Document 4J6BOavVzjQLOR8BQJ847oNzQ

FILE NAME: Ford (FD) DATE: 1988 DOC#: FD244 DOCUMENT DESCRIPTION: Car Shop Manual V-- ; *?;;>-V & - - r..-A r:far tgl it y n ^ r r lp w n i^ o r d C r o w n V ic t ii ssssS sr Auxiliary Equipment Body Shell, Exterior Him, Frame And Underbodv - Brakes '* Charaina System Doors, Hood, Luggage Compartment Door And Liftoate ' Identification Codes Instruments, Clusters, Controls And . Warning Systems Liahtfna System Maintenance And Lubrication Noise. Vibration And Harshness Seats Speed Control Steering Suspension Top And Exterior Finishes Trim, interior Ventilating, Heating And Air Conditioning Wheels And Tires Window Glass And Mechanisms Window Glass. Stationary Wiring Harnesses, Co' '*s And Circuit Protection e 35 47l 12 K 31 1 E 44 W 10 f 33 ,m 32 9 50 | 1P | 41I 37 5 13 ! 14 *f 4t) B 45 1 36 f 11 i 42 1 43 ;-d4( : mm^mmL \ . 'iS y } x ' r ch as r_r and - . r *}$:: i * . - ;s. v . : ' u1'K(- '/'.' % :''-S S & ?* * ' Ford Parts and Servie OvisOn Training and Publications D e p a rtm e n t U --f v- 'itches, loose hanging jewelry. rj w ork on a vehicle. = DEFENDANT'S ! EXHIBIT %* V^ 2. SHOP 02550 .,,TM irenPV fO R D 12-01-1 GROUP SECTION TITLE PAGE BRAKE BOOSTER, V AC U U M DASH M O U N T ED .............................................. 12-50-1 BRAKES, DISC-- SINGLE PISTON, SLIDING CALIPER-- F R O N T ............................. 12-20-1 BRAKES, DRUM-- SINGLE CYLINDER, DUAL PISTON-- R E A R .......................................12-02-1 (2000) SECTION TITLE PAGE BRAKES, HYDRAUUC--S E R V IC E ......................12-01-1 PARKING BRAKE, CABLE ACTUATEO - R EA R WHEELS .............................................. 12-70-1 SECTION 12-01 Brakes, Hydraulic--Service SUBJECT PAGE ADJUSTMENTS Brake Vacuum Booster Push Rod-ToMaster C y lin d e r ......... ................................12-01-24 Hydraulic System Bleeding ......................... 12-01-25 Manual B le e d in g .......................................... 12-01-25 Pressure B le e d in g ...................................... 12-01-26 Pressure Dllterential valve-- Centralizing . . . 12-01-26 CLEANING AND INSPECTION Brake B o o s te r ................................................12-01-32 Brake Hose ................................................... 12-01-33 Brake T u b in g ..................................................12-01-32 Disc Brakes ....................................................12-01-31 Drum Brakes ..................................................12-01-32 Hydraulic Lines .............................................. 12-01-32 DESCRIPTION Ford Crown Victoria/Mercury Grand M a rq u is......................................................... 12-01-3 Brake System-- D u a l.....................................12-01-3 Fluid Level In d ic a to r.....................................12-01-3 Master Cylinder ............................................ 12-01-3 Metering V a lv e .............................................. 12-01-3 Pressure Control V a lv e s ............................... 12-01-3 Lincoln Town Car ............................................ 12-01-2 Brake System-- Dual ..................................... 12-01-2 Metering V a lv e ....................................................12-01-2 Pressure Differential V a lv e ............................12-01-2 Proportioning V a lv e .......................................12-01-2 DIAGNOSIS AND TESTING Brake Pedal Free Height M easurem ents....... 12-01-7 Brake Pedal Travel M easurem ent.................... 12-01-8 SUBJECT PAGE DIAGNOSIS AND TESTING (Contd.) Ford Crown Victoria/Mercury Grand M a rq u is .........................................................12-01-6 Brake System D iagno sis............................... 12-01-6 Diagnostic T e ch n iq u e s................................. 12-01-6 Master C y lin d e r............................................ 12-01-6 Lincoln Town Car ............................................ 12-01-3 Brake System D iagno sis............................... 12-01-3 Diagnostic Techniques ................................. 12-01-4 Hydraulic S yste m .......................................... 12-01-4 Master C y lin d e r............................................ 12-01-4 Technique No. 2 ............................................ 12-01-5 Technique No. 3 ............................................ 12-01-5 Technique No. 4 ............................................ 12-01-5 Technique No. 5 ............................................ 12-01-5 Technique No. 6 ............................................ 12-01-5 Power Brake Functional Test ..........................12-01-8 OVERHAUL Master C y lin d e r..............................................12-01-29 Assem bly ................................................... 12-01-31 D isa sse m bly ................................................12-01-29 In spectio n ................................................... 12-01-31 REMOVAL AND INSTALLATION Brake Control Valve Assembly ...................... 12-01-28 Brake Pedal ................................................... 12-01-28 Master C y lin d e r..............................................12-01-27 Metering Valve A sse m b ly............................... 12-01-28 SPECIAL SERVICE T O O LS ................................. 12-01-34 SPECIFICATIONS ..............................................12-01-33 VEHICLE APPLICAT IO N ...................................... 12-01-2 SHOP 02551 PRODUCED BY FORD IN MALLIA V FORD 12-01-2 Brakes, Hydraulic-- Service 12-01-2 VEHICLE APPLICATION Lincoln Town Car, Ford Crown Vicloria/Mercury Grand Marquis. DESCRIPTION W ARNING: DO NOT INHALE DUST FROM BR AK ES, CLUTCHES OR ASSO CIATED CO M PO NENTS. INHALATIO N OF DUST CONTAINING ASBESTO S FIBERS CAN BE INJURIOUS TO YOUR HEALTH AND COULD CA U SE CAN CER OR A SB ESTO SIS. COMPRESSED AIR O R BRUSHES MUST NOT BE USED TO CLEAN BRAKES, BRAKE DRUMS. CLUTCHES AND ASSOCIATED COMPONENTS. A VACUUM CLEAN ER EQUIPPED FOR THIS PURPOSE SHOULD BE CAREFULLY USED TO REMOVE ANY DUST. ADHERENT DUST SHOULD BE REMOVED WITH A DAMP CLOTH. A N Y DUST SH O U LD BE CONTAINED IN A S E A L E D AND LABELED BAG FOR DISPOSAL WEAR AN A PPRO VED HIGH EFFICIENCY CARTRIDGE OR AIR LINE RESPIRATOR AND USE EXTRA CAUTION TO AVOID BREATHING THIS DUST. USE NON-ASBESTOS REPLACEMENT PARTS WHENEVER POSSIBLE. Lincoln Town Car Brake System-- Dual T h e se vohfctos have a dual brake system consisting of a dual master cylinder and a 3-way brake control valve assembly. The master cylinder has two hydraulic supply reservoirs; the reservoir that is nearest to the dash panel furnishes brake fluid to the front wheel brakes, while the other, closest to the radiator, is used to supply fluid to the rear wheel brakes. The 3-way brake control valve assembly consists of a pressure differential valve, metering valve and a proportioning valve in an aluminum body. If unequal hydraulic pressure occurs between the front and rear brakes, the pressure differential valve will sense the condition, activate the brake warning lamp switch, and turn on the warning lamp at the instrument panel. The metering valve regulates the hydraulic pressure to the front disc brakes. The pressure to the rear brakes is controlled by the proportioning valve. Pressure Differential Valve As previously stated, the pressure differential valve senses an unbalanced hydraulic pressure condition between the front and rear brake system. When there is a pressure loss in either system during a brake application, the valve piston will move off center, causing the brake warning lamp to come on. The pressure differential valve is located in the central bore of the control vaive body. The warning lamp will shut off when the brake system is accurately serviced, properly bled, and the brakes are applied to center the piston. The brake warning lamp switch is mounted on top of the control valve body. Under normal conditions when the differential valve piston is centrally located, the spring-loaded, warning switch plunger fits into the piston's tapered groove leaving the contacts of the warning switch open. Metering Vaive The metering valve limits the hydraulic pressure to the front disc brakes until a predetermined front hydraulic pressure has been reached. It is found in the forward end of the control valve's central bore between the front brake inlet port and the two outlet ports. This location provides an access to the valve's bleeder rod for purging the front brake system after performing brake service. Refer to Hydraulic System Bleeding. Proportioning Valve The proportioning valve regulates the hydraulic pressure in the rear brake system. It is located between the rear brake system inlet and outlet ports on the control valve. When the brake pedal is applied, the full rear brake fluid pressure passes through the proportioning valve to the rear brake system until the valve split point is reached. Above its split point, the proportioning valve begins to reduce the hydraulic pressure to the rear brakes, creating a balanced braking condition between the front and rear wheels. The proportioning valve's split point and slope performance is listed in Specifications. ONT INLET bsaB outlet := v jr Outlet HJ801-E L SHOP 025S2 PRODUCED BY FORD IN PALLIA V FORD 12-01*3 Brakes, Hydraulic-- Service 12-01-3 DESCRIPTION (Continued) Ford Crown Victoria/Mercury Grand Marquis Brake System -- Dual ' The dual hydraulic brake system is a conventional, pedal-actuated system with a master cylinder, pressure control valve, brake tubes and hoses. The dual system is comprised of tront brakes in one hydraulic circuit and the rear brakes in another. The master cylinder has a com m on reservoir, brake pressure control valve, and a fluid level indicator, all combined in one assembly. Pressure Control Valves The valve is screwed into the master cylinder. It limits the pressure level at the rear brakes to minimize rear wheel skidding during hard braking. The sedan and station wagon use the same valve. NO TE: For service of the master cylinder, the pressure control valve must be removed prior to removal of the snap ring and pistons. Failure to remove the valve first will result in loss of bypass function and may damage the bore, internal seals, and pistons. To determine whether bypass function is intact, check for extension of plastic poppet (refer .to illustration). During reassembly, the valve must be installed after the pistons and snap ring. REAR OUTLET Metering Valve The metering valve limits the hydraulic pressure to the front disc brakes until a predetermined front hydraulic pressure has been reached. The valve has ASSY a bleeder rod for purging the front brake system after performing brake service. Refer to Hydraulic System Bleeding. METERING VALVE FRONT OUTLET M930S-A CONTROL VALVE ROTATED 90 D EG R EES INTO VIEW ' H479I-A M aster Cylinder The master cylinder has a plastic reservoir, screw-in , pressure control valve, a n d a fluid level indicator . combined in one assembly. It is a front/rear split system master cylinder, with the rear outlet in the primary side (nearest to the dash panel) and the front outlet in the secondary side. There is a bleed screw opposite the rear outlet to be used for bleeding the primary side. D o n o t bleed through the pressure co n trol valve. The secondary outlet can be bled in the usual manner. The fluid level indicator replaces the pressure differential valve and is contained inside ilie plastic reservoir. When the reservoir fluid level is low, the fluid level indicator switch activates the brake warning lamp. The pressure control valve is threaded into the ' 'aster cylinder body and regulates hydraulic P assure level at the rear brakes to minimize rear , wneel skidding during hard braking. A lso included is j a bypassing feature that allows lull rear brake "ssure during a front brake system failure. Fluid Level Indicator The fluid level indicator replaces the pressure differential valve u sed in the previous brake systems. It is contained inside the body of the m aster cylinder plastic reservoir and activates the brake warning lamp whenever fluid level is low. DIAGNOSIS AND TESTING Lincoln Town Car Brake System Diagnosis Brake System Diagnosis charts are provided to assist in a broad diagnosis of the brake system's m echanical and hydraulic problems. In addition to these charts, there are specific com ponent diagnosis charts that cover the Master Cylinder and Brake Control Valve Assembly. DOP 02933 12-01-4 Brakes, Hydraulic-- Service DIAGNOSIS A N D TESTING (Continued) 12-01-4 Alw ays check the fluid level in the master cylinder before perform ing the test procedures. if the fluid level Is not within 3.18mm (.12-inch) of the top of the master cylinder reservoirs, add Heavy Duty B rake Fluid C 6AZ-19542-A or DOT-3 equivalent. If a brake is lo cked and the v e h icle m ust be moved, open a bleeder screw on front and rear wheels to let out enough fluid to relieve the pressure. T his bleeding operation will release the brakes but w ill not correct the cause of trouble. Hydraulic System Two major problems can occur in hydraulic brake systems: internal and external leaks. Hydraulic brake systems and their components, the master cylinder and valves, do not cause the vehicle to vibrate or pull, the brakes to grab or squeal, or the brake pedal to pulse. In most cases, they will not even make the brakes drag: The sources of these problems are found elsewhere in the brake system, but it is always a good policy to first check the entire hydraulic system lor leeks before continuing to diagnose any other brake problems. Master Cylinder Usually, the first and strongest indicator of anything wrong in the brake system is a feeling through the brake pedal. In diagnosing the condition of the master cylinder, the Master Cylinder Diagnosis charts not only make use of pedal feel as evidence of a brake problem, but also employ two other problem indicators, such as the illumination of the brake warning lamp and the brake fluid level In the master cylinder reservoirs. Note that the procedures refer to the use of diagnostic techniques. These techniques (Numbers 1 through 6) follow the diagnostic procedures. Normal Conditions The following conditions are considered normal and are not indications that the master cylinder is in need of service. C o ndition 1: Unequal brake fluid le v e ls in master cylinder reservoirs on front disc/rear drum b rake v e h ic le s . This condition is caused by displacement of fluid Irom the reservoir into the calipers to compensate lor normal lining wear. Top off the reservoirs. C o n d ition 2: A m om entary or slig h t squirt of brake fluid from one or both m aster cylinder reservoir cham bers upon application of brake pedal. This condition is caused by the fluid displacement through the reservoir compensating port(s) as the master cylinder pistons move forward m the bore when the brakes are applied. C ondition 3: A slight turbulence In the reservoir fluid occurring when the brake pedal Is released. Turbulence occurs as brake fluid relurns to the master cylinder after releasing the brakes. C o ndition 4: A trace o f brake fluid exists on b o o ste r sh e ll below the m aster cylin d e r m ounting flange. This condition results from the lubricating action of the master cylinder wiping seal. Abnorm al Conditions Changes in brake pedal feel or travel are indicators that something could be wrong-in the brake system. The diagnosis procedures and techniques In this Section use brake pedal feel, the warning lamp illumination, and brake fluid level as indicators in diagnosing brake system complaints. C o n d ition 1: Pedal goes down fast. This could be caused by an external or internal leak. C o n d ition 2: Pedal eases down slowly. This could be caused by an external or internal leak. C o n d ition 3: Pedal Is low and/or feels spongy. This condition may be caused by no fluid in the reservoir, reservoir cap vent holes clogged, rear brakes out of adjustment, or air In the hydraulic system. C o n d ition 4: Pedal effort excessive. This may be caused by a bind or obstruction in pedal/linkage, or insufficient booster vacuum. C o ndition 5: Rear brake lockup during light pedal force. This may be caused by wrong tire pressure, grease or fluid on linings/dam aged linings, improperly adjusted parking brakes, or damaged/ contaminated proportioning valve. C o ndition 6: Erratic pedal effort. This condition could be caused by brake booster malfunction, or extreme caliper piston knock back. NOTE: Prior to performing any diagnosis, ensure the brake system warning tamp is functional. The diagnosis techniques and service procedures are referenced in the Brake Master Cylinder Diagnosis charts. Reler to these charts for proper use of diagnosis techniques in diagnosing brake hydraulic system problems. Diagnostic Techniques Technique No. 1 A ir Trapped in Brake System 1. Remove master cylinder reservoir cap and verify that both reservoir chambers are filled with fluid. 2. Place the cap loosely on the master cylinder SHOP 02554 PRODUCED BY FORD IN MALLIA V FORD 12-01-5 Brakes, H ydraulic-- Service 12-01-5 DIAGNOSIS A N D TESTIN G (Continued) 3. With one technician acting a s an observer at the master cylinder and another technician . applying the brakes, pump the brakes rapidly 20 times. 4. O n the final application, hold the pedal in the applied position. 5. Rem ove the cap, and observe the fluid in the reservoirs. Quickly release the brake pedal. A geyser up to 15cm (6 inches) high will spout from the reservoir if the system h as air in it NOTE: Pumping the brake pedal compresses trapped air. When the brake pedal is released, the com pressed air expands, forcing brake fluid back into the master cylinder with sufficient . force to form a geyser. 6. Bleed the system in which the geyser occurs. Technique No. 2 M aster C ylinder Bypass Condition-- Check 1., Rem ove the master cylinder reservoir cap, and verify that both reservoir cham bers are filled with fluid. 2. With the reservoir cap removed, observe the fluid levels in both chambers, when the brake pedal is slowly depressed for one stroke and then quickly released. If the fluid level in a reservoir rises while the pedal goes down and drops when the pedal is released but the overall fluid level in the reservoir remains unchanged, the master cylinder is bypassing. Service the master cylinder. Technique No. 3 Checking the Cause of an Em pty Reservoir without an External Pressure Leak An empty reservoir condition may be caused by two types of non-pressure external leaks: T ype 1: A n external leak may occur at the master cylinder reservoir ca p b e cause o l im proper positioning of the gasket and cap. Reposition the cover and gasket assembly. T yp e 2: A n external leak may occur at the mounting end of the master cylinder because of a bore end seal leak. Service such a master cylinder. Technique No. 4 External Fluid Leaks-- Check It is p ossible that all evidence of fluid leakage may have been washed off if the vehicle has been operated in rain or snow, as brake fluid is water soluble. R efill the system, bleed, and apply the brakes several times. Examine the system to verify if the reservoir level is actually dropping. Locate and correct the external leak. Technique No. 5 Brake Pedal Reserve-- Check Vacuum -Powered Brakes On vacuum-power brake equipped vehicles where a low pedal or the feel of a bottomed out condition * exists, check for brake pedal reserve using the following procedure: 1. Operate the engine at idle with the transmission in either P A R K or N E U T R A L position. 