2007 FORD FIESTA lock

205-04-1 4 Front Drive Halfshafts 205-04-1 4
REMOVAL AND INSTALLATION
2. N0TE:lnstall a new intermediate shaft center
bearing cap and locknuts.
Install the intermediate shaft center bearing
cap.
I. Install the center bearing cap.
2. Attach the heatshield to the bearing cap.
3. Install the locknuts.
3. Install the right-hand halfshaft.
For additional information, refer to: Front
Halfshaft RH (205-04 Front Drive Halfshafts,
Removal and Installation).
Vehicles with manual transaxle
4. With the vehicle on the level surface, fill the
transaxle with transmission fluid until the oil
level is just below the bottom of the filler
hole.
Vehicles with automatic transaxle
5. Check the transmission fluid level and top
up with clean automatic transmission oil.
For additional information, refer to:
Transmission Fluid Drain and Refill
(307-01
Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40), General
Procedures).
2006.0 Fiesta 1212006 GI 52541 en
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206-00-2 Brake System - General Information 206-00-2
DESCRIPTION AND OPERATION
Brake System
Overview
A Brake system without Anti-lock
Brake
I I system (ABS)
I B I Brake system with ABS I
I 1 I Brake master cylinder I -
1 2 1 Reservoir I
1 4 1 Brake pedal I
1 5 1 Brake pressure reduction valve I
1 6 1 Rear drum brake I
171t disk brake I
8 ABS hydraulic unit with integrated control
1 1 unit
1 9 I Wheel speed sensors I
Vehicles without ABS are equipped with brake
pressure reduction valves for the rear wheel
brakes. They are located in the corresponding
brake circuits at the brake master cylinder.
Vehicles with ABS do not need brake pressure
reduction valves because they are equipped with
electronic brake distribution (EBD).
The handbrake is cable operated on the rear
brakes.
On vehicles with a petrol engine the necessary
vacuum for the brake booster is generated by the
intake manifold.
On vehicles with a diesel engine, a vacuum pump
driven by the engine provides the necessary
vacuum for the brake booster.
2006.0 Fiesta lu2006 G281357en
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206-00-3 Brake System - General Information 206-00-3
DIAGNOSIS AND TESTING
Brake System
The brakes system operates by transferring effort
applied to the brake pedal by the driver to the
brakes at each wheel.
The braking effort is distributed to each wheel,
using a hydraulic system. The system is assisted
using a vacuum brake booster that reduces pedal
effort and increases hydraulic pressure.
The parking brake operates on the rear wheels
and is applied using a hand operated control.
lnspection and Verification
N0TE:Before carrying out any diagnosis, make
sure that the brake system warning indicator is
functional.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
damage.
3. If an obvious cause for an observed or reported
concern is found, correct the case (if possible)
before proceeding to the next step.
4. If the cause if not visually evident, verify the
symptom and refer to the Symptom Chart.
Visual lnspection Chart
Road Test
1.
Perform a road test to compare actual vehicle
braking performance with the performance
standards expected by the driver. The ability of the
test driver to make valid comparisons and detect
performance deficiencies will depend on
experience.
Mechanical
- Tire pressure
- Wheels and tires
- Fluid leak from brake line(s)
The driver should have a thorough knowledge of
the brake system operation and accepted general
performance guidelines to make good comparisons
, and detect performance concerns.
An experienced technician will always establish a
route that will be used for all brake diagnosis road
tests. The road selected will be reasonably smooth and level. Gravel
or bumpy roads are not suitable
because the surface does not allow the tires to grip
the road equally. Crowned roads should be avoided
because of the large amount of weight shifted to
the low set of wheels on this type of road. Once
the route is established and consistently used, the
road surface variable can be eliminated from the
test results.
Before a road test, get a complete description of
the customer concerns or suspected condition.
From the description, the technician will be able to
match possible causes with symptoms. Certain
components will be identified as possible sources
while others will be eliminated by the evidence.
More importantly, the customer description can
reveal unsafe conditions which should be checked
or corrected before a road test. The description will
also help form the basic approach to the road test
by narrowing the concern to specific components,
vehicle speed or conditions.
Begin the road test with a general brake
performance check. Using the description of the
concern, test the brakes at different vehicle speeds
using both light and heavy pedal pressure.
Determine if the concern is in the front or rear
braking system. First use the foot brake and then
the parking brake. If the condition
(i.e. pull,
vibration, pulsation) occurs only on operation of
the parking brake, the concern is in the rear brake
system.
If the condition occurs when the foot brake
is depressed, the concern is in the front brake
system.
Avoid locking the brakes and sliding the tires. This
condition will not indicate brake efficiency. A heavily
braked but turning wheel will stop the vehicle in a
shorter distance than locked wheels.
