Hydraulic System: Description and Operation

Hydraulic Brake Actuation
This vehicle is equipped with a brake pedal actuated dual brake system. The system consists of the following:
^ brake pedal, fixed or adjustable
^ power brake booster
^ brake master cylinder
^ disc brake calipers
^ rear disc brake calipers
^ 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 one circuit and the rear wheel brakes, the other circuit.

Brake Fluid
WARNING: Use of any other than 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, Rush 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.

Use clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid, 6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25A.
^ 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 use contaminated brake fluid.








Brake Master Cylinder
The brake master cylinder is a dual-piston type.
The brake master cylinder is assisted by a power brake booster.
The following conditions are considered normal and not indications that the brake master cylinder is in need of repair or replacement:
^ 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 disc brake calipers/rear disc brake calipers to compensate for normal brake wear. Fill the brake master cylinder reservoir with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.
^ A momentary or slight squirt of brake fluid inside the brake master cylinder reservoir upon application of the brake pedal.
^ A trace of brake fluid found on the outside of the power brake booster below the brake master cylinder mounting flange. This condition results from the lubricating action of the brake master cylinder wiping seal.








Warning Switch, Brake Fluid Level
The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir.
When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid will cause this system to activate.

Brake Tubes and Hoses

CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which can result in brake tube failure.

If a section of brake tube is damaged, a new section of the same type, size, shape and length must be installed.
When installing hydraulic brake tubing, hoses, or connectors, tighten all connections to specifications. After installation, bleed the brake system.