Brake System Diagnosis and Repair Student Guide FCS-14354-REFigk ORDER NUMBER: FCS-14354-REF COURSE CODE: 38S07T0 January, 2006 Ford Customer Service Division Technical Training IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle • • Always wear safety glasses for eye protection • • • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure • • Do not smoke while working on the vehicle Set the parking brake when working on the vehicle If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation If you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation • Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood Use safety stands whenever a procedure requires you to be under the vehicle • Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide • Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice WARNING: Many brake linings contain asbestos fibers When working on brake components, avoid breathing the dust Breathing the asbestos dust can cause asbestosis and cancer Breathing asbestos dust is harmful to your health Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag If a vacuum bag suitable for asbestos is not available, cleaning should be done wet If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs Only technicians concerned with performing brake or clutch service should be present in the area Copyright © 2005 Ford Motor Company Produced and Coordinated by Technical Support Operations Ford Customer Service Division September, 2005 CUSTOMER EXPECTATIONS Customer Expectations: Service Make it convenient to have my vehicle serviced at your dealership The Service Advisor should demonstrate a genuine concern for my service needs Fix it right the first time Complete servicing my vehicle in a timely and professional manner Provide me with a clear and thorough explanation of the service performed Call me within a reasonable amount of time after my service visit to ensure that I'm completly satisfied Be responsive to questions or concerns I bring to your attention Expectation “Fix It Right The First Time, On Time.” Both service advisors and technicians are important players when it comes to Expectation #3 Why Customers tell us “Fixing It Right The First Time, On Time” is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to “Fix It Right The First Time, On Time.” We refer to this as “competency.” Technician’s Role Acquire the skills and knowledge for competency in your specialty via: STST New Model – Web Based Training – Web Based Training – Instructor Led – Instructor Led The Benefits The successful implementation of expectations means: – Satisfied customers – Repeat vehicle sales – Repeat service sales – Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business” CONTENTS Contents INTRODUCTION AND PREREQUISITE REVIEW OBJECTIVES Intro - FORD BRAKES SERVICE TECHNICIAN SPECIALITY TRAINING (STST) CURRICULUM Intro - Curriculum Goals Intro - Brake Systems Diagnosis and Repair Instructor-Led Course Description Intro - Course Objective Intro - Lesson Objectives Intro - Audience Intro - Course Prerequisites Intro - Evaluation Intro - Student Guide Intro - Service Standards Intro - PREREQUISITE REVIEW Prereq - LESSON ONE-MODULE 1:BRAKE SYSTEM DIAGNOSIS AND TESTING Symptom-to-System-to-Component-to-Cause Diagnostic Procedure Customer Concern Symptom Charts Pinpoint Tests Removal and Installation Disassembly and Assembly Other Component and Subsystem Tests PRELIMINARY BRAKE SYSTEM CHECKS DIAGNOSTIC TESTS External Leak Test Master Cylinder Non-Pressure External Leak Test Air Entrapment Test Master Cylinder Fluid Bypass Test (Internal Leak Test) Master Cylinder Compensating Port Test Hydro-Boost System Inspection Hydro-Boost Functional Check: Accumulator Test: Hydro-Boost Air Bleeding COMMON CUSTOMER CONCERNS Brake Roughness Normal Roughness Abnormal Roughness Brake Roughness Diagnosis 10 Brake Pedal Low or Feels Spongy 12 Brake Pedal Low or Feels Spongy Diagnosis 12 Pedal Eases Down Slowly 13 Pedal Eases Down Slowly Diagnosis 13 Pedal Goes Down Fast/Excessive Pedal Travel 14 Pedal Goes Down Fast/Excessive Pedal Travel Diagnosis 14 Brakes Pull or Drift 15 Brakes Pull or Drift