Lincoln Corsair Manuals

Lincoln Corsair: Brake System - General Information / Diagnosis and Testing - Brake System

Global Customer Symptom Code (GCSC) Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


Symptom Action
Stop/Steer/Ride > Stopping > Performance/Effectiveness > Sticks/Binds GO to Pinpoint Test G
Stop/Steer/Ride > Stopping > Lock-Up/Grab > Always GO to Pinpoint Test D
Stop/Steer/Ride > Stopping > Lock-Up/Grab > Cold GO to Pinpoint Test D
Stop/Steer/Ride > Stopping > Lock-Up/Grab > Hot GO to Pinpoint Test D
Stop/Steer/Ride > Stopping > Lock-Up/Grab > Intermittent GO to Pinpoint Test D
Stop/Steer/Ride > Stopping > Pedal Feel > Excessive Effort GO to Pinpoint Test H
Stop/Steer/Ride > Stopping > Pedal Feel > Long Travel GO to Pinpoint Test C
Stop/Steer/Ride > Stopping > Pedal Feel > Spongy/Mushy GO to Pinpoint Test C
Stop/Steer/Ride > Stopping > Pedal Feel > Spongy/Mushy GO to Pinpoint Test E
Stop/Steer/Ride > Stopping > Pedal Feel > Sticks/Binds GO to Pinpoint Test E
Stop/Steer/Ride > Stopping > Pulls > Always GO to Pinpoint Test B
Stop/Steer/Ride > Steering/Steering Wheel > Feel/Wander/Pull > Intermittent GO to Pinpoint Test B
Stop/Steer/Ride > Pedals/Lever > Brake > Loose/Attachment GO to Pinpoint Test F
Stop/Steer/Ride > Pedals/Lever > Brake > Power Function GO to Pinpoint Test F
Stop/Steer/Ride > Pedals/Lever > Brake > Sticks/Binds GO to Pinpoint Test F
Stop/Steer/Ride > Pedals/Lever > Brake > Sticks/Binds GO to Pinpoint Test H
Stop/Steer/Ride > Noise > Stopping > Cold GO to Pinpoint Test J
Stop/Steer/Ride > Noise > Stopping > Cold GO to Pinpoint Test K
Stop/Steer/Ride > Noise > Stopping > Cold GO to Pinpoint Test L
Stop/Steer/Ride > Noise > Stopping > Hot GO to Pinpoint Test J
Stop/Steer/Ride > Noise > Stopping > Hot GO to Pinpoint Test K
Stop/Steer/Ride > Noise > Stopping > Hot GO to Pinpoint Test L
Stop/Steer/Ride > Noise > Stopping > Intermittent GO to Pinpoint Test J
Stop/Steer/Ride > Noise > Stopping > Intermittent GO to Pinpoint Test K
Stop/Steer/Ride > Noise > Stopping > Intermittent GO to Pinpoint Test L
Stop/Steer/Ride > Noise > Stopping > Low Speed GO to Pinpoint Test J
Stop/Steer/Ride > Noise > Stopping > Low Speed GO to Pinpoint Test K
Stop/Steer/Ride > Noise > Stopping > Low Speed GO to Pinpoint Test L
Stop/Steer/Ride > Noise > Front > Intermittent GO to Pinpoint Test I

Symptom Chart(s)

Symptom Chart: Brake System

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

Condition Actions
The red brake warning indicator and the yellow ABS warning indicator are illuminated CHECK for ABS diagnostic trouble codes (DTCs).
REFER to: Anti-Lock Brake System (ABS) and Stability Control (206-09 Anti-Lock Brake System (ABS) and Stability Control, Diagnosis and Testing).
The red brake warning indicator is always/never on  
REFER to: Instrumentation, Message Center and Warning Chimes - Vehicles With: Head Up Display (HUD) (413-01 Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).
Vehicle pulls or drifts during braking   GO to Pinpoint Test B
Brake pedal goes down fast or eases down slowly   GO to Pinpoint Test C
Brakes lock up under light brake pedal force   GO to Pinpoint Test D
Excessive brake pedal travel (low/spongy pedal)   GO to Pinpoint Test E
Erratic brake pedal travel   GO to Pinpoint Test F
Brake drag   GO to Pinpoint Test G
Excessive brake pedal effort   GO to Pinpoint Test H

