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anual Bleeding The primary and secondary (front and rear) hydraulic brake systems are individual systems and are bled separately. Bleed the longest line first on the individual system being serviced. During the complete bleeding operation, DO NOT allow the brake master cylinder reservoir (2K478) to run dry. Keep the master cylinder reservoirs filled with High Performance DOT-3 Brake Fluid C6AZ-19542-AA or DOT-3 equivalent meeting Ford specification ESA-M6C25-A. Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. NOTE: Non-ABS vehicles have the brake master cylinder (2140) mounted at an angle to the horizontal, bleeding may be better performed if the vehicle is positioned so that the brake master cylinder is horizontal.
To bleed the brake system, position a suitable box wrench on the bleeder fitting on the brake wheel cylinder. Attach a rubber drain tube to the bleeder fitting. The end of the tube should fit snugly around the bleeder fitting.
Submerge the free end of the tube in a container partially filled with clean brake fluid, and loosen the bleeder fitting approximately three-quarters of a turn.
Have an assistant push the brake pedal (2455) down slowly through its full travel. Close the bleeder fitting, then return the brake pedal to full-release position. Repeat this operation until air bubbles cease to appear at the submerged end of the bleeder tube.
When the fluid is completely free of air bubbles, secure the bleeder fitting and remove the bleeder tube.
Repeat this procedure at the brake wheel cylinder on the opposite side. Refill the brake master cylinder reservoir after each wheel cylinder is bled, and install the master cylinder cap and gasket. Ensure the diaphragm-type gasket is properly positioned in the master cylinder cap. When the bleeding operation is completed, the fluid level should be at the MAX line to 4.0 mm (0.16 inch) below.
If the primary (front brake) system is to be bled, repeat Steps 2 through 5 at the right front brake caliper and ending at the left front brake caliper. Bleed the brake master cylinder at the bleed screw after all calipers are bled.
After disc brake service, ensure that the disc brake pistons are returned to their normal positions and the shoe and lining assemblies are properly seated. This is accomplished by depressing the brake pedal several times until normal pedal travel is established.
Check pedal feel. If brake pedal feels "spongy" repeat bleed procedure, or use the Vacuum method as outlined in Section 06-09, but bleed both rear calipers first.
You can also pressure bleed it. If the abs module needs to be bleed, that requires a special tool. If you have already tried the procedure posted and it didn't work, I'm not sure what next?
The brake fluid reservoir is on the drivers side of the engine mounted on top of the master cylinder that is near the firewall. It will have a cap that says brake fluid. On the side of the reservoir it will have a full and low mark. Use only dot 3 or dot 4 BRAKE FLUID if adding.
1. Verify fluid level in brake master cylinder. Top off with DOT 3 brake fluid as necessary. Leave cap off.
2. Raise vehicle on hoist.
3. Remove bleed port protective cap and install suitable size and length of clear hose (4) to monitor and divert fluid into suitable container.
4. Open up the bleed circuit by turning the thumb screw (3) counter clockwise this will start the air purge and fluid fill process.
5. Lower vehicle, but only enough to gain access to and fill the brake master cylinder. NOTE: Do not allow clutch master cylinder to run dry while fluid exits bleed port.
6. Top off brake master cylinder fluid level while air is purged and fluid drains from bleed port. Continue this until no air bubbles are seen and a solid column of fluid exists.
7. Close hydraulic bleed circuit, remove drain hose and replace dust cap on bleed port.
8. From driver's seat, actuate clutch pedal 60-100 times.
9. Apply parking brake. Start engine and verify clutch operation and pedal feel. If pedal feels fine and clutch operates as designed, stop here. If pedal still feels spongy or clutch does not fully disengage, excessive air is still trapped within the system, most likely at the master cylinder.
