2000 Ford ZX2 Brake Service (ONLINE REPAIR MANUALS)

Complaints about power brake operation should be handled as if two separate systems exist. Inspect for faults in the hydraulic system first. If it is satisfactory, start inspecting the power brake circuit. For a quick inspection of proper power unit operation, press the brake pedal firmly and then start the engine. The pedal should fall away slightly and less pressure should be needed to maintain the pedal in any position.

Another inspection begins with installation of a suitable pressure gauge in the brake hydraulic system. Take a reading with the engine Off and the power unit n...

On models with anti-lock brakes, the brake system power booster must be depressurized before disconnecting any hydraulic lines or fittings. Depressurize the system by pumping the brake pedal a minimum of 25 times with the ignition in the Off position.

After performing any service work, obtain a firm brake pedal before moving the vehicle.

Continental, Cougar, Mustang, Sable & Taurus

Removal

On models with air suspension, turn service switch Off before beginning repairs.

• Raise and support rear of vehicle, then remove wheel and tire assembly.
• Remove brake hose bracket to shock unit bra...

Disc brake service is critical due to the close tolerances required in machining the brake disc to ensure proper brake operation.

Maintaining close control of the shape of the rubbing surfaces is required to prevent brake roughness. In addition, the surface finish must be non-directional and maintained at a micro-inch finish. This is required to avoid pulls and erratic performance, and to promote long lining life and equal lining wear of both the lefthand and righthand brakes.

Do not attempt to refinish the rubbing ...

Hydraulic Brake Fluid Color

Hydraulic brake fluid must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine.

Fluid color in a normal brake system may vary from its original color for many reasons. A brake master cylinder may show significantly different shades fluid color between the two brake master cylinder reservoirs. Color may also appear to vary between cast steel and die cast aluminum reservoirs. Some reasons for discolorati...

Battery Ground Cable

Prior to service, disconnect battery ground cable and isolate as required.

System Depressurizing

On models equipped with anti-lock brakes, hyd...

System Components

Refer to Fig. for ABS component locations.

Hydraulic Control Unit (HCU)

The hydraulic unit consists of a valve body assembly, pump and a motor assembly. During normal braking, fluid from the brake master cylinder enters the HCU through inlet port located at the bottom of the unit. Then the fluid passes through four normally open isolation valves, one to each of the four wheels

If anti-lock brake control module senses that a wheel is about to lock, the module pulses the appropriate isolation valve, which in turn closes that valve which prevents any more fluid from ente...