Fuse:
„15 (10A)
„ 29 (15A)
„ 33 (15A)
„ 35 (15A)
z Battery junction box (BJB) Fuse:
„ABS 1 (50A)
„ ABS 2 (20A)
z Circuitry
z Damaged or corroded connectors
z Yellow ABS warning indicator
z Loose grounds
Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index DTC Description Source Action
B1318 Battery Voltage Low ABS Go To Pinpoint Test C .
B1342 ECU Is Defective ABS INSTALL a new anti-
lock brake control module;
REFER to Module . REPEAT the self-
test. B1484 Brake Pedal Input Open Circuit ABS Go To Pinpoint Test D . Klj . 2 ba
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REMOVAL AND INSTALLATION
Hydraulic Control Unit
Removal
1. Disconnect the battery ground cable(14301).
2. Disconnect the anti- lock-brake control module electrical connector.
3. NOTE: The 4 wheel anti- lock brake system (4WABS) with traction control is shown , the
4WABS without traction control system is similar with one less hydraulic line.
NOTE: Plug brake lines to prevent any brake fluid loss.
Disconnect the brake lines from the hydraulic control unit (HCU).
4. Remove the HCU bracket nuts to HCU.
5. Remove the HCU.
SECTION 206-
09A: Anti-Lock Control — Rear 2003 Mustang Workshop Manual Klj . 1 ba
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Inspection and Verification
1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical and electrical damage.
3. If the concern remains after the inspection, connect the scan tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan
tool menu. If the scan tool does not communicate with the vehicle: 1. Check that the program card is correctly installed.
2. Check the connections to the vehicle.
3. Check the ignition switch position.
4. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual.
5. Carry out the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: 1. CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418-00.
2. NO RESP/NOT EQUIP for the anti- lock brake control module, Go To Pinpoint Test A .
3. SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),
erase the continuous DTCs and carry out self- test diagnostics for the anti-lock brake
control module.
6. If the DTCs retrieved are related to the concern, go to the Anti- Lock Brake Control Module
Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnostics.
Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index
NOTE: If a wheel speed signal fault or a pump motor fault is detected, the yellow ABS warning
indicator cannot be reset with the key OFF and key ON method. The vehicle must be driven over 12
km/h (8 mph) for the anti- lock brake control module to do a re- check of the system before the yellow
ABS warning indicator is turned OFF. Visual Inspection Chart Mechanical Electrical
z
Low brake fluid
z Anti- lock brake sensor
z Anti- lock brake sensor indicator
z Base brake system
z Wheel bearings z
Central junction box (CJB) Fuse:
„5 (15A)
„ 15 (10A)
„ 29 (15A)
„ 33 (15A)
„ 35 (15A)
z Battery junction box (BJB) Fuse:
„ABS 1 (50A)
„ ABS 2 (20A)
z Circuitry
z Damaged or corroded connectors
z ABS warning indicator
z Loose grounds Klj . 2 ba
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REMOVAL AND INSTALLATION
Hydraulic Control Unit
Removal
1. Disconnect the battery ground cable(14301).
2. Disconnect the anti- lock-brake control module electrical connector.
3. NOTE: The 4 wheel anti- lock brake system (4WABS) with traction control is shown , the
4WABS without traction control system is similar with one less hydraulic line.
NOTE: Plug brake lines to prevent any brake fluid loss.
Disconnect the brake lines from the hydraulic control unit (HCU).
4. Remove the HCU bracket nuts to HCU.
5. Remove the HCU.
SECTION 206-
09B: Anti-Lock Control — Traction Control 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
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