Document 6R6EZYjYVw21QOyBkQD2GKjem

FILE NAME: Ford (FD) DATE: 1981 May 29 DOC#: FD147 DOCUMENT DESCRIPTION: Memo - EPA/OSHA Asbestos Exposure Program for Brake Mechanics with Industry Warning Information Attached tritar Ottica Ford Part and Sonde Dlriaion May 29, 1981 Mr. M. E. Hamburg cc Mr. G. G. Clickard Mr. E. J ..R ile y Subject: EPA/OSHA Asbestos Exposure Program fo r Brake Mechanics Ref: 1. EPA l e t t e r of b/Z l/81 2. A. B. M. Houston l e t t e r o f 5/21/81 Me have reviewed the EPA l e t t e r and attachments and also Mr. Houston1a l e t t e r and o ffe r the follow ing comments: 1. The Training and P ublications Dept, has published warnings in the brake sectio n o f the Car and Truck Shop Manuals regarding the h e a lth hazard of a i r blowing asbestos dust and recamnended the use of proper equipment fo r d u st removal. Copies of th is information are attached fo r your use. 2. The Training and P ublicatio n s Dept, has had no brake tra in in g programs in re c e n t years because th e re has been no new tech nology on brake service requirem ents Accordingly, we have not published tra in in g inform ation on asbestos dangers and handling procedures. Attachments E. P, Priebe ' 007386 PRODUCED BY FORD 12-G7-20 G eneral Hydraulic Brake Service 12-01-20 REMOVAL AND INSTALLATION 'RAKE DRUM _ VEHICLES THRU 9000 SERIES Use the following service procedures for both nydraulic and air brakes. FRONT BRAKE DRUM 1. Raise the vehicle until the tire clears the floor and remove the wheel and tire from the hub. Loosen the brake shoe adjusting screw until the shoes no longer touch rhe brake drum. Remove the grease cap and the gasket (if equipped) from the hub. 2. On vehicles with 9,000 lb front axles and hydraulic brakes, remove the locknut, lacking ring, dimpled washer and adjusting nut. On all other axles, remove the cotter pin, adjusting nut and flat washer from the spindle. ' 3. Remove the outer bearing cone and roller assembly. Pull the hub and drum assembly off the wheel spindle. 4. Remove the front wheel-to-hub retaining nuts (or rim and tire attaching nuts). Remove the wheel (or rim and tire) from the hub and drum. 5. Remove the brake drum retainers and attaching bolts, screws or bolts and nuts. 6. Remove the brake drum from the hub. 7. Check the drum for damage or wear, and repair nr replace if necessary. If a new drum will be installed, be sure to remove the protective coating w ith degreaser. Install new grease retainer seals whenever a wheel and hub is removed. 8. Place the brake drum to the hub and install the retainers and retaining bolts, screws, or bolts and nuts. 9. Install the hub and drum on the wheel spindle. Keep the hub centered an the sp in dle to prevent damage to the grease retainer or the spindle threads. 10* On vehicles with 9.000 lb front axles and hydraulic brakes install the outer bearing cone ond roller assembly, and the bearing adjusting nut. On all other axles, install the outer bearing cone and roller and flat washer on the spindle. Install the adjusting nut. 11. Install the wheel and tire an the hub. Then install the clamps (if applicable) and the wheel stud nuts. 12. While rotating the wheel, tighten the adjusting nut to specification. A djust wheel bearings as described in Group 11. 