Symptom Chart: NVH

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

Condition Actions
Vibration when the brakes are applied   GO to Pinpoint Test A
Rattling noise   GO to Pinpoint Test I
Squealing noise - occurs on first (morning) brake application   GO to Pinpoint Test J
Squealing noise - a continuous squeal   GO to Pinpoint Test J
Squealing noise - an intermittent squeal   GO to Pinpoint Test J
Groaning noise - occurs at low speeds with brake lightly applied (creeping)   GO to Pinpoint Test K
Grinding/moaning noise - continuous   GO to Pinpoint Test L

Pinpoint Tests

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


PINPOINT TEST A: VIBRATION WHEN BRAKES ARE APPLIED

Normal Operation and Fault Conditions

During moderate to heavy braking, noise from the HCU and pulsation in the brake pedal can be observed. Pedal pulsation coupled with noise during heavy braking or on loose gravel, bumps, wet or snowy surfaces is acceptable and indicates correct functioning of the ABS . Pedal pulsation or steering wheel nibble when the brakes are applied (frequency is proportioned to the vehicle speed) indicates a concern with a brake or suspension component.

Possible Sources

  • Brake disc(s)
  • Suspension components
  • Brake pads
A1 ROAD TEST THE VEHICLE - LIGHT BRAKING
  • Road test the vehicle. Warm the brakes by slowing the vehicle from 80 to 32 km/h (50 to 20 mph) using light brake force. At highway speeds of 89-97 km/h (55-60 mph), apply the brake using light pedal force.

Is there a vibration/shudder felt in the steering wheel, seat or brake pedal?
Yes GO to A4
No GO to A2

A2 ROAD TEST THE VEHICLE - MODERATE TO HEAVY BRAKING
  • Road test the vehicle. At highway speeds of 89-97 km/h (55-60 mph), apply the brake using a moderate to heavy pedal force.

Is there a vibration/shudder?
Yes GO to A3
No The concern is not present at this time.

A3 CHECK ABS (ANTI-LOCK BRAKE SYSTEM) OPERATION

NOTE: During moderate to heavy braking, noise from the Hydraulic Control Unit (HCU) and pulsation in the brake pedal can be observed. Pedal pulsation coupled with noise during heavy braking or on loose gravel, bumps, wet or snowy surfaces is acceptable and indicates correct operation of the ABS . Pedal pulsation or steering wheel nibble with the frequency proportional to vehicle speed indicates a concern with a brake or suspension component.

  • Road test the vehicle and apply the brakes on a dry, firm surface, then apply the brakes on a wet, snowy or loose surface (such as gravel).

Is the vibration/shudder only present on a wet, snowy or loose surface?
Yes This is a normal operating condition of the ABS .
No GO to A5

A4 ISOLATE BRAKE VIBRATION

NOTE: This test step is not applicable to vehicles with drum-in-hat type or electronic parking brakes. For vehicles with drum-in-hat or electronic parking brakes, proceed to the next test step. For all other vehicles, apply the parking brake to identify if the problem is in the front or rear brake.

  • Apply the parking brake to identify if the problem is in the front or rear brake. At highway speeds of 89-97 km/h (55-60 mph), lightly apply the parking brake until the vehicle slows down. Release the parking brake immediately after the test.

Is there a vibration/shudder?
Yes GO to A7
No GO to A5

A5 CHECK THE FRONT SUSPENSION
  • Check the front suspension.

Are all the suspension components in satisfactory condition?
Yes GO to A6
No REPAIR or INSTALL new components as necessary. TEST the system for normal operation.

