Ford Falcon. Manual — part 70

206-05-9

Parking Brake and Actuation

206-05-9

REMOVAL AND INSTALLATION (Continued)

Ute - Petrol

Ute - LPG

NOTE: Note on LPG Ute there are two sets of cotton

reels to support cable over the lenght of the LPG tank.

Installation
1. Route cables per diagrams above.
2. Ensure cable ferrules and white clips are seated

into equaliser.

3. Fit adjuster nut and adjust system as per sedan.

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206-06-1 Hydraulic

Brake

Actuation 206-06-1

SECTION : 206-06 Hydraulic Brake Actuation

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206-06-2

DESCRIPTION AND OPERATION

Hydraulic Brake Actuation . . . . . . . . . . . . . . . . . . . . . . . . . ..206-06-3

Hydraulic Brake System . . . . . . . . . . . . . . . . . . . . . . . . . ...206-06-3

Dual Hydraulic Brake System . . . . . . . . . . . . . . . . . . . . . . . ..206-06-3

Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . .206-06-3

Dual Master Cylinder Brake System (where fitted) . . . . . . . . . . . . . . . ..206-06-3

Power Brake Booster . . . . . . . . . . . . . . . . . . . . . . . . . . ...206-06-4

Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . ...206-06-5

DIAGNOSIS AND TESTING

Hydraulic Brake Actuation . . . . . . . . . . . . . . . . . . . . . . . . . ..206-06-6

Inspection and Verification . . . . . . . . . . . . . . . . . . . . . . . . ...206-06-6

Function

Test

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...206-06-7

Symptom

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206-06-7

Connector Circuit Reference . . . . . . . . . . . . . . . . . . . . . . . . 206-06-8

Pinpoint

Tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206-06-10

GENERAL PROCEDURES

Adjustable Brake Indexing . . . . . . . . . . . . . . . . . . . . . . . . ...206-06-16

System Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..206-06-16

Power Brake Booster Testing . . . . . . . . . . . . . . . . . . . . . . . ..206-06-16

Hydraulic Line Repair . . . . . . . . . . . . . . . . . . . . . . . . . . ...206-06-16

Brake Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 206-06-16

Brake Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 206-06-16

REMOVAL AND INSTALLATION

Brake Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 206-06-17

Brake Pedal Adjustment Motor . . . . . . . . . . . . . . . . . . . . . . . 206-06-20

Brake Pedal Motor Cables . . . . . . . . . . . . . . . . . . . . . . . . ...206-06-20

Brake Pedal Control Switch (where fitted) . . . . . . . . . . . . . . . . . . ...206-06-21

Brake and Cruise Pedal Switch Setting . . . . . . . . . . . . . . . . . . . ...206-06-21

Brake Pedal Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..206-06-22

Accelerator Pedal Pad . . . . . . . . . . . . . . . . . . . . . . . . . . .206-06-22

Power Brake Booster . . . . . . . . . . . . . . . . . . . . . . . . . . ...206-06-22

Dual Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . ...206-06-23

DISASSEMBLY AND ASSEMBLY

Electronic Throttle Control Module . . . . . . . . . . . . . . . . . . . . . ...206-06-24

Dual Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . ...206-06-24

206-06-2 Hydraulic

Brake

Actuation 206-06-2

SPECIFICATIONS

General Specifications

Description

Specification

Brake Fluid (Ford)

Mobil ESZ - M6C55A

Torque Specifications

Description

Nm

Adjuster Motor Retaining Bolts

5

± 0.5

(adjustable pedal)
Pedal Box Housing

22.5

± 3.4

Brake Booster Retaining Nuts

22.5

± 3.4

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206-06-3 Hydraulic

Brake

Actuation 206-06-3

DESCRIPTION AND OPERATION

Dual Master Cylinder Brake System

Hydraulic Brake Actuation

(where fitted)

Hydraulic Brake System

WARNING: Brake fluid contains polyglycol

ethers and polyglycols. Avoid contact with eyes.

Wash hands thoroughly after handling. If brake

fluid contacts eyes, flush 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.

Dual Hydraulic Brake System

The hydraulic brake system is a pedal operated,

front/rear split, dual line brake system that consists of

the following;

Power brake booster

The system consists of a dual master cylinder which

incorporates a proportioning valve, on some models

Brake master cylinder

only a pressure differential valve assembly, a ‘fast fill’

Brake pressure control valves (where fitted)

valve assembly and a switch. The switch on the

Front disc brake caliper assemblies

differential valve or fluid level switch activates a brake

Front disc brake rotors

fail warning light, located on the instrument panel.

Rear disc brake calipers

The primary system operates the front brakes and

secondary the rears.

Brake pipes and hoses
Anti-lock Brake System (ABS) components

Fast Fill Valve

The ‘fast fill’ (fast pressure build up) valve provides

Brake Master Cylinder

reduced pedal travel by rapidly overcoming the large

The brake master cylinder is a dual piston type. The

low pressure displacements associated with roll-back

master cylinder operates as follows;

disc brakes that allow for the elimination of pad to

When the brake pedal is applied, pressure is

rotor drag.

transferred by mechanical linkage to the primary

As well as a conventional secondary piston, the

and secondary systems.

cylinder incorporates a stepped primary piston located

Brake master cylinder pistons apply hydraulic

nearest the booster.

pressure to the two circuits.

The fluid moved by the larger diameter stepped piston

The master cylinder consists of;

is pushed over the primary seal of the smaller

diameter primary piston so bringing the brakes into

Primary and secondary pistons.

operation earlier.

Brake master cylinder reservoir with integral fluid

The ‘fast fill’ valve incorporates a pressure seal in one

level warning indicator (on all ABS cars and

direction, a one-way ball valve in the other and a

pressure differentiated switch on non ABS utes).

by-pass bleed groove. In operation, the ball valve

Fixed proportioning valve on non ABS cars.

retains fluid in the master cylinder until a pre-set line

pressure is reached, after which all further increases

in pressure are exhausted back into the reservoir,

reverting the operation of the master cylinder to that of

a normal unit. Recuperation is achieved by fluid

by-passing the pressure seal. The by-pass bleed

groove allows fluid to by-pass the ball valve ensuring

that a fluid passage is maintained between the brake

pressure circuit and reservoir in the brakes-off

position.

Pressure Differential and Proportioning Valve

Proportioning Valve (where fitted on non ABS ¾

tonne Utes)
The proportioning valve regulates the rear brake

system hydraulic pressure and is located between the

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