Ford Mondeo (petrol engines). Manual - part 33

and remove the clevis pin securing the servo
unit pushrod to the pedal cross-link arm.
7 On left-hand drive models, unscrew the nut
securing the pedal trunnion to the servo unit
pushrod inside the passenger compartment.
The nut is located near the top of the pedal,
and is accessible through an access hole. For
improved access, remove the lower facia
panel first.
8 Withdraw the servo unit from the bulkhead,
and remove it from the engine compartment.
On left-hand drive models, take care not to
damage the bulkhead rubber grommet as the
pushrod passes through it.
9 Note that the servo unit cannot be
dismantled for repair or overhaul and, if faulty,
must be renewed.

Refitting

10 Refitting is a reversal of the removal
procedure. Refer to Section 11 for details of
refitting the master cylinder.

Removal

1 Depress the brake pedal four or five times,
to dissipate any remaining vacuum from the
servo unit.
2 Disconnect the vacuum hose adaptor at the
servo unit, by pulling it free from the rubber
grommet (see illustration). If it is reluctant to
move, prise it free, using a screwdriver with its
blade inserted under the flange.
3 Detach the vacuum hose from the inlet
manifold connection, pressing in the collar to
disengage the tabs, then withdrawing the
collar slowly.
4 If the hose or the fixings are damaged or in
poor condition, they must be renewed.

Testing

5 Examine the non-return valve for damage
and signs of deterioration, and renew it if
necessary. The valve may be tested by
blowing through its connecting hoses in both
directions. It should only be possible to blow
from the servo end towards the inlet manifold.

Refitting

6 Refitting is a reversal of the removal
procedure. If fitting a new non-return valve,
ensure that it is fitted the correct way round.

Removal

1 On non-ABS models, the two pressure-
control relief valves (sometimes referred to as
pressure-conscious reducing valves) are
located on the master cylinder outlets to the
rear brake line circuits.
2 Unscrew and remove the fluid reservoir filler
cap, and draw off the fluid - see Section 11.
3 Position some rags beneath the master
cylinder, to catch any spilled fluid.
4 Clean around the valve to be removed.
Hold the PCR valve stationary with one
spanner, and unscrew the hydraulic pipe
union nut with another spanner. Pull out the
pipe, and bend it slightly away from the valve.
5 Unscrew the PCR valve from the master
cylinder.
6 Note that the primary and secondary PCR
valves have different thread diameters, to
prevent incorrect fitment. The primary valve
has a 12 mm diameter thread, and the
secondary valve has a 10 mm diameter thread
(see illustration).

Refitting

7 Refitting is a reversal of the removal
procedure. On completion, bleed the
hydraulic system as described in Section 15.

Removal

1 On ABS models, the pressure-control relief
valves are located on the ABS hydraulic unit
(see illustration).
2 Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
3 Remove the air cleaner assembly as
described in Chapter 4.
4 Remove the engine air inlet duct and air
plenum chamber.
5 Disconnect the low fluid level warning
multi-plug from the brake fluid reservoir.
6 Unscrew and remove the brake fluid
reservoir filler cap, and completely seal the
top of the reservoir using cling film or
adhesive tape. This will reduce loss of fluid
when the PCR valve is removed.
7 Unscrew the master cylinder mounting
nuts, and carefully withdraw the cylinder from
the servo unit, leaving the brake pipes still
connected to it. Move the master cylinder
over to the left-hand side of the engine

compartment, to rest against the left-hand
suspension turret. (Throughout this manual,
left- and right-hand are as seen from the
driver’s seat.)
8 Unscrew the servo unit mounting nuts, and
move the unit to one side.
9 Position some rags beneath the ABS unit,
to catch spilled fluid.
10 Clean around the valve to be removed.
Hold the PCR valve stationary with one
spanner, and unscrew the hydraulic pipe
union nut with another spanner. Pull out the
pipe, and bend it slightly away from the valve.
11 Unscrew the PCR valve from the ABS
unit.

Refitting

12 Refitting is a reversal of the removal
procedure. On completion, bleed the
hydraulic system as described in Section 15.