A6 CHECK THE FRONT BRAKE DISCS
  • Inspect the front brake discs.
    REFER to: Specifications (206-00 Brake System - General Information, Specifications).
    MACHINE or INSTALL new brake discs as necessary. REFER to: Brake Disc Machining (206-00 Brake System - General Information, General Procedures).
    REFER to: Brake Disc (206-03 Front Disc Brake, Removal and Installation).
  • Road test the vehicle.

Is the vibration/shudder present?
Yes GO to A7
No The concern has been repaired.

A7 CHECK THE REAR SUSPENSION
  • Check the rear suspension.

Are all the suspension components in satisfactory condition?
Yes INSPECT the rear brake discs or brake drums.
REFER to: Specifications (206-00 Brake System - General Information, Specifications).
MACHINE or INSTALL new brake discs or drums as necessary.REFER to: Brake Disc (206-04 Rear Disc Brake, Removal and Installation).
REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).
No REPAIR or INSTALL new components as necessary. TEST the system for normal operation.

PINPOINT TEST B: VEHICLE PULLS OR DRIFTS DURING BRAKING

Normal Operation and Fault Conditions

During braking, the vehicle should stop quickly from an initial pedal press and in a straight line. Sometimes, the vehicle pulls to one side or the other while braking. This indicates there is a concern with a brake or suspension component.

Possible Sources

  • Brake calipers and/or guide pins
  • Brake flexible hose
  • Brake pads
  • Brake discs
  • Tires
  • Suspension component(s) and/or wheel alignment
B1 INSPECT THE BRAKE SYSTEM COMPONENTS
  • Verify that there are no loose or damaged components.

Are there any loose or damaged components?
Yes INSPECT the brake system components and TIGHTEN to specification. INSTALL new components as necessary.
No GO to B2

B2 INSPECT WHEELS AND TIRES
  • Verify that there are no damaged components, uneven tire wear.

Are the wheels and tires in satisfactory condition. Is there any uneven tire wear?
Yes
REFER to: Wheels and Tires (204-04A Wheels and Tires, Diagnosis and Testing).
No GO to B3

B3 CHECK THE FRONT AND REAR SUSPENSION
  • Check the suspension components.
  • Check suspension alignment.

Are all the suspension components in satisfactory condition and within alignment specifications?
Yes GO to Pinpoint Test
No Perform suspension alignment.
REFER to: Suspension System (204-00 Suspension System - General Information, Diagnosis and Testing). REPAIR or INSTALL new components as necessary. TEST the system for normal operation.

PINPOINT TEST C: BRAKE PEDAL GOES DOWN FAST OR EASES DOWN SLOWLY

Normal Operation and Fault Conditions

The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. When the brake pedal is pressed, brake fluid is pushed through the double-walled steel tubes and flexible hoses to the front and rear disc brake calipers. The brake fluid enters the disc brake calipers, forcing the caliper pistons and brake pads outward against the brake disc friction surface, slowing or stopping rotation. When the brake pedal is released, brake fluid pressure is relieved, returning the front and rear disc brake caliper pistons and brake pads to the unapplied position. If the brake pedal goes down fast or eases down slowly, it indicates there is a concern with the brake system.

Possible Sources

  • Brake fluid leaks and/or air in the system
  • ABS / HCU
C1 INSPECT THE BRAKE SYSTEM COMPONENTS
  • Verify that there are no loose or damaged components.

Are there any loose or damaged components?
Yes INSPECT the brake system components and TIGHTEN to specification. INSTALL new components as necessary.
No GO to C2

C2 INSPECT THE SYSTEM FOR LEAKS AND AIR IN THE SYSTEM
  • Inspect the system for leaks. Bleed the brake system.

Is there any leaks in system?
Yes
REFER to: Brake System Pressure Bleeding (206-00 Brake System - General Information, General Procedures).
No The repair is complete. The system is operating correctly at this time.

PINPOINT TEST D: BRAKES LOCK UP UNDER LIGHT BRAKE PEDAL FORCE

Normal Operation and Fault Conditions

The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. When the brake pedal is pressed, brake fluid is pushed through the double-walled steel tubes and flexible hoses to the front and rear disc brake calipers. The brake fluid enters the disc brake calipers, forcing the caliper pistons and brake pads outward against the brake disc friction surface, slowing or stopping rotation. When the brake pedal is released, brake fluid pressure is relieved, returning the front and rear disc brake caliper pistons and brake pads to the unapplied position. The brakes can lock up during application due to overheating or faulty components. This condition indicates there is a concern with the brake system.