2. Apply the brake pedal until it stops moving downward or an increased resistance to the pedal travel occurs. NOTE: A clunk may be felt a s the pedal reaches this point. 3. Hold the pedal in the applied position, and raise the engine speed to approximately 2,000 rpm. 4. R e le a se the accelerator pedal, and observe if the brake pedal m oves downward as the engine returns to idle speed. NOTE: The additional movement of the brake pedal is the result of the increased, engine manifold vacuum which exerts more force on the brake booster during engine run down. This m eans that additional stroke is available in the m aster cylinder, and the brake system is not bottoming out as a customer may believe. Technique No. 6 Checking the M aster C ylinder for Open Com pensator Port(s) 1. Push brake pedal, and observe the fluid in master cylinder reservoirs. 2. A sm all spout should appear in one or both reservoirs upon brake application. 3. If no spout appears, loosen the master cylinder attaching bolts 6.0mm (.25 inch), hold the master cylinder out, and check for open com pensator port(s) as above. 4. if com pensation now occurs, verify booster push rod length and adjust if required. If not. service m aster cylinder. Alw ays check the fluid level'm the master cylinder before performing the te st procedures. If the fluid level is not within 3.18mm (. 12 inch) of the top of the master cylinder reservoirs, add Heavy Duty Brake Fluid C6AZ-19542-A or D OT-3 equivalent. If a brake is locked and the vehicle must be moved, open a bleeder screw to let out enough fluid to relieve the pressure. T his bleeding operation will release the brakes but will not correct the cause of trouble. SHOP 02555 PRODUCED BY FORD IN MAt-LIA V FORD 12-01-6 Brakes, Hydraulic-- Service 12-01-6 DIAGNOSIS AND TESTING (Continued) Ford Crown Victoria/Mercury Grand .Marquis Brake System Diagnosis ` Diagnosis of mechanical and hydraulic problems associated with the brake system is covered in this Section. In addition to the Brake System Diagnosis charts, further specific diagnosis charts are furnished for the master cylinder, brake control valve and the vacuum brake booster. Alw ays check the fluid level In the m aster cylinder before perform ing the test procedures. If the fluid level is not at the "M AX line on the master cylinder reservoirs, add Heavy Duty Brake Fluid (ESA-M6C25-A) C6AZ-19542-A or DOT-3 equivalent CAUTION: Use o f any other than the approved DOT 3 brake fluid w ill cause perm anent damage to brake components and will render the brakes inoperative. II a brake Is lo ck e d and the ve hicle m ust be moved, open a bleeder screw to let out enough fluid to relieve the pressure. This bleeding operation will release the brakes but wHl not correct the cause of trouble. Master Cylinder Normal Conditions The following conditions are considered normal and are not indications that the master cylinder is in need of service: Condition 1: New brake systems are not designed to produce as hard a pedal effort as in the p a st Complaints o l light pedal efforts should be compared to pedal efforts on another vehicle, same model and year. Condition 2: A trace ot brake fluid existing on the booster shell below the master cylinder mounting flange. This results Irom the normal lubncating action ol the master cylinder bore end seal. Condition 3: Fluid level will decrease with pad wear. Abnormal Conditions Changes in brake pedal feel or travel are indicators that something could be wrong in the The following conditions use brake pedal reel ano the warning lamp along with reservoir indicators in diagnosing brake system complaints. Condition 1: Pedal goes down la s t This could be caused by an external leak or internal leak. Condition 2: Pedal eases down slowly. This could be caused by an external leak or internal leak. Condition 3: Pedal is low and/or feels spongy. This condition may be caused by. no fluid in reservoir cap vent holes clogged, rear brakes out of adjustment, or air in the hydraulic system. C o n d itio n '4: Pedal effort excessive. This may be caused by a bind of obstruction in pedal/linkage or insufficient booster vacuum. C ondition 5: Rear brake lockup during light pedal force. This may be caused by wrong tire pressure, grease or fluid on linings/dam aged linings, improperly adjusted parking brakes, or damaged/ contaminated pressure control valve. Condition 6: Erratic pedal effort. This condition could be caused by brake booster malfunction, damaged fluid, control valve, or extreme caliper piston knock back. - C o n d ition 7: Brake warning lamp ON: This may be caused by low fluid level, ignition wire routing too d o se to fluid level indicator assembly, or float assembly damage. NOTE: Prior to performing any diagnosis, ensure that the brake system warning lamp is functional. The diagnosis techniques and service procedures are referenced in the Brake M aster Cylinder Diagnosis charts. Refer to these charts for proper use of diagnosis techniques in diagnosing brake hydraulic system problems. Diagnostic Techniques Technique No. 1 External Fluid Leake--Check It is possible that aD evidence of fluid leakage may have w ashed off, if the vehicle has been operated m rain or snow, as brake fluid is water soluble. Refill system, bleed, and apply the brakes several times. Examine the system to verify that the reservoir fluid level is actually dropping. Locate and correct the external leak. If fluid level drops and no external leak can be found, check lor a master cylinder bore end seal leak. Technique No. 2 Master Cylinder Bypass Condition Check 1. Check fluid in master cylinder. Fill reservoir if low or empty. 2 Observe fluid level in reservoir. If after several brake applications the fluid level remains the same, measure wheel turning torque required to rotate wheels with brakes applied as follows: Place transmission in N EU TRAL and raise front wheels off the ground. Apply brakes with a minimum of 445N (100 lbs) and hold for approximately 15 seconds. With brakes still applied, exert torque on front w heels to 101 N m (75 >-). 11 either wheel rotates, check internals of master cylinder and replace damaged parts. Technique No. 3 Reservoir Sealing Points-- Check An empty reservoir condition may be caused by two types ot non-pressure external leaks. SHOP 02556 PRODUCED BY FORD IN MALLIA V FORD 12-01-7 Brakes, Hydraulic-- Service 12-01-7 DIAGNOSIS A N D T E S T IN G (Continued) T ype 1: An external leak may occur at the master cylinder reservoir cap because of im proper positioning of the gasket and cap. Reposition cap and gasket. T ype 2: An external leak may occur at the reservoir mounting grommets. Service such a leak by installing new grommets. Technique No. 4 Brake Pedal Reserve-- Check Where a low pedal or the feel of a bottomed out condition exists, check for brake pedal reserve. 1 Operate engine at idle with the transmission in ' either P A R K or N E U T R A L position. 2. Depress brake pedal lightly three to four times. 3. Allow 15 seconds for vacuum to replenish booster. 4. Apply brake p e d a l until it sto p s m oving downward or an increased resistance to the pedal travel occurs. NOTE: This increased resistance may feel like something has bottomed out 5. Hold pedal irr applied position and raise the engine speed to approximately 2.000 rpm. 6. Release accelerator pedal and observe that brake pedal m oves downward a s engine returns to idle speed. NOTE- The additional movement of the brake p e d a f'is the result o f the increased engine manifold vacuum which exerts more force on the brake booster during engine rundown. This m eans that additional stroke is available n the master cylinder, and the brake system is not bottoming out a s a customer may believe. Brake Pedal Free Height Measurements Lincoln Town Car, Ford Crown Victoria/ Mercury Grand Marquis 1. With the engine running for full power brake operation and the parking brake fully released, measure the brake pedal free height. brake ped a l effo rt gauge ROTUNDA 1*0DEL 021^000! 2. Insert a slender, sharp-pointed prod through the carpet and sound deadener to the dash panel metal. Measure the distance to the center on top of the brake pedal pad. STEERING W H EEL RIM CHECKING VERTICAL POINTS STEERING COLUMN D E G R E E S STEEL MEASURING TAPE / GAUGE SURFACE NOTE: . A OtMEMSK) TO BE M EASURED TO SHEET METAL FROM TOP CENTER OF PAD. B DIMENSION TO B E M E A S U R E D P A R A L L E L TO THE VERTICAL CENTERLINE OF THE STEERING COLUMN WITH A 11 J N (13 L B S ) LO AO APPLIED TO THE CENTERLINE OF THE BRAKE PEDAL PAD. (CHECKS ON ROWER BRAKE VEHICLES MADE W ITH ENGINE RUNNING*. 1 VEHICLE LINCOLN TOWN CA R FORD CROWN VICTORIA/ 1M ERCU R * G R AN D MARQUIS FORD CROW N VICTORIA/ m ercury grand MAAOUIS j POUCE ONLY PEDAL FREE HEIGHT " A " (REF. O NLY) MAX. MIN. 206 28mm 187 96mm (8 2 INCHES) {7 4 INCHES) 218 4mm >2mrr> (8 6 INCHES) (7 8 INCHES) m axim um p e o a l TRAVEL (INCHES) 76 2mm (3 5 INCHES) tB 2mm (3 5 INCHES) H 3 t G 3. if the position of the pedal is not within sp ecificatio n , check the brake pedal for missing, worn, or damaged bushings, or taose attaching bolts, and replace them, if required. 4. If the p e d a l tree h e ig h t is s till out ol specification, check the brake pedal, booster o rm a ste r cylinder to be sure the correct parts are installed. Replace the worn or damaged parts as necessary. M M tt-C SHOP 02557 PRODUCED B Y F O R O IN M ALUA V FORD 12-01-8 Brakes, Hydraulic-- Service 12-01-8 DIAGNOSIS A N D TESTING (Continued) Brake Pedal Travel Measurement 1 Install the Brake Pedal Effort Gauge 021-00001 or equivalent on the brake pedal pad and check as follows. Refer to the illustration under Brake Pedal Free Height Measurements. Step 1.. 2. Hook a steel measuring tape to the brake pedal. Measure and record the distance from the brake pedal free height position to the reference point, which is at the six o clock position on the steering w h e e l n m . Refer to the illustration under Brake Pedal Free Height Measurements. Step 2. 3 With the steel tape still hooked to the brake pedal, depress the brake pedal hy pressing downward on the brake petal effort gauge Apply a 111 N (25 lb) load to the center of the pedal. Maintain the pedal 'o ^ n d m e a s u r e the distance from the brake pedal to the fixed reference point on the steering wheel ran parallel to the centerline of the steenng column. 4 The difference between the brake pe ta l [f height and the depressed pedal measuf^^ under a m N (25 lb) load should be 124mm (3.5 inches) maximum. 5 H the pedal travel is more than the maximum 5- dirnension specmcation. make severe reverse stops With a forward stop befwe each. Mov the v e h ic le in re ve rse and f o r w a r d f o r aoDroximatiafy 10 feet. Then, apply the brakes holding the brake pedal down until the vehtole is completely stopped. This will actuate ` e brak self-adjusters. If these stops do not bnng tne brake pedaf travel within specrfication make severaladditional forward and reverse stops as outlined above. fi If the second series of stops does not bring brake Dedal travel within specification, remove brake S f u m s ^ check the brake a l t e r s to ensure they are functioning. Check brake linings for wear or damage. Service or replace aH worn or damaged parts and non-functioning adjusters. Adjust the brake limng ou'SKle diameter to the approximate inside diameter or the brake drum with Brake Adj^tment Gaug D81L-1103-A or equivalent. Refer to section 12- 02. . If all the drum brake adjusters. ^ ake dnjm^ and brake shoe linings arefurcbonal and brake travel is not within specificatron check pedal assembly for missing or worn bushings or loose attachments. 3 If the above Steps do not bring the brake travel within specification, bleed the brake sys Power Brake Functional Test Vacuum Booster Inspect all hoses and connections. All unused vacuum connectors should be capped. Hoses and their connections should be property secured in oood condition with no holes or no collapsed areas. Inspect the check valve on the power unit for damage. . Booster Operation Check . 1. - C h e ck the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in PARK, stop theengine^ Depress the brake pedal several times to exhaust alt vacuum in the system. 3. W th the engine turned off araJaflyacuunrin the system exhausted, depress it in the applied position. Start theengine.if the vacuum system is operating, the pedal will move downward under If no motion is fell, the vacuum booster system is not functioning. 4 Remove the" vacuum hose from the brake ' booster check valve. Manifold vacuumshooM be available at the check valve end of thebose with the engine at idle speed and the transmission in N E U T R A L Ensure th a tafl unused vacuum outlets are property capped, hose co rre cto rs are properlyJ c u red- and vacuum hoses are in good condition. When it is established that available to the booster^connect ^ v* u u m hose to the booster, and repeat Step 3. np downward movement of the brake pedal is felt, replace the brake booster. 5. Operate the engine a minimum o flO s e ro n d s the check valve, then repeat the test If the pedal leets hard, replace the booster. If the brake pedal movement feels spongy, hleed the hydraulic system to remove air from the system. Refer to H ydraulic System Bleeding. 12-01-9 Brakes, Hydraulic-- Service DIAGNOSIS A N D T ES T IN G (Continued) B0 S,e' Dia9-- chart 12-01-9 CONDITION Brakes do not apply. Excesstve pedal travel or pedal goes to door. - Excessive pedal ellort to stop car. Spongy pedal. POSSIBLE SOURCE Insufficient brake tluid. Binding or damaged brake pedal linkage. Air in system. Loose brake tube end lutings. Malfunctioning master cylinder. * Drum brakes -- improperly adjusted. Loose wheel bearings -- Front. Loose or missing pedal bushings/ fasteners. Binding or damaged pedal linkage Engine vacuum loss Booster inoperative. Worn or contaminated linings Brake system. Air in system. Loose or improper brake pedal, pedal support, booster, master cylinder attachment. Brake system ACTION Add fluid, bleed system, check for leaks. Service as required. Bleed system. Tighten to specification Refer to Master Cylinder Diagnosis Guide. Check adjustment. Inspect brakes. Service as required. Adjust as required. Check and replace as required. Inspect Service as required - Check engine vacuum, and vacuum at check valve to booster. Service as required. Perform power brake (unction test or vacuum booster diagnosis inspect. Replace il necessary Inspect wheel cylinders or caliper pistons, restricted lines or hoses, contaminated brake lluid. improper operation of proportioning or metering valve Service as necessary. Bleed system Service as required. Inspect for damaged or distorted parts in brake caliper assemblies, cracked brake drums, mismachined anchor plates CH2957-D SHOP 02559 " PRODUCED BY FORD IN M ALUA V FORD 12-01-10 CONDITION Brakes Drag, Slow or Incomptele Release BRAKE SYSTEM DIAGNOSIS POSRIRI P PriMD/tf Parking brake cable out of adjustment or binding. Front wheel bearings out of adjustment. Blocked master cylinder compensator pons. On front disc brakes -- loose or missing innershoe clip. Brake adjustment (rear) On front disc brakes -- LH or RH shoes misassembied. Restriction in hydraulic system. Noise at Wheels When Brakes are Applied -- Snap or Clicks Wheel cylinders or caliper piston seizure. On drum brakes in three places -- brake shoes binding at backing plate ledges. On drum brakes in three places -- backing plate ledges worn On disc brakes -- loose or missing inner anti-rattle clip. On front disc brakes -- missing pm insulator. Noise at Wheels When Brakes are Applied -- Scrape or Grind On front disc brakes -- missing or loose pms. Worn brake linings Brake shoe interference with back of drum Binding at backing plate guide ledges Caliper to wheel or roior interference. Other brake system components: Warped or bent brake backing plate or splash shield, cracked drums or rotors. Tires rubbing against chassis or body Rotor to spindle interference. Use Disc Brake Caliper Slide Grease D7AZ-19590-A or equivalent ACTION Check cables for correct adjustment or bind. Check bearings for adjustment, wear, damage or bind. See Master Cylinder Diagnosis Guide. Inspect and replace tf required. Check and adjust. Check and service. Check and service. Check and service. Lubricate." Replace, and Jubneate Jedges. * Replace. Replace. Replace. Replace drums or rotors if heavily scored. Inspect. Replace as necessary. Lubricate. Replace as required. inspect and service. Inspect and service Replace as required. CH295B-D SHOP 02560 PRODUCED BY FORD IN MALUA V FORD 12-01-11 Brakes, Hydraulic-- Service DIAGNOSIS A N D TESTING (Continued) 12-01-11 BRAKE SYSTEM DIAGNOSIS - Continued CONDITION Noise at Wheels When Brakes are Applied -- Squeaks, Squeals, or Chatter POSSIBLE SOURCE Brake drums and linings, rotors and pads worn or scored. ACTION inspect, servies or replace. NOTE: Brake friction materials Inherently generate noise end heat In order to dissipate energy. As a result occasional squeal Is normal, and Is aggravated by severe environmental conditions such a* cold, heat wetness, snow, satt, mud, etc. This occasional squeal Is not a functional problem and does not Indicate any loss of brake effectiveness. Noise at Wheels. Brakes Not Applied -- Squeak or Squeal a On disc brakes -- missing or damaged brake pad Insulators. e On disc brakes -- burred or rusted calipers. Dirty, greased, contaminated or glared linings. Improper lining parts. On drum brakes -- loose lining rivets, weak, damaged or incorrect shoe retracting springs, loose or damaged shoe retaining pins, springs and dips, and grooved backing plate ledges. Wheeicover attachment. Loose wheel attaching lug nuts. Bent or warped backing plate causing interference with drum. Replace. Clean or deburr. Clean or replace. Lightly sand off glaze. Inspect for correct usage. Replace. Inspect, servied or replace. Seat covers with a rubber mallet. Service flanges or replace cover. Tighten to specification. Replace wheel if stud holes are damaged. Service or replace. Improper machining ol drum, causing interference with backing plate or shoe. Replace drum. Other brake system components: Loose or extra parts in brakes. Rear drum adjustment too tight causing lining to glaze. Worn, damaged, or insufficiently lubricated wheel bearings. On drum brakes -- weak, damaged or incorrect shoe retracting springs. On drum brakes -- grooved backing plate ledges. Improper positioning ol shoe in caliper. Outside diameter of rotor rubbing caliper housing. Improper installation ol disc brake anti-rattle dip. Inspect, service or replace as required. CH2950-D SHOP 02581 PRODUCED b y fo r d IN M A L L tA V FORD 12-01-12 Brakes, Hydraulic-- Service 12-01-12 DIAGNOSIS AND TESTIN G {Continued) BRAKE SYSTEM DIAGNOSIS -- Continued CONDiTION Noise at Wheels, Brakes Not Applied -- Growling, Click or Rattle POSSIBLE SOURCE Stones or foreign material trapped inside wheelcovers. ACTION Remove stones, etc. Loose grease cap. Loose wheel lug nuts. Service or replace. Tighten to