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06-00 Brake System, Service

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1. PERMANENT DAMAGE TO BRAKE COMPONENTS AND WILL RENDER THE BRAKES INOPERATIVE 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 MAX line on the brake master cylinder reservoir add High Performance DOT 3 Brake Fluid C6AZ 19542 AB or DOT 3 equivalent fluid meeting Ford specification ESA M6C25 A DOT 3 If a brake 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 service the locked components before proceeding Brake Booster Functional Test Inspect all hoses and connections All unused vacuum connectors should be capped Hoses and their connections should be properly secured and in good condition with no holes or collapsed areas Brake Booster Operation Check 1 Check hydraulic brake system for leaks or insufficient fluid 2 With transmission 7003 in NEUTRAL stop engine 6007 and apply parking brake control 2780 Apply brake pedal 2455 several times to exhaust all vacuum in the system 3 Apply brake pedal and hold it in the applied position Start engine If vacuum system is operating brake pedal will tend to move downward under constant foot pressure If no motion is felt the pow
2. Restricted brake lines or hoses Parking brake control or parking brake rear cable and conduits binding Rear brake components binding Damaged front wheel bearing Worn or damaged brake master cylinder Caliper slides binding Brakes out of adjustment Restriction in hydraulic system Binding seized rear wheel cylinders or caliper pistons Damaged brake master cylinder reservoir Leaking mounting grommets Leaking components lines hoses disc brake calipers rear wheel cylinder etc Cracked welds at brake shoe web Page 3 of 9 REPAIR or REPLACE as required REPAIR or REPLACE as required REPAIR LUBRICATE or REPLACE parts as required REFER to Section 06 05 REPAIR LUBRICATE or REPLACE parts as required CHECK bearings for adjustment wear damage ADJUST bearings PERFORM master cylinder diagnosis test REFER to Pinpoint Test R and Pinpoint Test T REPAIR as required REPLACE slide pins CLEAN grooves LUBRICATE slides ADJUST rear brakes REFER to Section 06 G2 REPAIR or REPLACE as required REFER to Section 06 06 REPAIR or REPLACE as required REFER to Section 06 03 or Section 06 02 REPLACE brake master cylinder reservoir REFER to Section 06 06 REPLACE grommets and brake master cylinder reservoir REPAIR as required BLEED system as required REPLACE rear brake shoe and lining in axle sets file C TSO tsocache V DTOM_5368
3. S VK us en file S VK60012 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger e Noise at Wheels When Brakes Are Applied Scrape or Grind e Noise at Wheels When Brakes Are Applied Squeaks Squeals or Chatter Brake shoes binding at backing plate ledges Machining marks on brake drums Backing plate ledges worn Loose or missing disc brake pad anti rattle clips Improper rotor finish after turning Improper positioning wear or damage of disc brake caliper Worn brake linings loose rivets or foreign material scraping brake components Brake shoe interference with back of brake drum shield to rotor clearance or binding at backing plate guide ledges Other brake system components Warped or bent brake backing plate causing interference with brake drum Cracked brake drums or disc brake rotors Loose brake shoe hold down springs Tires rubbing against chassis body or loose brake shoe hold down springs Worn or scored brake drums and lining or disc brake rotors Burrs or rust on disc brake caliper that would obstruct seating of shoe to disc brake caliper Page 4 of 9 CLEAN and LUBRICATE ledges REFINISH or REPLACE brake drums REFER to Section 06 02 REPLACE brake backing plate and LUBRICATE ledges REFER to Section 06 02 REPLACE REFER to Section 06 03 REFINISH or REPLACE disc brake rotors REFER to Section 06 03 INSPECT REPAIR or REPLACE REFER to Section 06
4. emergency stopping situations Customers often report brake problems in terms of brake pedal feel My brakes feel spongy or The brake pedal went to the floor or The brakes feel hard and have to apply much more force than usual are all possible customer complaints These complaints are often accompanied by reports that the vehicle Just didn t stop the way it should These simple complaints may indicate problems that are much more complex to diagnose and correct What makes understanding brake feel and stopping distance a challenge is that different brake systems have a different feel and a different braking response Feel is the result of several factors Stopping Perceptions EXPECTg AND Rater ING DIST ATE OF DECEE a a PEDAL FEEL AND TRAVEL r SYSTEM FIGHTS BACK O PRESSURE TO CALIPERS O AND DRUMS _ _ BRAKING FORCE BRAKING FORCE H9827 A Design Brake feel will vary from vehicle to vehicle even of the same design depending on how the vehicle is equipped Operation How the vehicle is used may also change the feel of the brakes Factors such as loading trailer towing and operating on steep grades or gravel roads can all affect the feel of the brakes Pedal Force and Travel file C TSO tsocache VDTOM_5368 S VK us en file S VK60011 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 7 of 7 The amount of force applied combined with the amount of brake pedal travel will affect the
5. position Did brake pedal return to original position Yes Vehicle OK GO to N2 N2 CHECK BRAKE PEDAL BINDING file C TSO tsocache V DTOM_5368 S VK us en file S VK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 13 of 18 e Check brake pedal to be sure it is operating freely Is the brake pedal operating freely Oooo e g o REPLACE power brake booster e any sticking or binding REPEAT PINPOINT TEST P VIBRATION PEDAL PUMPING LOW PEDAL BRAKE CHATTER P1 ISOLATION TEST e Perform road tests and static tests to isolate trouble to the front rear or parking brake system Has the condition been isolated REPAIR REPLACE or ADJUST components of system as necessary REFER to the appropriate REPEAT P1 section in Group 06 PINPOINT TEST Q HYDRAULIC LEAK TEST Q1 CHECK FOR LEAKS e Apply the brakes and check for leaks Are any leaks found Yes REPLACE leaking parts as required GO to Q2 Q2 REAR BRAKE LEAK CHECK e Inspect all rear wheel cylinders or rear disc brake calipers for leaks Do rear wheel cylinders or rear disc brake calipers check OK REPLACE or REBUILD rear wheel cylinders or GO to Q3 rear disc brake calipers as required file C TSO tsocache V DTOM_5368 S VK us en file S VK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 14 of 18 Q3 FRONT BRAKE LEAK CHECK e Inspect front disc brake calipers for leaks Do front disc brake calipers check OK RE
6. runout of front disc brake rotor Stones or foreign material trapped inside wheelcovers Loose wheel lug nuts Damaged worn or improperly adjusted wheel bearings Page 5 of 9 CLEAN or REPLACE INSPECT for correct usage If necessary REPLACE with correct type in axle sets REFER to Section 06 02 Section 06 03 INSPECT REPAIR or REPLACE as required REFER to Section 06 02 SEAT covers with a rubber mallet REPAIR flanges or REPLACE cover TIGHTEN to proper torque REPLACE wheel if stud holes are damaged REPLACE worn or damaged wheel bearings LUBRICATE and ADJUST REMOVE glaze from linings ADJUST brakes properly INSPECT REPAIR or REPLACE as required REFER to Section 06 02 or Section 06 03 as required REMOVE stones etc TIGHTEN to correct torque REPLACE wheel if stud holes are elongated REFER to Section 04 04 ADJUST or REPLACE as file C TSO tsocache V DTOM_5368 S VK us en file S VK60012 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger e Noise at Wheels Brakes Not Applied Squeaks Squeals or Chatter Grinding Noise Excessive Brake Lining Wear Brake Roughness Vibration or Pulsation e Groan Roughness or Chatter at Wheel Brakes Applied Loose or missing anti rattle clips or caliper pins Drum brake linings shoes loose or extra parts Worn damaged or dry wheel bearings Improperly lubricated wheel bearings Improperly a
7. the vehicle from approximately 80 to 56 km h 50 to 35 mph To use the parking brake e Hold the release handle out or press release button in while applying the parking brake Is vibration shudder present Oooo e g o CHECK the rear brakes GO to C2 for disc brakes GO to C3 for drum brakes CHECK the front brakes GO to C2 C2 RESURFACE DISC BRAKES e Resurface front disc brake rotors and road test vehicle Is shudder vibration present Yes GO to C4 Brake system repaired file C TSO tsocache VWDTOM_5368 S VK us en file S VK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 4 of 18 C3 REFINISH BRAKE DRUMS e Refinish brake drums and road test vehicle Is shudder vibration present Yes GO to C5 Brake system repaired C4 REPLACE DISC BRAKE PADS e Replace disc brake pads and road test vehicle Is shudder vibration present Yes REPLACE front disc brake rotors Brake system repaired C5 REPLACE BRAKE SHOES AND LININGS e Replace rear brake shoes and linings and road test vehicle Is shudder vibration present e PN DETERMINE which brake drum is at fault and REPLACE Brake system repaired PINPOINT TEST D PEDAL GOES DOWN FAST D1 ROAD TEST e Road test vehicle only if condition cannot be verified in shop e Statically depress brake pedal Does brake pedal operate properly Yes Vehicle OK GO to D2 file C TSO tsocache V DTOM_5368 S VK us en file S VK60013 HTM g
