2004 Ford Focus Brake Service (ONLINE REPAIR MANUALS)

Safety Precautions

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.

• Wear suitable respirator approved for asbestos dust use during all repair procedures.
• When cleaning brake dust f...

Pressure bleeding is recommended for all hydraulic brake systems. Ensure all dirt and contaminants are removed from master cylinder area prior to removing reservoir cap.

To prevent air from the pressure tank getting into the lines, do not shake the tank while air is being added to the tank or after it has been pressurized. Set the tank in the required location, bring the air hose to the tank, and do not move it during the bleeding operation. The tank should be kept at least one-third full.

On vehicles equipped with disc brakes and master cylinders without proportioners or press...

• Inspect components for damage and unusual wear.
• 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.
• Ins...

• Attach a rubber drain hose to bleeder screw of clutch master cylinder, then submerge free end of hose in a container partially filled with clean brake fluid.
• Slowly pump clutch pedal to floor several times and hold it.
• With clutch pedal held to floor,...

Removal

• Release parking brake.
• Raise and support vehicle, then remove tire and wheel assemblies.
• On models equipped with anti-lock brakes, remove wheel speed sensor.
• On all models, remove brake drum and wheel hub.
• Remove brake shoe hold down springs and pins, Fig. .
• Disconnect brake shoes from wheel cylinders. Hold wheel cylinder pistons in place with suitable rubber bands.
• Remove shoes from anchor block, Fig. .
• Push parking brake lever inward and remove cable, Fig. .
• Remove lower and upper return springs.
• Remove primary shoe from strut and brake shoe adjuster, Fig. .
• Remove secondary shoe f...

Whenever new brake components are installed in the hydraulic system, it is recommended that the entire hydraulic system be thoroughly flushed with clean brake fluid.

It may sometime become required to flush out the system due to the presence of mineral oil, kerosene, gasoline, etc., which will cause swelling of rubber piston cups and valves and render them inoperative.

Flushing is performed at e...