19 Pressure-control relief valve

(ABS models) - 
removal and refitting

18 Pressure-control relief valve

(non-ABS models) - 
removal and refitting

17 Vacuum servo unit vacuum

hose and non-return valve -
removal, testing and refitting

Braking system  9•13

9

17.2  Removing the plastic adaptor from

the servo unit

18.6  Pressure-control relief valve

locations

1  Primary PCR valve (12 mm)
2  Secondary PCR valve (10 mm)

19.1 Pressure-control relief valve locations

on the ABS hydraulic unit

1  PCR valve, rear right brake circuit
2  Outlet, front left brake circuit
3  Inlet, from brake master cylinder secondary 

circuit

4  PCR valve, rear left brake circuit
5  Outlet, front right brake circuit
6  Inlet, from brake master cylinder primary 

circuit

Note: If any part of the ABS hydraulic unit is
defective, it must be renewed as an assembly.
Apart from the relay box (Section 22),
individual spare parts are not available.

Removal

1 Remove both pressure-control relief valves
as described in Section 19.
2 Identify the location of the remaining brake
hydraulic pipes on the ABS hydraulic unit,
then unscrew the union nuts and pull out the
pipes. Carefully bend the pipes away from the
hydraulic unit, to allow the unit to be removed.
3 Disconnect the multi-plugs from the
hydraulic unit. To disconnect the main 22-pin
multi-plug, push the locktab, then swivel the
multi-plug outwards and unhook it.

Right-hand drive models

4 Have an assistant hold the brake pedal
depressed, then extract the spring clip and
remove the clevis pin securing the servo unit
pushrod to the pedal cross-link arm.
5 Remove the vacuum servo unit from the
engine compartment.

Left-hand drive models

6 Unscrew the nut securing the pedal
trunnion to the servo unit pushrod inside the
passenger compartment. The nut is located
near the top of the pedal, and is accessible
through an access hole. For improved access,
remove the lower facia panel first.
7 Remove the vacuum servo unit, together
with the pushrod, from the engine
compartment. Take care not to damage the
rubber grommet in the bulkhead.

All models

8 Unscrew the pump mounting nut.
9 Raise the left-hand side of the ABS
hydraulic unit, then swivel the unit out of the
right-hand mounting. Take care not to lose the
bracket studs and insulator ring.

Refitting

10 Locate the insulator ring on the pump
end, and fit the stud cap to the insulator ring.
11 Lower the ABS hydraulic unit into
position, right-hand end first.
12 Fit the right-hand bracket studs onto the
insulators.
13 Lower the left-hand end of the ABS
hydraulic unit onto the bracket, then fit and
tighten the pump mounting nut.

Left-hand drive models

14 Locate the vacuum servo unit and
pushrod on the bulkhead bracket, taking care
not to damage the rubber grommet.
15 Insert the pushrod in the pedal trunnion,
and tighten the nut.
16 Refit the lower facia panel if it was
removed.

Right-hand drive models

17 Locate the vacuum servo unit and
pushrod on the bulkhead bracket.
18 Refit the clevis pin and spring clip
securing the servo unit pushrod to the pedal
cross-link arm.

All models

19 Reconnect the multi-plugs to the
hydraulic unit.
20 Reconnect the brake pipes to the
hydraulic unit, and tighten the union nuts.
21 Refit both pressure-control relief valves,
with reference to Section 20.

Testing

1 Checking of the sensors is done before
removal, connecting a voltmeter to the
disconnected sensor multi-plug. Using an
analogue (moving coil) meter is not practical,
since the meter does not respond quickly
enough. A digital meter having an AC facility
may be used to check that the sensor is
operating correctly. To do this, raise the
relevant wheel then disconnect the wiring to
the ABS sensor and connect the meter to it.
Spin the wheel and check that the output
voltage is between 1.5 and 2.0 volts,
depending on how fast the wheel is spun.
Alternatively, an oscilloscope may be used to
check the output of the sensor - an alternating
current will be traced on the screen, of
magnitude depending on the speed of the
rotating wheel.
2 If the sensor output is low or zero, renew
the sensor.