8. 03 REPLACE rear brake shoes and linings REFINISH or REPLACE brake drums or disc brake rotors if excessively scored REFER to Section 06 03 Section 06 02 INSPECT REPLACE as necessary LUBRICATE REFER to Section 06 02 Section 06 03 INSPECT and REPAIR as necessary REFER to Section 06 02 Section 06 03 INSPECT REPAIR as necessary REFER to Section 04 04 INSPECT REPAIR or REPLACE as required REFER to Section 06 03 or Section 06 02 CLEAN or DEBURR disc brake caliper file C TSO tsocache V DTOM_5368 S VK us en file S VK60012 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger e Noise at Wheels Brakes Not Applied Squeak or Squeal e Noise at Wheels Brakes Not Applied Growling Click or Rattle Dirty greased or glazed linings Improper lining parts or loose rear brake adjustment Other brake system components Loose lining rivets Weak damaged or incorrect brake shoe retracting springs Loose or damaged shoe retaining pins brake shoe retracting springs and clips Grooved backing plate ledges Wheel covers improperly attached Loose wheel attaching lug nuts Worn dry or improperly adjusted wheel bearings Glazed linings adjustment too tight Other brake system components Stretched brake shoe retracting springs Bent or warped brake backing plate causing interference with brake drum Improper positioning of disc brake pad in disc brake caliper Excessive
9. 10 of 18 H1 ROUGH ROAD TEST e Road test vehicle under rough road conditions e Apply brakes slowly Are brakes good Yes Vehicle OK GO to H2 H2 WHEEL BEARING CHECK e Check for loose front wheel bearings Are front wheel bearings loose REPLACE front wheel bearing if damaged CHECK front disc brake rotor for thickness variances REFER to Section 06 03 TIGHTEN front wheel bearing assembly to specification REPEAT H1 PINPOINT TEST J BRAKES DRAG J1 BRAKE FUNCTION TEST e Road test vehicle and apply brakes Are brakes functional CHECK power brake vacuum booster push rod REPEAT J1 Vehicle OK PINPOINT TEST K BRAKE SHUDDER K1 ROAD TEST e With standard wheels and tires installed road test the vehicle and verify the condition Do the front brakes chirp shudder or vibrate file C TSO tsocache V DTOM_5368 S VK us en file S VK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 11 of 18 Yes No ee A front brake chirp is normal condition No K2 APPLY PARKING BRAKE e Lightly apply the parking brake while road testing the vehicle Does the vehicle shudder or vibrate when braking Yes CHECK the rear brakes GO to K4 CHECK the front brakes GO to K3 K3 RESURFACE DISC BRAKES e Resurface front disc brake rotors and road test vehicle Does the condition persist Yes REPLACE front disc brake rotors Brakes check OK K4 REFINISH DRUM BRAKES e Refinish
10. 1997 Aerostar Ranger Page 1 of 7 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual DIAGNOSIS AND TESTING Inspection and Verification When it comes to today s electrically controlled RABS 4WABS the diagnosis of many concerns requires following the diagnostic procedures exactly as they are outlined in the service manual But there is more to it than that You have to take the information given you by the customer and combine it with your understanding of brake systems in general This knowledge and information will help you make the most efficient use of the diagnostic procedures in this manual Getting Started Brake system diagnosis starts with the customer s concern It is best to get this information directly from the customer not just from a service write up Customers usually do their best to describe what they have been experiencing and what their concerns are But it is often necessary to ask questions and probe further in order to get a complete picture of the problem Customers may report that the brake pedal 2455 went to the floor when it actually only dropped part way Remember customers get used to how their vehicle s brakes are performing If the system suddenly behaves differently they may become alarmed Under these circumstances what they report may not be as clearly stated as it could be Your job is to listen carefully and ask probing questions about anything that doesn t fit your experience and u
11. 2 file C TSO tsocache VDTOM_5368 S VK us en file S VK60025 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1l of 1 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual CLEANING AND INSPECTION Brake Booster Inspect the power brake booster for damage misalignment or loose mounting nuts Make sure the vacuum supply hose connection is secure A trace of brake fluid below the brake master cylinder mounting is normal and is caused by the wiping action of the brake master cylinder piston seals file C TSO tsocache VDTOM_5368 S VK us en file S VK60024 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1l of 1 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual CLEANING AND INSPECTION Parking Brake Inspect the parking brake control 2780 and look for loose mounting bolts damaged or missing parts Operate the parking brake and check for binding or seized components Raise and support the vehicle and remove any debris that may interfere with parking brake operation Check the condition of the parking brake cables Look for abrasion or cables rubbing on body or frame parts Repair replace or reroute as necessary e Remove the brake drums 1126 and have an assistant operate the parking brake just enough to observe operation Look for damaged or missing parts e Lubricate parking brake parts with Disc Brake Caliper Slide Grease D7AZ 19590 A or equivalent meeting Ford speci
12. 5 Type II Torque Specifications Lb Lb Description Ft In Brake Tube To Brake Master Cylinder Nuts 15 20 A 14 Hub Spindle Nut Initial Torque 23 34 la 25 Hub Spindle Nut Final Torque Back Off from Initial Setting 120 to 180 Degrees and 2 03 18 file C TSO tsocache VDTOM_5368 S VK us en file S VK60034 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 4 of 4 Retighten to 2 26 20 Front Disc Brake Caliper Bracket Bolts Ranger 100 NOTE For service install a new bolt or reuse the old bolt with thread locking 130 compound such as Ford Threadlock and Sealer EQAZ 19554 AA or equivalent meeting Ford specification WSK M2G315 A5 Type Il Front Disc Brake Caliper Pin Bolts Ranger 52 65 38 48 file C TSO tsocache VDTOM_5368 S VK us en file S VK60034 HTM gen ref HTM 2011 04 28
13. CAUTION Be sure to adjust the wheel hub retainer to specifications after the runout check Refinish or replace the disc brake rotor as required Parallelism Parallelism is the variations in the thickness of the disc brake rotor If the two rubbing surfaces of the disc brake rotor are not parallel the disc brake rotor may cause excessive brake pedal travel a pulsating brake pedal or noise Two methods can be used to check if the two faces of a disc brake rotor are parallel A micrometer can be used to measure the disc brake rotor thickness at 12 points approximately 30 degrees apart and 25 4mm 1 inch from the outer edge of the disc brake rotor The other method is to measure the disc brake rotor on a precision lathe designed for machining disc brake rotors Attach two dial indicators one on each side of the disc brake rotor so that the stylus on each indicator contacts the rubbing surface directly opposite each other approximately 25 4mm 1 inch from the outer edge of the disc brake rotor Zero both indicators and rotate the disc brake rotor while watching both dials If the total readings of both indicators exceed the specified limit for parallelism the disc brake rotor must be refinished or replaced Refinishing Use a disc brake lathe to refinish the disc brake rotor Follow manufacturer s instructions Replace the disc brake rotor when the overall thickness is at or below the specified minimum thickness shown on the disc brake
14. NFLATE tires to correct pressure REPLACE tires with worn tread REFER to Section 04 04 file C TSO tsocache V DTOM_5368 S VK us en file S VK60012 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger e Brake Warning Light On e Vibration When Brakes Are Applied Grease or fluid on linings damaged linings Improper size or type of linings Over reaction of brake booster Lining sensitivity to moisture Other brake system components Loose or missing pins for caliper attachment Worn damaged or dry wheel bearings ABS HCU defective outlet dump valve Ranger 4x4 RABS Valve defective outlet dump valve Low brake fluid level Parking brake applied or not returning completely Shorted light circuit Damaged fluid level switch or float assembly Differential pressure switch shuttled Aerostar only due to leakage in hydraulic circuit or damaged differential switch Anti lock light does self check Loose lug nuts Cracked disc brake rotors Page 8 of 9 REPLACE lining in sets CLEAN rotors REPLACE with correct brake linings in sets REPLACE brake booster if required REFER to Section 06 07 DRY linings by applying brakes while moving INSPECT REPAIR REPLACE or LUBRICATE if required REFER to Section 06 03 or Section 06 02 REFER to Section 06 09B REFER to Section 06 Q9A ADD fluid CHECK for leaks and BLEED system as required RELEASE parkin
15. PLACE or REBUILD front disc brake calipers one as required RETEST Q4 MASTER CYLINDER LEAK CHECK e Disconnect the brake master cylinder connector tubes from the brake master cylinder e Plug the output ports using the appropriate size flared tube type plugs e Push down hard on the brake pedal Does the brake pedal slowly move downward REPLACE or REBUILD the brake master Hydraulic system checks OK cylinder as required PINPOINT TEST R BRAKE MASTER CYLINDER BYPASS CONDITION CHECK R1 FLUID LEVEL CHECK e Check the fluid level in the brake master cylinder reservoir Is the reservoir low or empty FILL the brake master cylinder reservoir to the correct level GO to R2 GO to R2 R2 FLUID LEVEL CHECK BRAKES APPLIED e Apply brakes very slowly several times while observing the brake fluid level in the brake master cylinder reservoir NOTE Brake master cylinder bypass typically occurs when the brakes are applied very slowly and line pressures are low A hard application can flare the internal lip seals out and result in a passing test where the concern may in fact be valid file C TSO tsocache V DTOM_5368 S VK us en file S VK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 15 of 18 Does the level remain the same GO to R3 Brake master cylinder checks OK R3 WHEEL TURNING TORQUE CHECK FRONT WHEELS Place transmission in NEUTRAL Raise front wheels off of ground Apply 445 N 100 Ibs evenly o
