CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Bleed hydraulic system whenever air has been introduced into system. Bleed master cylinder and brakes at all 4 wheels if master cylinder lines have been disconnected or master cylinder has run dry. Bleed brakes with pressure bleeding equipment or by manually pumping brake pedal while using bleeder tubes. Always bleed brakelines in sequence. See BLEEDING SEQUENCE . Before bleeding system, remove all vacuum from power unit by depressing brake pedal several times. Bleed master cylinder first, followed in sequence by rear wheel cylinders, anti-lock system components (if equipped) and calipers.
See BLEEDING SEQUENCE . COMPONENT BLEEDING NOTE: Master Cylinder Bleeding (Bench) 1. Support brake master cylinder body in a vise, and fill both fluid brake master cylinder reservoirs with brake fluid. 2. Install short brake tubes with the ends bent into the brake master cylinder reservoir. See Fig. 6 . 3. Slowly depress the primary piston until clear brake fluid flows from both brake tubes with no air bubbles. 4. Install the brake master cylinder into the vehicle. Remove the short brake tubes and install the master cylinder outlet tubes. 5. Refill the brake master cylinder reservoir as necessary. 6. Have an assistant depress and hold the brake pedal. Loosen a brake outlet tube at the master cylinder one at a time. Tighten the outlet tubes.
7. Repeat procedure until no air bubbles are seen in the expelled brake fluid. 8. Bleed the brake system. See SYSTEM BLEEDING . DO NOT allow reservoir to run dry during bleeding operation. Master Cylinder Bleeding (On-Vehicle) 1. Using a line wrench, disconnect the brake lines from the brake master cylinder. Install short brake tubes in master cylinder and position them so they curve into master cylinder reservoir, and ends of tubes are submerged in brake fluid. See Fig. 6 . 2. Fill master cylinder reservoir with clean brake fluid. Have an assistant pump brakes until clear, bubble- free fluid flows from both brake tubes. 3. Remove the short brake tubes and install the master cylinder outlet tubes. Refill the brake master cylinder reservoir as necessary. 4. Have an assistant depress and hold the brake pedal. Loosen a brake outlet tube at the master cylinder one at a time. 5. Tighten the outlet tubes. Repeat procedure until no air bubbles are seen in the expelled brake fluid. 6. Bleed the brake system. See SYSTEM BLEEDING . Four Wheel Anti-Lock Brake System Hydraulic Control Unit NOTE: This procedure only needs to be performed if the 4-Wheel Anti-Lock Brake System (4WABS) Hydraulic Control Unit (HCU) has been installed new. 1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 2. Connect a clear drain tube to the right rear bleeder screw and the other end in a container partially filled with recommended brake fluid. See Fig. 7 . 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the right rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary. 5. Tighten the bleeder screw. 6. Repeat procedure for the left rear bleeder screw, the right front bleeder screw and the left front bleeder screw, in that order. See BLEEDING SEQUENCE . 7. Connect the scan tool DLC cable adapter into the vehicle data link connector (DLC) under the dash, and follow the scan tool instructions for bleeding. Go to HELP menu on the scan tool. The Ford Service Function Card (FSF) must be used to get the help menu. 8. Repeat the conventional bleed procedure in steps. Gravity Bleeding Fill brake master cylinder with new brake fluid. Loosen both wheel cylinder bleeder screws and leave them open until clear brake fluid flows. Check master cylinder reservoir fluid level often and do not let it run dry. Tighten wheel cylinder bleeder screws. One at a time, loosen caliper bleeder screws. Leave bleeder screws open until clear fluid flows. Check fluid level often. Tighten caliper bleeder screws.Related Entry : how to clean 2002 ford windstar egr ports, 1998 ford windstar Brake Lines diagram, 2002 ford escort zx2 rear brake line, rattle in rear of ford windstar,