Document 6ROEVM159r4XjDdYDKByZ26B6

WARNINGS IN SHOP MANUALS (Asbestos Cases) The following is a review of Ford Motor Company car and truck shop manuals from 1950 to 1982 directed to any warnings in the manuals about asbestos dust in brake repairs. Since much of the language is repeated from year to year and within the various shop manuals issued in any given year, samples of each type of warning (or lack thereof) are attached as exhibits A through I. Reference will be made to a particular exhibit and the language contained therein. 1970 1974 1975 1975/76 1977 1977 1978 1978 1979 1980 19 80 1980 19 80 1980 1981 19 81 1981 1981 1981 Car Volume 1 Car Volume 1 Car Volume 1 Car Volume 1 Car Volume 1 Truck Volume 1 Car Volume 1 Truck Volume 1 Car Volume 1 Light Truck BCE* Medium/Heavy Truck BCE Fairmont/Zephyr T-Bird/Cougara BCE Pinto/Bobcat Mustang/Capri Granada/Monarch/ Versailles BCE Ford/Mercury Lincoln Continental/ Continental/Mark VI BCE Lincoln BCE Escort/Lynx BCE Light Truck BCE Medium/Heavy Truck BCE Courier BCE 12-01-08 12-01-12 12-01-23 12-01-24 12-01-29 12-01-22 12-01-32 12-01-22 12-01-31 12-01-20 12-01-20 12-01-22 A A A A B C D C 0 E E D 12-01-23 D 12-01-20 12-01-22 12-01-27 12-01-18 12-01-24 12-01-6 005222 E E F E E A PBODUCtU BY POBD SCF-FORD-0617 WARNINGS IN SHOP MANUALS Page 2 1982 1982 1982 1982 1982 1982 Lincoln Town/Mark VI Ford/Mercury BCE Lincoln Continental T-Bird/XR-7 Fairiront/Zephyr Granada/Cougar Mustang/Capri BCE Escort/Lynx BCE Light Truck BCE Medium/Truck . BCE Courier BCE 12-01-22 E 12-01-25 12-01-25 12-0112-10-6 12-01-05 E I H G A *BCE - Body, Chassis, Electrical } -- 005223 PRODUCED BY FORC 12-oi-oa General Brake Service 12-01-08 > 1 ] ii !III H " ' be Inspected lor "car or damage. 5. On Moating caliper type disc brakes, the caliper assembly must be removed from the spindle prior to re moval of the shoe and limn; assem blies. . ' 10- On floating caliper type disc brakes the calipers must not be inter changed from one Side to the other. V>hen the caliper is installed on its proper anchor plate and spindle, ihc bleeder screw will paint to the rear of the vehicle If a caliper is installed on the wrong side of the vehicle, it is ool possible to bleed the system property. 11- Do not attempt to clean or restore oil or grease soaked brake lin ings. When contaminated linings are found, brake linings must be replaced in complete axle sets.- DRUM BRAKES * replacement of the retracting and hold-down springs is strongly recom mended Oierhcared springs lose I heir pull and could cause the new lining la wear prematurels. if they are nor re. placed. II ihe brake drums are hear sported, indicating a oierheiled con dition, (hev should be replaced- i If the vehicle has 3Q.000 or more mi'es of operation on the brake lin ings or signs of overheating are pres ent when rehmng brakes, the wheel cylinders should be disassembled and inspected for wear and entrance of dirt into the cylinder. The cylinder cups should be replaced, thus avoiding future problems 6- Inspect ill other brake parts and replace any that are worn or dam aged. 7. Inspect the brake drum and. tf necessary, refimsh. Refer to Part 12-02 lor refinishing. I. Remove the wheel from the BRAKE BOOSTER drum, and remove the drum as out lined in Part 12-02 ' r . 2. Brush all-dust from the a backing ' Check noted in the booster Part 12-01. operation as Power Brake plates and interior of the brake Functional Test. It the brake booster drums. -J.,`'Irrspct'the brake shoes for ei-" is damaged or inoperative replace it with' a new booster The brake boost ctssive lining wear or shoe damage. If er is serviced only as an assembly. , the lining is worn within 1/22 inch of ' the rivet heads'`or if the shoes are ` HYDRAULIC UNES' " damaged, they must be replaced. Re place. any.- lining that had been coo-. . Steel tubing is used throughout the laminated with oil grease or brake . brake system with the exception of " fluid.' Replace lining in axle sets. the flexible hoses at the front wheels Prior to replacement of lining, the and at the rear axle housing, brake drum diameter should be cheeked to determine if oversize linings must be installed. 4.Check the condition at brake shoes, retracting springs, hold-down lube connection. Always bleed the applicable pri mary or secondary brake system sfter primary or secondary brake system hose or line replacement. Centralize springs, and drum for signs of ov the pressure differential valve after erheating. If the shoes have a slight bleeding (he system. blue coloring, indicating overheating. I BR IKE TUBING It a Section at the brake tubing be comes damaged, the entire section should be replaced with tubing of the same type. size, shape and length. Copper tubing should not be usrd in a hvdriulic system. When bending brskc tubing to fit underbody or rear axle conuturi. be careful not to ktnk or crack the lube. All brake tubing should be double flared properly to provide good leak proof connections Clean the brake tubing by flushing with clean brake fluid before installation. - When connecting a lube to a hose, lube connector, or brake cylinder, tighten the tube filling nut lo speci fied torque with Milbar Tool 1112 144 or equivalent. _ , BRAKE HOSE . ` A flexible brake hose should be re placed if It shows signs of softening, cracking, or other damage. When installing a new front brake hose, position the hose to avoid con tact with other chassis parts. Place a new copper gasket over the hose fiu lutg and thread the hose assembly into the front wheel cylinder Engage Ibc opposite end of the hose to the bracket on the frame. Insult the hor seshoe-type retaining clip, and con nect (he tube to the hose with the tube fitting nut. -' A rear brake hose should be in stalled so that it does not touch the muffler outlet pipe or shock absorber. Thread the hose into the rear brake tube connector Engage the front end of the hose to the bracket on the frame. Install the horseshoe-type re taining dip, and connect the tube to the hose with (he lube fitting nut. 005224 i /f7Q Cor S4y A-/ \SJ-l / /Z'g/'0f PRODUCED 8Y FORD 005225 12-0 >-29 Genera! Hydraulic Brak0 Service 12-01-29 & Clean ill parts in dean isopropyl alcohol, and inspect the pares for chipping, excessive wear or damage. When using a master cylinder repair Ut, Install all the pans supplied. 7. Be sure (hat all recesses, openings and interna! passages are open and dean. Place all pans an a dean pan or paper. 1 Inspect the master cylinder bore for signs of etching, pitting, seonng or rust If necessary to hone the master cylinder bore to repair damage, do sot exceed allowable hone specifications. Assembly 1. Dip all parts except the master cylinder body in dean brake fluid (E5A-M6C2J-A) Ford Part No. C6AZ-1954Z-A or DOT-3 equivalent. 2. Carefully insert the complete secondary piston and return spring v assembly in the tnas'er cylinder bore fFly, 23) '3 Install the primary piston assembly m the master cylinder bore 1 4 Depress the primary piston and install the snap ring m the cylinder bore groove. J. Install the push rod. boot and retainer on the push rod. if to equipped. Install the push rod assembly into the primary piston. Make sure the retainer ij properly seated and holding the push rod securely. 6. Position the inner end at the push rod boot (if so equipped) in the master cylinder body retaining groove. 7. Install the secondary piston siop bolt, if used, with an O-nng if screw is on bottom outside of master cylinder casting. S. Install the bleed screw (if so equipped). Install the gasket (diaphragm) in (he master cylinder filler cover Position the gasket as shown in Fig 23 Make sure the gasket is securely seated. J. Install the cover and gasket on the master cylinder and secure the cover into position with the retainer. s-- !- Pll-r, Typieal CLEANING AND INSPECTION DISC BRAKES Front wheel bearing end play is sets. Prior to replacement of lining, 1. Remove the wheel and ure from the critical and must be within the drum diameter should be checked hub Paid rotor- ' ' ' T ' ' sperniicnuoro. . - - .-- ionit'.w.