16. Page 1l of 1 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual ADJUSTMENTS Hydraulic Brake Fluid Color NOTE Brake fluid contaminated with a hydrocarbon mineral based fluid power steering or transmission fluid can be detected by an obvious swelling of the brake master cylinder filler cap gasket If the swollen gasket condition is present all brake system rubber parts must be replaced All brake tubes must be thoroughly flushed with High Performance DOT 3 Brake Fluid C6AZ 19542 AB or DOT 3 equivalent fluid meeting Ford specification ESA M6C25 A DOT 3 before the vehicle goes back into service Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116 Under this standard brake fluids are visually different from other automotive fluids such as transmission power steering and engine oil The color of the brake fluid in a normal brake system in service can vary from its original color for many reasons Sometimes a brake master cylinder 2140 may show significantly different shades of color of brake fluid in the brake master cylinder reservoir 2K478 Some of the reasons for the apparent difference in color in a system are listed below e Brake fluid discoloration can occur due to heat and or aging e Brake fluid discoloration can exist when different brands shades of brake fluid are used in topping off during normal service e Brake fluid discoloration can occur thr
17. Page 2 of 2 file C TSO tsocache VDTOM_5368 S VK us en file S VK60033 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Section 06 00 Brake System Service SPECIFICATIONS SPECIFICATIONS Brake System Component Specifications Front Disc Brake Lining And Rotor Dimensions Aerostar Truck Series Aerostar 4x2 Caliper Part Number RH FO9A AA Caliper Part Number LH FO9A AA Outer Dia of Rotor Braking Surface 261 2mm 10 28 In Inner Dia of Rotor Braking Surface 165 7mm 6 52 In Swept Area per Front Brake 56192mm 87 09 In Lining Width Inboard 41 5mm 1 63 In Lining Width Outboard 41 5mm 1 63 In Lining Area per Brake Inboard 4432mm 6 87 In Lining Area per Brake Outboard 5258mm 8 15 In Lining Thickness Inboard 9 32mm 367 In Lining Thickness Outboard 8 46mm 333 In Rotor Width 22 1mm 87 In No of Piston s per Brake One Caliper Piston Diameter 65 95mm 2 59 In Effective Radius 107 14mm 4 22 In Rotor Minimum Thickness 20 6mm 0 81 In Aerostar 4x4 FO9A AA FO9A AA 276 0mm 10 86 In 168 0mm 6 61 In 60721mm 94 11 In 41 5mm 1 63 In 42 1mm 1 63 In 5388mm 8 35 In 5887mm 9 12 In 9 32mm 376 In 8 46mm 333 In 22 1mm 87 In Vented Pin Rail One 65 95mm 2 59 In 115 14mm 4 53 In 20 6mm 0 81 In a Caliper Base Part Number RH 2B120 LH 2B121 Brake Lining An
18. and rear drivetrains are mechanically locked together in 4 wheel drive If the front wheels turn the rear wheels turn If the front wheels lock up the rear wheels lock up The RABS can t prevent lockup in the rear when the front brakes are applied hard enough to cause lockup on low traction surfaces For more information on the rear anti lock brake system RABS refer to Section 06 09A For more information on the four wheel anti lock brake system 4WABS refer to Section 06 09B The Vehicle That Keeps Coming Back If you get a vehicle that has been brought in for brake service frequently take a close look at the service history How long did that vehicle go before its first brake service What has happened since If components have been replaced are they the correct parts Recurring problems can be the result of some mistake made earlier in the service history file C TSO tsocache V DTOM_5368 S VK us en file S VK60011 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 6 of 7 Brake Pedal Feel and Stopping Distance A combination of things indicates whether brakes are working properly The feel of the brake pedal how rapidly the vehicle slows down and distance travelled before stopping If the brakes are working properly and we experience the expected feel and results we are confident If the brakes feel different and or the vehicle doesn t slow or stop as expected we feel uneasy even panicked This panic will be heightened in
19. brake drums and road test vehicle Does the condition persist Yes REPLACE brake drums REPEAT K1 Brakes check OK PINPOINT TEST L EXCESSIVE BRAKE PEDAL EFFORT BOOSTER SYSTEM OK L1 BRAKE PEDAL LINKAGE TEST e Detach booster push rod from brake pedal pin and depress brake pedal fully Has condition been corrected CHECK power brake booster vacuum SERVICE or REPLACE brake pedal linkage file C TSO tsocache V DTOM_5368 S VK us en file S VK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 12 of 18 availability REFER to Section 06 07 VERIFY system OK PINPOINT TEST M BRAKE NOISE M1 CHECK PEDAL NOISE e Run engine at fast idle for 10 seconds or longer Apply brake pedal and listen for noise Compare results with known good system Was a noise present Yes GO to M2 Vehicle OK M2 PUSH ROD ADJUSTMENT e Check and adjust power brake booster push rod Refer to Section 06 07 Is push rod OK REPLACE power brake booster REPEAT Step BLEED brake system PINPOINT TEST N SLOW OR INCOMPLETE BRAKE PEDAL RETURN N1 CHECK BRAKE PEDAL RETURN e Run engine at fast idle while making several brake applications Pull brake pedal rearward with approximately 44 5N 10 lbs force Release the brake pedal and measure the distance to the toe board Make a hard brake application Release the brake pedal and measure the brake pedal to toe board distance The brake pedal should return to its original
20. checked or corrected before the road test The description will also help form the basic approach to the road test by narrowing the problem to specific components vehicle speed or conditions The road test should begin with a general brake performance check With the customer s description as a guide the brake system should be tested at different vehicle speeds using both light and heavy brake pedal pressure On vehicles with rear drum brakes to determine if the problem is in the front or rear braking system the service brake pedal is used first then the parking brake If the condition i e pull vibration pulsation occurs only with the parking brake the problem is in the rear system If the condition occurs when the service brake pedal is pressed the problem is in the front system Vehicles with rear disc brakes require further testing to determine problem location Locking the brakes and sliding the tires should be avoided Locked brakes and sliding tires do not indicate brake efficiency A heavily braked and turning wheel will stop the vehicle in less distance than locked brakes If the problem becomes evident during this check it should be determined if it fits the description given before the road test If the problem is not evident an attempt should be made to duplicate the condition using the information from the description file C TSO tsocache V DTOM_5368 S VK us en file S VK60011 HTM gen ref HTM 2011 04 28 1997 Aerostar Range
21. contamination from grease or brake fluid 2 Inspect the rear wheel cylinder 2261 for signs of leakage 3 NOTE A good spring will make a dull thud when dropped on a concrete floor A heat damaged spring that has lost tension will make a distinctive ringing sound when dropped on a concrete floor Check the brake shoe adjusting screw springs and brake shoe retracting springs 2296 for signs of e heat damage e bends or damage to coils or shank e loss of tension 4 Check the brake backing plate shoe support pads for signs of scoring The support pads must be smooth and have a light coating of lithium grease 5 Inspect the brake drum for scratches scoring bell mouth and out of round conditions 6 Refer to Section 06 02 for additional service and repair procedures file C TSO tsocache VDTOM_5368 S VK us en file S VK60022 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 2 file C TSO tsocache VDTOM_5368 S VK us en file S VK60022 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page of 2 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual CLEANING AND INSPECTION Brake Thickness FRONT DISC Description O 2 Lining Thickness Inboard and Outboard 9 9mm 9 9mm 0 39 In 0 39 In REAR DISC inch Lining Minimum Thickness REAR DRUM Ranger Reg and SuperCab Under Ranger Reg SuperCab over All Truck Series 4580 GVWR 4580 GVWR Aerostar Lining Thickness 4 8mm 4 8
22. d Rotor Dimensions Ranger Page 1 of 4 1997 Aerostar Ranger Workshop Manual file C TSO tsocache VDTOM_5368 S VK us en file S VK60034 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 4 Truck Series Ranger 4x2 Ranger 4x4 Caliper Part Number RH F57A 2B120 DC F57A 2B120 AC Caliper Part Number LH F57A 2B121 DC F57A 2B121 AC Outer Dia of Rotor Braking Surface 261 2mm 286 6mm 10 28 In 11 28 In Inner Dia of Rotor Braking Surface 165mm 180mm 6 5 In 7 1 In Swept Area per Front Brake 58746mm 2 65686mm 2 41 1 In 2 101 8 In 2 Lining Dim Inboard 136 x 33 6mm 136 x 33 6mm 5 35 x 1 32 In 5 35 x 1 32 In a il Dim Outboard 136 x 33 6mm 136 x 33 6mm 5 35 x 1 32 In 5 35 x 1 32 In slain Area per Brake Inboard 54 5cm 2 54 5cm 2 8 45 In 7 8 45 In 2 Lining Area per Brake Outboard 54 5cm 2 54 5cm 2 8 45 In 2 8 45 In 2 Lining Thickness Inboard and Outboard 9 9mm 9 9mm 0 39 In 0 39 In Rotor Width 26 0mm 26 0mm 1 023 In 1 023 In Min Service 24 5mm 24 5mm 0 964 In 0 964 In Rotor Tye s Vented Rad Fins Vented Rad Fins Caliper Type Pin Slider Bolt On Anchor Pin Slider Bolt On Anchor Number of Pistons per Brake a e ane Caliper Piston Dia 46mm 46mm 1 81 In 1 81 In Effective Radius 107 8mm 120 7mm 4 21 In 4 75 In Rear Drum Brake Specifications Ranger Reg and SuperCab Under Ranger Reg SuperCab over Truck Series 4580 GVWR 4580 GVWR All Aerostar A
