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206-00-1 Brake System - General Information 206-00-1
SECTION 206-00 Brake System - General Information

VEHICLE APPLICATION:2008.50 Mondeo
CONTENTS PAGE
DESCRIPTION AND OPERATION

Brake System..................................................................................................................... 206-00-2
DIAGNOSIS AND TESTING

Brake System..................................................................................................................... 206-00-3
Principles of Operation....................................................................................................... 206-00-3
Inspection and Verification.................................................................................................. 206-00-3
Road Test........................................................................................................................... 206-00-3
Symptom Chart................................................................................................................... 206-00-4
Pinpoint Tests..................................................................................................................... 206-00-9
Component Tests................................................................................................................ 206-00-12
GENERAL PROCEDURES
Brake System Bleeding.................................................................................. (12 141 0) 206-00-14
Brake System Pressure Bleeding................................................................... (12 141 0) 206-00-15
Front Brake Disc Runout Check......................................................................................... 206-00-16
Rear Brake Disc Runout Check.......................................................................................... 206-00-18
DESCRIPTION AND OPERATION
Brake System
The braking system is of a diagonally split, dual
circuit design featuring front and rear disc brakes.
The hydraulic system has separate circuits for each
pair of diagonally opposed wheels (left front, right
rear and right front, left rear). The front brake
caliper is of a single sliding piston design which
makes sure that equal effort is applied through both
brake pads.
The parking brake control operates the rear brakes
through a cable system.
The brake master cylinder is of a tandem design
and is linked to a brake booster which reduces the
brake pedal effort. The tandem design will make
sure that in the event of one brake circuit failing
the other will remain fully operational.
The brake booster vacuum on vehicles with diesel
engine is provide by a camshaft driven vacuum
pump.
The anti-lock brake system (ABS) is controlled by
the hydraulic control unit (HCU), incorporated within
the hydraulic system, and only operates when the
wheel speed sensors detect the onset of wheel
lock up.
2008.50 Mondeo 3/2008 G939295en

Brake System
Principles of Operation An experienced brake technician will always
establish a route that will be used for all brake
The brake system operates by transferring effort diagnosis road tests. The roads selected will be
applied to the brake pedal by the driver to the reasonably smooth and level. Gravel or bumpy
brakes at each wheel. roads are not suitable because the surface does
not allow the tires to grip the road equally. Crowned
The braking effort is distributed to each wheel,
roads should be avoided because of the large
using an hydraulic system. The system is assisted
amount of weight shifted to the low set of wheels
using a vacuum brake booster that reduces pedal
on this type of road. Once the route is established
effort and increases hydraulic pressure. The
and consistently used, the road surface variable
parking brake operates on the rear wheels and is
can be eliminated from the test results.
applied using a hand operated control.
Before a road test, obtain a complete description
of the customer concerns or suspected condition.
Inspection and Verification From the description, the technician's experience
will allow the technician to match possible causes
1. Verify the customer concern. with symptoms. Certain components will be tagged
2. Visually inspect for obvious signs of mechanical as possible suspects while other will be eliminated
damage. by the evidence. More importantly, the customer
description can reveal unsafe conditions which
Visual Inspection Chart should be checked or corrected before the road
Mechanical test. The description will also help form the basic
approach to the road test by narrowing the concern
• Tire pressure
to specific components, vehicle speed or
• Wheels and tires conditions.
• Fluid leak from brake line(s)
Begin the road test with a general brake
• Fluid level performance check. Keeping the description of the
• Fluid contamination concern in mind, test the brakes at different vehicle
speeds using both light and heavy pedal pressure.
3. If an obvious cause for an observed or reported To determine if the concern is in the front or rear
concern is found, correct the cause (if possible) braking system, use the brake pedal and then use
before proceeding to the next step. the parking brake control. If the condition (pull,
vibration, isolation) occurs only with the parking
4. If the concern is not visually evident, verify the
brake, the concern is in the rear brake system.
symptom and refer to the Symptom Chart.
Avoid locking the brakes and sliding the tires.
Locked brakes and sliding tires do not indicate
Road Test brake efficiency. A heavily braked and turning
wheel will stop the vehicle in a shorter distance
Carry out a road test to compare actual vehicle than locked brakes.
braking performance with the performance
standards expected by the driver. The ability of the If the concern becomes evident during this check,
test driver to make valid comparison and detect verify it fits the description given before the road
performance deficiencies will depend on test. If the concern is not evident, attempt to
experience. duplicate the condition using the information from
the description.
The driver should have a thorough knowledge of
brake system operation and accepted general If a concern exists, use the Symptom Chart in order
performance guidelines to make good comparisons to isolate it to a specific sub-system and condition
and detect performance concerns. description. From this description, a list of possible
sources can be used to further narrow the cause
to a specific component or condition.
2008.50 Mondeo 3/2008 G939296en