specification. Replace it stud holes are elongated. Disc brake caliper -- loose or Inspect, service or replace. - missing anti-rattle clips or support pms. Drum brakes -- loose or extra parts. Inspect, remove or service. Brakes Putt to One Side Worn, damaged or dry wheel bearings. Unequal air pressure in tires. Inspect, lubricate or replace. Inflate tires to correct pressure. Grease or Huid on linings. Glazed linings. Replace. Loose or missing disc brake caliper attaching pins. Replace missing bolts. Tighten to specification. Improper size or type lining on one wheel. Replace with correct brake lining in axle sets. Stuck or seized wheel cylinder or calipers. Service or replace. Restricted brake lines or hoses. Service or replace. Other brake system components: Improper adjustment oi drum brakes. Inspect, service or replace as required. Improper positioning of disc brake shoe and lining in the caliper. Improperly adjusted, damaged or worn wheel bearings. Distorted drum brake linings. Missing, broken or stretched retracting or retaining springs and clips in arum brakes. CH2960-O SHOP 02562 PRODUCED BY FORD in m alu avfo rd 12-01-13 Brakes, Hydraulic-- Service 12-01-13 DIAGNOSIS A N D TESTIN G (Continued) CONDITION Brakes Grab or Lockup When Applied BRAKE SYSTEM DIAGNOSIS -- Continued POSSIBLE SOURCE Tires worn or incorrect pressure ACTION Inflate tires to correct pressure Replace tires with worn tread. Grease or fluid on linings -- damaged linings Inspect, service or replace. Improper size or type o<Imings. Replace with correct brake in axle sels. Other brake system components: Pins lor caliper attachment loose Of missing. Worn, damaged or dry wheel bearings. Improperly adjusted parking brake. Inspect, service or replace as required. Brake Warning Lamp On Hydraulic system Refer to Master Cylinder Diaqnosis Chart. e Shorted lamp circuit. Correct short in warning circuit e Parking brake not returned Refer to Parking Brake Will Not Release or Fully Fleturn Below Intermittent Loss ol Pedal e Brake warning lamp switch. e Loose wheel bearings. Replace. Adjust as required. ' Rough Engine Idle or Stall. Brakes Applied -- Power Brakes Only Vacuum leak in neutral switch. Perform Steps under Excessive Pedal Travel or Pedal Travel Goes to Floor. Check lines tor leaks. Service or replace as required. Vacuum booster Check vacuum booster lor internal leaks Replace if required. Parking Brake Control Will Not Latch (Manual Release) e Kinked or binding release cable. Control assemoly Inspect, service or replace Inspect, service or replace Parking Brake Control Will Not Latch (Automatic Release) Vacuum leak. e Vacuum switch. Service as required Test. Replace it necessary Parking Brake Wilt Not Release or Fully Return (Manual Release) e Control assembly e Cable disconnected. Control assembly binding. Service or replace Connect cable or replace. Service or replace. e Parking brake linkage binding Service or replace. e Rear brakes Parking Brake Will Not Release or Fully Return (Automatic Release) Vacuum line leakage or improper connections. Neutral switch Check rear brakes shoe retracting spnngs and parking brake levers On rear disc brakes verity levers return fully to released position Adjust cables or service caliper as required inspect and service Adjust or replace Control assembly. Service or replace CH2961-E SHOP 02S63 PRODUCED BY FORD IN M A L L IA V F O R D 12-01-14 Brakes, Hydraulic-- Service 12-01-14 DIAGNOSIS AND TESTIN G (Continued) VIBRATION WHEN BRAKES ARE APPLIED -- LINCOLN TOWN CAR TEST STEP RESULT ACTION TO TAKE AO |VERIFY CONDITION e Road lest vehicle without applying brakes at 40-80 km/h (25-50 mph). No vibration Vibration present A1 | REAR BRAKE VIBRATION GO lo A1. REFER to Section 18-01 to service this problem first REPEAT Slep. Road test vehicle with medium application on the parking brake only NOTE: Wllh manual releaae parking brake control, hold the parking brake release In release position during parking brake application. A2 SERVICE BRAKE VIBRATION e Road test vehicle with light and medium application on the pedal. GO to A2. CHECK rear drums lor excessive wear or runout. REFER to Section 12-02 lor rear drum brake procedures. REPEAT Step, or REFER to Section 12-25. Vehicle OK. CHECK front rotors tor excessive runout or cracks. REFER to Section 12-20 tor disc brake rotor procedures. REPEAT Step. SHOP 02964 PRODUCED BY FORD IN MALUA V FORD 12-01-15 B rakes, Hydraulic-- Service 12-01-15 DIAGNOSIS A N D T EST IN G (Continued) MASTER CYLINDER DIAGNOSIS -- LINCOLN TOWN CAR Brake Pedal Feel Conditions Diagnostic Action Condition 1 -- Pedal goes down last and brake ` warning lamp comes on. Condition 2 -- Pedal eases down slowly and brake warning lamp comes on. Pump brake pedal rapidly: II the brake pedal height builds up and holds, check lor ihe presence ol air. (Use Diagnostic Technique No. 1 ) II the brake pedal height builds up and then sinks down, check lor an external leak. (Use Diagnostic Technique No. 4) or a master cylinder by-pass (Use Diagnostic Technique No. 2.) II the brake pedal height fails to build up. check the fluid level in the master cylinder reservoir: If a reservoir is empty, add fluid; bleed the system; and check (or external teak. (Use Diagnostic Techniques No. 3 and No. 4 ) If the reservoirs are lull, check tor a gross master cylinder by-pass. (Use Diagnostic Technique No. 2.) This condition could be caused by an external leak in the brake system or an internal by-pass in the master cylinder. Apply the brakes several times while observing the lluid levels in the reservoirs. if the net fluid level in a reservoir eases down with each stroke cycle, check lor an external leak. (Use Diagnostic Technique No. 4) - It the lluid level in a reservoir rises while the pedal eases down and drops when the pedal is released, but the net fluid level remains unchanged, then service the master cylinder tor a fluid by-pass condition. Condition 3 -- Pedal is low and brake warning lamp does not come on. This condition may be caused by: air m the hydraulic system, or no lluid in one reservoir. II the reservoir is empty, add lluid. bleed, and check the system lor external leaks. (See Diagnostic Technique Nos. 3 and 4.) II the reservoir is lull, check tor the presence ol air in the hydraulic system (Use Diagnostic Technique No. 1) II this condition happens occasionally, check the front wheel bearings tor looseness. (Loose front wheel beanngs allow the disc rotor to knock the caliper piston back, creating excessive lining clearance ) Condition 4 - - Pedal feels spongy. This may be normal as newer brake systems are not designed to produce as hard a pedal as in the past To verily this, compare the pedal feel with another like vehicle. Check for the presence ol air in the hydraulic system. (Use Diagnostic Technique No 1). Condition 5 -- Pedal erratic -- no brake warning lamp. This may be caused by incomplete brake release, loose wheel beanngs. incorrect parking brake adjustment or blocked compensator holes m the master cylinder To verity, check wheel rotation and bearing tree play, parking brake tension and refer lo Diagnostic Technique No 6 lor master cylinder compensator hole check. SHOP 02565 PRODUCED BY FORD IN MALLIA V FORD 12-01-16 Brakes, Hydraulic-- Service 12-01-16 DIAGNOSIS A N D TESTIN G (Continued) BRAKE CONTROL VALVE DIAGNOSIS -- LINCOLN TOWN CAR Condition Diagnosis and Resolution 1. Premature front brake lock-up on wet or icy road during light pedal application and cold engine last idle operation. 1. Check tires and tire pressures. 2 Check brake linings for fluid, grease or other contamination. 3 Check and adjust engine idle lor normal dnving 4 Check metering valve by installing pressure gauges in front and rear bleed screws. Apply 1379 kpa (200 psi) to the system. Front brake system should read 620-965 kPa (90-140 psi) while rear system reads 1379 kPa (200 psi) 2 Rear brake lock-up during light brake pedal force. 5. Replace the brake pressure control valve it out oi specification. 1 Check tires and tire pressures. 2. Check brake linings lor fluid, grease or other contamination. 3. Install pressure gauges in the front and rear bleeder screw ports and apply 6897 kPa (1,000 psi) to the front brake system. The rear brake system pressure must be approximately 3445-4979 kPa 500-650 psi). 3. No rear brake lock-up under heavy brake pedal force. 4. Replace brake pressure control valve assembly if rear brake pressure is not within specification 1 Check tires and tire pressures. 2. Check brake linings for fluid, grease or other contamination. 3. Install pressure gauges in the front and rear wheel cylinder bleeder screw ports and apply 6897 kPa (1.000 psi) lo the front brake system. Tfw rear brake system pressure must be approximately 3448-4482 kPa (500-650 psi). 4. II no pressure is obtained, check lor damaged tubing 5. Replace the brake pressure control valve assembly d rear brake pressure is not within specification CH2943-0 SHOP 02566 PRODUCED BY FORD IN MALLIA V FORD 12-01-17 Brakes, Hydraulic-- Servie* 12-01-17 DIAGNOSIS A N D TESTIN G (Continued) EXCESSIVE BRAKE PEDAL EFFORT OR VACUUM LEAKS -- LINCOLN TOWN CAR TEST STEP AO VERIFY CONDITION RESULT ^ ACTION TO T AKE With engine oft, depress and release brake pedal live times to deplete all vacuum from boosler. Depress pedal, hold with light pressure. Stan ` engine. A1 | VACUUM BOOSTER LEAK TEST Pedal fals sightly, (o i< )^ GO to A1. then holds & > GO to A3. Run engine to medium speed, release accelerator and turn engine oH. Wait 90 seconds and apply brakes. Two or more applications should be power assisted. A2 POWER SECTION CHECK VALVE TEST Vehicle OK. GO to A2. Disconnect vacuum hose tor booster check valve at manifold. Blow into hose attached to check valve. Air passes through check valve ^ INSTALL new check valve and REPEAT Step A1. A3 ( POWER SECTION TEST Disconnect vacuum hose from booster check vacuum check valve. Run engine at idle. Check vacuum supply with a vacuum gauge. Air does not pass through check valve REPLACE booster. REPEAT Step AO. Above 40.5 kPa REPLACE booster. (12 in-Hg) and booster REPEAT Step AO. does not operate Below 40.5 kPa (12 In-Hg) ^ SERVICE or REPLACE vacuum hoaa and vacuum fittings. Also TUNE or SERVICE engine as required. REPEAT Step AO. CH3129-0 VACUUM BRAKE BOOSTER NOISE -- LINCOLN TOWN CAR TEST STEP RESULT ^ BO l VERIFY CONDITION ACTION TO TAKE e Run engine at fast idle lor 10 seconds or longer. Depress brake pedal and listen for noise. Compare results with known good system. Noise Vehicle OK. GOtoBI. B1 1 PUSH ROD ADJUSTMENT Check and adjust booster push rod. BLEED brake system. REPLACE booster. REPEAT Step BO. CH3130-E SHOP 02587 PRODUCED BY FORD IN M ALUA V FORD 12-01-18 Brakes, Hydraulic-- Service 12-01-18 DIAGNOSIS AND TESTIN G (Continued) SLOW OR INCOMPLETE BRAKE PEDAL RETURN -- LINCOLN TOWN CAR TEST STEP CO VERIFY CONDITION RESULT > ACTION TO TAKE Run engine at fast idle while making several brake applications. Pull brake pedal rearward with approximately 44.5 N (10 lbs) force. Release the pedal and measure the distance to the toe board. Make a heavy brake application. Release the brake pedal and measure the pedal to toe board distance. The pedal should return to its original position. C1 | BRAKE PEDAL BINDING Vehicle OK. GO to Cl. e Check pedal lo be sure H is operating Ireely. REPLACE booster. CORRECT any sticking or binding. REPEAT Step C l. CH3131-D SHOP 02588 PRODUCED BY FORD IN M ALUA V FORD 12-01-19 Brakes, Hydraulic-- Service 12-01-19 DIAGNOSIS A N D T E S T IN G (Continued) M ASTER CYLINDER DIAGNOSIS PED AL G O ES DOWN FAST -- FORD CROWN VICTOR!A/MERCURY GRAND MARQUIS TEST STEP RESULT ^ ACTION TO TAKE 0 VERIFY CONDITION Road test vehicle and depress brake pedal. A1 BRAKE FLUID LEVEL Vehicle OK. GO to A1. Check master cylinder brake fluid reservoir level. A2 PRESSURIZE SYSTEM GO to A2. CH ECK reservoir seating points (use Diagnostic Technique No. 3), ADD fluid and BLEED system. REPEAT Test AO. Pump brake pedal rapidly (five times). A3 BRAKE SYSTEM LEAKS Check lor external brake system leaks (use Diagnostic Technique No. 1). A4 MASTER CYLINDER BY-PASS TEST e Test lor master cylinder by-pass (use Diagnostic Technique No. 2). Pedal height builds up. ^ GO to A3. then sinks. Pedal height builds up ^ CH ECK rear brake and holds. adjustment and ADJUST it necessary, If condition Still exists. BLEED system for air. REPEAT Test AO. GO to A4. SERVICE as necessary, ADO fluid and BLEED system. REPEAT Test AO. System OK. 0P REPLACE damaged parts. ADD fluid and BLEED system. REPEAT Test AO. CH4600-A SHOP 02569 PRODUCED BY FORD INMALUAVFORD 12-01-20 B rakes, Hydraulic-- S ervice 12-01-20 DIAGNOSIS A N D TESTIN G (Continued) MASTER CYLINDER DIAGNOSIS -- Continued PEDAL EASES DOWN SLOWLY - FORD CROWN VtCTORIA/MERCURY GRAND MARQUIS TEST STEP BO VERIFY CONDITION RESULT ACTION TO TAKE Check if condition occurs during actual stopping application by depressing the brake pedal while the vehicle is moving. k Condition occurs only when vehicle is stationary. ^ No fiction required. (SEE Normal Condition No. 1.) B1 BRAKE SYSTEM LEAKS Condition occurs white GO to B1. vehicle is moving and braking performance is affected. Check for external brake system leaks. (Refer to Diagnostic Technique No. 1.) B2 MASTER CYLINDER BY-PASS TEST Test for master cylinder by-pass. (Reler to Diagnostic Technique No. 2.) GO to B2. SERVICE as necessary, ADO fluid and BLEED system. REPEAT Test 80. System OK. REPLACE damaged parts. ADD fluid and BLEED system. REPEAT Test BO. CH5470-A produced by ford in MALLIA V FORD 12-01-21 Brakes, Hydraulic-- S ervice DIAGNOSIS A N D T ES T IN G (Continued) 12-01-21 MASTER CYLINDER DIAGNOSIS PEDAL IS LOW AND/OR FEE LS SPONGY -- FORD CROWN VICTORIA/MERCURY GRAND MARQUIS TEST STEP CO VERIFY CONDITION RESULT ACTION TO TAKE Road test vehicle and apply brake pedal Vehicle OK C l BRAKE FLUID LEVEL CHECK GO to Cl. Check master cylinder brake lluid reservoir level GO to C2. C2 FILLER CAP VENT CHECK Check it tiller cap vent holes are clogged or dirty C3 BLEED BRAKE SYSTEM Bleed Drake system as descnbed in this section. C4 FRONT WHEEL BEARING AND ROTOR CHECK Adjust front wheel beanng. Refer to Section 11-10. Road test vehicle. CHECK reservoir sealing points (USE Diagnostic Technique No. 3). ADD fluid and BLEED system GO to C3 CLEAN as necessary REPEAT Test CO ' Condition corrected Condition persists Vehicle OK ^ GO to C4 Condition corrected Condition persists Vehicle OK ^ CHECK rotor lor thickness variation REFER to Section 12-20 CH5201-A SHOP 02571 PRODUCED BY FORD IN MALLIA V FORD 12-01-22 B rakes, H ydraulic---S e rvice 12-01-22 DIAGNOSIS A N D TESTING (Continued) MASTER CYLINDER DIAGNOSIS -- Continued PEOAL EFFORT EXCESSIVE -- FORD CROWN VICTORIA/MERCURV GRAND MARQUIS TEST STEP RESULT ^ ACTION TO TAKE DO VERIFY CONOITION e Depress brake pedal fully several limes. D1 BRAKE PEDAL LINKAGE TEST Vehicle OK. GO to 01. e Detach booster push rod from pedal pin and depress brake pedal fully. Pedal moves Ireely. Condition persists. CHECK booster vacuum availability as described under Vacuum Booster Diagnosis m this Section. ^ SERVICE or REPLACE brake pedal linkage. REPEAT Test DO. CHS202-A MASTER CYLINDER DIAGNOSIS -- Continued REAR BRAKE LOCKUP DURING LIGHT. BRAKE PEDAL FORCE -- FORD CROWN VICTORIA/MERCURV GRAND MARQUIS TEST STEP RESULT ^ EO | VERIFY CONDITION ACTION TO TAKE Road lesf vehicle and apply brakes lightly. Vehicle OK. E l TIRE INSPECTION Check lor excessive tire wear or improper tire pressures. Both rear lockup E2 BRAKE SHOE INSPECTION Inspect rear brake shoe linings lor grease or Huid on linings andor wear problems. E3 1 PRESSURE CONTROL VALVE TEST Install pressure gauges in LH Iron! and RH rear bleeder screws. Apply 6895 kPa (1000 psi) in the front brake system. The rear brake pressure must be between 3720-4270 kPa (540-620 psi). (O M GO to E3. GO to E2. SUBSTITUTE known good tires il worn. INFLATE to proper pressure. REPEAT Test EO. GO to E3. REPLACE il necessary. REPEAT Test EO. INSPECT parking brake and ADJUST as required. 0 > REPLACE valve. SHOP 02572 PRODUCED BY FORD IN M A L L I A V F O R D 12-01-23 Brake, Hydraulic---Servie 12-01-23 DIAGNOSIS A N D TESTING (Continued) MASTER CYLINDER DIAGNOSIS -- Continued EXCESSIVE AND/OR ERRATIC PEDAL TRAVEL -- FORD CROWN VICTORIA/MERCURY GRAND MARQUIS TEST STEP RESULT ^ ACTION TO TAKE FO VERIFY CONDITION Road test vehicle and apply brakes slowly. FI ROUGH ROAD TEST Road test vehicle under rough road conditions. Apply brakes slowly. F2 WHEEL BEARING CHECK Check lor loose wheel bearings. GO to Ft. GO to F2. Vehicle OK. GO to F2. CHECK rotor lor thickness variances. (REFER to Section 12-20 tor front disc overhaul procedures.) 0^ REPLACE wheel bearing II damaged. TIGHTEN wheel bearing assembly lo specification. REPEAT Test FO CH5204-A SHOP 02573 PRODUCED BY FORD IN M ALUAV FORD 12-01-24 B rakes, Hydraulic-- Service DIAGNOSIS A N D TESTIN G (Continued) 12-01-24 ^______ MASTER CYLINDER DIAGNOSIS - Continued BRAKE WARNING LAMP ON -- FORD CROWN VICTORIAfMERCURY GRAND MARQUIS ` TEST STEP GO | BRAKE FLUID LEVEL RESULT ^ ACTION TO TAKE Check master cylinder brake fluid reservoir level. G1 I BRAKE SYSTEM LEAKAGE Check reservoir sealing points and external brake system for leakage. (Refer to Diagnostic Techniques No. 1 and 3.) G2 | IGNITION WIRING CHECK GO to G2. GO to G1. FGI2L.L reservoir. GO lo SERVICE as necessary. ADD fluid and BLEED system. Check that ignition wiring is not within a 50.8mm (2 inches) radius of the reed switch Fluid Level Indicator (FLI) assembly. G3 FLOAT ASSEM BLY CHECK Check if float is stuck or if magnet is dislodged from float. GO to G3. REROUTE wiring as necessary. CHECK if ignition prove out circuit is working properly. REPLACE reservoir assembly. CH5477-A ADJUSTMENTS Brake Vacuum Booster Push Rod-ToMaster Cylinder The vacuum booster has an adjustable push rod (output rod) which is used to compensate for dimensional variations in an assembled booster. The push rod length is adjusted after each booster power unit has been assembled in production. A property adjusted push rod that remains within the booster after it was assembled in production should never require a service adjustment A booster that is suspected of having an improper push rod length will indicate either of the following: a. A push rod which is too long will prevent the master cylinder piston from completely releasing hydraulic pressure, eventually causing the brakes to drag. b. A push rod which ts too short will increase brake pedal travel and cause a clunk or groaning noise from the booster. II necessary, a booster push rod length can be verified with a push rod gauge using the following procedure: GAUGE DIMENSIONS -- 7 * 2 mm 13-INCHES} 31 75 mm (I IN C H E S ) / 12 7 mmn (0 5-INC:Hn) y: 24 9 mm (0 98-INCH) 76 2 mm (3-INCHES) 25 27 mm (O 996-INCH) __________ t ____ SHOP 02574 PRODUCED BY FORD IN MALLIA V FORD 12-01-25 A D JU S T M E N T S (Continued) Brakes, Hydraulic-- Service 12-01-25 1. W ithout d is c o n n e c tin g the bra ke tu b e s, disconnect the master cylinder, and set it away from the booster power unit. The m aster cylinder m ust be supported to prevent damaging the brake tubes. 