13. On vehicles with 9000 lb front axle and hydraulic brakes, install the dimpled washer with the dimple indexed in one of the holes in the adjusting nut. Install the locking ring lock nut and tighten to specification (refer to Group 11). Bend the locking ring over a flat of the lock nut. 14. Install the gasket (if equipped) and the grease cap, and tighten the wheel stud nuts to specification (refer to Group 11). Install the hub cap (if equipped), and adjust the brakes as described in this Part. si OVERHAUL Removal of dust and dirt from brake assemblies should be done by using the Rotunda Brake Vacuum (340009) or equivalent or Rotunda broka parts washer (model 620016) or equivalent. Brake assembly dust and dirt should net be removed by either blowing off with an air gun or vacuuming with a standard industrial vacuum because a health hazard from breathing asbestos dust may develop. Also, any machining done on brake linings or pads should be done using properly exhaust ventilated equipment. BRAKE DRUM REF1N1SHINO Minor scores on a brake drum can be removed with fine emery cloth, provided the emery is thoroughly cleaned off the drum after the operation. BRAKE DRUM REFlNtSHING Minor scores on a brake drum can be removed with fine emery cloth, provided the emery is thoroughly cleaned off the drum after rhe operation. A badly scored, rough, or out-of-round drum should be ground or turned on a drum lathe. Do not remove anv more material from the drum than is necessary to ide a smooth surface for the brake shoe contact, .^ke drum maximum braking surface diameter is shown on each brake drum (Fig. 10). Brake drums which exceed the maximum braking surface diameter shown on the brake drum, either through wear or refinishing, must be replaced. M 10S .IA FIG. 10 Brake Drum Maximum Braking Surface Diameter Marking Location-- Typical Medium - Heavy Truck Shown ' On all medium and heavy trucks, the maximum braking surface diameter specification, which is shown on each broke drum, allows for 0.060-inch machining cut over the original nominal drum diameter, plus 0.030inch additional wear before the drum must be replaced. After rtfinishing the broke surface runout must not exceed 0.070-ineh total indicator reading, measured from the bearing cup. 007387 PRODUCED BY FORD 007388 ~ l i II f u I ly ili anile B rake* fie iio ia l Saivn.e 12 O 1 22 i i icompieie axle set) on front wheels as required. The ruober caliDer insulators and the plastic sleeves must be replaced when linings are replaced. 3. Visually check the caliper. If the caliper housing is leaking, it should be replaced. If a seal is leaking, the caliper must be disassembled and new seals installed. If a piston is seized in the bore, a new caliper housing is required. R efer to Part 12-20 for disc brake rotor resurfacing procedure. Service Precautions 1. Grease or any other foretgn material must be kept off the lining surfaces of the rotor and external surfaces of the hub during service operations. In handling the rotor and caliper assemblies, avoid deformation of the brake rotor and nicking or scratching of brake linings. ' 2. If a caliper piston is removed for any reason, the piston seal must be replaced. 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 specifications. 5. To avoid bending or damaging the rotor splash shield on full right or left wheel turns, be sure the vehicle is centered on the hoist before servicing any front end components. 6. Riding of the brake pedal (common on left-foot applications) must be avoided during vehicle operation. 7. The wheel and tire must be removed separately from the brake rotor, unlike drum brakes where the wheel, tire, and drum can be removed as a unit. I hazard from breathing asbestos dust may / develop. 1 Inspect the brake shoes for excessive lining wear or shoe damage. If the lining is worn within 1/32 inch of the rivet heads or if the shoes are r 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 diam eter is w ithin specification by using the Rotunda brake drum micrometer (model 100010) or equivalent. If the braking surface diameter exceeds soecification, the drum must be replaced. ' Check the condition of brake shoes, retracting spnngs, hold-down springs, and drum for signs of overheating. If the shoes have a slight blue colonng, indicating overheating, the retracting and hold-down springs should be replaced. Overheated springs lose their pull and could cause the new lining to wear prematurely, If not replaced. If the brake drums are heat spotted. Indicating an overheated condition, they should be replaced. Inspect all other brake parts, and replace any that are worn or damaged. 