Pinpoint tests of the brake system (Focus 1)

A1: ROAD TEST OF THE CAR

1Road test the vehicle and apply the brake pedal.

• Is the vehicle being pulled or shifted?

→ Yes

Go to A2

→ No

The car is in good working order.

A2: CHECKING TIRE PRESSURE

1Check for excessive tire wear and incorrect tire pressure

• Are the tires in good condition?

→ Yes

If your vehicle has rear drum brakes, go to A3

If your vehicle has rear disc brakes, go to A4

→ No

ADJUST tire pressure or INSTALL new tires if excessive wear is present. CHECK system operation for proper operation.

A3: INSPECTION OF BRAKE PADS AND LININGS

1CHECK the brake pads and linings, looking for grease or fluid on the linings and signs of wear.

• Are there any faults?

→ Yes

INSTALL new brake pads. Refer to Section 206-02 for additional information. CHECK system operation. ROAD TEST (if necessary).

→ No

Go to A4

A4: CHECKING THE CALIPERS

1Inspect the caliper pistons and studs for signs of warping, leaking, or binding. Refer to Section 206-03 / 206-04 for additional information.

• Are the disc brake caliper pistons and pins warped, leaking or sticking?

→ Yes

REPAIR or INSTALL new pistons or studs as necessary. CHECK system for proper operation.

→ No

Go to A5

A5: INSPECTION OF BRAKE DISCS

1Check the brake discs for excessive wear or damage.

• Is there excessive wear or damage?

→ Yes

If necessary, REPAIR or INSTALL new brake discs. CHECK that the system is operating correctly.

→ No

Go to A6

A6: INSPECTING FRONT WHEEL BEARINGS

1Check the front wheel bearings. Refer to Section 204-00 for additional information.

• Are the wheel bearings in good condition?

→ Yes

Go to A7

→ No

INSTALL new wheel bearings. Refer to Section 204-01 for additional information. CHECK for proper system operation.

A7: CHECKING WHEEL ALIGNMENT ANGLES

1Check the vehicle's wheel alignment. For additional information, refer to Section 204-00.

• Are the wheel alignment angles within specification?

→ Yes

The car is in good working order.

→ No

Adjust wheel alignment if necessary. Refer to Section 204-00 for additional information.

NOTE:The brake system indicator lamp comes on for approximately five seconds when the ignition is turned on and then goes out.

B1: CHECKING THE RED BRAKE SYSTEM WARNING LAMP

1Enter the ON position.

• Is the red brake system indicator light on?

→ Yes

If your vehicle is equipped with ABS, Go to B2 Proceed to PINPOINT TEST B. If the vehicle is not equipped with ABS, Proceed to B3 Proceed to PINPOINT TEST B

→ No

The car is in good working order.

B2: CHECKING THE ABS SYSTEM

1Enter the OFF position.

2Disconnect the diagnostic tool.FDS2000

3Using WDS, perform an ABS diagnostic check.

• Are any faults found in the ABS system?

→ Yes

REPAIR or INSTALL new items as necessary. Refer to Section 206-09A / 206-09B / 206-09C for additional information.

→ No

Go to B3 Proceed to PINPOINT TEST B

B3: CHECKING THE PARKING BRAKE

1CHECK that the parking brake is fully released.

• Does the red brake system indicator light go out?

→ Yes

The car is in good working order.

→ No

Go to B5 Proceed to PINPOINT TEST B

B4: CHECK PARKING BRAKE SWITCH CIRCUIT FOR SHORT CIRCUIT "MASS"

1Disconnect the C930 parking brake switch.

• Does the red brake system indicator light go out?

→ Yes

INSTALL a new parking brake switch. CHECK the system for proper operation.

→ No

Go to B5 Proceed to PINPOINT TEST B

B5: CHECKING THE BRAKE FLUID LEVEL

1Check the brake fluid level in the brake fluid reservoir.

• Is the brake fluid level in the brake hydraulic reservoir at the MAX mark?