Diagnosis 15 Brake System Diagnosis and Repair September, 2005 i CONTENTS Red Brake Warning Indicator Always On 16 Brake Warning Indicator Always On Diagnosis 16 Brakes Lock Up (Grabbing) 17 Brakes Lock Up Diagnosis 17 Excessive Brake Pedal Effort 18 Excessive Brake Pedal Effort Diagnosis 18 Brakes Drag 19 Brakes Drag Diagnosis 19 Brake Noise 20 Normal Noise 20 Abnormal Noise 21 Brake Noise Diagnosis 21 Slow or Incomplete Brake Pedal Return 22 Slow or Incomplete Brake Pedal Return Diagnosis 22 LESSON ONE WORKSTATIONS 23 WORKSTATION 25 WORKSTATION 26 WORKSTATION 28 WORKSTATION 30 LESSON ONE-MODULE 2:BRAKE SYSTEM SERVICE INTRODUCTION TO BRAKE SYSTEM SERVICE 34 SERVICE PRECAUTIONS 35 BRAKE INSPECTION PROCEDURES 36 HYDRAULIC COMPONENT INSPECTION 36 Brake Master Cylinder Reservoir 37 BRAKE ROTOR INSPECTION 38 Rotor Visual Inspection 38 Rotor Runout 40 Rotor Thickness and Thickness Variation 41 BRAKE DRUM INSPECTION 42 Visual Inspection 42 Drum Diameter 43 Barrel Shape Drums 44 Out-of-Round Drums 44 Eccentric Drums 45 Bell-Mouth 45 Tapered Drum 46 DISC BRAKE PAD SERVICE 47 Disc Brake Pad Replacement 50 DRUM BRAKE INSPECTION AND LINING REPLACEMENT 52 DRUM BRAKE LINING SERVICE 53 Drum Brake Component Disassembly 54 Drum Brake Component Reassembly 55 PARKING BRAKE SERVICE 56 Linkage Inspection and Test 56 Rear Drum Brake Parking Brakes 56 Caliper Integrated Parking Brakes 58 Drum-In-Rotor Parking Brakes 59 DRUM BRAKE WHEEL CYLINDERS 60 DISC BRAKE CALIPERS 61 ii September, 2005 Brake System Diagnosis and Repair CONTENTS MASTER CYLINDER Bench Bleeding a Master Cylinder Installing a Master Cylinder BRAKE FLUID BRAKE SYSTEM BLEEDING Manual Bleeding Pressure Bleeding Gravity Bleeding Vacuum Bleeding BRAKE LINES AND HOSES Metal Brake Lines Brake Hoses 62 63 63 64 65 66 67 67 68 69 70 71 LESSON TWO DEMONSTRATION 1: BRAKE INSPECTION 73 DEMONSTRATION 2: MACHINING 77 BRAKE ROUGHNESS — CAUSES 78 Lateral Runout 78 Disc Thickness Variation 79 Lining Material Transfer 80 Rotor Corrosion 80 BRAKE ROUGHNESS — REPAIR 81 COMMON MACHINING PRACTICES FOR ROTORS 89 COMMON MACHINING PRACTICES FOR DRUMS 89 ROTUNDA PRO-CUT ON-CAR BRAKE LATHE (201-00002) 90 Brake Lathe Set-up 90 Attach Lathe To Mount Adapter 93 Compensate For Lathe Runout 94 Lathe Operation 98 On-Car Lathe Summary 102 LESSON TWO WORKSTATIONS 103 WORKSTATION 104 WORKSTATION 106 WORKSTATION 108 WORKSTATION 110 GLOSSARY Glossary - TOOL LIST Tool - ROTUNDA ORDER FORM Brake System Diagnosis and Repair September, 2005 iii CONTENTS iv September, 2005 Brake System Diagnosis and Repair INTRODUCTION INTRODUCTION Brake System Diagnosis and Repair September, 2005 Intro - INTRODUCTION FORD BRAKES SERVICE TECHNICIAN SPECIALITY TRAINING (STST) CURRICULUM Courses of The Ford Brakes Service Technician Speciality Training (STST) Curriculum The Ford Brakes Service Technician Speciality Training (STST) Curriculum consists of seven courses related to brake system diagnosis and service Each course in the curriculum is a “building block” for the next course in the curriculum This curriculum is designed for technicians who want to learn the methods and techniques to properly diagnose and service brake systems and components Curriculum Goals The goals of this curriculum are to provide: The necessary training to enable the technician to identify, diagnose and perform timely “Fix It Right The First Time On Time” repairs Increased customer satisfaction Increased technician productivity Fewer repeat repairs Brake Systems Diagnosis and Repair Instructor-Led Course Description This is the first instructor-led course in the Brakes Curriculum It is a two-day course facilitated by an instructor This course is designed to provide hands-on opportunities for technicians to learn and improve their skills using tools and equipment; and to apply knowledge learned in previous curriculum courses Course Objective Given the information presented in the Ford Brake Systems Diagnosis and Repair course, the necessary service information and tools, technicians will be able to perform accurate, timely, cost-effective diagnosis and repair of brake systems on Ford Motor Company vehicles Lesson