6. Inspect the brake drum and, if necessary, refinish. Refer to Rotunda Catalog Wheel Service, for a description of the various types of brake lathes available. The maximum inside braking surface diameter is shown on each brake drum (Fig. 21). 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 Part 12-02 for refinishing. 8. Do not attempt to clean or restore any oil or grease-soaked brake linings. When contaminated lin in g ; are found, they must be replaced In complete axle sets. 9. Always replace rubber caliper insulators and plastic sleeves when replacing linings. Do not lubricate the slide pins. 10. Caliper slide pins must be hand started into spindle before tightening. This is to insure that the large diameter of pin is through outer shoe holes to prevent binding or bending. Drum Brakes 1. Remove the wheel from the drum, and remove the drum, Part 12-02. Removal of dust and dirt from brake assemblies should be done by using the Rotunda brake vacuum (model 340009) or Rotunda brake parts washer (model 650016) or equivalent. Brake assembly dust and dirt should not be removed by blowing off with an air gun because a health FIG. 21 Location of Brake Drum Maximum Inaida Surface Marking* 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 aa an assembly, including the check valve. PRODUCED BY FORD Inter Ottica Ford Part and Service DWieion Tvme 1 , 198"! 007389 Mr. M. H. Hamberg . . . EPA./0SHA A sbestos Exposure Program Suo^ect. E .V - scrip t aid (2) bro- oU o" iB i " " eBts: s s r s S tn S S-- "? iS J S posal system, ltK 0 ^ _ appropriate. ^ i s s ' ~ in the U n - ta r . Id ta - address is the n >,>8 clearing method the P f S " f * cS f e e can f il le d . Ora popular brak method i s simply usi.no brushing off the -&^ COfl el " S = " n ` " `J S , 1? T i S e t c " " L eSn^t U ; Pf S ^ ! 5r i - - *5 cpamiBS t h 2 ; are f i= in " " S ^ i e s S s poiaoni " * s s trs f& s s -^ T s 3r J ^ ~ S ', r ta eaaharl). - . t tt-a brootare ard aUde-tape " ia S * S ? S k ^" ^ S a 'n a V r a - S r ^ a ^ - a adopt.* * * - ^ (p, * , ' ffe c tir e n e ss, the broc asbestos noison- . l n th e ana <* P * f ^ S d p . p l . o r " "g i ^ S c c p a i t o displaying a poster t available, th ^ | of brochures. S - a *-- W & F * " **" * . ^ t rord Hotor (U) fo u r C lass * e t i o n J e i l ^ t S c h a i c i a t a . I suggest K n es (c M aaaere I t does . D. E. Schwank PRODUCED BY FORD li N N G eneral H ydraulic Brahe Srvice_ 12-01-22 s. Remove the tine " d for cracks or poor fUre form. I f the f lir e is not co rre ct, cu t It o ff and repeat the process The finished flare must be v^uare with the line, free o f cru e t! and have S m o o th m a u n , surface to ensure a leakproof connection. Flaring a Una (Flaring-Bar Type) Refer to F tp . 15 * nd 17' 1 Cut o ff " I TM hten the required fength n in e . (A line = u tu n | to o lw d simplify m aking a clean and square cut). 2. square o ff the ends o f the tme wkh r a n d chamfer the end of the Une be flared. *E S t t ' S S the end o f the Une socks out about as f i r as the thickness o f the adaptor above the bar. or even with the bar. depending on the tool used. 4 Fll the adaptor onto the line and slide bar hito the yoke. U c k A e ta r p o sition w ith the Une beneath the yo kr sere**. 3 . F orm the s.ngle flare by tightening the yoke screw securely6. Release the screw and remove the adaptor. . 7 Form the double flare by lighening the yoke screw again, w ith second adaptor fitted, depending on the tool used. , B d o s e the screw bar. and flared line. die flare for cracksi p o o r Q a iT fo n n . and repeat the proceas if the flare is not correct. . 