\ne ihssl- the brake- dram 2. Inspect brake shoes and lining lor 3. Be sure the vehicle u centered on the braking surface diameter is within wear. U the lining is worn to within boist before servicing any front end specification If the braking surface ` * 1/S inch of the 'hoe. replace all (4) ' - components, to'a void bending or ' shoe and lining assenhlies (complete damaging the rotor splash shield on diameter exceeds specification, the drum must be replaced. axle set) O" front or rear wheels as , full right or,left wheel turns. _ 4. Check the condition of brake shoes, spprer-riata. '' Riding of the brake pedal (common rereading springs, hold-down 3. Yisuall' check the caliper. ff the - caliper-housing is leaking, it should be on left-foot applications) must be avoided during vehicle operation. springs, snd drum for signs of overheating. If the shoes hive a Slight replaced. If a seal is leaking, the 7. The whed and tire must be removed blue coloring, indicating overheating, caliper must be disassembled and newseals installed. If a poto.i is lazed her' ' * the bore, a new caliper hot ung is required. Refer to Pirt 12-20 for 4* rake `.eparately from the brake rotor, uninr drum brakes where the wheel, tire aad'drmn can be removed as a 2. Do not attempt tc dean oe restore oil the retracting snd hold-down spnngs should be replaeed. Overheated springs lose (heir pull and could cause the new lining to wear prtmanirelv, If aot replaeed. If the brake drams are mtor resurfacing procedure. ^' , , or grease-toaked brska linings. When beat spotted, indicating an overheated contaminated limnglare found, brake condition, they should be replaced. . }f - Hump must be replaced in complete 1 Inspect all other brake parts and OISC BRAKE SERWCr' axle sets. replace any that -cm or PRECAUTIONS .*> 1,`rl. L Q"-" er any other foreign material -ARUM BRAKE! - W3 .'/damaged. ' ** i -. Inspect (he brake drum and. if * " necessary, refinish. The maximum , must oe keg* off the linings surfaces ). Remove the wheal from the drum, inside broking surface diameter is ' of the rotor, end. external surfaces of an j remove the di urn as outlined in shown on each brake drum I Fig. 13). the hub during service operations. In -- Pan 12-02. If the maximum inside braking handling the rotor and caliper f 2. Use an industrial type vacuum j surface diameter shown an ihe drum assemblies, avoid defom.ation of the j cleaner to reglove all dust from \ is exceeded either by wear or brake rotor and mV king or scratching I the hacking plates and intertor of ^ refinisbing, the drum must be of brake linings. " the brake'drums. replaeed. Refer to Part 12.02 for 2. If k caliper piston is removed for any 3. Inspect the brake shoes for excessive refimshmg reason, the piston seal must be lining wear or shoe damage. If the " replaced. . - 2. During removal and installation of a ` lining ts worn within 1/32 inch of the rivet heads or tf the shoes are BRAKE BOOSTER wheel assembly, exercise care not to damaged, they must be replaeed. Check the booster operation as noted interfere with and damage the caliper Replace any lining that had been ' aitder Power Brake Functional Test If splash shield or the bleeder screw coataminaied with oil, grease or the brake booster is damaged or fining. broke fluid. Replace lining in aale inoperative, replace u uh a new booster. ./J ? 7 . .`Co*-- S/a, rfo-tucf /'n/.f /l-O/.-Jf. PRODUCED SY FORD r f- ',.'12-01-22- General Hydraulic Brake Service' '2-01., .VC .1 l | AJV, t .J.jee ' :V V.: !!- ' ' -I. Remove the line and inspedt the Hare for cracks or poor flare form. If the flacc ti not correct, cut it off and repeal the process, ' The finished flare must be square with the Ime, free of craclu and have a smooth mating surface to ensure a . leakproof connection. - Flaring a Line (Flaring-Bar Type) ' Refer to Ftp. 15 and 17. 1. Cut off and straighten the required 1 length of line. (A line cutting tool will _ simplify making a clean and square " cut)- . . fsr ss the thickness of the adapter above the bar. or even with the bar. depending on the tool used - 4. Fit (he adaptor onto (he line and slide the bar into the yoke Lock the bar in ' position with the line beneath the yoke screw. 3.' Form the single flare by lightening the yoke screw securely. 6. Release the screw and remove the adaptor . 7. Form the double flare by tighening the yoke screw again, with second adaptor filled, depending on the tool used. ' Z Square off the ends of the line with a ", file, and chamfer the end of the line ' to be flared. 3. Insert the line through its appropnate ribbed hole m the bar assembly until - - the end of the line sticks out about as ' t. Release the screw bar, and flared line, inspect the flare for cracks or poor flare form, and repeal the process tf the flare is not correct. 9. Repeat Steps 3 through .6 it the ' ' ` opposite wheel cylinder. ' ' ' FIG. 17 line Flaring (Flonnj Sor Typl ' BRAKE HOSE Replace a flexible brake hose ,r , shows signs of softening, eraekmi a other damage. When installing a new brake how. position the hose to avoid eontact wirt other vehicle pans. REMOVAL AND INSTALLATION 00522G BRAKE DRUM ... . . .. ' All Vehicles thru SOOO Series ' Use the following service proeedurs ' ' for both hydraulic and' air brakes. Since the F-100 thru F-3J0, E-10C-E-3JO and .'Bronco rear drums, and the P-500 (front ' and rear) procedures' apply to hydraulic -brakes only, they are covered ui Parr 12* i i 4. Remove the front wheel-to-hub retaining nuts (or rim and lire 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 bolt* and . nuts. ' - 6. Remove the brake drum/from the . huh. -` '" .FRONT BRAKE DRUM- 1. Raise the vehicle until the tire dears the floor and remove the wheel and tire from the hub. Loosen the brake shoe adjusting screw until the shoes no longer touch the brake drum. Remove (he grease cap and the gasket (if equipped) from the hub. Z On vehicles with 9,000 lb front sales and hydra ".lie brakes- remove the locknut, locking ring, dimpled washer and adjusting nut. On all other axies, remove the cotter pin, adjusting nut and flat washer from (he spindle. 3. Remove the outer bearing cone and roller assembly. Pull the hub and drum assembly off the wheel spindle. '7. Check the drum for damage or wear, - and repair or replace if necessary. If a new drum will be installed, be sure to remove the protective coating with degreaser. Install new grease retainer seals whenever a wheel and huh is removed. 8. Place the brake drum to the hub and install the retainers and retaining . holts, screws, or bolts and nuts. 9. install the hub and drum on the wheel spindle. Keep the hub centered on the spindle to prevent damage to the grease retainer or the spindle threads. 10. On vehicles with 9.000 tb front axles and hydraulic brakes install the outer bearing cone and roller assembly, uvl the bearing adjusting nut. On ill other axles, install the outer bcann| cone and roller and flat washer on ihj ' spindle Install the adjusting nut ,UT Install the wheel and tire on'the hub *' Then install the clamps (if applicable) .. tl and the wheel stud nuts.,,.. ; 12. While routing the wheel, tighten the' adjusting nut to specification. Adjuu ' wheel bearings as described in Group 11. . 13. On vehicles with 9000 lb front aalr and hydraulic brakes, install the dimpled washer with the dunpic indexed in one of the holes in the adjusting nut. Insult the locking nag lock nut and lighten to specification. Bend the locking nng over a (1st of the lock nuu -* - 14. Insull the gasket (if equipped) and the grose cap, and tighten the whed stud nuu to specification. Insull the hub eio (if equipped), and adjust the brakes ss described1 in this Part- \z OVERHAUL ,T7 An industrial type vacuum cleaner in BRAKE DRUM REFINISHING place of compressed air, u recommended E-100--E-3SD, F-100--F-350, U-100 to remove any dust and dirt present on Minor scores on a brake drum can be brake linings, pads, rotors and drums ccl removed with fine emery cloth, provided when performing wheel brake repairs. , the emery is thoroughly cleaned ofT the Abo, any machining done an brake < drum after the operation. linings or pads should be done using A badly scored, rough, or oui-of- properly exhaust ventilated equipment round drum should be ground or turned -a* /? 