Inspection and Verification: Notes

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury.

WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.

NOTE: Blistering or swelling of rubber brake components can indicate contamination of the brake fluid by a petroleum-based substance. Contaminated rubber components in the hydraulic brake system must be replaced and the entire hydraulic brake system must be flushed with clean, specified brake fluid to prevent recontamination.

NOTE: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled on a painted or plastic surface, immediately wash it with water.

NOTE: Always check the fluid level in the brake master cylinder reservoir before carrying out any test procedures. If the fluid level is not at the correct level, clean the reservoir cap before removing, then add clean, specified brake fluid.

NOTE: Prior to carrying out any diagnosis, make sure the red brake warning indicator is functional. Refer to INSTRUMENT CLUSTER (IC) AND WARNING CHIMES article.

The first indication that something may be wrong in the brake system is a change in the feeling through the brake pedal. The brake warning indicator in the instrument cluster and the brake fluid level in the brake master cylinder reservoir are also indicators of system concerns.

If a wheel is locked and the vehicle must be moved, open a bleeder screw at the locked wheel to let out enough fluid to relieve the pressure. Close the bleeder screw. This bleeding operation may release the brakes but will not correct the concern. If this does not relieve the locked wheel condition, repair the locked components before proceeding.

Inspect all hoses and connections. All unused vacuum connectors should be capped. Make sure hoses and their connections are correctly secured and in good condition with no holes, soft or collapsed areas.

Verify the customer concern.

Visually inspect for obvious signs of mechanical or electrical damage.

VISUAL INSPECTION CHART

Mechanical	Electrical
Brake master cylinder Brake master cylinder reservoir Brake booster Brake booster check valve Brake booster vacuum hose Brake hoses and tubes Brake caliper Brake caliper piston seals Brake caliper guide pins Brake disc Brake pads Brake pedal linkage Hydro-Boost® power steering fluid hoses and connections Wheel bearings Tires	Parking brake switch Brake fluid level switch Wiring, terminals or connectors

If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
If the cause is not visually evident, go to Symptom Chart - Brake System or Go to Symptom Chart - Noise, Vibration and Harshness (NVH) .
For low or spongy brake pedal concerns:
- check for fluid leaks. Repair as necessary.
- check and, if necessary, refill the brake master cylinder reservoir with clean, specified brake fluid.
- bleed the brake system and retest the brake pedal feel.
- if the brake pedal is still low or feels spongy, check the brake pedal mounting for looseness and correct installation. Check the power brake booster and the master cylinder for loose mounting. Correct as necessary and retest the system for normal operation.
For a slow or incomplete brake pedal return concern:
- inspect for binding, damage, correct installation or interference at the brake pedal.
- check the power brake booster for binding, damage and correct installation.