9. Repeat Steps 3 th ro u g h 6 at the opposite wheel cylinder. _____ *** H1171.4 FIG. 17 line Flaring (Flaring fior Type) rake hose Replace a flexible brake hose if it shows signs o f softening, cracking or other damage. When installing new brake hose position the hose to avoid contact with other vehicle parts. removal m a ke drum and in stallatio n a4 RReeim ove the f r o n t w h e e l-to -h u b "< <" bearing cone and roller the bearing adjusting nut. O n a ll other axles, install the outer bearrng cone and roller and flat washer on the jprndlc Install the adjusting nut. and the wheel stud nuts. r brakes only, they are covered a ? u or 6. Remove the b ra ke dru m from the hub. front brake drum 1 Raise the vehicle until the tire d ean * s sr ,. i hub. Lroo,,s"en*thierorSaae i " o,, .. * "S f i f equipped) from the hub. , 5 - ^ S S t a with T.000 lb front axles ^ .. remove the and hydraulic j:'mni-d washer locknut, locking nng. dimpW H e w d ru m will be installed, be sure to remove the protective coaling with dCu id*U new grease retainer *" whenever a wheel and hub is removed. , Place the brake drum to the hub and 1 K u ... "J 'bolts, screws, or bolts and nuts. "i s s i s i Bend the locking nng over a tu t o ^ lock nut. H . Install the^ k " d(`n gM ^ P h c r i and flat washer from the i. ^ n . o r s r v ` " " i *= - OVERHAUL ^ n in d u s tn ^ p e v a c u ^ d ^ ptoU^reomvov"e anyToSusE ^ ` din p^raenleocnt. brake linings, pads. b rlk e repairs. when performing brake A ls o . "7 m ` ChVn" l E done using lin in g s or pads should be properly exhaust ventilated eq P . . a i r * DRUM REFlNtSHINO 1R i a a o moo- m m . u-too EJS ^ x : ; W ,, . m i u n . more m lle n l' [' " a smooth s u rf* * necessary to provide . v drum th t b f l m braking'suifice dmter ^ dn. " " n" '! b m k in ^ u ria c e diameter shown on 007390 PRODUCED BY FORD r . .n * r d Hydraulic Broke S e rric_ *ChFaOuFtEF* LO"G'"E?S F I T SINGLE FLANE FIG. 15 Line Rarinfl 5* qU* nC' JtC O X D 0 * ? " OOUSLE FLANE , n-01-22 Form the double (lire by iiihem ng , he yoke sere again. >< second . L p w r fitted, depending on the tool g ^ c a s e the sere bar. and flared line. K p e c t the dare Tor cracks or poor ( W o r m , and repeat the process ,f the flare is not correct. 9. Repeat Steps 3 th ro u g h 6 at the opposite heel cylinder. IR A HOSI Replace a flexible brake hose if u sh o ts signs o f softening, cracking or "U , a ne brake h o s . position the hose to avoid contact with other vehicle parts. HO. 16 Une Fiorina (Split DU ^ H tm -a FIG. 17 lin * Flcring IFIonnfl 6 ' Type) r e m o v a l a n d in stallatio n H A K E DRUM 4. Rae ' ` Hh" l; - S ,h . hearing adjusting nut. On all - ta ll the outer bcanng u ti fcur" ? ? ? ? & * * S i * a i s = s = = i for both hydraulic g_l00_.3 5 Q and 5. nnd the heel stud nuts. oO * F' 10 ^ l i p'rttedures apply to Bronco rear drums, p covered r- hydraulic brakes only, they are Remove the brake drum from the a W hile ro u ^ \ Asl ^ t i i Adjust jn Part 12-02- i S S p s s ^ c H b e d in Group ]hoa FRONT brakb drum l. ^ * '^ ^ 5 * 5 the floor and remove tn ur t frromi-n tthhee hnuubo. Ltwscn ^in . - shoe adjusting brake drum . l0 n l ! L l TM S - 6 \ e gasket Banov the p a p " e ^ T n ^ b e instaUed. be sure ^remove the protective coating tth ie j ^ j ne* g r tw rrt>1>tr J e v * a wheel 1 hb r * brake drum to the hub and j. ftf equipped) f ^ m ^ h f t ^ e , Z On vehicles w i t h t h e *2- S a i 9. spindle. Keep the hah and l u i V%br " u h t h e dim ple d im pled aai-e holes in the indexed in one adjusting nut. InstaU locking ring 1 .f^ lion. lock nut and nghten t P ^ ofthc Bend the locking nng over a lo ck nut. - ,kA lS S ' i . i end flat ashcr from the spmdl , .