77 4 e, )So/. t on s drum lathe. Do not remove any more material from the drum than * necessary to provide t smooth surf***,of the brake shoe contact. Brake d<" maximum braking surface diameter u shown on each brake drum fFig- ' Brake drums which exceed the m**ll,"ia braking surface diameter shown o ,B* /l -o / -l z PRODUCED BY FORD *12-01-32' General Hydraulic Brake Servicr '2-01.32 (r-v . installed. If a piiton ii jelled in the bore, o new not replaced. If the brake drums are heat f. caliper housing is required.. - , spotted, indicating on overheated condition Refer to Part 12-20 for disc brake rotor they should be replaced. ' resurfacing procedure. . . , 5. Inspect all other brake parrs and replace any that . are worn or aomoged. .. DISC BRAKE SERVICE PRECAUTIONS 6. Inspect the brake drum ond. if necessary, lefinnh 1. Grease or ony other foreign material must be kept off the linings surfaces of the rotor, and externol surfaces of the hub during service operations. In handling the rofor and caliper assemblies, avoid deformation of the brake rotor and nicking or scratching of brake linings. 2.` If o caliper piston is removed for any reason, the The maximum inside braking surfoce diameter is shown on each broke drum (Fig. 33). if ,h, maximum inside braking surface diameter shown on the drum is exceeded either by we0r or refinishmg, the drum must be replaced. Refer to Port 12-02 for refinishmg. BRAKE BOOSTER "" - piston seal must be replaced. 3. During removal and installation of a wheel ossembly, exercise care not to interfere with ond . damage the caliper splash shield or the bleeder ` screw fitting. Check the booster ooerolion os noted under Power Brake Functional Test. If the broke Dooster is damaged or inoperative, replace it with o new booster. The brake booster is serviced only as on assembly, including the check valve. ' 4. Front wheel bearing end ploy is critical and must BRAKE TUBING ...I- be within specifications. V J. ` Be sure the vehicle is centered on thehoisf before' ` ` If a section of the brake tubing becomes damaged,, servicing any front end components, to avoid the entire section should be replaced with tubing of the ' bending or damaging the rotor splosh shield on full same type, sue, shape ond length. Capper tubing , right or left wheel turns. . should not be used in a hydraulic system. When 005227 ' 6v Riding of the brake pedal (common on left-foot . applications) must be avoided during vehicle bending broke tubing to lit underbody or rear axle contours, be careful not to kink or crack the lube.' . operation; . .... ` ,..7j, ..The wheel and fire must be removed separately HYDRAULIC LINES from the brake rotor, unlike drum brakes where the Double wall steel tubing is used throughout the btake wheel, tire and drum con be removed as a unit. system with the exception of the flexible hoses at the r-lVl^.8.-*. Do" nof attempt to clean or" restore oil or grease-. soaked brake linings. When contaminated linings front wheels, and ol,the,rear oxle Housing brake lube, connection.'. ' " .- ; , . . are found, brake linings must be replaced in ', . .complete axle sets: ' ' *' *"' ' . ' ` Always bleed the applicable primary or iecondary brake system after primary or ' ' 9. ' On Foirmont/Zephyr onfy, always replace rubber '. .. cqliper insulators and plastic sleeves when secondary broke system hose or line replacement. Centralize the pressure differential valve after bleeding replacing linings. Da not lubricate the slide pins. the system. ORUM BRAKES All brake tubing should be double flared properly to C: Remove the wheel from the drum, ond remove the drum as outlined in Part 12-02. wrt Use an industrial vacuum cleaner ta remove all dust | provide good leakproof connections. Clean the brake tubing by flushing with clean brake fluid before installation. from the backing plates and interior of the broke JL When connecting a tube to a hose, tube connector, drums. or brake cylinder, tighten the tube fitting nut' to Inspect the broke shoes for excessive lining wear or shoe damage. If the lining is worn within 1/32 ~ .specified torque with Mitbar Tool 11)2-144 or equivalent. . - - - inch of the rivet heads or if the shoes ore damaged, they must be replaced. Replace any lining that has BRAKE HOSE 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 A flexible brake base should be replaced if it shows signs of softening, crocking, or other damage. determine that the brake drum braking surface When installing a new front broke hose, position the diameter is within specification. If the broking hose to ovoid contact with other chassis parts. On all surface diameter exceeds specification, the drum vehicles except Foirmont/lephyr, place a new copper must be replaced. gasket over the hose fitting and thread the hose Check the condition of brake shoes, retrocting springs, hold-down springs, and drum for signs of overheating. If the shoes hove a slight blue assembly into the front wheel cylinder or eoliperFairmont/Zephyr front hose does not require a copper gasket and is reusable. Engage the opposite end ol th* coloring, indicating overheating, the retracting and hold-down springs should be replaced. Overheated springs lose their pull and could hose to the bracket on the frame. The while stripe on the hose should show no evidence of twisting. Install lh horseshoe-type retaining clip, and connect the tube to causa the new lining ta wear prematurely, if the hose with the tube fitting nut. 197? Cc- S/cy //^wt / rt/ / r ? * PRODUCED SV FORD 12-01-20 General Hydraulic Brake Service 12-01-30 OVERHAUL Removal of dujt and dirt from broke assemblies should be done by using the Rotunda brake vacuum [model 3-4-000?) or Rotunda brake parts washer (model 4500161 or an equivalent Brake assembly dust and dirt should not be removed by either blowing off with on air gun or voeuuming with a standard industrial vacuum cleaner because a heolth hazard from breathing in asbestos dust may develop. Also, any mochining done an brake linings or pads should be done using properly exhaust ventilated equipment Also, any machining done on brake linings or pads should be done using properly exhaust ventilated equipment. BRAKE DRUM REFINISHtNG ' ^ Minor scores on a brake drum ean be removed with fine emery cloth, provided the emery is thoroughly cleaned off the drum after the operation. A bodly scored, rough, or oul-of-round drum should be ground or turned on a drum lathe. [Refer to the lothe manufacturers instructions.) Do not remove any mare material from the drum than is necessary to provide a smooth surface for the brake shoe contoct. Brake drum maximum braking surface diameter is shown on each brake drum (Fig. 13). Broke drums which exceed the maximum braking surface diameter shown on the broke drum, either through wear or refinishing, must be reploced. The maximum broking surface diameter -specification, which is shown on each brake drum [Fig. 13), allows for a 1.52mm (0.060 inch) mochining cut over the original nominal drum diameter plus ,762mm [0.030 inch) additional wear before reaching the drum- discard diameter. . ` ' smxi enuu - TvriCM fluid or oil contamination that Is causing 0 brak pull, replace all four shoe ond lining assemblies ' 3. To check rotor runout, first eliminate the wheel beonng end play by tightening the od|ustmg nu, Then check to be sure the rotor can still be rota lei 4. Clamp a dial indicator to the spindle so the stylus contacts the rotor approximately one inch from th, outer edge. Rotate the rotor and lake an indicator reoding. If the reodmg exceeds .254mm (0 oto inch) total lateral runout within a six inch radius on the indicator, replace or re-surface the disc brake rotor. The following requirements must be met when re-surfacing disc broke rotors. Use a disc brake lothe to re-finish the disc brain rotors. (Follow the manufacturers instructions.) No more than ,503mm |0 020 Inch) of moienot may be machined equally of: each surface (A and B. Fig. 14). If rotor thickness falls below the minimum shown an each rotor, it must be replaced. 