2003 FORD MUSTANG brake

DESCRIPTION AND OPERATION
Hydraulic Brake Actuation
CAUTION: Blistering or swelling of rubber brake components may indicate contamination
of the brake fluid by a petroleum based substance. New rubber components must be installed
in the hydraulic brake system if contaminated and the entire hydraulic brake system must be
flushed with clean brake fluid to prevent recontamination.
This vehicle is equipped with a brake pedal actuated dual brake system. The system consists of the
following:
zpower brake booster (2005)
z brake master cylinder (2140)
z brake pressure control valve (2B091)
z disc brake calipers (2B120)
z rear disc brake calipers (2553)
z brake tubes and hoses
z anti- lock brake system (ABS) components
SECTION 206-
06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual Item Part Number Description
1 2K478 Master cylinder reservoir
2 2140 Master cylinder
3 — Pedal support bracket (part of 2455)
4 2455 Brake pedal Klj . 1 ba
32003 Mustang Workshop Manual
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The dual brake system is split front and rear with the front wheel brakes comprising of one circuit and
the rear wheel brakes, the other circuit.
Brake Fluid
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with
eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running
water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water
and induce vomiting. Get medical attention immediately.
Clean, fresh Ford High Performance DOT 3 Brake Fluid C6AZ-19542- AB or equivalent DOT 3 fluid
meeting Ford specification ESA- M6C25-A is the only brake fluid that should be used in Ford vehicles.
z Do not reuse brake fluid drained or bled from the system.
z Do not use brake fluid that has been stored in an open container.
z Do not mix different types of brake fluid.
Brake Master Cylinder
The brake master cylinder is a dual piston type. The brake master cylinder operates as follows: zWhen the brake pedal (2455) is depressed, pressure is applied by mechanical linkage to the
primary and secondary piston.
z Brake master cylinder pistons apply hydraulic pressure to the two hydraulic circuits.
z Brake master cylinder will not be overhauled, a new master cylinder is installed only.
The brake master cylinder consists of:
zbrake master cylinder reservoir (2K478)
z brake master cylinder body
Brake Master Cylinder Reservoir
NOTE: Whenever the brake master cylinder reservoir is removed from the brake master cylinder, new
grommets must be installed.
The brake master cylinder reservoir :
zis mounted to the brake master cylinder.
z holds fluid supply for each brake master cylinder hydraulic piston.
z provides visual fluid level markings.
z contains the brake master cylinder fluid level sensor. Klj . 2 ba
32003 Mustang Workshop Manual
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Brake Pressure Control Valve
The brake pressure control valve proportions the pressure to the rear brakes.
zWhen the brake pedal is applied, brake fluid pressure passes through the proportioning valves
to the rear brake system until the valve split point is reached.
z Above its split point, the proportioning valve begins to reduce the hydraulic pressure to the rear
brakes, creating a balanced braking condition between the front and rear brakes.
Brake Tubes and Hoses CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion which
could result in brake tube failure.
Steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly
double flared to provide strong leakproof connections. When bending the tubing to fit the underbody or
rear axle contours, be careful not to kink or crack the tube.
If a section of brake tube is damaged, the entire section must be removed and a new tube of the same
type, size, shape and length installed.
When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After
installation, bleed the brake system. For additional information, refer to Section 206 - 00 . Klj . 3 ba
32003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Pedal and Bracket
Removal
1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414 -
01 .
2. Remove the stoplight switch retaining pin.
3. Slide the stoplight switch (13480) and booster push rod from the brake pedal pin.
4. Remove the brake pedal bracket retaining bolt.
5. Remove the brake pedal bracket retaining nuts.
SECTION 206-
06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
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6. Remove the brake pedal and bracket.
Installation 1. To install, reverse the removal procedure. Klj . 2 ba
32003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Master Cylinder
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).
Installation
1. To install, reverse the removal procedure. zBleed the brake system. For additional information, refer to Section 206 - 00 .
SECTION 206-
06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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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-
06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Installation
1. To install, reverse the removal procedure. zBleed the brake system. For additional information, refer to Section 206 - 00 . Klj . 2 ba
32003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...