- S S S - is r - js f t ii "OVERHAUL b ra k e linings. I- d * . ^ ke^ . . r s . hen perform. heel * " * r P A ls o , any m achining done on 007391 produced by ford 007392 n-oi-ia re n e ra i H ydroufic fovm the single Ror, by r i g h t i n g the yoke s w 5. cur^W. , r, ik i , the screw and r*rnov. the adaptor. 6. c *K double Rar by tighening the yak u z r * 7. Ja*-- J ""* """`!'"s " *?" , ^ 8. Pt, * -- bar. orrd Pareri W l--P * Broke S e rv i 12-01-18 9. Repeat Step 3 through 6 at the opposite wheel cylinder. BRAKE HOSE Replace a flexible brake hose if it hows signs of softening. cracking or other damage. When installing a new brake hose, position the hose to avoid contact with other 'hide parts. pfoc H the Rar > not co" * c,` OVERHAUL ---- fshio.uld b-e 'don<edb"y>' usi g , , ^ waihr (model frnodd iU-0009) or R * " d ^ k . j w dust and dirt 1650016) or an blowing off with an should not he rer?yH . y . ^ a r d industrial vacuum oir gun or vacuuming 'with o breathing in cleaner because a ,h,aJ * hS ,^ m a c h in in g don. kaki 0U" - TvnCAL W l ^BRAKE DRUM REF1HISHIHG y f Ml T e ^ o \ r P^ d e i d h 11 rt' oraU 1' ly l. * i - r : * - -- A. badly scored, roug , (Refer to the lathe be ground or turned on a remove any more manufacturers '" ' truchons.l Do r ^ t rem ^ q material from the drum than Bmk. drum smooth surface fo -hi xw brake drum (Fg. Jiameter is shown on each in * TM ~i * shown on the brake bmktog * " * ? " , " flS .M M . -' b* drerupmla,ceedit.HeTrhetbmroaxgjmum bv,rar kainka^ suurrfa^ce, ^diame{Rtegr. " speclncation, whch is o machining cut 131 allows for a 1.52mm ( U . u o u . i .762mm over the original nminal drum the drum- (0.030 inch) additional wear before reo w discard diameter. PSONT DISC BRAKES . F1G. 13 J ^ S n l ^ O O - i - 3 5 0 , Bronco, andd FF-100--F-350 No more * - ^ " t^ .^ n d oy be ^ `^ " " K e k n e s . fa lls b e lo w the ' B, fig . 1A). In each rotor, it must bs rep1* " - minimum o _t , f the rotor must The finished braking su c _ (0 001 -inch): b. ft I P" "" 0 7 6 -; I0.TO lianctehr)atlotraulnIonudticmatuosrt rneoad,ng ond^th- jsuurofa^ce f^lm*h of the braking surfaces must be i I- ^s e mu -:" % -- ^ ^ , : nv i S ^ n d d HTavy Duty--- 1 2 -2 i Disc Brakes Sliding Caliper. ,f ^ 2. Measure the thickness . . * *i,e assembly i* I** fining thidtness at any pom backing plate mCVh*^io' n t^h . runou.jt A .c k Is finisnhe_di,0a,dWjuhst,othle bo arin g s as d o s c r ib o d ^ ^ (-x M p t Front k- ri"a 5. o , k I k . ' " 11 : . , 3. Then check to be sure the rotor can ^ ^ ltyUjl Clamp a dial indicatora e j p ^ -mCh from the contacts the rotor app 7 Qn indicator outer edge. Rotate the rotor and tax 6. Check th . caliper If >t is cracked .f | . ak,ng 7. ^abrasion. r :b Reploc them. x i= rh* produced by ford 007393 12-01-27 w o w B P .I HYDRAULIC BRAKE SERVICE PART 12-01 4. Check condltion o ^ ra k e ^ s h o e s ^ e tu of 5 Be sure vehicle is 5' vicing any dina or damaging rotor sp right or left wheel turns. u ^a vo id benon full 6. Biding of brake pedal A v o id e d plications) must be avo operation. during vehicle 7 The wheel and uTM" ' "E f k V d r u m S i " where ing, holddown sp g sliaht blue color overheating. If * " * A c t i n g and hold ing, indicating ver^aP |aced. Overheated down springs 3t1 uld J ^ i d cause new Un springs lose their pu I and could c ^ ,, ing l0 wear premaw te d, indicating an " aa" . S r = o n d l. io h , J , should da ta p la c d . s. R .,, , to pan 11-16. 'O' hd " < ^ cedure. unit. 8. Do not attem pt to ^ ^ ^ g ^ c o n t a m l nated Hr* soaked bra keJin' i e lin ',ngs m ust be replaced I S S . S & . S S and the rotor braking sur faces wiped clean. a. Do no. W b rto ... C O W . . Brake Booster Check booster o p e r a tio n s ^ ^ d ^ m a g e d Brake Functional e a n8w booster. * * as an assem y' eluding the check valve. Brake Tubing S?'uP; w ^ S = ` ` " from brake system. D^ a^ e' 3,r ~ Drum Brakes hal tire and drum assembly 1. Remove wheel, tire spindte. braKke duriums--. E a r n in g : Never ' ,, a section of b; akelJU X ? e T w i t M ^ n O the entire section sh u'dtJ and length. Copper w bthe same tyP0' ize' , a hydraulic system. ' " ^ ' bS . luBih to lit body 6 ? f f i i o u o k l h k or stack tuba. Hydraulic Lines pd tnroughout the 51 Doubl. S S t'e s o p 'o " ol ^ a ir ir a o d te a tw h ,- "* sa ro .