2006 FORD S-MAX brake

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Page 240 of 4402

$FORD S-MAX 2006 Service Repair Manual Component Tests Brake Booster 1. 1. Inspect\f\bll\fhoses\f\bnd\fconnections.\fAll\funused\fv\bcuum\fconnectors\fshould\fbe\f c \bpped.\fHoses\f\bnd\ftheir\fconnections\fshould\fbe\fcorrectly\fsecur$

Component Tests
Brake Booster 1. 1.
Inspect\f\bll\fhoses\f\bnd\fconnections.\fAll\funused\fv\bcuum\fconnectors\fshould\fbe\f
c
\bpped.\fHoses\f\bnd\ftheir\fconnections\fshould\fbe\fcorrectly\fsecured\f\bnd\fin\fgood\f
condition\fwith\fno\fholes\f\bnd\fno\fcoll\bpsed\f\bre\bs.\fInspect\fthe\fbr\bke\fbooster\fcheck\f
v\blve\ffor\fd\bm\bge.\f
2. 2.
Check\fthe\fhydr\bulic\fbr\bke\fsystem\ffor\fle\bks\for\flow\ffluid.\f
3

. 3.
With\fthe\ftr\bnsmission\fin\fPARK\f(\butom\btic\ftr\bnsmission),\fstop\fthe\fengine\f\bnd\f
o
per\bte\fthe\fp\brking\fbr\bke.\fOper\bte\fthe\fbr\bke\fped\bl\fsever\bl\ftimes\fto\fexh\bust\f\bll\f
v\bcuum\fin\fthe\fsystem.\f
4. 4.
With\fthe\fengine\fturned\fOFF\f\bnd\f\bll\fv\bcuum\fin\fthe\fsystem\fexh\busted\foper\bte\fthe\f
b
r\bke\fped\bl\f\bnd\fhold\fit\fdown.\fSt\brt\fthe\fengine.\fIf\fthe\fv\bcuum\fsystem\fis\foper\bting,\f
the\fbr\bke\fped\bl\fwill\ftend\fto\fmove\fdownw\brd\funder\fconst\bnt\ffoot\fpressure.\fIf\fno\f
motion\fis\ffelt,\fthe\fv\bcuum\fbooster\fsystem\fis\fnot\ffunctioning.\f
5. 5.
Remove\fthe\fv\bcuum\fhose\ffrom\fthe\fbr\bke\fbooster.\fM\bnifold\fv\bcuum\fshould\fbe\f
\b
v\bil\bble\f\bt\fthe\fbr\bke\fbooster\fend\fof\fthe\fhose\fwith\fthe\fengine\f\bt\fidle\fspeed\f\bnd\fthe\f
tr\bnsmission\fin\fPARK\for\fNEUTRAL.\fM\bke\fsure\fth\bt\f\bll\funused\fv\bcuum\foutlets\f\bre\f
correctly\fc\bpped,\fhose\fconnectors\f\bre\fcorrectly\fsecured\f\bnd\fv\bcuum\fhoses\f\bre\fin\f
good\fcondition.\fWhen\fit\fis\fest\bblished\fth\bt\fm\bnifold\fv\bcuum\fis\f\bv\bil\bble\fto\fthe\f
br\bke\fbooster,\fconnect\fthe\fv\bcuum\fhose\fto\fthe\fbr\bke\fbooster\f\bnd\frepe\bt\fStep\f3.\fIf\f
no\fdownw\brd\fmovement\fof\fthe\fbr\bke\fped\bl\fis\ffelt,\fthe\fv\bcuum\fbooster\fsystem\fis\f
not\ffunctioning.\f
6. 6.
Run\fthe\fengine\ffor\f\b\fminimum\fof\f10\fseconds\f\bt\ff\bst\fidle.\fStop\fthe\fengine\f\bnd\flet\f
t
he\fvehicle\fst\bnd\ffor\f10\fminutes.\fThen,\foper\bte\fthe\fbr\bke\fped\bl\fwith\f\bpproxim\btely\f
98N\f(20\flb)\fof\fforce.\fThe\fped\bl\ffeel\f(br\bke\f\bpplic\btions)\fshould\fbe\fthe\fs\bme\f\bs\f
noted\fwith\fthe\fengine\frunning.\fIf\fthe\fbr\bke\fped\bl\ffeels\fh\brd\f(no\fpower\f\bssist),\f
inst\bll\f\b\fnew\fcheck\fv\blve\f\bnd\fthen\frepe\bt\fthe\ftesting.\fIf\fthe\fbr\bke\fped\bl\fstill\ffeels\f
h\brd,\finst\bll\f\b\fnew\fbr\bke\fbooster.\fIf\fthe\fbr\bke\fped\bl\fmovement\ffeels\fspongy,\fbleed\f
the\fbr\bke\fsystem.\fRefer\fto\fGener\bl\fProcedures.\f
Brake Master C\blinder
Usu\blly,\fthe\ffirst\f\bnd\fstrongest\findic\btor\fof\f\bnything\fwrong\fin\fthe\fbr\bke\fsystem\fis\f\b\ffeeling\f
t h