23. djusted wheel bearings Binding caliper sliders Improperly adjusted wheel bearings Excessive rotor runout or thickness variation Loose wheel lug nuts Worn damaged dry or improperly adjusted wheel bearings Loose or worn front suspension components Page 6 of 9 required INSPECT REPAIR or REPLACE as required REFER to Section 06 03 INSPECT REMOVE or REPAIR REFER to Section 06 02 INSPECT LUBRICATE or REPLACE ADJUST bearings properly SERVICE as required REFER to Section 04 01A for 4x2 and Section 05 03A for Ranger and Section 04 01C for Aerostar 4x4 ADJUST or REPLACE as required REFER to Section 04 01A for 4x2 and Section 05 03A for Ranger SERVICE as required ADJUST or REPLACE as required REFER to Section 04 01A for 4x2 Section 05 03A for Ranger and Section 04 01C for Aerostar 4x4 SERVICE or REPLACE as required TIGHTEN to correct torque REPLACE wheel if stud holes are elongated REFER to Section 04 04 INSPECT LUBRICATE or REPLACE INSPECT REPAIR or REPLACE as required REFER to file C TSO tsocache V DTOM_5368 S VK us en file S VK60012 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger e Brakes Pull to One Side e Brakes Grab or Lock When Applied Brake drum cracked or out of round Disc brake caliper loose or missing parts also loose or bent dust shield Excessive wear or lateral runout of disc brake rotor Worn t
24. e brake system On the rear anti lock systems RABS pull the brake fluid level sensor connector and fasten it safely out of the way This will effectively disable the RABS but leave the normal power assisted brake system functioning normally Road test the vehicle With RABS disabled you will get a good feel for the functioning of the base brake system and any concerns Fix these concerns before testing the ABS itself This procedure will demonstrate the vehicle s deceleration before lockup This will help evaluate the vehicle s braking performance after correcting all concerns Use one of the deceleration tests referred to earlier for accurate measure of the deceleration rate With the RABS disconnected test for brake imbalance Apply pressure quickly to detect one wheel locking up before the other With RABS functioning this judgment can t be made Reactivate the RABS to check for the pedal pulsation Remember that the RABS shuts off below approximately 8 km h 5 mph which can result in lockup at the conclusion of a stop Operate vehicle safely to reach speed when testing Premature RABS Activation One concern that may be a challenge to isolate is premature RABS activation The first step is to thoroughly check out the base brake system If the base brake system checks out and there is still premature RABS activation there are several areas to take a close look at e A weak sensor signal Look for a bad wheel speed sensor chips on th
25. e caliper closely for wet areas that might indicate a leaking seal 4 Measure front disc brake rotor thickness parallelism and runout carefully Refer to Section 06 03 5 Resurface recondition or replace the front disc brake hub and rotor 1102 A visual inspection will not determine the required service unless the damage is obvious 6 Check for brake fluid contamination when inspecting the brake shoes and linings 2001 This may indicate a leaking piston seal assembly If a seal is leaking the disc brake caliper must be disassembled and inspected Refer to Section 06 03 7 Check for even wear from side to side If the set of brake shoes and linings on one side of the vehicle is excessively worn the caliper piston may be seized in the bore on the opposite side of the vehicle If a seized caliper piston is suspected the disc brake caliper must be disassembled and inspected Refer to Section 06 03 file C TSO tsocache VDTOM_5368 S VK us en file S VK60021 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 2 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual CLEANING AND INSPECTION Brakes Drum In order to properly inspect the rear brakes the brake drum 1126 must be removed Refer to Section 06 02 Check for the following conditions during a drum brake diagnosis 1 Inspect the brake shoe and lining material for wear beyond service limits uneven wear cracks scoring gouges
26. e pole piece or an air gap that s too high e A wiring problem Look for chafed wires that might be causing a faulty electrical circuit e A rear axle problem Rear axle malfunctions account for many premature RABS activation file C TSO tsocache V DTOM_5368 S VK us en file S VK60011 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 5 of 7 problems Look for rear axle speed sensor ring damage and for play in the differential that allows the rear axle speed sensor ring to move away from the wheel speed sensor The Rolling Skid NOTE Some initial momentary wheel lockup is permissible during this test ABS are designed to sense the RAPID deceleration rate of a wheel This is what warns of possible lockup Some tires have high peak traction which tends to fall off rapidly When a tire has this characteristic the ABS can easily perform as designed When increasing the braking force the tires rapidly decelerate and at the appropriate point the ABS kicks in at the wheel or axle that needs reduced pressure Brake pedal pulsations can be felt and on 4WABS the pump motor can be heard Tires with a tendency to develop peak traction which then falls off more slowly may slip some as they decelerate sometimes referred to as a rolling skid This was a typical characteristic of bias belted tires This condition may cause the ABS system not to activate because the wheel isn t fully locking up There may however be considerable squealing and
27. eel bearings for excessive end play or improper preload Does excessive end play or improper wheel bearing preload exist ADJUST wheel bearing preload or REPLACE INSPECT for and REPAIR hydraulic leaks wheel bearings RETEST system PINPOINT TEST B BRAKE WARNING INDICATOR ALWAYS ON B1 CHECK PARKING BRAKE SWITCH e With parking brake fully released disconnect the parking brake switch C202 Ranger or C309 Aerostar Did brake warning indicator light go out Yes REPLACE the parking brake switch RETEST GOtoB2 file C TSO tsocache V DTOM_5368 S VK us en file S VK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 3 of 18 B2 ISOLATE CIRCUITS 531 DG R 977 P W AND 162 LG R e With brake master cylinder reservoir fluid level OK disconnect the brake master cylinder fluid level switch C137 Ranger or C165 Aerostar Does the brake warning indicator light go out SERVICE ground short in Circuit 531 DG Y 977 P W or 162 LG R B3 TEST BRAKE FLUID LEVEL INDICATOR SWITCH e Test for continuity between fluid level switch C137 Ranger or C165 Aerostar circuit 512 T LG and ground Is there 10 000 ohms or more Yes REPLACE the brake master cylinder reservoir SERVICE short to ground in Circuit 512 T LG PINPOINT TEST C VIBRATION WHEN BRAKES ARE APPLIED C1 ISOLATE VIBRATION SHUDDER e Determine if vibration shudder is induced by the rear brakes by using the parking brake to slow
28. en ref HTM 2011 04 28 1997 Aerostar Ranger Page 5 of 18 D2 CHECK BRAKE FLUID LEVEL e Check brake fluid level Is fluid level within specifications GO to D3 CHECK reservoir sealing points ADD fluid and E BLEED system REPEAT Test D1 D3 PRESSURIZE SYSTEM e Pump brake pedal rapidly five times Does brake pedal maintain height throughout test CHECK rear brake adjustment and ADJUST if necessary If condition still exists BLEED GO to D4 system REPEAT Test D1 D4 INSPECT FOR BRAKE SYSTEM LEAKS e Perform Hydraulic Leak Test Pinpoint Test Q in this section Does system leak SERVICE as necessary ADD fluid and BLEED system REPEAT Test D1 GO to D5 D5 BRAKE MASTER CYLINDER BYPASS TEST e Perform Brake Master Cylinder Bypass Condition Check Pinpoint Test R in this section Is test OK System OK REPLACE damaged parts ADD fluid and y BLEED system REPEAT Test D1 PINPOINT TEST E PEDAL GOES DOWN SLOWLY file C TSO tsocache V DTOM_5368 S VK us en file S VK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 6 of 18 E1 ROAD TEST e Check if condition occurs during actual stopping application by depressing the brake pedal while the vehicle is moving Does condition occur when vehicle is moving E2 RECHECK BRAKE SYSTEM LEAKS e Perform Hydraulic Leak Test Pinpoint Test Q in this section Does system leak SERVICE as necessary ADD fluid and BLEED system REPEAT T
29. er brake booster system is not functioning Brake Booster 1 Remove vacuum booster hose from power brake booster and check valve connection Manifold vacuum should be available at the check valve end of the vacuum booster hose with engine at idle speed and transmission in NEUTRAL If manifold vacuum is available to the power brake booster connect vacuum booster hose to power brake booster and repeat Steps 2 and 3 of the brake booster functional test If no downward movement of brake pedal is felt replace power brake booster 2 Operate engine a minimum of 10 seconds at fast idle Stop engine and let vehicle stand for 10 minutes Then apply brake pedal with approximately 89 N 20 lbs of force Brake pedal feel should be the same as that noted with engine operating If brake pedal feels hard no power assist replace check valve and retest If brake pedal feels spongy bleed hydraulic system to remove air Refer to Section 06 06 for Hydraulic System Bleeding file C TSO tsocache V DTOM_5368 S VK us en file S VK60014 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 4 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 functioning of the power brake booster check valve Start and run the engine for at least 10 seconds Operate the bra