Possible Sources

  • Brake pads
  • Brake flexible hose
  • Brake discs
  • Brake calipers and/or guide pins
  • ABS / HCU
D1 INSPECT THE BRAKE SYSTEM COMPONENTS
  • Inspect the brake system components.

Are there any damaged components?
Yes INSTALL new components as necessary.
No GO to D2

D2 INSPECT ABS (ANTI-LOCK BRAKE SYSTEM) AND HCU (HYDRAULIC CONTROL UNIT)
  • Ignition ON.
  • Using a diagnostic scan tool, perform the ABS self-test.

Is any DTC present?
Yes
REFER to: Anti-Lock Brake System (ABS) and Stability Control (206-09 Anti-Lock Brake System (ABS) and Stability Control, Diagnosis and Testing).
No The repair is complete. The system is operating correctly at this time.

PINPOINT TEST E: EXCESSIVE BRAKE PEDAL TRAVEL (LOW/SPONGY PEDAL)

Normal Operation and Fault Conditions

.The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. When the brake pedal is pressed, brake fluid is pushed through the double-walled steel tubes and flexible hoses to the front and rear disc brake calipers. The brake fluid enters the disc brake calipers, forcing the caliper pistons and brake pads outward against the brake disc friction surface, slowing or stopping rotation. When the brake pedal is released, brake fluid pressure is relieved, returning the front and rear disc brake caliper pistons and brake pads to the unapplied position. Leaks and/or air in the system can cause a spongy brake pedal and loss of braking in the vehicle. This condition indicates there is a concern with the brake system.

Possible Sources

  • Brake fluid leaks and/or air in the system
  • ABS / HCU
  • Brake calipers and/or guide pins
  • Brake flexible hose
E1 INSPECT THE SYSTEM FOR LEAKS AND AIR IN THE SYSTEM
  • Inspect the system for leaks.

Is there any leaks in system?
Yes BLEED the brake system.
REFER to: Brake System Pressure Bleeding (206-00 Brake System - General Information, General Procedures).
No GO to E2

E2 CHECK THE BRAKE DISCS AND BRAKE PADS
  • Inspect the front and rear brake discs and brake pads.

    • REFER to: Specifications (206-00 Brake System - General Information, Specifications).
    • Install new front brake pads as necessary,
      REFER to: Brake Pads (206-03 Front Disc Brake, Removal and Installation).
    • Install new rear brake pads as necessary,
      REFER to: Brake Pads (206-04 Rear Disc Brake, Removal and Installation).

Are the brake discs and brake pads in satisfactory condition ?
Yes GO to E3
No REPLACE the components as necessary. Road test the vehicle to check if the concern has been repaired.

E3 INSPECT BRAKE CALIPERS AND/OR GUIDE PINS
  • Inspect the brake calipers and guide pins.

Are the brake calipers and guide pins in satisfactory condition?
Yes Road test the vehicle to check if the concern has been repaired. INSTALL new components as necessary.
No GO to E4

E4 INSPECT BRAKE FLEXIBLE HOSE
  • Inspect the brake flexible hoses during brake application.

Are the brake flexible hose in satisfactory condition?
Yes INSTALL a new brake hose as necessary.
REFER to: Front Brake Flexible Hose (206-03 Front Disc Brake, Removal and Installation).
REFER to: Rear Brake Flexible Hose (206-04 Rear Disc Brake, Removal and Installation). Road test the vehicle to check if the concern has been repaired.
No The repair is complete. The system is operating correctly at this time.

