Hydraulic System

WARNING: This page does not describe the selected car, but rather 13 other vehicles, including the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2003 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

The dual brake system is split front and rear with the front wheel brakes comprising one circuit and the rear wheel brakes, the other circuit. The vehicle is equipped with a brake pedal actuated dual brake system. See Figure. The system consists of the following:

Brake pedal (fixed or adjustable).
Power brake booster.
Brake master cylinder.
Front disc brake calipers.
Rear disc brake calipers.
Brake tubes and hoses.
Anti-Lock Brake System (ABS) components (if equipped).

The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. When the brake pedal is applied, brake fluid is pushed from the master cylinder through the metal tubing and flexible hoses to the rear disc brake calipers and the front disc brake calipers. The brake fluid enters the rear disc brake calipers, forcing the rear disc brake caliper pistons outward against the brake pads. The brake pads press against the braking surface on the brake discs. The front disc brake caliper pistons are forced outward against the brake pads, and contact the braking surface of the brake discs and hub. When the brake pedal is released, the pressure is relieved, returning the brake caliper pistons and the brake shoes and linings to the unapplied position. The ability of a brake system to stop the vehicle is dependent on the available traction.

Steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be properly double flared to provide strong leakproof connections. When bending the tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube, allow the tube to contact any other component, or come within 2" (50.8 mm) of the exhaust system. If a section of brake tube is damaged, the entire section must be replaced with a tube of the same type, size, shape and length.