2003 FORD MUSTANG brake fluid

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
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
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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-
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REMOVAL AND INSTALLATION
Reservoir
Removal
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.
1. Disconnect the brake master cylinder fluid level switch.
2. Use a suitable suction device to drain the brake master cylinder reservoir (2K478).
3. Carefully pry up on the brake master cylinder reservoir and remove.
Installation 1. NOTE: Whenever installing a new brake master cylinder reservoir, install new grommets.
Install the brake master cylinder reservoir. 1. Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542- AB
or equivalent fluid meeting Ford specification ESA- M6C25-A and insert the grommets
into the brake master cylinder (2140).
2. Press the brake master cylinder reservoir into the grommets until it is fully seated.
3. Connect the brake master cylinder fluid level switch.
4. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ- 19542- AB or equivalent fluid meeting Ford specification ESA- M6C25-A.
5. Bleed the brake master cylinder. For additional information, refer to Section 206 - 00 .
SECTION 206-
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22003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Control Valve
Removal
1. Disconnect the brake tubes.
2. Remove the brake fluid control valve bracket nut.
Installation 1. To install, reverse the removal procedure.
SECTION 206-
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22003 Mustang Workshop Manual
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DESCRIPTION AND OPERATION
Brake Booster —
Hydro-Boost
The Hydro- Boost brake booster is a hydraulically operated brake booster powered by the power
steering pump (3A674). The power steering pump provides the fluid pressure to operate both the
power brake booster and the power steering gear (3504).
A Hydro- Boost reserve system (accumulator) stores sufficient fluid under pressure to provide at least
two power- assisted brake applications in the event the power steering pump fluid flow is interrupted.
For low assist concerns on vehicles equipped with the Hydro- Boost system, refer to Section 211 - 00 to
check the power steering pump pressure and flow.
The brakes can also be applied manually if the reserve system is depleted.
Any leakage goes directly back to the power steering pump reservoir (3E764). SECTION 206-
07: Power Brake Actuation 2003 Mustang Workshop Manual Item Part Number Description
1 2140 Master cylinder
2 2B559 Hydro-Boost Klj . 1 ba
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GENERAL PROCEDURES
Hydro-
Boost Bleeding
1. NOTE: The Hydro- Boost power brake booster (2B560) is generally self- bleeding, and the
following procedure will normally bleed the air from the power brake booster. Normal operation
of the vehicle will further remove any additional trapped air.
Fill the power steering oil reservoir (3A697) with MERCON® Multi- Purpose ATF XT-2-QDX or
MERCON® equivalent.
2. Remove the powertrain control module (PCM) fuse to prevent the engine from starting.
3. Crank the engine for several seconds.
4. Check the fluid level in the power steering oil reservoir and add if necessary. Install the powertrain control module (PCM) fuse.
5. Start the engine.
6. With the engine running, turn the steering wheel (3600) from stop- to-stop twice. Turn the engine
off.
7. Depress the brake pedal (2455) several times to discharge the accumulator.
8. Repeat Steps 5 and 6.
9. If foaming occurs, stop the engine and allow the foam to dissipate.
10. Repeat Steps 5 and 6 as required, until all the air is removed from the system (when the foaming stops).
SECTION 206-
07: Power Brake Actuation 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Brake Booster —
Hydro-Boost
Removal WARNING: The power brake booster should not be carried by the accumulator, nor
should it ever be dropped on the accumulator. Check the snap ring on the accumulator for
correct seating before the power brake booster is used. The accumulator contains high-
pressure nitrogen gas and can be dangerous if mishandled.
WARNING: If the accumulator is to be disposed of, it must not be exposed to excessive
heat. Before discarding the accumulator, drill a 1.6- mm (1/16-inch) diameter hole in the end of
the accumulator can to relieve the gas pressure. Always wear safety glasses when performing
this operation.
1. With the engine off, depress the brake pedal (2455) several times to discharge the accumulator.
2. Disconnect the battery ground cable (14301). For additional information, refer to Section 414 -
01 .
3. Disconnect the fluid level sensor connector.
4. Disconnect the brake tubes.
SECTION 206-
07: Power Brake Actuation 2003 Mustang Workshop Manual Special Tool(s)
Installer Set, Teflon Seal
211-
D027 (D90P-3517- A) or
equivalent Klj . 1 ba
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