All about Ford Mondeo

General information
Braking system / General information


The braking system is of diagonally-split, dual-circuit design, with ventilated discs at the front, and drum or disc brakes (according to model) at the rear. The front calipers are of floating single-piston design, using asbestosfree pads. The rear drum brakes are of the leading and trailing shoe type. They are selfadjusting during footbrake operation. The rear brake shoe linings are of different thicknesses, in order to allow for the different proportional rates of wear.

Pressure-control relief (PCR) valves are fitted to the rear brakes, to prevent rear wheel lock-up under hard braking. The valves are sometimes referred to as pressure-conscious reducing valves. On non-ABS models, they are fitted in the master cylinder rear brake outlet ports; on ABS models, they are located on the ABS unit.

When rear disc brakes are fitted, the rear brake caliper is located on the front of the knuckle on Saloon and Hatchback models, and on the rear of the knuckle on Estate models (see illustration).

1.1 Rear disc brake location on Saloon/Hatchback models (A) and Estate models
1.1 Rear disc brake location on Saloon/Hatchback models (A) and Estate models (B)

1 Handbrake cable lever facing away from caliper 2 Handbrake cable lever facing towards caliper 3 Brake hose banjo bolt
4 Front of vehicle

The handbrake is cable-operated, and acts on the rear brakes. On rear drum brake models, the cables operate on the rear trailing brake shoe operating levers, and on rear disc brake models, they operate on levers on the rear calipers. The handbrake lever incorporates an automatic adjuster, which removes any slack from the cables when the lever is disengaged (see illustration).

1.2 Handbrake lever and associated components
1.2 Handbrake lever and associated components

1 Handbrake lever
2 Clock spring
3 Handbrake cable
4 Toothed segment and pawl to lock the handbrake lever 5 Fine-toothed segment for the clock spring 6 Pawl for the clock spring 7 Underbody bracket

Handbrake lever movement remains consistent at all times, and no adjustment is necessary or possible.

Where fitted, the anti-lock braking system (ABS) is of the four-channel low-pressure type (see illustration).

1.3 Anti-lock Braking System (ABS) and Traction Control System (TCS)
1.3 Anti-lock Braking System (ABS) and Traction Control System (TCS) component locations (left-hand-drive shown, right-hand-drive similar)

1 ABS/TCS unit
2 ABS/TCS warning lights 3 TCS switch
4 Rear wheel sensor ring location (drum brakes left, disc brakes right) 5 Stop-light switch
6 Self-test/diagnosis connectors 7 Front wheel sensor and ring 8 Throttle actuator

It uses the basic
conventional brake system, together with a Bendix ABS hydraulic unit fitted between the master cylinder and the four wheel brakes.

The hydraulic unit consists of a hydraulic actuator, an ABS brake pressure pump, an ABS module with built-in relay box, and two pressure-control relief valves. Braking at each of the four wheels is controlled by separate solenoid valves in the hydraulic actuator. If wheel lock-up is detected on a wheel when the vehicle speed is above 3 mph, the valve opens, releasing pressure to the relevant brake, until the wheel regains a rotational speed corresponding to the speed of the vehicle. The cycle can be repeated many times a second. In the event of a fault in the ABS system, the conventional braking system is not affected. Diagnosis of a fault in the ABS system requires the use of special equipment, and this work should therefore be left to a Ford dealer. Diagnostic connectors are located on the side of the left-hand front suspension turret.

The traction control system (TCS) is fitted as an option to some models, and uses the basic ABS system, with an additional pump and valves fitted to the hydraulic actuator (see illustration).

1.4 Solenoid valves fitted to the ABS/TCS hydraulic actuator
1.4 Solenoid valves fitted to the ABS/TCS hydraulic actuator

1 ABS/TCS actuator
2 ABS solenoid valves
3 TCS solenoid valves

If wheelspin is detected at a speed below 30 mph, one of the valves opens, to allow the pump to pressurise the relevant brake, until the spinning wheel slows to a rotational speed corresponding to the speed of the vehicle. This has the effect of transferring torque to the wheel with most traction. At the same time, the throttle plate is closed slightly, to reduce the torque from the engine. At speeds above 30 mph, the TCS operates by throttle plate adjustment only.


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