→ Yes

Go to B6 Proceed to PINPOINT TEST B

→ No

Add brake fluid to the brake fluid reservoir up to the MAX mark.

B6: CHECK THE BRAKE FLUID LEVEL SWITCH CIRCUIT FOR A SHORT CIRCUIT "MASS"

1Disconnect C810 brake fluid level switch.

• Does the red brake system indicator light go out?

→ Yes

INSTALL a new brake fluid level switch. CHECK the system for proper operation.

→ No

Go to B4 Proceed to PINPOINT TEST B

B7: CHECK ELECTRICAL CIRCUIT 31S - GC6 (BLACK/YELLOW) FOR SHORT TO GROUND"

1Enter the OFF position.

2Disconnect C809 instrument cluster.

3Measure the resistance between pin 20 of the instrument cluster connector C809, electrical circuit 31S-GC6 (black/yellow), and ground.

• Does the resistance exceed 10,000 ohms?

→ Yes

INSTALL a new instrument cluster. CHECK the system for proper operation.

→ No

REPAIR electrical circuit 31S-GC6 (black/yellow). CHECK for proper system operation.

C1: ROAD TEST OF THE CAR

1Road test the vehicle at speeds between 40-80 km/h (25-50 mph) without applying the brakes.

• Is there vibration?

→ Yes

CHECK for noise, vibration, and shaking. Refer to Section 100-04 for additional information. REPEAT road test if necessary.

→ No

Go to C2

C2: CHECKING FOR VIBRATION IN THE REAR BRAKES

NOTE:Apply the parking brake.

1Road test the vehicle at speeds between 40-80 km/h (25-50 mph), applying moderate force to the parking brake lever only.

• Is there vibration?

→ Yes

CHECK the rear brake discs or brake drums for excessive wear or cracks. For additional information, refer to Section 206-04 / 206-02.

→ No

Go to C3

C3: CHECKING FOR VIBRATION IN THE FRONT BRAKES

1Road test the vehicle at speeds between 40-80 km/h (25-50 mph) while applying light to medium pressure to the brake pedal.

• Is there vibration?

→ Yes

CHECK the front brake discs for excessive wear or cracks. Refer to Section 206-03 for additional information. CHECK for proper system operation.

→ No

The car is in good working order.

D1: CHECKING THE FORCE APPLIED TO THE BRAKE PEDAL

1Road test the vehicle and apply the brake pedal.

• Is the force applied to the brake pedal normal?

→ Yes

The car is in good working order.

→ No

Go to D2

D2: CHECKING THE BRAKE FLUID LEVEL

1Check the brake fluid level in the brake hydraulic reservoir

• Is the brake fluid level within specification?

→ Yes

Go to D3

→ No

CHECK the brake fluid reservoir seals. Refer to "Checking the Brake Master Cylinder" in this section. ADD brake fluid and BLEED the brake system. Refer to Bleeding - Under Pressure for additional information. Refer to Bleeding - Normal for additional information in this section. CHECK the system for proper operation. REPEAT the road test if necessary.

D3: CHECKING THE BRAKE PEDAL HEIGHT - INCREASING SYSTEM PRESSURE

1Press the brake pedal quickly five times.

• Does the brake pedal height increase and then remain at the new level?

→ Yes

BLEED the brake system. Refer to "Bleeding the Brake System" in this section. Check the bypass circuit in the cylinder. REPEAT the road test if necessary.

→ No

Go to D4

D4: CHECKING THE BRAKE SYSTEM FOR LEAKS

1Check for external leaks in the brake system.

• Any leaks detected?

→ Yes

REPAIR, ADD brake fluid and BLEED the brake system as necessary. Refer to Bleeding Air - Under Pressure in this section for additional information. CHECK for proper operation. REPEAT road test if necessary.

→ No

Go to D5

D5: CHECK BYPASS CIRCUIT IN CYLINDER.

1Check for bypass in the master cylinder. Refer to the section "Checking the Master Cylinder" in this section

• Any faults found?

