For Bleeding procedures, please refer to Bleeding the Brake System in this section.
Whenever service is performed on the ABS valve block or pump and motor assembly, the following procedure must be performed to make sure no air is trapped in the ABS control and modulator assembly. If this procedure is not done, the vehicle operator could experience a spongy pedal after the ABS is actuated. This procedure requires the use of the Ford New Generation STAR (NGS) Tester, or equivalent.
- First bleed the entire brake system conventionally as described above.
- Reattach the NGS Tester to the data link connector as though retrieving codes.
- Make sure the ignition is in the RUN position.
- Follow the instructions on the NGS screen. Choose the correct vehicle and model year, go to DIAGNOSTIC DATA LINK menu item, choose ABS MODULE, choose FUNCTION TESTS and choose SERVICE BLEED.
- The NGS will prompt you to depress the brake pedal. Make sure you press hard on the brake pedal, and hold it down for approximately 5 seconds while the NGS opens the outlet valves in the brake pressure control valve block. When the outlet valves are opened, you should immediately feel the pedal drop. It is very important that you continue pushing the pedal all the way to the floor. The NGS will then instruct you to release the brake pedal. After you release the brake pedal, the NGS will run the ABS hydraulic pump motor for approximately 15 seconds.
- Repeat the previous step to ensure that all air is bleed from the ABS unit. Upon completion, the NGS will display SERVICE BLEED PROCEDURE COMPLETED.
- Repeat the conventional bleeding procedure.
- Once complete, road test the vehicle and check for proper brake system operation.
Hydraulic Control Unit (HCU)
- Clean all dirt from and remove the brake master cylinder filler cap (2162), and fill the brake master cylinder reservoir with the specified brake fluid.
- Connect a clear waste line to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid.
Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw.
- Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
- Tighten the RH rear bleeder screw to 7 ft. lbs. (10 Nm), and disconnect the waste line.
- Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw, in that order.
- Connect a suitable scan tool DCL cable adapter into the vehicle-s Data Link Connector (DLC) under he dash, and follow the scan tool instructions.
- Repeat the system bleed procedure as outlined in Steps 1 through 5.