Ford Galaxy / Ford S-MAX. Manual — part 61

brake pedal feel as evidence of a brake concern.

Check for brake warning indicator illumination and the brake fluid level in the brake fluid
reservoir.

Normal Conditions

The following conditions are considered normal and are not indications that the brake
master cylinder is in need of repair.

1. 1. New brake systems are not designed to produce as hard a pedal effort as in the

past. Complaints of light pedal efforts should be compared to pedal efforts of
another vehicle, same model and year.

2. 2. During normal operation of the brake master cylinder, the brake fluid level in the

reservoir will rise during brake application and fall during release. The net brake
fluid level (after brake application and release) will remain unchanged.

3. 3. A trace of brake fluid exists on the brake booster shell below the master cylinder

mounting flange. This results from the normal lubricating action of the master
cylinder bore end seal.

4. 4. Brake fluid level will fall with brake pad wear.

Abnormal Conditions

Changes in brake pedal feel or travel are indicators that something could be wrong in the
brake system. The diagnostic procedure and techniques are brake pedal feel, brake warning
indicator illumination and low brake fluid level as indicators in diagnosing brake system
concerns. The following condition are considered abnormal and indicate that the brake
master cylinder is in need of repair.

1. 1. Brake pedal goes down fast. This could be caused by an external or internal leak.

2. 2. Brake pedal eases down slowly. This could be caused by an external or internal

leak.

3. 3. Brake pedal is low or feels spongy. This condition may be caused by no fluid in the

brake master cylinder reservoir, brake fluid reservoir cap vent holes blocked or air
in the hydraulic system.

4. 4. Brake pedal effort is excessive. This may be caused by a bind or obstruction in

pedal or linkage, blocked fluid control valve or insufficient brake booster vacuum.

5. 5. Rear brakes lock up during light pedal force. This may be caused by grease or fluid

on brake pads, damaged brake pads and linings, incorrectly adjusted parking
brakes, damaged or contaminated brake pressure control valve.

6. 6. Brake pedal effort is erratic. This condition could be caused by the brake booster

being in operative, extreme brake caliper piston knock back or incorrectly installed
brake pads.

7. 7. Brake warning indicators is always ON. This may be caused by low fluid level,

ignition wire routing too close to the fluid level indicator, or float assembly damage.

Bypass Condition Test

1. 1. Check the brake fluid level in the brake fluid reservoir. Fill the brake fluid reservoir

to the MAX mark if low or empty.

2. 2. Observe the brake fluid level in the brake fluid reservoir. If after several brake

applications, the brake fluid level remains the same, measure the wheel turning
torque required to rotate the wheels with rearward with brakes applied as follows:

Place the transmission in NEUTRAL and raise and support the vehicle. REFER to Section

100-02 Jacking and Lifting

.

With the aid of another technician, operate the brakes with a minimum of 445N (100 lb)
and hold for approximately 15 seconds. With the brakes still applied, exert torque on the
front wheels to 10.1 Nm (75 lbf.ft). If either wheel rotates, install a new brake master
cylinder.

Non-Pressure Leaks

Any empty brake fluid reservoir condition may be the result of two types of non-pressure
external leaks.

Type 1: An external leak may occur at the brake fluid reservoir cap because of incorrect
positioning of the gasket and cap.

Reposition the gasket and cap.

Type 2: An external leak may occur at the brake fluid reservoir mounting seals. Repair such
a leak by installing new seals.

Brake System - General Information -
Brake System Bleeding

S-MAX/Galaxy 2006.5 (02/2006-)

Print

General Procedures

General Equipment

Bleeding

WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with

the eyes. Wash hands thoroughly after handling. If brake fluid contacts the eyes, flush
the eyes for 15 minutes with cold running water. Get medical attention if irritation
persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately. Failure to follow these instructions may result in personal injury.

CAUTION: If brake fluid is spilt on the paintwork, the affected area must be

immediately washed down with cold water.
NOTE: Make sure that the vehicle is standing on a level surface.
NOTE: The system consists of separate circuits for each front and diagonally opposite rear
wheel. Each circuit can be bled independently.

Worldwide Diagnostic System (WDS)

1.

CAUTION: The brake fluid reservoir must

remain full with new, clean brake fluid at all
times during bleeding.

Install the bleed tube to the bleed nipple.

2. Immerse the end of the bleed tube in a bleed jar

containing a small quantity of approved brake
fluid.

3. Position the bleed jar base at least 300 mm

above the bleed nipple to maintain fluid pressure
and prevent air leaking past the threads of the
bleed nipple.

4. Loosen the bleed nipple by one-half turn.

5. Operate the brake pedal fully (pumping brake

fluid and air into the bleed jar) and allow the
brake pedal to return to the rest position.

6. Fill the brake fluid reservoir to the MAX mark.

7. Continue operating the brake pedal until air-free

fluid is being pumped into the bleed jar.

8. With the brake pedal fully depressed tighten the

bleed nipple.

9.

CAUTION: Make sure that the bleed

nipple cap is installed after bleeding the
brake line(s). This will prevent corrosion to
the bleed nipple. Failure to follow this
instruction may result in the bleed nipple
becoming seized.

Repeat the procedure for the remaining brake
lines.

Brake System - General Information -
Brake System Pressure Bleeding

S-MAX/Galaxy 2006.5 (02/2006-)

Print

General Procedures

General Equipment

Bleeding

WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with

the eyes. Wash hands thoroughly after handling. If brake fluid contacts the eyes, flush
the eyes for 15 minutes with cold running water. Get medical attention if irritation
persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately. Failure to follow these instructions may result in personal injury.

CAUTION: If brake fluid is spilt on the paintwork, the affected area must be

immediately washed down with cold water.
NOTE: Make sure that the vehicle is standing on a level surface.
NOTE: The system consists of separate circuits for each front and diagonally opposite rear
wheel. Each circuit can be bled independently.

Worldwide Diagnostic System (WDS)
Brake/clutch system pressure bleeder/filler

1. Fill the brake fluid reservoir to the MAX mark.

2.

CAUTIONS:

Make sure that the pressure within the

brake system does not exceed 1 bar.

Make sure that the pressure bleeding

equipment is filled with new brake fluid to
the correct specification.

Using the

brake/clutch system pressure

bleeder/filler

, pressure bleed the system in

accordance with the manufacturer's instructions.

3.

CAUTION: Make sure that the bleed

nipple cap is installed after bleeding the
brake line(s). This will prevent corrosion to
the bleed nipple. Failure to follow this
instruction may result in the bleed nipple
becoming seized.

Fill the brake fluid reservoir to the MAX mark as
necessary.