4+ +Brake++System

2003 Mustang Workshop Manual .
1 1
SECTION 206-00: Brake System — General Information 2003 Mustang Workshop Manual
SPECIFICATIONS
Torque Specifications
Description Nm lb-ft lb-in
Front disc brake caliper bleeder screw 12-18 9-13 —
Front master cylinder brake tube 22-28 17-20 —
Rear bleeder screw 20 15 —
Rear master cylinder brake tube 15-20 11-14 —
Master cylinder bleeder screws 9 — 80
file:///C:/Ford/2000-2004/tsocache/SHEF_4464/S3B~us~en~... 17.11.2011
2003 Mustang Workshop Manual .1 2
DESCRIPTION AND OPERATION
Brake System
Component Locations
Part
Item Number Description
1 2C346 Four wheel anti-lock brake system (4WABS)
hydraulic control unit and control module assy (non-

traction)
1 2C353 Four wheel anti-lock brake system (4WABS)
hydraulic control unit and control module assy
(traction)
2 2B559 Hydro-Boost brake booster and brake master
cylinder assy
3 2B195 Vacuum brake booster and brake master cylinder
assy
4 2K327 Rear disc brake assy
5 2780 Parking brake control
6 2B119 Front disc brake assy
The vehicle is equipped with a vacuum-assisted or a hydro-boost power braking system. Refer to
Section 206-07 .
The braking system is a front-to-rear split hydraulic system. Refer to Section 206-06 .
The front wheel brakes utilize a dual piston brake caliper and disc brake system. Refer to Section 206-
03 .
The rear brakes utilize a single piston brake caliper and disc brake system. Refer to Section 206-04 .
The parking brake system is a mechanical system that is controlled by an independent hand-operated
parking brake control and is self-adjusting. Refer to Section 206-05 .
A 4-wheel anti-lock brake system or anti-lock brake system with traction control (4WABS) is optional
equipment on all models except Cobra. Cobra has ABS and traction control as standard equipment.
Refer to Section 206-09A .
DIAGNOSIS AND TESTING
Brake System
Refer to Wiring Diagrams Cell 60 , Instrument Cluster for schematic and connector information.
Refer to Wiring Diagrams Cell 97 , Daytime Running Lamps for schematic and connector information.
Special Tool(s)
73 Digital Multimeter
105-R0051 or Equivalent
ABS Brake and Pressure Test

Kit
107-02350 or Equivalent
Tire and Wheel Runout Gauge

Set
134-00199 or Equivalent
Inspection and Verification
WARNING: Use of any other than the approved DOT 3 brake fluid will cause permanent
damage to brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with
eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with
running water for 15 minutes. Get medical attention if irritation persists. If taken internally,
drink water and induce vomiting. Get medical attention immediately.
CAUTION: Do not spill brake fluid onto painted surfaces. If spilled, wipe up immediately.
NOTE: Always check the fluid level in the brake master cylinder reservoir (2K478) before performing
the test procedures. If the fluid level is not at the correct level, add High Performance DOT 3 Brake
Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.
NOTE: Prior to performing any diagnosis, make sure the brake warning indicator is functional. For
additional information, refer to Section 413-01 .
The first indication that something may be wrong in the brake system is a change in the feeling through
the brake pedal (2455). 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 (1007)
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 cause of trouble. 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.
Non-Pressure Leaks
The only part of the brake system that could have a brake fluid loss that does not appear when the
system is under pressure is the brake master cylinder reservoir area. Brake fluid loss can be caused
by a missing or poorly-fitted brake master cylinder filler cap (2162), a punctured or otherwise damaged
brake master cylinder reservoir, a missing or damaged brake master cylinder filler cap gasket, or by
missing, damaged or poorly-fitted sealing grommets between the brake master cylinder (2140) and the
brake master cylinder reservoir.
The brake master cylinder reservoir grommets are not separately serviceable and must be installed
new as part of a new brake master cylinder reservoir.
Install a new flexible brake hose if it shows signs of softening, cracking or other damage.
When installing a new brake hose, position the hose to avoid contact with other vehicle components.
Road Test
Perform a road test to compare actual vehicle braking performance with the performance standards
expected by the driver. The ability of the test driver to make valid comparisons and detect performance
deficiencies will depend on experience.
The driver should have a thorough knowledge of brake system operation and accepted general
performance guidelines in order to make good comparisons and detect performance problems.
Select a road that is reasonably smooth and level. Gravel or bumpy roads are not suitable because the
surface does not allow the tires to grip the road equally. Avoid crowned roads.
A key factor in evaluating brake concerns is the deceleration rate. This varies from vehicle to vehicle
and with changes in operating conditions. It is evident how well the brakes are working after just a few
applications.
Avoid locking the brakes. Locked brakes are not an indication of braking efficiency.
Visual Inspection Chart

Mechanical Electrical
Brake master cylinder Parking brake switch
Brake caliper piston Damaged or corroded wiring harness
Brake discs Brake master cylinder fluid level switch
Brake pads
Power brake booster

Brake pedal linkage
Vacuum booster hose
Tires
Foreign material
For low or spongy brake pedal concerns:
check and, if necessary, refill the brake master cylinder reservoir.

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 brake 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.
Vibration When Brakes are Applied
For vibration concerns when brakes are applied, perform the following procedure.
Visually inspect:
tire condition and pressure.

suspension bushings and ball joints.
Correct as necessary.
1. Verify and isolate the concern. Brake roughness can be felt in:
the steering wheel.
the seat.
the brake pedal.
2. After verifying the concern, check for related concerns in the:

On-Line Automotive Service Information System (OASIS).
Technical Service Bulletins.
3. Check wheel bearing end-play and correct as necessary.
4. NOTE: Begin at the front of the vehicle unless the vibration has been isolated to the rear.
Remove the tire and wheel.
5. Remove the brake caliper.
6. Measure and record the brake disc thickness. Install a new brake disc if the thickness after
machining will be at or below specification. The specification is molded into the brake disc. Do
not machine a new brake disc.
7. For vehicles with a two-piece hub and brake disc assembly:

Match-mark before disassembly.
Remove the brake disc.
Using a die grinder with a mild abrasive (Scotch Brite® type), remove any rust or
corrosion from the hub and brake disc mounting surfaces.
Align the match-marks and reinstall the brake disc on the hub.
8. CAUTION: Do not use a bench lathe to machine brake discs.
NOTE: The depth of cut must be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter
cuts will cause heat and wear. Heavier cuts will cause poor brake disc surface finish.
Using on-vehicle brake lathe, machine the brake discs. Follow the manufacturer's instructions.
After machining, make sure the brake disc still meets the thickness specification.
9. Using a dial indicator, verify that the brake disc lateral runout is now within vehicle specification.
10. Remove any metal chips.
11. Remove the hub adapter.
12. Remove any remaining metal chips from the machining operation.
13. CAUTION: Do not carry out this step on rear drum-in-hat brake discs.
For vehicles with a two-piece hub and a non drum-in-hat brake disc assembly:
Remove the brake disc from the hub.
Remove any remaining metal chips from hub and brake disc mounting surfaces and from
the ABS sensor.
Apply High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA to the mounting
surfaces.
Using the match-marks, mount the brake disc on the hub.
14. Install the caliper and check brake operation.
Symptom Chart
Symptom Chart
Condition Possible Sources Action
The Brakes Pull or Tire air pressure. Go To Pinpoint Test A .
Drift Wheel alignment.
Brake pads.
Brake components.
Suspension
component.
The Red Brake Instrument cluster. Go To Pinpoint Test B .
Warning Indicator Is Circuit.
Always On Parking brake.

Brake fluid level.
Vibration When Rear disc brakes. REFER to Section 100-
Brakes Are Applied Front disc brakes. 04 .
Brake Pedal Goes Brake fluid level. FILL the brake master
Down Fast cylinder reservoir.
BLEED the system.
Air in system. BLEED the system.
Brake master PERFORM the brake
cylinder. master cylinder
component test in this
section.
The Brake Pedal Air in system. BLEED the system.
Eases Down Slowly REFER to Bleeding —
System in this section.
section.
Brake Lockup During Disc brake Go To Pinpoint Test C .
Light Brake Pedal component.
Force Parking brake
component.
Anti-lock brake
control system.
Excessive/Erratic Leak in hydraulic Go To Pinpoint Test D .
Brake Pedal Travel system.
Air in system.
Disc brake caliper.
Brake master
cylinder.
Brakes Drag Parking brake REPAIR or INSTALL new
component. components as
necessary. REFER to
Section 206-05 .
Disc brake caliper. REPAIR or INSTALL a
new brake caliper as
necessary. REFER to
Section 206-03 and
Section 206-04 .
Brake booster-to- ADJUST the push rod.
brake master REFER to Section 206-
cylinder push rod 07 .
adjustment.
section.
Excessive Brake Power brake PERFORM the brake
Pedal Effort booster. booster component test
in this section.
Power brake PERFORM the check
booster check valve component test in
valve (2365). this section.
Power brake REROUTE, REPAIR or
booster hose. INSTALL a new brake
booster hose as
necessary.
Red Brake Warning Circuit. REFER to Section 413-
Indicator Inoperative Bulb. 01 .
Brake Noise Disc brake MACHINE or INSTALL a
component. new brake component as
necessary. REFER to
Section 206-03 or
Section 206-04 .
Hydro-Boost, No Power steering Go To Pinpoint Test E .
Power Assist pump.
Linkage.
Power steering
fluid flow.
Hydro-boost unit.
Hydro-Boost Erratic Supply hose. Go To Pinpoint Test F .
Operation, Sticks, Hydro-boost unit.
Binds or Grabs
Hydro-Boost Brake Leakage. Go To Pinpoint Test G .
System Operation Hydro-boost unit.
Suspect
Pinpoint Tests
PINPOINT TEST A: THE BRAKES PULL OR DRIFT
Test Step Result / Action to Take

A1 CHECK THE TIRES
NOTE: Check tire pressure with the brakes off. Yes
Check tires for uneven and excessive wear and for correct GO to A2 .
pressure.
No
CORRECT as necessary.
RETEST for normal
operation.
Are the tires OK?

A2 CHECK THE ALIGNMENT
Check the caster, camber and toe. Refer to Section 204- Yes
00 . GO to A3 .
No
CORRECT alignment as
necessary. REFER to Section
204-00 . RETEST for correct
operation.
Is the alignment OK?

A3 CHECK THE DISC BRAKE COMPONENTS
Check all disc brake calipers, anchor plate guide pins and Yes
brake pads for binding, wear, damage, contamination and GO to A4 .
correct installation.
No
REPAIR or INSTALL new
components as necessary.
RETEST for normal
operation.
Are the disc brake calipers, anchor plate guide pins

and brake pads OK?
A4 ROAD TEST THE VEHICLE
Road test the vehicle, and observe whether the drift Yes
occurs with or without the brakes applied. REPAIR or INSTALL new
Does the drift or pull occur with the brakes applied? front disc brake caliper or
anchor plate guide pins on
the side opposite to the
direction of the drift or pull.
No
REPAIR or INSTALL new
front disc brake caliper or
anchor plate guide pins on
the side of the vehicle in the
direction of the drift or pull.
PINPOINT TEST B: THE RED BRAKE WARNING INDICATOR IS

ALWAYS ON

B1 CHECK THE BRAKE MASTER CYLINDER FLUID
LEVEL SWITCH
Key in OFF position. Yes
Disconnect: Brake Master Cylinder Fluid Level Switch GO to B2 .
C124.
Connect a fused jumper from C124-2 circuit 977 No
(PK/WH) to C124-3 circuit 128 (VT/YE). INSTALL a new brake master
cylinder reservoir. TEST the

system for normal operation.
Key in ON position.
Does the brake warning indicator stay on?
B2 CHECK PARKING BRAKE SWITCH
Disconnect: Parking Brake Switch. GO to B3 .
Key in ON position.
Does the brake warning light stay on? No
INSTALL a new parking brake
switch. TEST the system for
normal operation.
B3 CHECK THE GEM
Disconnect: GEM C201e. REPAIR the GEM. TEST the
Measure resistance to ground at C201e-13. system for normal operation.
No
For vehicles without Daytime
Running Lights (DRL), GO to
B4 . For vehicles with DRL, GO
to B5 .
Is the resistance greater than 10,000 ohms?

B4 CHECK CIRCUITS 977 (VT/WH), 22 (LB/BK) AND 128
(VT/YE)
Remove the fused jumper from C124. Yes
Measure the resistance to ground at C124-2. REPAIR the ground short in
circuit 128 (VT/YE). TEST the
No
REPAIR the ground short in
circuit 977 (VT/WH) or circuit 22
(LB/BK). TEST the system for
normal operation.

B5 CHECK CIRCUIT 128 (VT/YE)
Remove the fused jumper from C124. Yes
Measure the resistance to ground at C201e-13. GO to B6 .
No
circuit 128 (VT/YE). TEST the

B6 CHECK DAYTIME RUNNING LIGHTS (DRL) MODULE
Disconnect: DRL Module C1030. Yes
Measure the resistance to ground at C124-2. REPAIR the DRL module. TEST
the system for normal operation.
No
circuit 22 (LB/BK) or 977
(VT/WH). TEST the system for
normal operation.
PINPOINT TEST C: BRAKE LOCKUP DURING LIGHT BRAKE PEDAL

FORCE

C1 INSPECT THE TIRES
Inspect the tires for uneven or excessive Yes
wear, correct pressure, correct size and GO to C2 .
type.
Are the tires OK? No
CORRECT as necessary. RETEST for
normal operation.
C2 CHECK THE BRAKE CALIPER
COMPONENTS
Inspect the brake pads and brake discs for Yes
wear, damage, contamination and correct GO to C3 .
installation.
Are the brake components OK? No
normal operation.
C3 CHECK THE PROPORTIONING VALVE
Install the gauges from the ABS brake and Yes
pressure test kit on one front and one rear INSPECT the disc brake calipers and
bleeder screw. INSTALL new calipers as necessary.
Apply 6895 kPa (1000 psi) to the front RETEST for normal operation.
brake system.
Is the pressure in the rear system 3516- No
2003 Mustang Workshop Manual . 10 15
4481 kPa (510-650 psi)? INSTALL a new proportioning valve.

