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Chapter 10
Braking system
Contents
ABS module - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .25
Brake discs - inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Brake hydraulic system - bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Brake hydraulic system - fluid renewal . . . . . . . . . . . . . . . . . . . . . . .3
Brake pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .14
Brake pipes and hoses - inspection, removal and refitting . . . . . . .21
Control module (April 1992 on) - removal and refitting . . . . . . . . . .31
Front brake disc - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .5
Front brake pads - inspection and renewal . . . . . . . . . . . . . . . . . . . .7
Front caliper - overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Front caliper - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .9
G (gravity) switch (April 1992 on) - removal and refitting . . . . . . . . .33
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Handbrake cable - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Handbrake cable - removal and refitting . . . . . . . . . . . . . . . . . . . . .23
Handbrake control lever - removal and refitting . . . . . . . . . . . . . . . .24
Hydraulic unit - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .15
Hydraulic unit accumulator - removal and refitting . . . . . . . . . . . . .17
Degrees of difficulty
Easy, suitable for
Fairly easy, suitable
novice with little
for beginner with
experience
some experience
Specifications
General
System type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System make:
Models up to April 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models from April 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic system
Fluid type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure warning switch operates at . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake pads
Lining minimum thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake discs
Run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thickness variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum thickness:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear - Estate models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic unit fluid reservoir - removal and refitting . . . . . . . . . . . .16
Hydraulic unit hoses - removal and refitting . . . . . . . . . . . . . . . . . . .20
Hydraulic unit pressure switch - removal and refitting . . . . . . . . . . .19
Hydraulic unit pump and motor - removal and refitting . . . . . . . . . .18
Master cylinder (April 1992 on) - removal and refitting . . . . . . . . . .27
Pedal Travel Sensor (PTS) (April 1992 on) - removal and refitting . .32
Rear brake disc - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .6
Rear brake pads - inspection and renewal . . . . . . . . . . . . . . . . . . . .8
Rear caliper - overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Rear caliper - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .11
Rear disc splash shield - removal and refitting . . . . . . . . . . . . . . . .13
Vacuum servo unit (April 1992 on) - testing, removal and refitting .28
Vacuum servo unit check valve (April 1992 on) - removal, testing and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Valve block and pump assembly (April 1992 on) - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Wheel sensors - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .26
Fairly difficult,
Difficult, suitable for
suitable for competent
experienced DIY
DIY mechanic
mechanic
Discs all round, hydraulic operation, anti-lock braking system
(ABS). Handbrake by mechanical operation of rear calipers
Teves MK II ABS
Teves MK IV ABS
Hydraulic fluid to Ford spec SAM-6C9103-A
130 to 190 bar (1885 to 2755 lbf/in
100 to 110 bar (1450 to 1595 lbf/in
1.5 mm (0.06 in)
0.15 mm (0.006 in) maximum
0.015 mm (0.0006 in) maximum
22 mm (0.87 in)
Cast into outer rim (typically 8.9 mm/0.35 in)
18 mm (0.71 in)
10•1
Very difficult,
suitable for expert
DIY or professional
2
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2
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10
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