Symptom Chart
Symptom Possible Sources Action

• The brakes pull or drift • Wheel alignment angles. • CHECK the wheel alignment
angles.
REFER to: Specifications (204-
00 Suspension System -
General Information,
Specifications).
• Brake pads. • CHECK and INSTALL new
components as necessary.
REFER to:
Brake Pads (206-03 Front Disc
Brake, Removal and Installa-
tion),
Brake Pads (206-04 Rear Disc
tion).
• Brake disc. • CHECK and INSTALL new
REFER to:
Front Disc Brake (206-03 Front
Disc Brake, Diagnosis and
Testing),
Rear Disc Brake (206-04 Rear
Testing).
• Brake caliper. • CHECK and INSTALL new
REFER to:
Brake Caliper (206-03 Front
Disc Brake, Removal and
Installation),
Brake Caliper (206-04 Rear
Installation).
• The red brake warning indicator • Brake fluid level sensor. • REFER to the diagnostic tool.
is always on
• Parking brake control. • RELEASE and ADJUST the
parking brake.
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
2008.50 Mondeo 3/2008 G939296en


• Excessively worn brake pads. • CHECK and INSTALL new
REFER to:
tion),
tion).
• Brake master cylinder primary • INSTALL a new brake master
piston cup. cylinder. REFER to: (206-06
Hydraulic Brake Actuation)
Brake Master Cylinder - LHD
(Removal and Installation),
Brake Master Cylinder - RHD
(Removal and Installation).
• Vibration when brakes are • Brake pads. • CHECK and INSTALL new
applied components as necessary.
REFER to:
tion),
tion).
REFER to:
Installation),
Installation).
REFER to:
Testing),
Testing).
• The pedal goes down fast • Air in system. • BLEED the system.
REFER to: Brake System
Bleeding (206-00 Brake
System - General Informa-
tion, General Procedures).
2008.50 Mondeo 3/2008 G939296en


• Brake master cylinder • Carry out the brake master
cylinder component test in this
section.
REFER to:
Testing),
Testing).
REFER to:
tion),
tion).
• The pedal eases down slowly • Brake caliper • CHECK and INSTALL new
CHECK and INSTALL new
REFER to:
Installation),
Installation).
• Brake master cylinder. • Carry out the brake master
section.
• The pedal is low or feels • Air in system. • Bleed the system.
spongy REFER to: Brake System
Bleeding (206-00 Brake
System - General Informa-
tion, General Procedures).
2008.50 Mondeo 3/2008 G939296en


REFER to:
tion),
tion).
• Brake booster • CARRY out the brake booster
component test in this section.
• Brake lockup during light brake • Brake pads. • CHECK and INSTALL new
pedal force components as necessary.
REFER to:
tion),
tion).
REFER to:
Testing),
Testing).
• Brake booster. • CARRY out the brake booster
• Excessive/erratic brake pedal • Insufficient grease on sliding • APPLY grease where neces-
travel parts. sary.
REFER to:
tion),
tion).
2008.50 Mondeo 3/2008 G939296en


REFER to:
Testing),
Testing).
• Wheel bearing. • CHECK or INSTALL a new
wheel bearing. REFER to:
Front Wheel Bearing (204-01
Front Suspension, Removal
and Installation),
Rear Wheel Bearing (204-02
Rear Suspension, Removal
and Installation).
• Brake pedal. • GO to Pinpoint Test A.
• Brake drag • Brake booster. • Carry out the brake booster
REFER to:
Installation),
Installation).
• Stability assist system (if • REFER to the diagnostic tool.
equipped)
• Brake pedal. • GO to Pinpoint Test B.
• Slow or incomplete brake pedal • Stability assist system (if • REFER to the diagnostic tool.
return equipped)
• Brake master cylinder. • Carry out the brake master
section.
• Brake pedal. • GO to Pinpoint Test C.
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Pinpoint Tests
PINPOINT TEST A : EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK FOR BRAKE PEDAL RETURN
1 Run the engine at fast idle whilst making several
brake applications.
2 Pull the brake pedal upwards.
3 Release the brake pedal and measure the
distance from the rubber to the floor.
4 Make a hard brake application.
distance from brake pedal rubber to the floor.
The brake pedal should return to its original
position.
• Does the brake pedal return to its original
position?
→ Yes
Vehicle is OK.
→ No
GO to A2.
A2: CHECK FOR BRAKE PEDAL BINDING
1 Check the brake pedal to make sure it is oper-
ating freely.
• Is the brake pedal operating freely?
→ Yes
INSTALL a new brake booster. REFER to:
Brake Booster - LHD (206-07 Power Brake
Actuation, Removal and Installation),
Brake Booster - RHD (206-07, Removal and
Installation).
TEST the system for normal operation.
→ No
REPAIR or INSTALL new brake pedal and
bracket. REFER to: (206-06 Hydraulic Brake
Actuation)
Brake Pedal and Bracket - LHD (Removal and
Installation),
Brake Pedal and Bracket - RHD (Removal and
Installation).
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PINPOINT TEST B : BRAKES DRAG
B1: CHECK FOR BRAKE PEDAL RETURN
brake applications
position.
position?
→ Yes
Vehicle is OK.
→ No
GO to B2.
B2: CHECK FOR BRAKE PEDAL BINDING
ating freely.
→ Yes
Installation).
→ No
Actuation)
Installation),
Installation).
2008.50 Mondeo 3/2008 G939296en