RETEST for normal operation.
PINPOINT TEST D: EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL

D1 CHECK FOR SPONGY PEDAL
Key in ON position. Yes
Operate the brake pedal and note pedal feel. BLEED the brake system. REFER to
Does the pedal feel spongy? Bleeding — System in this section.
RETEST for normal operation.
No
GO to D2 .
D2 CHECK THE BRAKE PEDAL
Inspect the brake pedal and bracket for Yes
binding, obstruction or damage. GO to D3 .
Is the brake pedal OK?
No
REPAIR or INSTALL a new brake pedal as
necessary. RETEST for normal operation.
D3 CHECK THE BRAKE COMPONENTS
Inspect the calipers bolts, anchor plate bolts Yes
and anti-rattle springs for binding, damage, GO to D4 .
contamination and correct installation.
Are the bolts and springs OK? No
REPAIR or INSTALL new components as
necessary. RETEST for normal operation.
D4 CHECK THE BOOSTER AND MASTER
CYLINDER
Check the power brake booster and brake Yes
master cylinder for correct installation and INSPECT the front wheel bearings for
correct push rod adjustment. Refer to wear, damage and correct installation and
Section 206-06 and to Section 206-07 . the rear axle end play. CORRECT as
Are the power brake booster and the necessary. RETEST for normal operation.
brake master cylinder OK?
No
normal operation.
PINPOINT TEST E: HYDRO-BOOST, NO POWER ASSIST

E1 CHECK FLUID LEVEL IN POWER STEERING
PUMP
Check fluid level in power steering pump. Yes
Is level within specification? GO to E2 .
No
CHECK for leakage of power steering
fluid. ADD fluid as necessary.
E2 CHECK ACCESSORY DRIVE BELT
Check accessory drive belt tension and Yes

condition. Refer to Section 303-05 . GO to E3 .
Is the accessory drive belt OK?
No
INSTALL a new accessory drive belt.
REFER to Section 303-05 .
E3 CHECK POWER STEERING HOSES
Check power steering pressure hoses, power Yes
steering gear pressure hoses and power GO to E4 .
steering return hose for cracks or leaks.
Do power steering pressure hose, power No
steering gear hose and power steering INSTALL new hoses as necessary.
return hose check OK? REFER to Section 211-00 .
E4 CHECK BRAKE PEDAL LINKAGE
Check brake pedal linkage for binding or Yes
sticking operation. GO to E5 .
Does pedal linkage check OK?
No
INSTALL new pedal linkage as necessary.
E5 CHECK POWER STEERING PUMP SPEED
Check engine idle speed against Yes
specifications. GO to E6 .
Is engine idle speed OK?
No
SET engine idle speed to specification.
REFER to Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
E6 CHECK FOR PLUGGED RETURN HOSE
NOTE: The return hose from the oil cooler to Yes
the power steering reservoir has an in-line INSTALL a new power steering return
filter in the hose. hose.
Disconnect power steering return hose from
power steering fluid cooler and power No
steering pump reservoir. GO to E7 .
Pass air through hose from the oil cooler end.
Is hose plugged?
E7 CHECK POWER STEERING PUMP FLOW
AND RELIEF
Test power steering pump for correct flow Yes
and relief pressure. Refer to Section 211-00 . INSTALL a new power brake hydro-boost
Is power steering pump operating unit. REFER to Section 206-07 .
correctly?
No
INSTALL a new power steering pump.
PINPOINT TEST F: HYDRO-BOOST ERRATIC OPERATION, STICKS,

BINDS OR GRABS
Result / Action to
Test Step
Take
F1 CHECK SUPPLY HOSE
Check for obstructions in power steering return hose and Yes
connections between the power steering pump reservoir and REMOVE

between the power steering pump reservoir and the hydro-boost obstructions or
power brake booster. INSTALL a new
Are there any obstructions? hose.
No
GO to F2 .
F2 CHECK BOOSTER OPERATION
Have an assistant check the fluid in the power steering pump Yes
reservoir while rapidly applying the brake pedal approximately one System OK.
inch.
Does the fluid show any movement or spouting? No
INSTALL a new
hydro-boost
assembly.
PINPOINT TEST G: HYDRO-BOOST BRAKE SYSTEM OPERATION

SUSPECT

G1 CHECK BASIC OPERATION
Press and release brake pedal several times to deplete all Hydro-boost is OK.
hydraulic pressure from the hydro-boost power brake
booster. No
Press and hold brake pedal with light pressure. GO to G2 .
Key in START position.
Does the brake pedal fall slightly and hold, and is less
pressure now required to hold brake pedal at the new
position?
G2 CHECK FOR HYDRAULIC BRAKE LEAK
With engine running, press and release brake pedal several Yes
times. GO to G3 .
Hold brake pedal down with medium pressure, 34-47 Nm
(25-35 lb-ft). No
Does brake pedal move toward floor? GO to G4 .
G3 CHECK FOR LEAKS — BRAKE FLUID LINES
Check for leaks at brake lines, including brake master Yes
cylinder and brake hose. COMPLETE master cylinder
Do components check OK? By-Pass Condition Test in
this section.
No
INSTALL new hoses and
lines as necessary.
G4 CHECK HYDRO-BOOST CONNECTIONS
Clean the hydro-boost power brake booster, power steering Yes
pressure hose, power steering gear pressure hose and GO to G5 .
power steering return hose and connection.
Start engine and run at idle. No
Check hose connections for leakage. REPAIR or INSTALL new
Do hose connections check OK? hose and connections as
necessary.
G5 CHECK FOR HYDRO-BOOST LEAK
Engine running at idle speed. Yes

GO to G6 .
CAUTION: Do not hold the brake pedal at 444 Nm
(100 lb) force for more than 5 seconds at a time. No
Apply brake pedal with approximately 444 Nm (100 lb) INSTALL a new hydro-boost
force and hold. unit.
Check hydro-boost unit input seal, housing seal,
accumulator seal, piston seal and spool plug seal for
leakage.
Is hydro-boost unit free of leaks?
G6 CHECK RESERVE RETENTION
Engine running at idle speed. Yes
Hydro-boost unit is OK.
CAUTION: Do not hold the brake pedal at 444 Nm
(100 lb) force for more than 5 seconds at a time. No
Charge system to pressure by holding the steering wheel at INSTALL a new hydro-boost
stop or by pressing the brake pedal with approximately 444 unit.
Nm (100 lb) force.
Key in OFF position.
Wait five seconds.
Press brake pedal and observe if there is any power brake
reserve.
Is there any power brake reserve?
Component Tests
Brake Booster
1. Check the hydraulic brake system for leaks or insufficient fluid.
2. With the transmission (7003) in NEUTRAL, stop the engine (6007) and apply the parking brake
control (2780). Apply the brake pedal several times to exhaust all vacuum in the system.
3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system
is operating, the brake pedal will tend to move downward under constant foot pressure. If no
motion is felt, the power brake booster system is not functioning. Continue with the following
steps.
4. Remove the vacuum booster hose from the check valve connection. Manifold vacuum must be
available at the check valve end of the vacuum booster hose with the engine at idle speed and
the transmission in NEUTRAL. If the manifold vacuum is available to the power brake booster,
connect the vacuum booster hose to the power brake booster check valve and repeat Steps 2
and 3.
5. If no downward movement of the brake pedal is felt, install a new power brake booster.
6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle
stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lb) of force. The
brake pedal feel should be the same as that noted with the engine operating. If the brake pedal
feels hard (no power assist), install a new power brake booster check valve and retest. If the
brake pedal feels spongy, bleed the hydraulic system to remove air. For additional information,
refer to Bleeding — System in this section.
Check Valve
The function of the power brake booster check valve is to allow manifold vacuum to enter the power
brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full
throttle operation.
To test the function of the power brake booster check valve :
Start and run the engine for at least 10 seconds.

Operate the brake pedal to check for power assist.
Disconnect the vacuum booster hose from the power brake booster check valve. Do not remove
the power brake booster check valve from the power brake booster.
There should be enough vacuum retained in the brake booster for at least one more power-
assisted brake operation.
Brake Master Cylinder — Normal Conditions
The following conditions are considered normal and are not indications that the brake master cylinder
is in need of service.
Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake master
cylinder reservoir will rise during brake application and fall during release. The net fluid level (i.e., after
brake application and release) will remain unchanged.
Condition 2: A trace of brake fluid will exist on the booster shell below the master cylinder mounting
flange. This results from the normal lubricating action of the master cylinder bore and seal.
Condition 3: Fluid level will decrease with pad wear.
Brake Master Cylinder — Abnormal Conditions
Changes in brake pedal feel or travel are indicators that something could be wrong in the brake
system. GO to Symptom Chart for abnormal condition diagnosis.
Bypass Condition Test
1. Disconnect the brake lines at the brake master cylinder.
2. Plug the outlet ports of the brake master cylinder.
3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an
internal leak and must be rebuilt or replaced.
Compensator Port Check
The purpose of the compensator ports in the brake master cylinder is to supply any additional brake
fluid required by the system due to brake pad wear and to allow brake fluid returning from the brake
lines to the brake master cylinder to enter the brake master cylinder reservoir.
The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir.
Turbulence seen in the brake master cylinder reservoir upon application or release of the brake pedal
is normal and shows that the compensating ports are not plugged.
GENERAL PROCEDURES
Bleeding —Components
Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-F224,
New Generation STAR (NGS)

Tester
418-F052, or equivalent scan
tool
NGS Flash Cable
418-F120 (007-00531) or
Equivalent
Master Cylinder Priming — In-Vehicle or Bench
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never
reuse the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled
onto a painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new
components, air can enter the system and cause spongy brake pedal (2455) action. This requires
bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be
bled manually or with pressure bleeding equipment.
NOTE: When a new brake master cylinder (2140) has been installed or the system has been emptied,
or partially emptied, it should be primed to prevent air from entering the system.
1. For in-vehicle priming, disconnect the brake lines.
2. For bench priming, mount the brake master cylinder (2140) in a vise.
3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir
(2K478), and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.
4. Have an assistant pump the brake pedal (2455), or slowly depress the primary piston until clear
fluid flows from both brake tubes, without air bubbles.
5. If the brake master cylinder has been primed at the bench, install it in the vehicle. For additional
information, refer to Section 206-06 .
6. Remove the short brake tubes, and install the brake outlet tubes.
7. Bleed each brake tube at the brake master cylinder as follows:

1. Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal.
2. Loosen the rear most brake tube fittings until a stream of brake fluid comes out. While
the assistant maintains pressure on the brake pedal, tighten the brake tube fitting.
3. Repeat this operation until clear, bubble-free fluid comes out.
4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at
the front brake tube.
Master Cylinder Priming — 4.6L
1. CAUTION: Use only bleed screws on the engine side of the brake master cylinder
(2140). The hydro-boost bleed screw, located near the dash on the hydro-booster
casting, is for the booster cavity filled with power steering fluid, not brake fluid.
Connect a clear waste line to the bleed screw closet to the booster first and the other end in a
container partially filled with recommended brake fluid.
2. Open the bleeder screw, have an assistant push the brake pedal down slowly through full travel,
close the bleeder screw, then return brake pedal slowly to full released position. Wait five
seconds, then repeat operation until air bubbles cease to appear.
3. Repeat Step 2 for bleeder screw farthest from hydro-booster.
Four Wheel Anti-Lock Brake System (4WABS) Hydraulic Control Unit (HCU)
NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS) hydraulic
control unit (HCU) has been installed new or if the HCU lines have been opened.
1. Clean all dirt from and remove the brake master cylinder filler cap (2162), and fill the brake
master cylinder reservoir (2K478) with the specified brake fluid.
2. Connect a clear waste line to the RH rear bleeder screw (2208) and the other end in a container
partially filled with recommended brake fluid.
3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal (2455), tighten the RH rear bleeder screw.
Repeat until clear, bubble-free fluid comes out.
Refill the brake master cylinder reservoir as necessary.
4. Tighten the RH rear bleeder screw, and disconnect the waste line.
5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper (2B120)
bleeder screw, and the LH front disc brake caliper bleeder screw, in that order.
6. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the
dash, and follow the scan tool instructions.
7. Repeat the system bleed procedure as outlined in Steps 1 through 5.
Caliper
1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper
(2B120) was disconnected.
Place a box end wrench on the disc brake caliper bleeder screw (2208). Attach a rubber drain
tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a
container partially filled with clean brake fluid.
2. Have an assistant pump the brake pedal (BP) (2455) and then hold firm pressure on the brake
pedal.
3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw.
Refill the brake master cylinder reservoir (2K478) as necessary.
4. Tighten the disc brake caliper bleeder screw. Refer to Specifications.
GENERAL PROCEDURES
Bleeding —System
Manual
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never
reuse the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled
onto a painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new
components, air can get into the system and cause spongy brake pedal action. This requires bleeding
of the hydraulic system after it has been correctly connected. The hydraulic system can be bled
manually or with pressure bleeding equipment.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH
rear bleeder screw and submerge the free end of the tube in a container partially filled with
clean brake fluid.
3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the RH rear bleeder screw.
5. Tighten the RH rear bleeder screw.
6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw.
7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain
tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in
a container partially filled with clean brake fluid.
8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out.
While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake
caliper bleeder screw.
10. Tighten the RH front disc brake caliper bleeder screw. For additional information, refer to
Specifications in this section.
11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw.
Pressure
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the
adapter.
Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank
hose to the fitting on the adapter.
3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH
rear bleeder screw, and submerge the free end of the tube in a container partially filled with
clean brake fluid.
4. Open the valve on the bleeder tank.
5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then
tighten the RH rear bleeder screw and remove the rubber hose.
6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the
RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder
screw.
7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter.
GENERAL PROCEDURES
Hydraulic Leak Check

1. NOTE: Brake fluid is water soluble and it is possible that all evidence of fluid leakage has been
washed off if the vehicle has been operated in the rain or snow.
Make sure the brake master cylinder reservoir (2K478) is full.
2. Apply the brakes several times and make sure the brake pedal (2455) feel is not spongy. If
necessary, bleed the system. For additional information, refer to Bleeding—System in this
section.
3. If the reservoir level is dropping, inspect the brake components, fittings and lines to locate the
source of the leak.
GENERAL PROCEDURES
Runout Check —Brake Disc and Hub
Special Tool(s)
Brake Measurement Kit
134-R0199 or equivalent
Material
Item Specification
High Temperature Nickel Anti-
Seize Lubricant ESE-M12A4-
A
F6AZ-9L494-AA
CAUTION: The brake disc (1126) runout specification must be met to ensure correct brake
performance without roughness complaints.
CAUTION: Do not install brake discs that are less than the minimum thickness specified.
Do not machine a brake disc below the minimum thickness specification.
NOTE: When installing brake discs, always align the painted match marks on the brake discs with
those on the front hub or rear axle.
NOTE: When installing brake discs, always apply anti-seize lubricant to the brake disc-to-front hub or
to the brake disc-to-rear axle mating surfaces.
1. Do not remove the tire and wheel assembly. Tighten the wheel nuts to specification with a
torque stick or torque wrench.
2. Raise and support the vehicle.
3. Assemble the Brake Measurement Kit, using the spherical tip extension.
4. Locate an opening on the inboard side of the dust shield that will allow the dial indicator tip to be
positioned at least 5 mm (0.2 inch) from the outer edge of the brake disc.
5. NOTE: Do not clamp the gauge set to a vehicle component separated from the brake disc by a
flexible joint, such as a ball joint or body mount.
Clamp the Brake Measurement Kit on the vehicle, making sure the flexible indicator arm and
probe tip do not touch the dust shield or tire while rotating.
6. NOTE: For rear wheel measurement only, have an assistant push in on the wheel cover or axle
shaft center while rotating the wheel.
Rotate the wheel for six revolutions, and record the total indicated runout.
7. If the total indicated runout exceeds the maximum specification, remove the brake disc. For
additional information, refer to Section 206-03 for front or to Section 206-04 for rear.
8. Clean the brake disc mounting face of dirt, rust and foreign material.
9. For front wheels, measure and record the total indicated runout of the hub face outside the stud
circle.
10. Install a new front hub if the total indicated runout exceeds the maximum specification. For
additional information, refer to Section 204-01 .
Repeat the hub runout measurement.
11. NOTE: Clean the axle flange surface before measuring.
NOTE: For rear wheels, press inward on the axle shaft while measuring the rear axle runout.
For rear wheels, measure and record the total indicated runout at a point on the axle shaft
outside the stud circle.
12. If the total indicated runout exceeds the maximum specification, inspect the rear axle. For
additional information, refer to Section 205-00 . Repair as necessary.
Repeat the rear brake disc runout measurement.
13. If the brake disc TIR is still out of specification, measure and record the thickness of the brake
disc. If thickness is sufficient to machine the brake disc to the runout specification, go to Step
14. If the thickness is not sufficient, install a new brake disc and recheck the TIR.
14. NOTE: Brake disc machining must be done with an on-vehicle lathe. Follow the lathe
manufacturer's instructions.
Machine the brake disc if final thickness will not be less than the maximum specification.
Recheck the brake disc runout.
SECTION 206-03: Front Disc Brake 2003 Mustang Workshop Manual