PINPOINT TEST F: ERRATIC BRAKE PEDAL TRAVEL

Normal Operation and Fault Conditions

The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. When the brake pedal is pressed, brake fluid is pushed through the double-walled steel tubes and flexible hoses to the front and rear disc brake calipers. The brake fluid enters the disc brake calipers, forcing the caliper pistons and brake pads outward against the brake disc friction surface, slowing or stopping rotation. When the brake pedal is released, brake fluid pressure is relieved, returning the front and rear disc brake caliper pistons and brake pads to the unapplied position. If the brake pedal goes down fast or eases down slowly, it indicates there is a concern with the brake system.

Possible Sources

  • Brake pedal
  • ABS / HCU
F1 INSPECT THE BRAKE PEDAL
  • Inspect the brake pedal for binding, obstructions and correct interface to booster rod.

Are the brake pedal components attached correctly? Are there any loose or damaged components?
Yes REPAIR as necessary. CHECK the brake pedal fasteners for correct torque.
REFER to: Brake System Pressure Bleeding (206-00 Brake System - General Information, General Procedures).
No The system is operating correctly at this time.

PINPOINT TEST G: BRAKE DRAG

Normal Operation and Fault Conditions

The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. When the brake pedal is pressed, brake fluid is pushed through the double-walled steel tubes and flexible hoses to the front and rear disc brake calipers. The brake fluid enters the disc brake calipers, forcing the caliper pistons and brake pads outward against the brake disc friction surface, slowing or stopping rotation. When the brake pedal is released, brake fluid pressure is relieved, returning the front and rear disc brake caliper pistons and brake pads to the unapplied position. The vehicle will experience dragging if the brake fluid pressure is not relieved or the brake pads do not return to the unapplied condition. This condition indicates there is a concern with the brake system.

Possible Sources

  • Parking brake component
  • Brake caliper and/or guide pins
  • Brake flexible hose
  • ABS / HCU
G1 INSPECT THE PARKING BRAKE SYSTEM
  • Inspect the parking brake system.

Is any concern present?
Yes
REFER to: Parking Brake (206-05 Parking Brake and Actuation, Diagnosis and Testing).
No GO to G2

G2 INSPECT BRAKE CALIPERS AND/OR GUIDE PINS
  • Inspect the brake calipers and guide pins.

Are the brake calipers and guide pins in satisfactory condition?
Yes Road test the vehicle to check if the concern has been repaired.
No The repair is complete. The system is operating correctly at this time.

PINPOINT TEST H: EXCESSIVE BRAKE PEDAL EFFORT

Normal Operation and Fault Conditions

The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. When the brake pedal is pressed, brake fluid is pushed through the double-walled steel tubes and flexible hoses to the front and rear disc brake calipers. The brake fluid enters the disc brake calipers, forcing the caliper pistons and brake pads outward against the brake disc friction surface, slowing or stopping rotation. When the brake pedal is released, brake fluid pressure is relieved, returning the front and rear disc brake caliper pistons and brake pads to the unapplied position. The brake booster provides assistance to the pedal effort applied by the driver. If excessive pedal effort is required while applying the brakes, it indicates there is a concern within the brake system.

Possible Sources

  • Brake pads
  • ABS / HCU
H1 INSPECT ABS (ANTI-LOCK BRAKE SYSTEM) AND HCU (HYDRAULIC CONTROL UNIT)
  • Ignition ON.
  • Using a diagnostic scan tool, perform the ABS self-test.

Is any DTC present?
Yes
REFER to: Anti-Lock Brake System (ABS) and Stability Control (206-09 Anti-Lock Brake System (ABS) and Stability Control, Diagnosis and Testing).
No GO to H2

H2 CHECK BRAKE PADS
  • Inspect the brake pads.

Is any concern present?
Yes INSTALL new components as necessary. REFER to: Brake Pads (206-03 Front Disc Brake, Removal and Installation).
REFER to: Brake Pads (206-04 Rear Disc Brake, Removal and Installation).
No The repair is complete. The system is operating correctly at this time.

PINPOINT TEST I: RATTLING NOISE

Normal Operation and Fault Conditions

Some squealing noise from the brake system is acceptable under certain conditions such as cold start or low speed brake application. Under all other general driving conditions, the vehicle must come to a stop on brake application and the brake system operation must not create noise. A rattling noise from the brakes indicate a concern with the brake system.

