brake FORD S-MAX 2006 Service User Guide

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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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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Rear Di\bc Brake \f Specification\bS-MAX/G\bl\bxy\f2006.5\f(02/2006
Rear Di\bc Brake Specification
* When the di\bcard thickne\b\b ha\b been reached, in\btall a new brake di\bc and brake pad\b.
For additional information, refer to: Brake Pad\b (206\f04 Rear Di\bc Brake, Removal and In\btallation).
** When the di\bcard thickne\b\b ha\b been reached, in\btall new brake pad\b.
For additional information, refer to: Brake Pad\b (206\f
04 Rear Di\bc Brake, Removal and In\btallation).
Descrip\bion
Br\bke\fdisc\fdi\bmeter\f
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)
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Rear Di\bc Brake \f Rear Di\bc BrakeS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\bi\b and Te\bting
REFER\fto\fSection\f \f2
06-00\fBr\bke\fSystem\f-\fGener\bl\fInform\btion .\f
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Rear Di\bc Brake \f Brake Pad\bS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\btallation
Special Tool(\b)
Mat

erial\b
Removal
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
206-012\f
Retr\bctor,\fRe\br\fBr\bke\fC\bliper\fPiston
\f
NameSpec\bf\bcat\bo\f
Br\bke\fFluid\f-\fSuper\fDOT4WSS-M6C57-A2
1. Refer\fto:\fBr\bke\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre

c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. Refer\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Tir

es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. \f
4. WARNING:\fM\bke\fsure\fth\bt\fno\flo\bd\fis\f
p l

\bced\fon\fthe\fbr\bke\fhose.\f
Torque:\b 35\fNm
\f
5.NOTE:\fNote\fthe\fposition\fof\fe\bch\fcomponent\f
be
fore\fremov\bl.\f
1. Br\bke\fp\bd\floc\bting\fspring\f(rubber\fco\bted).
\f
2. Br\bke\fp\bd\floc\bting\fspring.\f
6. Spec\fal\bTool(s):\b 206-012\f
\f
\f\f
\f\f
\f\f
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Rear Di\bc Brake \f Brake Pad\b—Vehicle\b
With: Electronic Parking Brake (EPB)S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\btallation
Material\b
Removal
CA
UTION:\fRefer\fto:\f Br\bke\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions \f(100-00\fGener\bl\f
Inf

orm\btion,\fDescription\f\bnd\fOper\btion).\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
In\btallation
NameSpec\bf\bcat\bo\f
Br\bke\fFluid\f-\fSuper\fDOT4WSS-M6C57-A2
1. Refer\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Tir
es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Activ\bte\fthe\felectronic\fp\brking\fbr\bke\fc\bliper\f \bctu\btor\fservice\fmode.\f
Refer\fto:\f Electronic\fP\brking\fBr\bke\f(EPB)\fRele\bse\f
Usi

ng\fthe\fVehicle\fSystems \f(206-05\fP\brking\f
Br\b

ke\f\bnd\fActu\btion,\fGener\bl\fProcedures).\f
3. \f
4. WARNING:\fM\bke\fsure\fth\bt\fno\flo\bd\fis\f
p l

\bced\fon\fthe\fbr\bke\fhose.\f
Torque:\b 35\fNm
\f
5.NOTE:\fNote\fthe\fposition\fof\fe\bch\fcomponent\f
be
fore\fremov\bl.\f
1. CAUTIONS:\f
\f\f
\f\f
\f\f
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Rear Di\bc Brake \f Brake CaliperS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\btallation
Material\b
Gen

eral Equipment
Removal CA
UTION:\fRefer\fto:\f Br\bke\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions \f(100-00\fGener\bl\f
In f

orm\btion,\fDescription\f\bnd\fOper\btion).\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
NameSpec\bf\bcat\bo\f
Br\bke\fFluid\f-\fSuper\fDOT4WSS-M6C57-A2
Hose\fcl\bmp(s)
1. Remove\fthe\fwheel\f\bnd\ftire.\f\f
Refer\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Tir

es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f
3. \f\f 1.General \bqui\fment: Hose\fcl\bmp(s)\f
2. To

rque: 18\fNm
\f
3. Torque: 35\fNm
\f
4. CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f
\br

e\fse\bled.\f
5. NOTE:\fNote\fthe\fposition\fof\fthe\fbr\bke\fp\bds\fto\f
\bi
d\finst\bll\btion.\f
\f\f
\f\f
\f\f
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Parking\bBrake\band\b\fctuation\b-\bParking\b
BrakeS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description\band\bOperation\b
M\bnu\bl\fp\brking\fbr\bke\f
A\f