31 73mv II 29 INCHI o oo -a soBrtxm lejoo mem MINIMUM OVgftAU, THICKNCSS 29 97mm It 160 MOO 600 I6.99 0,M9m 10 090 inch MINIMUM OVgRAlU rMicN(U 79* II 130 ^ FMIU4 AND 9 230 ABOVf UOO CVW 14 x It ( ISO-290 20^>*Mn (1 ISO IMCNl 0330 moo INCH| _1 fl_ 9 100 HOO/4)O0CVWa WITH FOWIR IRAKCl minimum ovtiuu. TMlCKJtClI (t 120 INCH) 005228 1 MU M 41 I 1QCMS0 AND BRONCO 9 2901* J1. 9 290 4900 CVHR ItXCtrr Moo 4*00/4100 CW*R WHIN FOMlR IRAKIS! K*009 16 FIG. 14 Disc Broke Rotor Service Limits FIG. 13 Reor Broke Drum Maximum Inside Braking Surface Diameter Marking Location--E-100---350, Bronco, and F100--F-350 FRONT DISC BRAKES 1. Remove the shoe and Finings as described in Part 12-24 Disc Brakes--Light ond Heavy Duty-- Sliding Cotiper. 2. Measure the thickness of the brake lining. If the lining thickness ot any point on the assembly is less thon ,794mm (1/32 inch) above the backing plate or rivets, o- if the lining shows evidence of brake The finished braking surfaces of the rotor must be flat ond porallel within 0.025mm (0 001-ineM: lateral runout must not exceed 0.076mm (0 003 inch) total indicotor reading, and the surface finish of the braking surfaces must be )6 to SO micro inches. When the runout check is finished, adjust the bearings as described in Part 11-10, Wheel Hubs and Bearings--Front (except Front Wheel Drive) to prevent bearing failure. 5. Check the rotor for scoring Remove minor scold with a fine emery cloth. If the rotor is excessive*! scored, re-finish or replace the rotor if necessary- / 9 f ^ 'i "'I' 7~r~* e A iT4,^ /Tc-i-c/ 6aAj /<rf. ^ /i-er-iq PRODUCED BY FORD 005229 "f H; FAflT 12-01 GENERAL HYDRAULIC BRAKE SERVICE 12-01-27 b* of ti ev Of n. 31 it b- "h ! ir I ! '--ni-.'-' s 1 } r'T B sure vehicle is centered on hoist before ser* vicing any front end components, to avoid ben ding or damaging rotor splash shield on full right or le/t wheel turns. 4 Riding of brake pedal (common on left-front ap plications) must be avoided during vehicle operation. 7 The wheel and tire must be removed separately Irom the brake rotor, unlike drum brakes where the wnee), tire and drum can be removed as a unit. 4. Check condition of brake shoes, retracting spr ing, holddown springs, and drum for signs of overheating If shoes have a s.ight blue color ing, Indicating overheating, retracting and hold down springs should be replaced Overheated springs lose their pull and could cause new lin ing to wear prematurely, it not replaced. II brake drums are heat spotted, Indicating an overheated condition, they should be replaced 5. Refer to part 11-15, tor hub nut tightening pro cedure. A Do not attempt to clean or restore oil or greasesoaked brake linings. When contaminated lin ings are found, brake linings must be replaced Incomplete axle sets and the rotor braking sur faces wiped clean. g Do not lubricate caliper slide pins. Brake Booster Check booster operation as noted under Power Brake Functional Test. If brake booster is damaged or Inoperative, replace it. with a new booster. The brake booster is serviced only as an assembly, in cluding the check valve. to Calipers must be Installed with bleed screws In an upward position for proper Oleeding of air . .. B. ra. ke Tu. bin. g -> ' from brake system. ' If a section of brake tubing becomes damaged, Drum Brakes .^ '.k. ,, the entire section should be replaced with tubing ol ' ....................... ' .1. Remove wheel, tire and drum assembly from V spindle. ;' , -` */- the same type, size, shape and length. Copper tub ing should not be used in a hydraulic system. When bending brake tubing to fit body contours, be careful not to kink or crack tube. . . ?. Use an industrial vacuum cleaner to remove all " dust from backing plates and interior of the brake drums. WARNING: Never Inhale dust from brake linings. Asbestos dust when inhaled can be injurious to 1 health. Do not blow out dust with an air line. A vacuum cleaner equipped tor this purpose, brush or 'g should be carefully used to remove any dust. 4 Any dust should be contained in a sealed bag forj disposal. .. ^ Hydraulic Lines * ' Double wall steel tubing is used throughout the brake system with the exception of the flexible hoses at the front and rear wheels. Always bleed applicable primary or secondary brake system after primary or secondary brake system hose or line replacement. Centralize pressure differential valve after bleeding system. 3. Inspect brake shoes for excessive lining wear or shoe damage. It lining Is damaged or worn ' within 1/32 Inch of the rivet heads on riveted lin ings or within 0.060 inch of the shoe on bonded linings, they must replaced. Replace any lining that has been contaminated with oil. grease, or . brake fluid. Replace lining in axle sets. Prior to replacement of lining, drum diameter should be checked to determine that brake drum braking surface diameter is within specifications. If ` braking surface diameter exceeds specifica- Hon, drum must be replaced. , All brake tubing should be property double flared to providb good leakproof, connections. Clean brake tubing by flushing with clean brake fluid before installation. _ * . , When connecting a tube to a hose, tube connec tor, or brake cylinder, tighten tne tube fitting nut to specified torque with the D81L-600-A inch-pound torque wrench. 4 .**. ' *. ***. * * . * :* ' . ^................... ,, s * ,, . v * . ' ' J . . -r*- J f* o **.*.'' ** ' * PRODUCED BY FORD 13-JO-6 roue urum * A- I V-o i C?! lEMOVAt AND INSTALLATION v "/ p* Wlowmg opply to vehicles equipped with either 2. Assemble the cast spoke spider and drum assembly ,, o* hydraulic brokes. WARNING: Never inhale dust from brake linings. * dust wJ,en '"haled can be injurious to ^uh. Do not blow out dust with an air line. A cleaner equipped for this purpose, brush reg should be carefully used to remove any **,<. Any dust should be contained in a sealed bag , \ disposalCA5T SPOKE WHEELS / fconoval , loise the vehicle until the tire cleors the floor and install safety stands. Remove the tire and rim assembly by removing the clamps and nut. } Remove the cast spoke wheel and drum assembly from the front or rear axle. to the front or rear axle. Adjust the wheel beormgs and the axle shaft installation, if necessary, per the appropriate Section in Group 11 3. Install the tire and wheel assembly on the cost spake wheel. Refer to Section 11 -<71, Wheels, Rims and Tires for the procedure. 4. Tighten the front and rear wheel clamps to 299-352 N-m [220-260 fl-lbs). DISC WHEELS--OUTBOARD MOUNTED DRUMS Removal 1. Raise the vehicle until the tire clears the floor and install safety stands. Remove the nuts retaining the tire and wheel assembly to the hub [Fig. 6). } Remove the drum from the cast spoke wheel by 2. Remove the drum from the hub. removing the nuts, bolts and washers. 4 Check the drum for damage or wear and repair or reploce if necessary. If a new drum will be instolled, remove the protective coating with a degreaser. 3. Check the drum for damage or wear and repair or replace as necessary. If a new drum is installed, be sure to remove fhe protective coating with degreaser. .NOTE: Replace the drum with the same type and NOTE: Replace drums with drums of the same type '' sire.-failure to do so will affect vehicle Failure to do' so will affect vehicle Irock and' performance. Replace easr drums with cost drums. performance. Replace east drums only with cast Reploce centrifuse drums only with eentrifuse drums. Replace centrifuse drums only with A v drums. . . ..." .s' , V-v-rr-.. "`"i-'f centrifuse drums. .r\ >- r; . kneiitUtion . .' -t, Assemble the drum to the cast spoke spider. Tighten the nuts to 299-352 N-m [220-260 ft-lbs). , Check wheel grease seals for leakage. If the hub r-' is removed'from the axle, install new wheel grease * seals. '" - .... 005230 I I 4 Broke Drum Mountings "/fj-y /Vej/rVy EH q"|ripi '" A jAy ,^-w /.- ' ..<*/< c - ppoduced by fopd Generol Hydraulic Brake Service 12-01-19 i Injert the line through its appropriate ribbed hole *" ^ fa bar assembly until the end of the line sticks out about os far aj the thickness of the odapter obove the bar, or even with the bar, depending an the tool used. ^ p-|( (be adapter onto the line and slide the bar into iKc yoke. Lock the bor in position with the line beneath the yoke screw form the single flore by tightening the yoke screw securely. ^ feleose the screw and remove the odaptor. j Form the double flare by tighening the yoke screw ogain, with second adaptor fitted, depending on the tool used. 8. Release the screw bor, and flared line. Inspect the flare for cracks or poor flare lo/m, and repeot the process if the flare is not correct. 