2007 FORD FIESTA brakes

100-00-23 General Information 100-00-23
DESCRIPTION AND OPERATION
RoadIRoller Testing
I Road or roller testing may be carried out for various
reasons and a procedure detailing pre-test checks,
engine starting and stopping, pre-driving checks,
on-test checks and final checks to be completed
on completion of the test is given below.
Unless complete vehicle performance is being
checked, the full road test procedure need not be
carried out. Instead, those items particularly
relevant to the
system(s) being checked can be
extracted.
Pre-Test Checks
A WARNING:lf the brake system hydraulic
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt
to road test the vehicle until the reason for
the low fluid level, excessive pedal travel
or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional
tests of those systems and circuits which affect the
safe and legal operations of the vehicle, such as
( , brakes, lights and steering, should always be
carried out before the road or roller test.
With the ignition switched off, check:
- the engine oil level.
- the engine coolant level.
- the tires, for correct pressure, compatible types
and tread patterns, and wear within limits.
- that there is sufficient fuel in the tank to
complete the test.
- all around the engine, transmission and under
the vehicle for oil, coolant, hydraulic and fuel
leaks. Make a note of any apparent leaks and
wipe off the surrounding areas to make it easier
to identify the extent of the leak on completion
of the test.
Starting the Engine
N0TE:On initial drive away from cold and within
the first 1.5 km (1 mile), do not depress the
accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of
25 kmlh
(15 mileslh). Never operate at high engine speed
or with the accelerator pedal at full travel whilst the
engine is cold.
With the ignition switched off, check:
- that the parking brake is applied.
- that the gear lever is in the neutral position.
- that all instrument gauges (except fuel gauge)
read zero.
With the ignition switched on, check:
- that the ignition controlled warning lamps are
illuminated.
- that the engine temperature gauge registers a reading compatible with the engine temperature.
- that the fuel gauge registers a reading
appropriate to the fuel level in the tank.
- the operation of the parking brake warning lamp
and fluid level warning indicator.
Road or Roller Testing
A CAUTI0N:lf road testing, check the brake
operation while still traveling at low speed
before continuing with the test. If the
brakes pull to one side, or appear to be
otherwise faulty, do not continue with the
road test until the fault has been found and
rectified.
During the road or roller test, check:
- that the clutch pedal operation is not stiff or
heavy.
- that the initial gear engagement is smooth and
there is no evidence of clutch drag.
- that the parking brake control operates smoothly
and releases quickly and completely.
- that the clutch takes up the drive smoothly,
without slip or judder.
- that gear changing is smooth with no abnormal
noises or vibrations from the transmission.
- the engine power output is satisfactory, full
power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and engine
speed returns to idle correctly.
- there is no excessive or abnormally colored
smoke from the engine under normal driving,
heavy load or overrun conditions.
- that steering operation, including power steering
(if equipped), is smooth, accurate, not
excessively heavy or with excessive free play
or vibration.
- that the steering does not pull to one side and
self centers smoothly after cornering.
2006.0 Fiesta 1212006 GI 7375en
procarmanuals.com

100-00-24 General Information 100-00-24
DESCRIPTION AND OPERATION
- that the speedometer, coolant temperature - oil, coolant, hydraulic, air and fuel leaks.
gauge and tachometer (if equipped) register the - abnormal temperature of any moving
correct readings and operate correctly.
components or assemblies, for example wheel
(
- that the switches and controls operate smoothly hubs, transmission and axle, which might
and positively, warning and indicator lamps
indicate over tightness or lack of lubrication.
operate correctly and the direction indicator
control self cancels when the steering is
returned to the straight ahead position.
- that the heating and ventilation systems operate
correctly and effectively.
- the brake operation and efficiency.
Brake Testing
A WARNING:When brake testing, avoid
breathing the fumes from hot brakes, this
may contain asbestos dust which is
hazardous to health. Failure to follow this
instruction may result in personal injury.
For additional information, refer to: Health
and Safety Precautions
(1 00-00 General
Information, Description and Operation).
CAUTIONS:
A Avoid brake testing on busy roads where
it may cause inconvenience or danger to
other road users.
A Brake testing which includes heavy brake
applications should not be carried out with
new brake
padsldiscs or liningsldrums
until the components have bedded-in. New
brake friction components will not reach
full efficiency until the bedding-in process
is complete.
Test the brakes at several speeds within the normal
operating range using both light and heavy pedal
pressure. Note any tendency to snatch, pull or
drag, and any undue delay in application or
release.
Allow the vehicle to coast and note any tendency
to pull to one side, or evidence that the brakes are
binding.
After stopping the vehicle (not immediately after a
period of heavy braking), carefully check the brake
temperature.
A brake disc or brake drum that feels
hot or is appreciably hotter than the others,
indicates that the brake is binding.
After completion of the test, check for:
2006.0 Fiesta 1212006 GI 7375en
procarmanuals.com

