Brake Bleeding: Service and Repair

Bleeding-Hydraulic System

Special Tool(s)

Brake Master Cylinder-Bench Bleed

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: Brakes contain asbestos fibers. Avoid breathing dust. Breathing asbestos dust may cause asbestosis and cancer.

Breathing asbestos dust is hazardous to your health.

Dust and dirt present on brake assemblies may contain asbestos fibers that are hazardous to health when made airborne by cleaning with compressed air or by dry brushing.

Brake assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum 164-R3600 or equivalent. Dust and dirt from vacuum should be disposed of in such a manner that prevent dust exposure, such as sealed bags. The bag must be labeled as per OSHA instructions and the trash hauler notified as to the bag's contents.

If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators.

WARNING: Grinding or sanding on brake linings, pads, rotors, or drums should be done only while using properly exhaust-ventilated equipment.

OSHA requires areas where asbestos- dust generation is possible to be isolated and posted with warning signs. Only technicians concerned with performing brake service should be present in the area.

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 replacement, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been properly connected.

1. Support the brake master cylinder body in a soft jaw vise, and fill the brake master cylinder reservoir with specified brake fluid.
^ Use Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-I or equivalent meeting Ford specification ESA-M6C25-A, DOT 3.

2. Install plugs in the front and rear brake outlet ports.

3. Loosen the plug in the front outlet port and slowly depress the primary piston.

4. Tighten the plug in the front outlet port and release the primary piston.
5. Repeat this procedure until clear, bubble-free brake fluid flows.
6. Repeat steps 3, 4, and 5 for the rear outlet port with the front outlet port plugged.
7. Tighten the plugs and attempt to depress the primary piston. The piston will not depress if all the air is bled out of the system.
8. Install the reservoir cap and install the brake master cylinder in the vehicle.

Brake Master Cylinder-In-Vehicle Bleed

1. Disconnect the brake outlet lines from the brake master cylinder and cap the lines.
2. Install short brake hoses with ends submerged in the brake master cylinder reservoir.

3. Fill the brake master cylinder reservoir with Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 or equivalent meeting Ford specification ESA-M6C25-A, DOT 3.
4. Have an assistant pump the brake pedal until clear, bubble-free brake fluid flows from both brake hoses.

5. Remove the short brake hoses and install the brake outlet lines.

Pressure Bleed
1. Clean the outside of the brake master cylinder reservoir.

2. Remove the reservoir cap and fill the brake master cylinder reservoir with brake fluid.
^ Use Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 or equivalent meeting Ford specifications ELSA-M6C25-A, DOT 3.

3. 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 Brake Bleeder to the brake master cylinder reservoir, and attach the Brake Bleeder tank hose to the fitting on the adapter.

4. Attach a rubber drain hose to the RH rear bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid.
5. Open the valve on the Brake Bleeder tank.

6. Loosen the bleeder screw. Leave open until clear, bubble-free brake fluid flows, then close the bleeder screw and remove the rubber hose.

7. Tighten the wheel cylinder bleeder screw.
8. Continue bleeding the rest of the system, going in order from the LH rear wheel to the RH front wheel, ending with the LH front wheel.
9. Close the Brake Bleeder tank valve and remove the tank hose from the adapter, and remove the adapter.

10. Fill the brake master cylinder reservoir and install the reservoir cap.
^ Use Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 or equivalent meeting Ford specification ESA-M6C25-A, DOT 3.

Gravity Bleed
1. Fill the brake master cylinder reservoir with Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 or equivalent meeting Ford specification ESA-M6C25-A, DOT 3.

2. NOTE: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry.

If equipped with rear drums, loosen the RH rear wheel cylinder bleeder screw and leave open until clear, bubble-free brake fluid flows.

3. Tighten the wheel cylinder bleeder screw.

4. NOTE: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry.

If equipped with rear disc brakes, loosen the RH rear disc brake caliper bleeder screw and leave open until clear, bubble-free brake fluid flows.

5. Tighten the rear disc brake caliper bleeder screw.

6. NOTE: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry.

Continue bleeding the rest of the system, going in order from the LH rear wheel, to the RH front wheel, ending with the LH front wheel.