2. With the engine idling, gauge and adjust the push rod length. A force of approximately 22.24 N (5 lbs) applied to the push rod with the gauge will ensure that the push rod is seated within the power unit. Manual Bleeding The primary and secondary (front and rear) hydraulic brake systems are individual systems and are bled separately. Bleed the longest line first on the individual system being serviced. During the complete bleeding operation, DO NOT allow the reservoir to run dry. Keep the . master cylinder reservoirs filled with Heavy Duty Brake Fluid C6AZ-19542-A or DOT-3 equivalent. Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. _ NOTE: On vehicles which have the master cylinder mounted at an angle to the horizontal, bleeding may be better performed if the vehicle is positioned so that the master cylinder is horizontal. 1. To bleed the brake system, position a suitable box wrench on the bleeder fitting on the brake wheel cylinder. Attach a rubber drain tube to the bleeder fitting. The end of the tube should fit s n u g ly around the bleeder fitting. 2. Submerge the free end of the tube in a container partially filled with clean brake fluid, and loosen the bleeder fitting approximately three-quarter turn. - 3. H ave an assistant push the brake pedal down slowly through its full travel. C lo se the bleeder fitting, then return the pedal to the full-released position. Repeat this operation until air bubbles ce a se to appear at the submerged end of the bleeder tube. 4. W hen the fluid is completely free of air bubbles, secure the bleeder fitting, and remove the 3. Install the master cylinder on the power unit. bleeder tube. Gradually alternate the tightening of the 5. Repeat this procedure at the brake wheel retaining nuts to 18-34 N -m (13-25 Ib-ft). cylinder on the opposite side. Refill the master 4. With the engine idling and the master cylinder reservoir cover removed, observe the fluid surface in the reservoirs when the brake pedal is applied rapidly. Some fluid movement should occur in the forward reservoir, if fluid surface movement did not occur, the push rod is adjusted too long and the procedure must be repeated to prevent eventual brake drag. cylinder reservoir after each wheel cylinder is bled, and install the master cylinder cover (cap on Ford Crown Victoria/M ercury Grand Marquis) and gasket. Ensure the diaphragm- type gasket Is properly positioned In the master cylinder cover. When the bleeding operation is completed, the fluid level should be filled to full or within 3mm (.12- inch) of the top of the reservoir or the MAX line indicated on the reservoir (Ford Crow n I Victoria/Mercury Grand Marquis). Hydraulic System Bleeding When any part of the hydraulic system has been disconnected for service or replacement, air may enter the system causing a spongy pedal action. Bleed the hydraulic system after it has been properly connected to ensure that all air is expelled. 6. If the primary (front brake) system is to be bled, repeat Steps 2 through 5 at the right front brake caliper and ending at the left front brake caliper. 7. O n F o rd Crow n V ic to ria /M e rc u ry Grand M arquis vehicles the master cylinder also has a ble e d e r fitting. Use the sam e procedure described in Steps 1 through 4 to bleed the m aster cylinder. 8. Alter disc brake service, ensure that the disc brake pistons are returned to their normal positions and the shoe and lining assemblies are properly seated. This is accomplished by depressing the brake pedal several times until normal pedal travel is established. SHOP 02575 PRODUCED BY FORD Ml IN M A tU A V FORD 12-01*26 A D JU S T M EN T S (Continued) Brake, Hydraulic-- Service 12-01-26 Pressure Bleeding For pressure bleeding, use a bladder-type bleeder tank only, such as the Rotunda Brake Bleeder 104 00064 or equivalent. This type bleeder, with a rubber diaphragm, separates the brake fluid from the pressurized air charge. . Bleed the longest lines first. The bleeder tank should contain enough new brake fluid to complete the bleeding operation. Use Heavy Duty Brake Fluid C6AZ-19542-A or DOT-3 equivalent. Never reuse brake fluid that has been drained from the hydraulic system . The tank sh ou ld be charged with approximately 69-207 k P a (10-30 psi) of air pressure. Never exceed 345 kPa (50 psi) pressure. 1. Clean all dirt from the m aster cylinder reservoir cover. 2. Rem ove the master cylinder reservoir cover and rubber gasket. Fill the master cylinder reservoir with the specified brake fluid. Install the pressure bleeder adapter tool to die master cylinder, and attach the bleeder tank hose to the fitting on the adapter. Master cylinder pressure bleeder adapter tools can be obtained from various manufacturers. Follow the instructions of the manufacturer to install the adapter. 3. If the rear wheel cylinders (the secondary brake system) are to be bled, use a suitable box wrench on the bleeder fitting at the right, rear brake wheel cylinder. Attacn a bleeder tube snugly around the bleeder fitting. 4. Open the valve on the bleeder tank to admit pressurized brake fluid into the master cylinder reservoir. ' 5. Submerge the rree end o f the tube in a container partially tilled with clean brake fluid, and loosen the bleeder fitting. 6. When air bubbles cease to appear in the lluid at the submerged end of the bleeder tube, close the bleeder fitting. Rem ove the tube. 7. Repeat Steps 4, 5 and 6 at the left rear wheel cylinder. 8. On front brakes, repeat Steps 4 ,5 and 6 starting at the RH from disc caliper and ending at the LH front disc caliper. On metering valves, the release rod must be pushed in and held while bleeding the primary brake system. 9. When the bleeding operation is completed, close the bleeder tank valve, and remove the tank hose from the adapter fitting. 10. After disc brake service, ensure disc brake pistons are returned to their normal positions and the shoe and lining assemblies are properly seated. This is accom plished by depressing the brake pedal several times until normal pedal travel is established. 11. Remove the pressure bleeder adapter tool from master cylinder. Fill the master cylinder reservoir on Lincoln Town Car, or lo the M AX line on Ford Crown Victoria/Mercury Grand Marquis. Install the master cylinder cover and ga ske t Ensure the diaphragm-type gasket is property positioned In the master cylin d e r cover. Pressure Differential Valve-- Centralizing Lincoln Town Car After any service or bleeding of the primary (front brake) or secondary (rear brake) system, the dual brake warning (amp switch should be shut off by centralizing the pressure differential valve's piston. T o centralize the pressure differential valve and turn off the warning lamp after a service operation, perform the following procedure: 1. Turn the ignition switch to A C C or ON position. 2. Depress the brake pedal and the piston will center itself, causing the brake warning lamp to go out (if it w as illuminated). 3. Turn the ignition switch to O F F position. 4. Before driving the vehicle, check operation of the brakes, and ensure that a firm pedal is obtained Hjura-o SHOP 02578 PRODUCED BY FORD IN MALUA V FORD 12*01-27 REM OVAL AND INSTALLATION Brakes, Hydraulic-- Service 12-01-27 Master Cylinder Removal . 1. Rem ove the brake tubes from the primary and secondary outlet ports of the master cylinder. 2. Rem ove the two nuts attaching the master cylinder to the brake booster assembly. 3. Slide the master cylinder forward and upward from the vehicle. Installation 1. Position the master cylinder assem bly onto the two studs on the booster assembly. 2. Install the attaching nuts. Tighten to 18-34 N m (13-25 Ib-ft). 3. Install the front and rear brake tubes to the master cylinder outlet ports. Tighten to 14-24 N-m (10-18 ib-ft). 4. Fill the master cylinder with the specified brake fluid to full or within 3mm (.12-inch) of the top of the dual reservoirs on Lincoln Town Car. Fill to the M AX line on reservoir on Ford Crown Victoria/Mercury Grand Marquis. Use Heavy Duty Brake Fluid C6AZ-19542-A or DOT-3 equivalent. 5. Bleed the master cylinder and the primary and secondary brake systems. 6. Operate the brakes several times, then check for external hydraulic leaks. ROUTE HOSE THROUGH ADJUSTABLE STRAP SI3M 7-S ON DASH PANEL. PULL STRAP SNUG AFTER INSTALLATION ACCELERATOR CABLE NS10967-S2 TIGHTEN TO B -U N ffi (6-1DL8FT) SPEED CONTROL DUMP VALVE NUT N62CK8I-S2 TIGHTEN TO 14-27 N m 0 0 -2 0 LB-FT) ROUTE HOSE BELOW ACCELERATOR CABLE AND B6L&W CRUISE CONTROL CA B LE IN THIS A R E A ROUTE HOSE FORWARO OP CRUISE CONTROL CABLE IN THIS A REA VIEW X PIN 30699-5IC0 VIEW V SPEED CONTROL PM MUST BE LOCKED IN P L A C E A S SHOWN 2005 ASSY FORO CROWN VICTORIA. MERCURY GRANO LUfiOOlS FLUIO LEV EL IN B R A K E MASTER CYLINDER MUST B E FR O M FU LL TC 6 35mm { 25 INCHES) FROM TOP MEASUREO AT LOW POINT O F RESERVOIR N0OOT97 S 2 N24001 9-6-S 3455 A S S V - * r=n. SPAC 13480 ASST ^V \ a* * ' y / w \ \v 26129 / ' V C ? ' )l\ 2 R E O D / ^ j VIEW A PUSH ROO 2Bt95 ASSY 360699-S100 o DIRECTION OPTIONAL CO LOR REO FOR IDENTIFICATION Nft0053B>S)00 INNER COWL 365759-S2 4 EOO T IG H T E N TO ift-33 N m ltO-25 L8-FT) 2A 302 ASSY VIEW X SHOP 02577 PRODUCED BY FORD IN M ALUA V FORD 12-01-28 Brake, Hydraulic-- Service R EM O VA L A N D INSTALLATIO N (Continued) 12-01-28 Brake Control Valve Assembly Lincoln Town Car Removal 1. Disconnect the brake warning lamp switch wire harness connector from the warning lamp switch. t 2. Disconnect the front brake system inlet tube and the rear system inlet tube from the brake control valve assembly. 3. Disconnect the LH and RH front brake outlet tubes from the brake control valve assembly. 4. Disconnect the rear system outlet tube from the brake control valve assembly. 5. Remove the screw that retains the brake control valve assembly on the frame. Rem ove the assembly from the vehicle. The brake control valve assembly is serviced only as an assembly. Installation 1. Position the brake control valve assembly on the frame. Install one mounting screw for frame mounting. Tighten to 10-14 N-m (7-11 Ib-ft). 2. Connect the rear brake outlet tube to the control valve assembly. Tighten the tube nut to 13.5- 24 N -m (10-18 Ib-ft). 3. Connect the rear brake inlet tube to the control valve assembly. Tighten the tube nut to 13.5-24 N m (10-18 Ib-ft). 4. Connect the right front brake outlet tube to the brake control valve assembly. Tighten the tube nut to 13.5-24 N m (10-18 Ib-ft). 5. Connect the left front brake outlet tube to the brake control valve assembly. Tighten the tube nut to 13.5-24 N-m (10-18 Ib-ft). 6. Connect the front brake inlet tube to the brake control valve assembly. Tighten the tube nut to 13.5- 24 N -m (10-18 Ib-ft). 7. Connect the brake warning lamp switch wiring harness connector to the brake warning lamp switch. Verify connection by turning ignition switch to START position; lamp must com e on. Also, confirm that the two locking fingers on the connector are locked into the switch. 6. Bleed the brake system and centralize the pressure differential valve. NOTE: During the brake system bleeding operation on vehicles equipped with a metering valve, the metering valve bleeder rod must be pushed in (pressure bleeding). Metering Valve Assembly Ford Crown Vlctoria/Mercury Grand Marquis Removal 1. Disconnect the front brake system inlet tube and the rear system inlet tube from the brake control valve assembly. 2. Disconnect the LH and RH front brake outlet tubes from the metering valve assembly. 3. Remove the screw that retains the brake control valve assembly on the frame. Remove ' the assembly from the vehicle. The metering valve assembly Is serviced only as an assembly. Installation 1. Position the metering valve assembly on the frame. Install one mounting screw for frame mounting. Tighten to 10-14 N -m (7-11 Ib-ft). 2. Connect the right front brake outlet tube to the brake control valve assembly. Tighten the tube nut to 13.5-24.N -m (10-18 Ib-ft). 3. Connect the left front brake outlet tube to the brake control valve assembly. Tighten the tube nut to 13.5-24 N m (10-18 Ib-ft). 4. Connect the front brake inlet tube to the brake control valve assembly. Tighten the tube nut to 13.5-24 N -m (10-18 Ib-ft). 5. Bleed the brake system. NOTE: During the brake system bleeding operation the metering valve bleeder rod must be pushed in (pressure bleeding). Brake Pedal Removal 1. Disconnect battery ground cable. 2. Disconnect the stoplamp switch wire connector from the switch. 3. L o o se n the b oo ste r nuts approxim ately 6.35mm (1/4-inch) at the pedal support. Rem ove the push rod retainer and nylon washer. Slide the stoplamp switch outboard along the brake pedal pin just far enough for the outer hole of the switch frame to clear the pin. Remove the switch by sliding it downward. Remove the black stoplamp switch bushing from the push rod. 4. Slide the push rod and nylon washer off the pedal pin. 5. Rem ove the locknut and then remove the pivot bolt, brake pedal, pivot spacer, and bushings from the pedal support. SHOP 02578 PRODUCED BY FORD IN MALUA V FORD 12-01-29 Brakes, Hydraulic-- Service R E M O V A L A N D IN STA LLA TIO N (Continued) OVERHAUL 12-01-29 Installation .-. 1 Apply a coating of S A E 10W4O engine oil to the bushings. Locate bushings and pivot spacer in the brake pedal hub. , 2 Position the brake pedal assem bly in the pedal support, and install the pivot bolt. Install the locknut. Tighten the nut to 14-27 N-m (10-20 Ib-ft). 3. Install the inner nylon washer (if the vehicle is not equipped with speed control), the master cylinder push rod, and the black stoplamp switch bushing on the brake pedal pin. Position the stoplamp switch so that it straddles the push rod with the slot on the pedal pin and the switch outer frame hole just clearing the pin. Slide the switch upward onto the pin andpush rod Slide the assembly inboard toward the brake pedal arm. Install the outer nylon washer and the push rod retainer. Lock retainer securely. 4 Tighten the booster attaching nuts to 18-34 ' N-m (13-25 Ib-ft). 5. Connect the stoplamp switch wire to the switch. 6. Connect battery ground cable. 7. Ch eck the brake pedal free height and travel measurements, as outlined. Master Cylinder Disassembly 1. C le a n the outside of the m aster cylinder thoroughly. Rem ove the cover and diaphragm on Lincoln Town C a r (cap and gasket on Ford Crow n V lctoria/M ercury Grand Marquis). Alw ays discard brake fluid. 2. O n Fo rd C ro w n V lc to ria /M e rc u ry Grand Marquis remove pressure control valve by unscrewing from m aster cylinder. The master cylinder internals cannot be removed unless the pressure control valve is removed. 3. D epress the primary piston, and rem ove snap ring from retaining groove at the open end of the bore. N O TE: If master cylinder is to be put into vise to aid in disassembly, mount into vise by flange only to avoid dam age to bore or reservo areas. SHOP 02579 PRODUCED BY FORD IN MAUUA V FORD 12-01-30 B rakes, Hydraulic-- Service 12-01-30 O V ER H A U L (Continued) 4. R e m ove prim ary and se co n d a ry p is to n assemblies Irom master cylinder. Tap open end of cylinder on bench to remove pistons. If . secondary piston does not readily com e out, apply air pressure to secondary outlet port to assist removal. Lincoln Town Car 5. On Lincoln Town Car vehicles if brass tube seats are not reusable, remove as follows: Using an Easy-Out tool, remove tube seats by threading tool firmly into seat and tapping tool and seat o u t COMER RETAINER 2B246 SHOP 02580 PRODUCED BY FORD IN MALLIA V FORD 12-01-31 O V E R H A U L (Continued) Brakes, Hydraulic-- Service 12-01-31 Inspection 1. Wash master cylinder body, especially bore, along with primary and secondary piston assemblies in clean brake lluid. Denatured or isopropyl alcohol can be used instead. 2. Inspect seals on primary and secondary piston assemblies lor cuts, nicks, scratches, or signs of wear and for presence of any blistering or swelling. B lis te r in g or s w e llin g In d ic a te s c o n ta m in a tio n o f b ra k e flu id by a petroleum -based so lve n t o r oil. In that ca s e , a ll ru b b er c o m p o n e n ts in the b ra ke hydraulic system m ust be inspected and replaced, and the entire system must be flushed with clean brake fluid to prevent recontam ination. R eplace the follow ing com ponents: 7. On Lincoln Town Car bleed m aster cylinder, and install plugs into outlet ports. Do not fill reservoir more than half full because the position of m aster cylinder in vehicle is not horizontal and can cause spillage. 8. Fill and bleed master cylinder on Ford Crown Victoria/Mercury Grand Marquis. 9. Install cap and diaphragm on master cylinder reservoir, and secure with bail wire retainer (Lincoln Town Car). 10. Install cap and gasket on master cylinder reservoir for Ford Crown Victoria/Mercury Grand Marquis vehicles. CLEANING AND INSPECTION Brake control valve (Lincoln Town Car). Metering valve (Ford Crown Victoria/Mercury Grand Marquis. Front brake caliper seals. Rubber front brake hoses. Rear wheel cylinder seals. - Disc Brakes 1. Remove the wheel and lire from the hub and rotor. 2. Inspect brake shoes and lining for wear. If the lining is worn to within 3mm (1/ 8-inch) of the shoe, replace all (four) shoe and lining Rubber rear brake hoses. assemblies (complete axle set) on front wheels Master cylinder reservoir diaphragm (Lincoln Town Car). as required. The rubber caliper pin insulators must be replaced when linings are replaced. Master cylinder cap gasket (Ford Crown Victoria/Mercury Grand Marquis). 3. inspect master cylinder bore for pitting, corrosion, or heavy wear. Heavy wear is characterized by scoring or galling of metal. NOTE: The aluminum body of the master cylinder is anodized. Some signs of bore wear 3. Visually check the caliper. If the caliper housing is leaking, it should be replaced, if a seal is leaking, the caliper must be disassem bled and new seals installed. If a piston is seized in the bore, a new caliper housing is required. Refer to Section 12-20 for disc brake rotor resurfacing procedure. on the anodized surface, as evidenced by Service Precautions * lighter areas of the anodized surface, are 1. Grease or any other foreign material must be M normal and not detrimental. Honing o f th e kept off the lining surfaces of the rotor and b o re o n aluminum m a ste r cy lin d e rs Is n o t external surfaces of the hub during service p erm itted as the a n o d ic co ating and operations. In handling the rotor and caliper hardness could be removed. assemblies, avoid deformation of the brake Assem bly rotor and nicking or scratching of brake linings. 1. On Lincoln Town Car vehicles replace tube 2. If a caliper piston is removed for any reason, the seats if they were removed. Tube seats can be piston seal must be replaced. replaced by either pressing in with a vise or by rapping in using a suitable sized brass or wood dowel. Be sure to remove any debris or chips which may form. Refer to illustration under Master Cylinder Disassembly, Step 4. 2. Dip replacement piston assemblies in Heavy Duty Brake Fluid C6A2-19542-A or DOT-3 equivalent for lubrication prior to assembly into 3. During removal and installation of a wheel assembly, exercise care not to interfere with the caliper splash shield or the bleeder screw fitting. 4. Front wheel bearing end play is critical and must be within specification. 