1995 Ford Windstar Brake Service (ONLINE REPAIR MANUALS)

The four wheel anti-lock brake system prevents wheel lockup by automatically modulating brake pressure during an emergency stop. The system uses an ABS control module and a hydraulic control unit (HCU) to control both front and rear brakes separately. When the brakes are applied, fluid is forced from the brake master cylinder to the hydraulic control unit (HCU), then to the wheels. One circuit of the master cylinder feeds the left front and right rear brakes. The other circuit feeds the right front and left rear brakes. If the ABS control module senses that a wheel is about to lock,...

Except Windstar

Bleed primary and secondary hydraulic brake systems separately, bleeding the longest line first on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has been drained from the hydraulic system. Ensure proper bleed sequence is followed.

On Aerostar, Bronco, E-Series, Explorer, F-Series and Ranger models, the bleed order is right rear, left rear, right front, left front.

On Villager models, the bleed order is left front, right front, left rear, right rear.

• Loosen master cylinder to hydraulic line nuts and wrap sho...

Brake Drums

Any time brake drums are removed for brake service, braking surface diameter should be checked with a suitable micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If braking surface diameter exceeds specifications, the drum must be replaced. If braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced.

Minor scores should be removed with sa...

When working on or around brake assemblies, care must be taken to prevent breathing asbestos dust, as many manufacturers incorporate asbestos fibers in the production of brake linings. During routine service operations, precautions should be taken to minimize exposure. Do not sand or grind brake linings unless suitable local exhaust ventilation equipment is used to prevent excessive asbestos exposure.

• Wear a suitable respirator approved for asbesto...

Aerostar, Explorer & Ranger

These models use a pin sliding caliper type system, Fig. , in which the caliper slides on two pins attached to the spindle assembly.

Bronco, E-150 & F-150

These models use the LD (Light Duty) pin rail sliding caliper type system, Fig. , in which the single piston caliper slides on two pins attaching the caliper to the spindle assembly.

E-250-350, F-250-350 & F-Super Duty, Front

These models use the HD (Heavy Duty) pin rail sliding caliper type system, Fig. ,...

Brake System Bleed

Refer to "Hydraulic Brake Systems" for brake bleeding procedure.

Component Replacement

Hydraulic Control Unit (HCU)

• Disconnect battery ground cable.
• Disconnect 24-pin connector from ABS control module.
• Disconnect 2-pin power and ground connector from ABS control module.
• Remove two tubes from inlet ports and four tubes from outlet ports of HCU.
• Remove three attaching bolts retaining EHCU assembly to mounting bracket, then lower EHCU assembly down and out of engine compartment.
• Separate HCU from ABS control module by removing four torx head screws and disconnecting pump mot...