Initial Inspection and Diagnostic Overview

WARNING LAMP
Prior to performing any diagnosis, make sure the Brake System Warning Indicator is functional.

BRAKE FLUID LEVEL
Always check the fluid level in the brake Master Cylinder before performing the test procedures.

Fill brake Master Cylinder with specified brake fluid to between MAX line and 4.0 mm (0.16 inch) below line on reservoir. Use High Performance DOT-3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT-3 equivalent meeting Ford specification ESA-M6C25-A.

CAUTION: Use of any other than the approved DOT-3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative.

NOTE: If a brake is locked and the vehicle must be moved, open a bleeder screw to let out enough fluid to relieve the pressure. This bleeding operation may release the brakes but will not correct the cause of trouble.

TIRES
- Wheels and tires must be cleared of any foreign matter.
- Adjust Tire pressure to the correct specification.
- If tires exhibit uneven wear or feathering, the cause must be corrected before optimal braking performance can be achieved..
- Check steering and suspension components for damage or wear and if necessary, check and adjust front alignment.

NOTE: Check vehicle Certification label for proper tire pressure.

WHEEL BEARINGS
Wheel bearing endplay is critical and must be within specification (zero end play).

PULSATION
Brake pulsation/brake roughness that is present during brake application is caused by either foreign material build-up or contamination on the rotor brake surface or uneven brake rotor thickness, excessive runout or out of round drums.

TSB's - Once the symptom has been identified and verified, check for applicable Technical Service Bulletins (TSB's).