All about Ford Mondeo

Brake check (Every 10 000 miles or 12 months)
Routine maintenance and servicing / Brake check (Every 10 000 miles or 12 months)


Note: For detailed photographs of the brake system, refer to Chapter 9.

1 The work described in this Section should be carried out at the specified intervals, or whenever a defect is suspected in the braking system. Any of the following symptoms could indicate a potential brake system defect: (a) The vehicle pulls to one side when the brake pedal is depressed.

(b) The brakes make scraping or dragging noises when applied.

(c) Brake pedal travel is excessive.

(d) The brake fluid requires repeated toppingup.

2 A brake pad wear warning light is fitted, and it is illuminated when the thickness of the front (or rear) disc brake pad linings reach the minimum amount. However, a physical check should be made to confirm the thickness of the linings, as follows.

Disc brakes
3 Jack up the front or rear of the vehicle, as applicable, and support it on axle stands.

Where rear brake pads are fitted, also jack up the rear of the vehicle and support on axle stands.

4 For better access to the brake calipers, remove the wheels.

5 Look through the inspection window in the caliper, and check that the thickness of the friction lining material on each of the pads is not less than the recommended minimum thickness given in the Specifications. Note: Bear in mind that the lining material is normally bonded to a metal backing plate.

6 If it is difficult to determine the exact thickness of the pad linings, or if you are at all concerned about the condition of the pads, then remove them from the calipers for further inspection (refer to Chapter 9).

7 Check the remaining brake caliper(s) in the same way.

8 If any one of the brake pads has worn down to, or below, the specified limit, all four pads at that end of the car must be renewed as a set (ie all the front pads or all the rear pads).

9 Measure the thickness of the discs with a micrometer, if available, to make sure that they still have service life remaining. If any disc is thinner than the specified minimum thickness, renew it (refer to Chapter 9). In any case, check the general condition of the discs. Look for excessive scoring and discolouration caused by overheating. If these conditions exist, remove the relevant disc and have it resurfaced or renewed (refer to Chapter 9).

10 Before refitting the wheels, check all brake lines and hoses (refer to Chapter 9). In particular, check the flexible hoses in the vicinity of the calipers, where they are subjected to most movement. Bend them between the fingers (but do not actually bend them double, or the casing may be damaged) and check that this does not reveal previously-hidden cracks, cuts or splits (see illustration).

23.10 Checking the condition of a flexible brake hose
23.10 Checking the condition of a flexible brake hose

Rear drum brakes
11 Chock the front wheels, then jack up the rear of the vehicle and support on axle stands.

12 For better access, remove the rear wheels.

13 To check the brake shoe lining thickness without removing the brake drums, prise the rubber plugs from the backplates, and use an electric torch to inspect the linings of the leading brake shoes (see illustration). Check that the thickness of the lining material on the brake shoes is not less than the recommendation given in the Specifications.

23.13 Prise the rubber plugs from the backplates to inspect the leading brake
23.13 Prise the rubber plugs from the backplates to inspect the leading brake shoe linings

14 If it is difficult to determine the exact thickness of the brake shoe linings, or if you are at all concerned about the condition of the shoes, then remove the rear drums for a more comprehensive inspection (refer to Chapter 9) (see illustration).

23.14 If the lining is bonded to the brake shoe, measure the lining thickness
23.14 If the lining is bonded to the brake shoe, measure the lining thickness from the outer surface to the metal shoe, as shown here; if the lining is riveted to the shoe, measure from the lining outer surface to the rivet head

15 With the drum removed, check the shoe return and hold-down springs for correct installation, and check the wheel cylinders for leakage of brake fluid. Check the friction surface of the brake drums for scoring and discoloration. If excessive, the drum should be resurfaced or renewed.

16 Before refitting the wheels, check all brake lines and hoses (refer to Chapter 9). On completion, apply the handbrake and check that the rear wheels are locked. The handbrake is self-adjusting, and no manual adjustment is possible.


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