rough\fthe\fbr\bke\fped\bl.\fIn\fdi\bgnosing\fthe\fcondition\fof\fthe\fbr\bke\fm\bster\fcylinder,\fcheck\f
M\bke\f\b\fh\brd\fbr\bke\f\bpplic\btion.\f4
Rele\bse\fthe\fbr\bke\fped\bl\f\bnd\fme\bsure\fthe\fdist\bnce\ffrom\fbr\bke\fped\bl\f
rubber\fto\fthe\ffloor.\fThe\fbr\bke\fped\bl\fshould\freturn\fto\fits\forigin\bl\fposition.\f5
Does\fthe\fbr\bke\fped\bl\freturn\fto\fits\forigin\bl\fposition?\f
Yes Vehicle\fis\fOK.\f
No GO\fto\fC2 .\f\f
C2: CHECK FOR BRAKE PEDAL BINDING
Check\fthe\fbr\bke\fped\bl\fto\fm\bke\fsure\fit\fis\foper\bting\ffreely.\f1
Is\fthe\fbr\bke\fped\bl\foper\bting\ffreely?\f
Yes
INSTALL\f\b\fnew\fbr\bke\fbooster.\fREFER\fto\fSection\f \f206-07\fPower\fBr\bke\f
Ac t

u\btion .\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No R

EPAIR\for\fINSTALL\fnew\fbr\bke\fped\bl\f\bnd\fbr\bcket.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
Стр. 5 из 7
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Page 243 of 4402

$FORD S-MAX 2006 Service Repair Manual Brake S\bstem \f General Information \f Brake S\bstem BleedingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f General Procedures General Equipment Bleeding WARNING:\fBr\bke\ffluid\fcont\bins\fpolygly$

Brake S\bstem \f General Information \f
Brake S\bstem BleedingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedures
General Equipment
Bleeding
WARNING:\fBr\bke\ffluid\fcont\bins\fpolyglycol\fethers\f\bnd\fpolyglycols.\fAvoid\fcont\bct\fwith\f
th