SPECIFICATIONS
General Specifications
Item Specification
Disc brake lining wear limit 1.0 mm (0.040 in)
Disc thickness (Mustang/Mustang Cobra) 26 mm (1.02 in)/28 mm (1.10 in)
Disc lateral runout 0.05 mm (0.002 in)
Disc thickness variation 0.009 mm (0.00035 in)
Hub runout 0.025 mm (0.001 in)
Description Nm lb-ft
Disc brake caliper bolt 31 23
Front brake hose bolt 40 30
Front disc brake caliper anchor plate bolt 115 85
Disc brake caliper bleeder screw 10 7

Front Disc Brake

Front Disc Brake Components
Item Part Number Description

1 — Bleeder screw and bleeder screw cap assy
2 2N386 Caliper bolt
3 2B296 Guide pin
4 2A492 Guide pin boot
5 2B120 Disc brake caliper
6 2B164 Anti-rattle spring
7 2B292 Front disc brake caliper anchor plate
8 385116-S2 Flow bolt
9 2078 Front brake hose
Disc Brake Caliper Components

1 2B120 Disc brake caliper
2 2L126 Bleeder screw cap
3 2208 Bleeder screw
4 2B164 Anti-rattle spring
5 2196 Caliper piston
6 2B115 Piston seal
7 2207 Piston dust boot
8 2L200 Pad slipper
9 2B292 Front disc brake caliper anchor plate
10 2001 Brake pads
11 2A492 Guide pin boot
12 2B296 Guide pin
13 2N386 Caliper bolt
The front disc brake caliper (2B120):
bolts to the front disc brake caliper anchor plate (2B292), which bolts to the front wheel spindle
(3105).
is a pin slider, dual piston design.
The front brake discs (1125):
are of a ventilated full-cast design, with non-directional cooling fins.

are serviced with the disc brake caliper and front disc brake caliper anchor plate removed.
The front brake disc shield (2K005):
is riveted to the front wheel spindle.

protects the front wheel bearings and inboard surface of the front brake disc.
The pads:
are housed in the front disc brake caliper anchor plate.

are of a non-asbestos, non-metallic composition.

REMOVAL AND INSTALLATION
Pads
Removal
1. Remove brake master cylinder filler cap (2162). Check brake fluid level in brake master cylinder
reservoir (2K478). Remove fluid until brake master cylinder reservoir is half full.
2. Raise and support the vehicle. For additional information, refer to Section 100-02 .
3. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 .
4. CAUTION: Install new pads if worn to or past the specified thickness above the
metal backing plate or rivets. Install pads in complete axle sets.
Inspect the pads for wear and contamination.
5. Remove the caliper bolts.

1. Hold the guide pins stationary.
2. Remove and discard the caliper bolts.
6. CAUTION: Do not pry in caliper sight hole to retract pistons as this can damage the
pistons and boots.
CAUTION: When removing the disc brake caliper (2B120), never allow it to hang
from the brake hose. Provide a suitable support.
Lift the caliper off the anchor plate (2B292).
7. Remove the pads and the pad slippers.

1. Remove the pads and verify thickness.
2. Remove and discard slippers.
8. Measure the front brake disc thickness.

Install a new front brake disc (1125) if not within specification.
9. Inspect the disc brake caliper.

If leaks or damaged boots are found, disassembly is required. For additional information,
refer to Caliper in this section.
10. Inspect the front disc brake anchor plate assembly.

Check the guide pin boots for damage.
Check the guide pins for binding and damage.
Worn or damaged pins should be installed new.
Installation
1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the
pad lining material. Do not install contaminated pads.
NOTE: Install all hardware supplied with pad kits.
Install the pads.

1. Install the new pad slippers.
2. Install the pads.
2. NOTE: Use a wood block or used pad to protect pistons and boots.
Compress the caliper pistons (2196).
3. Make sure the anti-rattle spring is correctly positioned in the caliper.
4. CAUTION: Use care not to damage the bleeder screw or front brake disc shield.
Install the disc brake caliper.

2. Install the caliper bolts.
5. Install the wheel and tire assembly. For additional information, refer to Section 204-04 .
6. Lower the vehicle.
7. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ-
19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Install brake
master cylinder filler cap.
8. Inspect brake operation.

Brake Pads —Cobra

Removal
1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full.
3. Remove the tire and wheel assembly. For additional information, refer to Section 204-04 .
4. CAUTION: Install new pads if worn to or past the specified thickness above the
metal backing plate or rivets. Install new pads in complete axle sets.
Inspect the pads for wear and contamination.
5. Remove the caliper locating pin E-clip.
6. Remove the caliper locating pin.
7. Remove the caliper.
8. Remove the brake pads.
9. Measure the brake disc thickness.

Install a new brake disc if not within specification.

11. NOTE: Use a wood block or used pad to protect pistons and boots.
Compress the caliper pistons (2196).
Installation
1. Follow the removal procedure in reverse order.

Caliper
Removal
3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact
with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes
with running water for 15 minutes, get medical attention if irritation persists. If taken
internally, drink water and induce vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is
spilled onto a painted or plastic surface, wash it with water immediately.
Disconnect the front brake hose (2078).

1. Remove the front brake flow bolt.
2. Disconnect the front brake hose.
3. Remove and discard the copper washers. Plug the front brake hose.

5. Lift the caliper off the anchor plate (2B292).

Installation
1. Make sure the anti-rattle spring is correctly positioned in the caliper.
2. CAUTION: Make sure guide pin boots are correctly seated or damage to guide pins
can occur.
Install the disc brake caliper.

2. Install the caliper bolts.
3. NOTE: Use new copper washers.
Install the front brake hose.
4. Bleed the caliper. For additional information, refer to Section 206-00 .
6. Fill the brake master cylinder reservoir (2K478) with clean High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Install
brake master cylinder filler cap (2162).
7. Check the brake system operation.

Brake Caliper —Cobra

Removal
3. Remove the caliper locating pin E-clip.
4. Remove the caliper locating pin.
5. Remove the front brake flow bolt.
6. Remove the caliper.
Installation
1. NOTE: Use new copper washers on front brake flow bolt.
Follow the removal procedure in reverse order.

Bleed the caliper. For additional information, refer to Section 206-00 .

Brake Caliper Anchor Plate —Cobra

Removal
1. Remove the pads. For additional information, refer to Brake Pads—Cobra in this section.
2. Remove the anchor plate bolts.
Installation

Brake Caliper Anchor Plate

Removal
1. Remove the pads. For additional information, refer to Pads in this section.
2. Remove the anchor plate (2B292).

1. Remove and discard the anchor plate bolts.
2. Remove the anchor plate.
Installation
1. CAUTION: Use correct type and length bolts.

Install new anchor plate bolts.

Disc
Removal
1. Remove the front disc brake caliper anchor plate (2B292). For additional information, refer to
Brake Caliper Anchor Plate in this section.
2. Match mark the hub (1104) and the brake disc (1125).
3. If necessary, remove and discard the keeper nuts.
4. NOTE: If the brake disc cannot be easily removed, apply Rust Penetrant and Inhibitor F2AZ-
19A501-A or equivalent meeting Ford specification ESR-M99C56-A to the mating surfaces.
Remove the brake disc from the hub.
Installation
1. Clean rust and foreign material from the mating surfaces of the hub and brake disc.
Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent to clean the brake disc
and hub.
2. Apply High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting

Ford specification ESE-M12A4-A to the hub flange.
3. Align the match marks and install the brake disc.
4. Install the anchor plate (2B292). For additional information, refer to Brake Caliper Anchor Plate
in this section.
5. Check the total indicated runout (TIR). For additional information, refer to Section 206-00 .

Shield
Removal
1. Remove the brake disc (1125). For additional information, refer to Disc in this section.
2. Remove the brake disc shield (2K004).

1. Drill out three brake disc shield rivets.
2. Remove the brake disc shield.
Installation
1. Install the brake disc shield.

1. Position the shield.
2. Secure with three rivets.
2. Install the brake disc. For additional information, refer to Disc in this section.

DISASSEMBLY AND ASSEMBLY
Caliper
Disassembly
1. Remove the disc brake caliper (2B120). For additional information, refer to Caliper in this
section.
2. Drain the remaining brake fluid from disc brake caliper.
3. Apply low air pressure to the fluid port in the disc brake caliper.
1. Place a block of wood between the caliper bridge and the caliper pistons (2196).
2. Apply low air pressure to the fluid port in the disc brake caliper and force out the caliper
pistons to the block of wood.
4. Remove the caliper pistons.

1. Remove the block of wood.
2. Remove the caliper pistons.
5. Remove and discard the piston seals and boots.
6. Remove and discard the bleed screw and cap.
Assembly
1. CAUTION: Do not hone the caliper bores. Caliper pistons are not available for
honed caliper bores.
Clean and inspect the caliper pistons and the disc brake caliper.
Remove dirt and debris.
Examine the caliper pistons for surface irregularities, scoring or wear. Damaged caliper
pistons should be installed new.
Clean the caliper bores with Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent
meeting Ford specification.
If the caliper bores are corroded or excessively scored, install a new disc brake caliper.
Lubricate the caliper pistons and piston seals before assembly.
2. CAUTION: Never reuse piston seals and dust boots.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Lubricate the caliper piston, piston seal and caliper bores with clean High Performance DOT 3
Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-
A.
3. Install the caliper piston.
1. Install the piston seal.

2. Install the piston boot on the piston.
3. CAUTION: Be careful not to damage or dislodge the piston seal.
Insert the caliper piston.
4. CAUTION: Be careful not to cock the caliper piston.
Press the caliper piston into the bore.
4. Install a new bleed screw and cap.
5. Install the disc brake caliper. For additional information, refer to Caliper in this section.
SECTION 206-04: Rear Disc Brake 2003 Mustang Workshop Manual

SPECIFICATIONS
General Specifications
Item Specification
Disc brake lining wear limit 1.0 mm (0.040 in)
Disc thickness 15 mm (0.59 in)
Disc lateral runout 0.102 mm (0.004 in)
Disc thickness variation 0.01 mm (0.0004 in)
Hub runout —
Rear wheel brake hose-to-rear disc brake caliper retaining bolt 40 30 —
Rear disc brake support bracket bolts 103 76 —
Brake disc shield bolts 9-12 — 80-106
Rear brake pin retainer 33 25 —

Rear Disc Brake
The rear disc brake system consists of:
solid, full-cast brake disc (2C026).

hydraulically activated rear disc brake caliper (2552).
integral mechanically (cable) operated parking brake mechanism that is self-adjusting.
Rear Disc Brake System Components

1 2552 Rear disc brake caliper
2 2C028 Brake disc shield
3 N606675-S2 Bolt (3 req'd each side)
4 1104 Wheel hub
5 2C026 Brake disc
6 4B423 Rear wheel hub retainer
7 W623485-S2 Nut (2 req'd each side)
8 N805163-S100 Bolt (4 req'd)

Caliper
Special Tool(s)
Rear Caliper Piston Adjuster
206-026 (T87P-2588-A)
Removal
1. Raise the vehicle on a hoist. For additional information, refer to Section 100-02 .
3. Disengage the parking brake cable end from the parking brake lever arm.
4. Remove the parking brake cable retaining clip.
5. Remove the parking brake cable and conduit.
6. Remove the rear disc brake caliper brake hose bolt.
7. Remove the rear brake pin retainers (2N386) and remove the caliper.
Installation
1. NOTE: Use new copper washers.

Bleed the brake system. For additional information, refer to Section 206-00 .

Pads
Special Tool(s)
206-026 (T87P-2588-A)
Removal
1. Use a suitable suction device to lower the brake fluid level in the master cylinder reservoir.
4. Inspect the pads for wear or contamination, install new if worn to or past specification.
5. CAUTION: Do not allow the rear disc brake caliper (2552) to hang from the rear
wheel brake hose (2A442).
Remove the rear disc brake caliper bolts and position the caliper aside.
7. Remove the slippers.
8. CAUTION: Use a hub-mount brake lathe if necessary to machine the brake disc.
Measure the brake disc, resurface and or install new as necessary.
9. Compress the rear disc brake piston and adjuster (2B588) into rear disc brake caliper using
Rear Caliper Piston Adjuster.
Installation
1. CAUTION: Install the brake pads in full axle sets. Do not install new brake pads on
only one side of vehicle.
Install the new slipper and brake pads.
2. Position the caliper on the anchor plate and install the bolts.
4. Lower the vehicle.
5. WARNING: Use of any other than approved DOT 3 or DOT 4 brake fluid will cause
permanent damage to components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact
with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes
with running water for 15 minutes. Get medical attention if irritation persists. If taken
internally, drink water and induce vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is

spilled onto a painted or plastic surface, immediately wash it with water.
Check the fluid level at the master cylinder. Add fluid if necessary.
6. WARNING: Pump the brake pedal several times to make sure the caliper piston is
extended to its operating position. Failure to follow these instructions may result in
personal injury.
Verify correct brake operation.
7. Recheck the master cylinder fluid level.

Disc
Removal
1. Remove the rear disc support bracket (2B511). For additional information, refer to Support
Bracket in this section.
2. Remove the brake disc (2C026).
Installation

Brake Caliper Support Bracket

Removal
3. CAUTION: Do not allow the rear disc brake caliper (2552) to hang from the rear
wheel brake hose (2A442)
Remove the rear disc brake caliper bolts and position the caliper aside.
5. Remove the rear disc support bracket (2B511) bolts and bracket.
Installation
1. NOTE: New bolts must be used when reinstalling the rear disc support bracket.

Shield
Removal
1. Remove the brake disc (2C026). For additional information, refer to Disc in this section.
2. Remove the brake disc shield bolts.
Installation

DISASSEMBLY AND ASSEMBLY
Caliper
Special Tool(s)
206-026 (T87P-2588-A)
Rear Caliper Spring

Compressor Set
206-S027 (T87P-2588-B)
Disassembly
1. Remove the rear disc brake caliper (2552). For additional information, refer to Caliper in the
Removal and Installation portion of this section.
2. Drain the brake fluid from the rear disc brake caliper.
3. Secure the rear disc brake caliper in a vise.
4. Turn the rear disc brake piston and adjuster (2B588) counterclockwise with Rear Caliper Piston
Adjuster.
5. Remove the rear disc brake piston and adjuster from the caliper bore.
6. Remove and discard the piston dust boot seal and piston seal from the caliper bore.
7. CAUTION: The parking brake lever pin retainer clip (2A746) and spring cover are
spring-loaded. Use care when removing the parking brake lever pin retainer clip.
Remove the parking brake lever pin retainer clip.