30. ere possible same manufacturer Any tire or wheel 1007 that is damaged should be replaced Refer to Section 04 04 Wheels and tires must be cleared of any foreign matter and tire pressures adjusted to the correct file C TSO tsocache V DTOM_5368 S VK us en file S VK60011 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 7 specification as detailed in Section 04 04 If tires exhibit uneven wear or feathering the cause must be corrected Check steering and suspension components for damage wear and if necessary check and adjust steering alignment Refer to Section 04 00 Road Test A road test should be performed 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 An experienced brake technician will always establish a route that will be used for all brake diagnosis road tests The road selected will be reasonably smooth and level Gravel or bumpy roads are not suitable because the surface does not allow the tires to grip the road equally Crowned roads should be avoided because of the large amount of weight shifted to the low set of wheels on this type of road Once the route i
31. est E1 E3 MASTER CYLINDER BYPASS TEST e Perform Brake Master Cylinder Bypass Condition Check Pinpoint Test R in this section Is test OK REPLACE damaged parts ADD fluid and System OK BLEED system REPEAT Test E1 PINPOINT TEST F PEDAL IS LOW OR FEELS SPONGY F1 BRAKE PEDAL CHECK e Statically apply brake pedal e Road test vehicle only if condition cannot be verified in shop Does brake pedal operate properly Yes Vehicle OK GO to F2 file C TSO tsocache V DTOM_5368 S VK us en file S VK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 7 of 18 F2 BRAKE PEDAL RESERVE CHECK Key ON engine running at idle with transmission in PARK or NEUTRAL Depress brake pedal lightly three or four times Wait 15 seconds to allow the vacuum to replenish Push down on brake pedal until it stops moving downward or an increased resistance to the brake pedal travel occurs NOTE This increased resistance may feel like the pedal has bottomed out e Hold the brake pedal in the applied position while increasing the engine speed to 2000 rpm e Release the accelerator pedal Does the brake pedal move downward as engine speed returns to normal Oooo e g o CHECK vacuum to power brake booster GO to Ea REFER to Section 06 07 F3 BRAKE FLUID LEVEL CHECK e Check brake fluid level Is brake fluid level within specifications GO to F4 CHECK brake master cylinder reservoir sealing poi
32. feel and stopping response Some drivers are stronger than others and can force the brake pedal down further Spring or Give in the System This is a very important concept A braking system isn t rigid Every part has some give For example the disc brake calipers 2B120 flex a little as force is applied flexible hoses swell a little under pressure and shoe return springs are extended The combination of these and other points where the system gives a little results in a springiness that fights back against the hydraulic pressure This fighting back is felt through the brake pedal As parts of the system become worn or corroded this fighting back feel may change file C TSO tsocache VDTOM_5368 S VK us en file S VK60011 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 9 Section 06 00 Brake System Service DIAGNOSIS AND TESTING 1997 Aerostar Ranger Workshop Manual Symptom Chart Brake System Service BRAKE SYSTEM SERVICE e Brakes Not Working Excessive Pedal e Low fluid level e ADD fluid BLEED system CHECK for leaks and BLEED Travel Brake Pedal Feels Spongy When Fully Applied file C TSO tsocache V DTOM_5368 S VK us en file S VK60012 HTM gen ref HTM 2011 04 28 Worn or damaged four wheel ABS hydraulic control unit Ranger only Worn or damaged RABS valve accumulator or outlet dump valve Rear brakes out of adjustment Front wheel bearing out of adjustment Brake master c
33. fication ESA M1C172 A file C TSO tsocache VDTOM_5368 S VK us en file S VK60026 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1l of 1 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual ADJUSTMENTS Brake Pedal On dual brake master cylinder 2140 with power brake booster equipped vehicles the brake systems are designed to permit a full stroke of the brake master cylinder when the brake pedal 2455 is fully depressed A brake pedal clearance adjustment is not required If brake pedal travel seems restricted check for obstructions file C TSO tsocache VDTOM_5368 S VK us en file S VK60027 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1l of 1 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual ADJUSTMENTS Free Play To release the brakes fluid must flow back to the brake master cylinder 2140 through a return port when brake pedal pressure is released To be sure the brake master cylinder piston moves back far enough to expose the return port free play is built into the brake pedal linkage on power brake booster systems This prevents the caliper piston or wheel cylinder piston from becoming trapped in a partially released position If a problem is suspected the push rod and brake pedal 2455 should be checked to make sure they are not binding Pedal free play is not always perceptible in dash mounted booster systems because the operating clearance for the brake ma
34. g brake CORRECT short in brake warning light circuit REPLACE plastic brake master cylinder reservoir REPAIR leakage in hydraulic circuit or REPLACE combination valve REFER to Diagnostic Charts in Section 06 09A or Section 06 O9B TIGHTEN lugnuts to specification REPLACE rim if stud holes are elongated REFER to Section 04 04 REPLACE front disc brake rotor REFER to Section 06 03 file C TSO tsocache V DTOM_5368 S VK us en file S VK60012 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Front disc brake rotors brake drums out of round or improper machining Worn or improperly adjusted wheel bearings Loose or worn front suspension components Excessive radial or lateral runout on wheel and tire Page 9 of 9 MACHINE disc brake rotors or brake drums or REPLACE as required ADJUST or REPLACE wheel bearings as required TIGHTEN loose components to specifications REPLACE worn or damaged components ADJUST or REPLACE tire or wheel to ELIMINATE excessive runout on tire or wheel as required REFER to Section 04 04 file C TSO tsocache VDTOM_5368 S VK us en file S VK60012 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 18 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual DIAGNOSIS AND TESTING Pinpoint Tests DIAGNOSTIC PINPOINT TEST INDEX OOOO Deion fa Brakes Pull or Drift Brake Warning Indicator Always On Vibration W
35. ger Page 3 of 4 The only part of the brake system that could have a brake fluid loss that did not appear when the system is under pressure is the brake master cylinder reservoir area Brake fluid loss could be caused by a missing or poorly fitted brake master cylinder filler cap from a punctured or otherwise damaged brake master cylinder reservoir by a missing or damaged brake master cylinder filler cap gasket or at the sealing grommets between the brake master cylinder and the brake master cylinder reservoir The brake master cylinder reservoir grommets are not separately serviceable and must be replaced with a new brake master cylinder reservoir NOTE The wet appearance of the outer cover of rubber brake hoses is called sweating This is a normal condition for neoprene rayon braid hose The sweating condition is not evidence of a brake fluid leak and will not result in a loss of pressure in the system Replace a 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 parts 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 turbule
36. hen Brakes Are Applied Pedal Goes Down Fast Pedal Goes Down Slowly Pedal Is Low or Feels Spongy Brake Lockup During Light Brake Pedal Force Excessive and or Erratic Pedal Travel Brakes Drag Brakes Shudder Brake Pedal Excessive Effort Booster System OK Brake Noise Slow or Incomplete Brake Pedal Return Vibration Pedal Pumping Low Pedal or Brake Chatter Hydraulic Leak Test Brake Master Cylinder Bypass Condition Check Excessive Pedal Effort Brake Fluid Loss Brake Master Cylinder Internal Test OK PINPOINT TEST A BRAKES PULL OR DRIFT A1 INSPECT TIRE PRESSURE e Measure air pressure in all four tires Is tire pressure within specifications Yes GO to A2 ADJUST tire pressure file C TSO tsocache V DTOM_5368 S VK us en file S VK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 18 A2 CHECK CALIPER AND REAR WHEEL CYLINDERS e Check the front disc brake caliper pistons pins or rear wheel cylinders for binding leakage or sticking Do the front disc brake caliper pistons pins or rear wheel cylinders bind or stick e REPAIR or REPLACE components as GO to A3 necessary A3 INSPECT FRONT DISC BRAKE ROTORS AND BRAKE DRUMS e Inspect the disc brake rotors and or brake drums for excessive runout or damage Does excessive runout or damage exist o e S o O REPAIR or REPLACE disc brake rotor or brake GO to A4 drum as necessary A4 INSPECT WHEEL BEARINGS e Inspect front and rear wh
37. inder reservoir GO to T2 with no brake warning indicator REPLACE brake master cylinder reservoir T2 FLUID LEVEL CONDITION e Apply and release brake pedal one full stroke Observe reservoir fluid level as brake pedal is released Does fluid level change External leak outside of the brake master cylinder REPAIR leak GO to T3 T3 MASTER CYLINDER CONDITION Wipe off exterior of brake master cylinder brake master cylinder filler cap and gasket with clean cloth Road test vehicle and pump brakes Check if brake master cylinder exterior is dry or wet Check for fluid from bore end of power brake booster at dash Is brake master cylinder dry External leak in brake master cylinder REPAIR GO 10 IE brake master cylinder T4 BRAKE PEDAL CONDITION CHECK file C TSO tsocache V DTOM_5368 S VK us en file S VK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 18 of 18 e Apply pressure to brake pedal one full stroke and release repeat 3 more cycles Does brake pedal go down 3 175mm 0 125 inch each time CHECK entire brake system for major leak REPAIR as required Brake master cylinder OK file C TSO tsocache VDTOM_5368 S VK us en file S VK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 4 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual DIAGNOSIS AND TESTING Component Tests A WARNING USE OF ANY OTHER THAN THE APPROVED DOT 3 BRAKE FLUID WILL CAUSE
