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HOMESERVICE MANUALSFORD2004ECONOLINE E150, VAN CARGO, 4.6 WREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 302 (BRAKE SYSTEM)DIAGNOSIS AND TESTINGBRAKE SYSTEMINSPECTION AND VERIFICATIONROAD TEST
2004 Ford Econoline E150, Van Cargo, 4.6 W

Road Test

2004 Ford Econoline E150, Van Cargo, 4.6 WSECTION Road Test
WARNING: This page is about a different car, the 2004 Mercury Monterey and 2004 Ford Freestar. However, it is still accessible from the selected car via links, so may be relevant.

The technician should have a thorough knowledge of the brake system operation and accepted general braking guidelines in order to detect any problems.

Select a road that is reasonably smooth and level. Gravel or bumpy roads are not suitable because the surface does not allow the tires to grip the road equally. Avoid crowned roads.

A key factor in evaluating brake concerns is the deceleration rate. This varies from vehicle to vehicle and with changes in operating conditions. It is evident how well the brakes are working after just a few applications.

For low or spongy brake pedal concerns:

  • bleed the brake system and retest the brake pedal feel.
  • if the brake pedal is still low or feels spongy, check the brake pedal mounting for looseness and correct installation. Check the brake booster and the brake master cylinder for loose mounting. Correct as necessary and retest the system for normal operation.
  • check the fluid level. The fluid level must be at or above the minimum mark. If the fluid level is below the minimum mark, check the system for leaks.

    For a slow or incomplete brake pedal return concern:

  • inspect for binding, damage, correct installation or interference at the brake pedal.
  • check the brake booster for binding, damage and correct installation.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.