→ Yes

INSTALL a new master cylinder, ADD brake fluid and BLEED the brake system. Refer to Bleeding - Under Pressure for additional information. Refer to Bleeding - Normal for additional information in this section. CHECK that the system is operating properly.

→ No

The system is working properly.

E1: ROAD TEST - CHECKING BRAKE PEDAL OPERATION

1CHECK if this condition occurs when actually attempting to stop by pressing the brake pedal in a moving vehicle.

• Does the condition occur while the vehicle is moving?

→ Yes

Go to E2

→ No

Go to E3

E2: CHECKING FOR LEAKS IN THE BRAKE SYSTEM

1Check for external leaks in the brake system.

• Are there any external leaks in the brake system?

→ Yes

REPAIR as necessary. ADD brake fluid and BLEED the brake system. For additional information, refer to Bleeding Air - Under Pressure in this section. CHECK for proper system operation.

→ No

Go to E3

E3: CHECKING THE BYPASS CHANNEL OF THE BRAKE MASTER CYLINDER

1Check the master cylinder bypass passage. Refer to the "Checking the Master Cylinder" section in this section.

• Any faults found?

→ Yes

INSTALL a new master cylinder, ADD brake fluid and BLEED the brake system. Refer to Bleeding - Under Pressure for additional information. Refer to Bleeding - Normal for additional information in this section. CHECK that the system is operating properly.

→ No

The system is working properly.

F1: CHECKING FOR PEDAL "SOFTNESS"

1Road test the vehicle and apply the brake pedal.

• Is the brake pedal force normal?

→ Yes

The car is in good working order.

→ No

Go to F2

F2: CHECKING THE BRAKE PEDAL TRAVEL RESERVE

NOTE:You may feel increased resistance, like the pedal is going to the floor.

1Engine idling.

2Press the brake pedal lightly three or four times.

3Wait 15 seconds for the vacuum to re-establish.

4Press the brake pedal until it stops moving downwards or the resistance to pedal movement increases

5Keep the brake pedal depressed while increasing engine speed to 2000 rpm.

6Release the accelerator pedal.

• Does the brake pedal move down when the engine speed returns to idle?

→ Yes

Go to F3

→ No

CHECK the vacuum supply to the brake booster. Refer to Section 206-07 for additional information.

F3: CHECKING THE BRAKE FLUID LEVEL

1Check the level of working fluid in the brake hydraulic reservoir.

• Is the brake fluid level within specification?

→ Yes

BLEED the brake system. For more information, refer to Bleeding Air - Under Pressure in this section. CHECK that the system is operating properly.

→ No

CHECK the brake fluid reservoir seals. Refer to "Brake Master Cylinder" in this section. ADD brake fluid and BLEED the brake system. Refer to Bleeding - Under Pressure for additional information. Refer to Bleeding - Normal for additional information in this section. CHECK that the system operates correctly. REPEAT the road test if necessary.

G1: CHECKING THE BRAKE LOCK

1Road test the vehicle and apply light pressure to the brake pedal.

• Are the rear brakes locking?

→ Yes

Go to G2 Proceed to PINPOINT TEST G

→ No

The car is in good working order.

G2: INSPECTION OF BRAKE PADS

1Inspect the brake pads for grease or brake fluid on the linings, wear, damage, proper installation, correct size and type.

• Any faults found?

→ Yes

INSTALL new brake pads. Refer to Section 206-02 / 206-04 for additional information.

CHECK that the system is operating correctly. REPEAT the road test if necessary.

→ No

The car is in good working order

H1: ROAD TEST ON A ROUGH ROAD

1Perform a road test of the vehicle under difficult driving conditions.

2Apply the brake pedal slowly.

• Are the brakes working properly?

→ Yes

The car is in good working order.

→ No

Go to H2

H2: CHECKING WHEEL BEARINGS

1Check the front wheel bearing installation. Refer to Section 204-01 for additional information.

• Are the front wheel bearings not seated tightly?