Objectives Each lesson of this course starts with a list of objectives for the participants The lesson objectives are designed to support the course objective Audience This course is designed for any Ford and Lincoln and Mercury service technicians who are enrolled in the Ford Brakes Service Technician Speciality Training (STST) Curriculum Additionally, this course is also designed for training service technicians of Ford Designated Fleets Intro - September, 2005 Brake System Diagnosis and Repair LESSON WORKSTATION DISC BRAKE INSPECTION, DISASSEMBLY, AND REASSEMBLY STUDENT ANSWER SHEET Directions: Remove one of the front brake calipers and rotor as instructed Inspect the components and determine if a concern exists using the procedures outlined in the student reference guide and the electronic service publication Answer the following questions as you proceed Raise the front of the vehicle and place on jack stands Check for bearing play and tie rod end play Are these components OK? If no, what is the concern _ Remove the wheel Inspect for abnormal wear of the tires Are the tires okay? _ If no, what is the concern? Remove the caliper and caliper bracket Inspect the pads for wear What measurement did you obtain? _ What is the wear specification? _ Visually inspect the caliper Are the housing, seals, and hose OK? _ If no, what is the concern? Suspend the caliper Remove the rotor and clean the mounting faces of both the hub and rotor Using the vehicle's lug nuts, (flat side towards the rotor) mount the rotor to the hub Measure the thickness of the rotor at _ points, 25.4mm (1 inch) from the outboard edge What is the largest difference between any two readings? What is the smallest rotor thickness measurement? What is the specification for rotor minimum thickness? _ WORKSHEET CONTINUED ON NEXT PAGE 104 September, 2005 Brake System Diagnosis and Repair LESSON WORKSTATION DISC BRAKE INSPECTION, DISASSEMBLY, AND REASSEMBLY STUDENT ANSWER SHEET (CONTINUED) Install Rotunda Disc Rotor and Ball Joint Gauge 134-R0199 or equivalent (See illustrations in workshop manual.) Measure rotor runout approximately 9.5mm (0.375 inch) inboard from the outer edge of the rotor What measurement did you obtain? _ Remove the rotor Measure the runout of the hub face What measurement did you obtain? _ What symptom could hub or rotor lateral runout cause _ 10 Reinstall the rotor, caliper bracket, and caliper 11 Reinstall the front wheel, lower the vehicle, and tighten the lug nuts to specification What is the torque specification for the lug nuts? END OF WORKSHEET Brake System Diagnosis and Repair September, 2005 105 LESSON WORKSTATION MOTORCRAFT VS OE / SERVICE PUBLICATION NAVIGATION STUDENT ANSWER SHEET Part One Directions: Insert the disc labeled Workstation and open the file Index htm Answer the following questions as you proceed How long can the development process for OE friction material take? Which brake pad has the most sophisticated use of shims, slots, and chamfers to reduce noise? How many times must the above stop be performed in a row without the brakes fading due to overheating? How many pounds of pedal pressure must the test be performed with? _ Do Motorcraft brake pads meet the same standards as OE brake pads for stopping distance or fade resistance? (Circle One) YES or NO Motorcraft brake pads come with attaching hardware in of the kits to match OE pads Approximately how many brake applications occur per mile driven? _ Are Super Duty brake pads the same as OE? Why? Super Duty backing plates use _ between the plate and friction material WORKSHEET CONTINUED ON NEXT PAGE 106 September, 2005 Brake System Diagnosis and Repair LESSON WORKSTATION MOTORCRAFT VS OE / SERVICE PUBLICATION NAVIGATION STUDENT ANSWER SHEET (CONTINUED) Part Two Directions: Review TSB 03-19-10, answer the following questions What are the Road Test diagnostic procedures that must be performed for this TSB? What should be done on a vehicle with a build date of August, 2001 that pulls to the right when braking? If after replacing the brake pads and burnishing the linings in diagnostic procedure 1, the vehicle still pulls, what