100-04-6 Noise, Vibration and Harshness 100-04-6
DIAGNOSIS AND TESTING
2. AccelerationIDeceleration: With slow
acceleration and deceleration, a shake is
sometimes noticed in the steering
wheellcolumn,
seats, front floor panel, front door trim panel or
front end sheet metal. It is a low frequency
vibration (around
9-1 5 cycles per second). It
may or may not be increased by applying the
brakes lightly. REFER to
Idle
BoomIShakeNibration in the Driveline Noise
and Vibration Symptom Chart.
High Speed: A vibration is felt in the front floor
panel or seats with no visible shake, but with
an accompanying sound or rumble, buzz, hum,
drone or booming noise. Coast with the clutch
pedal depressed (manual transmission) or shift
control selector lever in "N" (NEUTRAL)
(automatic transmission) and engine idling. If
vibration is still evident, it may be related to
wheels, tires, front brake discs, wheel hubs or
front wheel bearings. REFER to Shake and
Vibration While Driving in the Driveline Noise
and Vibration Symptom Chart.
4. Engine rpm Sensitive: A vibration is felt
whenever the engine reaches a particular rpm.
It will disappear in neutral coasts. The vibration
can be duplicated by operating the engine at
the problem rpm while the vehicle is stationary.
It can be caused by any component, from the
accessory drive belt to the clutch or torque
converter which turns at engine speed when the
vehicle is stopped. REFER to Shake and
Vibration While Driving in the Driveline Noise
and Vibration Symptom Chart.
5. Noise and Vibration While Turning: Clicking,
popping or grinding noises may be due to the
following:
worn, damaged or incorrectly installed front
wheel bearing.
damaged
powertrainldrivetrain mounts.
Road Conditions
An experienced technician will always establish a
route that will be used for all NVH diagnosis road
tests. The road selected should be reasonably
smooth, level and free of undulations (unless a
particular condition needs to be identified). A
smooth asphalt road that allows driving over a
range of speeds is best. Gravel or bumpy roads
are unsuitable because of the additional road noise produced.
Once the route is established and
consistently used, the road noise variable is
eliminated from the test results.
N0TE:Some concerns may be apparent only on
smooth asphalt roads.
If a customer complains of a noise or vibration on
a particular road and only on a particular road, the
source of the concern may be the road surface. If
possible, try to test the vehicle on the same type
of road.
Vehicle Preparation
Carry out a thorough visual inspection of the
vehicle before carrying out the road test. Note
anything which is unusual. Do not repair or adjust
any condition until the road test is carried out,
unless the vehicle is inoperative or the condition
could pose a hazard to the technician. After
verifying that the condition has been corrected,
make sure all components removed have been
installed.
Power Steering Conditions
c !
Check for the noise in the following conditions to
verify the customer concern.
Check for the noise in several temperature
conditions.
Is the noise from when the vehicle was new?
Can the noise be repeated constantly or is it
random?
Check the condition of the vehicle age, mileage
and service record.
Interview the customer to find the operating
condition in which the noise will occur. Test the
vehicle based on the
detail(s) from the customer
interview.
Follow the power steering operation noise
condition tables below, to find which condition
the noise will occur.
Power Steering Operation Noise Check
Step 1 : Check for NVH concerns from non-steering
components, which may sound like noises coming
from the steering system.
I:. ':
2006.0 Fiesta 121zoo6 G37349en
procarmanuals.com