→ Yes

If the front wheel bearing is damaged, INSTALL a new one. Refer to Section 204-01 for additional information. CHECK the system for proper operation.

→ No

CHECK for front brake disc thickness difference. Refer to Section 206-03 for additional information.

I1: ROAD TEST OF THE CAR

1Road test the vehicle and apply the brakes.

• Are the brakes functioning properly?

→ Yes

The car is in good working order.

→ No

INSPECT individual wheel cylinders or brake calipers and, if necessary, INSTALL new wheel cylinders or brake calipers. Go to I2

I2: CHECKING THE BRAKE BOOSTER

1Check the brake booster tappet adjustment and travel. Refer to Section 206-07 for additional information.

• Is the pusher in good condition?

→ Yes

The car is in good working order.

→ No

INSTALL a new brake booster. Refer to Section 206-07 for additional information. CHECK the system for proper operation.

J1: VACUUM CHECK

1Disconnect the vacuum hose from the brake booster.

2Connect a vacuum tester/leak tester to the vacuum hose.

3Enter the START position.

4Start the engine and allow it to reach normal operating temperature.

5Determine the vacuum pressure.

• Is the vacuum pressure 40.5 kPa?

→ Yes

Go to J2

→ No

FIND and REPAIR the cause of the low vacuum. CHECK the system is working properly.

J2: SYSTEM INSPECTION

1Enter the OFF position.

2Connect the vacuum hose.

3Inspect the brake booster, rubber bushing and all components of the vacuum system, paying attention to the presence of cracks, holes, unreliable connections or missing clamps/clamps.

4Press the brake pedal five times to release the vacuum. Depress the brake pedal and hold it down.

• Does the brake pedal move down when the engine is started?

→ Yes

The vacuum system is in good working order.

→ No

Go to J3

J3: CHECKING THE BRAKE BOOSTER CHECK VALVE

1Check the brake booster check valve. Refer to the "Brake Booster" section in this section.

• Is the brake booster check valve in good condition?

→ Yes

CHECK the brake booster. Refer to "Checking the Brake Booster" in this section. If necessary, INSTALL a new brake booster. CHECK that the system is operating correctly.

→ No

INSTALL a new brake booster check valve. CHECK the system for proper operation.

K1: CHECKING THE BRAKE PEDAL RETURN TRAVEL

1Run the engine at high idle speed while applying the brake pedal several times.

2Pull the brake pedal back with a force of approximately 44.5 N.

3Release the brake pedal and measure the distance to the driver's footwell rubber.

4Press the brake pedal firmly.

5Release the brake pedal and measure the distance between the brake pedal and the driver's footrest. The brake pedal should return to its original position.

• Does the brake pedal return to its original position?

→ Yes

The car is in good working order.

→ No

Cars manufactured up to 01.1999 Go to K2 Cars manufactured since 01.1999 Go to K3

K2: CHECKING BRAKE PEDAL STICKING

1Check the brake pedal and make sure that the brake pedal moves freely.

• Does the brake pedal move freely?

→ Yes

INSTALL a new brake booster. Refer to Section 206-07 for additional information. CHECK the system for proper operation.

→ No

REPAIR or INSTALL a new brake pedal bracket. Refer to Section 206-06 for additional information. CHECK for proper system operation.

K3: CHECKING FOR BRAKE PEDAL STICKING

1Check the brake pedal and make sure that the brake pedal moves freely.

• Does the brake pedal move freely?

→ Yes

INSTALL a new brake booster. Refer to Section 206-07 for additional information. CHECK the system for proper operation.

→ No

Go to K4

K4: CHECKING THE BRAKE PEDAL LINKAGE

1Check for clearance between the brake pedal and the brake pedal return lever.

• Is there a gap between the brake pedal and the brake pedal return lever?.

→ Yes

INSTALL a new brake pedal bracket. Refer to Section 206-06 for additional information. CHECK the system for proper operation.

→ No

CHECK the position of the brake pedal bracket and the brake pedal return lever. CHECK the correct operation of the system.