should you next? _ In Diagnostic Procedure 2, if a vehicle still pull when braking after swapping the pads and rotors from side to side, what should you next? _ A What else should be done if the build date is July 1, 2000? _ _ _ END OF WORKSHEET Brake System Diagnosis and Repair September, 2005 107 LESSON WORKSTATION DRUM BRAKE INSPECTION, DISASSEMBLY AND ASSEMBLY STUDENT ANSWER SHEET Directions: Disassemble, inspect, and reassemble the drum brake assembly using information in the electronic service publications Answer the questions as you proceed What type of brake assembly are you working on? (Circle One) LEADING-TRAILING OR DUO-SERVO What is the maximum allowable inside diameter of the brake drum? Inspect the brake shoe linings What is the minimum allowable thickness for the type of shoe you are working on? Are the brake shoes you are working on usable? (Circle One) YES or NO If you found that these brake shoes were contaminated, what items could be the cause of the contamination? During your inspection, you pull back the lower edges of the wheel cylinder boots and find a slight amount of brake fluid What action should you take? WORKSHEET CONTINUED ON NEXT PAGE 108 September, 2005 Brake System Diagnosis and Repair LESSON WORKSTATION DRUM BRAKE INSPECTION, DISASSEMBLY AND ASSEMBLY STUDENT ANSWER SHEET (CONTINUED) As you disassemble the brakes, complete the following list: COMPONENT OK NG REASON (IF NG) Brake Shoes Hold Down Springs and Pins Return Springs Self Adjuster Wheel Cylinder Bleeder Valve Brake Drum Parking Brake Cable Lever Backing Plate During reassembly, what lubricant(s) should be used, and where should it be applied? What is the largest inner diameter measurement you found on this brake drum? 10 Using the brake adjustment gauge, adjust the brake shoes prior to installing the drum 11 After performing any brake service, what must be done prior to moving the vehicle? END OF WORKSHEET Brake System Diagnosis and Repair September, 2005 109 LESSON WORKSTATION BRAKE SERVICE PROCEDURES STUDENT ANSWER SHEET Directions: Using the information you have learned and your student reference guide, perform the requested tasks and answer the following questions What is the purpose of bench bleeding a master cylinder? _ Bench bleed a master cylinder Have the instructor check your work when you have removed all the air from the master cylinder and initial here What is the only part of the brake system that could have a brake fluid loss that does not appear when the system is under pressure? Because of the variations in wear patterns, it is essential that you inspect the and _ edges of both brake pads The taper between the leading and trailing edges of a brake pad must not exceed: _ How is disc thickness variation determined? On a leading/trailing brake assembly, which shoe will exhibit the most wear? On a duo-servo brake assembly, which shoe will exhibit the most wear? A drum that shows excessive wear at the center of its friction surface is said to be: 10 Out-of-Round brake drums will usually cause: 11 A is where the open end of the brake drum distorts outward due to high braking temperatures, and excessive braking pressures 12 A _ is indicated by angled wear of the brake shoes WORKSHEET CONTINUED ON NEXT PAGE 110 September, 2005 Brake System Diagnosis and Repair LESSON WORKSTATION BRAKE SERVICE PROCEDURES STUDENT ANSWER SHEET 13 How are drum brake wheel cylinders inspected? _ 14 Brake fluid contaminated with a hydrocarbon/mineral based fluid (transmission fluid, power steering fluid) can be detected by: 15 Contamination of the brake hydraulic system requires: 16 What is the bleeding sequence for diagonally split systems? 