204-01 -1 4 Front Suspension 204-01 -1 4
REMOVAL AND INSTALLATION
Detach the brake caliper and anchor plate N0TE:Use a 5 mm Allen key to prevent the ball
from the wheel knuckle. joint stud from rotating. f
6. Remove the brake disc.
Remove and discard the retaining washer (if
equipped).
Vehicles with anti-lock brakes
7. Detach the wheel speed sensor from the
wheel knuckle.
All vehicles
*= &AUTION:L~~~~ the tie-rod end retaining
nut in place to protect the ball joint stud. Loosen
the tie-rod end retaining nut.
k
&AuTl~N:~rotect the ball joint seal using
a soft cloth to prevent damage.
Using the special tool, detach the tie-rod end
from the wheel knuckle.
1. Release the tie-rod end.
2. Remove and discard the tie rod end retaining
nut.
/'-
lorn A~AuT10N:~rotect the ball joint seal
using a soft cloth to prevent damage.
Detach the lower arm ball joint from the
wheel knuckle.
2006.0 Fiesta 1212006 GI 83759en
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204-01 -1 6 Front Suspension 204-01 -1 6
REMOVAL AND INSTALLATION
Using the special tool, attach the wheel hub 5. AWARNING:lnstall a new tie-rod end to the halfshaft.
retaining nut. Failure to follow this f
3m ACAUTION:M~~~ sure the heat shield is
installed to prevent damage to the ball joint.
Install the heat shield.
4m &AUTION:T~~ lower arm pinch bolt must
be installed from the rear of the wheel
knuckle. instruction
may result in personal injury.

N0TE:Use a 5 mm Allen key to prevent the ball
joint stud from rotating.
Attach the tie-rod end to the wheel knuckle.
Vehicles with anti-lock brakes
6. Attach the wheel speed sensor to the wheel
knuckle.
Attach the lower arm ball joint to the wheel
knuckle.
All vehicles
7. Install the brake disc.
8m &AUTION:DO not twist the brake hose
when attaching the brake caliper to prevent
damage to the brake hose.
2006.0 Fiesta 1212006 GI 83759en
procarmanuals.com

204-01 -1 7 Front Suspension 204-01 -1 7
REMOVAL AND INSTALLATION
Attach the brake caliper and anchor plate to
With the aid of another technician, apply the
the wheel knuckle.
brakes and pre-load the wheel bearing by
/ 1 I installing the wheel hub retaining nut.
9. CAUTIONS:
AMake sure the brake hose is correctly 11. Install the wheel and tire.
located in the brake hose support bracket to For additional
information, refer to: Wheel
prevent damage to the brake hose.
A
and Tire (204-04 Wheels and Tires,
Removal and Installation).
AMake sure the brake hose retaining clip 12m Tighten the wheel hub retaining nut. is located on the underside of the brake hose
support bracket to prevent damage to the
brake hose.
j Attach the brake hose to the brake hose
support bracket.
lo' AwARNING:~~~~~~~ a new wheel hub
retaining nut. Failure to follow this
instruction may result in personal injury. 13.
Tighten the strut and spring assembly top
mount retaining nuts.
--
2006.0 Fiesta 1212006 GI 83759en
procarmanuals.com

204-02-2 Rear Suspension 204-02-2
SPECIFICATIONS
Torque Specifications
I Shock absorber upper mount retaining bolts I 25 I 18 I - I
Item
Shock absorber lower mount retaining bolt
I Trailing arm bushing retaining bolts I 125 1 92 I - I
Nm
115
I drum brakes I I I I
Beam axle retaining bolts
Wheel spindle retaining bolts
- Vehicles with rear
Wheel spindle retaining bolts
- Vehicles with rear
disc brakes
Ib-ft
85
I Wheel hub retaining nut 1 235 1 173 1 - I
I b-in
-
115
70
I Brake hose to brake caliper union I 15 I 11 I - I
I Brake tube to brake hose union I 15 I 11 I - I
85
52
I Wheel speed sensor retaining bolt I 9 I - I 80 I
-
-
2006.0 Fiesta 1212006 GI 52540en
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204-02-1 0 Rear Suspension 204-02-1 0
REMOVAL AND INSTALLATION
Beam Axle(l5 231 0)
f
General Equipment 5. Detach the parking brake cable from the (.
beam axle bracket on both sides. I Transmission jack
I Securing strap I
I Electric hand drill I
I Blind rivet gun I
Removal
Vehicles with rear drum brakes
1. Release the parking brake.
2. Remove the rear wheels and tires.
For additional information, refer to: Wheel
and Tire (204.04 Wheels and Tires, Removal 6. Remove the brake dIIlm and wheel spindle
and Installation). assembly
on both sides.
3. Detach the rear wheel speed sensor and
brake hose retaining bracket from the beam
axle on both sides.
Remove the retaining bolt.
7m &AUTION:S~~~~~~ the brake backing
plate, wheel cylinder and brake shoes
assembly to prevent load being placed on
the brake hose.
4. Disconnect the parking brake cable on both
Detach the brake backing plate, wheel
sides. cylinder and brake shoes assembly from the
beam axle on both sides.
2006.0 Fiesta 1212006 G183767en
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