Possible Sources

  • Caliper guide pins or guide pin bolts
  • Missing or damaged anti-rattle clips or springs
  • Loose brake disc shield
I1 CHECK CALIPER GUIDE PINS OR PINS BOLTS
  • Inspect the caliper guide pins and guide pin bolts.

Is any concern present?
Yes INSPECT the caliper guide pins and guide pin bolts. INSTALL new components as necessary.
No GO to I2

I2 CHECK FOR ANTI-RATTLE CLIPS OR SPRINGS
  • Inspect anti-rattle clips or springs for missing or damage.

Is any concern present?
Yes INSPECT the brake pads for missing clips or broken springs. INSTALL new components as necessary.
No GO to I3

I3 CHECK BRAKE DISC SHIELD
  • Inspect brake disc shield and bolts.

Is any concern present?
Yes TIGHTEN the brake disc shield bolts to specification. REFER to: Brake Disc Shield (206-03 Front Disc Brake, Removal and Installation).
REFER to: Brake Disc Shield (206-04 Rear Disc Brake, Removal and Installation).
No The repair is complete. The system is operating correctly at this time.

PINPOINT TEST J: SQUEALING NOISE

Normal Operation and Fault Conditions

During driving, there should not be any squealing noise except while cold start, low speed and intermittent. A continuous squealing noise from the brakes indicates a concern with the brake system.

Possible Sources

  • Brake pads
J1 CHECK SQUEALING NOISE
  • Perform a road test and confirm the concern.
  • Is the squealing noise:
    • upon cold start
    • at low speeds
    • intermittent

Is the squealing noise after cold start, at low speeds or intermittent?
Yes This condition is acceptable. Caused by humidity, cold, low brake pad temperature, snow, mud and etc.
No GO to J2

J2 CHECK SQUEALING NOISE - CONTINUOUS
  • Perform a road test and confirm the concern.

Is the squealing noise continuous?
Yes Replace the 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).
No The system is operating correctly at this time.

PINPOINT TEST K: GROANING NOISE - OCCURS AT LOW SPEEDS WITH BRAKE LIGHTLY APPLIED (CREEPING)

Normal Operation and Fault Conditions

Some squealing noise from the brake system is acceptable under certain conditions such as cold start or low speed brake application. Under all other general driving conditions, the vehicle must come to a stop on brake application and the brake system operation must not create noise. A groaning noise from the brake system at low vehicle speeds or light application of the brake pedal indicates a concern with the brake system.

Possible Sources

  • Brake pads
K1 CHECK GROANING NOISE
  • Ignition ON.
  • Perform a road test, apply brake lightly at low speeds and check groaning noise.

Is any groaning noise occurs at low speeds with brake lightly applied?
Yes Acceptable condition. Groaning noise will not occurs continuously.
No The repair is complete. The system is operating correctly at this time.

PINPOINT TEST L: GRINDING/MOANING NOISE - CONTINUOUS

Normal Operation and Fault Conditions

Some squealing noise from the brake system is acceptable under certain conditions such as cold start or low speed brake application. Under all other general driving conditions, the vehicle must come to a stop on brake application and the brake system operation must not create noise. A continuous grinding or moaning noise from the brake system on application of the brakes indicates a concern with the brake system.

Possible Sources

  • Brake pads
  • Brake disc
L1 CHECK GROANING NOISE
  • Ignition ON.
  • Perform a road test, apply brake and check groaning noise.

Is any groaning noise occurs continuously?
Yes INSPECT the brake pads, brake discs and attaching hardware for damage. VERIFY brake components are within specifications. INSTALL new components as necessary. REFER to: Front Disc Brake (206-03 Front Disc Brake, Diagnosis and Testing).
REFER to: Rear Disc Brake (206-04 Rear Disc Brake, Diagnosis and Testing).
No The repair is complete. The system is operating correctly at this time.


    Specifications

    ..

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