2007 FORD FIESTA Workshop Manual

206-00-5 Brake System - General Information 206-00-5
DIAGNOSIS AND TESTING
Symptom Possible Sources
Action
Grease or fluid on the brake
shoes or brake pads; glazed
linings. INSTALL
new brake shoes or
brake pads. REFER to:
Brake Shoes (206-02 Drum Brake, Removal and Installa-
tion),
Brake Pads (206-03 Front Disc
Brake, Removal and Installa-
tion),
Brake Pads (206-04 Rear Disc Brake, Removal and Installa-
tion).
I Stuck or seized calipers. I GO to Pinpoint Test A. I
Brake warning indicator always
on Low
brake fluid level. FILL the reservoir. CHECK the
brake and clutch system for
leaks including brake fluid in
the brake booster.
--
Leaking brake master cylinder
primary piston cup. INSTALL a new brake master
cylinder. REFER to: (206-06
Hydraulic Brake Actuation)
Brake Master Cylinder
- RHD
(Removal and Installation),
Brake Master Cylinder
- LHD
(Removal and Installation).
Parking brake control not fully
released. FREE UP and
ADJUST the
parking brake cable. REFER
to: (206-05 Parking Brake and
Actuation)
Parking Brake (Diagnosis and Testing),
Parking Brake Cable Adjust-
ment
- Vehicles With: Rear
Drum Brakes (General
Procedures),
Parking Brake Cable Adjust-
ment
- Vehicles With: Rear
Disc Brakes (General
Procedures).
INSTALL new components as
necessary.
I Shorted indicator circuit. I GO to Pinpoint Test B. I
2006.0 Fiesta 12/2006 G28494en
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206-00-6 Brake System - General Information 206-00-6
DIAGNOSIS AND TESTING
Symptom
Vibration when the brakes are
applied Possible
Sources Action
Grease or fluid on the brake
shoes or brake pads; glazed
linings. INSTALL
new brake shoes or
brake pads. REFER to:
i
Brake Shoes (206-02 Drum
Brake, Removal and Installa-
tion),
Brake Pads (206-03 Front Disc
Brake, Removal and Installa-
tion),
Brake Pads (206-04 Rear Disc Brake, Removal and Installa-
tion).
Worn or damaged brake shoes
or brake pads. INSTALL
new brake shoes or
brake pads. REFER to:
Brake Shoes (206-02 Drum
Brake, Removal and Installa-
tion),
Brake Pads (206-03 Front Disc
Brake, Removal and Installa-
tion),
Brake Pads (206-04 Rear Disc
Brake, Removal and Installa-
tion).
Loose caliper mounting
bolt(s). TIGHTEN the caliper mounting
bolt(s). REFER to:
Specifications (206-03 Front Disc Brake, Specifications),
Specifications (206-04 Rear Disc Brake, Specifications).
Insufficient grease on sliding grease
where neces-
parts.
Damaged brake drum contact
surface. REFER to: Brake Drum (206-
02 Drum Brake, Removal and
Installation).
Loose or missing rear wheel
spindle bolts. TIGHTEN or
INSTALL new rear
wheel spindle bolts.
REFER to: Specifications (204-
02 Rear Suspension, Specifications).
Go to Pinpoint Test
C.
2006.0 Fiesta 1212006 G28494en
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206-00-7 Brake System - General Information 206-00-7
DIAGNOSIS AND TESTING
1 Pedal goes down fast
Possible Sources Action
Leak in the hydraulic system. REPAIR the leak. CHECK the
entire hydraulic system. FILL
and BLEED the brake system.
REFER to: (206-00 Brake
System
- General Information)
Brake System Bleeding
(General Procedures),
Brake System Pressure
Bleeding (General Proced-
ures).
Air in the system.
CHECK for leaks. BLEED the
brake system. REFER to: (206-
00 Brake System
- General
Information)
Brake System Bleeding
(General Procedures),
Brake System Pressure
Bleeding (General Proced-
u res).
Worn brake master cylinder piston cups or scored cylinder
bore. INSTALL
a new brake master
cylinder. REFER to: (206-06
Hydraulic Brake Actuation)
Brake Master Cylinder
- RHD
(Removal and lnstallation),
Brake Master Cylinder
- LHD
(Removal and lnstallation).