Unload the spring tension from the parking brake lever pin retainer clip and spring cover
using Screw and Cross Block, a 6-mm washer head nut and a 1/2-inch drive 14-mm
socket.
Remove the parking brake lever pin retainer clip with suitable snap-ring pliers.
Remove Screw and Cross Block.
8. Remove the following components:

1. spring cover
2. spring
3. washer
4. key plate
5. push rod
6. strut pin
7. push rod O-ring
9. Remove and discard the O-ring seal from the push rod.
10. Remove the parking brake lever (2A637).

1. Remove the parking brake return spring (2456).
2. Remove the limiting bolt (2A795).
3. Remove the parking brake lever.
4. Remove the parking brake lever shaft seal from the caliper bore.
Assembly
1. CAUTION: Do not reuse piston seals or dust boots. Install new seals or dust boots
or damage to the vehicle can occur.
NOTE: Use new brake fluid when assembling and bleeding the brake system.
NOTE: Lightly lubricate the parking brake lever bore, limiting bolt, parking brake lever shaft and
parking brake shaft recess with Silicone Dielectric Compound D7AZ-19A331-A or equivalent
meeting Ford specification ESE-M1C171-A.
Follow the disassembly procedure in reverse order.
SECTION 206-05: Parking Brake and Actuation 2003 Mustang Workshop Manual
SPECIFICATIONS
Description Nm Lb/Ft
Parking brake control-to-cowl nut 17 13
Brake hose clip mounting bolt 12 9
Parking Brake

1 2780 Parking brake control
2 2552 Rear disc brake caliper
The parking brake system is cable-actuated and controlled by an independent hand-operated parking
brake control (2780). To apply parking brake, pull parking brake control upward as far as possible.
The parking brake system is an AUTO-ADJUST system. The spring in the parking brake control
continuously adjusts the cable tension in the system.
Brake Warning System
A parking brake warning indicator:
is located in the instrument panel.

illuminates to signal the driver the parking brake is applied or to signal a low fluid condition.
remains lit when a brake malfunction has occurred.
Parking Brake
1. Verify the customer's concern by operating the parking brake system to duplicate the condition.
2. Inspect to determine if one of the following mechanical or electrical concerns apply:

Damaged parking brake control Parking brake signal switch
Binding/damaged parking brake cables
3. If the inspection reveals obvious concern(s) that can be readily identified, service as necessary.
4. If concern(s) remains after the inspection, determine the symptoms. GO to Symptom Chart .
Symptom Chart
Symptom Chart
Parking Brake Will Not Parking brake Go To Pinpoint Test
Apply control. A.
Parking brake
cable.
Parking Brake Will Not Parking brake Go To Pinpoint Test
Release cable. B.
Parking brake
control.
Pinpoint Tests
PINPOINT TEST A: PARKING BRAKE WILL NOT APPLY

A1 CHECK THE PARKING BRAKE
CABLES
Raise and support the vehicle. Refer Yes
to Section 100-02 . INSTALL a new parking brake cable as

Inspect for broken or binding parking necessary. TEST the system for normal
brake cables or broken guide clips. operation.
Is there a parking brake cable
concern? No
GO to A2 .
A2 CHECK THE PARKING BRAKE
CONTROL
Operate the parking brake control. Yes
Does the parking brake control INSTALL a new parking brake lever. RESTORE
operate smoothly? vehicle and TEST the system for normal
operation.
No
REPAIR the binding condition in the parking brake
control. TEST the system for normal operation.
PINPOINT TEST B: PARKING BRAKE WILL NOT RELEASE

B1 CHECK PARKING BRAKE CONTROL
Raise and support the vehicle. Refer to Yes
Section 100-02 . GO to B2 .
Release parking brake by pulling
upward on hand lever and pushing No
release button. INSTALL a new parking brake control.
Did parking brake release? RESTORE the vehicle and TEST the system for
normal operation.
B2 CHECK PARKING BRAKE CABLES
Loosen tensioner. Refer to Parking Yes
Brake Cable Tension Release in this GO to B3 .
section.
Move the gearshift lever to NEUTRAL No
position. INSTALL new parking brake cables. RESTORE
Rotate rear wheels by hand. the vehicle and TEST the system for normal
Did rear wheels turn freely? operation.
B3 CHECK REAR PARKING BRAKE
LEVERS
Disconnect parking brake levers one at Yes
a time. INSTALL a new parking brake lever. RESTORE
Rotate wheel affected by disconnected vehicle and TEST the system for normal
parking brake lever. operation.
Did wheel turn freely?
No
REPAIR or INSTALL a new rear brake
component if worn or damaged. TEST the
GENERAL PROCEDURES
Parking Brake Cable Tension Release
1. CAUTION: If any component in the parking brake system requires repair or if the
rear axle housing (4010) is removed, the cable tension must be released.
Place the parking brake control (2780) in the released position.
2. Remove the console. For additional information, refer to Section 501-12 .
3. With an assistant inside the vehicle, raise and support the vehicle. For additional information,
refer to Section 100-02 .
4. Pull the parking brake cable and equalizer rearward.
5. CAUTION: Do not remove the steel pin until the parking brake cable and
equalizer/rear cable and conduits are connected to the parking brake control. Pin
removal releases the tension in the ratchet wheel causing the spring to unwind and
release tension.
Insert a steel pin through holes in the lever to the ratchet wheel.
Parking Brake Control

Removal
Place the parking brake control (2780) in the released position.
2. Remove the console. For additional information, refer to Section 501-12 .
3. Remove the parking brake control studs.
4. NOTE: Self adjust pawl must be off to allow wind up.
Place the control handle in the fully downward position, then pull the control handle forward to
wind-up the self-adjusting mechanism.
5. Insert a steel pin through hole in the lever to the ratchet wheel, then carefully release the spring
tension onto the pin.
6. NOTE: Keep tension on the cable so cable end does not fall out of equalizer.
Disconnect the parking brake cable.
Installation
1. NOTE: Make sure cable ends are attached to the equalizer.
Cable and Conduit —Front

Removal
Release the cable tension. For additional information, refer to Parking Brake Cable Tension
Release in this section.
2. Disconnect the parking brake rear cables and conduits.
3. Remove the parking brake control nuts.
4. Disconnect the parking brake cable.
5. Pull the front cable and equalizer through the floorpan from inside the vehicle.
Installation
Cable and Conduit

Removal
NOTE: The RH rear is shown, the LH is similar.
Release the cable tension. For additional information, refer to Parking Brake Cable Tension
Release in this section.
2. Disconnect the parking brake rear cable and conduit.
3. Using a 13 mm (0.52 in) box-end wrench, depress the conduit retaining prongs and remove the
parking brake rear cable and conduit.
4. Remove the parking brake rear cable and conduit from the routing clip bolts.
5. Disconnect the parking brake rear cable and conduit from the parking brake lever (2A637).
6. Remove the clip from the rear disc brake caliper (2552).
7. Remove the parking brake rear cable and conduit from the rear disc brake caliper.
Installation
SECTION 206-06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual

SPECIFICATIONS
Brake master cylinder nuts 25 19
Brake pedal bracket nuts 25 19
Brake pedal bracket bolt 23 17
Brake fluid control valve 19 15
Hydraulic tube connections 17 13
Brake fluid control valve bracket nut 14 11

Hydraulic Brake Actuation

1 2K478 Master cylinder reservoir
2 2140 Master cylinder
3 — Pedal support bracket (part of 2455)
4 2455 Brake pedal
CAUTION: Blistering or swelling of rubber brake components may indicate contamination

of the brake fluid by a petroleum based substance. New rubber components must be installed
in the hydraulic brake system if contaminated and the entire hydraulic brake system must be
flushed with clean brake fluid to prevent recontamination.
This vehicle is equipped with a brake pedal actuated dual brake system. The system consists of the
following:
power brake booster (2005)

brake master cylinder (2140)
brake pressure control valve (2B091)
disc brake calipers (2B120)
rear disc brake calipers (2553)
brake tubes and hoses
anti-lock brake system (ABS) components
The dual brake system is split front and rear with the front wheel brakes comprising of one circuit and
the rear wheel brakes, the other circuit.
Brake Fluid
eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running
water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water
and induce vomiting. Get medical attention immediately.
Clean, fresh Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid
meeting Ford specification ESA-M6C25-A is the only brake fluid that should be used in Ford vehicles.
Do not reuse brake fluid drained or bled from the system.

Do not use brake fluid that has been stored in an open container.
Do not mix different types of brake fluid.
Brake Master Cylinder
The brake master cylinder is a dual piston type. The brake master cylinder operates as follows:
When the brake pedal (2455) is depressed, pressure is applied by mechanical linkage to the
primary and secondary piston.
Brake master cylinder pistons apply hydraulic pressure to the two hydraulic circuits.
Brake master cylinder will not be overhauled, a new master cylinder is installed only.
The brake master cylinder consists of:
brake master cylinder reservoir (2K478)

brake master cylinder body
Brake Master Cylinder Reservoir
NOTE: Whenever the brake master cylinder reservoir is removed from the brake master cylinder, new
grommets must be installed.
The brake master cylinder reservoir :
is mounted to the brake master cylinder.

holds fluid supply for each brake master cylinder hydraulic piston.
provides visual fluid level markings.
contains the brake master cylinder fluid level sensor.
Brake Pressure Control Valve
The brake pressure control valve proportions the pressure to the rear brakes.
When the brake pedal is applied, brake fluid pressure passes through the proportioning valves
to the rear brake system until the valve split point is reached.
Above its split point, the proportioning valve begins to reduce the hydraulic pressure to the rear
brakes, creating a balanced braking condition between the front and rear brakes.
Brake Tubes and Hoses
CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion which
could result in brake tube failure.
Steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly
double flared to provide strong leakproof connections. When bending the tubing to fit the underbody or
rear axle contours, be careful not to kink or crack the tube.
If a section of brake tube is damaged, the entire section must be removed and a new tube of the same
type, size, shape and length installed.
When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After
installation, bleed the brake system. For additional information, refer to Section 206-00 .

Pedal and Bracket

Removal
1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-
01 .
2. Remove the stoplight switch retaining pin.
3. Slide the stoplight switch (13480) and booster push rod from the brake pedal pin.
4. Remove the brake pedal bracket retaining bolt.
5. Remove the brake pedal bracket retaining nuts.
6. Remove the brake pedal and bracket.
Installation
1. To install, reverse the removal procedure.

Master Cylinder
Removal
1. Disconnect the fluid level sensor connector.
2. Disconnect the brake tubes.
3. Remove the brake master cylinder nuts.
4. Remove the brake master cylinder (2140).
Installation


Master Cylinder —Hydro-Boost

Removal
4. Remove the brake master cylinder (2140).
Installation


Reservoir
Removal
1. Disconnect the brake master cylinder fluid level switch.
2. Use a suitable suction device to drain the brake master cylinder reservoir (2K478).
3. Carefully pry up on the brake master cylinder reservoir and remove.
Installation
1. NOTE: Whenever installing a new brake master cylinder reservoir, install new grommets.
Install the brake master cylinder reservoir.

1. Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542-AB
or equivalent fluid meeting Ford specification ESA-M6C25-A and insert the grommets
into the brake master cylinder (2140).
2. Press the brake master cylinder reservoir into the grommets until it is fully seated.
3. Connect the brake master cylinder fluid level switch.
4. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or equivalent fluid meeting Ford specification ESA-M6C25-A.
5. Bleed the brake master cylinder. For additional information, refer to Section 206-00 .

Control Valve
Removal
2. Remove the brake fluid control valve bracket nut.
Installation
SECTION 206-07: Power Brake Actuation 2003 Mustang Workshop Manual

SPECIFICATIONS
Power brake booster nuts 25 19
Brake master cylinder nuts 25 19
Hydraulic tube connections 17 13
Power steering pressure lines 19 14

Brake Booster —Vacuum

Power Brake Booster

2 2B560 Hydro-Boost
3 2005 Power brake booster
The vacuum type power brake booster (2005):
is a dual diaphragm, vacuum assisted power brake booster

reduces brake pedal force and travel distance.
is located on the LH side of the bulkhead in the engine compartment, between the brake pedal
(2455) and the brake master cylinder (2140).
is divided into separate chambers by the diaphragms.
will not operate if vacuum is restricted or if any of the vacuum related power brake components
fail.
is installed as an assembly.
If the power assist fails, the brake system will continue to operate with increased brake pedal effort.
Hose and Check Valve
The power brake booster check valve (2365):
is located on the front of the power brake booster.

is installed separately; (install a new grommet when installing a new check valve).
is positioned between the power brake booster and the power brake booster hose.
closes when the engine is turned off.
in the closed position, traps engine vacuum in the power brake booster
retains vacuum to provide several power assisted brake applications with the engine off.

2 2005 Power brake booster

Brake Booster —Hydro-Boost

The Hydro-Boost brake booster is a hydraulically operated brake booster powered by the power
steering pump (3A674). The power steering pump provides the fluid pressure to operate both the
power brake booster and the power steering gear (3504).
A Hydro-Boost reserve system (accumulator) stores sufficient fluid under pressure to provide at least
two power-assisted brake applications in the event the power steering pump fluid flow is interrupted.
For low assist concerns on vehicles equipped with the Hydro-Boost system, refer to Section 211-00 to
check the power steering pump pressure and flow.

2 2B559 Hydro-Boost
The brakes can also be applied manually if the reserve system is depleted.
Any leakage goes directly back to the power steering pump reservoir (3E764).

GENERAL PROCEDURES
Hydro-Boost Bleeding
1. NOTE: The Hydro-Boost power brake booster (2B560) is generally self-bleeding, and the
following procedure will normally bleed the air from the power brake booster. Normal operation
of the vehicle will further remove any additional trapped air.
Fill the power steering oil reservoir (3A697) with MERCON® Multi-Purpose ATF XT-2-QDX or
MERCON® equivalent.
2. Remove the powertrain control module (PCM) fuse to prevent the engine from starting.
3. Crank the engine for several seconds.
4. Check the fluid level in the power steering oil reservoir and add if necessary. Install the
powertrain control module (PCM) fuse.
5. Start the engine.
6. With the engine running, turn the steering wheel (3600) from stop-to-stop twice. Turn the engine
off.
7. Depress the brake pedal (2455) several times to discharge the accumulator.
8. Repeat Steps 5 and 6.
9. If foaming occurs, stop the engine and allow the foam to dissipate.
10. Repeat Steps 5 and 6 as required, until all the air is removed from the system (when the
foaming stops).

