Ford Fiesta: Brake System - General Information / Brake System Inspection. General Procedures

Materials

Inspection

Brake Pads

1. Inspect the brake pads for contamination. If the friction material shows evidence of contamination, install new brake pads.
   Refer to: Brake Pads (206-03 Front Disc Brake, Removal and Installation).
   Refer to: Brake Pads (206-04 Rear Disc Brake, Removal and Installation).
   

1. Inspect and measure the thickness of the brake pad friction material. Minor surface cracks do not require pad replacement, however, if there are missing chunks or cracks in the lining through to the backing plate, install new brake pads. If the thickness of the friction material is less than the specified thickness, install new brake pads. If the friction material shows taper wear that is not within specifications, install new brake pads and verify the caliper guide pins are functioning correctly.
   Refer to: Specifications (206-00 Brake System - General Information, Specifications).
   Refer to: Brake Pads (206-03 Front Disc Brake, Removal and Installation).
   Refer to: Brake Pads (206-04 Rear Disc Brake, Removal and Installation).
   

Brake Disc

1. Inspect the brake discs and measure the brake disc thickness and record the measurement. If the brake disc is cracked or otherwise damaged, install a new brake disc. If the measurement is below the minimum thickness specification, install a new brake disc.
   Refer to: Specifications (206-00 Brake System - General Information, Specifications).
   Refer to: Brake Pads (206-03 Front Disc Brake, Removal and Installation).
   Refer to: Brake Pads (206-04 Rear Disc Brake, Removal and Installation).
   

1. If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that caused by pads worn down to the backing plate, should also be machined. In order to machine, discs must be above the minimum thickness specification.
   Refer to: Brake Disc Machining (206-00 Brake System - General Information, General Procedures).
   

Brake Caliper

1. Inspect the brake calipers for leaks, damage to seals and piston corrosion or binding. If the brake caliper is leaking or otherwise damaged, install a new brake caliper.
   Refer to: Brake Caliper (206-03 Front Disc Brake, Removal and Installation).
   Refer to: Brake Caliper (206-04 Rear Disc Brake, Removal and Installation).
   

1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper wear or the guide pins are difficult to move, disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for wear, damage and corrosion. If bore is worn or damaged, replace the damaged component. Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material from the caliper guide pin bores. Clean any remaining foreign material from the bores with brake parts cleaner and compressed air. Assemble the caliper seals, boots and guide pins. Use an ample amount of the specified grease to lubricate the bores and guide pins. Inspect the brake pads.
   Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESA-M1C200-A) (ESE-M1C171-A)

Brake Shoes

1. Inspect the brake shoes for contamination. If the friction material shows evidence of contamination, install new brake shoes.
   Refer to: Brake Shoes (206-02 Drum Brake, Removal and Installation).
   

1. Inspect and measure the thickness of the brake shoe friction material. Minor surface cracks do not require shoe replacement, however, if there are missing chunks or cracks in the lining through to the backing plate, install new brake shoes. If the thickness of the friction material is less than the specified thickness, install new brake shoes.
   Refer to: Specifications (206-00 Brake System - General Information, Specifications).
   Refer to: Brake Pads (206-03 Front Disc Brake, Removal and Installation).
   Refer to: Brake Pads (206-04 Rear Disc Brake, Removal and Installation).
   

1. Verify the mounting hardware is installed and operating correctly. Install new hardware as necessary.
   Refer to: Brake Shoes (206-02 Drum Brake, Removal and Installation).
   

1. Verify correct brake shoe adjustment.
   Refer to: Brake Shoe Adjustment (206-02 Drum Brake, General Procedures).
   

Brake Drum

NOTE: It is generally not required to install new brake drums to address noise issues. Heavily scored brake drums, similar to that caused by shoes worn down to the backing plate, should be machined. In order to machine, drums must be below the maximum diameter specification.

1. Inspect the brake drums and measure the brake drum diameter. Record the measurements.
   Refer to: Specifications (206-00 Brake System - General Information, Specifications).
   

1. If the brake drum is cracked, damaged or if the diameter measurement is more than the maximum specification, install a new brake drum.
   Refer to: Brake Drum (206-02 Drum Brake, Removal and Installation).
   

Wheel Cylinder

1. Inspect the wheel cylinders for leaks, damage to seals, and piston corrosion or binding. If the wheel cylinder is leaking or otherwise damaged, install a new wheel cylinder.
   Refer to: Wheel Cylinder (206-02 Drum Brake, Removal and Installation).
   

Brake Flexible Hose

1. Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any other signs of damage. Install a new brake flexible hose if the hose shows signs of softening, cracking or other damage.
   

Brake Tubes

1. Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage. If a section of the brake tube is damaged, replace the entire section with a new tube of the same type, size, shape and length. When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to specifications.
   

Brake Master Cylinder

1. Inspect the brake master cylinder for fluid leaks and install a new master cylinder or brake fluid reservoir if signs of excessive leaking are present.
   Refer to: Brake Master Cylinder (206-06 Hydraulic Brake Actuation, Removal and Installation).
   Refer to: Brake Fluid Reservoir (206-06 Hydraulic Brake Actuation, Removal and Installation).
   

1. If there are no leaks present, check the master cylinder for correct operation .
   Refer to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).
   

Brake Booster

1. Inspect the brake booster for excessive corrosion or damageand inspect the vacuum hoses for leaks and kinks. Install a new brake booster if signs of excessive corrosion or damage is found. Repair or replace vacuum hoses as necessary.
   Refer to: Brake Booster (206-07 Power Brake Actuation, Removal and Installation).