17 What is the bleeding sequence for front/rear split systems? _ 18 Cut a six-inch piece of brake line and make a double flare on one end and an ISO flare on the other end Bend the brake line in two places following the instructor example Have the instructor inspect the flares and initial here END OF WORKSHEET Brake System Diagnosis and Repair September, 2005 111 LESSON NOTES 112 September, 2005 Brake System Diagnosis and Repair GLOSSARY ABS Anti-lock Brake System Advance Trac Ford stability assist system BOO Brake ON/OFF BPP Switch Brake Pedal Position Brake Pedal Reserve The distance between the bottom of the brake pedal and the floor Brake Pedal Free Play The distance that the brake pedal is applied before braking begins to occur CAN Controller Area Network DOT Department of Transportation DTC Diagnostic Trouble Code DTV Disc Thickness Variation EBD Electronic Brake Distribution EHCU Electronic Hydraulic Control Unit (ABS module that is co-located with HCU) HCU Hydraulic Control Uni Hydro-Boost Hydraulic brake boosting system IVD Interactive Vehicle Dynamics (another term for Advance Trac) KOEO Key On Engine Off KOER Key On Engine Running LED Light Emitting Diode LPA Low Pressure Accumulator MIL Malfunction Indicator Lamp Multiplexing A computer strategy that allows module-to-module communication during normal vehicle operation NGS New Generation STAR Tester OBD On-board Diagnostics PC/ED Powertrain Control/Emission Diagnosis PCM Powertrain Control Module PID Parameter Identification Protocol A computer language that allows communication between control modules PSI Pounds per Square Inch PWM Pulse Width Modulated RPM Revolutions Per Minute Brake System Diagnosis and Repair September, 2005 Glossary - GLOSSARY SIG RTN Signal Return SSCC Symptom-to-System-to-Component-to-Cause SW B+ Switched Battery Voltage TC Traction Control TPS Throttle Position Sensor TSB Technical Service Bulletin VECI Vehicle Emissions Control Information VIN Vehicle Identification Number VSS Vehicle Speed Sensor WSS Wheel Speed Sensor WDS World Diagnostic System WOT Wide Open Throttle Glossary - September, 2005 Brake System Diagnosis and Repair TOOL LIST TOOL LIST Rotunda Pro-Cut On Car Brake Lathe 201-00002 Vise-Grip Type Dial Indicator 134-R0199 (Shipped w/Rotunda Brake Lathe) Rotunda Brake Pedal Effort Gauge 014-R1051 Rotunda Vacuum Bleeder 164-R1570 Accutorq® Wheel Nut Tightening Sockets 164-R0324 Rotunda ABS and Brake Pressure Test Kit 107-02353 Disc Brake Caliper Lubricant (XG-3-A) Silicone Brake Caliper Grease and Dielectric Compound (XG-3-A) or equivalent meeting Ford specifications ESE-M1C171-A Ford Premium Long Life Grease (XG-1-C) Brake System Diagnosis and Repair September, 2005 Tool - TOOL LIST Tool - September, 2005 Brake System Diagnosis and Repair QTY PART I BAL OF NO ITEM NUMBER PREFIX Dealer Parts Code #: Dealer Name: Address: City, State, Zip: Phone #: Fax #: Attention: Order Date: Ship to arrive by (Date or ASAP): Address: City, State, Zip: (if required) COL ADDITIONAL SPECIFICATIONS COL ORDER FORM OPTIONAL: CATALOG PAGE NO PART II DESCRIPTION Prices subject to change without notice EXTENDED TOTAL AUTHORIZED DEALERSHIP SIGNATURE (BUYER) PRINT NAME FCSD CREDIT MANAGER APPROVAL (ORDERS OVER $4,000) PART III TOTAL UNIT PRICE FAX NUMBER 1-800-762-6181 ❏ 36 Mo (Minimum $5,000) Buyer, having been quoted both an installment Price and a lesser Cash Price, hereby purchases from Seller on installment price basis, upon the terms and conditions set forth on the face hereof, the equipment to be delivered and installed at Buyer’s premises, as described above and agrees to pay Seller the Installment Price therefore as so set forth until paid in full ❏ 30 Day Open Account Installment Plan (Fixed Rate) ❏ 12 Mo (Minimum $1,000) ❏ 24 Mo (Minimum $3,000) ❏ 48 Mo (Minimum $10,000) ❏ 60 Mo (Minimum $15,000) (Reverse side must be completed) ❏ 90 Days Same as Cash (Minimum $1,000) Notice To Buyer: 315-195 Do not sign this contract before you read it or if it contains any blank spaces You are entitled to an exact copy of the contract you sign Under the law you have the right to pay off in advance the full amount due and under certain circumstances to obtain partial refund of the time charge BUYER ACKNOWLEDGES RECEIPT OF A TRUE AND COMPLETELY FILLED IN COPY OF THIS CONTRACT AT THE TIME OF SIGNING September 1999 FOR TELEPHONE ORDERS USE THE ROTUNDA TOLL-FREE NUMBER 1-800-ROTUNDA (768-8632) DEALER: Be sure you have completed Parts I and II for all orders, Part III for Installment Plan Orders 315-195 (Previous editions may not be used) Payment and Terms of Payment