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2. For bench priming, mount the brake master cylinder (2140) in a vise.
3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir
(2K478), and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid
C6AZ- 19542- AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25- A.
4. Have an assistant pump the brake pedal (2455), or slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles.
5. If the brake master cylinder has been primed at the bench, install it in the vehicle. For additional information, refer to Section 206 - 06 .
6. Remove the short brake tubes, and install the brake outlet tubes. Klj . 2 ba
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7. Bleed each brake tube at the brake master cylinder as follows:
1. Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal.
2. Loosen the rear most brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting.
3. Repeat this operation until clear, bubble- free fluid comes out.
4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube.
Master Cylinder Priming — 4.6L
1. CAUTION: Use only bleed screws on the engine side of the brake master cylinder
(2140). The hydro- boost bleed screw, located near the dash on the hydro- booster
casting, is for the booster cavity filled with power steering fluid, not brake fluid.
Connect a clear waste line to the bleed screw closet to the booster first and the other end in a
container partially filled with recommended brake fluid.
2. Open the bleeder screw, have an assistant push the brake pedal down slowly through full travel, close the bleeder screw, then return brake pedal slowly to full released position. Wait five
seconds, then repeat operation until air bubbles cease to appear.
3. Repeat Step 2 for bleeder screw farthest from hydro- booster. Klj . 3 ba
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Four Wheel Anti-
Lock Brake System (4WABS) Hydraulic Control Unit (HCU)
NOTE: This procedure only needs to be performed if the 4- wheel anti-lock brake (4WABS) hydraulic
control unit (HCU) has been installed new or if the HCU lines have been opened.
1. Clean all dirt from and remove the brake master cylinder filler cap (2162), and fill the brake master cylinder reservoir (2K478) with the specified brake fluid.
2. Connect a clear waste line to the RH rear bleeder screw (2208) and the other end in a container partially filled with recommended brake fluid.
3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal (2455), tighten the RH rear bleeder screw.
zRepeat until clear, bubble- free fluid comes out.
z Refill the brake master cylinder reservoir as necessary.
4. Tighten the RH rear bleeder screw, and disconnect the waste line. Klj . 4 ba
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5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper (2B120)
bleeder screw, and the LH front disc brake caliper bleeder screw, in that order.
6. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the scan tool instructions.
7. Repeat the system bleed procedure as outlined in Steps 1 through 5.
Caliper 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper
(2B120) was disconnected.
Place a box end wrench on the disc brake caliper bleeder screw (2208). Attach a rubber drain
tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. Klj . 5 ba
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2. Have an assistant pump the brake pedal (BP) (2455) and then hold firm pressure on the brake
pedal.
3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw.
zRepeat until clear, bubble- free fluid comes out.
z Refill the brake master cylinder reservoir (2K478) as necessary.
4. Tighten the disc brake caliper bleeder screw. Refer to Specifications. Klj . 6 ba
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GENERAL PROCEDURES
Bleeding —
System
Manual
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 installation of new
components, air can get into the system and cause spongy brake pedal action. This requires bleeding
of the hydraulic system after it has been correctly connected. The hydraulic system can be bled
manually or with pressure bleeding equipment.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid.
2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with
clean brake fluid.
SECTION 206-
00: Brake System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the RH rear bleeder screw.
zRepeat until clear, bubble- free fluid comes out.
z Refill the brake master cylinder reservoir as necessary.
5. Tighten the RH rear bleeder screw.
6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw.
7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in
a container partially filled with clean brake fluid.
8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake
caliper bleeder screw.
zRepeat until clear, bubble- free fluid comes out.
z Refill the brake master cylinder reservoir as necessary.
10. Tighten the RH front disc brake caliper bleeder screw. For additional information, refer to Specifications in this section. Klj . 2 ba
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11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw.
Pressure 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid.
2. 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 the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank
hose to the fitting on the adapter.
3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH
rear bleeder screw, and submerge the free end of the tube in a container partially filled with
clean brake fluid. 4. Open the valve on the bleeder tank. Klj . 3 ba
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