PINPOINT TEST C : SLOW OR INCOMPLETE BRAKE PEDAL RETURN
C1: CHECK FOR BRAKE PEDAL RETURN
brake applications.
position.
position?
→ Yes
Vehicle is OK.
→ No
GO to C2.
C2: CHECK FOR BRAKE PEDAL BINDING
ating freely.
→ Yes
Installation).
→ No
Actuation)
Installation),
Installation).
2008.50 Mondeo 3/2008 G939296en

Component Tests Brake Master Cylinder
Usually, the first and strongest indicator of anything

Brake Booster wrong in the brake system is a feeling through the
brake pedal. In diagnosing the condition of the
1. Inspect all hoses and connections. All unused brake master cylinder, check brake pedal feel as
vacuum connectors should be capped. Hoses evidence of a brake concern.
and their connections should be correctly
Check for brake warning indicator illumination and
secured and in good condition with no holes
the brake fluid level in the brake fluid reservoir.
and no collapsed areas. Inspect the brake
booster check valve for damage.
2. Check the hydraulic brake system for leaks or Normal Conditions
low fluid.
3. With the transmission in PARK (automatic The following conditions are considered normal
transmission), stop the engine and operate the and are not indications that the brake master
parking brake. Operate the brake pedal several cylinder is in need of repair.
times to exhaust all vacuum in the system. 1. New brake systems are not designed to produce
4. With the engine turned OFF and all vacuum in as hard a pedal effort as in the past. Complaints
the system exhausted operate the brake pedal of light pedal efforts should be compared to
and hold it down. Start the engine. If the vacuum pedal efforts of another vehicle, same model
system is operating, the brake pedal will tend and year.
to move downward under constant foot 2. During normal operation of the brake master
pressure. If no motion is felt, the vacuum cylinder, the brake fluid level in the reservoir will
booster system is not functioning. rise during brake application and fall during
5. Remove the vacuum hose from the brake release. The net brake fluid level (after brake
booster. Manifold vacuum should be available application and release) will remain unchanged.
at the brake booster end of the hose with the 3. A trace of brake fluid exists on the brake booster
engine at idle speed and the transmission in shell below the master cylinder mounting flange.
PARK or NEUTRAL. Make sure that all unused This results from the normal lubricating action
vacuum outlets are correctly capped, hose of the master cylinder bore end seal.
connectors are correctly secured and vacuum
hoses are in good condition. When it is 4. Brake fluid level will fall with brake pad wear.
established that manifold vacuum is available
to the brake booster, connect the vacuum hose
to the brake booster and repeat Step 3. If no Abnormal Conditions
downward movement of the brake pedal is felt,
Changes in brake pedal feel or travel are indicators
the vacuum booster system is not functioning.
that something could be wrong in the brake system.
6. Run the engine for a minimum of 10 seconds The diagnostic procedure and techniques are brake
at fast idle. Stop the engine and let the vehicle pedal feel, brake warning indicator illumination and
stand for 10 minutes. Then, operate the brake low brake fluid level as indicators in diagnosing
pedal with approximately 98N (20 lb) of force. brake system concerns. The following condition
The pedal feel (brake applications) should be are considered abnormal and indicate that the
the same as noted with the engine running. If brake master cylinder is in need of repair.
the brake pedal feels hard (no power assist),
install a new check valve and then repeat the 1. Brake pedal goes down fast. This could be
testing. If the brake pedal still feels hard, install caused by an external or internal leak.
a new brake booster. If the brake pedal 2. Brake pedal eases down slowly. This could be
movement feels spongy, bleed the brake caused by an external or internal leak.
system. Refer to General Procedures. 3. Brake pedal is low or feels spongy. This
condition may be caused by no fluid in the brake
master cylinder reservoir, brake fluid reservoir
cap vent holes blocked or air in the hydraulic
system.
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4. Brake pedal effort is excessive. This may be Type 2: An external leak may occur at the brake
caused by a bind or obstruction in pedal or fluid reservoir mounting seals. Repair such a leak
linkage, blocked fluid control valve or insufficient by installing new seals.
brake booster vacuum.
5. Rear brakes lock up during light pedal force.
This may be caused by grease or fluid on brake
pads, damaged brake pads and linings,
incorrectly adjusted parking brakes, damaged
or contaminated brake pressure control valve.
6. Brake pedal effort is erratic. This condition could
be caused by the brake booster being in
operative, extreme brake caliper piston knock
back or incorrectly installed brake pads.
7. Brake warning indicators is always ON. This
may be caused by low fluid level, ignition wire
routing too close to the fluid level indicator, or
float assembly damage.
Bypass Condition Test
1. Check the brake fluid level in the brake fluid

