Initial Inspection and Diagnostic Overview
Special Tool(s)
Inspection and Verification
WARNING: Use of any other than the approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative.
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 spill brake fluid onto painted surfaces. If spilled, wipe up immediately.
NOTE: Always check the fluid level in the brake master cylinder reservoir before performing the test procedures. If the fluid level is not at the correct level, add High Performance DOT 3 Brake Fluid PM-1 or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.
NOTE: Prior to performing any diagnosis, make sure the brake warning indicator is functional.
The first indication that something may be wrong in the brake system is a change in the feeling through the brake pedal. The brake warning indicator in the instrument cluster and the brake fluid level in the brake master cylinder reservoir are also indicators of system concerns.
If a wheel is locked and the vehicle must be moved, open a bleeder screw at the locked wheel to let out enough fluid to relieve the pressure. Close the bleeder screw. This bleeding operation may release the brakes but will not correct the cause of trouble. If this does not relieve the locked wheel condition, repair the locked components before proceeding.
Inspect all hoses and connections. All unused vacuum connectors should be capped. Make sure hoses and their connections are correctly secured and in good condition with no holes, soft or collapsed areas.
Non-Pressure Leaks
The only part of the brake system that could have a brake fluid loss that does not appear when the system is under pressure is the brake master cylinder reservoir area. Brake fluid loss can be caused by a missing or poorly-fitted brake master cylinder filler cap, a punctured or otherwise damaged brake master cylinder reservoir, a missing or damaged brake master cylinder filler cap gasket, or by missing, damaged or poorly-fitted sealing grommets between the brake master cylinder and the brake master cylinder reservoir
The brake master cylinder reservoir grommets are not separately serviceable and must be installed new as part of a new brake master cylinder reservoir.
NOTE: The wet appearance on the outer cover of rubber brake hoses is called "sweating." This is a normal condition for neoprene rayon braid hose. The sweating condition is not evidence of a brake fluid leak and will not result in a loss of pressure in the system.
Install a new flexible brake hose if it shows signs of softening, cracking or other damage.
When installing a new brake hose, position the hose to avoid contact with other vehicle components.
Road Test
Avoid locking the brakes. Locked brakes are not an indication of braking efficiency.
Visual Inspection Chart
For low or spongy brake pedal concerns:
^ check and, if necessary, refill the brake master cylinder reservoir.
^ bleed the brake system and retest the brake pedal feel.
^ if the brake pedal is still low or spongy, check the wheel bearings.
For a slow or incomplete brake pedal return concern:
^ inspect for binding, damage, correct installation or interference at the brake pedal.
^ check the power brake booster for binding, damage and correct installation.
For vibration concerns when brakes are applied:
^ refer to Noise, Vibration and Harshness Diagnosis.
Adjustable Pedals With Memory Feature (Navigator only)
1. Verify the customer concern by operating the adjustable pedals.
NOTE: If the adjustable pedals are not installed on the vehicle, when a self-test is carried out, the module will set pedal codes.
2. Visually inspect for obvious signs of mechanical or electrical damage.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the scan tool does not power up, refer to the scan tool manual.
5. Carry out the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with:
^ CKT914, CKT915 or CKT70-ALL ECUS NO RESP/NO 1 EQUIP. Refer to Module Communications Network.
^ NO RESP/NOT EQUIP for Driver Seat Module (DSM), GO to Pinpoint Test A. Test A
^ System passed, retrieve and record the continuous DTCs and carry out self-test diagnostics for the DSM.
6. If the DTCs retrieved are related to the concern, go to the DSM Diagnostic Trouble Code (DTC) Index. Diagnostic Trouble Code Tests and Associated Procedures
7. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnostics. Symptom Related Diagnostic Procedures