Hydraulic System: Testing and Inspection

Inspect the brake lines and hoses for cracks, swelling or other damage and replace if necessary.

Only steel tubing manufactured specifically for brake systems should be used throughout the brake system with the exception of the flexible hoses at the front and rear wheels. Check fluid level. If the fluid level is below the line in the brake master cylinder reservoir, add the required amount of fluid. Use High Performance DOT-3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT-3 equivalent meeting Ford specification ESA-M6C25-A. If DOT 3 is not available use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4.

Brake Master Cylinder
Inspect brake master cylinder mounting. The brake master cylinder mounting nuts and brake tube nuts must be tight. The brake tube nuts must not show signs of leakage. Tighten brake tube nuts to 16 - 20 Nm (112 - 14 ft. lbs.). Tighten brake master cylinder nuts to 23 Nm (17 ft. lbs.).

The following conditions are considered normal and are not indications that the brake master cylinder is in need of service.
^ Low fluid level detected without signs of leakage. This condition is caused by displacement of fluid from the brake master cylinder reservoir into the disc brake calipers to compensate for normal brake wear. Add fluid as needed. If very low, check for worn brake pads or shoes.
^ A momentary or slight squirt of brake fluid from the brake master cylinder reservoir upon application of the brake pedal. This condition is caused by 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 master cylinder reservoir fluid when the brake pedal is released. Turbulence occurs as brake fluid returns to the brake master cylinder after releasing the brakes.
^ 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 master cylinder wiping seal.


Brake Tubing
Inspect the brake tubes under the vehicle for damage and proper routing. Check the hoses connecting the brake tubes to the disc brake calipers, to the rear wheel cylinders and /or to the rear disc brake calipers for any signs of damage, cracking or softening. The hose fittings must be tight without signs of leakage.

Always bleed the applicable primary or secondary brake system after primary or secondary brake system hose or line replacement. Bleed the longest line first.

When connecting a tube to a hose, tube connector or brake cylinder, tighten the tube fitting nut to specification.