Brake Booster —Vacuum

Removal
01 .
2. Remove the air cleaner housing. For additional information, refer to Section 303-12 .
4. Position the brake master cylinder (2140) aside.
5. With the engine off, depress the brake pedal (2455) several times to discharge the accumulator.
Disconnect the booster vacuum hose.
6. Remove the stoplight switch self-locking pin.
7. Remove the stoplight switch (13480) and the brake booster push rod from the brake pedal pin.
8. Remove the power brake booster nuts.
9. Remove the power brake booster (2005).
Installation

Brake Booster —Hydro-Boost
Special Tool(s)
Installer Set, Teflon Seal
211-D027 (D90P-3517-A) or
equivalent
Removal
WARNING: The power brake booster should not be carried by the accumulator, nor
should it ever be dropped on the accumulator. Check the snap ring on the accumulator for
correct seating before the power brake booster is used. The accumulator contains high-
pressure nitrogen gas and can be dangerous if mishandled.
WARNING: If the accumulator is to be disposed of, it must not be exposed to excessive

heat. Before discarding the accumulator, drill a 1.6-mm (1/16-inch) diameter hole in the end of
the accumulator can to relieve the gas pressure. Always wear safety glasses when performing
this operation.
1. With the engine off, depress the brake pedal (2455) several times to discharge the accumulator.
01 .
5. Disconnect the power steering return line hose (3A005).
6. Disconnect the power steering pressure lines.
7. Remove the self-locking pin.
8. Remove the stoplight switch (13480) and the brake booster push rod from the brake pedal pin.
9. Remove the power brake booster nuts.
10. Remove the power brake booster nut.
11. Remove the booster.
Installation

Install new Teflon® seals on the power steering pressure fittings.
Bleed Hydro-Boost. For additional information, refer to Hydro-Boost Bleeding in this

section.
SECTION 206-09A: Anti-Lock Control — Rear 2003 Mustang Workshop Manual

SPECIFICATIONS
Anti-lock brake control module screws 3 — 26
Brake line fittings to hydraulic control unit 19 14 —
Front anti-lock brake sensor bolt 7 — 62
Hydraulic control unit to mounting bracket nuts 18 13 —
Rear anti-lock brake sensor bolt 7 — 62

Anti-Lock Control
The four wheel anti-lock brake system (4WABS) consists of the following components:
anti-lock brake control module (2C346)

front anti-lock brake sensor (2C205)
front anti-lock brake sensor indicator (2C182)
hydraulic control unit (2C286)
rear anti-lock brake sensor (2C216)
rear anti-lock brake sensor indicator (2C189)
yellow anti-lock brake system (ABS) warning indicator

Anti-Lock Control
Refer to Wiring Diagrams Cell 42 , Anti-Lock Brake for schematic and connector information.
Special Tool(s)
(WDS)
418-F224,

Tester
tool
73 Digital Multimeter or
equivalent
105-R0051
Principles of Operation
The anti-lock brake control module receives wheel speed readings from each anti-lock brake sensor
and processes this information to determine if an ABS event is necessary. The anti-lock brake sensor
electrically senses each tooth of the anti-lock brake sensor indicators as it passes through the anti-lock
brake sensor's magnetic field.
The anti-lock brake control module continuously monitors and compares the rotational speed of each
wheel, and when it detects an impending wheel lock, modulates hydraulic brake pressure to the
appropriate brake caliper. This is accomplished by the anti-lock brake control module triggering the
hydraulic control unit (HCU) to open and close the appropriate solenoid valves. Once the affected
wheel returns to normal speed, the anti-lock brake control module returns the solenoid valves to their
normal position, and normal (base) braking resumes.
The anti-lock brake control module is self-monitoring. When the ignition switch is turned to the RUN
position, the anti-lock brake control module will do a preliminary electrical check, and at approximately
12 km/h (8 mph) the pump motor is turned on for approximately one half-second. Any malfunction of
the ABS will cause the ABS to shut off and the yellow ABS warning indicator to illuminate, however,
normal power assisted braking remains.
The ABS control module has the ability to store multiple DTCs in memory.
1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical and electrical damage.

Low brake fluid Central junction box (CJB)Fuse:
Anti-lock brake sensor 15 (10A)
Anti-lock brake sensor indicator 29 (15A)
Base brake system 33 (15A)
35 (15A)
Battery junction box (BJB) Fuse:
ABS 1 (50A)
ABS 2 (20A)
Circuitry
Damaged or corroded connectors
Yellow ABS warning indicator
Loose grounds
3. If the concern remains after the inspection, connect the scan tool to the data link connector
(DLC) located beneath the instrument panel and select the vehicle to be tested from the scan
tool menu. If the scan tool does not communicate with the vehicle:
1. Check that the program card is correctly installed.
2. Check the connections to the vehicle.
3. Check the ignition switch position.
4. If the scan tool still does not communicate with the vehicle, refer to the scan tool Manual.
5. Carry out the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with:
1. CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418-
00.
2. NO RESP/NOT EQUIP for the anti-lock brake control module, Go To Pinpoint Test A .
3. SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),
erase the continuous DTCs and carry out self-test diagnostics for the anti-lock brake
control module.
6. If the DTCs retrieved are related to the concern, go to the Anti-Lock Brake Control Module
Diagnostic Trouble Code (DTC) Reference Chart to continue diagnostics.
7. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnostics.
Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index
NOTE: If a wheel speed signal fault or a pump motor fault is detected, the yellow ABS warning
indicator cannot be reset with the key OFF and key ON method. The vehicle must be driven over 12
km/h (8 mph) for the anti-lock brake control module to carry out a re-check of the system before the
yellow ABS warning indicator is turned OFF.

DTC Description Source Action
B1318 Battery Voltage Low ABS Go To Pinpoint Test C .
B1342 ECU Is Defective ABS INSTALL a new anti-lock brake control module;
REFER to Module . REPEAT the self-test.
B1484 Brake Pedal Input Open Circuit ABS Go To Pinpoint Test D .
B1596 Repair Continuous Codes ABS REPAIR the DTCs retrieved.

C1095 ABS Hydraulic Pump Motor ABS Go To Pinpoint Test E .
Circuit Failure
C1145 RF Anti-Lock Brake Sensor ABS Go To Pinpoint Test F .
Input Circuit Failure
C1155 LF Anti-Lock Brake Sensor ABS Go To Pinpoint Test F .
C1165 RR Anti-Lock Brake Sensor ABS Go To Pinpoint Test F .
C1175 LR Anti-Lock Brake Sensor ABS Go To Pinpoint Test F .
C1222 Anti-Lock Brake Sensor ABS Go To Pinpoint Test G .
Mismatch
C1233 LF Anti-Lock Brake Sensor ABS Go To Pinpoint Test H .
Input Signal Missing
C1234 RF Anti-Lock Brake Sensor ABS Go To Pinpoint Test H .
C1235 RR Anti-Lock Brake Sensor ABS Go To Pinpoint Test H .
C1236 LR Anti-Lock Brake Sensor ABS Go To Pinpoint Test H .
C1266 ABS Valve Power Relay ABS Go To Pinpoint Test I .
Circuit Failure
Anti-Lock Brake Control Module Parameter Identification (PID) Index

PID Description Expected Value
CCNTABS Number of Continuous DTCS in one count per bit
the Anti-Lock Brake Control
Module
BOO_ABS Brake Switch Input OFF, ON
PMP_MTR ABS Pump Motor OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
BG, OFFOBG, ON---, ONO--, ON-B-, ON--G, ONO-
G, ON-BG, ONOBG
VLV_CTR ABS Valve Control Relay OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
LF_WSPD LF Wheel Speed 0-255 MPH
RF_WSPD RF Wheel Speed 0-255 MPH
LR_WSPD LR Wheel Speed 0-255 MPH
RR_WSPD RR Wheel Speed 0-255 MPH
ABSLF_I LF ABS Inlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
ABSLF_O LF ABS Outlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
ABSRF_I RF ABS Inlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
ABSRF_O RF ABS Outlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
ABSR_I Rear ABS Inlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
ABSR_O Rear ABS Outlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
Anti-Lock Brake Control Module Active Command Index
Anti-Lock Brake Control Module Active

Command Index
Active Command Display Action
ABS OUTPUT CONTROL ABS POWER OFF, ON
DSBL TOG OFF, ON
LF INLET OFF, ON
LF OUTLET OFF, ON
RF INLET OFF, ON
RF OUTLET OFF, ON
R INLET OFF, ON
R OUTLET OFF, ON
Symptom Chart
Symptom Chart
NOTE: Refer to the Wiring Diagrams for connector numbers stated in the Pinpoint
tests.
No communication with the anti- CJB Fuse 29 Go To Pinpoint
lock brake control module (15A). Test A .
Circuitry.
Anti-lock brake
control module.
Unable to enter self-test. Anti-lock brake Go To Pinpoint
control module. Test B .
The yellow ABS warning Circuitry. Go To Pinpoint
indicator does not self-check Anti-lock brake Test J .
control module.
Instrument cluster.
Spongy brake pedal with no Air in the brake Go To Pinpoint
warning indicator system. Test K .

Base brake REFER to
system. Section 206-
00 .
Poor vehicle tracking during Air in the brake Go To Pinpoint
anti-lock function system. Test L .
Hydraulic control REFER to
unit (HCU). Section 206-
Base brake 00 .
system.
Pinpoint Tests
PINPOINT TEST A: NO COMMUNICATION WITH THE ANTI-LOCK

BRAKE CONTROL MODULE
Result / Action to
Test Step
Take
A1 CHECK CIRCUIT 601 (LB/PK) FOR AN OPEN
Disconnect: Anti-Lock Brake Control Module C135. GO to A2 .
Key in ON position.
Measure the voltage between anti-lock brake control module C135 No
Pin 8, Circuit 601 (LB/PK), harness side and ground. REPAIR the circuit.
REPEAT the self-
test.
Is the voltage greater than 10 volts?

A2 CHECK THE ANTI-LOCK BRAKE CONTROL MODULE GROUNDS
Measure the resistance between anti-lock brake control module Yes
C135 Pin 12, Circuit 1205 (BK), harness side and ground; and INSTALL a new
between anti-lock brake control module C135 Pin 15, Circuit 397 anti-lock brake
(BK/WH), harness side and ground. control module;
REFER to Module .
REPEAT the self-
test.
No
REPAIR the circuit
in question.
REPEAT the self-
test.
Are the resistances less than 5 ohms?
PINPOINT TEST B: UNABLE TO ENTER SELF-TEST

B1 CHECK THE COMMUNICATIONS TO THE
ANTI-LOCK BRAKE CONTROL MODULE
Check the communications to the anti-lock Yes
brake control module. INSTALL a new anti-lock brake control
Does the scan tool communicate with the module; REFER to Module . REPEAT the
anti-lock brake control module? self-test.
No
Go To Pinpoint Test A .
PINPOINT TEST C: DTC B1318, BATTERY VOLTAGE LOW
Result / Action to
Test Step
Take
C1 CHECK BATTERY VOLTAGE
Measure the battery voltage between the positive and negative Yes
battery posts with the key ON engine OFF (KOEO), and with the GO to C2 .
engine running.
No
REFER to Section
414-00 .
Is the battery voltage between 10 and 13 volts with KOEO, and

between 11 and 17 volts with the engine running?
C2 CHECK THE VOLTAGE TO THE ANTI-LOCK BRAKE CONTROL
MODULE
Disconnect: Anti-Lock Brake Control Module C135. GO to C3 .
Key in ON position.
CLEAR the DTCs.
REPEAT the self-
test.

C3 CHECK THE ANTI-LOCK BRAKE CONTROL MODULE GROUNDS

REFER to Module .
REPEAT the self-
test.
No
REPAIR the circuit
in question.
CLEAR the DTCs.
REPEAT the self-
test.
PINPOINT TEST D: DTC B1484, BRAKE PEDAL INPUT OPEN

CIRCUIT

D1 CHECK THE STOPLAMPS FOR CORRECT OPERATION
Depress the brake pedal while checking the stoplamps. Yes
Do the stop lamps illuminate? GO to D2 .
No
REFER to Section 417-
01 .
D2 CHECK THE BRAKE PEDAL INPUT TO THE ANTI-LOCK
Disconnect: Anti-Lock Brake Control Module C135. INSTALL a new anti-lock
Measure the voltage between anti-lock brake control module brake control module;
C135 Pin 6, Circuit 511 (LG), harness side and ground, while REFER to Module .
depressing and releasing the brake pedal. REPEAT the self-test.
No
REPAIR Circuit 511 (LG)
and Circuit 810 (RD/LG)
as necessary. CLEAR
the DTCs. REPEAT the
self-test.
Is the voltage greater than 10 volts with the brake pedal

depressed and zero volts with the brake pedal released?
PINPOINT TEST E: DTC C1095, ABS HYDRAULIC PUMP MOTOR

FAILURE
Result / Action to
Test Step
Take
E1 CHECK THE PUMP MOTOR FOR CONTINUOUS OPERATION

Check the pump motor for continuous operation. Yes
Is the pump motor running continuously? INSTALL a new
anti-lock brake
control module;
REFER to Module .
REPEAT the self-
test.
No
GO to E2 .
E2 CHECK CIRCUIT 534 (YE/LG) FOR AN OPEN
Disconnect: Anti-Lock Brake Control Module C135. GO to E3 .
Measure the voltage between anti-lock brake control module C135
Pin 13, Circuit 534 (YE/LG), harness side, and ground. No
REPAIR the circuit.
CLEAR the DTCs.
REPEAT the self-
test.

E3 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
C135 Pin 12, Circuit 1205 (BK), harness side and ground. GO to E4 .
No
REPAIR the circuit.
CLEAR the DTCs.
REPEAT the self-
test.
Is the resistance less than 5 ohms?

E4 CHECK THE PUMP MOTOR FOR OPERATION
Disconnect: Pump Motor Connector. Yes
Connect a 30A fused heavy jumper wire between the positive battery INSTALL a new
post and pump motor connector Pin 1 (component side); and anti-lock brake
momentarily connect a heavy jumper between negative battery post control module;
and pump motor connector Pin 2 (component side). REFER to Module .
REPEAT the self-
test.
No
INSTALL a new
HCU; REFER to
Hydraulic Control
Unit . CLEAR the
DTCs. REPEAT
the self-test.
Does the pump motor operate?
PINPOINT TEST F: DTC C1145 (RF), C1155 (LF), C1165 (RR), C1175
(LR), ANTI-LOCK BRAKE SENSOR INPUT CIRCUIT FAILURE

F1 CHECK THE SUSPECT ANTI-LOCK BRAKE
SENSOR CIRCUIT FOR SHORT TO POWER
Disconnect: Anti-Lock Brake Control Module C135. REPAIR the circuit in question.
Key in ON position. CLEAR the DTCs. REPEAT the self-
Measure the voltage between anti-lock brake test.
control module C135 Pins, harness side and
ground as follows: No
GO to F2 .
Anti-Lock Brake Control
DTC Module C135 Pin Circuit
C1145 4 514
(RF) (YE/RD)
C1155 20 521
(LF) (TN/OG)
C1165 1 494
(RR) (TN/LG)
C1175 22 496 (OG)
(LR)
Is any voltage present?

SENSOR CIRCUIT FOR SHORT TO GROUND
Measure the resistance between anti-lock brake GO to F4 .

GO to F3 .
C1145 4 514
(RF) (YE/RD)
C1155 20 521
(LF) (TN/OG)
C1165 1 494
(RR) (TN/LG)
C1175 22 496 (OG)
(LR)

SENSOR FOR A SHORT TO GROUND
Disconnect: Suspect Anti-Lock Brake Sensor. Yes
Measure the resistance between suspect anti-lock If RF, REPAIR Circuit 514 (YE/RD)
brake sensor Pin 1 (component side) and ground. and Circuit 516 (YE/BK), as
necessary. CLEAR the DTCs.
REPEAT the self-test. If LF, REPAIR
Circuit 521 (TN/OG) and Circuit 522
(TN/BK), as necessary. CLEAR the
DTCs. REPEAT the self-test. If RR,
REPAIR Circuit 494 (TN/LG) and
Circuit 492 (BN), as necessary.
CLEAR the DTCs. REPEAT the self-
test. If LR, REPAIR Circuit 496 (OG)
and Circuit 499 (GY/BK), as
REPEAT the self-test.
No
INSTALL a new anti-lock brake
sensor; REFER to Sensor—Front or
Sensor—Rear . CLEAR the DTCs.
SENSOR CIRCUIT FOR FOR AN OPEN
control module C135 pins, harness side and
suspect anti-lock brake sensor, harness side as No
follows: REPAIR the circuit in question.
Anti-Lock Anti-Lock test.

