Hi,

I have just replaced both front brake calipers on my 2003 Ford Galaxy 2.3 (the front right caliper was starting to sieze - seal had been damaged and piston badly pitted with rust).

On bleeding the brakes I have been unable to get a decent pedal. I have done a lot of brake bleeding in the past on other cars with no problems. I have tried manual bleeding (pumping pedal etc), I have used a vacuum bleed kit (run off my air compressor and I have tried pressure bleeding with a Gunsons Eezi bleed kit. All seem to work ok with no air bubbles coming out, just clear clean fluid. I have now used nearly 3 litres of brake fluid!!!

The brakes were working fine before I replaced the calipers. I have in the past had an intermittent hiss coming from the brake servo when the brake pedal is released although not happened in the last few months.

I am pretty sure that there are no airlocks in the system but cannot be 100% certain. I have heard of air getting trapped up in the ABS unit but  I don't think this is the case and I don't know how I can clear it other than by doing the above bleeding

My next plan is to replace the Servo and the brake master cylinder but that is a big and expensive job and was wondering if anyone had any other thoughts / suggestions before I go down that route.

All comments greatly appreciated.

Thanks

Richard

 

Have you also done a bleed from the rear brakes?

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Thanks for the reply

Yes I have bled the rear brakes. I have also tried different sequences of bleeding starting at different wheels etc. I am a fairly competent DIY mechanic although would not class myself as an engineer. I have been working on cars for at least forty years including servicing on WRC Rallies. I think this problem may be peculiar the the Ford Galaxy model and wondered if anyone else has had the same problem.

Richard

 

 

Just had another thought. When I have been pumping the pedal to bleed the brakes the pedal is quite easy to press at first as though there is little resistance and then resistance is felt as the pedal nears the floor. I would have expected more resistance throughout the whole pedal travel. This is what has led me to think that there might be a master cylinder problem although the brakes worked fine before I replaced the calipers.

All comments gratefully received as sometimes it is quite easy to miss the obvious.

Thanks 

Richard

You can use Forscan (or other Ford specific diags) to cycle the ABS pump for a full fluid bleed.  That's what I'd try next personally.

Hi Tom,

That sounds like a good suggestion but I have never heard of Forscan. What is Forscan and how do I obtain and use it.

I have a VAG COM cable and software on order at the moment. Will this do the same as Forscan?

Many thanks

Richard

VAGCOM is equivalent to Forscan, but only works on VAG group cars, Forscan is specifically for Ford and Mazda.  I know the Galaxy was technically a VW Sharan underneath but the modules will all use Ford software.

Forscan is a free download program for a laptop, or a paid app on smart phones.  You just need a modified ELM327 cable or wireless dongle to use it.  We recommend the ones from Tunnelrat electronics as the quality can be hit and miss on the cheaper ones.

Forscan itself is very intuitive, even more so than VAGCOM (I use both myself) so you should pick it up easily.  ABS bleeding is under 'service procedures' and will give you instructions of what to do and when once you select it.

 

Hi Tom,

Thank you for your comprehensive reply. I have looked into this a bit more now and the Forscan option sounds like good route to go down.

I have ordered a modified ELM327 cable from Tunnelrat Electronics following your advice.

I should be able to use it on my other Fords as well.

I will let you know how I get on.

Thanks again 

Richard

Forscan is very handy indeed and the tunnelrat cable has switchable hs-can and ms-can so you can do dralership level diagnostics and hex coding if need be.

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Hi Tom / Clive,

Have now got the Tunnelrat ELM327 and got the Forscan Software running but am getting an error - DTC,s in PCM - P1000 (OBD systems readiness test not completed) and I am unable to run the service procedures. Looks like I may need to obtain an Extended Lease to run this function.

I can get a free 2 month trial for the extended lease. 

What do you think?

Richard

 

Hi Richard,

I don't think you need an extended licence for this.

Did it scan through all the modules or did it just get stuck at that PCM fault?  

I've had that fault on a few Fiestas but only after a second scan normally.  Not really sure why but it usually clears if you run the engine for a few minutes and then try again.   