38. ires Unequal air pressure in tires Grease or fluid on linings Glazed linings Loose or missing disc brake caliper pin Improper size or type of lining on one wheel Improper size wheel cylinder on one wheel Stuck or seized pistons in wheel cylinders or seized calipers Restricted brake lines or hoses Other brake components Improper adjustment of drum brakes Improper positioning of disc brake shoe and lining in the caliper Fit of caliper to knuckle Improperly adjusted damaged or worn wheel bearings Distorted drum brake shoes Worn brake linings or scored rotor Missing broken or stretched retracting or retaining springs and clips Suspension or steering Tires worn or incorrect pressure Page 7 of 9 Section 04 00 REPLACE drum if required REFER to Section 06 02 REPAIR or REPLACE as required REFER to Section 06 03 REPLACE rotor REFER to Section 06 03 REPLACE tires REFER to Section 04 04 INFLATE tires to correct pressure CLEAN SAND or REPLACE linings CLEAN disc brake rotors REPLACE missing pin REFER to Section 06 03 REPLACE with correct brake linings in sets REPLACE with correct wheel cylinder REFER to Section 06 02 REPAIR or REPLACE as required REFER to Section 06 03 or Section 06 02 REPAIR or REPLACE as required INSPECT ADJUST REPAIR or REPLACE as required REFER to Section 06 02 or Section 06 03 REPAIR as required I
39. ke pedal to check for power assist Disconnect the vacuum booster hose from the power brake booster There should be enough vacuum retained in the power brake booster for at least one more power assisted brake operation Vacuum System Test To test the vacuum system refer to Pinpoint Test S in this section Brake Master Cylinder Normal Conditions The following conditions are considered normal and are not indications that the brake master cylinder 2140 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 power brake booster shell below the brake master cylinder mounting flange This results from the normal lubricating action of the brake master cylinder bore and seal Condition 3 Brake fluid level will decrease with disc brake pad wear Abnormal Conditions Changes in brake pedal feel or travel are indicators that something could be wrong in the brake system Refer to the Symptom Chart for abnormal condition diagnosis Bypass Condition Test For the bypass condition test refer to Pinpoint Test R in this section Non Pressure Leaks file C TSO tsocache V DTOM_5368 S VK us en file S VK60014 HTM gen ref HTM 2011 04 28 1997 Aerostar Ran
40. linder filler cap on the brake master cylinder reservoir Brake Rotor Disc Each time the brakes are serviced the disc brake rotor should be checked for scoring runout parallelism and thickness Disc brake rotor scoring and runout may be checked on most brakes with the disc brake rotor either on or off Disc brake rotor specifications are listed in the Specifications at the end of this section Runout Disc brake rotor lateral runout is the side to side movement or wobble of the disc brake rotor as it rotates Excessive runout may cause vibration brake pedal pumping low brake pedal 2455 or brake chatter Use the following procedure to check disc brake rotor runout 1 Tighten the wheel hub retainer to eliminate all end play from the wheel bearing Be sure the disc brake rotor can be turned 2 Attach Dial Indicator with Bracketry TOOL 4201 C or equivalent to some part of the vehicle suspension so the stylus of the indicator touches the surface of the disc brake rotor approximately 25 4mm one inch from outer edge of the disc brake rotor 3 Adjust the dial indicator to mid travel Zero the scale on the dial indicator Slowly turn the disc brake rotor one complete turn and note the high and low readings on the dial The total between the high file C TSO tsocache V DTOM_5368 S VK us en file S VK60032 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 3 and low reading must not exceed the specified runout limit 4 As
41. llowing conditions are considered normal and are not indications that the brake master cylinder reservoir 2K478 is in need of service Low brake fluid level detected without signs of leakage This condition is caused by displacement of brake fluid from the brake master cylinder reservoir into the front disc brake calipers 2B120 to compensate for normal brake wear Add brake fluid as needed A momentary or slight squirt of brake fluid from the brake master cylinder reservoir upon application of the brake pedal 2455 This condition is caused by brake fluid displacement through the brake master cylinder reservoir compensating port as the brake master cylinder pistons move forward in the bore when the brakes are applied Slight turbulence in the brake fluid when the brake pedal is released Turbulence occurs as brake fluid returns to the brake master cylinder 2140 after releasing the brakes A trace of brake fluid found on the outside of the power brake booster 2005 below the brake master cylinder mounting flange This condition results from the lubricating action of the master cylinder wiping seal Make sure all ports and vents in the brake master cylinder are open and free of foreign matter Brake Tubing Clean new brake tubing with isopropyl alcohol Inspect for cracks kinks or other damage Replace as necessary file C TSO tsocache VDTOM_5368 S VK us en file S VK60025 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of
42. mm 4 8mm Primary 19 In 189 In 189 In Lining Thickness 7 1mm 6 2mm 6 2mm Secondary 28 In 245 In 245 In Lining Length Primary 154 9mm 214 9mm 214 9mm 6 10 In 8 46 In 8 46 In Lining Length 223 5mm 243 8mm 243 6mm Secondary 8 80 In 9 6 In 9 59 In file C TSO tsocache VDTOM_5368 S VK us en file S VK60023 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 2 file C TSO tsocache VDTOM_5368 S VK us en file S VK60023 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 2 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual CLEANING AND INSPECTION Hydraulic System i 4 5 NOTE If dirt is found in any part of the hydraulic system flush the entire system with clean isopropyl alcohol Clean brake parts in clean isopropyl alcohol or use the Rotunda Brake Parts Washer 065 00016 or equivalent Inspect all parts for wear or damage Check the wheel cylinder or caliper bore for rust scores or other damage Be sure the bleeder screw passage is clean and open Replace all parts that are worn or damaged Brake Master Cylinder Clean all brake master cylinder parts in clean isopropyl alcohol or use the Rotunda Brake Parts Washer 065 00016 or equivalent and inspect the parts for wear or damage Replace them if required When a master cylinder repair kit is used follow the instructions in the kit and install all of the parts provided The fo
43. n file S VK60011 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 4 of 7 Detecting Causes of Brake Problems ABS brake systems with their electronically controlled components provide a greater degree of braking control than ever before The fault codes generated by the built in diagnostics make solving many concerns a simple matter However it isn t always possible to immediately nail the culprit when something isn t working properly Eliminate the obvious first and gradually close in on the real concern Start with the clues found during basic inspection Correct the obvious problems and see how that affects the performance of the system Save the potentially difficult possibilities for last Many times the concern will be corrected before you have to get into more challenging areas The most difficult concerns are often intermittent Make sure the problem is really an intermittent brake issue and not an intermittent operating condition Get as much information as possible Talk to the primary driver Find out how often it actually happens what time of day what the load is what the road conditions are and what the weather is like Listen carefully There may be important clues in the answers Isolating ABS As WARNING DO NOT DISABLE THE FRONT BRAKES IF YOU DO STOPPING DISTANCES MAY BE EXTREMELY LONG ESPECIALLY IN VEHICLES THAT ARE UNLOADED Many concerns that seem at first to be ABS related are actually problems with the bas
44. nce in the brake master cylinder reservoir If turbulence is seen in the brake master cylinder reservoir upon release of the brake pedal this is normal and shows that the compensating ports are not plugged Brake Combination Valve Aerostar If there is a brake system concern such as premature rear brake lockup that cannot be attributed to the rear anti lock brake system RABS the cause may be a malfunctioning brake combination valve Check the brake combination valve by substituting the suspected bad valve with a known good one If the condition persists recheck the RABS Refer to Section 06 09A file C TSO tsocache V DTOM_5368 S VK us en file S VK60014 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 4 of 4 file C TSO tsocache VDTOM_5368 S VK us en file S VK60014 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 1 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual CLEANING AND INSPECTION Brakes Disc Front 1 NOTE For service install a new disc brake caliper bracket bolt Ranger only or reuse the old bolt with thread locking compound such as Ford Threadlock and Sealer EQAZ 19554 AA or equivalent meeting Ford specification WSK M2G315 A5 Type Il Tighten to 100 130 Nm 74 96 lb ft Inspect the disc brake caliper 2B120 and mounting for loose or damaged parts 2 Check the front brake hose 2078 and front disc brake caliper fitting for leaks or damage 3 Check the disc brak
