Document 51NoQ9V889vpeVy466O2Kp0V

Contents CONTENTS INTRODUCTION AND PREREQUISITE REVIEW OBJECTIVES.....................................................................................................................................................Intro -1 FORD BRAKES SERVICE TECHNICIAN SPECIALITY TRAINING (STST) CURRICULUM ......................... Intro - 2 Curriculum Goals...................................................................................................................................... Inlro - 2 Brake Systems Diagnosis and Repair Instructor-Led Course Description.............................................. Intro - 2 Course Objective......................................................................................................................................... Intro -2 Lesson Objectives....................................................................................................................................... Intro -2 Audience........................................ Intro - 2 Course Prerequisites................................................................................................................................ Intro - 3 Evaluation.................................................................................................................................................. Intro - 3 Student Guide.............................................................................................................................................. Intro -3 Service Standards....................................................................................................................................... Intro -4 PREREQUISITE REVIEW............................................................................................................................. Prereq -1 LESSON ONE-MODULE 1:BRAKE SYSTEM DIAGNOSIS AND TESTING Symptom-to-System-to-Component-to-Cause Diagnostic Procedure...............................................................2 Customer Concern..............................................................................................................................................2 Symptom Charts..................................................................................................................................................2 Pinpoint Tests...................................................................................................................................................... 2 Removal and Installation.................................................................................................................................... 2 Disassembly and Assembly................................................................................................................................ 2 Other Component and Subsystem Tests............................................................................................................2 PRELIMINARY BRAKE SYSTEM CHECKS................................................................................................................ 3 DIAGNOSTIC TESTS.......................................................................................................................................... 4 External Leak Test....................................................................................................................................... 4 Master Cylinder Non-Pressure External Leak Test.............................................................................................4 Air Entrapment Test.............................................................................................................................................5 Master Cylinder Fluid Bypass Test (Internal Leak Test)..................................................................................... 5 Master Cylinder Compensating Port Test........................................................................................................... 6 Hydro-Boost System Inspection......................................................................................................................... 7 Hydro-Boost Functional Check:.......................................................................................................................... 7 Accumulator Test:................................................................................................................................................8 Hydro-Boost Air Bleeding................................................................................................................................... 8 COMMON CUSTOMER CONCERNS......................................................................................................................... 9 Brake Roughness................................................................................................................................................9 Normal Roughness..............................................................................................................................................9 Abnormal Roughness..........................................................................................................................................9 Brake Roughness Diagnosis.............................................................................................................................10 Brake Pedal Low or Feels Spongy.................................................................................................................... 12 Brake Pedal Low or Feels Spongy Diagnosis................................................................................................... 12 Pedal Eases Down Slowly................................................................................................................................ 13 Pedal Eases Down Slowly Diagnosis............................................................................................................... 13 Pedal Goes Down Fast/Excessive Pedal Travel................ :.......................................... ..................................14 Pedal Goes Down Fast/Excessive Pedal Travel Diagnosis............................................................................. 14 Brakes Pull or Drift............................................................................................................................................. 15 Brakes Pull or Drift Diagnosis........................................................................................................................... 15 Brake System Diagnosis and Repair September, 2005 i