Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSLINCOLN2006ZEPHYRREPAIR AND DIAGNOSIS (SINGLE PAGE)BRAKESTRACTION CONTROLBRAKE SYSTEM - GENERAL INFORMATIONDIAGNOSIS AND TESTINGBRAKE SYSTEMSYMPTOM CHART

2006 Lincoln Zephyr

Symptom Chart

2006 Lincoln ZephyrSECTION Symptom Chart

SYMPTOM CHART

Condition	Possible Sources	Action
The red brake warning indicator is always on	Parking brake not fully released	RELEASE the parking brake.
	Low brake fluid level	FILL the brake fluid reservoir to the MAX line. INSPECT the hydraulic system for leaks. REPAIR as necessary. INSPECT the brake pads for wear. REPAIR as necessary.
	Brake warning indicator circuit malfunction	REFER to INSTRUMENT CLUSTER .
	Brake master cylinder inoperative	CARRY OUT the BRAKE MASTER CYLINDER TESTS .
Red brake warning indicator inoperative	Circuitry Bulb Instrument cluster	REFER to INSTRUMENT CLUSTER .
The brakes pull or drift	Tire air pressure	CHECK the tires for uneven or excessive wear and correct inflation.
	Brake pads	CHECK the brake pads for uneven taper or excessive wear. REPAIR as necessary.
	Brake components	CHECK the brake tubes, hoses, discs and the hubs for damage. REPAIR or INSTALL new components as necessary.
	Suspension component	INSTALL new suspension components as necessary.
	Wheel alignment	CHECK the wheel alignment. REFER to SUSPENSION SYSTEM-GENERAL INFORMATION .
Brake pedal goes down fast	Brake fluid level	INSPECT the system for leaks. REPAIR as necessary. FILL the brake master cylinder reservoir. BLEED the system. REFER to BRAKE SYSTEM BLEEDING .
	Air in system	INSPECT the system for leaks. REPAIR as necessary. BLEED the system. REFER to BRAKE SYSTEM BLEEDING .
	Brake master cylinder	CARRY OUT the BRAKE MASTER CYLINDER TESTS .
The brake pedal eases down slowly	Air in system	INSPECT the system for leaks. REPAIR as necessary. BLEED the system. REFER to BRAKE SYSTEM BLEEDING .
The brake pedal eases down slowly	Brake master cylinder	CARRY OUT the BRAKE MASTER CYLINDER TESTS .
Brake lockup under light brake pedal force	Brake pads	CHECK the brake pads for uneven taper or excessive wear. REPAIR as necessary.
	Brake component	CHECK the brake components for correct operation. REPAIR as necessary.
	Parking brake component	REPAIR or INSTALL new components as necessary. REFER to PARKING BRAKE & ACTUATION .
	Anti-lock brake system (ABS)	CHECK the ABS. REFER to VEHICLE DYNAMIC SYSTEMS .
Excessive/erratic brake pedal travel	Leak in hydraulic system Air in system Disc brake caliper	INSPECT the system for leaks. REPAIR as necessary. BLEED the system. REFER to BRAKE SYSTEM BLEEDING .
	Brake master cylinder	CARRY OUT the BRAKE MASTER CYLINDER TESTS .
	Brake pads	CHECK the brake pads for excessive wear. REPAIR as necessary.
	Brake pedal	CHECK the brake pedal for binding or obstructions. REPAIR as necessary.
Brakes drag	Parking brake component	REPAIR or INSTALL new components as necessary. REFER to PARKING BRAKE & ACTUATION .
	Brake caliper guide pins	REPAIR or INSTALL new caliper guide pins. REFER to FRONT DISC BRAKE or REAR DISC BRAKE .
	Disc brake caliper	REPAIR or INSTALL new brake calipers as necessary. REFER to FRONT DISC BRAKE or REAR DISC BRAKE .
	Brake booster	CARRY OUT the BRAKE BOOSTER component test.
	Brake master cylinder	CARRY OUT the BRAKE MASTER CYLINDER TESTS .
	Brake pads/shims	INSPECT brake pads and shims for damage. REFER to FRONT DISC BRAKE or REAR DISC BRAKE .
Excessive brake pedal effort	Brake booster	CARRY OUT the BRAKE BOOSTER .
	Brake booster check valve	CARRY OUT the Check Valve component test.
	Brake booster manifold vacuum hose	REROUTE, REPAIR or INSTALL new components as necessary.
Rattling noise	Caliper mounting bolts loose	CHECK the caliper bolts. TIGHTEN to specifications.
	Damaged or worn caliper guide pins or retainers	CHECK the caliper guide pins and retainers for lubrication and correct operation. LUBRICATE or INSTALL new components as necessary. REFER to BRAKE CALIPER GUIDE PINS .
	Missing or damaged shims, anti-rattle clips or springs	CHECK the brake pads for missing clips or broken springs. INSTALL new components as necessary. REFER to FRONT DISC BRAKE or REAR DISC BRAKE .
	Loose brake disc shield	INSPECT the brake discs shields. REPAIR as necessary.
Clicking noise - with brakes applied and anti-lock brake system (ABS) engaged	ABS hydraulic control unit	Acceptable condition.
Squealing noise - occurs on first (morning) brake application	Brake pads	Acceptable condition. Caused by humidity and low brake pad temperature.
Squealing noise - a continuous squeal	Brake pads worn below minimum thickness	INSPECT the brake pads for excessive wear, taper wear or uneven wear. VERIFY the brake pads are within minimum specifications. REFER to SPECIFICATIONS .
Squealing noise - an intermittent squeal brought on by cold, heat, water, mud or snow	Brake pads	Acceptable condition.
Groaning noise - occurs at low speeds with the brake lightly applied (creeping)	Brake pads	Acceptable condition.
Grinding noise - continuous	Brake pads worn below minimum thickness	INSPECT the brake pads, brake discs and attaching hardware for damage. VERIFY the brake pads are within minimum specifications. REFER to SPECIFICATIONS .
Moaning noise	Brake linings contaminated with grease or oil	INSPECT the brake pads for contamination. REPAIR or INSTALL new components as necessary. REFER to FRONT DISC BRAKE and REAR DISC BRAKE .
Vibration when brakes are applied	Uneven brake pad wear Brake disc pad transfer Brake disc Suspension components	COMPLETE the brake system inspection described in INSPECTION AND VERIFICATION . GO to PINPOINT TEST A .
Brake vibration/shudder - occurs when the brake pedal is released	Brake caliper guide pins	INSPECT the brake caliper guide pins for correct operation. REFER to BRAKE CALIPER GUIDE PINS .
	Brake drag	INSPECT the brake pads for premature wear. REPAIR or INSTALL a new caliper as necessary. REFER to FRONT DISC BRAKE and REAR DISC BRAKE .

RENDER: 1.0x

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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.