 

Hi Tom,

Just seems to get stuck at the PCM P1000  Fault.

When I do a key on engine off on demand sellf test I get the P1000 and I also get a fault code 1709 (PNP out of self test range).

I assume this is what is stopping it complete the modules.

I am still looking but I cannot find out what fault code 1709 (PNP out of self test range) means.

Is there a list of the Forscan fault codes somewhere?

Regards

Richard

 

Ignore my last message re: fault code 1709. This was just clutch pedal not pressed during test (athough I was not requsted to press it). I found the fault codes on Forscan website.

However still getting stuck on the PCM P1000 fault code and I cannot seem to get around it whatever I do.

Richard

Hmm, that's got me stumped too I'm afraid.  

Might be worth asking on the Forscan forum in case it's a known Galaxy issue?

P1000 is OBD monitor testing incomplete, may be related to failing to press the pedal?

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Hi Tom / Clive,

Eventually managed to clear the P1000 problem by talking the car for a drive (not ideal with a spongy brake pedal) but it did clear after about 10 miles.

It would not clear after more than half an hour by just running engine on the drive (tried this about 5 times).

So one step nearer but still unable to run any service procedures.

When I press the Service Procedures Icon (Spanner Symbol) it just displays Module - PCM and Name - PATS Programming. If I try to run that it says that I need an extended licence. Am I being a bit thick here and missing something?

The forscan site implies I should be able to run at least some service functions with getting an extended licence?

Thanks for all your help so far.

Richard

Last message should have read "without getting an extended licence".

Richard

 

If your Galaxy is a MK2 then FORScan might not work properly on it. See the following which was cut and pasted from the FORScan FAQ page.

General What car brands and models are supported? Absolute majority of Ford, Mazda, Lincoln and Mercury models starting from 1996 model year are supported. Exception are quite rare: models unified with other manufacturers, for example Ford Galaxy Mk2. Models manufactured before 1996 usually have diagnostic interfaces not supported by ELM327. However, there are exceptions too. For example, Ford Scorpio II (1994 MY). No other brands are supported yet. Support for other brands is planned but not in the near future If your car is not a MK2 then post a screenshot of what you see when you connect to FORScan. ABS Service Bleed is not supported for all cars, but if it is you do not need an Extended Licence.

Hi John,

Yes I had noticed that the Mk2 Galaxy could be a problem but mine is a 2003 Mk1.

Looks like I need to contact Forscan support.

Thanks

Richard

Forscan Support advise that the modules on my Galaxy are VW ones and consequently as Forscan does not support VW protocol will not work on my car. 

Shame as the Forscan tests worked well but service procedures not available.

I am now going down the VAG COM route to see if I can get that software to work.

Richard. 

Aye I believe it's basically a VW Sharan under the skin.

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1 hour ago, Stoney871 said:

Aye I believe it's basically a VW Sharan under the skin.

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I think someone mentioned that earlier in the thread...

However, I don't think VAGCOM will work.  If you bought a new Galaxy you'd have it serviced at Ford, not VW, so it must use Ford software.  I have a feeling you'll only be able to access it with the proper Ford diags if it's not compatible with Forscan though.  

It's a shame we don't have any MK1 Galaxy regulars that could confirm.

I also don't think VAGCOM will work for the reasons stated above.

I don't know if the braking system is a Ford or Volkswagen one, but it might be worth checking the Volkswagen Forums to see if your problem is a common one and if there is a fix. 

I think someone mentioned that earlier in the thread...
However, I don't think VAGCOM will work.  If you bought a new Galaxy you'd have it serviced at Ford, not VW, so it must use Ford software.  I have a feeling you'll only be able to access it with the proper Ford diags if it's not compatible with Forscan though.  
It's a shame we don't have any MK1 Galaxy regulars that could confirm.

Didn't notice that vw reference.

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I am still trying the VAG-COM route at present just to see if it will work.

However I am unable to download the VCDS-Lite release 1.2 software to run with my KKL VAG-COM for 409.1 cable.

(the execute program box does not appear after pressing the download button).

Does anyone know the reason why?

Richard