2006 BRAKES Hydraulic Brake Actuation (2024)

SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

DESCRIPTION AND OPERATION

Hydraulic Brake Actuation

The hydraulic brake system consists of:

• the vacuum brake booster (E-150, E-250 and E-350). For additional information, refer to POWER BRAKE ACTUATION.
• the Hydro-Boost® brake booster (E-450). For additional information, refer to POWER BRAKE ACTUATION.
• the brake master cylinder.
• the front disc brake calipers. For additional information, refer to FRONT DISC BRAKE.
• the rear disc brake calipers. For additional information, refer to REAR DISC BRAKE.
• the anti-lock brake system (ABS) components. For additional information, refer to VEHICLE DYNAMIC SYSTEMS.
• the brake tubes and hoses.

Brake Fluid

Use only clean, fresh DOT 3 motor vehicle brake fluid in the hydraulic brake system.

• Do not reuse the brake fluid drained or bled from the system.
• Do not use brake fluid that has been stored in an open container.
• Do not use contaminated brake fluid.
• Do not mix different types of brake fluid.

Brake Master Cylinder

The brake master cylinder is a dual-piston type containing a primary and a secondary piston. When the brake pedal is applied, a mechanical linkage applies force to the brake booster. The brake booster multiplies the force applied to the brake pedal and transmits the multiplied force to the brake master cylinder pistons. The brake master cylinder pistons transmit the force applied to the hydraulic brake fluid. The pressure created by the force of the hydraulic fluid is directed to the wheel brake assemblies through the brake lines and hoses. This hydraulic pressure then forces the brake caliper pistons outward against the brake pads and the brake pads against the brake rotor friction surfaces, slowing the wheel speed. When the brake pedal is released, the hydraulic force is removed, allowing the brake pads to retract slightly from the brake rotor friction surface and allowing the wheels to rotate.

On speed-control equipped vehicles, the brake master cylinder has a speed control deactivator switch located on the underside of the brake master cylinder casting which acts as a redundant safety device. For additional information, refer to SPEED CONTROL.

Brake Master Cylinder Reservoir

The brake master cylinder reservoir holds a supply of brake fluid for the master cylinder and the brake hydraulic system. The master cylinder reservoir is mounted to the top of the master cylinder and is sealed to the master cylinder body with grommets. The master cylinder reservoir has visual fluid markings allowing fluid level inspection without removal of the reservoir cap. The master cylinder reservoir contains a brake fluid level sensor. The brake fluid level sensor is a magnetic reed switch which, when the fluid drops to a predetermined level, will activate the red brake warning lamp on the instrument cluster. For additional information on the red brake warning lamp, refer to INSTRUMENT CLUSTER.

Brake Tubes and Hoses

The brake lines and hoses transmit the hydraulic pressure to the wheel brake assemblies.

All brake lines must be correctly double-flared to provide strong, leak proof connections. When bending brake tube to fit the underbody or rear axle contours, be careful not to kink or crack the brake tube.

When routing a brake tube, allow 51 mm (2 inches) of clearance between the brake tube and the exhaust system or any moving components.

If a section of brake tube is damaged, the entire section must be replaced with a brake tube of the same type, size, shape and length as originally installed.

When installing new hydraulic brake tubes, hoses or connectors, tighten all connections securely. When the installation is complete, bleed the brake system. For additional information, refer to BRAKE SYSTEM-GENERAL INFORMATION.

DIAGNOSIS AND TESTING

Hydraulic Brake Actuation

Refer to BRAKE SYSTEM-GENERAL INFORMATION.

REMOVAL AND INSTALLATION

Brake Pedal and Bracket

Fig. 1: Identifying Brake Pedal & Bracket With Torque Specifications
Courtesy of FORD MOTOR CO.

Removal and Installation

1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES.
2. Release the fuse block assembly from the brake pedal bracket and position aside.

   Fig. 2: Locating Fuse Block Assembly
   Courtesy of FORD MOTOR CO.

3. Disconnect the brake booster push rod.
   • Remove the brake pedal cotter pin cover.
   • Remove the brake pedal cotter pin.
   • Remove the stoplamp switch.
   • Remove the brake booster push rod bushing.
   • Disconnect the brake booster push rod from the brake pedal pin.
4. Remove the 2 brake pedal bracket nuts.
   • To install, tighten to 25 Nm (18 lb-ft).
5. Remove the 4 brake booster nuts.
   • To install, tighten to 25 Nm (18 lb-ft).
6. Remove the brake pedal and bracket assembly.
7. To install, reverse the removal procedure.

Brake Master Cylinder

MATERIAL REFERENCE

Fig. 3: Identifying Brake Master Cylinder Components
Courtesy of FORD MOTOR CO.