*-s system hose or aP, t er bleeding system, pressure differential valve _ - - J T " '' e x c e s s W . lining . . . ^ D in s p e c t Brake *)" U | X or shoe damage ' lm .na d ao n riveted lm- w ith in 1/32 inch of riv\ the shoe on bonded Toga or w ithin - 0, ' d R.trtaoe any lining liinnaint gha,sthbencn" "co' nnt.a.rmn lS d waxi- "sets. Prior tto brake fluid. Replace Ln'^g diam eter should be replacement of lining, brak8 drum braking checked to determine that 0 .|flc a tio ns. braking exceeds specif.ca- btiroan. d?um m ust be replaced. A1, brake tubing sb u' d J * , P''c^nn ecS ns. Clean ,, lo re installai,on. When connecting a tube to a torque wrench. ^ f-ltting nut to ihCh-POPhd l cj !c l V C ac^ J c PRODUCED BY FORD 12-4 Braking System 12-4 T CD CD K CS3 CS A -- P iston Housing B -- Braks Fluid C ---P isto n D -- ln n s r Braks Pd F -- Brak Disc E _ P a d H o u sin g (A n ch o r B rackst) G -- O u ts r Brak Pad FF12Q5---2A FIG. 5 S s c tlo n a l V is w o f F ro n t C a llp s r Simultaneously, the transverse cable is placed in tension by the eq ua lize r causing the a ctu a tin g lever on the right hand brake ossembly to activa te the brake shoes (Fig. 10). BRAKE SERVO T h . Brake Servo, if installed, is o f the suspended vacuum ty p e . W ith the e n g in e ru n n in g , vacuum is supplied to the Servo unit through o non-return valve. Bath sides o f the cham ber diap hrag m in the Servo are subjected to equal vacuum. In itia l m ovem ent of the brake pedal admits atmospheric pressure to the rear ot the diaphragm , resulting in a pressure difference which causes the diaphragm to move forw a rd. The bra ke pedal e ffo rt is assisted and reduced by the movement of the diaphragm . GENERA1 NOTE E very 60,000 km (36,000 m iles), bra ke cylinde r M ats, fle x ib le hoses and h y d ra u lic flu id should be re p la c e d . Brake * r * f* " * eompenen* must ba kept dan o f a n y f o r e ig n m a tte r. If necessary, any M , u.l' e com ponents should be w a she d in clean b ra k flu id , industrial alcohol or m ethylated sp in ti fa remove any foreign m atter and dried w ith a clean non-fluffy doth. Do not us a mineral base flu id such as petrol or paraffin. Brake fluid must not be allowed lo come into contact with brake pads/shoes or with disc or drum surfaces. Due to the com p le xity o f braking systems, when replacing or overhauling components, care must be taken to ensure that only correct parts are installec. ' " '* A ny brake flu id accidentally spilled onto a painted surface must be cleaned o ff im m ediately using cold w ater to prevent dam ag* to paint-work. -. __ rWAANINO: Care should be taken to avoid In haling dust from brake linings. Asbestos dust when Inhaled may be Injurious to health. Do not blow out dust with an air lino. A vacuum cloanor equippod for this purpose, brush, or rag should bo carefully used to remove any dust. Any dust should bo eontal nod In a soolod bag far disposal. JACKING THE VEHICLE Before commencing any repairs that in v o lv . jacking th vehicle it i t e tte n tia l th a t th vehicle lacking in s tru c tio n ! c o n to in e d in S ection 11/ O tn e ro Description, ore followed. /??* F * 4 T & produced by ford if': i: MT fe? ! : C . 007395 12-01-20 G eneral H ydraulic Brak Srvtc_ 12-0 WQ 5 Install me bleed screw (if so ecupped). In s til me ' asket (diaphragm) in the master cy linings are found, brake linings must be replaced in complete axle sets. Always replace rubber caliper insulators and 9. plastic sleeves when replacing linings. Do not lubricate the I'd pins. the retainer. CLEANING AND INSPECTION Disc Brakes !. Remove the wheel and tire from the hub and rotor. 