7. Fill the brake master cylinder reservoir with fluid and install the reservoir cap.
^ Use Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 or equivalent meeting Ford specification ESA-M6C25-A, DOT 3.

Gravity Bleed-Wheel Cylinder Only

1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry.

Loosen the wheel cylinder bleeder screw and leave open until clear bubble-free brake fluid flows.

2. Tighten the wheel cylinder bleeder screw.
3. Fill the brake master cylinder reservoir with Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 or equivalent meeting Ford specification ESA-M6C25-A, DOT 3.

Gravity Bleed-Front Disc Brake Caliper Only

1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry.

Open the front disc brake caliper bleeder screw. Leave open until clear bubble-free brake fluid flows.

2. Tighten the front disc brake caliper bleeder screw.
3. Fill the brake master cylinder reservoir with Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 or equivalent meeting Ford specification ESA-M6C25-A, DOT 3.

Gravity Bleed-Rear Disc Brake Caliper Only (Mexico Only)

1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry.

Open the rear disc brake caliper bleeder screw. Leave open until clear bubble-free brake fluid flows.

2. Tighten the rear disc brake caliper bleeder screw.
3. Fill the brake master cylinder reservoir with Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 or equivalent meeting Ford specification ESA-M6C25-A, DOT 3.

Manual Bleed

1. If equipped with rear drum brakes, attach a rubber drain hose to the RH rear bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid.
2. Have an assistant pump the brake pedal ten times and then hold firm pressure on the brake pedal.

3. Loosen the RH rear bleeder screw until clear, bubble-free brake fluid flows. Have an assistant maintain pressure on the brake pedal while tightening the bleeder screw.

4. Tighten the wheel cylinder bleeder screw.

5. If equipped with rear disc brakes, attach a rubber drain hose to the RH rear disc brake caliper bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid.
6. Have an assistant pump the brake pedal ten times and then hold firm pressure on the brake pedal.

7. Loosen the RH rear disc brake caliper bleeder screw until clean, bubble-free brake fluid flows. Have an assistant maintain pressure on the brake pedal while tightening the bleeder screw.

8. Tighten the rear disc caliper bleeder screw.
9. Continue bleeding the rest of the system, going in order from the LH rear wheel, to the RH front wheel, ending with the LH front wheel.

1. Attach a rubber drain hose to the wheel cylinder bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid.
2. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal.

3. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry.

Loosen the wheel cylinder bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the wheel cylinder bleeder screw.
^ Repeat until clear, bubble-free fluid flows.

4. Tighten wheel cylinder bleeder screw.

Manual Bleed-Front Disc Brake Caliper Only

1. Attach a rubber drain hose to the front disc brake caliper bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid.
2. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal.

3. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry.

Loosen the front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the front disc brake caliper bleeder screw.
1 Repeat until clear, bubble-free fluid flows.

4. Tighten the front disc brake caliper bleeder screw.

Manual Bleed-Rear Disc Brake Caliper Only (Mexico Only)

1. Attach a rubber drain hose to the rear disc brake caliper bleeder screw and submerge the free end of the hose in a container partially filled with clean brake fluid.
2. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal.

3. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry.

Loosen the rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the rear disc brake caliper bleeder screw.
^ Repeat until clear, bubble-free fluid comes out.

4. Tighten the rear disc brake caliper bleeder screw.

System Bleed-Anti-Lock Brakes Only

1. NOTE: Performing the SYSTEM BLEED FUNCTION on the diagnostic tool drives trapped air from the hydraulic control unit (HCU). Subsequent bleeding removes the air from the brake hydraulic system to the bleeder screws.

NOTE: The engine must be running to provide adequate voltage to the HCU module during the anti-lock control portion of the system bleed.

Connect the diagnostic tool.
2. Start the engine and depress the brake pedal to half of the full travel position.
3. Access FUNCTION TEST mode and press the trigger to run the SYSTEM BLEED FUNCTION.
4. Manually bleed the brake hydraulic system.
5. Repeat the procedure performing a total of two diagnostic tool cycles and two manual bleed cycles; the bleed procedure is complete.