a If Buyer has requested the Dealer Open Account payment plan via the Ford Dealer Statement in Part II of the order form, and Seller agrees to sell pursuant to such plan, then Buyer shall pay the total purchase price shown on the invoice b If Buyer has requested the Installment Plan (Fixed Rate) in Part II of the order form, and Seller agrees to sell pursuant to such Plan, then Buyer shall pay the Down Payment (if any), and the Time Balance in equal monthly installments in accordance with the terms set forth below c If Buyer has requested the Installment Plan (Variable Rate) in Part II of the order form, and Seller agrees to sell pursuant to such Plan, then Buyer shall pay the Total Cash Price and any interest thereon in accordance with the Loan and Security Agreement to be executed by Buyer and Seller Title Title to Equipment purchased by Buyer from Seller shall pass to Buyer upon Seller’s receipt of all amounts owing by Buyer to Seller hereunder Risk of Loss Seller shall be responsible for risk of loss until Equipment is delivered to the location set forth herein, at which time risk of loss shall be the responsibility of Buyer Acceptance and Inspection Buyer shall be deemed to have accepted Equipment upon Seller’s delivery Equipment shall be deemed to have been delivered in good condition unless Buyer gives Seller notice to the contrary within 10 days after Seller’s delivery Delays Seller shall not be liable for any failure or delay in delivering Equipment, or for any failure to perform any provision hereof, resulting from fire, flood or other casualty, riot, strike or other labor difficulty, governmental regulation or other restriction, or any other cause beyond Seller’s control Unconditional Obligation Buyer’s obligation to make payments to Seller or its assignee shall be absolute and unconditional and shall continue unmodified despite any loss, damage or other interruption in the use of Equipment The obligation of Buyer to pay in full any amounts due under this contract shall not be subject to dispute, claim, counterclaim, defense or other right which Buyer may have to assert against Seller or the manufacturer of Equipment Buyer acknowledges that: (a) Buyer has selected Equipment and Manufacturer, and Buyer has determined Equipment’s suitability and fitness for the Buyer’s purpose, (b) Seller is not the manufacturer of Equipment, and (c) Manufacturer issues its own warranty and performs the obligations under such warranty Warranty THE MANUFACTURER’S WARRANTY SHALL BE BUYER’S EXCLUSIVE REMEDY, RECOURSE OR DAMAGE FOR ANY DEFECT IN WORKMANSHIP OR MATERIAL OR ANY FAILURE OF THE EQUIPMENT SELLER MAKES NO WARRANTIES, REPRESENTATIONS, INDEMNITIES OR GUARANTEES WHATSOEVER WITH RESPECT TO EQUIPMENT EITHER EXPRESS OR IMPLIED, ARISING BY LAW OR CUSTOM, INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THE LIABILITY OF THE SELLER SHALL BE LIMITED TO EXPRESS OBLIGATION TO DELIVER THE EQUIPMENT UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE OR RESPONSIBLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES, WHETHER FORESEEABLE OR UNFORESEEABLE, WHICH BUYER MAY INCUR, EXPERIENCE OR CLAIM, INCLUDING, BUT NOT LIMITED TO, CLAIMS FOR LOSS OF PROFITS, INTERRUPTION IN BUSINESS, LOST OPPORTUNITY, WORK STOPPAGE OR OTHER IMPAIRMENT OF ASSETS, ARISING OUT OF MISREPRESENTATION, NEGLIGENCE, STRICT LIABILITY, IN TORT OR OTHERWISE, ON ACCOUNT OF ENTERING INTO OR RELYING ON THIS AGREEMENT, EVEN IF SELLER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES Freight and Taxes Freight costs and applicable taxes will be added to the final invoice and will be borne by Buyer Security Interest Buyer hereby grants to Seller a continuing security interest in the Equipment, including all products and proceeds thereof, until all amounts due hereunder are paid Buyer agrees to execute, and pay filing fees for, any financing statement or other documents deemed necessary by Seller to maintain a valid security interest in the Equipment 10 Maintenance Buyer shall use the Equipment carefully and properly Buyer, at Buyer’s own expense, shall maintain and repair all items of the Equipment in order