reservoir. Fill the brake fluid reservoir to the
MAX mark if low or empty.
2. Observe the brake fluid level in the brake fluid
reservoir. If after several brake applications, the
brake fluid level remains the same, measure
the wheel turning torque required to rotate the
wheels with rearward with brakes applied as
follows:
Place the transmission in NEUTRAL and raise and
support the vehicle. REFER to: (100-02 Jacking
and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
With the aid of another technician, operate the
brakes with a minimum of 445N (100 lb) and hold
for approximately 15 seconds. With the brakes still
applied, exert torque on the front wheels to 10.1
Nm (75 lbf.ft). If either wheel rotates, install a new
brake master cylinder.
Non-Pressure Leaks
Any empty brake fluid reservoir condition may be

the result of two types of non-pressure external
leaks.
Type 1: An external leak may occur at the brake
fluid reservoir cap because of incorrect positioning
of the gasket and cap.
Reposition the gasket and cap.
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GENERAL PROCEDURES
Brake System Bleeding(12 141 0)

General Equipment 9.
CAUTION: Make sure that the bleed nipple
Worldwide Diagnostic System (WDS) cap is installed after bleeding the brake
line(s). This will prevent corrosion to the
bleed nipple. Failure to follow this instruction
Bleeding may result in the bleed nipple becoming
WARNING: Brake fluid contains polyglycol seized.
ethers and polyglycols. Avoid contact with Repeat the procedure for the remaining brake
the eyes. Wash hands thoroughly after lines.
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.
CAUTION: If brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
NOTE: Make sure that the vehicle is standing on
a level surface.
NOTE: The system consists of separate circuits
for each front and diagonally opposite rear wheel.
Each circuit can be bled independently.
1.
CAUTION: The 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 (pumping 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.
2008.50 Mondeo 3/2008 G17458en

GENERAL PROCEDURES
Brake System Pressure Bleeding(12 141 0)

General Equipment
Worldwide Diagnostic System (WDS)
Brake/clutch system pressure bleeder/filler
Bleeding
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.
CAUTION: If brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
NOTE: Make sure that the vehicle is standing on
a level surface.
NOTE: The system consists of separate circuits
for each front and diagonally opposite rear wheel.
Each circuit can be bled independently.
1. Fill the brake fluid reservoir to the MAX mark.
2. CAUTIONS:
Make sure that the pressure within the
brake system does not exceed 1 bar.
Make sure that the pressure bleeding

equipment is filled with new brake fluid to
the correct specification.
Using the brake/clutch system pressure
bleeder/filler, pressure bleed the system in
accordance with the manufacturer's
instructions.
3.
CAUTION: Make 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
may result in the bleed nipple becoming
seized.
Fill the brake fluid reservoir to the MAX mark
as necessary.
2008.50 Mondeo 3/2008 G17459en

GENERAL PROCEDURES
Front Brake Disc Runout Check

Special Tool(s) 2. 1. Position the dial indicator gauge so that it
contacts the brake disc face approximately
Dial Indicator Gauge (Metric)
10 mm from the outer edge (inner face
205-069
measurement shown).
Special Tool(s): 205-069, 205-070, 206-003
2. Slowly rotate the brake disc and note the
15046 readings.
3. Repeat sub-steps 1 and 2 on the brake disc
outer face.
Holding Fixture, Dial Indicator 4. If any of the measurements exceed the brake
Gauge disc runout specification, a new brake disc
205-070 must be installed and the brake disc runout
re-checked.
Refer to: Specifications (206-03 Front Disc
15022A Brake, Specifications).
Holding Fixture, Dial Indicator 1