Brake Control Brake
DTC Module Sensor Circuit
C1145 C135 Pin 4 C160 Pin 1 514
(RF) (YE/RD)
C1145 C135 Pin 5 C160 Pin 2 516
(RF) (YE/BK)
C1155 C135 Pin 20 C150 Pin 1 521
(LF) (TN/OG)
C1155 C135 Pin 21 C150 Pin 2 522
(LF) (TN/BK)
C1165 C135 Pin 1 C3117 Pin 2 494
(RR) (TN/LG)
C1165 C135 Pin 3 C3117 Pin 1 492 (BN)
(RR)
C1175 C135 Pin 22 C3116 Pin 2 496 (OG)
(LR)
C1175 C135 Pin 23 C3116 Pin 1 499
(LR) (GY/BK)

F5 CHECK THE ANTI-LOCK BRAKE SENSOR
Measure the resistance between suspect anti-lock Yes
brake sensor Pin 1 (component side) and suspect INSTALL a new anti-lock brake
anti-lock brake sensor Pin 2 (component side). control module; REFER to Module .
No
Is the resistance between 1280 and 1920 (front)

or 1830 and 2760 (rear) ohms?
PINPOINT TEST G: DTC C1222, ANTI-LOCK BRAKE SENSOR

MISMATCH

G1 CHECK THE VEHICLE
COMPONENTS
Check for correct wheel and tire Yes
size, front-to-rear and side-to- GO to G2 .
side.
Check for excessive bearing No
end play. REPAIR as necessary. CLEAR the DTCs. REPEAT the
Check the anti-lock brake self-test.
sensor indicator for a
deformation or missing teeth.
Are the conditions OK?
G2 TEST DRIVE THE VEHICLE
Enter the following diagnostic Yes
mode on the diagnostic tool: INSTALL a new anti-lock brake control module; REFER
CLEAR the DTCs. to Module . REPEAT the self-test.
Key in ON position. No
Test drive the vehicle over 24 If another DTC is retrieved, GO to the Anti-Lock Brake
kph (15 mph). Control Module Diagnostic Trouble Code (DTC) index.
Enter the following diagnostic If no DTCs are retrieved, the system is OK.
mode on the diagnostic tool:
Retrieve DTCs.
Is DTC C1222 retrieved?
PINPOINT TEST H: DTC C1233 (LF), C1234 (RF), C1235 (RR), C1236
(LR), ANTI-LOCK BRAKE SENSOR INPUT SIGNAL MISSING

H1 CHECK THE SUSPECT ANTI-LOCK BRAKE
SENSOR
Check the suspect anti-lock brake sensor Yes
mounting. GO to H2 .
Check the suspect anti-lock brake sensor for
excessive dirt build up, obstructions, and No
damage. REPAIR as necessary. CLEAR the
Is the suspect anti-lock brake sensor and DTCs. REPEAT the self-test.
mounting OK?
SENSOR INDICATOR
indicator for corrosion, nicks, bridged teeth, GO to H3 .
damaged teeth, correct mounting, and alignment
with the anti-lock brake sensor. No
Check the air gap and bearing end play. INSTALL a new anti-lock brake sensor
Is the suspect anti-lock brake sensor indicator; REFER to Sensor—Front or
indicator OK? Sensor—Rear . CLEAR the DTCs.
H3 CHECK THE ANTI-LOCK BRAKE SENSOR
OUTPUT
Enter the following diagnostic mode on the INSTALL a new anti-lock brake control
diagnostic tool: CLEAR the DTCs.. module; REFER to Module . REPEAT
Key in OFF position. the self-test.
Key in ON position.
Have an assistant monitor the anti-lock brake No

control module PIDs LF_WSPD, RF_WSPD, INSTALL a new anti-lock brake
LR_WSPD, and RR_WSPD while driving at sensor; REFER to Sensor—Front or
various speeds. Sensor—Rear . CLEAR the DTCs.
NOTE: The vehicle must be driven 16 km/h (10 REPEAT the self-test.
miles) during this test step.
Test drive the vehicle for 16 kmh (10 miles).
Are the anti-lock brake control module PIDs
approximately the same at all times?
PINPOINT TEST I: ABS VALVE POWER RELAY CIRCUIT FAILURE

I1 CHECK CIRCUIT 534 (YE/LG) FOR AN OPEN
Disconnect: Anti-Lock Brake Control Module C135. GO to I2 .
Measure the voltage between anti-lock brake control
module C135 Pin 13, Circuit 534 (YE/LG), harness side No
and ground. REPAIR the circuit. CLEAR
the DTCs. REPEAT the self-
test.

I2 CHECK CIRCUIT 532 (OG/YE) FOR AN OPEN
Key in ON position. REPAIR the open in Circuit
Measure the voltage between anti-lock brake control 532 (OG/YE). CLEAR the
module C135 Pin 14, Circuit 532 (OG/YE), harness side DTCs. REPEAT the self-test.
and ground.
No
GO to I3 .
Is the voltage less than 5 volts?

I3 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
Measure the resistance between anti-lock brake control Yes
module C135 Pin 12, Circuit 1205 (BK), harness side and INSTALL a new anti-lock
ground. brake control module.
REFER to Module in this
section. CLEAR the DTCs.
No
REPAIR the circuit. CLEAR
the DTCs. REPEAT the self-
test.
PINPOINT TEST J: THE YELLOW ABS WARNING INDICATOR DOES

NOT SELF-CHECK

J1 CHECK THE ABS WARNING INDICATOR CIRCUITRY
Disconnect: Anti-Lock Brake Control Module C135. INSTALL a new anti-lock brake
Key in ON position. control module; REFER to
Depress and release the shorting bar connector Module . TEST the system for
internal to the anti-lock brake control module C135, normal operation.
harness side, while checking the yellow ABS warning
indicator in the instrument cluster. No
Does the yellow ABS indicator illuminate with the REFER to Section 413-01 .
shorting bar released and turn OFF with the
shorting bar depressed?
PINPOINT TEST K: SPONGY BRAKE PEDAL WITH NO WARNING

INDICATOR

K1 CHECK THE VEHICLE COMPONENTS
Check the brake pedal and power Yes
booster/brake master cylinder for correct GO to K2 .
attachment.
Are the components OK? No
REPAIR as necessary. TEST the system for
normal operation.
K2 BLEED THE BRAKE SYSTEM
Bleed the brake system; Refer to Section Yes
206-00 . INSTALL a new HCU; REFER to Hydraulic
Check for spongy brake pedal. Control Unit . TEST the system for normal
Is the brake pedal spongy? operation.
No
The brake system is OK. TEST the system
for normal operation.
PINPOINT TEST L: POOR VEHICLE TRACKING DURING ANTI-LOCK
FUNCTION

L1 BLEED THE BRAKE SYSTEM
Bleed the brake system. Refer to Section Yes
206-00 . GO to L2 .
Check for vehicle tracking poorly.
Does the vehicle track poorly? No
The brake system is OK. TEST the
L2 CHECK THE LF ABS VALVE OPERATION
Lift the vehicle and rotate all the wheels to Yes
make sure they rotate freely (the vehicle must INSTALL a new HCU; REFER to
be in neutral). Hydraulic Control Unit . TEST the system
NOTE: Trigger must be depressed twice. for normal operation.
Each press will run the pump motor for two
seconds. No
Trigger the anti-lock brake control module GO to L3 .
active command PMP MOTOR ON for four
seconds.
Apply moderate brake pedal effort.
Have an assistant attempt to rotate the LF
wheel while the pump motor is running.
Does the LF wheel rotate?
L3 CHECK THE LF ABS VALVE RELEASE
Apply moderate brake pedal effort. Yes
active command LF INLET and LF OUTLET.
NOTE: The scan tool will energize the valves No
for only two seconds per trigger press. GO to L8 .
Have an assistant rotate the LF wheel
immediately after depressing trigger.
L4 CHECK THE RF ABS VALVE OPERATION
NOTE: Trigger must be depressed twice. Yes
Each press will run the pump motor for two INSTALL a new HCU; REFER to
seconds. Hydraulic Control Unit . TEST the system
Trigger the anti-lock brake control module for normal operation.
seconds. No
Apply moderate brake pedal effort. GO to L5 .
Have an assistant attempt to rotate the RF
Does the RF wheel rotate?
L5 CHECK THE RF ABS VALVE RELEASE
active command RF INLET and RF OUTLET.
Have an assistant rotate the RF wheel
L6 CHECK THE REAR ABS VALVE OPERATION
NOTE: Trigger must be depressed Yes
twice.Each press will run the pump motor for INSTALL a new HCU; REFER to
two seconds. Hydraulic Control Unit . TEST the system

seconds. No
Apply moderate brake pedal effort. GO to L7 .
Have an assistant attempt to rotate the LR
and RR wheels while the pump motor is
running.
Does the LR or RR wheel rotate?
L7 CHECK THE REAR ABS VALVE RELEASE
Trigger the anti-lock brake control module The ABS system is operating correctly.
active command R INLET and R OUTLET.
Have an assistant rotate the LR and RR
wheels immediately after depressing trigger.
Does the LR or RR wheel rotate?
L8 CHECK FOR DTCS
Carry out the anti-lock brake control module Yes
self-test. GO to the Anti-Lock Brake Control Module
Are any DTCs retrieved? Diagnostic Trouble Code (DTC) Index.
No
INSTALL a new HCU; REFER to
Hydraulic Control Unit . TEST the system

Sensor Indicator —Rear
Special Tool(s)
Pinion Bearing Cone Remover
205-D002 (D79P-4621A)
Axle Bearing/Seal Plate

205-090 (T75L-1165-B)
Sensing Ring Replacer

206-041 (T89P-20202-A)
Removal
1. Remove the rear axle shaft bearing, refer to Section 205-02A or Section 205-02B .
2. Using the special tool, remove the anti-lock brake sensor indicator from the axle shaft.
Installation
1. Using the special tools, align the rear anti-lock brake sensor indicator to the rear axle shaft.
2. Using the special tools, press the rear anti-lock brake sensor on the rear axle shaft to
specification.
3. Install the rear axle shaft bearing, refer to Section 205-02A .

Hydraulic Control Unit

Removal
1. Disconnect the battery ground cable(14301).
2. Disconnect the anti-lock-brake control module electrical connector.
3. NOTE: The 4 wheel anti-lock brake system (4WABS) with traction control is shown , the
4WABS without traction control system is similar with one less hydraulic line.
NOTE: Plug brake lines to prevent any brake fluid loss.
Disconnect the brake lines from the hydraulic control unit (HCU).
4. Remove the HCU bracket nuts to HCU.
5. Remove the HCU.
6. Remove the pump motor electrical connector.
7. Remove the anti-lock-brake control module screws.
8. Remove the anti-lock-brake control module from the HCU.
Installation
1. NOTE: The brake system must be bled after the HCU is installed or replaced. Refer to Section
206-00 .
To install, reverse the removal procedure.

Module
Removal
1. Remove the hydraulic control unit (HCU). Refer to Hydraulic Control Unit .
Installation
206-00 .

Sensor —Front
Removal
2. Remove the inner fender splash shield.

1. Remove the inner fender splash shield push pins.
2. Remove the inner fender splash shield screw.
3. Remove the front anti-lock brake sensor electrical connector.
4. Remove the front anti-lock brake sensor harness from the anti-lock brake sensor harness clips.
5. Remove the front anti-lock brake sensor.

1. Remove the front anti-lock brake sensor bolt.
2. Remove the anti-lock brake sensor harness from the harness clips.
Installation

Sensor —Rear
Removal
1. Remove the rear passenger seat.
2. Disconnect the rear anti-lock brake sensor electrical connector.
4. Remove the rear anti-lock brake sensor harness from the floor pan.
5. Remove the anti-lock brake sensor harness bracket bolt.
6. NOTE: The sensor may be siezed to the axle. Use Rust Penetrant and Inhibitor F2AZ-19A501-
A meeting Ford specification ESR-M99C56-A to loosen the sensor for removal.
Remove the rear anti-lock brake sensor.
1. Remove the rear anti-lock brake sensor bolt.

2. Remove the rear anti-lock brake sensor.
Installation
1. NOTE: Be sure to apply High Temperature Nickel Anti-Sieze Lubricant F6AZ-9L494-AA

meeting Ford specification ESE-M124A-A to the sensor body where it will make contact when
installed.
SECTION 206-09B: Anti-Lock Control — Traction Control 2003 Mustang Workshop Manual
SPECIFICATIONS
Anti-lock brake control module screws 3 — 26
Brake line fittings to hydraulic control unit 19 14 —
Front anti-lock brake sensor bolt 7 — 62
Hydraulic control unit to mounting bracket nuts 18 13 —
Rear anti-lock brake sensor bolt 7 — 62
Anti-Lock Control —Traction Control

The four wheel anti-lock brake system (4WABS) with traction control consists of the following
components:
anti-lock brake control module (2C346)

front anti-lock brake sensor (2C204)/(2C205)
front anti-lock brake sensor indicator (2C182)
hydraulic control unit (2C286)
powertrain control module (12A650)
rear anti-lock brake sensor (2C190)/(2C216)
rear anti-lock brake sensor indicator (2C189)
traction control switch
yellow anti-lock brake system (ABS) warning indicator
Anti-Lock Control —Traction Control

Refer to Wiring Diagrams Cell 42 , Anti-Lock Brake System for schematic and connector information.
Special Tool(s)
(WDS)
418-F224,

Tester
tool
73 Digital Multimeter or
equivalent
105-R0051
Principles of Operation
The anti-lock-brake control module receives wheel speed readings from each anti-lock brake sensor
and processes this information to determine if an ABS event is necessary. The anti-lock brake sensor
electrically senses each tooth of the anti-lock brake sensor indicators as it passes through the anti-lock
brake sensor's magnetic field.
The anti-lock brake control module continuously monitors and compares the rotational speed of each
wheel and, when it detects an impending wheel lock, modulates brake pressure to the appropriate
brake caliper. This is accomplished by triggering the hydraulic control unit (HCU) to open and close the
appropriate solenoid valves. Once the affected wheel returns to normal speed, the anti-lock brake
control module returns the solenoid valves to their normal position, and normal (base) braking
resumes.
The anti-lock brake control module is self-monitoring. When the ignition switch is turned to the RUN
position, the anti-lock brake control module will do a preliminary electrical check, and at approximately
12 km/h (8 mph) the pump motor is turned on for approximately one half-second. Also during all
phases of operation the anti-lock brake control module (after the vehicle is in motion) checks for
correct operation of the anti-lock brake sensors. Any malfunction of the ABS will cause the ABS to shut
off and ABS warning indicator to illuminate; normal power assisted braking, however, remains.
The ABS control module has the ability to store multiple DTCs in memory.
The traction control system controls wheelspin by modulating the engine torque by communicating to
the powertrain control module (PCM) and by applying, then releasing, the appropriate brake to restore
traction when one or both drive wheels lose traction and begin to spin during acceleration.
The traction control system can be disabled by depressing the traction control switch. The traction
control system will reset and return to normal traction assist when the ignition switch is cycled or when
the traction control switch is depressed again.
1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical and electrical damage.