10. Top off brake master cylinder fluid level with DOT 3 brake fluid as necessary.
POWER BLEEDING CLUTCH HYDRAULIC CIRCUIT
1. Remove reservoir cap and connect bleeder cap to reservoir. NOTE: Use Bleeder Cap/Modified reservoir cap adapter Snap-on #901-059 or equivalent.
2. Connect service filling machine to bleeder cap. NOTE: Use Service Filling Machine/Brake power bleeder Brake power bleeder or equivalent.
3. Service filling machine should be pressurized to at least 2.5 bar (36 PSI).
4. Remove dust cap from bleeder valve and connect the transparent bleeder hose to bleeder valve.
5. Place the other end of hose in the bleeder container to capture the used fluid. The end of the hose MUST be submerged in the DOT 3 brake fluid.
NOTE: Use Bleeder Container To capture hydraulic fluid and Transparent Bleeder Hose To route fluid to container.
6. Turn on the service filling machine.
7. Crack open the bleeder valve (3).
8. Allow fluid to flow out of bleed port until no more air bubbles can be seen in the transparent bleeder hose.
9. Once fluid is free of air bubbles; make 15 quick actuations between clutch pedal stop positions.
10. Close the bleeder valve and disconnect the service filling machine.
11. To remove remaining air, actuate pedal 10 times slowly between pedal stop positions.
12. Check clutch pedal to see if vehicle is properly bled.
13. If vehicle is not properly bled, repeat procedure.
14. Remove bleeder cap from reservoir and replace reservoir cap.
15. Disconnect transparent bleeder hose from bleeder valve and replace dust cap.
Remove the cap from the master cylinder reservoir. Add DOT3 or DOT4
brake fluid from a sealed container to the reservoir until the level
reaches the full mark on the side of the reservoir. Reinstall the cap
Remove the cap from the master cylinder reservoir. Add DOT3 or DOT4 brake fluid from a sealed container to the reservoir until the level reaches the full mark on the side of the reservoir. Reinstall the cap
fill master cylinder, start at right rear. the way I do it is make sure cap is back on master cylinder. pump the brakes a few times then hold them. have another person open the bleeder valve at the tires until brakes go to floor. hold them down until bleeder is retightened but be sure master cylinder is not out of fluid. then go to left rear and do the same procedure, then right front, then left front. check fluid and if air is all out there should be brakes. good-day ! THIS IS HOW I HAVE ALWAYS DONE IT ! heres a little trick of sorts. you can change a master cylinder, and if you bench bleed it first. and no fluid is lost from the master cylinder lines you do not need to bleed the whole system. but make sure cylinder is full of fluid before putting on vehicle and all air is out of master cylinder.
Unplug the brake lines from master cylinder. Be careful with brake fluid spilling out, it is toxic and corrosive.If needed use a plastic container to collect fluid.
Disconnect electrical connectors.
Unscrew the nuts securing the master cylinder to the brake booster.
Remove master cylinder.
Perform procedure in reverse order to install the new master cylinder. After installation is complete, refill the master cylinder with brake fluid and perform brake bleeding procedure.Use only brake fluid stated in manufacturer specifications.
Here a diagram. The master cylinder is part 10 below reservoir part 9:
Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills.
With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve.
Fill the brake master cylinder reservoir with DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm.
Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
Install a transparent hose over the end of the bleeder valve.
Submerge the open end of the transparent hose into a transparent container partially filled DOT-3 brake fluid from a clean, sealed brake fluid container.
Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal.
Loosen the bleeder valve to purge air from the wheel hydraulic circuit.
Tighten the bleeder valve, then have the assistant slowly release the brake pedal.
Wait 15 seconds, then repeat these steps until all air is purged from the same wheel hydraulic circuit.
Repeat this procedure with the LEFT FRONT, then LEFT REAR and finally the RIGHT FRONT.
Fill the brake master cylinder reservoir to the maximum-fill level with DOT-3 brake fluid from a clean, sealed brake fluid container.
Slowly depress and release the brake pedal. Observe the feel of the brake pedal.