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

Materials

Name	Specification
Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound XG-3-A	ESA-M1C200-A ESE-M1C171-A

1
Inspect the brake pads for contamination. If the friction material shows signs 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).
2
Inspect and measure the brake pad friction material thickness. Minor surface cracks do not require pad replacement; however, if friction material is missing or cracked down to the backing plate, install new brake pads. If the friction material thickness is less than specified, install new brake pads. If the friction material shows taper wear beyond specification, install new brake pads and check that the caliper guide pins operate 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).

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, 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).
2
If diagnosis reveals vibration in the steering wheel, seat or brake pedal during braking that is speed dependent, refinish the brake disc. Brake discs with heavy scoring, similar to that caused by brake pad wear down to the backing plate, must also be refinished. To refinish, the discs must be thicker than minimum thickness. Specification.
Refer to: Brake Disc Refinishing (206-00 Brake System - General Information, General Procedures).

1
Inspect the brake calipers for leaks, corrosion damage or seized seals and piston. 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).
2
The guide pins must slide with a reasonable amount of hand force. If the brake pads have 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 the bore is worn or damaged, replace the damaged component. Use a wire brush, rolled 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 the specified lubricant in sufficient quantity to lubricate the bores and guide pins. Inspect the brake pads.
Material: Motorcraft® Silicone Brake Caliper Lubricant and Dielectric Compound / XG-3-A (ESA-M1C200-A) (ESE-M1C171-A)

1
Inspect the brake shoes for contamination. If the friction material shows signs of contamination, install new brake shoes.
Refer to: Brake Shoes (206-02 Drum Brake, Removal and Installation).
2
Inspect and measure the brake shoe friction material thickness. Minor surface cracks do not require shoe replacement; however, if the lining has missing pieces or cracks down to the backing plate, install new brake shoes. If the friction material thickness is less than specified, 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).
3
Make sure the mounting hardware is installed and operating correctly. If necessary, install new hardware.
Refer to: Brake Shoes (206-02 Drum Brake, Removal and Installation).
4
Check that the brake shoe adjustment is correct.
Refer to: Brake Shoe Adjustment (206-02 Drum Brake, General Procedures).

1
Inspect the brake drums and measure the brake drum diameter. Record the measurements.
Refer to: Specifications (206-00 Brake System - General Information, Specifications).
2
If the brake drum is cracked, damaged or if the diameter measurement exceeds the maximum specification, install a new brake drum.
Refer to: Brake Drum (206-02 Drum Brake, Removal and Installation).

Inspect the wheel cylinders for leaks, seal damage and piston corrosion or seizure. 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).

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

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

1
Inspect the brake master cylinder for fluid leaks. Install a new master cylinder or brake fluid reservoir if there are signs of excessive leakage.
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).
2
If there are no leaks, check the brake master cylinder for correct operation.
Refer to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).

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