Low brake fluid Central junction box (CJB) Fuse:
Anti-lock brake sensor 5 (15A)
Anti-lock brake sensor indicator 15 (10A)
Base brake system 29 (15A)
Wheel bearings 33 (15A)
35 (15A)
Battery junction box (BJB) Fuse:
ABS 1 (50A)
ABS 2 (20A)
Circuitry
Damaged or corroded connectors
ABS warning indicator
Loose grounds
3. If the concern remains after the inspection, connect the scan tool to the data link connector
(DLC) located beneath the instrument panel and select the vehicle to be tested from the scan
tool menu. If the scan tool does not communicate with the vehicle:
1. Check that the program card is correctly installed.
2. Check the connections to the vehicle.
3. Check the ignition switch position.
4. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual.
5. Carry out the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with:
1. CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418-
00.
2. NO RESP/NOT EQUIP for the anti-lock brake control module, Go To Pinpoint Test A .
3. SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),
erase the continuous DTCs and carry out self-test diagnostics for the anti-lock brake
control module.
6. If the DTCs retrieved are related to the concern, go to the Anti-Lock Brake Control Module
Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnostics.
NOTE: If a wheel speed signal fault or a pump motor fault is detected, the yellow ABS warning
indicator cannot be reset with the key OFF and key ON method. The vehicle must be driven over 12
km/h (8 mph) for the anti-lock brake control module to do a re-check of the system before the yellow
ABS warning indicator is turned OFF.

DTC Description Source Action
B1318 Battery Voltage Low ABS/TC Go To Pinpoint Test C .
B1342 ECU Is Defective ABS/TC INSTALL a new anti-lock brake control
module; REFER to Module . REPEAT the
self-test.
B1484 Brake Pedal Input Open Circuit ABS/TC Go To Pinpoint Test D .
B1596 Repair Continuous Codes ABS/TC REPAIR the DTCs retrieved.
C1095 ABS Hydraulic Pump Motor Circuit ABS/TC Go To Pinpoint Test E .
Failure
C1145 RF Anti-Lock Brake Sensor Input ABS/TC Go To Pinpoint Test F .
Circuit Failure
C1155 LF Anti-Lock Brake Sensor Input ABS/TC Go To Pinpoint Test F .
Circuit Failure
C1165 RR Anti-Lock Brake Sensor Input ABS/TC Go To Pinpoint Test F .
Circuit Failure
C1175 LR Anti-Lock Brake Sensor Input ABS/TC Go To Pinpoint Test F .
Circuit Failure
C1222 Anti-Lock Brake Sensor Mismatch ABS/TC Go To Pinpoint Test G .
C1233 LF Anti-Lock Brake Sensor Input ABS/TC Go To Pinpoint Test H .
Signal Missing
C1234 RF Anti-Lock Brake Sensor Input ABS/TC Go To Pinpoint Test H .
Signal Missing
C1235 RR Anti-Lock Brake Sensor Input ABS/TC Go To Pinpoint Test H .
Signal Missing
C1236 LR Anti-Lock Brake Sensor Input ABS/TC Go To Pinpoint Test H .
Signal Missing
C1266 ABS Valve Power Relay Circuit ABS/TC INSTALL a new anti-lock brake control
Failure module; REFER to Module . REPEAT the
self-test.
C1805 Mismatched PCM and/or Anti-Lock ABS/TC CLEAR the DTCs. RETRIEVE the DTCs. If
Brake Control Module DTC C1805 is retrieved, check the PCM
and Anti-Lock Brake Control Module is for
the correct vehicle. INSTALL a new PCM or
anti-lock brake control module as
necessary. CLEAR the DTCs. REPEAT the
self-test.
U1009 SCP (J1850) Invalid or Missing Data ABS/TC CARRY OUT the PCM self-test.
for Engine Torque
for Engine RPM
for Transmission/Transaxle/PRNDL
for Engine Systems
U1262 SCP (J1850) Communication Bus ABS/TC REFER to Section 418-00 .
Fault

PID Description Expected Value
CCNTABS Number of Continuous DTCS in one count per bit
the Anti-Lock Brake Control
Module
BOO_ABS Brake Switch Input OFF, ON
PMP_MTR ABS Pump Motor OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
VLV_CTR ABS Valve Control Relay OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
LF_WSPD LF Wheel Speed 0-255 MPH
RF_WSPD RF Wheel Speed 0-255 MPH
LR_WSPD LR Wheel Speed 0-255 MPH
RR_WSPD RR Wheel Speed 0-255 MPH
ABSLF_I LF ABS Inlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
ABSLF_O LF ABS Outlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
ABSRF_I RF ABS Inlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
ABSRF_O RF ABS Outlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
ABSLR_I LR ABS Inlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
ABSLR_O LR ABS Outlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
ABSRR_I RR ABS Inlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
ABSRR_O RR ABS Outlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
G, ON-BG, ONOBG
LF_TC_P LF Traction Control Priming OFF, ON
Valve
RF_TC_P RF Traction Control Priming OFF, ON
Valve
LR_TC_P LR Traction Control Priming OFF, ON
Valve
RR_TC_P RR Traction Control Priming OFF, ON
Valve
LF_TC_S LF Traction Control Switching OFF, ON
Valve
RF_TC_S RF Traction Control Switching OFF, ON
Valve
LR_TC_S LR Traction Control Switching OFF, ON
Valve
RR_TC_S RR Traction Control Switching OFF, ON
Valve
T/ALVAL Left Traction Control Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
Output State BG, OFFOBG, ON---, ONO--, ON-B-, ON--G, ONO-
G, ON-BG, ONOBG
T/ARVAL Right Traction Control Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-
Output State BG, OFFOBG, ON---, ONO--, ON-B-, ON--G, ONO-
G, ON-BG, ONOBG

Active Command Display Action
ABS OUTPUT CONTROL ABS POWER OFF, ON
DSBL TOG OFF, ON
LF INLET OFF, ON
LF OUTLET OFF, ON
RF INLET OFF, ON
RF OUTLET OFF, ON
LR INLET OFF, ON
LR OUTLET OFF, ON
RR INLET OFF, ON
RR OUTLET OFF, ON
TRACTION CONTROL PRIMARY AND SWITCHING VALVE CONTROL LF TC PRV OFF, ON
LF TC SWV OFF, ON
RF TC PRV OFF, ON
RF TC SWV OFF, ON
LR TC PRV OFF, ON
LR TC SWV OFF, ON
RR TC PRV OFF, ON
RR TC SWV OFF, ON
Symptom Chart
Symptom Chart
NOTE: Refer to the wiring diagrams for connector numbers stated in the pinpoint
test.
No communication with the anti- CJB Fuse 29 Go To Pinpoint
lock brake control module (15A). Test A .
Circuitry.
Anti-lock brake
control module.
Unable to enter self-test Anti-lock brake Go To Pinpoint
control module. Test B .
The yellow ABS warning indicator Circuitry. Go To Pinpoint
does not self-check Anti-lock brake Test I .
control module.
Instrument
cluster.
Spongy brake pedal with no Air in the brake Go To Pinpoint
warning indicator system. Test J .
Base brake REFER to
system. Section 206-
Hydraulic control 00 .
unit (HCU).
Poor vehicle tracking during anti- Air in the brake Go To Pinpoint
lock function system. Test K .
Hydraulic control REFER to
unit (HCU). Section 206-
Base brake 00 .
system.
The traction control is CJB 5 (15A). Go To Pinpoint
inoperative—does not operate Circuitry. Test L .
correctly Traction control
switch.
Instrument
cluster.
Anti-lock brake
control module.
The traction control indicator is Circuitry. Go To Pinpoint
inoperative—traction control Traction control Test M .
switch switch.
Instrument
cluster.
Pinpoint Tests
PINPOINT TEST A: NO COMMUNICATION WITH THE ANTI-LOCK

Result / Action to
Test Step
Take
A1 CHECK CIRCUIT 601 (LB/PK) FOR AN OPEN
Disconnect: Anti-Lock Brake Control Module C141. GO to A2 .
Key in ON position.
REPEAT the self-

test.

A2 CHECK THE ANTI-LOCK BRAKE CONTROL MODULE GROUNDS
REFER to Module .
REPEAT the self-
test.
No
REPAIR the circuit
in question.
REPEAT the self-
test.
PINPOINT TEST B: UNABLE TO ENTER SELF-TEST

B1 CHECK THE COMMUNICATIONS TO THE
ANTI-LOCK BRAKE CONTROL MODULE
Check the communications to the anti-lock Yes
brake control module. INSTALL a new anti-lock brake control
Does the scan tool communicate with the module; REFER to Module . REPEAT the
anti-lock brake control module? self-test.
No
Go To Pinpoint Test A .
PINPOINT TEST C: DTC B1318, BATTERY VOLTAGE LOW
Result / Action to
Test Step
Take
C1 CHECK BATTERY VOLTAGE
Measure the battery voltage between the positive and negative Yes
battery posts with the key ON engine OFF (KOEO), and with the GO to C2 .
engine running.
No
REFER to Section
414-00 .
Is the battery voltage between 10 and 13 volts with KOEO, and

between 11 and 17 volts with the engine running?
C2 CHECK THE VOLTAGE TO THE ANTI-LOCK BRAKE CONTROL
MODULE
Disconnect: Anti-Lock Brake Control Module C141. GO to C3 .
Key in ON position.
CLEAR the DTCs.
REPEAT the self-
test.

C3 CHECK THE ANTI-LOCK BRAKE CONTROL MODULE GROUNDS
REFER to Module .
REPEAT the self-
test.
No
REPAIR the circuit
in question.
CLEAR the DTCs.
REPEAT the self-
test.
PINPOINT TEST D: DTC B1484, BRAKE PEDAL INPUT OPEN

CIRCUIT

D1 CHECK THE STOPLAMPS FOR CORRECT OPERATION
Depress the brake pedal while checking the stoplamps. Yes

Do the stop lamps illuminate? GO to D2 .
No
REFER to Section 417-
01 .
D2 CHECK THE BRAKE PEDAL INPUT TO THE ANTI-LOCK
Disconnect: Anti-Lock Brake Control Module C141. INSTALL a new anti-lock
Measure the voltage between anti-lock brake control module brake control module;
C141 Pin 6, Circuit 511 (LG), harness side and ground, while REFER to Module .
depressing and releasing the brake pedal. REPEAT the self-test.
No
REPAIR Circuit 511 (LG)
and Circuit 810 (RD/LG)
as necessary. CLEAR
the DTCs. REPEAT the
self-test.
Is the voltage greater than 10 volts with the brake pedal

depressed and zero volts with the brake pedal released?
PINPOINT TEST E: DTC C1095, ABS HYDRAULIC PUMP MOTOR

FAILURE
Result / Action to
Test Step
Take
E1 CHECK THE PUMP MOTOR FOR CONTINUOUS OPERATION
Check the pump motor for continuous operation. Yes
Is the pump motor running continuously? INSTALL a new
anti-lock brake
control module;
REFER to Module .
REPEAT the self-
test.
No
GO to E2 .
E2 CHECK CIRCUIT 534 (YE/LG) FOR AN OPEN
Disconnect: Anti-Lock Brake Control Module C141. GO to E3 .
Measure the voltage between anti-lock brake control module C141
Pin 13, Circuit 534 (YE/LG), harness side, and ground. No
REPAIR the circuit.
CLEAR the DTCs.
REPEAT the self-
test.

E3 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
C141 Pin 12, Circuit 1205 (BK), harness side and ground. GO to E4 .
No
REPAIR the circuit.
CLEAR the DTCs.
REPEAT the self-
test.

E4 CHECK THE PUMP MOTOR FOR OPERATION
Disconnect: Pump Motor Connector. Yes
Connect a 30A fused heavy jumper wire between the positive battery INSTALL a new
post and pump motor connector Pin 1 (component side); and anti-lock brake
momentarily connect a heavy jumper between negative battery post control module;
and pump motor connector Pin 2 (component side). REFER to Module .
REPEAT the self-
test.
No
INSTALL a new
HCU; REFER to
Hydraulic Control
Unit . CLEAR the
DTCs. REPEAT
the self-test.
Does the pump motor operate?
PINPOINT TEST F: DTC C1145 (RF), C1155 (LF), C1165 (RR), C1175
(LR), ANTI-LOCK BRAKE SENSOR INPUT CIRCUIT FAILURE

SENSOR CIRCUIT FOR SHORT TO POWER
Disconnect: Anti-Lock Brake Control Module C141. REPAIR the circuit in question.
Key in ON position. CLEAR the DTCs. REPEAT the self-
Measure the voltage between anti-lock brake test.

GO to F2 .
C1145 4 514
(RF) (YE/RD)
C1155 20 521
(LF) (TN/OG)
C1165 1 494
(RR) (TN/LG)
C1175 22 496 (OG)
(LR)
Is any voltage present?