45. nderstanding of brake system functioning Verify the Complaint Once you are satisfied that you understand the customer s concerns take the vehicle on the road yourself Many brake concerns involve a wide variety of noises and pulsations that can only be experienced while operating the vehicle Make sure the vehicle s tires are inflated properly Make your brake application evaluation on level dry hard smooth pavement that is free from oil grease or loose dirt Back in the Shop The next step in servicing a brake complaint is a thorough inspection of the system Brake Master Cylinder Look for leaks Clean the unit and remove the brake master cylinder filler cap Check the fluid level Check the condition of the gasket Hydraulic Leaks On vehicles with power brakes with the engine 6007 running apply 667 N 150 Ibs force to the brake pedal and hold for ten seconds If brake pedal height cannot be maintained for 10 seconds or the brake warning light comes on service is required Occasional brake squeal can be caused by environmental conditions such as cold ambient temperatures heat rain snow salt mud hot ambient temperatures or high humidity This occasional squeal is not a functional problem and does not indicate any loss in brake effectiveness Visually examine front and rear tires and wheel assemblies for damage such as uneven wear tread washouts or sidewall damage Make sure the tires are of the same size type and wh
46. nts ADD fluid and BLEED system F4 FILLER CAP VENT CHECK e Check if brake master cylinder filler cap vent holes are clogged or dirty Are holes clogged or dirty Yes CLEAN as necessary REPEAT Test F1 GO to F5 F5 BLEED BRAKE SYSTEM e Bleed brake system Refer to Section 06 06 Has the condition been corrected Yes file C TSO tsocache VDTOM_5368 SVK us en file SVK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 8 of 18 Vehicle OK go to F6 F6 FRONT WHEEL BEARING ADJUSTMENT e Check front wheel bearings for proper adjustment Are bearings properly adjusted O e J SS CHECK rear brake adjustment and ADJUST if ADJUST front wheel bearings REPEAT Test necessary REPEAT Test F1 F1 PINPOINT TEST G BRAKE LOCKUP DURING LIGHT BRAKE PEDAL FORCE G1 TIRE CHECK e Check tires for uneven wear and correct pressure Is there a wear or pressure concern Oo w o SS ae tire concern REFER to Section 04 GO to G2 G2 BRAKE SHOE AND LINING CHECK e Inspect brake shoe and linings for contamination correct installation damage correct size and type Is there a brake shoe and lining concern a REPAIR or REPLACE brake shoe and lining GO to G3 REFER to Section 06 02 Section 06 03 EE G3 PARKING BRAKE CHECK e Inspect parking brake components for damage or seized condition Is there a parking brake concern file C TSO tsocache V DTOM_5368 S VK us en file S VK60013 HTM gen
47. on power brake booster Booster and brake pedal linkage binding caused by worn bushings or corrosion Worn or damaged power brake booster Brake lining worn glazed contaminated or improper type Rear brake shoe and lining improperly installed Page 2 of 9 hose for misposition near heat source REPOSITION as required BLEED system REFER to Section 06 06 SERVICE or REPLACE brake master cylinder filler cap as required PERFORM master cylinder diagnosis test REFER to Pinpoint Test R and Pinpoint Test T REPAIR as required REPAIR or REPLACE as required REFER to Section 06 02 REPAIR or REPLACE as required REFER to Section 06 07 REPAIR as required BLEED system REFER to Section 06 06 LIGHTEN load and ADVISE owner of correct load limits of vehicle REPLACE damaged or leaking vacuum booster hoses CLEAN or REPLACE filter REPLACE worn bushings or CLEAN and LUBRICANT linkage REPLACE power brake booster REFER to Section 06 07 REPLACE brake lining in axle sets REPOSITION brake shoes properly and ELIMINATE any binding REFER to Section 06 02 file C TSO tsocache V DTOM_5368 S VK us en file S VK60012 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger e Brakes Drag Slow or Incomplete Release e Empty Reservoir e Noise at Wheels When Brakes Are Applied Snap or Clicks Seized caliper pistons in rear wheel cylinders or disc brake calipers
48. ough the dissolving of color dye used on brake master cylinder internal springs in manufacturer s assembly procedure file C TSO tsocache VDTOM_5368 S VK us en file S VK60031 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 3 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual ADJUSTMENTS Brake Fluid Level Check A 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 FIFTEEN MINUTES GET MEDICAL ATTENTION IF IRRITATION PERSISTS IF TAKEN INTERNALLY DRINK WATER AND INDUCE VOMITING GET MEDICAL ATTENTION IMMEDIATELY Check the brake fluid level in the brake master cylinder reservoir 2K478 on the brake master cylinder 2140 The brake fluid level should be at or near the MAX mark If the brake fluid level is low inspect the brake system and add brake fluid as directed in the following procedure Brake System Service 1 A WARNING USE OF A BRAKE FLUID THAT DOES NOT MEET DOT 3 SPECIFICATION COULD DAMAGE THE HYDRAULIC BRAKE SYSTEM AND CAUSE BRAKE FAILURE Clean and remove the brake master cylinder filler cap from the brake master cylinder reservoir 2 Fill the brake master cylinder reservoir to the MAX line with High Performance DOT 3 Brake Fluid C6AZ 19542 AB or DOT 3 equivalent fluid meeting Ford specification ESA M6C25 A DOT 3 3 Install the brake master cy
49. r Page 3 of 7 If a concern exists the brake system symptom chart in this section should be used in order to isolate it to a specific subsystem and condition description From this description a list of possible causes can be used to further narrow the cause to a specific component or condition Pedal Reserve To check brake pedal reserve with the engine running apply 667 N 150 lbs force and observe the extent of brake pedal travel There should be at least 20 reserve travel distance available 150 POUNDS FORCE 20 MINIMUM RESERVE PEDAL TRAVEL AND FEEL Hydraulic Parts Check hydraulic hoses and tubes for leaks cracks chafing and distortions The fasteners that hold these components in place should also be checked Wheel Cylinder Drum Brakes NOTE Don t pry under or otherwise disturb the dust boot This may destroy a very important seal If there is leakage it will find its way around the dust boot With the brake drum 1126 removed check for loose or worn parts Check the rear wheel cylinder 2261 for leakage around the dust boot Disc Brake Caliper Check for proper installation leakage caliper slide lubrication and excessive wear along caliper supports Dual Circuit Warning Light Functions e Apply the parking brake e Check that the light comes on when you start the engine e Release the parking brake Check that the brake warning light goes off file C TSO tsocache VDTOM_5368 S VK us e
50. ref HTM 2011 04 28 1997 Aerostar Ranger Page 9 of 18 CORRECT parking brake concern REFER to Section 06 05 GO to G4 G4 WHEEL BEARING CHECK e Raise vehicle enough to relieve weight on tires e Pull alternately on front and rear of each tire to check for loose or damaged wheel bearings Is there a wheel bearing concern CORRECT the wheel bearing concern REFER to the appropriate section in Group 04 or GO to G5 Section 05 G5 POWER BRAKE BOOSTER PUSH ROD CHECK Support the brake master cylinder and remove the brake master cylinder mounting nuts Position the brake master cylinder out of the way With a shop fabricated gauge check the power brake booster push rod adjustment The exposed end of the power brake booster push rod should be within 24 89 25 27mm 0 980 0 995 in of the brake master cylinder mounting surface on the power brake booster Does the power brake booster push rod require adjustment G6 ABS CHECK e Perform the appropriate diagnostic tests in Section 06 09A or Section 06 09B to check for defective dump valve Is there an anti lock brake system concern REPAIR or REPLACE the worn or damaged anti lock brake system component REFER to Section 06 09A or Section 06 09B To CHECK for possible missed symptoms GO to G1 PINPOINT TEST H EXCESSIVE AND OR ERRATIC PEDAL TRAVEL file C TSO tsocache V DTOM_5368 S VK us en file S VK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page
51. rotor Refer to Specifications at the end of this section for minimum discard disc brake rotor thickness maximum brake surface lateral runout thickness variation and surface finish Service Limits As WARNING NEVER INSTALL A DISC BRAKE ROTOR THAT HAS BEEN TURNED TO MINIMUM WEAR OR DISCARD THICKNESS Measure the thickness of the disc brake rotor to determine if it is within Specifications listed at the end of this section Disc brake rotor minimum discard thickness is stamped on the disc brake rotor Disc brake rotors have a minimum thickness dimension minimum wear thickness or discard thickness This is not the refinishing dimension file C TSO tsocache V DTOM_5368 S VK us en file S VK60032 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 3 of 3 file C TSO tsocache VDTOM_5368 S VK us en file S VK60032 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 2 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual ADJUSTMENTS Brake Drum Maximum Diameter Brake drum maximum diameter is molded into the rim of the brake drum 1126 The brake drum may be machined enough to correct scoring but only up to the MAX DIA dimension If after machining the brake drum inside braking surface diameter exceeds the specification it must be discarded m Ai BRAKE DRUM TYPICAL 1126 file C TSO tsocache VDTOM_5368 SVK us en file SVK60033 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger
