2005 Ford Freestyle Brake Service (ONLINE REPAIR MANUALS)

Power brake operation concerns should be handled as if two separate systems exist.

• Inspect for faults in hydraulic system first.
• If hydraulic system is satisfactory, inspect power brake circuit.
• Press brake pedal firmly and then start engine.
• Pedal should fall away slightly and less pressure should be needed to maintain pedal in any position.
• Install of suitable pressure gauge in brake hydraulic system.
• Record pressure with engine off and power unit not operating.
• Maintain pedal height, start engine and record measurement.
• There should be substantial pressure increase in second measurem...

Power Booster, Replace

Crown Victoria, Grand Marquis, Marauder & Town Car

• Disconnect fluid level sensor connector.
• Position speed control cable aside.
• Disconnect power brake booster check valve.
• Remove brake master cylinder mounting nuts.
• Remove wiring harness bracket and position aside.
• Remove brake master cylinder and position aside.
• Remove push-pins and instrument close-out panel.
• Remove stoplight switch retaining pin.
• Slide stoplight switch and booster push rod off brake pedal pin.
• Remove mounting nuts and power brake booster.
• Reverse procedure to install. Torque mounting nuts ...

Brake System Bleed

Manual

The primary and secondary (front and rear) hydraulic brake systems are individual systems and are bled separately. Bleed longest tube first on individual system being serviced. During complete bleeding operation, Do not allow the master cylinder reservoir to run dry. Never reuse brake fluid that has been drained from hydraulic system or has been allowed to stand in an open container for an extended period of time.

• To bleed brake system, position a suitable box wrench on bleeder fitting on brake wheel cylinder. Attach rubber drain hose to bleeder fitting.
• Sub...

Parking Brake

Crown Victoria, Grand Marquis, Marauder & Town Car

• Apply parking brake control fully with 100 lbs., foot pedal effort, then release brake control.
• Place transmission in Neutral position, then raise and support vehicle.
• With parking brake control in Off position, grasp pensioner around housing.
• Unlock clip by pulling downward with suitable hook tool place into rounded end of clip and support pensioner.
• Tensioner spring will take up cable slack and load cables, while holding pensioner, lock clip by pushing up on bottom of clip. If clip does not slide up move assembly slightly ...

Disc brake service is critical because of 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 rubbin...

Bendix Diaphragm System

These units are of the vacuum suspended system. Some units are of the single diaphragm system, while others are of the tandem diaphragm system. Both single piston and double piston or split system master cylinders are used.

The vacuum suspended diaphragm system units utilize engine manifold vacuum and atmospheric pressure for its power. It consists of three basic elements combined into a single power unit. The three basic elements of the single diaphragm system are:

• Vacuum power section which includes front and rear shell, power diaphragm, return spring and push...