5. To avoid bending or damaging the rotor splash cylinder. Attempting to assemble piston shield on lull right or left wheel turns, the vehicle assemblies with dry seals can ruin them. 3. Install secondary (smaller) piston assembly into bore, spring end first. must be centered on the hoist before servicing any front end components. 6. Riding of the brake pedal (common on left-foot 4. Install primary piston assembly, spring end first. applications) must be avoided during vehicle 5. Depress primary piston, and install snap ring. operation. i 6. O n Ford C row n V ic to ria /M e rc u ry G ra n d 7. Tfrhoemwthheeeblraankde trioretomr,uusntlbikee rdermumovebdraskeepsawrahteerley i I Marquis vehicles install pressure control valve by screwing into master cylinder. Tighten to the wheel, tire, and drum can be removed as a j 13-24 N-m (10-18 Ib-ft). unit. SHOP 02SB1 PRODUCED BY FORD INMALLIAVFORD 12-01-32 B rakes, Hydraulic-- S e rv ice 12-01-32 CLEAN IN G A N D INSPECTION (Continued) 9. Do not attempt to clean or restore any oil or grease-soaked brake linings. When . contaminated linings are found, they must be replaced in complete axle sets. 9. Always replace rubber caliper pin insulators when replacing linings. Do not lubricate the slide pins. 10. Caliper slide pins must be hand started into spindle before tightening. This is to ensure that the large diameter of pin is through outer shoe holes to prevent binding or bending. Be careful not to damage the rubber caliper pin insulator when inserting the slide pins. 6. Inspect the brake drum and, if necessary, refinish. The maximum inside braking surface diameter is shown on each brake drum. If the maximum inside braking surface diameter shown on the drum is exceeded either by wear or refinishing, the drum must be replaced. Refer to Section 12-02 for refinishing. Drum Brakes 1. Remove the wheel from the drum, and remove the drum. Refer to Section 12-02. 2. Removal of dust and dirt from brake assemblies should be done by using the Rotunda Brake Vacuum 091-00001 or Rotunda Brake Parts Washer 065-00016 or equivalent. WARNING: BRAKE ASSEMBLY DUST AND DIRT SH O U LD NOT BE R EM O VED BY BLOWING OFF WITH AN AIR GUN BECAUSE A HEALTH HAZARD FROM BREATHING ASBESTOS DUST MAY DEVELOP. 3. Inspect the brake shoes for excessive lining wear or shoe damage. If the lining is worn within .794mm (1/32-inch) of the rivet heads or if the shoes are damaged, they must be replaced. Replace any lining that has been contaminated with oil, grease, or brake fluid. Replace lining in axle sets. Prior to replacement of lining, the drum diameter should be checked to determine that the brake drum braking surface diameter is within specification by using the Rotunda Brake Drum Micrometer 010-00010 or equivalent If the braking surface diameter exceeds specification, the drum must be replaced. 4. Check the condition of brake shoes, retracting springs, hold-down springs, and drum for signs of overheating. If the shoes have a slight blue coloring, indicating overheating, the retracting and hold-down springs should be replaced. Overheated springs lose their puH and could cause the new lining to wear prematurely, if not replaced. If the brake drums are heat spotted, Indicating an o verh eated condition, they should be replaced. 5. Inspect all other brake parts, and replace any that are worn or damaged. Brake Booster Check the booster operation as noted under Power Brake Functional Test If the brake booster is damaged or inoperative, replace it with a new booster. The brake booster Is serviced only as an assembly. Including the check valve. Brake Tubing If a section ot the brake tubing becomes damaged, the entire section should be replaced with tubing of the same type, size, shape, and length. Copper tubing should not be used in a hydraulic system. When bending brake tubing to fit underbody or rear axle contours, be careful not to kink or crack the tube. Hydraulic Lines Double wall steel tubing is used throughout the brake system with the exception of the flexible hoses at the front wheels and at the rear axle housing brake tube connection. Alw ays bleed the applicable primary or secondary brake system after primary or se c o n d a ry brake system h o se or line re p la c e m e n t. Centralize the pressure differential valve after bleeding the system on Lincoln Town Car. All brake tubing should be properly double flared to provide good leakproof connections. Clean the brake tubing by flushing with clean brake fluid before installation. When connecting a tube to a hose, tube connector, or brake cylinder, tighten the tube fitting nut to specification. SHOP 02582 PRODUCED BY FORD IN MALLIA V FORD 12-01-33 Brakes, Hydraulic-- Service CLEA N IN G AND INSPECTION (Continued) 1 12-01-33 Brake Hose A flexible brake hose should be replaced if it shows signs of softening, cracking, or other damage. When installing a new front brake hose, position the hose to avoid contact with other chassis parts. Two new sealing washers should be used when a front hose is replaced. For all vehicle lines, engage the opposite end of the hose to the bracket on the frame. Install the horseshoe-type retaining clip, and connect the tube to the hose with the tube nut. A rear brake hose should be installed, so that it does not touch adjacent chassis parts or body. The white stripe on the hose should show no evidence of twisting. On rear drum brake vehicles, position the hose junction block on the axle, and attach with a bolt and lockwasher. Connect the rear brake tubes `to the junction block. Engage the front end of the hose to the bracket on the frame. Install the horseshoe-type retaining clip, and connect the tube to the hose with the tube fitting nut. SPECIFICATIONS TOftOUE SPECIFICATIONS D e scrip tio n Lincoln Town Car Hfl Lb-Ft Master Cyknder to Booster 18-34 13-25 Booster to Oasn Panel 18-34 13-25 Pressure Odferenlial (Metering) Valve Bracket Bolts and Nuts 6-15 7-11 Wheel Cybnde Bleeder Screw 10-20 7 5-15 Cakper Bleeder Screw - - Brake Hose Connection to Caliper 27-40 20-30 Brake Line Connection k>Rear Axle Housing, Integral Type 34-45 25-33 Hydraulic Tube Connections* 3.6 x 24 -- _ 716xW - - 1/2x20 - - M 6 x IB - - Brake Pedal Pivot Sltait Nut 14-27 10-20 *AI hydraulic tines must be tightened to the specific torque value and be free ot fluid leakage. Ford Crown Victoria/ Mercury Grand Marquis N*m Lb-FI 18-34 13-25 18-34 13-25 9-15 7-11 10-20 7 5-15 8 20 6-15 41-61 30-45 34-45 25-33 14-24 14-24 14-24 14-24 14-27 10-18 10-18 10-18 10-18 10-20 CH2963-H Vehicle Lincoln Town Car Ford Crown VtdcmaMercury Grand Marquis Type 3-Way Master Cylinder Pressure D iffe re n tia l Ves No Control Vshre Metering IN 3-Wey Stand Alone Proportioning S p lit Slope 300 9 15mm ( 36 meli) 300 10 16mm { 40 mehl CHS209-A BRAKE POPSTER AFFIXATIONS Booster Type end Size Vehicle Vacuum Single Diaphragm Lincoln Town Car Ford Crown Victona/Mercury Grand Marqua Sedan Ford Crown Vctona/Mercury Grand Marqua Station Wagon CH2962-E L MASTER CYUNOER BORE DIAMETER Vehicle mm Lincoln Town C ar 25 4 Ford Crown Victoria. Mercury Grand M arquis Inch t 0 CH3W6-C SHOP 02583 PRODUCED BV Fo r d IN MALLIA V FORD 12-01-34 SPECIAL SERVICE TOOLS B rakes, Hydraulic-- Service Tool Number T71P-U02A D81L-1109-A TOCL-4201-C D n crlp U o n Disc Rotor Surface 6*05 Brake Adjustment Gauge dial tovicator w ii Bracfcelry ' c h jisa o ROTUNDA EQUIPMENT Model 01000010 oet-ooooi 091-00001 005-00015 10440064 DeecrtgUon Brake Own Micrometer Brake Pedal EHort Gauge Brake and Clufcfi Service Vacuum Brake Pare Waster Brake Bleeder CHS190-A 12-01-34 SHOP 02584 PRODUCED BY FORD IR MALLIA V FORD 12-02-1 Brakes, Drum-- Single Cylinder, Dual Piston-- R ear 12-02-1 SECTION 12-02 Brakes, Drum--Single Cylinder, . Dual Piston-- Rear SUBJECT PAGE ADJUSTMENTS Brake Shoes ..................................................... 12-02-1 CLEANING AND INSPECTION .............................12-02-5 DESCRIPTION Brake System, Drum ........................................ 12-02-1 OVERHAUL ' Brake Drum Refinishing .................................. 12-02-5 Brake Shoes ..................................................... 12-02-5 R e lin in g ................................... 12-02-5 Wheel Cylinders ................................................12-02-5 SUBJECT PAGE REMOVAL AM) INSTALLATION Brake Backing P la te .......................................... 12-02-5 Brake Drums ......................................................12-02-2 Brake Shoes ......................................................12-02-3 Wheel Cylinder ...............................................12-02-4 SPECIAL SERVICE TOOLS ...................................12-02-7 SPECIFICATIONS .................................................. 12-02-0 VEHICLE APPLICATION........................................ 12-02-1 VEHICLE APPLICATION Lincoln Town Car, Ford Crown Victoria/Mercury Grand Marquis. DESCRIPTION WARNING: DO NOT INHALE DUST FROM BRAKES, CLUTCHES OR ASSOCIATED COMPONENTS. INHALATION OF DUST CONTAINING ASBESTOS FIBERS CAN BE INJURIOUS TO YOUR HEALTH AND COULD CAUSE CANCER OR ASBESTOSIS. COMPRESSED AIR OR BRUSHES MUST NOT BE USED TO CLEAN BRAKES, BRAKE DRUMS, CLUTCHES AND ASSOCIATED COMPONENTS. A VACUUM CLEANER EQUIPPED FOR THIS PURPOSE SHOULD BE CAREFULLY USED TO REMOVE ANY DUST. ADHERENT DUST SHOULD BE REMOVED WITH A DAMP CLOTH. ANY DUST SHOULD BE CONTAINED IN A SEALED AND LABELED BAG FOR DISPOSAL. WEAR AN APPROVED HIGH EFF ICIEN CY C A R T R I D G E OR AIR LINE RESPIRATOR AND USE EXTRA CAUTION TO AVOID BREATHING THIS DUST. USE NON-ASBESTOS REPLACEMENT PARTS WHENEVER POSSIBLE. Brake System, Drum These vehicles are equipped with front disc brakes and rear drum brakes. The front and rear brakes are actuated by separate hydraulic systems, so if a leak occurs in either system, the remaining system is still operative. The rear drum brakes utilize internal, hydraulically actuated, expanding brake shoes that are applied against a rotating brake drum. The m ost im portant fact co ntributing to the effectiveness of fhe braking force supplied by the drum brake is the brake shoe pressure or force directed against the drum (Fig. 1). With the vehicle moving in either the forward or reverse direction with the brakes >r the applied force of the brake shoe, pressing n jainst the brake drum, will increasingly multiply itself jecause the brake's anchor pin acts as a brake shoe stop and prohibits the brake shoe from its tendency to .iJow the movement of the rotating drum; this results in wedging action between the brake shoe and brake drum. The wedging action combined with the applied brake force creates a self-multiplied brake force. Another factor that contributes to the braking force supplied by the brake drum is the servo-action which results when one brake shoe pushes against the other. The brake force of the primary brake shoe is amplified by the force or pressure transmitted from the primary shoe to the secondary shoe through an adjuster screw, which acts as a connecting link between the two shoes (Fig. 2). Forward and reverse servo-action is also provided when the parking brake is applied. The parking brake is mechanically actuated by a cable system that pulls on the parking brake lever, causing the lever to pivot against the parking brake Ink located between the shoes (Fig. 2). Ires action expands the brake shoes, pressing them toward the brake drum. A D JU STM EN TS Brake Shoes After any brake service work, obtain a firm brake pedal before moving the vehicle. Adjusted brakes must not drag; wheels must turn freely. The hydrauBc drum brakes are self-adjusting and require a manual adjustment only after the brake shoes have been refined, replaced, or when the length of the adjusting screw has been changed while performing some other service operation. The manual adjustment is performed with the drums removed, using the tool and the procedure detailed below. When adjusting the rear brake shoes, check the parking brake cables for proper adjustment Ensure that the equalizer operates freely with the shoes centered on the backing plate. E n su re that the upper ends of the brake shoes are seated on the anchor pin. The parking brake link should have 0.127-0.64mm (0.005-0.025 Inch) end play after overcoming the load of the parking brake Rnk anti-rattle spring. To adjust the brake shoes: 1. Determine inside cSameter ot the drum braking surface, using Brake Adjustment Gauge D81L1103-A or equivalent (Fig. 3). SHOP 02585 IN M AJLXUA0VBFyOFRODR 12-02-2 Brakes, Drum-- Single Cylinder, Dual Plstnn-- Rear 12-02-2 FIG. 1 Brake Shoe Pressure Against Brake Drum 2. Adjust the brake shoe diameter to fit the gauge (Fig. 3). Hold the automatic adjusting lever out ot engagement while rotating the adjusting screw to prevent burring the screw slots. Ensure the adjusting screw rotates freely. If necessary, lubricate the screw threads with a thin, uniform coating of Multi-Purpose Long-Life Lubricant C1AZ-19590-B or equivalent h u i.f FIG. 3 Brake Shoes Adjustment 3. Rotate Brake Adjustment Gauge 081L-1103-A or equivalent around the brake shoes to be sure of the setting. 4. Apply a small quantity of Disk Brake Caliper Slide Grease D7AZ-19590-A or equivalent to the points where the shoes contact the backing plate, being careful not to get the lubricant on the linings. 5. Install the drums. Install the drum retaining nuts and tighten securely. 6. Install the wheels on the drums, and tighten the nuts to specification. 7. Complete the adjustment by applying the brakes several times with a minimum of 111 N (25 lbs) pressure (power brakes) while backing the vehicle. After each stop, the vehicle must be moved forward. 8. After the brake shoes have been properly adjusted, check the operation of the brakes by making several stops from varying forward speeds. REM O VAL AND INSTALLATION Brake Drums Removal 1. Raise the vehicle so the tire is clear of the floor. Refer to the Pre-Delivery manual. Section 50-04. 2. Remove the wheelcover and wheel. 3. Remove the drum retainer nuts, and remove the brake drum. If the drum will not come off, pry the rubber plug from the backing plate. Insert a narrow screwdriver through the hole in the backing plate, and disengage the adjusting lever from the adjusting screw (Fig. 4). 4. While holding the adjustment lever away from the screw, back-off the adjusting screw with the brake adjusting tool (Fig. 4). Be very careful not to burr, chip, or damage the notches in the adjusting screw, otherwise, the self-adjusting mechanism will not function properly. - S H O P 0286 PiiNnumDAa l?lrEiaDvafyoFrOdD 12-02*3 B rak es, Drum -- S>ng>e C ylin d er, D u al P isto n -- B e a r 12-02-3 Installation 1. Remove the protective coating from a new drum with carburetor degreasec Sand drum lightly and wipe with a cloth soaked with denatured alcohol. 2. Adjust the brakes as outlined under Brake Shoe Adjustments. Place the drum over the brake assembly and into position. 3. Install the drum retainer nuts and tighten securely. Install the wheel on the axle shaft flange studs against the drum, and. tighten the attaching nuts to specification. Install wheelcover. 4. Lower vehicle. . Brake Shoes Removal 1 With the wheel and drum removed, install Brake Cylinder Clamp 081L-1103-B or equivalent over the ends of the brake cylinder (Fig. 5). 2 Remove the shoe-to-anchor springs with Brake Shoe R and R Spring BT-11 or equivalent (Fig. 5), and unhook the cable eye from the anchor pin. 3. Remove the shoe guide (anchor pin) plate (Fig. 2). 4. Remove the shoe hold-down springs, shoes, adjusting screw, pivot nut, socket and automatic adjustment parts. 5. Remove the parking brake link, spring and retainer. Disconnect the parking brake cable from the parking brake lever. 6. After removing the rear brake secondary shoe, disassemble the parking brake lever from the shoe by removing the retaining clip and spring washer (Bg. 2). installation 1. Before installing the rear brake shoes, assemble the parking brake lever to the secondary shoe, and secure it with the spring washer and retaining clip. 2. Apply a light coating ol Brake Caliper Slide Grease D7AZ-19590-A or equivalent at the points where the brake shoes contact the backing plate. Be careful not to get any lubricant on the brake linings. FIG. 5 Retracting Spring--Removal 3. Position the brake shoes on the backing plate. The primary shoe with the short lining faces toward the front of the vehicle. The secondary shoe (long lining) faces rearward. Secure the assembly with the hold-down springs. Install the parking brake link, spring and retainer. Back-off the parking brake adjustment; then, connect the parking brake cable to the parking brake lever (Fig. 2). 4. Install the shoe guide (anchor pin) plate on the anchor pin. 5. Place the cable eye over the anchor pin with the crimped side toward the drum. 6. Install the primary shoe to anchor spring (Fig. 6). 7. Install the cable guide on the secondary shoe web with the flanged hole fitted into the hole in the secondary shoe web. Thread the cable around the cable guide groove (Fig. 2). It Is Imperative that the cable be positioned in this groove and not between the guide and the shoe web. 8. Install the secondary shoe-to-anchor spring (Fig. 6). Be certain that the cable eye is not cocked or binding on the anchor pin when installed. All parts should be flat on the anchor pin. 9. Remove the brake cylinder clamp after both shoeto-anchor springs have been installed. 10. Apply a thin, uniform coat of Multi-Purpose Long Life Lubricant C1AZ-19590-B or equivalent to the threads and the socket end of the adjusting screw. Turn the adjusting screw into the adjusting pivot nut (Fig. 2) to the limit of the threads, and then back-off one-half turn. Interchanging the brake shoe adjusting screw assemblies from one side of the vehicle to the other would cause the brake shoes to retract rather than expand each time the automatic adjusting mechanism operated. To prevent installation on the wrong side of the vehicle, the socket end of the adjusting screw is stamped with an R or L (Fig. 7). Place the adjusting socket on the screw and install this assembly between the shoe ends with the SHOP 02567 PRODUCED BY FORD IN MALLIA V FORD 12-02-4 Brakes, Drum-- Singlo Cylinder, Dual Piston-- Rear 12-02-4 adjusting screw toothed wheel nearest the secondary shoe. 12. Hook the cable hook into the hole in the adjusting lever. The adjusting levers are stamped with an R or L to indicate their installation on RH or LH brake assembly (Fig. 7). 13. Position the hooked end of the adjuster spring completely into the large hole in the primary shoe web. Connect the loop end of the spring to the adjuster lever hole. 14. Pull the adjuster lever, cable and automatic adjuster spring down and toward the rear, engaging the pivot hook in the large hole of- the secondary shoe web (Fig. 2). 