1
Gauge (Disc Brake) 205-069
206-003 206-003
2
12003
1
205-070
1. Remove the following items:
1. Wheel and tire.
E44412
Refer to: Wheels and Tires (204-04 Wheels
and Tires, Diagnosis and Testing).
3. 1. Measure the brake disc thickness at eight
2. Brake pads.
positions, 45 degrees apart and
Refer to: Brake Pads (206-03 Front Disc approximately 15 mm from the outer edge of
Brake, Removal and Installation). the brake disc.
2. If any of the measurements exceed the brake
disc thickness variation specification, a new
brake disc must be installed and the brake
disc runout re-checked.
Refer to: Specifications (206-03 Front Disc
Brake, Specifications).
E44414
2008.50 Mondeo 3/2008 G543363en

GENERAL PROCEDURES
4. If all the brake disc runout measurements and
the thickness variation are within the
specifications, check the wheel balance.
2008.50 Mondeo 3/2008 G543363en

GENERAL PROCEDURES
Rear Brake Disc Runout Check

Special Tool(s) 2. 1. Position the dial indicator gauge so that it
contacts the brake disc face approximately
Dial Indicator Gauge (Metric)
10 mm from the outer edge (inner face
205-069
measurement shown).
Special Tool(s): 205-069, 205-070, 206-003
2. Slowly rotate the brake disc and note the
15046 readings.
3. Repeat sub-steps 1 and 2 on the brake disc
outer face.
Holding Fixture, Dial Indicator 4. If any of the measurements exceed the brake
Gauge disc runout specification, a new brake disc
205-070 must be installed and the brake disc runout
re-checked.
Refer to: Specifications (206-04 Rear Disc
15022A Brake, Specifications).
Holding Fixture, Dial Indicator 1

1
Gauge (Disc Brake) 205-069
206-003 206-003
2
12003
1
205-070
1. Remove the following items:
1. Wheel and tire.
E44412
Refer to: Wheels and Tires (204-04 Wheels
and Tires, Diagnosis and Testing).
3. 1. Measure the brake disc thickness at eight
2. Brake pads.
positions, 45 degrees apart and
Refer to: Brake Pads (206-04 Rear Disc approximately 15 mm from the outer edge of
Brake, Removal and Installation). the brake disc.
2. If any of the measurements exceed the brake
disc thickness variation specification, a new
brake disc must be installed and the brake
disc runout re-checked.
Refer to: Specifications (206-04 Rear Disc
Brake, Specifications).
E44414
2008.50 Mondeo 3/2008 G998060en

GENERAL PROCEDURES
4. If all the brake disc runout measurements and
the thickness variation are within the
specifications, check the wheel balance.
2008.50 Mondeo 3/2008 G998060en

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206-00-1 Brake System - General Information 206-00-1

SECTION 206-00 Brake System - General Information

DESCRIPTION AND OPERATION

DIAGNOSIS AND TESTING

2008.50 Mondeo 3/2008 G939295en

2008.50 Mondeo 3/2008 G939296en

Symptom Possible Sources Action

2008.50 Mondeo 3/2008 G939296en

Symptom Possible Sources Action

2008.50 Mondeo 3/2008 G939296en

Symptom Possible Sources Action

2008.50 Mondeo 3/2008 G939296en

Symptom Possible Sources Action

2008.50 Mondeo 3/2008 G939296en

Symptom Possible Sources Action

2008.50 Mondeo 3/2008 G939296en

2008.50 Mondeo 3/2008 G939296en

2008.50 Mondeo 3/2008 G939296en

2008.50 Mondeo 3/2008 G939296en

Usually, the first and strongest indicator of anything

2008.50 Mondeo 3/2008 G939296en

Bypass Condition Test

1. Check the brake fluid level in the brake fluid

Any empty brake fluid reservoir condition may be

2008.50 Mondeo 3/2008 G939296en

Brake System Bleeding(12 141 0)

2008.50 Mondeo 3/2008 G17458en

Brake System Pressure Bleeding(12 141 0)

Make sure that the pressure bleeding

2008.50 Mondeo 3/2008 G17459en

Front Brake Disc Runout Check

Holding Fixture, Dial Indicator 1

2008.50 Mondeo 3/2008 G543363en

2008.50 Mondeo 3/2008 G543363en

Rear Brake Disc Runout Check

Holding Fixture, Dial Indicator 1

2008.50 Mondeo 3/2008 G998060en

2008.50 Mondeo 3/2008 G998060en

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