Removal

Front wheel sensor

3 Apply the handbrake, jack up the front of
the vehicle and support it on axle stands.
Remove the relevant wheel.
4 Unscrew the sensor mounting bolt located
on the steering knuckle, and withdraw the
sensor (see illustrations).
5 Remove the sensor wiring loom from the

support brackets on the front suspension
strut and wheel arch.
6 Prise out the stud clips, and remove the
Torx screws and screw clips holding the wheel
arch liner in position. Withdraw the liner.
7 Disconnect the multi-plug, and withdraw
the sensor and wiring loom.

Rear wheel sensor

8 Chock the front wheels, and engage 1st
gear (or “P”). Jack up the rear of the vehicle
and support it on axle stands. Remove the
relevant wheel.
9 Unscrew the sensor mounting bolt, located
on the brake backplate (drum brakes) or rear
suspension knuckle (disc brakes), and
withdraw the sensor.
10 On disc brake models, prise out the stud
clips, and remove the Torx screws and screw
clips holding the wheel arch liner in position.
Withdraw the liner.
11 Disconnect the sensor wiring loom from
the supports on the rear suspension strut (or
knuckle) and wheel arch.
12 Working inside the vehicle, lift the rear
seat cushion, then disconnect the multi-plug
for the sensor wiring loom (see illustration).
13 Withdraw the sensor and wiring loom
through the rubber grommet in the rear floor.

Refitting

Front and rear wheel sensors

14 Refitting is a reversal of the removal
procedure.

Removal

1 Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2 Detach the vacuum hose from the inlet
manifold connection, pressing in the collar to
disengage the tabs, then withdrawing the
collar slowly.
3 To improve access, free the heater hose
from its retaining clips, and position it clear of
the relay box.
4 Disconect the wiring connector(s) from the
relay box and, where necessary, the speed
sender unit.

22 ABS relay box - 

removal and refitting

21 ABS wheel sensor - 

testing, removal and refitting

20 ABS hydraulic unit - 

removal and refitting

9•14 Braking system

21.4  Unscrew the mounting bolt  and

remove the ABS sensor

21.12  Rear ABS sensor wiring multi-plug

located beneath the rear seat

5 Slacken and remove the four Torx retaining
screws, and withdraw the relay box from the
hydraulic unit (see illustration).

Refitting

6 Refitting is a reversal of the removal
procedure. Do not overtighten the relay box
retaining screws, as the plastic is easily
cracked

Removal

1 Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2 Using a small screwdriver and a suitable
pad (to protect the facia), prise out the TCS
inhibitor switch from the facia.

3 Disconnect the multi-plug from the switch,
and withdraw the switch.

Refitting

4 Refitting is a reversal of the removal
procedure.

Removal

1 The TCS throttle actuator is located in the
front right-hand corner of the engine
compartment. First disconnect the battery
negative (earth) lead (Chapter 5, Section 1).
2 Disconnect the wiring multi-plug at the TCS
actuator (see illustration).
3 Prise off the motor cover (see illustration).

4 Turn the upper throttle control segment, to
provide some play in the accelerator cable
leading to the throttle housing, then
disconnect the cable by unhooking the end
stop. Release the cable from the motor
housing support (see illustrations).
5 Turn the lower accelerator control segment,
to provide play in the accelerator cable from
the accelerator pedal, then disconnect the
cable by unhooking the end stop. Release the
cable from the motor housing support (see
illustration).
6 Unscrew the mounting bolts, and lift out the
TCS throttle actuator (see illustration).

Refitting

7 Refitting is a reversal of the removal
procedure. Adjust the accelerator cables as
described in Chapter 4.

Removal

1 Disconnect the battery negative (earth) lead
(Chapter 5, Section 1).
2 Remove the lower facia panel, with
reference to Chapter 11.
3 Disconnect the wiring multi-plug from the
switch.
4 Rotate the switch anti-clockwise by a
quarter-turn, and withdraw it from the pedal
bracket (see illustration).