15. After installation, check the action of the adjuster by pulling the cable between the cable guide and the adjuster lever toward the secondary shoe web, far enough to lift the lever past a tooth on the adjusting screw wheel. The lever should snap into position behind the next tooth, and the release of the cable should cause the adjuster spring to return the lever to its original position. This return action of the lever will turn the adjusting screw one tooth. If pulling the cable does not produce the action described, or if the lever action is sluggish instead of positive and sharp, check position of lever on the adjusting screw toothed wheel (Fig. 4). With the brake in a vertical position (anchor at the top), the lever should contact the adjusting wheel 4.763mm i .794mm (3/16 inch 1/32 inch) above the centerline of the screw. If the contact point is below this centerline, the lever will not lock on the teeth in the adjusting screw wheel, and the screw will not be turned. Perform brake shoe adjustment, o determine the cause of this condition: a. Ensure that the upper or anchor pin end of the cable is pulled toward the cable guide as far as possible and that the end fitting is pointing toward the cable guide. b. Check the cable end fittings. The cable should completely fill or extend slightly beyond the FIG. 7 Adjusting Screw and Lever Identification crimped section of the fittings. If it does not meet this specification, possible damage is indicated, and the cable assembly should be replaced. c. Check the cable length. Measure from the Inside edge ol the hook to the far edge of the anchor hole. The cable length for 279mm (11irtch) brakes is 282.6mm (11 1/B-inches). The tolerance on cable length is plus or minus ,397mm (1/64-inch). d. Check the cable guide lor damage. The cable groove should be parallel to the shoe web, and the body of the guide should lie flat against the web. Replace the guide if it shows damage. e. Check the pivot hook on the lever. The hook surfaces should be square with the body of the lever for proper pivoting. Replace the lever if the hook shows damage. f. Verify that the adjusting screw socket is property seated in the notch in the shoe web. 16. Ensure that the upper ends of the brake shoes are seated against the anchor pin and that the shoes are centered on the backing plate. If they are not seated, back-off the parking brake system adjustment to obtain 0.127-0.64mm (0.005-0.025inch) play alter overcoming the load of the parking brake link spring. Wheel Cylinder Removal 1. Remove the wheel and brake drum. 2. Remove the brake shoe assemblies. 3. Disconnect the brake tube from the brake cylinder at the backing plate. The tube wiH separate from the cylinder when the cylinder is removed from the backing plate. 4. Remove the wheel cylinder attaching bolts and remove the cylinder. Installation Wipe the end(s) of the hydraulic line to remove any foreign matter before making connections. 1. Position the cylinder on the backing plate, and finger-tighten the brake tube to the cylinder. SHOP 02588 PRODUCED BY FORD IN MALUA V FORD 12-02-5 Brakes, D ru m -S in g le Cylinder, Dual Piston-- Rear 12-02-5 2. Secure me cylinder to me backing plate by installing me attaching bolts. Tighten bolts to 14-28 N-m (10-20 Ib-ft). 3. Tighten the tube fitting nut to 14-24 N- m (10-18 Ibft) with Tube Nut Wrench 1112-144 or equivalent. 4. Install the links in me ends of the wheel cylinder, and install the shoes and adjuster assemblies. 5. Adjust me brakes. Install the brake drum and wheel. Bleed the brakes. Brake Backing Plate Removal 1. Remove me wheel and brake drum. Disconnect the brake line from the brake cylinder. 2. Remove the brake shoes, adjuster assemblies and the wheel cylinder. 3. Remove me axle shaft. Refer to the Powertrain manual, Group 15. 4. Remove the backing plate. Installation 1. The rear backing plate is mounted on the axle housing flange with four bolts. Tighten to 28-54 N-m (20-40 Ib-ft). 2. Install the rear axle shaft, seal, if required, and me new backing plate. Refer to the Powertrain manual. Group 15. 3. Install the wheel cylinder, and connect the brake line as indicated in preceding Steps. 4. Install the brake shoes adjuster assemblies. Connect me parking brake cable to me lever. 5. Adjust me brake shoes, and install the brake drums and wheels. Bleed the brake system, and centralize the pressure differential valve as outlined in Section 12-01. CLEANING AND INSPECTION 1. Use Rotunda Brake and Clutch Service Vacuum 091-00001 or equivalent to remove all dust from backing plates and interior of brake drums. 2. Inspect brake shoes for excessive lining wear or shoe damage. If fining is damaged or worn within 0.79mm (1/32-inch) of the rivet heads on riveted linings it must be replaced. Replace any lining that has been contaminated with oil, grease or brake fluid. Replace lining in axle sets only. Never replace just one shoe ot a brake assembly. Replace bom leading and trailing shoes. Prior to replacement of lining, drum diameter should be checked to determine that brake drum diameter is within specification. If braking surface diameter exceeds specification, drum must be replaced. 3. Check condition of brake shoes, retracting spring, hold-down springs, and drum for signs of overheating. If shoes have a slight blue coloring, indicating overheating, retracting and hold-down springs should be replaced. Overheated springs lose their tension and could allow new lining to drag and wear prematurely, if not replaced. 4. Inspect all other brake parts and replace any that are worn or damaged. 5. Inspect brake drum and, if necessary, refinish. The maximum inside diameter is shown on each brake drum. .It maximum inside diameter is exceeded either by wear or refinishing, drum must be replaced. OVERHAUL Brake Drum Refinishlng Minor sco res on a brake drum can be removed with sandpaper. D o not refinish drums to remove score marks. A drum surface which is highly polished can cause the brake to lock-up. This polished condition should be removed either with sandpaper or by reiinishing the drum. A drum that Is out of round sufficiently enough to cause vehicle vibration or noise when braking, should be refinished. Remove only enough stock to true-up the drum. Brake drum maximum inside diameter is show n on each drum. Refer to Section 12-01. If the maximum inside diameter shown on the drum Is exceeded either through wear or refinishlng, the drum must be replaced. Check the inside diameter of the brake drum with Brake Adjustment Gauge D81L-1103-A or Rotunda Brake Drum M icrom eter 010-00010 or equivalent. After a drum 3 refinished, wipe the refinished surface with a cloth soaked in clean denatured alcohol. If one drum is refinished, the opposite drum on the same axle should a lso be refinished to the sam e diameter. Brake Shoes Rellnlng Brake linings that are worn to within 0.79mm (1 /32-inch) of a rivet head or have been contaminated with brake fluid, grease or oil must be replaced. Failure to replace worn linings will result in a scored drum. When it Is necessary to replace linings, they must also be replaced on the wheel on the opposite side of the vehicle. Inspect brake shoes for distortion, cracks or looseness. If these conditions exist, the shoe must be discarded. Do not attempt to service a damaged brake shoe. 1. W ash the brake shoes thoroughly in a clean solvent. Dry thoroughly. R em ove all burrs or rough spots from the shoes. 2. Check the inside diameter of the brake drum with Brake Adjustment Gauge D81L-1103-A or Rotunda Brake Drum Micrometer 010-00010 or equivalent 3. Position the new lining on the shoe. Starting in the center, insert and secure the rivets, working alternately towards each end. Replacement Wirings are ground and no further grinding is required. 4. C h e ck the clearance between the shoe and lining. The lining must seat tightly against the shoe with not more than 0.20mm (0.008 inch) clearance between any two rivets. Wheel Cylinders Wheel cylinders should not be disassembled unless they are leaking. Carefully pull lower edges of wheel cylinder boots away from cylinders to see if the interior o l the cylinder is wet with brake fluid. Excessive fluid at this point Indicates leakage past piston cups and a need for wheel cylinder overhaul. NOTE: A slight amount ot fluid is nearly always present and acts as a lubricant for the piston. It is not necessary to remove the brake cylinder from the backing plate to s h o p ozsee PRODUCED BY FORD IN MALUA V FORD 12-02-6 Brakes, Drum-- Single Cylinder, Dual Piston-- Rear 12-02-6 disassemble, inspect, hone and overhaul the cylinder. Removal is necessary only if the cylinder is damaged or scored beyond service. Disassembly 1 .. Remove the links and the rubber boots from the ends of the brake cylinder. Remove the pistons; cups, and return spring and expander assembly from the cylinder bore (Rg. 8). 2. Remove the bleeder screw from the cylinder. 3. Discard ail rubber parts, and wash all other parts in clean denatured alcohol. 4. Inspect pistons for scratches, scoring or other visible damage. Replace if necessary. Always discard the rubber caps and dust boots. 5. Inspect the cylinder bore for score marks or rust If either condition is present the cylinder bore must be honed. However, the cylinder should not be honed more then 0.08mm (0.003-Inch) beyond its original diameter. 6. Wash the cylinder with clean denatured alcohol after honing, and dry it with compressed air. 7. Check the bleeder hole to ensure it is open. Assembly Use all parts in the wheel cylinder service kit 1. Apply a light coating oi heavy duty brake fluid to all internal parts. 2. Thread the bleeder screw into the cylinder and tighten to specification. 3. Insert the return spring and expander assembly, cups, and pistons Into their respective positions in the cylinder bore (Rg. 8). Place a boot over each end of the cylinder. FIG. Brake Wheel Cylinder-- Typical SPECIFICATIONS SOBE CHAWCTERS -- BRAKE DRUM, W HEEL CYUWOCB, AMO MASTER CYUMOCR VrtW i Una*) 'fcwn Car SOI (302 CIO) Fad Down VictorW Mercury rand Marquis S w kn Wagon. P o ta , T a i and M a r Ibw FordCttwn Velona/ Mwcury Grand MkjU j Sedan Except Pofce, TW and Haler te r U m . Runout 0.007 Ua>. ADOMtHe Hon 0.003 10000 Brake Orun Boring L M (Ilex.) 10.000 11.030 11.090 10.000 10.060 n W WnNI vjWlOTs BO U OtMMtt (taw 0.9375 0.9375 0.9375 CH290W SHOP 02580 PRODUCED By FORD IN MAL LIA V FORD 12-02-7 Brakes, Drum-- Sin g le Cylinder, Dual Piston-- R ear 12-02-7 DBUM BR A K! UM MO DtMEHSiOMS PUCHES) Lincoln Iwwi Car, Ford Crown Vioona/Mercury Grant Marqua S.0L (302 CID) A l Ford Crown Vtona/Mercury Grand Marqua, Station Wagons and Sortons (Potreo) PooM on Primary Secondary Primary Secondary TORQUE SPECIFICATIONS Ottcrfptfon Wheel Cylinder K) Baching Ptale Screws Rear Brake Backing Plate to Axle Housng Wheel Cylinder Bleeder Screw W hHl to Hut) and Drum N-m 14.28 ' 28-54 10-20 96-155 Lb-ft 10-20 20-40 75-15 70-U 5 CH 2 9M -E SPECIAL SERVICE TOOLS Tool Number DB1L-1103-A OS1L-1103-8 DB1L-77060-A M *er 1112-144 ST-11 (Snap-On) Description Brake Adjustment Gauge - ' Brake Cylinder dam p Snap Ring Piers Tube Nut Wrencri Brake Shoe R and R Spring 00141-C Color Codo Orango-TMow Qray-yUow Orango-Vottow Gray-Yetow Brake S h a 10 10 It 11 Boor lin in g Stas 2-50 X 8.55 2.50 a 10.45 2X 5x9.38 2X5 X 12.12 CH2907-H ROTUNO E O U P M O flHoM 01000010 ' 08600010 091-00001 0MC0|pttMI Braks Drum Mkaomolor Braks Pans W M mt Brake and Cfckb Service Y teum o sm -A SHOP 02591 SECTION 12-20 Brakes, D isc-S in g le Piston, Sliding Caliper-- Front ' SUBJECT DESCRIPTION Anchor Plate ...................................................12-20-1 Brakes, Disc .................................................. 12-20-1 Caliper Assembly ........................................... 12-20-1 Rotor ............................................................... 12-20-1 Rotor and Splash Shield ..................... 12-20-1 DIAGNOSIS .............................................. ' 12-20-8 OVERHAUL Caliper ........................................................... 12-20-5 Rotor Retlnishing ........................................... 12-20-5 SUBJECT PAGE REMOVAL AND INSTALLATION Brake Shoa and Unkra ................... Caliper Assembly ............. Hub and Rotor ................. Rotor Splash SW ekf............. SPECIAL SERVICE TOOLS .. SPECIFICATIONS ............... VEHICLE APPLICATION........ ............. 12-20-2 ............. 12-20-2 t ........... 12-20-10 ............. 12-20-1 VEHICLE APPLICATION Lincoln Town Car, Ford Crown Victoria/Mercury Grand Marquis. DESCRIPTION WARNING: DO NOT INHALE DUST FROM BRAKES, C LU T C H E S OR A S S OCI AT E D CO M PO NENTS. INHALATION OF DUST CONTAINING ASBESTOS CIBERS CAN BE INJURIOUS TO YOUR HEALTH AND DOULD CAUSE CA NC ER OR ASBESTOSIS. COMPRESSED AIR OR BRUSHES MUST NOT BE USED TO CLEAN BRAKES, BRAKE DRUMS, CLUTCHES AND ASSOCIATED COMPONENTS. A VACUUM CLEANER EQUIPPED FOR THIS PURPOSE ?HOULD BE CAREFULLY USED TO REMOVE ANY OUST. ADHERENT DUST SHOULD BE REMOVED WITH A DAMP CLOTH. ANY DUST SHOULD BE CONTAINED IN A SEALED AND LABELED BAG FOR DISPOSAL. WEAR AN APPROVED HIGH =F I C I E N C Y C A R T R I D G E OR AIR L I N E RESPIRATOR AND USE EXTRA CAUTION TO AVOID BREATHING THIS DUST. USE NON-ASBESTOS REPLACEMENT PARTS WHENEVER POSSIBLE. Brakes, Disc 'rent disc brakes are standard on all vehicles. Drum orakes are used on the rear wheels. 'JOTE: Brake friction materials inherently generate Cise and heat to dissipate energy. As a result, .ccasional squeal is possible and it is aggravated by .evere environmental conditions such as cold, hot, wet, ;'.ow salt, mud, etc R o to r The cast iron disc is of the ventilated rotor-type. c;>rporating non-directional cooling tins, and is integral h the wheel hub. A splash shield bolted to the spindle - used to prevent road contaminants Irom contacting "~n inboard rolor surface and to direct cool air to the j *es. The wheel provides protection for the outboard "a c e of the rotor Caliper Assem bly The caliper assembly consists of a pin slider-type caliper housing, inner and outer shoe and lining assemblies and a single phenolic piston. The caliper assembly slides on two locating pins which also act to position the caliper and to attach the outer shoe to the combination anchor plate and spindle. The caliper housing contains a single phenolic piston. The piston has a moulded rubber dust boot on its outer end that attaches to a cylinder bore groove to prevent cylinder contamination. There is also a rectangular section rubber piston seal located in the cylinder bore providing sealing between the cylinder and piston (Fig. 1). A groove is also cut inside the phenolic piston lor inner brake shoe d ip retention. The outer brake shoe and lining assembly is longer lhan the inner sh oe and lining assembly. Both inner and outer shoe lining assemblies are attached to the caliper by spring clips. The inner and outer clip are riveted to the lining assembly. The inner shoe is attached to the caliper by installing the spring clip to the inside of the caliper piston. The outer shoe clips directly to the caliper housing. The outer shoes are RH and LH and must not be interchanged. Two rubber caliper pin insulators are installed in the caliper attaching holes. The Insulators prevent rnetaMo-metal contact between the locating pins and the caliper. Anchor Plate The anchor plate is an integral part of the spindle. Spindles are RH or LH, and are not interchangeable. Rotor and Splash Shield The rotor is a cast iron disc design, similar to existing designs, which attaches to the combination spindle/ anchor plate in the same manner as existing front disc rotors. The splash shield is made of a glass filled nylon material. Attachment ot the shield to the spindle is accomplished by using three bolts. SHOP 025B2 PRODUCED BY FORD IN MALLIA V FORD 12-20-2 Brakes, Disc-- Single Piston, Sliding Caliper-- Front 12-20-2 REM OVAL AND INSTALLATION Service Precautions 1. Grease or any other foreign material must be kept off lining surfaces and braking surfaces of rotor, and external surfaces of hub during service operation. In handling rotor and caliper assemblies, avoid deformation, nicking or scratching of brake linings and rotor. 2. If a caliper piston is removed for any reason, piston seal and dust boot must be replaced. Exercise care not to damage plastic piston by protecting it from contact with any metal or sharp edged objects. 3. During removal and installation of a wheel assem bly, exerctse care not to interfere with or dam age caliper splash shield, if so equipped, or the bleeder screw fitting. Vehicle must be centered on hoist before servicing any front end components to avoid bending or damaging rotor splash shield, if so equipped, on full right or left wheel turns. 5. Do not attempt to clean or restore oil or greasesoaked brake lining. W hen contaminated linings are found, brake linings must be replaced in complete axle sets and rotor braking surfaces wiped clean. 6 The LH and RH calipers must be installed on the correct side of the vehicle to be sure bleed is in the topmost position for proper purging of air from the front brake system during bleeding. Caliper Assem bly Removal 1 Rem ove the wheel and tire assem bly from the hub Use care to avoid damage to, or interference witti the bleeder screw fitting during removal. ' . D isconnect the flexible brake hose from the raliper. To disconnect the hose, loosen the tube 'iitmg that connects the hose to the brake tube at the bracket on the frame. Plug the brake tube Remove the horseshoe-shaped retaining clip from the hose and bracket, disengage the hose from the bracket, then remove the hollow bolt that attaches the hose assem bly to the caliper. Mark the LH ana RH caliper and hose assem blies with chalk prior to removal from the vehicle so they can be positioned correctly during installation. 3. Remove the caliper locating pins (Fig. 2). 4. Lift the caliper from the integral spindle/anchor plate and rotor. Installation 1. Install the caliper assem bly over the rotor with the outer brake shoe against the rotor's braking surface. This prevents pinching the piston boot between the inner brake shoe and the piston. M ake sure the correct caliper is installed on the correcl anchor plate according to the way they were marked during disassembly. 2. Ensure the locating pins are free of oil, grease and dirt. Apply Ford Silicone Dielectric G rease D7AZ19A331-A or equivalent to locating pins and inside of insulators. 3. Connect the locating pins to the integral spindle/ anchor plate, the outer shoes and lining and the caliper insulators. Ensure the locating pins are free of oil, grease and dirt. The caliper locating pins must be hand inserted into the outer shoe and hand started. Ensure that the large diameter of the pins goes through the outer shoe holes so that possible binding or bending is prevented. Ensure that the caliper rubber insulators are not damaged during pin insertion. 4. Tighten caliper locating pins to 54-81 N -m (40-60 Ib-ft). 5. Install the flexible brake hose to the caliper with hollow bolt and two new sealing washers. Tighten hose fitting to 27-41 N -m (20-30 Ib-ft). 6. Position the upper end of the flexible brake hose in its bracket and install the retaining clip. Do not twist the hose. R em ove the plug trom the brake tube. Connect the brake tube to the hose with the tube fitting nut. Tighten to 13-24 N-m (10-18 Ib-ft). 7. Bleed the brake system and centralize the brake pressure differential valve. 8. Fill the master cylinder to F U LL or within 6.35mm (1/4-inch) from the top of the reservoir. 9. Install the wheel and tire assembly. Tighten wheel attaching nuts to 109-142 N -m (80-105 Ib-ft). 10. To position the brake linings, apply the brake pedal several times before moving the vehicle. 