2003 FORD MUSTANG brake fluid

REMOVAL AND INSTALLATION
Pads
Removal
1. Use a suitable suction device to lower the brake fluid level in the master cylinder reservoir.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
4. Inspect the pads for wear or contamination, install new if worn to or past specification.
5. CAUTION: Do not allow the rear disc brake caliper (2552) to hang from the rear
wheel brake hose (2A442).
Remove the rear disc brake caliper bolts and position the caliper aside.
6. Remove the brake pads.
SECTION 206-
04: Rear Disc Brake 2003 Mustang Workshop Manual Special Tool(s)
Rear Caliper Piston Adjuster
206-
026 (T87P-2588- A) Klj . 1 ba
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1.
CAUTION: Install the brake pads in full axle sets. Do not install new brake pads on
only one side of vehicle.
Install the new slipper and brake pads.
2. Position the caliper on the anchor plate and install the bolts.
3. Install the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
4. Lower the vehicle.
5. WARNING: Use of any other than approved DOT 3 or DOT 4 brake fluid will cause
permanent damage to 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: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is
spilled onto a painted or plastic surface, immediately wash it with water.
Check the fluid level at the master cylinder. Add fluid if necessary.
6. WARNING: Pump the brake pedal several times to make sure the caliper piston is
extended to its operating position. Failure to follow these instructions may result in
personal injury.
Verify correct brake operation. Klj . 3 ba
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DISASSEMBLY AND ASSEMBLY
Caliper
Disassembly
1. Remove the rear disc brake caliper (2552). For additional information, refer to Caliper in the Removal and Installation portion of this section.
2. Drain the brake fluid from the rear disc brake caliper.
3. Secure the rear disc brake caliper in a vise.
4. Turn the rear disc brake piston and adjuster (2B588) counterclockwise with Rear Caliper Piston Adjuster.
SECTION 206-
04: Rear Disc Brake 2003 Mustang Workshop Manual Special Tool(s)
Rear Caliper Piston Adjuster
206-
026 (T87P-2588- A) Rear Caliper Spring
Compressor Set
206-
S027 (T87P-2588- B) Klj . 1 ba
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NOTE:
Use new brake fluid when assembling and bleeding the brake system.
NOTE: Lightly lubricate the parking brake lever bore, limiting bolt, parking brake lever shaft and
parking brake shaft recess with Silicone Dielectric Compound D7AZ-19A331- A or equivalent
meeting Ford specification ESE- M1C171-A.
Follow the disassembly procedure in reverse order. Klj . 4 ba
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DESCRIPTION AND OPERATION
Parking Brake
The parking brake system is cable-
actuated and controlled by an independent hand- operated parking
brake control (2780). To apply parking brake, pull parking brake control upward as far as possible.
The parking brake system is an AUTO- ADJUST system. The spring in the parking brake control
continuously adjusts the cable tension in the system.
Brake Warning System
A parking brake warning indicator:
zis located in the instrument panel.
z illuminates to signal the driver the parking brake is applied or to signal a low fluid condition.
z remains lit when a brake malfunction has occurred.
SECTION 206-
05: Parking Brake and Actuation 2003 Mustang Workshop Manual Item Part Number Description
1 2780 Parking brake control
2 2552 Rear disc brake caliper Klj . 1 ba
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SPECIFICATIONS
SECTION 206-
06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft Brake master cylinder nuts 25 19
Brake pedal bracket nuts 25 19
Brake pedal bracket bolt 23 17
Brake fluid control valve 19 15
Hydraulic tube connections 17 13
Brake fluid control valve bracket nut 14 11 Klj . 1 ba
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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
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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
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