If the concern becomes evident during this check,
make sure it fits the description given before the
road test. If the concern is not evident, attempt to
duplicate the condition using the information from
the description.
If a concern exists, use the Brake System Symptom
Chart in order to isolate it to a specific sub-system
and condition description. From this description, a
list of possible sources can be used to further
narrow the cause to a specific component or
condition.
- -
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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206-00-20 Brake System - General Information 206=00-20
DIAGNOSIS AND TESTING
TEST CONDITIONS
DETAILSIRESULTSIACTIONS
F4: BLEED THE BRAKE SYSTEM
rn Check for air in the brake system. Bleed the
brake system. REFER to: (206-00 Brake System
- General lnformation)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Procedures)
.
Is the condition still present?
+ Yes
GO to F5.
+ No
Vehicle OK.
F5: CHECK FRONT WHEEL HUB RETAINING NUT
Check the front wheel hub retaining nut for
looseness.
Is the front wheel hub retaining nut loose?
+ Yes
INSTALL a new front wheel hub retaining nut.
REFER to: Specifications (204-01 Front
Suspension, Specifications).
Do not reuse the
frontwheel hub retaining nut.
TEST the system for normal operation.
+ No
CHECK the parking bake adjustment. REFER
to: (206-05 Parking Brake and Actuation)
Parking Brake Cable Adjustment
- Vehicles With:
Rear Drum Brakes (General Procedures),
Parking Brake Cable Adjustment
- Vehicles With:
Rear Disc Brakes (General Procedures).
PINPOINT TEST G
: BRAKE LOCK UP DURING LIGHT BRAKE PEDAL FORCE
TEST CONDITIONS
DETAILSIRESULTSIACTIONS
I GI : ROAD TEST-THE VEHICLE I
Road test the vehicle and apply the brake pedal
lightly.
Do the rear brakes lock up?
+ Yes
GO to G2. GO to Pinpoint Test G.
+ No
Vehicle OK.
2006.0 Fiesta 12/2006 G28494en
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Brake System - General Information
DIAGNOSIS AND TESTING
evidence of a brake concern. Check for the brake
warning indicator illumination and the fluid level in
the master cylinder reservoir.
Normal Conditions
The following conditions are considered normal
and are not indications that the brake master
cylinder is in need of service.
- Modern brake systems are not designed to
produce as hard a pedal effort as in the past.
Complaints of light pedal efforts should be
compared to pedal efforts of another vehicle, of
the same model and year.
- During normal operation of the brake the fluid
level in the reservoir will rise during brake
application and fall during release. The net fluid
level
(i.e., after brake application and release)
will remain unchanged.
- A trace of brake fluid will exists on the brake
booster shell below the master cylinder
mounting flange. This results from the normal
lubricating action of the master cylinder bore
end seal.
- The fluid level will fall with brake shoe and lining
wear.
Abnormal Conditions
N0TE:Prior to performing any diagnosis, make
sure the brake system warning indicator is
functional.
Changes in brake pedal feel or travel are indicators
that something could be wrong with the braking system. The diagnostic procedure and techniques
use brake pedal feel, warning indicator illumination
and low brake fluid level as indicators in diagnosing
braking system concerns. The following conditions
are considered abnormal and indicate that the
brake master cylinder is in need of service.
- The brake pedal effort is excessive. This may
be caused by a bind or obstruction in the pedal
.
or linkage, clogged fluid control valve or ( ' insufficient booster vacuum.
- The rear brakes lock up during light pedal force.
This may be caused by incorrect tire pressures,
grease or fluid on the brake shoes and linings,
damaged brake shoes and linings, incorrectly
adjusted parking brake, or damaged or
contaminated brake pressure control valves.
- The brake pedal effort is erratic. This condition
could be caused by a brake booster malfunction,
extreme caliper piston knock back or incorrectly
installed brake shoes and linings.
- The brake warning indicator is ON. This may
be caused by low fluid level, ignition wire routing
too close to the fluid level indicator assembly,
or float assembly damage.
Bypass Condition Test
1. Check the fluid in brake master cylinder. Fill the
brake master cylinder reservoir if low or empty.
2. Observe the fluid level in the brake master
cylinder reservoir. If after several brake
applications, the fluid level remains the same,
measure the wheel turning torque required to
rotate the wheels with the brakes applied as
follows:
Place the transaxle in NEUTRAL and raise and
support the vehicle. REFER to: (1 00-02 Jacking
and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
Apply the brakes with a minimum of 445 N (100
Ib) and hold for approximately 15 seconds. With
the brakes still applied, exert a torque on the front
wheels of 10.1 Nm (75
1b.R). If either wheel rotates,
install a new brake master cylinder. REFER to:
(206-06 Hydraulic Brake Actuation)
- The brake pedal goes down fast. This could be Brake Master Cylinder - RHD (Removal and
caused by an external or internal leak. Installation),
- The brake
pedal eases down slowly. This could Brake Master Cylinder - LHD
(Removal and
be caused by an external or internal leak. Installation).
