1992 Ford Probe Brake Service (ONLINE REPAIR MANUALS)

Never use copper tubing as a replacement for steel tubing. Copper tubing is subject to fatigue cracking and corrosion which could result in brake system failure.

Steel tubing is used to conduct hydraulic pressure to the brakes. All fittings, tubing and hose should be inspected for rusted, damaged or defective flared seats. The tubing is equipped with a double flare/inverted seat or I.S.O. flare to insure more positive seating in the fitting. To repair or reflare tubing, proceed as follows:

DOUBLE FLARE/INVERTED SEAT

• Cut off the damaged seat or damaged tubing.
• Ream out any burrs or ...

CALIPER, REPLACE

The hydraulic system must be depressurized before disconnecting any hydraulic lines or fittings. Depressurize the system by pumping the brake pedal a minimum of 25 times with the ignition switch in the OFF position.

EXCEPT ASPIRE, CAPRI, ESCORT, FESTIVA, PROBE & TRACER

Before removing calipers, mark lefthand and righthand calipers so they can be installed in the same position.

• On 1994 Continental, Sable and Taurus models, turn air suspension service switch off.
• On all models, raise and support front of vehicle, then remove wheel and tire assembly.
• Loosen brake tube fi...

• On models equipped with anti-lock brakes, prior to disconnecting any hydraulic lines or fittings, hydraulic system must be depressurized by pumping the brake pedal a minimum of 25 times with ignition switch in OFF position.
• On all models, grease or any other foreign material must be kept off caliper, disc surfaces and external hub surfaces during service procedures. Handling brake disc and caliper should be done in a way to avoid deforming disc and nicking or scratching brake linings.
• If inspection reveals rubber piston seals are worn or damaged, they should be replaced immediately.
• Du...

BRAKE PEDAL HEIGHT

• Check distance from center of pedal pad to floor.
• Distance should be 8.74-8.94 inches.
• If adjustment is required, loosen stop lamp switch locknut.
• Rotate switch until pedal height is 8.74-8.94 inches.
• After adjustment, tighten switch locknut.

BRAKE PEDAL FREEPLAY

• If equipped with power brakes, depress pedal a few times in order eliminate vacuum in power booster.
• Depress brake pedal by hand, then check brake pedal freeplay (until valve plunger contacts stopper plate, then resistance is felt...

Brake System Bleed

Pressure bleeding is recommended for all hydraulic brake systems.

The bleeding operation itself is fairly well standardized. The first step in all cases is cleaning the dirt from the filler cap before removing it from the master cylinder. This should be done thoroughly.

Pressure bleeding is fastest because the master cylinder doesn't have to be refilled several times, and the job can be done by one person. To prevent air from the pressure tank getting into the lines, do not shake the tank while air is being added to the tank or after it has been pressurized. Set t...

MASTER CYLINDER OVERHAUL

Disassemble

• Clean outside of master cylinder thoroughly. Drain brake fluid from master cylinder.
• Remove stop bolt and pressure control valves, if equipped.
• Using a screwdriver, carefully pry up on reservoir and remove it from master cylinder body.
• Remove fluid control valve, if equipped.
• Depress primary piston and remove snap ring from retaining groove at open end of bore.
• Remove primary and secondary piston assemblies from master cylinder. If secondary piston does not come out, apply air pressure to secondary outlet port to remove.

Inspection

When disassembled...