25 Stop-light switch - 

removal and refitting

24 TCS throttle actuator -

removal and refitting

23 TCS inhibitor switch -

removal and refitting

Braking system  9•15

9

24.4B  Releasing the cable from the motor

housing support

24.4A  Disconnecting the accelerator cable

(arrowed) from the upper throttle control

segment

24.5  Disconnecting the accelerator cable

(arrowed) from the lower throttle control

segment

24.6  Removing the TCS actuator

22.5  Removing the ABS relay box

24.2  Disconnecting the multi-plug

(arrowed) at the TCS actuator

24.3  Removing the TCS motor cover

25.4  Removing the stop-light switch

Refitting and adjustment

5 With the switch removed, reset it by fully
extending its plunger.
6 Depress the brake pedal until the distance
between the pedal and mounting bracket is as
shown (see illustration).
7 Hold the pedal in this position, and refit the
stop-light switch to the mounting bracket .
8 With the switch securely clipped in position,
release the brake pedal, and gently pull it fully
back to the at-rest position. This will
automatically set the adjustment of the stop-
light switch.
9 reconnect the wiring connector and the
battery, and check the operation of the switch
prior to refitting the lower facia panel (Chapter 11).

Removal

1 Raise the front and rear of the vehicle, and
support it on axle stands. Fully release the
handbrake lever.
2 Remove the centre console as described in
Chapter 11.
3 Working beneath the vehicle, release the
exhaust system from the rubber mountings.
Lower the exhaust system as far as possible,
supporting it on blocks or more axle stands.
4 Detach the exhaust heat shield from the
underbody.
5 Unhook the secondary (rear) handbrake
cables from the equaliser bar.
6 Working inside the vehicle, unscrew and
remove the two mounting bolts securing the
handbrake lever to the floor (see illustration).

7 Turn the handbrake lever upsidedown, then
disconnect the primary cable end from the
segment.
8 Withdraw the handbrake from inside the
vehicle.

Refitting

9 Refitting is a reversal of the removal
procedure, making sure that the primary cable
is correctly located in the segment. Check the
operation of the handbrake before returning
the vehicle to normal service.

Removal

Primary (front)

1 Remove the handbrake lever as described
in Section 26.
2 Prise the grommet from the underbody,
and withdraw the cable from beneath the
vehicle.

Secondary (rear)

3 Chock the front wheels, and engage 1st
gear (or “P”). Jack up the rear of the vehicle
and support it on axle stands. Fully release
the handbrake lever.
4 Remove the relevant rear wheel.

5 Working beneath the vehicle, release the
exhaust system from the rubber mountings.
Lower the exhaust system as far as possible,
supporting it on blocks or more axle stands.
6 Unbolt the exhaust heat shield from the
underbody.
7 Unhook the relevant cable from the
equaliser bar.
8 On drum brake models, remove the rear
brake shoes on the relevant side as described
in Section 6, then remove the outer cable from
the backplate by compressing the three
retaining lugs (use a suitable ring spanner)
and pushing the cable through (see
illustration).
9 On disc brake models, unhook the end of
the cable from the handbrake operating arm
on the rear caliper.
10 Release the lugs securing the outer cable
to the underbody brackets, then release the
cable from the clips, and withdraw it from
under the vehicle (see illustrations).

Refitting

All cables

11 Refitting is a reversal of the removal
procedure, but make sure that the cable end
fittings are correctly located. Check the
operation of the handbrake before returning
the vehicle to normal service.

27 Handbrake cables -

removal and refitting

26 Handbrake lever - 

removal and refitting

9•16 Braking system

25.6  To ensure correct adjustment,

position the brake pedal as shown prior to

refitting the switch to its mounting bracket

26.6  Handbrake lever mounting bolts

27.8  Using a ring spanner to compress the

retaining lugs securing the outer cable to

the backplate

27.10A  Release the lugs using a ring

spanner . . .

27.10B  . . . and remove the outer cable

from the underbody brackets