9. Repeat Steps 3 through 6 at the opposite wheel cylinder. BRAKE HOSE Replace a flexible brake hose if it shows ligns of softening, cracking or other damage When installing a new brake hose, position the hose to avoid contact with other vehicle parts OVERHAUL 005231 WARNING: Never inhale dust from brake linings. Asbestos dust when inhaled can be injurious lo health. Do not blow out dust with an .air line. A vacuum cleaner equipped for this purpose, brush or rag shoula be carefully used to remove any dust. Any dust should be contained in a sealed bag for disposal. ' Removal of dust and dirt from brake assemblies thould.be done by using the Rotunda brake vacuum Imodcl 34-0009) or Rotunda brake parts washer [model .660016) or on equivalent. Brake assembly dust and dirt should not be removed by either blowing off with an air gun or vacuuming with a standard industrial vacuum (leaner because o health hazard from breathing In oibeslos dust may develop. Also, any machining done on broke linings or pads should be done using properly ekhaust ventilated equipment. Also, any machining done on brake linings or pads should be dona using properly exhaust ventilated equipment. ' I FIG. 13 Rear Brake Drum Maximum Inside (' Braking Surface Diameter Marking ' location--E-1Q0---350, Bronco, and F- 100^*350 . ... .. .. v BRAKE DRUM REF1N1SHING % - . Minor scares on a brake drum eon be removed with fine emery cloth, provided the emery is thoroughly gleaned off the drum after the operation. A badly scored, rougn, or out-of-rcund drum :hoj'"v be ground or turned an a drum lathe. (Refer lo the lathe manufacturers imstiuctiaca.) Qrs oat remove any mare oterial from the drum than is necessary to provide a smooth surface for the brake shoe contact. Brake drum maximum braking surface diameter is shown on each broke drum (Fig. 13). Broke drums which exceed the "oximum braking surface diameter shown on the brake d'um, either through wear or refiniihing, mutt be 'placed. The maximum braking surface diameter specification, which is shown on each broke drum (Fig. 131. allows lor a 1.52mm (0.060 inch) machining cut ^er the original nominal drum diameter plus .762mm 10.030 inch) additional wear before reaching the drum- discard diameter. .. . NONT DISC BRAKES '" -L .Remove the shoe and linings ox described in Section . 12-24 Disc Brakes--light and Heavy Outy-- Sliding Caliper. `Measure the thickness of the brake lining, if the lining thickness at any point on the assembly is less than ,794mm (1/32 inch) above the backing plate or rivets, or if the lining shows evidence of brake fluid or oil contamination that is causing a braka pull, replace ail four shoe and lining assemblies. 3. To check rotor runout, first eliminule the wheel bearing end play by tightening the adjusting nut Then check toba sure the rotor can still be rotated. 4. Clamp a dial indicator to the spindle so the stylus contacts the rotor approximately one inch from the outer edge. Rotate the rotor and take on Indicator reading. If the reading exceeds ,254mm (0.010 inch) total lateral runout within o six inch radius on the indicator, replace or re-surface the disc broke rotor. The following requirements must be met whan re-surfacing disc braka rotors. . Usa a disc, brake lathe lo re-finish the disc brake rotors. (Follow the manufacturers instructions.) No more than .50Bmm (0.020 inch) of material may be machined equally off each surface (A and B, Fig. 14). if tofar thickness foils below the minimum shown on each rotar, it must be replaced. / So'Jj &` C.U.J S"/r 1 yj Yl'-Ct -/f PRODUCED BY FORD U-01-25 GENERAL HYDRAULIC BRAKE SERVICE 12-01-25 005232 HUB NUT NflOl 4*5)00 TIGHTEN NUT TO U3 37 \ N-m Mio-roou-rn after hub is seated using shcial hub installer tool ratine* a 00 not use wuract WRENCH FOR REMOVAL OR INSTal LATJON OF HUB NUT AFTER NUT (S TOROUfiO OIFORM HUT CQUJtfl WTO 5LOT QF ORiVISHAFT USING TOOL AS IN QtCATID IN THIS FIGURE THE NUT MUST NOT SFUT OR CRACC WHEN STAR eo IF NUT a SnJT ON CRACREO AFTER STAR ing. rr must be removio ano REPLACED WITH NEW, UNUSSO NuT. NO IT REMOVING ON MOVING A KUS nut AFTER staking MOU1RCS THE NUT l( RCFLACEO WITH A NEW ftt/r . % . THE STARING TOOL CAN W FASRtCAfCO FROM AN DUSTED HAROINEO CHISEL THE CORRECT RAOM5 ON THE CHISEL TlF Wia FflfVENT IMFROFCR STAKtftO. 00 NOT AT. TIMFTTO STARE WITH A SMARF U3GIO TOOL :*l -Av- + ri RA0IU9 I )UU i 23 FABRICATE TOOL *" `/***?**'. *v - FIG. 1.1 Hub Nut Installation A** i>p /V *' v **' Refer to Section 11-12, Front-Hubs for nut lightening procedure. * * . * . < * 1 H , .1 ... * . - 5. Be sure vehicle Is centered on hoist before ' servicing any front end components, to avoid bending or damaging rotor splash shield on full right or left wheel turns. " 6.-* Riding of brake pedal (common on left-front applications) must be avoided. 7. The wheel and tire must ue removed separately from the brake rotor, unlike drum brakes where the wheel, tire and drum can be removed as a unlt- , .. - 8. Do not attempt to clean or restore oil or grease soaked brake linings. When contaminated lin ings are found, brake linings must be replaced In complete axle sets and the rotor braking sur faces wiped clean. 9. Do not lubricate caliper slide pins. Drum Brakes .1. Remove wheel and tire assembly and drum assembly from spindle. " 2. Remove drum assembly from spindle. Use an industrial vacuum cleaner to remove all dust from backing plates and interior of the brake drums.- s *, .) -WARNING: Dust and dirt conditions present op wheel brake assemblies and rotors and drums, may contain asbestos libers that can represent a poten tial health hazard when made airborne by cleaning with compressed air. a *' ' All wheel brake assemblies should therefore be cleaned only with a vacuum cleaner suitable for use with asbestos libers. This type ol vacuum cleaner is available through the Rotunda Dealer Equipment Catalog. Dust and dirt from the vacuum cleaner should be disposed ol in a manner that prevents dust exposure. _ 10. Calipers must be installed with bleed screws in Any service done on brake linings, pads, rotors . an upward position lor proper bleeding of air and drums, should be done using properly exhaust from brake system. \ ventilated equipment. ^ j'ffrj '' ^ ' . ' S'pc ' y?- /1 4/ -i'S PPODUCEO BY FORD 12-01-08 General Brake Service 12-01-08 be msoected for wear or damage 9- On floating caliper type disc brakes. the caliper assembly must be removed from the spindle prior lo re moval of the shoe and lining assem blies. 10. On floating caliper typo disc brakes the calipers must not be inter changed from one side to the other When the caliper is installed on its proper anchor plate and spindle, the bleeder screw will point to the rear of the vehicle. If a caliper is installed on the wrong side of the vehicle, it is not possible to bleed the system properly 11. Do not attempt to clean or restore oil or grease soaked brake lin ings. When contaminated linings arc found, brake linings must be replaced in complete axle sets., DRUM BRAKES 1. Remove the wheel from the drum, and remove the drum as out- `lined in Part 12-02. 2. Brush alt dust from the backing plates and interior of the brake drums. ' 3: Inspect the brake shoes lor ex cessive lining wear or shoe damage If the lining is worn within 1/32 inch of the rive! heads or if the shoes are damaged, they must be replaced. Re place any lining that had -been con taminated with oil grease `or brake fluid. Replace lining in axle sets. Prior lo replacement of lining, the drum diameter should be checked to determine if oversize linings must be installed. . , 4. Check the condition of brake shoes, retracting springs, hold-down springs, and drum for signs of ov erheating. If the shoes have a slight blur, coloring, indjeatmg overheating. replacement of the retracting and hold-down springs is sirongly recom mended 0*trhealcd springs loe ineir pull and could cause the new lining lo wear prematurely, if ihrr are not re placed. II the brake druma ire heat Spotted, indicating a oierliealed con dition. ihrv should be replaced. 