to keep them TERMS & CONDITIONS in good order and condition and, in particular, shall comply fully with the maintenance, operating, usage or other instructions provided by the manufacturer Buyer authorizes Seller, or any third party appointed by Seller, to inspect the Equipment when necessary Buyer shall at all times keep the Equipment free and clear of all liens, charges or encumbrances 11 Personal Property Ford proprietary diagnostic equipment (including the software, if applicable) shall be kept at Buyer’s premises as listed on the reverse side and shall remain personal property regardless of how and to what degree it may be affixed or attached to any building or structure or what may be the consequence of its removal from such building or structure Buyer shall not encumber the Equipment (including software, if applicable) until all amounts owing to Seller hereunder are paid In addition, Seller grants to Buyer, and Buyer accepts, a non-exclusive license to use the Equipment (including the software, if applicable) in accordance with the terms and conditions set forth herein The license (and Equipment) shall not be leased, sold, assigned or otherwise transferred, in whole or in part In the event, Buyer proposes to lease, sell assign or otherwise transfer the Equipment (and/or its software, if applicable), in whole or in part, to any person or entity, Ford Motor Company shall have a Right of First Refusal to purchase the Equipment (including all software, if applicable) for Ten and 00/100 Dollars ($10.00) in U.S currency 12 Insurance and Indemnification Buyer shall defend, indemnify and hold harmless Seller from and against, and at Buyer’s own expense provide insurance satisfactory to Seller covering any and all losses, damages, claims, expenses and other liabilities (including attorney’s fees,) relating to or arising out of: (I) damage, loss, theft, or destruction of the Equipment, or (ii) death, injury or property damage connected with the use, operation or condition (including without limitation, defects whether or not discoverable by any party) of the Equipment Buyer shall promptly notify Seller of any such claim Seller shall have the right to participate, at its own expense, in any proceeding for which Buyer has undertaken the defense of Seller, and in no event shall Buyer settle any claim against Seller without Seller’s prior written consent, Buyer shall provide evidence of such insurance to Seller upon demand Seller is under no obligation to examine any insurance certificate or advise Buyer that its insurance does not comply with the requirements set forth herein The losses covered by insurance shall in all cases be payable to Seller and Buyer as their interests may appear If Buyer fails to insure the Equipment as herein provided, Seller may, but is not obligated to, place such insurance upon the Equipment and the Buyer agrees to pay to Seller on demand the premiums for such insurance placed by Seller In no event shall any insurance coverage be deemed to limit or replace Buyer’s obligation to indemnify Seller as provided herein 13 Default In the event that Buyer: (a) fails to pay any amount due hereunder within ten (10) days of the due date, (b) fails to comply with any other provision hereof, (c) files, or if there is filed against Buyer, any petition under any bankruptcy or insolvency laws or suffers the appointment of any trustee or receiver for all or any part of Buyer’s business or assets, or (d) has any assignment (voluntarily or involuntarily), lien, attachment or levy issued against the Equipment (unless such petition, assignment or appointment, lien, attachment or levy is withdrawn or nullified within twenty (20) days) then Buyer shall be in default hereunder and all of Buyer’s indebtedness and obligations to Seller shall, at Seller’s option, become immediately due and payable, and Seller may, at its option, terminate this contract and repossess any and all items of Equipment with or without legal process and sell the same at private or public sale without prior notice to Buyer to the extent permitted by law Upon request, Buyer shall deliver the Equipment to