2. inspect brake ^ w f t h m ' l ' r ^ n c h o T S Ihoe* Drum Brakes 1. Remove the wheel from the drum, and remove the drum, Part 12-02. ' I 2. "Removal of dust and dirt from brake assemblies should be done by using the R lu/''da braka vacuum (model 340009) or Rotunda brake p r a washer (model 650015) or equivalent. Brake assembly dust and dirt should not be removed by wowing off With in r gun because a health hazard from breathing astanos dust may develop ^ S i c e all ( ^ rS o n ^ ^ , ^ e V w ^ e f S,e (complete axle se ^ o . nSulators and the replaced. 3. visually cl, * w ^ is leaking, it should P sassefnbied and bora, a new calipe housing is required. Inspect me brake shoes for excessive lining wear w l h S damage. If me lining is worn wrth.n i/32 E H = Iis SSas^SSSS Beler .0 Part 1 2 - I ' * = * " r " " S',r,aC' " 9 procedure. S d S iS S IZ S --- -- replaced. Service Precautions . 4. Check the condition of b" kdSu ^ f o r signs , Grass, or any Ollier foreign TM " | TM st " S sopvreinrghse,a^tin' g^ . ^If ft^heo se s have tahesir|e3thrat cbtilnug9 ' ott me lining " rta= 's ^ TM c ? o i 6 o n s. In surfaces of me hub dun 9 assemblies, avoid be replaced. handling me rotor f l dr" ^ 0t ^ n d nicking or deformation of the braxe rou scratching of brake linings. v .rh e .te d springs lose their Pul' andr^ ' f t - u s e the new Un ng 2 I, a caliper pislon is ramovri lor any reason, me ` piston seal must be replaced. 3. " S i o v e r h e a t e d conditio, they should be replaced. aspect all other brake parts and replace any that 5. are worn of damaged. - - S X m" S p " * * " " " " " screw fitting. 6. Inspect me brake 4 Front wheel bearing end play is critical and must Refer to me Ro t u n d a ^ e s of brake lathes a descnpbon of the vanous typ 5Urfac* be within specifications. available. The maximum m s^e brakt ^ (Pg> 5 To avoid bending w d? ^ ^ p ll^ s rbesure me diameter Is shown on `chbbraVing surface 19). If the maximum inside J3 J ^ ed Blther s a g ."iir ? any front end components. diameter shown on me brum is l d. bv wear or refinish.ng, me drum must De rep Refer to Part 12-02 for refintshing. 6` -S t C iv iS d S r iS v '. ^ operation. 7 The Wheel and Sr. must Ira 7 - Iron, me bra. r. m the wheel, tire, and drum can oe re as a unit .. a. Brake Booster Check me booster operation as Brake Functional Test If the bra ^ damaged star The brak r o 'S T .e.TM iS ' "*y . . " " 1 1 1 ' the check vetve. / `J t o 2 PRODUCED E Y FORD 007396 12-01-20 G eneral Hydraulic Brake Service 12-01-20 OVERHAUL Removal of dust and d irt from brake assemblies fshould be done by using the Rotunda Brake Vocuum (340009) or equivalent or Rotunda brake parts washer (model 650016) or equivalent. Brake assembly dust and d irt should n o t be removed by either blow ing o ff w ith an air gun or vacuuming with a standard industrial vacuum because a health hazard from b re a th in g asbestos dust may develop. Also, any machining rlr>ne on brake linings or pads should be done using properly exhaust ventilated equipment. BRAKE DRUM REFINISHING M inor scores on a brake drum can be removed w ith fin e emery clo th , p ro vid e d the emery is th o ro u g h ly cleaned o ff the drum after the operation. BRAKE DRUM REFINISHING M inor scores on a brake drum can be removed w ith fin e emery clo th , p ro vid e d the em ery is th o ro u g h ly cleaned o ff the drum after the operation. A bodly scored, rough, or out-of-round drum should be ground or turned on a drum lathe. Do not remove any more m aterial from the drum than is necessary to provide a smooth surface for the brake shoe contact. T Brake drum m axim um b ra k in g surface