5. If the vehicle has JO 000 or more miles of operation on the brake lin ings or signs of overnealing are pres ent -hen relinmg brakes, the wheel cylinders should be disassembled and inspected for wear and entrance of dirt into the cylinder. The cylinder cups should oe replaced, thus avoiding future problems 6 Inspect ill other brake parts and replace any that are worn or dam aged 7. Inspect the brake drum and, tf necessary, refimsh. Refer to Pan 12-02 for refinishing BR 4KE TUBINC If a lection of the brake tubing be comes damaged, the enure 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 lo fit underbody or rear axle contours, be careful not to kink or crack the lube All brake tubing should be double flared properly to provide good leak proof connections Clean the brake tubing by Hushing with dean brake fluid before installation. When connecting a tube lo a hose tube connector ar brake cylinder, tighten the lube filling nut lo speci fied torque with Milbar Tool 1112 144 or equivalent. BRAKE HOSE BRAKE BOOSTER ' Cheek the booster operation as noted in Part 12-01 Pow-r Brake Functional Test. If the brake booster is damaged or inoperative replace it with a new booster The brake boost, er is seriictd only as an assembly. HYDRAULIC LINES ' Steel tubing is used throughout the brake system with the exception of ' the flexible hoses at the front wheels and at the rear axle homing brake tube connection. Always bleed Ibr applicable pH. marj or secondary brakr system alter primary or secondary brakr svarem hose or line replacement. Centralize the pressure differential valve after bleeding the system. ' A flexible brake hose should be re placed if il shows signs of softening, cracking, or other damage. When installing a new front brake hose, position ihc hose to avoid con tact with other caassti parts. Place a new copper gasket over the hose Til ting and thread the hose assembly into the front wheel cylinder. Engage the opposite end of the hose to the bracket on the frame. Install the hor seshoe-type retaining dip, and con nect the lube to the hose with the tube fitting nut. - A rear brake husc should be in stalled so that it does not touch the muffler outlet pipe or shock absorber. Thread the hose into the rear brake tube connector. Engage the front end of the hose to the bracket on the frame. Install the horseshoe-type re taining dip. and connect the tube to the hose with the tube fitting nut 005233 T PPOOUCEO BY FORD I2-OM9 General Hydraulic Braka Service 12-01-29 S. Qean til parts in clean isopropyl alcohol. and inspect tbe parts for chipping, escEssve wear or damage, When using a master cylinder repair kit, install all the parts supplied. 7 Be lure that all recesses, openings and internal passages ire open and clean. Place all parts on a clean pin or paper S. Inspect the master cylinder bore for signs of etching, pitting, scoring or rust. If necessary to hone the master cylinder bore to repair damage, do not escccd allowable hone specifications. Assembly 1. Dtp si) parts except the master cylinder body in clean brake fluid (ESA-M6C25-A) Ford Part No C6AZ-19542-A or DOT-3 equivalent 2. Carefully insert tbe complete secondary piston and return spring assembly in tbe master cylinder bore (Fig. 23). -J Install the primary piston assembly m , the master cylinder bore. ' 4. Depress the primary piston and install (he snap nng in the cylinder bore groove. . j Install (he push rod, boot and retainer on the push rod, ifso equipped. Insrail tbe push rod assembly into the primary piston. Make snrs tha retainer Is properly seated and holding the push rod securely. 6. Position the inner end of the push rod boot (If so equipped} m the master cylinder body retaining groove. 7. Install tbe secondary piston stop bolt, if used, with an O-nng if screw tj on bottom outside of master cylinder .casting. 8. Install the bleed screw (if to equipped). Install the gasket (diaphragm) in the master cylinder filler cover, Position the gasket as shown in Fig 23. Make sure the gasket b securely seated. 9 Install the eoe- and gasket on the master cylinder and secure the cover into position with the retainer Rl*f Pllp| Hun-c FIG. 2A Removing Snap Ring--- Typical 005234 CLEANING AND INSPECTION DISC BRAKES 4. Front wheel bearing end play is 1. Remove the wheel and tire from the hub and rotor. 2. Inspect brake shoes and lining for wear. If the lining is worn to within "' l/r inch of the shoe, replace all (4) shoe and lining assemblies (complete sale set) on front or rear wheels as appropriate. 3. Visually cheek the caliper. If the caliper housing is leaking, u should be replaced. If a seal is leaking, the caliper must be disassembled and new seals installed. If a piston is seized us the bore, a new caliper housing is repaired. Refer to Part 12-20 for disc araka rotor resurfacing procedure^.... critical and must be within specifications. 3. Be sure the vehicle is centered on the hoist before servicing any front end components, to'avoid bending or damaging the rotor splash shield on full right or left wheel turns. 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 tbe brake rotor, unlike drum brakes where the wheel, tire tad drum can be removed as a unit. I. Do oot attempt to clean or restore ail ' or grease-soaked brake linings. When 'contaminated linings are found, brake linings must be replaced in complete DISC BRAKE SERVICE- axle seta. - PRECAUTIONS ( * -1!-. Oreaoc or any other foreign material- DRUM BRAKES. . must be kept ofT the linings surfaca 1. Remove the wheel from tbe drum, ' of the rotor, tnd external surfaces of and remove the (trim as outlined in the hub during service operations. In Pin 12-02. bsndJing the rotor and caitper 2. Use an mouitnal type vacuum issoabliea, avoid defortnnuon of the cleaner to remove all dust from brake rotor and nicking or scratching the backing plates and interior of of brake linings. 1 If s caliper piston is removed for sny the brake drums. 3. Inspect the brake shoes for excessive reason, tbe piston sent must be lining wear or shoe damage. If the replaced. ' ' lining is worn within 1/32 inch of tbe 3 During removal and installation of s rivet heads or if (he ihocs are wheel assembly, exercise care not to damaged, .the; must be replaced. interfere with and damage the caliper ' Replace any lining that haa been iplssb shield or the bleeder screw contaminated with oil. grease or fitting. brake fluid. Replace lining in sale sets. Pnor to replacement of lining, the drum diameter should be checked to determine that the brake drum braking surface diameter is within specification. If the braking surface diameter exceeds specification. Ihc drum must be replaced. 4. Check (he condition of brake shoes, retracting springs, hold-down springs, and drum Tor signs of overheating. If the shoes have a slight blue coloring, indicating overheating, the retracting and hold-down spring! should be replaced. Overheated springs lose their pull and could cause tha new lining to wear prematurely, if not replaced- If the brake drums are heat spotted, indicting an -vr-beited condition, they should he replaced i. Inspect all other brake parts and replace any that are worn or damaged- * d.-Inspect.tbe brake drum and, if ' necessary', refinish. Tbe maximum Inside braking surface diameter Is shown on each broke drum (Fig. 23). If tbe maximum inside braking surface diameter shown on the drum is exceeded either by wear or refinishing. the drum must be ' replaced. Refer to Pan 12-02. for rcfinuhing. 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. * * i*i. PRODUCED BY FORO 12-01-27 General Hydraulic Brake Service '2-01., 8. Remove the line and inspect the flare for cracks or poor flare form If the flare is not correct, cut it ofT and repeat the process. The finished flare must be square With Ihe line, free of cricks and have a smooth mating surface to ensure a leakproof connection. Flaring a Lino (Flaring-Bor Typ| Refer to Figs. 13 and 17 1. Cut off and straighten the required length ofltne. (A line cutting tool will . simplify making a clean and square cut). 