Removal and Installation

All vehicles

1. Disconnect the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES.
2. Use a suitable suction device to remove the brake fluid from the brake master cylinder reservoir.
3. Remove the coolant reservoir bolts and position the reservoir aside.
   • To install, tighten to 10 Nm (89 lb-in).
4. Disconnect the speed control deactivator switch connector.

   Fig. 4: Locating Speed Control Deactivator Switch Connector
   Courtesy of FORD MOTOR CO.

5. Disconnect the brake fluid level switch electrical connector.

   Fig. 5: Locating Brake Fluid Level Switch Electrical Connector
   Courtesy of FORD MOTOR CO.

6. Disconnect the brake master cylinder tubes from the brake master cylinder.
   • To install, tighten to 18 Nm (13 lb-ft).
   • On vehicles with traction control and stability assist, tighten to 28 Nm (21 lb-ft).

Diesel engine equipped vehicles

7. Disconnect the coolant hoses from the air cleaner outlet tube.

   Fig. 6: Locating Coolant Hoses & Air Cleaner Outlet Pipe
   Courtesy of FORD MOTOR CO.

8. Loosen the clamp and disconnect the air cleaner outlet tube.
   • To install, tighten to 4 Nm (35 lb-in).
9. Disconnect the mass air flow (MAF) sensor electrical connector.
10. Disconnect the 3 latches and remove the air cleaner cover.

    Fig. 7: Locating Latches & Air Cleaner Cover
    Courtesy of FORD MOTOR CO.

Gasoline engine equipped vehicles

11. Remove the 2 powertrain control module (PCM) bracket nuts and position the PCM and bracket aside.
    • To install, tighten to 20 Nm (15 lb-ft).

      Fig. 8: Locating Powertrain Control Module Bracket Nuts
      Courtesy of FORD MOTOR CO.

All vehicles

NOTE:

The brake master cylinder nuts are a torque-prevailing type and cannot be reused.

12. Remove and discard the brake master cylinder nuts.
    • To install, tighten to 23 Nm (17 lb-ft).
    • On vehicles with traction control and stability assist, tighten to 15 Nm (11 lb-ft).
13. Remove the brake master cylinder.
14. To install, reverse the removal procedure.
    • Bleed the brake system. For additional information, refer to BRAKE SYSTEM-GENERAL INFORMATION.

Brake Master Cylinder - Hydro-Boost®

MATERIAL REFERENCE

Fig. 9: Identifying Brake Master Cylinder - Hydro-Boost® With Torque Specifications
Courtesy of FORD MOTOR CO.

Removal and Installation

All vehicles

1. Disconnect the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES.
2. Use a suitable suction device to remove the brake fluid from the brake master cylinder reservoir.
3. Remove the coolant reservoir bolts and position the reservoir aside.
   • To install, tighten to 10 Nm (89 lb-in).

Diesel engine

4. Disconnect the coolant hoses from the air cleaner outlet tube.

   Fig. 10: Locating Coolant Hoses & Air Cleaner Outlet Pipe
   Courtesy of FORD MOTOR CO.

5. Loosen the clamp and disconnect the air cleaner outlet tube.
   • To install, tighten to 4 Nm (35 lb-in).
6. Disconnect the mass air flow (MAF) sensor electrical connector.

   Fig. 11: MAF Sensor Electrical Connector
   Courtesy of FORD MOTOR CO.

7. Disconnect the 3 latches and remove the air cleaner cover.

   Fig. 12: Locating Latches & Air Cleaner Cover
   Courtesy of FORD MOTOR CO.

Gasoline engines

8. Disconnect the power cable at the power distribution box and position the box aside.

All vehicles

9. Disconnect the brake fluid level switch electrical connector.
10. Disconnect the speed control deactivator switch electrical connector.
11. Disconnect the master cylinder brake lines.
    • To install, tighten to 18 Nm (13 lb-ft).
    • For vehicles equipped with traction control and stability assist, tighten to 28 Nm (21 lb-ft).
12. Remove the nuts and the power steering line clamp.
    • To install, tighten to 9 Nm (80 lb-in).

NOTE:

Discard the brake master cylinder nuts. They are a torque-prevailing type and cannot be reused.

13. Remove and discard the brake master cylinder nuts.
    • To install, tighten to 26 Nm (19 lb-ft).
14. Remove the power steering line bracket.

    Fig. 13: Locating Power Steering Line Bracket
    Courtesy of FORD MOTOR CO.

15. Remove the brake master cylinder.
16. To install, reverse the removal procedure.
    • Bleed the brake system. For additional information, refer to BRAKE SYSTEM-GENERAL INFORMATION.