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Brake System Bleeding: Manual

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the DOT 3 motor vehicle brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system.
NOTE: Due to the complexity of the fluid path within the rear integral parking brake calipers, it is necessary to press and release the parking brake during the bleed procedure.
NOTE: If the hydraulic control unit (HCU), or any component upstream of the HCU are installed new, carry out the Brake System Pressure Bleeding procedure first without the diagnostic tool, followed by the Brake System Bleed procedure using the diagnostic tool. The Component Bleeding - Rear Brake Caliper procedure is not required as the rear calipers were not replaced.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Bleeding the system with pressure bleeding equipment is the preferred method.
  1. Connect the diagnostic tool cable adapter into the vehicle data link connector (DLC) under the dash and follow the diagnostic tool instructions.
  2. Clean all the dirt from the area, remove the brake master cylinder reservoir cap and fill the brake master cylinder reservoir with the specified brake fluid.
    Fig 1: Identifying Brake Master Cylinder Fluid Reservoir Cap And Max Fill Line
    G03983412Courtesy of FORD MOTOR CO.
  3. Remove the rear bleeder cap and place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid.
    Fig 2: Locating Rubber Drain Tube On Bleeder Screw
    G03983413Courtesy of FORD MOTOR CO.
  4. Have an assistant hold firm pressure on the brake pedal.
  5. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw.
    • Press and release the parking brake 5 times.
    • Repeat until clear, bubble-free fluid comes out.
    • Refill the brake master cylinder reservoir as necessary.
  6. Tighten the RH rear bleeder screw and install the bleeder cap.
    • Tighten to 10 Nm (89 lb-in).
  7. Repeat Steps  3- 6 for the LH rear bleeder screw.
  8. Remove the rear bleeder cap and place a box end wrench on the RH front brake caliper bleeder screw. Attach a rubber drain tube to the RH front brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid.
    Fig 3: Attaching Rubber Drain Tube To Brake Caliper Bleeder Screw
    G03983414Courtesy of FORD MOTOR CO.
  9. Have an assistant hold firm pressure on the brake pedal.
  10. Loosen the RH front brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front brake caliper bleeder screw.
    • Repeat until clear, bubble-free fluid comes out.
    • Refill the brake master cylinder reservoir as necessary.
      Fig 4: Locating RH Front Brake Caliper Bleeder Screw
      G03988486Courtesy of FORD MOTOR CO.
  11. Tighten the RH front brake caliper bleeder screw and install the bleeder cap.
    • Tighten to 12 Nm (9 lb-ft).
  12. Repeat Steps  8- 11 for the LH front brake caliper bleeder screw.
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