2. Square ofT the ends of the Une with a file, and chamfer the end of the line to be flared. 1. Insert the line through its appropriate ribbed hole in the bar assembly until the end of the line sucks out about as far as the thickness of the adaptor' above the bar, or even with the bar, depending on the tool used. ' 4 Fit the adaptor onto the line and slide the bar into the yoke. Lock the bar in position with ihe line beneath the yoke screw ' 3. Form the single flare by tightening the yoke screw securely, 6 Release the screw and remove tbe adaptor 7 Form the double flare by ughening the yoke screw again, with second adaptor fitted, depending on Ihe tool used 8. Release the screw bar, and flared line. Inspect the flare for cracks or poor flare form, and repeat the process if (he flare is not correct. 9. Repeit Steps 3 through 6 at the opposite wheel cylinder Type) BRAKE HOSE Replace a flexible brake hose if * shows signs of softening, cracking Other damage. a When installing a new brake ho*, position the hose to avoid contact mu' other vehicle parts. REMOVAL AND INSTALLATION BRAKE DRUM , 4. Remove the front wheel-lo*hub bearing cone and roller assembly, sad All Vehicles thru 9000 Series ` Use the following service procedures for both hydraulic and air brakes. Since the F-100 thru F-350. E-IOO-EOSO and Bronco rear drums, and the P-300 (front.-- .. and rear) procedures apply to hydraulic brakes only, they are covered in Part 12- ` retaining nuts (or rim and tire attaching nuts). Remove the wheel (or rim and tire) from the hub and drum. Remove the brake drum retainers and attaching bolts, screws or bolts and nuts. - Remove the brake drum from, tbe the bearing adjusting nut. On ill other aslea. install the outer beaneg cone and roller and flat washer on the spindle. Install the adjusting put. ' `If. Install tbe wheel and lire on the huh' Then install the clamps (if applicable) , and the wheel stud nuts.",, . FRONT BRAKE DRUM Sub. ' 12. While rotating the wheel, tighten the^. '' 7 Check the drum for damage or wear, adjusting nut to specification. Adjust 1. Raise the vehicle until tbe tire clean and repair or replace if necessary. If wheel bearings as described m Group the floor and remove the wheel and a new drum wilt be installed, be sure . U. . .. tire from the bub. Loosen the brake , hoe adjusting screw until tbe shoo to remove tbe protective coating with degreaser. no longer touch the brake drum Remove tbe grease cap and the gasket lastall new grease retainer teals whenever a wheel end bub Is removed. (if equipped) from the bub. 8. Place the brake drum to the bub and 2. On vehicles with 9.000 lb front axles install the retainers and retaining -nd hydraulic-brakes, remove the . _ - 'bolts, scr3v.t, or b-1'* and ""EL locknut, locking ring, dimpled washer and adjusting nut. On all other axis, 9 Install the hub and drum on tbe wbed remove the cotter pin. adjusting nut spindle. Keep tbe bub centered on the II On vehicles with 9000 lb front site and hydraulic brakes, install the dimpled washer with the dimplr indexed in one of the boles in ihr adjusting out. Install the locking nng lock nut and tighten to speofieinoo. Bend the locking nng over a flat ofthe lock nut. 14. Install the gasket (if equipped) rnd and flat washer from the spindle. 3. Remove the outer bearing cone and spindle to prevent damage to the grease retainer or tbe spiedle threads. the grease cap, and tighten tbe whed stud nuts to specification. Install the roller assembly. Pull the bub and 10 On vehicles with 9,000 lb front axles hub cap (if equipped), and tdjusi the drum assembly off the wbed spindle. and hydraulic brakes install tbe outer brakes as described in this Part. OVERHAUL Ait industrial type vacuum cleaner ut place of compressed air, is recommended to remove any dust and dirt present on brake lrninp, pads, tutors and drums ect, when performing wheel brake repairs. Also, any maehinmg done on brake linings or pads should be done using properly exhaust ventilates! equipment. BRAKE DRUM REFINISHING E-100---350, FOOD--F-350, U-100 Minor scores on a brake drum can be removed with fine emery cloth, provided (be emery is thoroughly cleaned off tbe drum after (he operation. A badly scored, rough, or out-of round drum should be ground or turned on a drum lathe. Do not remove *7 mote material from tbe drum than <* necessary to provide a smooth surface f<* the brike shoe contact. Brake drum maximum braking surface diameter shown on each brake drum (Fig Brake drums which exceed the maxim* braking surface diameter shown on t 005235 l2-bi-32 ' v~* ' General Hydraulic Brdk Strvirs- 12-Ql^j installed. If a piston is seized In the bore, o new caliper housing is required. -- . . . Refer to Part 12-20 for dlte broke rotor resurfacing procedure. . DISC BRAKE SERVICE PRECAUTIONS 1. Grease or any other foreign material must be kept off the linings surfoees 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 lining*. ... 2. ` If a caliper piston is removed for ony reason, the piston seal must be replaced.. . . ,,' 3. During removal and installation of a wheel assembly, exercise care not to interfere with and damage the caliper splash shield or the bleeder ' screw fitting. w ' ' 4. Front wheel bearing end play is critical and must be within specifications. 2. Be sure the vehicle is centered on the hoist before servicing ony front end components, to ovoid bending or damaging the rotor splash shield on full right or left wheel turns. 6. Riding of the brake pedaf (common an left.foot applications) must be avoided during vehicle operation. 7. The wh.eel 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. 8. Do not attempt to clean or restore ail oc greasef soaked brake linings. When contaminated linings ore found, brake linings must be replaced in complete' axle sets. ` , 9. On Fairmont/Zephyr only, always reolace rubber coliper insulators and plastic sleeves when replacing linings. Do not lubricate the slfda pins. not replaced, if the brake drums are heat spotted, indicating an overheated.condition they should be replaced. * ' 5. Inspect all other brake ports and replace any that ore worn or damaged. 6. Inspect the broke drum ond, if necessary, lefinish. The maximum inside braking surface diameter Is shown on each brake drum (Fig. 33). If the maximum inside braking surface diameter shown on the drum is exceeded either by weor or refinishing, the drum must be replaced Refer to Port 12-02 )0,' refinishing. BRAKE BOOSTER' ' ' ' Check the booster operation as noted under Power Brake Functional Test, if the brake booster Is domoged ' or inoperative, reploce it with o new booster The brake booster is serviced only as an assembly, including fhe check valve. - BRAKE TUBING . If a section of the brake tubing becomes damaged,,' the entire section should be replaced with tubing of the same type, size, shape ond length. Copper tubing should not be used in a hydraulic system. When bending broke 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 broke - system with the exception of the flexible hoses at the fcont wheels ond at the rear axle housing brake tube connection. ' Always bleed the applicable .primary or secondary broke system after primary or secondary broke system hose or line replacement. ' Centralize the pressure differential valve after bleeding the system. DRUM BRAKES 1. Remove the wheel from the drum, and remove the drum as outlined in Part 12-02. 2. Use an industrial vacuum cleaner to remove all dust from the bucking plates and interior of the brake drums. . '" 3. Inspect the brake shoes for excessive lining wear or shoe domage. If the lining is worn within 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. 