1996 Ford Escort Brake Service (ONLINE REPAIR MANUALS)

• On models equipped with anti-lock brakes, hydraulic system must be depressurized prior to disconnecting any hydraulic lines or fittings, by pumping the brake pedal a minimum of 25 times with ignition in Off position.
• On all models, grease or any other foreign material must be kept off caliper, disc surfaces and external hub surfaces during service procedures. Handling brake disc and caliper should be done in a way to avoid deforming disc and nicking or scratching brake linings.
• If inspection reveals rubber piston seals are worn or damaged, they should be replaced immediately.
• During wh...

• Inspect components for damage and unusual wear. Replace as necessary.
• Inspect wheel cylinders. Boots which are torn, cut, or heat damaged indicate need for wheel cylinder replacement. Fluid spilling from boot center hole, or wetness around wheel cylinder ends indicates cup leakage and need for wheel cylinder replacement. A small amount of fluid is always present and is considered normal, acting as lubricant for cylinder pistons.
• Inspect backing p...

Master Cylinder Overhaul

Disassemble

• Clean outside of master cylinder thoroughly. Drain brake fluid from master cylinder.
• Remove stop bolt and pressure control valves, if equipped.
• Using a screwdriver, carefully pry up on reservoir and remove it from master cylinder body.
• Remove fluid control valve, if equipped.
• Depress primary piston and remove snap ring from retaining groove at open end of bore.
• Remove primary and secondary piston assemblies from master cylinder. If secondary piston does not come out, apply air pressure to secondary outlet port to remove.

Inspection

When disassembled...

When working on or around brake assemblies, care must be taken to prevent breathing asbestos dust. Many manufacturers incorporate asbestos fibers in the production of brake linings. During routine service operations, the amount of asbestos dust from brake lining wear is at a low level due to a chemical breakdown during use. Do not sand or grind brake linings unless suitable local exhaust ventilation equipment is used to prevent excessive asbestos exposure.

The brake shoe and lining assemblies should be replaced if the lining is worn to within ^1/32 inch of rivet heads (riveted linings...

Pushrod

Proper adjustment of the master cylinder pushrod is necessary to ensure proper operation of the power brake system. A pushrod that is too long will prevent the master cylinder piston from completely releasing hydraulic pressure, eventually causing the brakes to drag. A pushrod that is too short will cause excessive brake pedal travel and cause groaning noises to come from the booster when the brakes are applied. A properly adjusted pushrod that remains assembled to the booster with which is was matched during production should not require service adjustment. However, if the b...

Wiring Diagrams

Refer to "Wiring Diagrams" in "Vehicle Systems."

Quick Test

For Quick Test and diagnostic trouble code identification, refer to Figs. and on Aspire models and Figs. and on Escort and Tracer models.

Warning Indicator

The anti-lock brake warning indicator will come on to warn the driver of an ABS failure. Normal brake system operation will still be available. However, the wheels will lock up under hard braking.

On-Board Diagnostics

On-Board Diagnostics is divided into two specialized tests, the "Key ON-Engine Running (KOER) Test" and the "Continuous Test." Before performi...