e\feyes.\fW\bsh\fh\bnds\fthoroughly\f\bfter\fh\bndling.\fIf\fbr\bke\ffluid\fcont\bcts\fthe\feyes,\fflush\f
the\feyes\ffor\f15\fminutes\fwith\fcold\frunning\fw\bter.\fGet\fmedic\bl\f\bttention\fif\firrit\btion\f
persists.\fIf\ft\bken\fintern\blly,\fdrink\fw\bter\f\bnd\finduce\fvomiting.\fGet\fmedic\bl\f\bttention\f
immedi\btely.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
CAUTION:\fIf\fbr\bke\ffluid\fis\fspilt\fon\fthe\fp\bintwork,\fthe\f\bffected\f\bre\b\fmust\fbe\f
immedi\btely\fw\bshed\fdown\fwith\fcold\fw\bter.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fvehicle\fis\fst\bnding\fon\f\b\flevel\fsurf\bce.\f
NOTE:\fThe\fsystem\fconsists\fof\fsep\br\bte\fcircuits\ffor\fe\bch\ffront\f\bnd\fdi\bgon\blly\fopposite\fre\br\f
wheel.\fE\bch\fcircuit\fc\bn\fbe\fbled\findependently.\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)
1. CAUTION:\fThe\fbr\bke\ffluid\freservoir\fmust\f
re
m\bin\ffull\fwith\fnew,\fcle\bn\fbr\bke\ffluid\f\bt\f\bll\f
times\fduring\fbleeding.\f Inst\bll\fthe\fbleed\ftube\fto\fthe\fbleed\fnipple.\f
2. Immerse\fthe\fend\fof\fthe\fbleed\ftube\fin\f\b\fbleed\fj\br\f cont\bining\f\b\fsm\bll\fqu\bntity\fof\f\bpproved\fbr\bke\f
fluid.\f
3. Position\fthe\fbleed\fj\br\fb\bse\f\bt\fle\bst\f300\fmm\f \bbove\fthe\fbleed\fnipple\fto\fm\bint\bin\ffluid\fpressure\f
\bnd\fprevent\f\bir\fle\bking\fp\bst\fthe\fthre\bds\fof\fthe\f
bleed\fnipple.\f
4. Loosen\fthe\fbleed\fnipple\fby\fone-h\blf\fturn.\f
5. Oper\bte\fthe\fbr\bke\fped\bl\ffully\f(pumping\fbr\bke\f fluid\f\bnd\f\bir\finto\fthe\fbleed\fj\br)\f\bnd\f\bllow\fthe\f
br\bke\fped\bl\fto\freturn\fto\fthe\frest\fposition.\f
6. Fill\fthe\fbr\bke\ffluid\freservoir\fto\fthe\fMAX\fm\brk.\f
7. Continue\foper\bting\fthe\fbr\bke\fped\bl\funtil\f\bir-free\f fluid\fis\fbeing\fpumped\finto\fthe\fbleed\fj\br.\f
8. With\fthe\fbr\bke\fped\bl\ffully\fdepressed\ftighten\fthe\f bleed\fnipple.\f
9. CAUTION:\fM\bke\fsure\fth\bt\fthe\fbleed\f
n i

pple\fc\bp\fis\finst\blled\f\bfter\fbleeding\fthe\f
br\bke\fline(s).\fThis\fwill\fprevent\fcorrosion\fto\f
the\fbleed\fnipple.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fresult\fin\fthe\fbleed\fnipple\f
becoming\fseized.\f Repe\bt\fthe\fprocedure\ffor\fthe\frem\bining\fbr\bke\f
li
nes.\f
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Page 244 of 4402

$FORD S-MAX 2006 Service Repair Manual Brake S\bstem \f General Information \f Brake S\bstem Pressure BleedingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f General Procedures General Equipment Bleeding WARNING:\fBr\bke\ffluid\fcont\bins$

Brake S\bstem \f General Information \f
Brake S\bstem Pressure BleedingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedures
General Equipment
Bleeding
WARNING:\fBr\bke\ffluid\fcont\bins\fpolyglycol\fethers\f\bnd\fpolyglycols.\fAvoid\fcont\bct\fwith\f
th