d ia m e te r is shown on each brake drum (Fig. 9). Brake drums which exceed the maximum braking surface diam eter shown V on the brake drum, either through wear or refinishing, must be replaced. FIG. 9 B ra ke D rum M a x im u m B ra kin g S urface D ia m e te r M a rk in g Location-- T ypical M e d iu m -- H eavy Truck Shawn On a ll medium and heavy trucks, the maximum b ra k in g surface d ia m e te r sp e c ific a tio n s , w hich is shown on each bra ke drum, allow s for 1.52mm (0.060 Inch) m achining cut over the o rig in a l drum d iam e te r, plus 0.762m m (0 .0 3 0 inch) a d d itio n a l w e a r b e fo re the drum must be replaced. A fte r refin ish in g the bra ke surface ru n o u t must not exceed 1.77mm (0.07 0 inch) to ta l in d ic a to r re a d in g , measured from the bearing cup. On medium and heavy trucks, if the drum d ia meter is less tha n 0.762mm (0.03 0 inch) oversize a fte r re fin ish in g , in sta ll standard linin gs an the brake as sem blies. If the d ia m e te r is over 0.762mm (0.03 0 inch), in sta ll oversize or shimmed linings. BRAKE SHOE AND PARKING BRAKE BAND REUNING 1. Remove the rivets holding the old lining and remove the lining. 2. Clean the shoe or band thoroughly with cleaning fluid, especially the rim surface. W ipe the shoe or band dry and remove all burrs or rough spats from the shoe. Da n o t use shoes w ith e lo n g a te d riv e t holes, a bent or w o rn shoe web or rim . 3. On service brake, check the inside diameter of the brake drum. 4. Position a new lin in g on the shoe or band. The prim ary and secondary linings are marked. Install new rivets, beginning with the rivet holes near the center o f the lh oe . O n some vehides, the primary lining is shorter than the secondary lining. If this con dition exists, position the shorter (primary) lining in line w ith the heel end of the shoe. Do n o t le t b ra k e flu id , o il, o r grease touch the brake lin in g . I f a b ra k e lin in g k it Is used fo rep la ce the w o rn lin in g s, fo llo w the Instructions In the k it an d in sta ll all the p a rti provided. 5. Check the clearance between the lining and shoe rim. The lining must seat snugly against the rim with not m ore than 0.127mm (0.005 inch) separation betw een any two rivets. If only the linin gs ore re p la c e d on duo-servo single anchor brakes with fix e d a n ch o r pins, the brake linings must be cam g ro u n d 0.25mm (0 .0 1 0 ineh) a t the ends a fte r the lin in g s a re rive te d to the b ra ke shoe. BRAKE CYLINDER 1. Clean a ll brake cylinder parts in clean isopropyl alcohol or the Rotunda brake parts washer (model 650016) or equivalent. Inspect all parts fo r wear or dam age. Check the cylinder bore for rust, scores, o r o th e r d a m a g e . Be sure the b le e d e r screw passage is clean and open. Replace all parts that are worn or damaged. 2. If d irt is found in any part of the hydraulic system, flush,the entkftjysfem with.clean.urjpropyl alcohol. MASTER CYLINDER 1. Clean all master cylinder parts in clean isopropyl alcohol or the Rotunda brake parts washer (model 65 00 16 ) or equivalent, and inspect the parts for w ear or dam age. Replace them if required. W h e n a m a s te r c y lin d e r re p a ir k it is used, fe llo w the Instru ctio n s In th e k it and in s ta ll all o f the parts p ro vid e d . 2. M ake sure that all ports and vents in the master cylinder are open and free of foreign m atter. 3. On a single brake system master cylinder, check the spring valve (riveted to the front end of the piston). If it is loose or has moved so the piston ports ore open, replace the piston. 4. Inspect the cylinder walls for scores or rust. Remove scores and rust or obtain a smooth wall surface by h o n in g the c y lin d e r w alls, but not mare than 0.076m m (0.003 inch) of m a terial. Remove any PRODUCEDby ford