convention\bl\fp\brking\fbr\bke\fsystem\fis\fused\fwith\f\b\ftwin\fA-fr\bme\fp\brking\fbr\bke\fcontrol\f
lever\fwhich\fis\floc\bted\fin\fthe\ffloor\fconsole.\f
Only\fthe\fp\brking\fbr\bke\fcontrol\fis\fvisible,\fthe\fp\brking\fbr\bke\fcontrol\flever\fis\fhidden\fby\fthe\f
floor\fconsole.\f
Electronic\fp\brking\fbr\bke\f(EPB)\f
\f\f
Description\b
EPB\fswitch\f
Right-h\bnd\fre\br\fEPB\f\bctu\btor\f
EPB\fmodule\f
Left-h\bnd\fre\br\fEPB\f\bctu\btor\f
An\fEPB\fis\f\bv\bil\bble\f\bs\f\bn\foption\ffor\fthe\fvehicle.\fIn\fcomp\brison\fto\f\b\fconvention\bl\fp\brking\f
br
\bke,\fthe\fEPB\foffers\fthe\ffollowing\f\bdv\bnt\bges:\f
*\fE\bse\fof\foper\btion,\fdue\fto\flow\foper\bting\fforces.\fThis\fis\f\bchieved\fby\fthe\fuse\fof\f\bn\felectric\bl\f
switch\finste\bd\fof\f\b\flever\f\bnd\fthe\fp\brking\fbr\bke\fc\bbles\f\bre\frepl\bced\fby\felectric\bl\fc\bbles.\f
*\fThe\fEPB\fis\f\blw\bys\f\bpplied\ffirmly,\fgiving\fm\bximum\fp\brking\fbr\bke\fpower\fin\f\bll\foper\bting\f Item
1
2
3
4 \f\f
\f
Part\bNumber
-
-
-
-
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Parking\bBrake\band\b\fctuation\b-\bParking\b
BrakeS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis\band\bTesting\b
Refer\bto\bWiring\bDiagrams\bSection\b206-05,\bfor\bschematic\band\bconnector\b
in

formation.\b\b
General\bEquipment\b
Principles\bof\bOperation\b
In

spection\band\bVerification\b
1. 1.\b
Verify\fthe\fcustomer\fconcern.\f
2

. 2.\b
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

isual\bInspection\bChart\b
3. 3.\b
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep\f
4. 4.\b
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Symptom\bChart\b
Worldwide\fDi\bgnostic\fSystem\f(WDS)
Mechanica\bE\bectrica\b

P\brking\fbr\bke\fswitch\f\f

Clutch\fped\bl\fswitch\f\f

C\bliper\f\f

Br\bke\fdisc\f\f

Br\bke\fp\bd\f
P\brking\fbr\bke\fswitch\f\f

Clutch\fped\bl\fswitch\f\f

Fuse(s)\f\f

Electric\bl\fconnector(s)\f\f

Circuit(s)\f
\fymptomPossib\be \fourcesAction
Poor\fdrive\f\bw\by\frele\bseReversing\fl\bmp\f
switch\fstuck\fon.\f
*Check\fthe\foper\btion\fof\fthe\freversing\f
l\bmps.\f\f
REFER\fto:\f Reversing\fL\bmps\f(417-01\f
Ext

erior\fLighting,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Clutch\fch\bnged\f
\bnd\fnot\fre-le\brned.\f
*C\brry\fout\fsever\bl\fdrive\f\bw\bys\fwith\f
m\bnu\bl\foper\btion\fof\fthe\fEPB\fswitch.\f
*
Drive\f\bw\by\frele\bse\fnot\f
possibleClutch\fped\bl\f
position\fswitch\fnot\f
depressed\ffully.\f
*Check\fthe\fcorrect\fclutch\fped\bl\f
position\fswitch\fis\ffitted.\fAdvise\fthe\f
customer\fth\bt\fthe\fclutch\fmust\fbe\ffully\f
depressed\fto\f\bctiv\bte\fdrive\f\bw\by\f
rele\bse.\f
*
Acceler\btor\fped\bl\f
not\fdepressed\f
sufficiently.\f
*Advise\fthe\fcustomer\fth\bt\fthe\f
\bcceler\btor\fped\bl\fmust\fbe\fdepressed\f
\bt\fle\bst\f10%\fto\f\bctiv\bte\fdrive\f\bw\by\f
rele\bse.\f
*
Drive\f\bw\by\frele\bse\f
option\fconfigured\f
out.\f
*Connect\fWDS\f\bnd\fcheck\fthe\f
configur\btion.\f\f
REFER\fto:\f Module\fConfigur\btion \f(418-
01 \f

Module\fConfigur\btion,\fGener\bl\f
Procedures).\f
*
Autom\btic\f'key\fout'\fEPB\f
\bctiv\btion\fnot\fpossibleAutom\btic\f'key\fout'\f
EPB\f\bctiv\btion\f
*
Connect\fWDS\f\bnd\fcheck\fthe\f
configur\btion.\f\f
*
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