2003 FORD MUSTANG ABS

8. Disconnect the shock absorber at the suspension lower arm and bushing. Discard the nut and
the bolt.
9. Remove and discard the cotter pin and the nut.
10. Using the special tool, disconnect the tie- rod link at the knuckle. 11. Disconnect the suspension upper arm and bushing at the knuckle. Discard the nut and the bolt. Klj . 3 ba
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7. Connect the suspension upper arm and bushing to the knuckle.
1. Position the suspension upper arm and bushing on the knuckle.
2. Install the new bolt and a new nut. Do not tighten the nut at this time.
8. Connect the tie- rod end to the knuckle.
1. Position the tie- rod link in the knuckle.
2. Install a new nut.
3. Install a new cotter pin.
9. Raise the suspension until the shock absorber is compressed to the previously established alignment mark (curb height). Klj . 7 ba
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10. Connect the shock absorber to the suspension lower arm and bushing and install the new bolt
and a new nut.
11. Tighten the nut.
12. Lower the suspension and remove the jack stand.
13. Apply Anti- Seize Lubricant to the rear brake anti- lock sensor where it contacts the axle housing
and install the anti- lock sensor.
z Use High Temperature Nickel Anti- Seize Lubricant F6AZ-9L494-AA or equivalent
meeting Ford specification ESE-M124A- A.
14. Install the rear brake disc. For additional information, refer to Section 206 - 04 .
15. Tighten the retainer. Klj . 8 ba
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DESCRIPTION AND OPERATION
Brake System
Component Locations
SECTION 206-
00: Brake System — General Information 2003 Mustang Workshop Manual Item Part
Number Description
1 2C346 Four wheel anti-
lock brake system (4WABS) Klj . 1 ba
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The vehicle is equipped with a vacuum-
assisted or a hydro-boost power braking system. Refer to
Section 206 - 07 .
The braking system is a front- to-rear split hydraulic system. Refer to Section 206 - 06 .
The front wheel brakes utilize a dual piston brake caliper and disc brake system. Refer to Section 206 -
03 .
The rear brakes utilize a single piston brake caliper and disc brake system. Refer to Section 206 - 04 .
The parking brake system is a mechanical system that is controlled by an independent hand- operated
parking brake control and is self- adjusting. Refer to Section 206 - 05 .
A 4- wheel anti- lock brake system or anti-lock brake system with traction control (4WABS) is optional
equipment on all models except Cobra. Cobra has ABS and traction control as standard equipment.
Refer to Section 206 - 09A . hydraulic control unit and control module assy (non-
traction)
1 2C353 Four wheel anti-
lock brake system (4WABS)
hydraulic control unit and control module assy
(traction) 2 2B559 Hydro-Boost brake booster and brake master
cylinder assy 3 2B195 Vacuum brake booster and brake master cylinder
assy
4 2K327 Rear disc brake assy
5 2780 Parking brake control
6 2B119 Front disc brake assy Klj . 2 ba
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DIAGNOSIS AND TESTING
Brake System
Refer to Wiring Diagrams Cell
60 , Instrument Cluster for schematic and connector information.
Refer to Wiring Diagrams Cell 97 , Daytime Running Lamps for schematic and connector information.
Inspection and Verification 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: 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 spill brake fluid onto painted surfaces. If spilled, wipe up immediately.
NOTE: Always check the fluid level in the brake master cylinder reservoir (2K478) before performing
the test procedures. If the fluid level is not at the correct level, add High Performance DOT 3 Brake
Fluid C6AZ- 19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA- M6C25-A.
NOTE: Prior to performing any diagnosis, make sure the brake warning indicator is functional. For
additional information, refer to Section 413 - 01 .
The first indication that something may be wrong in the brake system is a change in the feeling through
the brake pedal (2455). The brake warning indicator in the instrument cluster and the brake fluid level SECTION 206-
00: Brake System — General Information 2003 Mustang Workshop Manual Special Tool(s)
73 Digital Multimeter
105-
R0051 or Equivalent ABS Brake and Pressure Test
Kit
107-
02350 or Equivalent Tire and Wheel Runout Gauge
Set
134-
00199 or Equivalent Klj . 1 ba
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not machine a new brake disc.
7. For vehicles with a two- piece hub and brake disc assembly:
z Match-mark before disassembly.
z Remove the brake disc.
z Using a die grinder with a mild abrasive (Scotch Brite® type), remove any rust or
corrosion from the hub and brake disc mounting surfaces.
z Align the match- marks and reinstall the brake disc on the hub.
8. CAUTION: Do not use a bench lathe to machine brake discs.
NOTE: The depth of cut must be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter
cuts will cause heat and wear. Heavier cuts will cause poor brake disc surface finish.
Using on- vehicle brake lathe, machine the brake discs. Follow the manufacturer's instructions.
After machining, make sure the brake disc still meets the thickness specification.
9. Using a dial indicator, verify that the brake disc lateral runout is now within vehicle specification.
10. Remove any metal chips.
11. Remove the hub adapter.
12. Remove any remaining metal chips from the machining operation.
13. CAUTION: Do not carry out this step on rear drum- in-hat brake discs.
For vehicles with a two- piece hub and a non drum- in-hat brake disc assembly:
z Remove the brake disc from the hub.
z Remove any remaining metal chips from hub and brake disc mounting surfaces and from
the ABS sensor.
z Apply High Temperature Nickel Anti- Seize Lubricant F6AZ-9L494-AA to the mounting
surfaces.
z Using the match- marks, mount the brake disc on the hub.
14. Install the caliper and check brake operation.
Symptom Chart Symptom Chart
Condition
Possible Sources Action
z The Brakes Pull or
Drift z
Tire air pressure.
z Wheel alignment.
z Brake pads.
z Brake components.
z Suspension
component. z
Go To Pinpoint Test A .
z The Red Brake
Warning Indicator Is z
Instrument cluster.
z Circuit. z
Go To Pinpoint Test B . Klj . 4 ba
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Pinpoint Tests
PINPOINT TEST A: THE BRAKES PULL OR DRIFT booster hose as
necessary.
z Red Brake Warning
Indicator Inoperative z
Circuit.
z Bulb. z
REFER to Section 413 -
01 .
z Brake Noise zDisc brake
component. z
MACHINE or INSTALL a
new brake component as
necessary. REFER to
Section 206 - 03 or
Section 206 - 04 .
z Hydro-Boost, No
Power Assist z
Power steering
pump.
z Linkage.
z Power steering
fluid flow.
z Hydro-boost unit. z
Go To Pinpoint Test E .
z Hydro-Boost Erratic
Operation, Sticks,
Binds or Grabs z
Supply hose.
z Hydro-boost unit. z
Go To Pinpoint Test F .
z Hydro-Boost Brake
System Operation
Suspect z
Leakage.
z Hydro-boost unit. z
Go To Pinpoint Test G .
Test Step Result / Action to Take
A1 CHECK THE TIRES
NOTE:
Check tire pressure with the brakes off.
z Check tires for uneven and excessive wear and for correct
pressure.
z Are the tires OK? Yes
GO to
A2 .
No
CORRECT as necessary.
RETEST for normal
operation. A2 CHECK THE ALIGNMENT
z
Check the caster, camber and toe. Refer to Section 204 -
00 . Yes
GO to
A3 .
No
CORRECT alignment as
necessary. REFER to Section 204 - 00 . RETEST for correct
operation. Klj . 6 ba
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