I Brake disc brake 'knock back' I Install a new brake disc. I
I loose wheel bearings.) I I
(Brake pads push the brake
caliper piston back into brake
caliper. Caused by excessive
brake disc lateral
runout or
Worn brake shoes or brake
pads. REFER to:
Brake Disc (206-04
Rear Disc Brake, Removal
and Installation). INSTALL new brake shoes or
brake pads. REFER to:
Brake Shoes (206-02 Drum
Brake, Removal and Installa-
tion),
Brake Pads (206-03 Front Disc
Brake, Removal and Installa-
tion),
Brake Pads (206-04 Rear Disc Brake, Removal and Installa-
tion).
GO to Pinpoint Test D.
2006.0 Fiesta 1212006 G28494en
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206-00-8 Brake System - General Information 206-00-8
DIAGNOSIS AND TESTING
Svm~tom Possible Sources Action
Pedal eases down slowly Air in the system.
Malfunctioning brake master
cylinder.
BLEED the brake system.
REFER to: (206-00 Brake
System
- General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Proced-
ures).
GO to Pinpoint Test E.
Brake, Removal and Installa-
tion),
Brake Pads (206-03 Front Disc
Brake, Removal and Installa-
tion),
Brake Pads (206-04 Rear Disc
Brake, Removal and Installa-
Pedal is low or feels spongy
I tion). I
Brake lockup during light brake I
Worn brake shoes or brake
pads.
pedal force INSTALL new brake shoes or
brake pads. REFER to:
Hydraulic system.
Incorrect tire pressures.
Tires worn.
Glazed or worn brake shoes or
brake pads.
Brake booster.
GO to Pinpoint Test F. I
INFLATE the tires to the correct
pressure.
INSTALL new tires. I
brake pads. REFER to:
Brake Shoes (206-02 Drum
Brake, Removal and Installa-
tion),
Brake Pads (206-03 Front Disc Brake, Removal and Installa-
tion),
Brake Pads (206-04 Rear Disc
Brake, Removal and Installa-
tion).
GO to Pinpoint Test G.
Excessive or erratic pedal
travel Worn brake shoes or brake
pads. INSTALL new brake shoes or
brake pads. REFER to:
Brake Shoes (206-02 Drum Brake, Removal and Installa-
tion),
Brake Pads (206-03 Front Disc Brake, Removal and Installa-
tion),
I
Brake Pads (206-04 Rear Disc
Brake, Removal and Installa-
tion).
2006.0 Fiesta 1212006 G28494en
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206-00-9 Brake System - General Information 206-00-9
DIAGNOSIS AND TESTING
Symptom
Brakedrag
Excessive brake pedal effort
Brake noise
I
i
i
Slow or incomplete brake pedal
return Possible Sources
Action
Brake discs.
Brake booster.
Incorrectly adjusted brake light
switch. Brake pressure control valve.
Seized brake caliper or wheel
cylinder. Parking brake applied or
malfunction.
Seized parking brake cables.
Seized brake caliper slide pins.
Brake booster inoperative.
Worn or contaminated brake
shoes or brake pads.
Worn brake shoes or brake
pads.
Brake booster.
Brake booster.
Brake master cylinder.
GO to Pinpoint Test H.
GO to Pinpoint Test I.
ADJUST the brake light switch.
PERFORM a brake booster
functional test REFER to the
component tests.
INSTALL new brake shoes or
brake pads. REFER to:
Brake Shoes (206-02 Drum Brake, Removal and Installa-
tion),
Brake Pads (206-03 Front Disc
Brake, Removal and Installa-
tion),
Brake Pads (206-04 Rear Disc Brake, Removal and Installa-
tion).
GO to Pinpoint Test J.
INSTALL new brake shoes or
brake pads. REFER to:
Brake Shoes (206-02 Drum Brake, Removal and Installa-
tion),
Brake Pads (206-03 Front Disc
Brake, Removal and Installa-
tion),
Brake Pads (206-04 Rear Disc
Brake, Removal and Installa-
tion).
