2003 Ford ZX2 Brake Service (ONLINE REPAIR MANUALS)

Preliminary Inspection

Verify concern by driving vehicle. Look for problems in other areas which may affect ABS: suspension and steering components, tire integrity and air pressure, wheel bearings and brake components common to all brake systems. The hydraulic anti-lock actuator assembl...

Brake Roughness

If roughness or vibration is encountered during highway operation or if pedal pumping is experienced at low speeds, the disc may have excessive thickness variation. Measure the disc at 12 points with a micrometer at a radius approximately one inch from the edge of the disc. If thickness measurements vary by more than .0005 inch, replace the rotor.

Excessive later...

Pressure bleeding is recommended for all hydraulic disc brake systems.

Do not reuse brake fluid drained from the hydraulic system when bleeding the brakes. Ensure disc brake pistons are returned to their normal positions and the shoe and lining assemblies are properly seated.

Do not shake the pressure bleeder tank while air is being added or after it has been pressurized. This will prevent air from the tank getting into the lines. Do not move the tank during the bleeding operation. The tank should be kept at least one third full.

On models equipped with power brakes, exhaust the...

Remove wheels and inspect brake disc, caliper and linings. Inspect wheel bearings and repack if required.

If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.

If caliper is removed when installing new components, clean all components in alcohol, then wipe dry using lint-free cloths. Blow out drilled passages and bores with compressed air. Inspect dust boots for punctures or tears, replace as required.

Inspect piston bores in both housings for scoring or pitting. Bores showing light scratches or corrosion can be cleaned with crocus clo...

Power Booster, Replace

Continental

• Remove battery, then disconnect speed control actuator electrical connector.
• Remove two retaining nuts and speed control actuator cable and position aside.
• Remove two strut tower brace nuts and brace.
• Remove windshield wiper motor, then rubber grommet from lower cowl panel.
• Remove lower cowl panel nut and bolts, then lower cowl panel.
• Disconnect power brake booster check valve, then master cylinder.
• Remove retaining nut and evaporative emission canister purge valve.
• Disconnect EVAP electrical connector, then vacuum hoses.
• Remove instrument close...

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...