11. Road test vehicle. Brake Shoe and Lining Removal 1. Remove the m aster cylinder cap. Check fluid level in the primary (large) reservoir. Rem ove brake fluid unnl the reservoir is half fuii. Discard this fluid 2. Remove the wheel and tire assembly from the huo Be careful to avoid damage lo. or interference with the caliper splash shield vr bleeder screw fitting 3. Remove the calipe- locating Dins (Fig 2). SHOP 02593 PRODUCED bv fo r d IN MALLtA V FORD 12-20-3 Brakes, Disc-- Single Piston, Sliding Caliper-- Front 12-20-3 FIG. 2 Brake Components--Disassembly and Assembly 4. Lift the caliper assembly from the integral spindle/ anchor plate and rotor. Rem ove the outer shoe from the caliper assembly. 5. Remove the inner shoe and lining assembly. Inspect both rotor braking surfaces. Minor scoring or buildup of lining material does not require machining or replacement of rotor. 6. Suspend the caliper inside the fender housing. Be careful not to damage the caliper or stretch the brake hose. 2. Install new locating pin insulators in the caliper housing. Check to see if both insulator flanges straddle the housing holes. Do not attempt to install rubber insulators with a sharp edge tool. (Refer to Fig. 3 for installation tool that can help with insulator installation). 3. Install the correct inner shoe and lining assembly in the caliper piston(s). Care should be taken not to bend the shoe d ip s in the piston, or distortion and rattles can result. Installation '* Install the correct outer brake shoe and lining assembly (RH/LH), ensuring that the clips are 1. Use a 10cm (4 inch) C-clam p and a wood block property seated. The outer shoes are marked LH or 7cm (2 3 /4 -in c h ) x 2 .5 c m <1-in c h ) a n d R H and must be installed in the proper caliper. approximately 19mm (3/4-lnch) thick to seat the caliper hydraulic piston in its bore. Do not apply C- 5. Install the caliper to the rotor, and connect the clamp directly to phenolic piston surfaces. This must be done to provide clearance for the caliper assembly to tit over the rotor when it is installed with new linings. Remove the C-clamp from the caliper. (The caliper piston will remain seated in its bore). locating pins to' the integral spindle/ancnor plate, the outer brake shoe and lining, and the caliper insulators. Ensure the locating pins are free of oil. grease, and dirt The caliper locating pins must be hand inserted into the outer shoe a r il hand started prior to tightening. Ensure that the large diameter ________________ SHOP 025S4 PRODUCED BY FORD IN MALUA V FORD 12-20-4 B ra k e s , Disc?-- S in g le Platon . S lid in g C a lip e r-- f r o n t 12-20-4 of the pins is through the outer shoe hole to prevent possible binding or bending. 6. Install the w heel and tire assembly. Tighten the wheel attaching nuts to 109-142 N -m (80-105 Ibft). 7. Pump the brake pedal prior to moving the vehicle to position the brake linings. Refill the master cylinder. 8. Road test the vehicle. Hub and Rotor Removal Refer to Fig. 4. 1. Remove the wheel and tire from the hub. B e careful to avoid damage to, or interference with, the bleeder screw fitting and caliper splash shield. 2. Remove the caliper assembly from the spindle and the rotor a s outlined. If the caliper does not require servicing, it is not necessary to disconnect the brake hose or remove the caliper from the vehicle. Position the caliper out of the way, and support it with a wire to avoid damaging the caliper or stretching the hose. Insert a clean, cardboard spacer between the linings to prevent the inner and outer shoes from falling on the floor. Handle the rotor and caliper assemblies to avoid damage to the rotor and n ickin g , s c ra tc h in g or contamination of the brake linings. 3. Remove the grease cap from the hub. Rem ove the cotter pm, nut retainer and adjusting nut. ' Grasp the hub and rotor assembly, and pull it outward far enough to loosen the washer and outer w heel bearing. Push the hub and rotor back onto the spindle, and rem ove the washer and outer w heel bearing. 5. R em ove the hub and rotor assembly bom the spindle. Installation 1. If the rotor is being replaced, remove the protective coating from the new rotor with Carburetor and Combustion Cham ber Cleaner D9AZ-19579-B or equivalent. Pack a new set of bearings with Multi Purpose Long-Life Lubricant C1AZ-19590-B or equivalent, ana install the inner bearing cone and roller assembly in the inner cup. Pack grease lightly between the bps of a new grease seal and install the seal. If the original rotor is being installed, ensure the grease bn the hub is cle a n and adequate, the inner bearing and grease s e a l are lubricated and in good condition, and the rotor braking surfaces are dean. 2. Install the hub and rotor assem bly on the spindle. K eep the assem bly centered on the spindle to prevent damage to the inner grease retainer or spindle threads. 3. Install the outer w heel bearing, washer and start the adjusting nuL 4. Adjust the wheel bearings. Refer to Section 1 1 -10. Then install the nut retainer, colter pin and grease cap. 5. Install the caliper assem bly on the spindle as oqt lined. 6. Install the wheel and tire assembly. Tighten wheel attaching nuts to 109-142 N -m (80-105 Ib-ft). SHOP 02595 PRODUCED BY FORD IN MALLIA V FORD 12-20-5 Brakes, Disc-- Single Piston, Sliding Caliper-- Front 12-20-5 7. Install wheelcover. 8. Apply the brake pedal several times to properly position the brake shoe and lining assemblies. Rotor Splash Shield Removal Refer to Fig. 4. 1. Remove the caliper and the hub and rotor assembly as outlined. It is not necessary to disconnect hydraulic connections. 2. Rem ove the three bolts attaching the splash shield to the spindle and remove the shield. 3. Rem ove and discard the splash shield-to-spindle gasket. Installation 1. Install a new splash shield-to-spindle gasket. 2. If the shield is bent or damaged, replace it with a straight shield. Position the shield on the spindle. Install the attaching bolts. Tighten to 13-20 N-m (115-177 lb-in). 3. Install the hub and rotor assembly and the caliper as outlined. NOTE: The splash shield is made of plastic, and cannot be bent or adjusted (except on Police vehicles). OVERHAUL Alter any service work, pump the brake pedal to obtain a firm brake pedal before moving the vehicle. Riding the brake pedal (common on left-foot application) must be avoided when driving the vehicle. Caliper Disassembly 1. Rem ove the caliper assembly from spindle and rotor a s outlined. Do not use screwdriver or similar tool to pry piston back into cylinder bore. Use a Cclamp. Remove outer shoe by slipping down caliper leg until the clip is disengaged. Remove inner sh oe by pulling it straight out of piston. NOTE: Removal force may be as high as 196-294 N (20-30 lbs). 2. Disconnect the caliper from the hydraulic system, and blow the piston out by using air pressure. Apply air pressure to the fluid port in the caliper with Air Nozzle Assembly Tool 7000-DE or equivalent (Fig. 5) to remove the piston. If the piston is seized and cannot be forced from the caliper, tap lightly around the piston while applying air pressure. Do not use a screwdriver or similar tool to pry the piston out of the bore, because it may result in damage to the piston. Cushion the piston's impact against the caliper iron when blowing it out of the bore by placing shop towels between the piston and caliper bridge. Use care because the piston can develop considerable force from pressure buildup. 3. Rem ove the dust boot from the caliper assembly. 4. Rem ove the rubber piston seal Irom the cylinder and discard it. Cleaning and Inspection Clean all metal parts with isopropyl alcohol. Then, dean out and dry the grooves and passageways with com pressed air. Ensure that caliper bore and component parts are thoroughly clean. Check the cylinder bore and piston lor damage or excessive wear. Replace the piston if it is pitted or scored, or on Police vehicles il the chrome plating is worn off. The piston should also be replaced if it does not meet the requirements in Fig. 6. Assembly t. When assembling the caliper, examine the piston for surface irregularities or small chips and cracks (Fig. 6). If necessary, replace the piston. Be sure to clean foreign material from piston surfaces and lubricate them with brake fluid before inserting it into the caliper. 2. When installing the piston back into the bore, use a wood block or another flat stock, like an old shoe lining assembly, between the C-clamp and piston. Do not apply C-clamp directly to the piston surface, because this can result in damage to the piston. Ensure the piston is not cocked. 3. Apply a film of clean brake fluid to the new caliper piston seal, and install it in the cylinder bore. Ensure the seal is not twisted but is firmly seated in the groove. 4. Install a new dust boot by setting the flange squarely in the outer groove of the caliper bore. 5. Coat the piston with brake fluid, and install the piston in the cylinder bore. Spread the dust boot over the piston as it is installed. Seat the dust boot in the piston groove. 6. Ensure the dust boot is tight in the boot groove on the piston. 7. To install the inner shoe with its 3-linger clip attached to the shoe into the piston, grab each end of the shoe, making it square with the piston, and push firmly until the shoe clip snaps into the piston. Do not allow the shoe or clip tangs to cock during installation; this avoids bending the clip. 8. Install the caliper over the rotor as outlined. Rotor Refinishlng Refer to Brake Diagnosis in Section 12-01 for conditions necessitating rotor refinishing. Brake roughness (vibration or pedal pulsation) that is present during service brake application is caused by either rotor thickness variation or corrosion buildup on the rotor braking surfaces. Check with Rotor Thickness Gauge T75P-1102-B or equivalent. This thickness variation can occur with rotor wear in excess of 19311 km (12,000 miles) use. Rotor turning may thus be necessary beyond the warranty period. The rotors should only be turned as a last resort. The suspension and brake systems of passenger vehicles are designed and built to tolerate rotor thickness variations well above previous brake designs. Rotor replacement should only be required for such circumstances as damaged rotors, bearings, or heavy rotor scoring where rotor turning is not possible. If pedal pulsation occurs, attempt stopping the vehicle with the transmission in NEUTRAL. If roughness is gone, the drivetrain should be inspected, if the SHOP 02586 PRODUCED BY FORD IN MALLIA V FORD 12-20-6 Brakes. Disc-- Single Platon, Sliding Caliper-- Front 12-20-6 20119 A SSY RH 2 0 1 1 6 A SSY LH COTTER PIN C ADJUST) N( BEARING AOJU9TMEHT tighten adjusting NUT while ROTATING HUB AND ROTOR ASST COUNTER CLOCKWISE TO > l H-m(17-25L0-FT). BACK OFF ADJUSTING NUT 1/2 TURN. RETIGHTEN TO $.1-3.2 N m<10-26 LB-IN) (F1HGCft-TIGHT) SELECTIVELY POSITION NUT RETAINER B ON ADJUSTING NUT SO THAT A SET OF SLO TS A R E IN LINE W ITH CO TT ER FIN HOLE. ADJUSTING NUT MUST NOT B E AOTATED N THIS O PERATION. L O C K AD JU STIN G HUT A NO NUT RETAINER WITH COTTER PIN C. CAUPER ASSY 2 0 1 1 9 LH 20116 RH COMBINATION SPINOLE AND ANCHOR PLATE 3106 LH 3107 RH SCAEW AFTER MANUAL 8LEEDJNG TIGHTEN T O 15-16 N m (126-146 LB-IN) NUT RETAINER 8 COMBINATION CALIPER LOCATING AND ATTACHING PIN 28296 4 REQ'O HAND START PINS TIGHTEN TO 55-61 N m (40-60 IB-FT) VIEW Y SPREAD ENO S ANO BENO AROUND r e t a in e r ROTOR IK002 A S S Y 2 REO'O COTTER PIN n 045-s 2 REO'O NUT RETAINER \ 3&5&0-S GASKET N800191-S 2 REO'O SPLASH SHIELD 2K005 LH 2K004 RH COLOR BLACK. NYLON SCREW 56516 S2 6 REO 0 TIGHTEN TO >3 20 N m (115-177 LB IN) FIG. 4 Caliper, Shield and Rotor Assem blies H2609-G SHOP 02597 PRODUCED BY PORO in m auiavfo rd 12-20-7 Brakes, D isc-- Single Piston, Sliding CaHper-- fro n t 12-20-7 FIG. S Piston Removal From Caliper-- Typical FIG. 6 Surface Irregularities ol Phenolic Piston VtM cU Baa* Un* Salting 12$ Bad Roux Minimum TMekneea Ford Crown Victor/ Mercur, Gland Marqua, boeom Town Car .40 972 Rctt5 hawig a ihickn toss Sian shoam han must tie ragtacad regardless ot tne micrometer gauge bar and ban measurements. 0 0 * 7 5 -0 FIG. 7 Front Rotor Micrometer Gauge Bar Baseline Setting--Front Rotor Minimum Thickness roughness remains, inspect the brakes. If corrosion buildup is the cause, hand sand the brake pads and rotor braking surfaces to remove the scale. If buildup is light, the condition should disappear after a lew brake applications. Rotunda Disc Brake Lathe model 054-00020 or equivalent should be used to refinish disc brake rotors. Front Rotor Rotor minimum thickness must not be less than show n in Fig. 7, nor le ss than th e num ber past on the inside of the rotor after refinishing. Lateral FKJ. a Gauging Front Rotor Inner Braking Surface runout ot the braking surfaces must not exceed 0. 0 9 .m (0.003 Inch), arid the surface finish is to be In the 90/15 micro-inch range. Maximum allowable stock removal of the inner rotor braking surface is determined by the use of D isc Rotor Surface Gauge T71P-1102-A and Rotor Gauge Ban T74P-1102-A or equivalent (Fig. 8) as follows: 1. Rem ove the inner grease retainer and bearing assem bly from the hub and rotor assembly. Wipe the inner and outer bearing cups clean. 2. Carefully place the gauge ball in the inner bearing cup (do not drop). 3. Install Disc Rotor Surface Gauge Adapter T79L- 1102-A or equivalent to micrometer, and set the micrometer to the baseline setting dimension (Fig. 7). 4. Position the micrometer gauge bar on the rotor inner braking surface with the micrometer centered over the ball (Fig. 8). To measure the distance between the micrometer baseline setting and the baH, turn the micrometer down to touch the top of the baH. and calculate the difference between that reading and the baseline setting. This distance is equal to the maximum allowable stock removal from the inside braking surface only. II the micrometer end at the baseline setting touches the ball, no additional stock removal is allowed. If the micrometer must be retracted from the baseline setting to allow the legs to set on the rotor surface, the rotor has had more than allowable stock removed, and the rotor assembly must be replaced. 5. C h e ck the rotor lor the maximum amount of stock that can be removed from the rotor thickness. Measure actual rotor thickness with micrometer, and subtract minimum allowable thickness (cast in in d ivid u al rotor). Total m aterial rem oval (combination of both sides) must not exceed this amount on SHOP 02388 PRODUCED BY F O R D IN MALUA V FORD 12-20-8 Brakes, D isc-- Single Piston, Sliding Caliper-- Front 12-20-8 If the rotor thickness Is less than the minimum (Fig. 7), the rotor must be replaced regardless of the gauge bar and ball measurement Rotor minimum thickness is also shown on each rotor. 6. Position the rotor in the lathe arbor. Never use a lathe that cuts only one lace of the rotor at a time; it must be a simultaneous straddle cut. Install a dial indicator to read rotor lateral runout near the center of the rotor face. If runout is 0.05mm (0.002 inch) or below, proceed to machine rotor. If runout is over 0.05mm (0.002 inch), loosen rotor on the arbor, and rotate the rotor 90 degrees. Read the runout, and if it is below 0.05mm (0.002 inch), proceed to machine the rotor. If runout is still over 0.05mm (0.002 inch), again loosen the rotor, and rotate it an additional 90 degrees. Check the runout. If the runout is 0.05mm (0.002 inch) or less, .proceed to machine the rotor. If the runout still exceeds 0.05mm (0.002 inch), return the rotor to the best runout position obtained. If the rotor runout can be brought below 0.13mm (0.005 inch), proceed to machine the rotor. If the rotor cannot be brought below 0.13mm (0.005 inch) runout, it must be replaced. 7. Set the cutting tool to contact only the high spot on the rotor, then adjust the cutting tool to the minimum depth required to clean up the rotor face. Do not exceed the allowable stock removal for the Inner braking surface or total rotor thickness. Before installing the rotor on the spindle, clean all chips from the rotor, and flush new grease through the bearing with a bearing packing tool. DIAGNOSIS The diagnosis chart covers service procedures that are common for front disc brake concerns. Using this chart to diagnose brake problems, may virtually eliminate the need for turning or replacing disc brake rotors except for those with extended mileage. Replacing rotors should be limited to vehicles Involved In accidents and rotors extremely scored. Turning of rotors should be limited to rotors experiencing certain wheel bearing problems. PRODUCED BY FORD IM MALLIA V FORD 12-20-9 Brakes, Disc-- Single Platon, Sliding Caliper-- Front 12-20-9 CONDITION Grind -- A loud, harsh rubbing noisa. FRONT DISC BRAKE DIAGNOSIS POSSIBLE SOURCE e Bound caliper and/or brake shoes. e It caliper is not bound, and brake linings are worn to rivets causing rotor to be scored within warranty period, customer abuse (riding brake pedal) is cause. Rattle, Clunk, Knock -- A series ot stop short sounds in quick succession. Roughness -- An unsmooth feeling wMs braWrig evidenced by a pulsating brake pedal. a Wheel bearings not lubricated (verify noise is coming from bearings). Bent loose, missing or worn components: e Caliper support pins Pin bushings Inner/outer shoe dips e Oust shield e Corrosion buildup on rotor surfaces. Wheel/tire imbalance. Drivelrain imbalance. a Rear brake roughness. a Rotor thickness vanation. Front wheel bearings misadjusted. Squeal -- A loud, sharp. hlghpitched moderately prolonged sound that occurs while braking. Occasional or intermittent brake squeal may result from environmental conditions such as cold, heat wetness, snow, salt mud, etc. This condition is not a functional one end wifi not affect braking effectiveness. e Brake fining arxVor rotor surface contamination evidenced by glazed surfaces. ACTION Service as necessary. * This is not a chargeable warranty claim. No warranty claims are to be accepted tor fining replacement, rotor replacement, or rotor turning under these conditions. Service and replace as necessary. Lubricate and replace bearings and seals as necessary. e Tighten or replace. Replace as necessary. Service or replace as necessary, e Service as necessary. * Hand sand corrosion from rotor braking surfaces and glaze from finings. # Verify and service as necessary. # Attempt stopping vehicle in NEUTRAL transmission position. II roughness is gone, drivelrain should be inspected. e Inspect and service as necessary. Diagnose per Section 12-01, service per Section 12-20. e Record rotor thickness variation, replace rotor if thickness variation, when removed from vehicle, exceeds 0.020mm (0.0008 inch). Replace rotor. Inspect and adjust beanng setting as necessary. e Remove caliper assembly from spindle and remove inner and outer linings. Rotor removal from rear drive vehicles is not necessary. Hand sand glaze from finings arid both braking surfaces of rotor. Use Garnet Paper 100A (medium gnt) or aluminum oxide 150J (medium). Follow the applicable service procedures when replacement ot brake pad insulators is necessary, instead of replacing the entire shoe id lining assembly when the pads are not worn. SHO P 02600 PRODUCED BY FORD IN MALLIA V FORD 12-20-10 Brakes, D isc-- Single Piston, Sliding Caliper-- Front 12-20-10 SPECIFICATIONS FWOWT DISC BRAKE DtMOiSIOWS Deecrlptioft Lining Mattnai Unente Item C m . Fond Crown VlctorW Mercury Brand Marquis Rneted Lining Six* 638 x 1.79 outer 5.39 x 1.85 inner Lining Wear Lm l (From Shoe Surface) Uning lo Rotor Clearance (Brakes Released) Cetpar Cyknd Bore Diameter Master Cyinder Bora Diameter .125 0.0000.010 2.88 1.000 From Rotor Nonwiat ThkXness Front Rotor Minmum Ttiicfcneaa Front Rotor Diameter 1.03 .972 11.08 ou& * 7.07 inside Front Rotor AIo m M Runou Front Flolor Fresh (liao-inches) 0.003 1090 Front Rotor ThidmeieWrfadon 04)005 Ma. Gauge BdM ietm aierBesaln Sating Sea Overhaul Sacton (SM naiu a Sah TtdowM is atom on eft Rota. CH2S77-0 10B0UK SPtORCATtOa D w e*dos. toeateg Ftea to Sphda and Awfter Plat* M a H oasio Caspar M a Heat te Brak Tuba Spiate S N W d B o ta S p M e a d Andar P lao Nat $4-81 27-41 13-24 13-20 Ite 40-80 20-30 10-18 115-177 (IWn) CKM S4C SPECIAL SERVICE TOOLS Toot Hunte tr T71P.1B-A T74P-1102-A T75P-1102-B T79L-1108-A TOOL-7000-OE ROTUNOA EQLtPMP fT Modal 0544)0020 Description Dhe Rotor Sudata Gauge Rotor Gauge Bat Rotor TNcknaaa Gauge Rotor INctoeaa Gauge Adapter Air N d a Assembly CH3I43C Deecflptton Disc Bratta Latia CHS194-A SHOP 02601 . PRODUCED BY FORD IN MALUA V FORD 12-50-1 Brake Booster, Vacuum-- Dash Mounted 12-50-1 SECTION 12-50 Brake Booster, V acuum Dash Mounted SUBJECT PAGE ADJUSTMENTS Brake Booster-To-Master Cylinder Push Hod ....................................................... 