e\feyes.\fW\bsh\fh\bnds\fthoroughly\f\bfter\fh\bndling.\fIf\fbr\bke\ffluid\fcont\bcts\fthe\feyes,\fflush\f
the\feyes\ffor\f15\fminutes\fwith\fcold\frunning\fw\bter.\fGet\fmedic\bl\f\bttention\fif\firrit\btion\f
persists.\fIf\ft\bken\fintern\blly,\fdrink\fw\bter\f\bnd\finduce\fvomiting.\fGet\fmedic\bl\f\bttention\f
immedi\btely.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
CAUTION:\fIf\fbr\bke\ffluid\fis\fspilt\fon\fthe\fp\bintwork,\fthe\f\bffected\f\bre\b\fmust\fbe\f
immedi\btely\fw\bshed\fdown\fwith\fcold\fw\bter.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\fvehicle\fis\fst\bnding\fon\f\b\flevel\fsurf\bce.\f\f
NOTE:\fThe\fsystem\fconsists\fof\fsep\br\bte\fcircuits\ffor\fe\bch\ffront\f\bnd\fdi\bgon\blly\fopposite\fre\br\f
wheel.\fE\bch\fcircuit\fc\bn\fbe\fbled\findependently.\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)
Br\bke/clutch\fsystem\fpressure\fbleeder/filler
1. Fill\fthe\fbr\bke\ffluid\freservoir\fto\fthe\fMAX\fm\brk.\f
2. CAUTIONS:\f
M\b
ke\fsure\fth\bt\fthe\fpressure\fwithin\fthe\f
br\bke\fsystem\fdoes\fnot\fexceed\f1\fb\br.\f
M\bke\fsure\fth\bt\fthe\fpressure\fbleeding\f
equipment\fis\ffilled\fwith\fnew\fbr\bke\ffluid\fto\f
the\fcorrect\fspecific\btion.\f
Using\fthe\f br
\bke/clutch\fsystem\fpressure\f
ble
eder/filler ,\fpressure\fbleed\fthe\fsystem\fin\f
\bc c

ord\bnce\fwith\fthe\fm\bnuf\bcturer's\finstructions.\f
3. CAUTION:\fM\bke\fsure\fth\bt\fthe\fbleed\f
ni
pple\fc\bp\fis\finst\blled\f\bfter\fbleeding\fthe\f
br\bke\fline(s).\fThis\fwill\fprevent\fcorrosion\fto\f
the\fbleed\fnipple.\fF\bilure\fto\ffollow\fthis\f
instruction\fm\by\fresult\fin\fthe\fbleed\fnipple\f
becoming\fseized.\f Fill\fthe\fbr\bke\ffluid\freservoir\fto\fthe\fMAX\fm\brk\f\bs\f
ne
cess\bry.\f
Стр. 1 из 1
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Page 245 of 4402

$FORD S-MAX 2006 Service Repair Manual Brake S\bstem \f General Information \f Front Brake Disc Runout CheckS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f General Procedures Special Tool(s) 205-069\f Di\bl\fIndic\btor\fG\buge\f(Metric)\f$

Page 247 of 4402

$FORD S-MAX 2006 Service Repair Manual Brake S\bstem \f General Information \f Rear Brake Disc Runout CheckS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f General Procedures Special Tool(s) 205-069\f Di\bl\fIndic\btor\fG\buge\f(Metric)\f 2$

Page 257 of 4402

$FORD S-MAX 2006 Service Repair Manual Rear Di\bc Brake \f Specification\bS-MAX/G\bl\bxy\f2006.5\f(02/2006 Rear Di\bc Brake Specification * When the di\bcard thickne\b\b ha\b been reached, in\btall a new brake di\bc and brake pad\b. For$

Page 258 of 4402

$FORD S-MAX 2006 Service Repair Manual Rear Di\bc Brake \f Rear Di\bc BrakeS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Diagno\bi\b and Te\bting REFER\fto\fSection\f \f2 06-00\fBr\bke\fSystem\f-\fGener\bl\fInform\btion .\f Стр. 1 из$

Page 259 of 4402

$FORD S-MAX 2006 Service Repair Manual Rear Di\bc Brake \f Brake Pad\bS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Removal and In\btallation Special Tool(\b) Mat erial\b Removal N O TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fco$

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