- The
brake pedal is low and or feels spongy. This
condition may be caused by no fluid in the brake
Non-Pressure Leaks master cylinder reservoir, reservoir cap vent
holes clogged or air in the hydraulic system.
Any empty brake master cylinder reservoir
condition may be caused by two types of
non-pressure external leaks.
2006.0 Fiesta 1212006
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206-00-32 Brake System - General Information 206-00-32
GENERAL PROCEDURES
Brake System Bleeding(l2 141 0) /'. ,
All Vehicles Repeat the procedure for the remaining brake
A WARNING:Brake fluid contains polyglycol lines.
ethers and polyglycols. Avoid contact with
General
Equipment
9m ACAUTION:M~~~ sure that the bleed nipple
the eyes. Wash hands thoroughly after
Vehicles with anti-lock brakes handling. If brake fluid contacts the eyes,
flush the eyes for
15 minutes with cold 10. N0TE:This step is only necessary when
running water. Get medical attention
if changing the brake fluid to remove the used
irritation persists.
If taken internally, drink brake
fluid from the hydraulic control unit
water and induce vomiting. Get medical (HCU).
Worldwide
Diagnostic System (WDS)
attention immediately. Failure to follow
Using WDS, bleed the brake system.
these instructions may result in personal'
injury.
CAUTI0N:If brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water. cap
is installed after bleeding the brake
N0TE:Make sure that the vehicle is standing on a
level surface.
line(s). This will prevent corrosion to the
bleed nipple. Failure to follow this instruction
Bleeding may result in the bleed nipple becoming
seized.
N0TE:The system consists of separate circuits for
each front and diagonally opposite rear wheel.
Each circuit can be bled independently.
ACAUTION:T~~ brake fluid reservoir must
remain full with new, clean brake fluid at all
times during bleeding.
Install the bleed tube to the bleed nipple.
2. Immerse the end of the bleed tube in a bleed
jar containing a small quantity of approved
brake fluid.
3. Position the bleed jar base at least 300 mm
above the bleed nipple to maintain fluid
pressure and prevent air leaking past the
threads of the bleed nipple.
4. Loosen the bleed nipple by one-half turn.
5. Operate the brake pedal fully ipumping brake
fluid and air into the bleed jar) and allow the
brake pedal to return to the rest position.
6. Fill the brake fluid reservoir to the MAX mark.
7. Continue operating the brake pedal until
air-free fluid is being pumped into the bleed
jar.
8. With the brake pedal fully depressed tighten
the bleed nipple.
2006.0 Fiesta IZIZOO~ GI 7458en
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206-00-33 Brake System - General Information 206-00-33
GENERAL PROCEDURES
Brake System Pressure Bleeding(l2 141 0)
Bleeding
i General Equipment Vehicles with anti-lock brakes
All vehicles
Worldwide Diagnostic System (WDS)
Brakelclutch system pressure bleederlfiller
A WARNING: Brake fluid contains polyglycol
ethers and polyglycols. Avoid contact with
the eyes. Wash hands thoroughly after
handling. If brake fluid contacts the eyes,
flush the eyes for
15 minutes with cold
running water. Get medical attention if
irritation persists. If taken internally, drink
water and induce vomiting. Get medical
attention immediately. Failure to follow
these instructions may result in personal
injury.
4. N0TE:This ste.p is only necessary when
changing the brake fluid to remove the used
A CAUTI0N:If brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
/
brake fluid from the hydraulic control unit
I N0TE:Make sure that the vehicle is standing on a
level surface.
N0TE:The system consists of separate circuits for
each front and diagonally opposite rear wheel.
Each circuit can be bled independently.
I. Fill the brake fluid reservoir to the MAX mark.
2. CAUTIONS:
AMake sure that the pressure within the
brake system does not exceed
1 bar.
n~ake sure that the pressure bleeding
equipment is filled with new brake fluid to
the correct specification.
Using the
brakelclutch system pressure
bleederlfiller, pressure bleed the system in
accordance with the manufacturer's
instructions.
3n ACAUTION:M~~~ sure that the bleed nipple
cap is installed after bleeding the brake
line(s). This will prevent corrosion to the
bleed nipple. Failure to follow this instruction
I may result in the bleed nipple becoming
seized.
Fill the brake fluid reservoir to the
MAX mark
as necessary. (HCU).
Using
WDS, bleed the brake system.
2006.0 Fiesta 1212006
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