SENSOR CIRCUIT FOR SHORT TO GROUND
GO to F3 .
C1145 4 514
(RF) (YE/RD)
C1155 20 521
(LF) (TN/OG)
C1165 1 494
(RR) (TN/LG)
C1175 22 496 (OG)
(LR)

SENSOR FOR A SHORT TO GROUND
Disconnect: Suspect Anti-Lock Brake Sensor. Yes
Measure the resistance between suspect anti-lock If RF, REPAIR Circuit 514 (YE/RD)
brake sensor Pin 1 (component side) and ground. and Circuit 516 (YE/BK), as
REPEAT the self-test. If LF, REPAIR
Circuit 521 (TN/OG) and Circuit 522
(TN/BK), as necessary. CLEAR the
DTCs. REPEAT the self-test. If RR,
REPAIR Circuit 494 (TN/LG) and
Circuit 492 (BN), as necessary.
test. If LR, REPAIR Circuit 496 (OG)
and Circuit 499 (GY/BK), as
No
SENSOR CIRCUIT FOR FOR AN OPEN
suspect anti-lock brake sensor, harness side as No
follows: REPAIR the circuit in question.
Anti-Lock Anti-Lock test.
Brake Control Brake
DTC Module Sensor Circuit
C1145 C141 Pin 4 C145 Pin 1 514
(RF) (YE/RD)
C1145 C141 Pin 5 C145 Pin 2 516
(RF) (YE/BK)
C1155 C141 Pin 20 C144 Pin 1 521
(LF) (TN/OG)
C1155 C141 Pin 21 C144 Pin 2 522
(LF) (TN/BK)
C1165 C141 Pin 1 C319 Pin 2 494
(RR) (TN/LG)
C1165 C141 Pin 3 C319 Pin 1 492 (BN)
(RR)
C1175 C141 Pin 22 C320 Pin 2 496 (OG)
(LR)
C1175 C141 Pin 23 C320 Pin 1 499
(LR) (GY/BK)

F5 CHECK THE ANTI-LOCK BRAKE SENSOR
Measure the resistance between suspect anti-lock Yes
brake sensor pin 1 (component side) and suspect INSTALL a new anti-lock brake
anti-lock brake sensor pin 2 (component side). control module; REFER to Module .
No
Is the resistance between 1280 and 1920 (front)

or 1830 and 2760 (rear) ohms?
PINPOINT TEST G: DTC C1222, ANTI-LOCK BRAKE SENSOR

MISMATCH

G1 CHECK THE VEHICLE
COMPONENTS
Check for correct wheel and tire Yes
size, front-to-rear and side-to- GO to G2 .
side.
Check for excessive bearing end No
play. REPAIR as necessary. CLEAR the DTCs. REPEAT
Check the anti-lock brake sensor the self-test.
indicator for a bent sensor ring or
missing teeth.
Are the conditions OK?
G2 TEST DRIVE THE VEHICLE
Enter the following diagnostic Yes
mode on the diagnostic tool: INSTALL a new anti-lock brake control module;
CLEAR the DTCs. REFER to Module . REPEAT the self-test.
Key in ON position. No
Test drive the vehicle over 24 If another DTC is retrieved, GO to the Anti-Lock Brake
km/h (15 mph). Control Module Diagnostic Trouble Code (DTC) index.
Enter the following diagnostic If no DTCs are retrieved, system is OK.
mode on the diagnostic tool:
Retrieve DTCs.
Is DTC C1222 retrieved?
PINPOINT TEST H: DTC C1233 (LF), C1234 (RF), C1235 (RR), C1236
(LR), ANTI-LOCK BRAKE SENSOR INPUT SIGNAL MISSING

SENSOR
mounting. GO to H2 .
Check the suspect anti-lock brake sensor for
excessive dirt build up, obstructions, and No
damage. REPAIR as necessary. CLEAR the
Is the suspect anti-lock brake sensor and DTCs. REPEAT the self-test.
mounting OK?
SENSOR INDICATOR
indicator for corrosion, nicks, bridged teeth, GO to H3 .
damaged teeth, correct mounting, and
alignment with the anti-lock brake sensor. No
Check the air gap and bearing end play. INSTALL a new anti-lock brake sensor
Is the suspect anti-lock brake sensor indicator; REFER to Sensor Indicator—
indicator OK? Front or Sensor Indicator—Rear .
CLEAR the DTCs. REPEAT the self-test.
H3 CHECK THE ANTI-LOCK BRAKE SENSOR
OUTPUT
Enter the following diagnostic mode on the INSTALL a new anti-lock brake control
diagnostic tool: CLEAR the DTCs. module; REFER to Module . REPEAT
Key in OFF position. the self-test.
Key in ON position.
Have an assistant monitor the anti-lock brake No
control module PIDs LF_WSPD, RF_WSPD, INSTALL a new anti-lock brake sensor;
LR_WSPD, and RR_WSPD while driving at REFER to Sensor—Front or Sensor—
various speeds. Rear . CLEAR the DTCs. REPEAT the
NOTE: the vehicle must be driven 16 km (10 self-test.
miles) during this test step.
Test drive the vehicle for 16 km (10 miles).
Are the anti-lock brake control module PIDs
approximately the same at all times?
PINPOINT TEST I: THE YELLOW ABS WARNING INDICATOR DOES

NOT SELF-CHECK

I1 CHECK THE ABS WARNING INDICATOR CIRCUITRY
Disconnect: Anti-Lock Brake Control Module C141. INSTALL a new anti-lock brake
Key in ON position. control module; REFER to
Depress and release the shorting bar connector Module . TEST the system for
internal to the anti-lock brake control module C141, normal operation.
harness side, while checking the yellow ABS warning
indicator in the instrument cluster. No
Does the yellow ABS indicator illuminate with the REFER to Section 413-01 .
shorting bar released and OFF with the shorting
bar depressed?
PINPOINT TEST J: SPONGY BRAKE PEDAL WITH NO WARNING

INDICATOR

J1 CHECK THE VEHICLE COMPONENTS
Check the brake pedal and power Yes
booster/brake master cylinder for correct GO to J2 .
attachment.
Are the components OK? No
REPAIR as necessary. TEST the system for
normal operation.
J2 BLEED THE BRAKE SYSTEM
Bleed the brake system; REFER to Section Yes
206-00 . INSTALL a new HCU; REFER to Hydraulic
Check for spongy brake pedal. Control Unit . TEST the system for normal
Is the brake pedal spongy? operation.
No
The brake system is OK. TEST the system
PINPOINT TEST K: POOR VEHICLE TRACKING DURING ANTI-LOCK

FUNCTION

K1 BLEED THE BRAKE SYSTEM
Bleed the brake system; REFER to Section Yes
206-00 . GO to K2 .
Check for vehicle tracking poorly.
Does the vehicle track poorly? No
The brake system is OK. TEST the
K2 CHECK THE LF ABS VALVE OPERATION
Lift the vehicle and rotate all the wheels to Yes
make sure they rotate freely (the vehicle must INSTALL a new HCU; REFER to
be in neutral). Hydraulic Control Unit . TEST the system
NOTE: Trigger must be depressed twice. for normal operation.
Each depress runs the pump motor for two
seconds. No
Trigger the anti-lock brake control module GO to K3 .

seconds.
Apply moderate brake pedal effort.
Have an assistant attempt to rotate the LF
K3 CHECK THE LF ABS VALVE RELEASE
active command LF INLET and LF OUTLET.
NOTE: Trigger must be depressed twice. No
Each depress runs the pump motor for two GO to K10 .
seconds.
Have an assistant rotate the LF wheel
K4 CHECK THE RF ABS VALVE OPERATION
Each depress runs the pump motor for two INSTALL a new HCU; REFER to
seconds. No
Apply moderate brake pedal effort. GO to K5 .
Have an assistant attempt to rotate the RF
K5 CHECK THE RF ABS VALVE RELEASE
for only two seconds per trigger press. GO to K10 .
Have an assistant rotate the RF wheel
K6 CHECK THE LR ABS VALVE OPERATION
seconds. No
Have an assistant attempt to rotate the LR
Does the LR wheel rotate?
K7 CHECK THE LR ABS VALVE RELEASE
active command LR INLET and LR OUTLET.
Have an assistant rotate the LR wheel
Does the LR wheel rotate?
K8 CHECK THE RR ABS VALVE OPERATION

seconds. No
Have an assistant attempt to rotate the RR
Does the RR wheel rotate?
K9 CHECK THE RR ABS VALVE RELEASE
Trigger the anti-lock brake control module The ABS system is operating correctly.
Have an assistant rotate the RR wheel
Does the RR wheel rotate?
K10 CHECK FOR DTCS
Carry out the anti-lock brake control module Yes
self-test. GO to the Anti-Lock Brake Control Module
Are any DTCs retrieved? Diagnostic Trouble Code (DTC) Index.
No
INSTALL a new HCU; REFER to
Hydraulic Control Unit . TEST the system
PINPOINT TEST L: THE TRACTION CONTROL IS INOPERATIVE—

DOES NOT OPERATE CORRECTLY

L1 CHECK THE TRACTION CONTROL SWITCH CIRCUITRY
Disconnect: Instrument Cluster C251. INSTALL a new
Key in ON position. instrument cluster,
Measure the voltage between instrument cluster C251 Pin 9, REFER to Section 413-
Circuit 959 (GY), harness side and ground, while depressing 01 . TEST the system
and releasing the traction control switch. for normal operation.
No
GO to L2 .
Is the voltage greater than 10 volts with the traction control

switch depressed and zero volts with the traction control
switch released?
L2 CHECK CIRCUIT 959 (GY) FOR AN OPEN

Disconnect: Traction Control Switch C239. GO to L3 .
Measure the resistance between instrument cluster C251 Pin 9,
Circuit 959 (GY), harness side and traction control switch C239 No
Pin 4, Circuit 959 (GY), harness side. REPAIR the circuit.
TEST the system for
normal operation.

L3 CHECK CIRCUIT 489 (PK/BK) FOR AN OPEN
Measure the voltage between traction control switch C239 Pin INSTALL a new traction
3, Circuit 489 (PK/BK), harness side and ground. control switch. TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system for
normal operation.
PINPOINT TEST M: THE TRACTION CONTROL INDICATOR IS

INOPERATIVE—TRACTION CONTROL SWITCH
Result / Action to
Test Step
Take
M1 CHECK CIRCUIT 960 (BK/LB)
Disconnect: Instrument Cluster C251. GO to M2 .
Disconnect: Traction Control Switch C239.
Measure the resistance between instrument cluster C251 Pin 8, No
Circuit 960 (BK/LB), harness side and traction control switch C239
Pin 5, Circuit 960 (BK/LB), harness side; and between instrument
cluster C251 Pin 8, Circuit 960 (BK/LB), harness side and ground.
Is the resistance less than 5 ohms between the instrument

cluster and traction control switch and greater than 10,000
ohms between instrument cluster and ground?
M2 CHECK CIRCUIT 489 (PK/BK) FOR AN OPEN
Measure the voltage between traction control switch C239 Pin 3, GO to M3 .
Circuit 489 (PK/BK), harness side and ground.
No
REPAIR the circuit.
TEST the system
for normal
operation.

M3 CHECK THE TRACTION CONTROL SWITCH INDICATOR
Connect: Traction Control Switch C239. INSTALL a new
Key in ON position. instrument cluster;
Momentarily connect a fused (10A) jumper wire between instrument REFER to Section
cluster C251 Pin 8, Circuit 960 (BK/LB), harness side and ground, 413-01 . TEST the
while observing the traction control switch indicator. system for normal
operation.
No
INSTALL a new
traction control
switch. TEST the
system for normal
operation.
Does the traction control switch indicator illuminate?
Sensor Indicator —Rear
Special Tool(s)
Pinion Bearing Cone Remover
205-D002 (D79P-4621A)
Axle Bearing/Seal Plate

205-090 (T75L-1165-B)
Sensing Ring Replacer

206-041 (T89P-20202-A)
Removal
1. Remove the rear axle shaft bearing, refer to Section 205-02A or Section 205-02B .
2. Using the special tool, remove the anti-lock brake sensor indicator from the axle shaft.
Installation
1. Using the special tools, align the rear anti-lock brake sensor indicator to the rear axle shaft.
2. Using the special tools, press the rear anti-lock brake sensor on the rear axle shaft to
specification.
3. Install the rear axle shaft bearing, refer to Section 205-02A .
Hydraulic Control Unit

Removal
1. Disconnect the battery ground cable(14301).
2. Disconnect the anti-lock-brake control module electrical connector.
3. NOTE: The 4 wheel anti-lock brake system (4WABS) with traction control is shown , the
4WABS without traction control system is similar with one less hydraulic line.
NOTE: Plug brake lines to prevent any brake fluid loss.
Disconnect the brake lines from the hydraulic control unit (HCU).
4. Remove the HCU bracket nuts to HCU.
5. Remove the HCU.
Installation
206-00 .
Module
Removal
1. Remove the hydraulic control unit (HCU). Refer to Hydraulic Control Unit .
Installation
206-00 .
Sensor —Front
Removal

1. Remove the inner fender splash shield push pins.
2. Remove the inner fender splash shield screw.
3. Remove the front anti-lock brake sensor electrical connector.
4. Remove the front anti-lock brake sensor harness from the anti-lock brake sensor harness clips.

1. Remove the front anti-lock brake sensor bolt.
2. Remove the anti-lock brake sensor harness from the harness clips.
Installation
Sensor —Rear
Removal
1. Remove the rear passenger seat.
2. Disconnect the rear anti-lock brake sensor electrical connector.
4. Remove the rear anti-lock brake sensor harness from the floor pan.
5. Remove the anti-lock brake sensor harness bracket bolt.
6. NOTE: The sensor may be siezed to the axle. Use Rust Penetrant and Inhibitor F2AZ-19A501-
A meeting Ford specification ESR-M99C56-A to loosen the sensor for removal.
Remove the rear anti-lock brake sensor.
1. Remove the rear anti-lock brake sensor bolt.

2. Remove the rear anti-lock brake sensor.
Installation
1. NOTE: Be sure to apply High Temperature Nickel Anti-Sieze Lubricant F6AZ-9L494-AA

meeting Ford specification ESE-M124A-A to the sensor body where it will make contact when
installed.
Switch —Traction Control

Removal and Installation
1. NOTE: If the vehicle is equipped with an automatic transmission, position the shift lever in the 1
position before detaching the floor console finish panel.
Lifting from both sides, detach the floor console finish panel.
2. Disconnect the electrical connector and position the finish panel out of the way.
3. Reaching behind the center finish panel, push and detach the switch from the finish panel.
4. Disconnect the electrical connector and remove the switch.

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2003 Mustang Workshop Manual .

hydraulic control unit and control module assy (non-

ABS Brake and Pressure Test

Tire and Wheel Runout Gauge

Inspection and Verification

Visual Inspection Chart

Power brake booster

For low or spongy brake pedal concerns:

check and, if necessary, refill the brake master cylinder reservoir.

For a slow or incomplete brake pedal return concern:

Vibration When Brakes are Applied

tire condition and pressure.

2. After verifying the concern, check for related concerns in the:

3. Check wheel bearing end-play and correct as necessary.

Remove the tire and wheel.

5. Remove the brake caliper.

not machine a new brake disc.

7. For vehicles with a two-piece hub and brake disc assembly:

8. CAUTION: Do not use a bench lathe to machine brake discs.

10. Remove any metal chips.

11. Remove the hub adapter.

14. Install the caliper and check brake operation.

Always On Parking brake.

PINPOINT TEST A: THE BRAKES PULL OR DRIFT

Test Step Result / Action to Take

Are the tires OK?

Is the alignment OK?

Are the disc brake calipers, anchor plate guide pins

PINPOINT TEST B: THE RED BRAKE WARNING INDICATOR IS

Test Step Result / Action to Take

cylinder reservoir. TEST the

Is the resistance greater than 10,000 ohms?

Is the resistance greater than 10,000 ohms?

Is the resistance greater than 10,000 ohms?

Is the resistance greater than 10,000 ohms?

PINPOINT TEST C: BRAKE LOCKUP DURING LIGHT BRAKE PEDAL

Test Step Result / Action to Take

4481 kPa (510-650 psi)? INSTALL a new proportioning valve.

PINPOINT TEST D: EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL

Test Step Result / Action to Take

PINPOINT TEST E: HYDRO-BOOST, NO POWER ASSIST

Test Step Result / Action to Take

Check accessory drive belt tension and Yes

PINPOINT TEST F: HYDRO-BOOST ERRATIC OPERATION, STICKS,

connections between the power steering pump reservoir and REMOVE

PINPOINT TEST G: HYDRO-BOOST BRAKE SYSTEM OPERATION

Test Step Result / Action to Take

Engine running at idle speed. Yes

1. Check the hydraulic brake system for leaks or insufficient fluid.

To test the function of the power brake booster check valve :

Start and run the engine for at least 10 seconds.

Brake Master Cylinder — Normal Conditions

Condition 3: Fluid level will decrease with pad wear.

Brake Master Cylinder — Abnormal Conditions

Bypass Condition Test

1. Disconnect the brake lines at the brake master cylinder.

2. Plug the outlet ports of the brake master cylinder.

Compensator Port Check

New Generation STAR (NGS)

Master Cylinder Priming — In-Vehicle or Bench