52. s e Push down on brake pedal and hold e Key ON engine running Does the brake pedal move downward when the engine is started Yes Vacuum system is OK GO to S3 S3 COMPONENT ISOLATION CHECK e Key OFF e Reconnect the vacuum gauge to the same point as in Step S1 but leave the rest of the system connected e Key ON engine running at idle until vacuum reaches 51 64 kPa 15 19 in Hg e Key OFF e Observe vacuum gauge for 1 minute Does vacuum pressure drop more than 3 4 kPa 1 in Hg DISCONNECT each component one at a time and REPEAT the test procedures in Step S3 until the leaking component is found PLUG the GO to 4 disconnected vacuum line while performing the test procedures REPAIR or REPLACE as required S4 BOOSTER LEAK CHECK Key ON Run engine until vacuum reaches 51 64 kPa 15 19 in Hg Key OFF Push down on the brake pedal and hold for a few seconds and release Does the vacuum drop to 0 kPa 0 in Hg file C TSO tsocache VDTOM_5368 SVK us en file SVK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 17 of 18 REPLACE or REBUILD power brake booster as System checks OK REMOVE vacuum gauge required and RECONNECT all vacuum lines PINPOINT TEST T BRAKE FLUID LOSS BRAKE MASTER CYLINDER INTERNAL TEST OK T1 FLUID LEVEL CHECK e Check fluid level in brake master cylinder reservoir Is fluid level in brake master cylinder reservoir full Low or empty brake master cyl
53. s established and consistently used the road surface variable can be eliminated from the test results A key factor in evaluating brake concerns is the deceleration rate During braking all of us are sensitive to whether or not the vehicle is slowing at the rate we have come to expect This varies from vehicle to vehicle and with changes in operating conditions It is evident how well the brakes on a particular vehicle are working after just a few applications Stopping Distance Method For this test you need to mark out or find a driving lane that is 3 7m 12 ft wide You also need to place two markers along this lane 7 5m 25 ft apart At a speed of 32 km h 20 mph drive down the center of the lane and apply the service brakes when you reach the first marker Observe whether the vehicle comes to a smooth stop before the second marker Also note whether it pulled to the right or left and whether it went beyond the 3 7m 12 ft width For trucks under 4500 kg 10 000 Ibs a commonly accepted standard is a smooth stop within 7 5m 25 ft while staying within the lane Before a road test get a complete description of the customer concerns or suspected condition From the description experience will allow possible causes to be matched with symptoms Certain components will be tagged as possible suspects while others will be eliminated by the evidence More importantly the customer s description can reveal unsafe conditions which should be
54. smoking of the tires and sometimes even skid marks This is a concern the customer may report Have the customer take you for a drive to demonstrate Observe how the driver activates the brakes Before beginning the test adjust the outside rearview mirrors so you can observe the rear wheels Have the owner apply the brakes normally during a hard stop Ford recommends speeds of no more than 24 km h 15 mph for this test If you feel the ABS activate rolling skid isn t the problem If the ABS doesn t activate have the driver increase the pressure until they squeal and smoke Hold in this position Observe rearview mirrors for evidence of smoke It is also helpful to have an assistant standing nearby who can watch the wheels from a better angle during the test Check to see if the wheels continue to rotate for the duration of the stop Finally see if increasing the pressure even more will cause the ABS to activate If it does the vehicle is experiencing the slow drop off from peak traction discussed above This last step applying extra pressure is very important to the diagnosis Many drivers back off on the brakes when they hear the squeal because they think and understandably so that a wheel or wheels are locking up Correcting this problem may mean explaining that the system is functioning fine and the wheels are not locking up RABS and 4 Wheel Drive When diagnosing RABS concerns on a 4 wheel drive vehicle remember that the front
55. ster cylinder piston is adjusted at the booster push rod rather than the brake pedal linkage Refer to Section 06 07 for instructions on dash mounted booster push rod adjustment file C TSO tsocache VDTOM_5368 S VK us en file S VK60028 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 1 Section 06 00 Brake System Service 1997 Aerostar Ranger Workshop Manual ADJUSTMENTS Brakes Rear Drum A WARNING BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS AVOID CONTACT WITH 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 Rear brake shoes and linings 2200 are adjusted automatically by sharply applying brake while alternately driving the vehicle forward and reverse Brake adjustment occurs during reverse stops only Manual brake adjustment is required when the brake shoes are replaced or if the brake shoe adjusting lever cables 2A178 have malfunctioned Refer to Section 06 02 Keep the brake master cylinder reservoir 2K478 filled with High Performance DOT 3 Brake Fluid C6AZ 19542 AB or DOT 3 equivalent fluid meeting Ford specification ESA M6C25 A DOT 3 Never use brake fluid that has been drained from the system file C TSO tsocache VDTOM_5368 SVK us en file SVK60030 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger
56. ver a period of 30 seconds to the brakes and hold for approximately 15 seconds e While holding brakes exert 101 N 75 lbs force to front wheels Does either wheel rotate l Front chamber of brake master cylinder checks SERVICE brake master cylinder as required OK GO to R4 R4 WHEEL TURNING TORQUE CHECK REAR WHEELS Place transmission in NEUTRAL e Raise rear wheels off of ground Apply 445 N 100 Ibs evenly over a period of 30 seconds to the brakes and hold for approximately 15 seconds e While holding brakes exert 101 N 75 lbs force to rear wheels Does either wheel rotate SERVICE brake master cylinder as required aa See anne ie er aan ene PINPOINT TEST S EXCESSIVE PEDAL EFFORT VACUUM BOOST SYSTEM S1 VACUUM CHECK e Disconnect vacuum booster hose from booster e Connect Rotunda Vacuum Pressure Tester 059 00008 or equivalent to the vacuum hose with a T fitting e Key on engine running Allow engine to reach normal operating temperature e Record the vacuum reading Is the vacuum reading at least 51 64 kPa 15 19 in Hg file C TSO tsocache VDTOM_5368 S VK us en file S VK60013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 16 of 18 Yes GO to S2 LOCATE and REPAIR source of low vacuum S2 SYSTEM INSPECTION e Key OFF e Reconnect the vacuum line e Inspect power brake booster check valve rubber grommet and all vacuum plumbing for cracks holes bad connections or missing clamp
57. xle Usage 2540 2750 2650 Front 2580 2650 2800 Axle Usage 2750 2950 2750 3200 2950 Rear DSSA DSSA DSSA i 228 6 x 44 45mm 254 x 63 5mm 9x 10 x 1 75 In 4 2 5 In a Ranger SuperCab with Limited Slip axles have 254 x 63 5mm 10 x 2 5 inch rear brake regardless of file C TSO tsocache VWDTOM_5368 S VK us en file S VK60034 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 3 of 4 GVWR b 228 6 x 44 45mm 9 x 1 75 In standard with 2 3L engine Bore Diameters Rear Wheel Cylinders Ranger Reg and SuperCab Ranger Reg SuperCab over All Truck Series Under 4580 GVWR 4580 GVWR Aerostar Rear Wheel Cylinder 19 0mm 19 0mm 22 23mm Bore Inches 0 75 0 75 875 In Rear Drum Brake Lining Dimensions Ranger Reg and SuperCab Under Ranger Reg SuperCab over All Truck Series 4580 GVWR 4580 GVWR Aerostar Lining Thickness 4 82mm 4 80mm 4 80mm Primary 19 In 189 In 189 In Lining Thickness 7 1mm 6 2mm 6 2mm Secondary 28 In 245 In 245 In Lining Length Primary 154 9mm 214 9mm 214 9mm 6 10 In 8 46 In 8 46 In Lining Length 223 5mm 243 8mm 243 6mm Secondary 8 80 In 9 6 In 9 59 In General Specifications Power Brake Booster Push Rod Length mm in 24 89 25 27 0 980 0 995 Lubrication High Performance DOT 3 Brake Fluid C6AZ 1954 AB ESA M6C25 A DOT 3 Disc Brake Caliper Slide Grease D7AZ 19590 A ESA M1C172 A Ford Thread Lock amp Sealant EOAZ 19554 AA WSK M2G315 A
58. ylinder or booster dash unit mounting loose Disc brake caliper attachment loose Worn or damaged brake shoe adjusting lever cables Glazed worn scored or damaged brake linings Drums out of round or rotors with excessive runout Front brake hose improperly positioned system REFER to Section 06 09B Symptom Chart REFER to Section 06 09A Symptom Chart ADJUST rear brakes REFER to Section 06 02 ADJUST front wheel bearings REFER to Section 04 01A for all 4x2 vehicles Section 05 03A for Ranger and Section 04 01C for Aerostar 4x4 TIGHTEN nuts and bolts to specification REPLACE or TIGHTEN as required REMOVE drum and CHECK lining for proper adjustment REPLACE brake shoe adjusting lever cables REFER to Section 06 02 REPLACE rear brake shoes and linings REFER to Section 06 02 REFINISH or REPLACE if wear exceeds limits REFER to Section 06 03 Section 06 02 CHECK front brake 1997 Aerostar Ranger e Excessive Pedal Travel or Brake Pedal Goes to Floor Consistently e Excessive Pedal Effort to Fully Apply Brakes Air in system Reservoir cap vent hole clogged Hydraulic system Brake drums worn bad wear pattern or cracked Loose or improper attachment of brake pedal pedal support booster and brake master cylinder External leak Air in system Overloaded vehicle Insufficient vacuum to power brake booster Restricted air filter

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