GO to Pinpoint Test K.
GO to Pinpoint Test L.
2006.0 Fiesta 1212006 G28494en
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206-00-1 0 Brake System - General Information 206-00-1 0
DIAGNOSIS AND TESTING
Pinpoint Tests
PINPOINT TEST A : BRAKES PULL OR DRIFT
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS
A1 : ROAD TEST THE VEHICLE
Road test the vehicle and apply the brake pedal.
Does the vehicle pull or drift?
+ Yes
GO to A2.
+ No
Vehicle OK.
A2: TIRE INSPECTION
Check for excessive wear or incorrect tire pres-
sures.
Are the tires in good condition?
-, Yes
GO to A3.
+ No
INFLATE the tires to the correct pressure.
INSTALL new tires if excessively worn. TEST
the system for normal operation.
A3: BRAKE SHOE OR BRAKE PADS AND LINING INSPECTION
Inspect the brake shoes or brake pads for
grease or fluid on the linings and or wear
concerns.
Are any concerns present?
+ Yes
INSTALL new brake shoes or brake pads.
REFER to:
Brake Shoes (206-02 Drum Brake, Removal and
Installation),
Brake Pads (206-03 Front Disc Brake, Removal
and Installation),
Brake Pads (206-04 Rear Disc Brake, Removal
and Installation).
TEST the system for normal operation.
+ No
GO to A4.
2006.0 Fiesta 1212006 G28494en
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206-00-1 1 Brake System - General Information 206-00-1 1
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESULTSIACTIONS
1 A4: CHECK PRESSURE CONTROL VALVE-RIGHT-HAND REAR --
Install pressure gauges in the left-hand front
and right-hand rear bleed nipples. Apply the
brake to read 6895
kPa (1000 psi) at the left-
hand front wheel.
- Read the pressure at right-hand rear wheel.
Does the pressure gauge read between 4692-
5164
kPa (680-750 psi) at the right-hand rear
wheel?
-+ Yes
INSPECT the brake calipers and INSTALL
new components as required. GO to A5.
-+ No
INSTALL a new right-hand rear brake pres-
sure control valve. BLEED the brake system.
REFER to: (206-00 Brake System
- General
Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures). TEST the system for normal operation.
2006.0 Fiesta 1212006 G28494en
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206=00-I 2 Brake System - General Information 206-00-1 2
DIAGNOSIS AND TESTING
TEST CONDITIONS
I A5: CHECK PRESSURE CONTROL VALVE-LEI T-HAND REAR I
Install pressure gauges in the right-hand front
and left-hand rear bleed nipples. Apply the brake
to read 6895
kPa (1000 psi) at the right-hand
front wheel.
- Read the pressure at left-hand rear wheel.
Does the pressure gauge read between 4692-
5164
kPa (680-750 psi) at the left-hand rear
wheel?
+ Yes
INSPECT the brake calipers and INSTALL
new components as required. REFER to:
Brake Shoes (206-02 Drum Brake, Removal and Installation),
Brake Pads (206-03 Front Disc Brake, Removal
and Installation),
Brake Pads (206-04 Rear Disc Brake, Removal
and Installation).
TEST the system for normal operation.
+ No
INSTALL a new left-hand rear brake pressure
control valve. BLEED the brake system.
REFER to: (206-00 Brake System
- General
Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Procedures).
TEST the system for normal operation.
PINPOINT TEST B
: BRAKE WARNING INDICATOR ALWAYS ON
TEST CONDITIONS
DETAILS/RESULTS/ACTIONS
I B1: CHECK BRAKE WARNING INDICATOR I
N0TE:The brake warning indicator should only illuminate when the ignition switch is in the START or
RUN position and the parking brake is applied.
I Ignition switch in position II.
Release the parking brake.
- Check the fluid level in the reservoir is at the
MAX mark.
Does the brake warning indicator illuminate?
+ Yes
REFER to: lnstrument Cluster
- Vehicles Built
Up To: 1 012005 (41 3-01 lnstrument Cluster,
Diagnosis and Testing).
2006.0 Fiesta 12/2006 G28494en
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