Seller at a place designated by Seller Repossession and/or sales of the Equipment upon such default shall not affect the Seller’s right to retain all payments made prior to repossession or to recover the balance due hereunder for any deficiency Buyer shall reimburse Seller all costs of collection, repossession and resale (including reasonable attorneys’ fees, court costs and other expenses incurred by Seller.) Buyer hereby releases Seller from any liability for damages resulting from repossession hereunder The rights and remedies of Seller, in the event of default herein mentioned shall not be deemed exclusive but shall be cumulative and in addition to all other rights and remedies existing under law, and may be enforced successively or concurrently Waiver by Seller of any default shall not be deemed a waiver of any other default 14 General The waiver by either party of, or failure to claim, a breach of any provision of this contract shall not be deemed to be a waiver of any provision of this contract, shall not be deemed to be a waiver of any subsequent breach or to affect in any way the effectiveness of such provision This contract constitutes the entire agreement between the par- ties and may not be changed except by an instrument in writing signed by the party to be charged This contract may not be assigned by Buyer without the Seller’s prior written consent Seller may assign this contract at any time but shall not thereby be relieved from any liability hereunder In the event that one or more clauses of this contract are found to be unenforceable, illegal or contrary to public policy by court of competent jurisdiction, the remainder of this contract shall remain in full force and effect except for the unenforceable, illegal or other provisions This agreement is a Michigan agreement and shall be interpreted, construed and enforced in accordance with the laws of the State of Michigan, United States of America Each of the parties here to agrees that any legal or equitable action or proceeding with respect to this agreement shall be brought only in any court of the State of Michigan, or in any court of the United States of America sitting in Michigan, and each of the parties hereto submits to and accepts generally and unconditionally the jurisdiction of those courts with respect to such party’s person and property Each party hereby irrevocably waives any objection to the laying of venue of any such action or proceeding in the above described courts $ $ 15 Finance Charge Monthly portion of Finance Charge (Part III, Item 3) due is calculated each month by multiplying 1/12 of the annual finance charge rate times the remaining portion of the Unpaid Balance of Cash Price, and is added to the portion of the Unpaid Balance of Cash Price due each month PART III Cash Price $ Installment Plan Agreement Down Payment (if any) $ Unpaid Balance of Cash Price (Difference between and 2) Finance Charge (Finance charge will reduce each month) Call 1-800-768-8632 for the current finance charge rate $ $ Time Balance (3 + 4) Number of Installments ❏ 12 ❏ 24 ❏ 36 ❏ 48 ❏ 60 equal monthly installments Taxes and transportation (if any) will be billed separately Installment Payment Price (1 + 4) 315-195 Date: Prices subject to change without notice MAIL COMPLETED ORDER FORM TO: ROTUNDA EQUIPMENT PROGRAM P.O Box 1450 Kenosha, WI 53141 I agree to pay the time Balance set forth in accordance with the above schedule and the terms and conditions of this order form Dealer Signature: September 1999 ... FORM Brake System Diagnosis and Repair September, 2005 iii CONTENTS iv September, 2005 Brake System Diagnosis and Repair INTRODUCTION INTRODUCTION Brake System Diagnosis and Repair September, 2005. .. September, 2005 Brake System Diagnosis and Repair INTRODUCTION NOTES Brake System Diagnosis and Repair September, 2005 Intro - INTRODUCTION NOTES Intro - September, 2005 Brake System Diagnosis and Repair. .. September, 2005 Brake System Diagnosis and Repair PREREQUISITE REVIEW NOTES Brake System Diagnosis and Repair September, 2005 Prereq - PREREQUISITE REVIEW NOTES Prereq - September, 2005 Brake System Diagnosis