12-50-1 DESCRIPTION ....................................................12-50-1 DIAGNOSIS AND TESTING ...............................12-50-2 SUBJECT PAGE REMOVAL AND INSTALLATION Brake Booster, Vacuum ............................... 12-50-2 SPECIFICATIONS ............................................. 12-50-3 VEHICLE APPLICATION.................................... 12-50-1 VEHICLE APPLICATION Lincoln Town Car, Ford Crown Victoria/Mercury Grand Marquis. DESCRIPTION The diaphragm-type brake booster is self-contained and is mounted o n the engine side of the dash panel. The vacuum brake booster utilizes engine intake manifold vacuum and atmospheric pressure for its power. Adjustm ent of the push rod and replacem ent o f the check valve are the only services perm itted on the brake booster. if any brake booster is damaged or inoperative, replace it with a new booster. The brake booster (including the check valve) is serviced only as an assembly. ADJUSTMENTS Brake Booster-To-Master Cylinder Push Rod The vacuum booster has an adjustable push rod (output rod) which is used to compensate for dimensional variations in an assembled booster. The push rod length is adjusted after each booster power unit has been assembled in production. A properly adjusted push rod that rem ains assembled to the booster with w hich it was matched in production should never require a service adjustment. A booster that is suspected of having an improper push rod length will indicate either ol the following: A push rod that is too long will prevent the master cylinder piston from completely releasing hydraulic pressure, eventually, causing the brakes to drag. A push rod that is too short will increase brake pedal travel and cause a groaning noise to come from the booster. If necessary, booster push rod length can be verified with a push rod gauge (Fig. 1) by using the following procedure: 1. Without disconnecting the brake tubes, disconnect the master cylinder, and set it away from the booster power unit. The master cylinder must be supported to prevent damaging the brake lubes 2. With the engine running, gauge and adjust the push rod length (Fig. 2) A force Of approximately 22N (5 lbs) applied to the push rod with the gauge will ensure lhat the push rod is sealed within the power unit. SHOP 02602 PRODUCED BY FORD IN MALL1AV FORD 12-50-2 Brake Booster, Vacuum -- Dash Mounted 12-50-2 3. Install the master cylinder on the power u nit Gradually alternate tightening the retaining nuts to 18-34 N-m (13-25 Ib-tt). Refer to Section 12-01. 4. With the engine running and the master cylinder reservoir cover removed, observe the fluid surface in the reservoirs when the brake pedal is applied rapidly. NOTE: Some fluid movement should occur in the forward reservoir. If fluid surface movement did not occur, the push rod is adjusted too long, and the procedure must be repeated to prevent eventual brake drag. REMOVAL AND INSTALLATION Brake Booster, Vacuum Removal Refer to Fig. 3. 1. Working in e n g in e compartment, disconnect battery ground cable. Remove master cylinder from booster. Set it aside without disturbing hydraulic lines. It is not necessary to disconnect brake lines, but care should be taken so brake lines are not kinked. Kinking of brake tines can lead to tube damage. 2. Disconnect manifold vacuum hose from booster check valve. ' 3. Working inside vehicle, below instrument panel, remove stoplamp switch connector. Remove switch retaining pin. Slide stoplamp switch off from brake pedal prrr ju st far enough for outer plate of stoplamp switch to clear pin, and then remove switch from pin. Be careful not to dam age switch during removal. 4. Rem ove booster-to-dash panel attaching nuts. Slide booster push rod, nylon washers and bushing . off brake pedal pin. 5. Rem ove booster assem bly from dash panel by sliding push rod out from engine side of dash panel. Installation 1 . P la ce booster in position on dash panel. 2. Working inside vehicle, install inner nylon washer, booster push rod and bushing on brake pedal pin. S ecure booster to dash panel with self-locking nuts. Tighten to 18-34 N -m (13-25 Ib-ft). 3. Position stoplamp switch so that it straddles booster push rod with switch slot toward pedal blade and hole just clearing pin. Slide switch com pletely onto pin. Be careful not to bend or deform switch. 4. Install nylon w a sh on pin, and secure all parts to pin with hairpin retainer. M ake sure retainer is fully in stalled and locked over pedal pin. Install stoplam p switch wiring connector on stoplamp switch. 5. Connect manifold vacuum hose to booster check valve using hose clamp. 6. Install master cylinder to booster studs. Tighten attaching nuts to 18-34 N -m (13-25 Ib-ft). 7. Connect battery ground cable. Start engine and check power brake function. DIAGNOSIS AND TESTING Refer to Section 12-01. MAS1ER CYLINDER SSY 2*032 - f ORO CRO W N VlCtO R IAI MERCURY GRANO MARQUIS FKX 3 Vacuum Booster installation M2Y04-0 ________________________________________________________ _______________ . SHOP 02803 PRODUCED BY FORD in m a lu a vfo r d 12-50-3 Brake Booster, Vacuum-- Dash Mounted SPECIFICATIONS TOflOUE SPECIFICATIONS DMCrtpUoo Boosw-to-Dash Panel LocKbiq Nut Masier Cylm bHo-Boostef Lociung Nub f f f ll 18-34 18-34 Lb-FI 13-25 13-25 CH3052-D 12-50-3 SHOP 02604 'SE SX S' 12-70-1 Parking Brake, C ab le Actuated-- R ear W heels 12-70-1 SECTION 12-70 Parking Brake, Cable Actuated-- Rear Wheels SUBJECT adjustm ents Parking Brake .......................... Cable Adjustment ................ DESCRIPTION Control Assemblies .............. DIAGNOSIS AND TESTING Vacuum Release Parking Brake Operation T e s t .................... REMOVAL AND INSTALLATION Cable, f r o n t ............... ........... PAGE 12-70-2 12-70-2 12-70-1 12-70-1 12-70-2 12-70-2 SUBJECT PAGE 'REMOVAL AND INSTALLATION (Cont'd) Cable, Intermediate .......................................12-70-5 Cables, Rear ................................................. 12-70-5 Control Assembly ..........................................12-70-2 SPECIAL SERVICE TOOLS ................................. 12-70-5 SPECIFICATIONS ............................................. 12-70-5 VEHICLE A P PLIC A T IO N .......................................12-70-1 VEHICLE APPLICATION Lincoln Town Car, Ford Crown Victoria/Mercury Grand Marquis. DESCRIPTION. The parking brake control assembly is shown in Fig. 1. The parking brake system s are shown in Figs. 2 and 3. Control Assemblies An independent foot-operated parking brake control actuates the rear w heel brake shoes through a cable system (Fig., 1). The parking brake warning lamp can be actuated by the parking brake control. It warns the driver to release the parking brake control belore driving the vehicle. II the lamp remains lit, a brake malfunction has occurred. The automatic (vacuum) release-type is standard equipment. The automatic vacuum-type parking b r a k e system h as a vacuum power unit with mounting bracket bolted to the FIG. 1 Parking Brake Control Assembly-- Automatic Release-- Ford Crown Victoria/Mercury Grand Marquis ' control assembly. The vacuum-actuated diaphragm within the unit is connected by a rod to the upper end of the release lever. Hoses connect the vacuum motor to the engine manilold through a vacuum release switch at the steering column. The vacuum motor is actuated to release the parking brake w henever the engine is running and the transmission is in a forward driving gear. The automatic parking brake control has a manual release T-handle which extends from under the LH side ol the instrument panel. Pulling this handle releases the parking brake. DIAGNOSIS AND TESTING Vacuum Release Parking Brake Look closely at the operation of the brake linkage as the parking brak pedal is depressed. Then, check the operation of the brake linkage when the manual release lever is activated. These checks will indicate whether the manual parking brake control linkage is operating properly or requires service or adjustment. Adjustment may be necessary if the parking brake is unable to prevent moderate vehicle movement. Perform tests ol the parking brake system and controls after making sure the linkage and manual controls operate properly. When testing a parking brake vacuum release system, a minimum o l 34 kPa (10 in-Hg) should be available at a points w here vacuum is applied. This can be checked with a gauge, such as Rotunda Vacuum Tester 021 00014 or equivalent. Failure to maintain 34 kPa (10 in-Hg) during vacuum system tests could be caused by a loose hose connection, resulting in a vacuum leak. When checking for vacuum between two points, trace the hose along its entire routing to ensure it is not crossed with another hose or connected to the wrong connection. All ol the vacuum parking brake control checks areito be performed with the engine running at idle speed. To detect any teaks in the parking brake hoses or to find disconnected or improperly connected hoses, listen for a hissing sound along the hose routing. SHOP 02605 PRODUCED BY FORD IN MALLIA V FORD 12-70-2 Parking Brake, Cable Actuated-- R e ar W heels 12-70-2 CAUTION: Oo not apply air pressure to the vacuum system under any circumstances because the actuator diaphragm In the parking brake vacuum motor may be damaged. 3. 4. Disconnect vacuum hose from the vacuum release motor. Disconnect wiring connector from the parking brake warning lamp switch. 1. Start engine and run it at idle speed. With the transmission shift control in N EU TR A L, depress ' parking brake pedal to apply parking brake. Mpve transmission shift control to D range, and observe the parking brake sector to see il the sec,tor returns 5. Rem ove three screws attaching control assembly to cowl side panel. 6. Rem ove clip and cable end from brake control clevis. to its zero travel position when the parking brake 7. Using a 13mm box end wrench to depress ! releases. If parking brake releases, the parking retaining tabs on cable fitting, remove conduit from vacuum control is working property. ^ control assembly. ; NOTE: The parking brake vacuum release does 8. Rem ove control assembly fromvehicle. j not operate with transmission in R E V E R S E . Installation ' 2. If parking brake does not release, test for vacuum at the vacuum line connected to the parking brake 1. Position die control assembly in the vehicle. release vacuum motor. This can be accomplished 2. Fit the cable assembly through its mounting hole, by removing the hose from each com ponent and attaching it to the vacuum gauge. Vacuum will be and press tabbed retainer intoplace.Ensure tabs . are securely locked into place. Connect the cable available at the vacuum motor only when the end fitting to the control. . transmission selector is in the 0 range. Connect two distributor tester vacuum hose adapters 3. Install attaching screws to cowl side bracket. Tighten screws to 23-35 N -m (17-26 Ib-ft). together with a coupling as a connector attaching the gauge. A minimum of 34 kPa (10 in.-Hg) is 4. Connect the vacuum hose to the vacuum release required to actuate the parking brake vacuum actuator. motor. If a minimum reacting is not present when checking each of the above components, they must be replaced. 5. Connect wiring connector to parking brake warning lamp switch. 6. Check parking brake operation. Adjust as required. Operation Test Check operation of the parking brake with vehicle on a Cable, Front hoist and parking brake fully released. Refer to the Pre Removal Delivery manual, Section 50-04. If there is any slack in the cables or it rear brakes drag when w heels are turned, adjust as required. 1. Raise vehicle on h o ist Refer to the Pre-Delivery manual,' Section 50-04. 2. Loosen adjusting nut at adjuster. ADJUSTMENTS Parking Brake Cable Adjustment 1. Make sure that parking brake is fully released. 2. Place the transmission in N E U T R A L Raise the vehicle on an axle-type hoist Refer to the Pre Delivery manual. Section 50-04. 3. D is c o n n e c t ca b le from interm ediate ca ble connector located along LH frame side rail. 4. Using a 13mm wrench to depress retaining tabs, remove conduit retainer from frame. At the rear of the fender panel, remove screw holding plastic inner fender apron to the frame. 5. Pull back the fender apron to expose the spring d ip retainer that holds the parking brake cable to the frame. Remove the dip. 3. Tighten adjusting nut against cable equalizer, causing a rear wheel brake drag (Figs. 2 and 3). 6. Pull the cable through the frame and let it hang in wheel housing. Loosen adjusting nut until rear brakes are fully released, m ere should be no brake drag. 11 brake cables are replaced in any system having a foot operated control assembly, stroke parking brake control with approximately 450N (100 lbs) pedal effort, then release control and repeat this step. 4. Lower vehicle and check operation of parking brake. 7. L o w e r v e h ic le and, in sid e the passen ger com partment, rem ove the cover of sound deaoener from the cable at the dash panel. Rem ove the spring retainer and cable end from the d e v is at the parking brake control. 8. Using a 13mm box end wrench, depress the retaining tabs and remove conduit from control assembly. REMOVAL AND INSTALLATION 9. Push the cable down through the dash panel, and remove cable from inside the wheel housing. Control Assembly Removal Refer to Figs. 2 and 3. 1 Fully release the parking brake. 2. Remove all tension from the rear cables by backing off the adjusting nut from the equalizer or adjuster. in s ta lla tio n 1. Start the cable through the opening in the dash panel inside the passenger compartment. 2. Connect the end of the cable to the parking brake control clevis, and secure it with a spring clip. Press tabbed conduit retainer into parking brake control. Install the sound deadener cover patch al the dash panel. SHOP 02808 PRODUCEO BY FORD IN MALLIA V FORD 12-70-3_____________________ P a rtin g B rake, C a b le A ctuated-- B e a r W h eels______________ _______ 12-70-3 SHOP 02607 PRODUCED BY FORD IN MALLlA V Fo r d FIG. 2 Parking Brake System, Rear Drum Brakes'-- Lincoln Town Car 12-70-4 Parkin g Brake, C a b le Actu ated-- R e a r W heel______________________ 12-70-4 _ TJ FIG . 3 P a rk in g Brake System, Rear Drum Brakes-- Ford Crown Victorla/Mercury Grand Marquis SHOP 02609 % 2***> " ? o*d 12-70-5 Parking Brake, Cable Actuated-- Rear W heels 12-70-5 3. Raise vehicle, and insert the cable through the frame member toward rear of the vehicle. Press the tabbed conduit retainer into frame hole. 4. Behind the fender apron, install the cable-to-frame spring clip retainer. 5. Connect front cable to the intermediate cable connector on the LH side frame rail. 6. Adjust the parking brake. ' 7. Lower vehicle. Cable, Intermediate Removal 1. Raise vehicle on a hoist. Refer to the Pre-Delivery manual. Section 50-04. 2. Loosen the cable adjusting n u t 3. Disconnect parking brake release spring at frame. 4. Disconnect the cable from the cable connectors, and remove H from vehicle. Installation t. Attach the intermediate cable to the front and rear cable connectors. Ensure rearward end of cable goes through release spring before attaching cable to the connector. 2. Attach the release spring to frame. 3. Adjust parking brake. 4. Lower vehicle. Cables, Rear Removal 1. Raise vehicle. Remove adjuster nut at adjuster. 2. Disconnect parking brake release spring at frame. 3. Disconnect LH cable from the intermediate cable connector. . 4. Using a 13mm box end wrench to depress retaining tabs, remove LH conduit retainer from rod adjuster. Rem ove cable retainer from the LH lower arm. 5. Release R H cable tabbed conduit retainer from the frame. Rem ove the clip retaining the RH cable to the frame crossmember. 6. Remove cable retainer from RH lower arm, and disconnect cable from retainer on RH upper arm. 7. Remove rear wheels and brake drums. 8. Working on the wheel side of the rear brake, remove the brake automatic adjuster spring. Compress the prongs on the parking brake cable retainer, so they can pass through the hole in the brake backing plate. Pull cable retainer through hole. 9. With the tension off the cable spring at the parking brake lever, lift the cable end out of the slot in the lever. Remove ca ble through backing plate hole. 10. Remove the cab les from the vehicle. Installation 1. Position the ca b le s approximately in their installed position. Insert enough of the parking brake cable through the brake backing plate hole, so the cable v end can be attached to the parking brake lever on the rear brake shoe. 2. Pull the excess s la c k from the cable wire inside the brake, and push the cable conduit through the backing plate hole until the retainer prongs expand. - The prongs must be securely locked in place. Install the autom atic brake adjuster spring. 3. Install the brake drum s and rear wheels. 4. Attach the RH cable to the RH upper and lower arm, frame crossm em ber, and through the frame bracket using the existing retaining clips. Press tabbed retainer into crossm em ber hole untH it is securely locked into place. 5. Attach the LH ca b le to the LH lower arm with retainer, and route cable toward front of vehicle. B e sure to route ca b le over the RH cable. 6. Install the LH ca b le through the flanged hole in the adjuster, and p re ss tabbed retainer into place. 7. Connect the LH ca ble end to the connector at the intermediate cable. 8. Insert the threaded rod of the RH cable through two holes in the adjuster. Loosely attach the adjuster nut 9. Install the cable release springs to the frame attaching hole. 10. Adjust the parking brake. 11. Lower vehicle. SPECIFICATIONS TORQUE SKCm CXtlO N S Description Paitnng B>M Coned AssemWr Mounting Nutt and Capscrewi Nm ' 23-as Lb-fl 17 26 CHM1-0 SPECIAL SERVICE TO O LS ROTUNDA EO O M KtrT Mm M 021-00014 OSSUlptlutl Vacuum Tester CHM7SC SHOP 02808 PRODUCED BY FORD IN MALLIA V FORD