Ford Galaxy / Ford S-MAX. Manual — part 59

seat to allow the air to escape.
Push on the tripode housing to stop, then
pull it back 25 mm (x = 95 mm).
Remove the screwdriver.

6. Special Tool(s):

204-169

Torque:

21 Nm

7. Refer to:

Front Halfshaft LH

(205-04 Front Drive

Halfshafts, Removal and Installation).
Refer to:

Front Halfshaft RH

(205-04 Front Drive

Halfshafts, Removal and Installation).

Front Drive Halfshafts - Outer Constant
Velocity (CV) Joint Boot

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

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Removal and Installation

Special Tool(s)

Removal

Installation

204-169
Clamping Tool, Boot Retaining Clamp

1. Remove the inner CV joint boot.

Refer to:

Inner Constant Velocity (CV) Joint Boot

(205-04 Front Drive Halfshafts, Removal and
Installation).

2.

1.

Fill the CV joint with grease.
Insert a small screwdriver under the boot
seat to allow the air to escape.

2. Special Tool(s):

204-169

Torque:

21 Nm

3. Install the inner CV joint boot.

Refer to:

Inner Constant Velocity (CV) Joint Boot

(205-04 Front Drive Halfshafts, Removal and
Installation).

Brake System - General Information -
Brake System

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

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Description and Operation

The braking system is of a diagonally split, dual circuit design featuring front and rear disc
brakes.

The hydraulic system has separate circuits for each pair of diagonally opposed wheels (left
front, right rear and right front, left rear). The front brake caliper is of a single sliding
piston design which makes sure that equal effort is applied through both brake pads.

The parking brake control operates the rear brakes through a cable system. There is also
an electronic parking brake (EPB) system available.

The brake master cylinder is of a tandem design and is linked to a brake booster which
reduces the brake pedal effort. The tandem design will make sure that in the event of one
brake circuit failing the other will remain fully operational.

The brake booster vacuum on vehicles with diesel engine is provide by a camshaft driven
vacuum pump.

The anti-lock brake system (ABS) is controlled by the hydraulic control unit (HCU),
incorporated within the hydraulic system, and only operates when the wheel speed sensors
detect the onset of wheel lock up.

Brake System - General Information -
Brake System

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

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Diagnosis and Testing

Principles of Operation

The brake system operates by transferring effort applied to the brake pedal by the driver to
the brakes at each wheel.

The braking effort is distributed to each wheel, using an hydraulic system. The system is
assisted using a vacuum brake booster that reduces pedal effort and increases hydraulic
pressure. The parking brake operates on the rear wheels and is applied using a hand
operated control.

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious signs of mechanical damage.

Visual Inspection Chart

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause

(if possible) before proceeding to the next step.

4. 4. If the concern is not visually evident, verify the symptom and refer to the

Symptom Chart.

Road Test

Carry out a road test to compare actual vehicle braking performance with the performance
standards expected by the driver. The ability of the test driver to make valid comparison
and detect performance deficiencies will depend on experience.

The driver should have a thorough knowledge of brake system operation and accepted
general performance guidelines to make good comparisons and detect performance
concerns.

An experienced brake technician will always establish a route that will be used for all brake
diagnosis road tests. The roads 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 is established and consistently
used, the road surface variable can be eliminated from the test results.

Before a road test, obtain a complete description of the customer concerns or suspected
condition. From the description, the technician's experience will allow the technician to
match possible causes with symptoms. Certain components will be tagged as possible
suspects while other will be eliminated by the evidence. More importantly, the customer
description can reveal unsafe conditions which should be checked or corrected before the
road test. The description will also help form the basic approach to the road test by
narrowing the concern to specific components, vehicle speed or conditions.

Mechanical

Tire pressure
Wheels and tires
Fluid leak from brake line(s)
Fluid level
Fluid contamination