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 puli ond could cause the new lining to wear prematurely, if All brake tubing should be double flared properly to provide good leakproof connections. Clean tha broke tubing by flushing with clean brake fluid before ins tallation. When connecting a tube to a hose, lube connector, or broke cylinder, tighten the tube fitting nut to specified lorque"With Milbs-f Tool llJ2-14jsr equivalent. , BRAKE HOSE A flexible brake hose should bo 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. On all vehicles except Fairmant/Zephyr, place a new copper gasket over tha hose fitting and thread the hose assembly into the front wheel cylinder or caliper. Fairmant/Zephyr front hose does not require a coppe' gasket and is reusable. Engage the opposite end of the hose to the bracket on the frame. The white stripe on the hose should show no evidence of twisting. Install the horseshoe-type retaining clip, and connect the tube to the hose with the lube fining nut. 005236 . JOftaT HHuuuuiD BY FOBD ji.---- - t !l 12-01-20 General Hydraulic 8rake Service 12-01-20 OVERHAUL Removal of dust and dirt from broke assemblies should be done by using the Rotunda brake vacuum (model 34-0009) or Rotunda brake parts washer (model 65001d| or an equivalent. Brake assembly dust end dirt should not be removed by either blowing off with an air gun or vocuuming with o standard industrial vacuum cleaner becouse a health hazard from breathing in asbestos dust may develop Also, any machining done on brake linings or pads should be done using properly exhoust ventilated.eguipment. AIsa. any machining done on brake linings or pads should be done using properly exhaust ventilated equipment. BRAKE DRUM REFINISHING Minor scores an a brake drum can be removed with fine emery cloth, provided the emery is thoroughly cleaned off the drum after the operation. "1 A bodly scored, rough, or out-of-round drum should be ground or turned on o drum lathe. (Refer to the lathe manufacturers instructions.) Do not remove any more material from the drum than is necessary to provide a smooth surface for the brake shoe contact. Brake drum maximum braking surface diameter it shown on each brake drum (Fig. 13). Brake drums which exceed the maximum braking surface diameter shown an the broke drum, either through weor or refinishing, must bo replaced. The maximum braking surface diameter specification, which is shown on each brake drum (Fig 13), allows for a 1.52mm (0.060 inch) machining cut over the original nominal drum diameter plus .762mm (0.030 inch) additional wear before reoching the drum- discard diameter. - , fluid or oil contamination that is causing a brqk, pull, replace all four shoe ond lining assemblies 3. To check rotor runout, first eliminate the *hj bearing end play by tightening the adjusting nU| Then check to be sure the rotor can still be rotated 4 Clamp a dial mdicotor to the spindle so the stylu, contocts the rotor approximately one inch from )h outer edge Rotate the rotor and take an indicate, reading. If the reading exceeds 254mm (0 0)0 inch) total lateral runout within a six inch radius on the indicator, replace or re-surface the disc brake rotor. The fallowing requirements must be met when re-surfacing disc brake rotors. Use a disc brake lathe to re-finish the disc brake rotors (Follow the manufacturers instructions.) No mare than .508mm (0.020 inch) of material moy be machined equally off each surface (A ond 6, Fig. 14). If rotor thickness falls below the minimum shown on each rotor, it must be replaced. -=L>rSI TS-- II 3S 1NCMI a 00 -0 SOB--.--. 10 030 INCVI MINIMUM QVlAAbl Tnicansu 9 97mm II ISO INCHI J l%tn IQ IQ INCni 0 00 Q.S0frA 10420 INC-- MINIMUM OVtRALL TMICKNCSJ ;# n ITOtMCM) F.2SQ 14 X 41 AMO F SO AAOVf UOO CVVI (4 X 2) I ISO-350 30 nmeet It 190 INCH) Q.OQ O.S06mm fO.WO INCH) F 100 1400)4700 6Vn* WITH POWtA IRAKI! 005237 FIG. 13 Rear Brake Drum Maximum Inside Braking Surface Diameter Marking Location--E-10Q--E-350, Bronco, and F10O--F-350 FRONT DISC BRAKES 1. Remove the shoe and linings as described in Part 12-24 Disc Brakes--light ond Heavy DutySliding Caliper. 2. Measure the thickness of the brake lining. If the lining thickness at any paint on the assembly is less thon ,794mm (1/32 inch) above the backing plate or rivets, or if the lining shows evidence of brake FIG. 14 Disc Brake Rotor Service limit! The finished broking surfaces of the rotor muil be flat and parallel within 0.025mm (0.001 -inch); lateral runout must not exceed 0.076mm (0.003 inch) totol indicator reading, ond the surface finish of the broking surfaces must be 16 to 80 micro inches. When the runout check is finished, adjust the bearings as described in Part 11-10, Wheel Hubs ond Bearings--Front (except Front Wheel Drive) to prevent bearing failure. 5. Cheek the rotor for scaring. Remove minor scores with a fine emery cloth. If the rotor is excessively scored, re-finish or replace the rotor if necessary. PRODUCED BV FORD ;jUtf 12-01 general hydraulic brake service 12 01-27 . g, 3Ure vehicle is centered on hoist before ser vicing any front end components, to avoid ben(jing or damaging rotor splash shield on full right or left wheel turns 4 Riding of brake pedal (common on left-front ap plications) must be avoided during vehicle operation. 7 The wheel and tire must be removed separately Irom the brake rotor, unlike drum brakes where the wheel, tire and drum can be removed as a unit. 4. Check condition of brake shoes, retracting spr ing, holddown springs, and drum lor signs of overheating. If shoes have a slight blue color ing, indicating overheating, retracting and hold down springs should be replaced. Overheated springs lose their pull and could cause new lin ing to wear prematurely, if no! replaced. If brake drums are heat spotted, Indicating an overheated condition, they should be replaced. 5. Refer to part 11-15, for hub nut tightening pro cedure. t Do not attempt to clean or restore oil or grease- joaked brake linings. When contaminated lin ings are found, brake linings must be replaced In complete axle sets and the rotor braking sur faces wiped clean. i j Do not lubricate caliper slide pins. to Calipers must be Installed with bleed screws in ,an upward position for proper bleeding of air ' from brake system. " Drum Brakes w x. 1. Remove wheel, tire and drum assembly from ' spindle. '% ' --- . 2. Use an Industrial vacuum cleaner to remove all ' dust from backing plates and Interior of (he brake drums. . WARNING: Never Inhale dust from brake linings, Asbestos dust when inhaled can be Injurious to health. Do not blow out dust with an air line. A vacuum deanerequlpped for this purpose, brush or r*g should be carefully used to remove any dust. Any dust should be contained In a sealed bag lor aitposal. . 3. Inspect brake shoes for excessive lining wear or shoe damage. If lining Is damaged or worn within 1/32 Inch of the rivet heads on riveted lin ings or within 0.060 Inch of the shoe on bonded linings, they must replaced. Replace any lining lhat has been contaminated with oil, grease, or brake fluid. Replace lining in axle sets. Prior to replacement of lining, drum diameter should be checked to determine that brake drum braking turface diameter is within specifications. If braking surface diameter exceeds specificsHon, drum must be replaced. Brake Booster Check booster operation as noted under Power Brake Functional Test. If brake booster is damaged or Inoperative, replace,it with a new booster The brake booster is serviced only as an assembly, In cluding the check valve. Brake Tubing i ' * ,* .* * *' . 1 . "i`*m * " **' * If a section of brake tubing becomes damaged, the entire section should be replaced with tubing of the same type, size, shape and length. Copper tub ing should not be used in a hydraulic system When bending brake tubing to lit body contours, be -careful not to kink or crack tube. -. Hydraulic Lines - Double wall steel tubing Is used throughout the brake system with the exception of the flexible hoses at the front and rear wheels. . Always bleed applicable primary or secondary brake system after primary or secondary brake system hose or line replacement. Centralize pressure differential valve alter bleeding system. All brake tubing should be properly double flared to provide good feSKproof connections Clean brake tubing by flushing with clean brake fluid before Installation. When connecting a tube to a hose, tube connec tor, or brake cylinder, tighten the tube fitting nut to specified torque with the D81L-600-A inch-pound torque wrench. 005238 PROOUCEO BY FOP IEMOVAL and installation rv* following apply to vehiclej equipped with either ^ Ot hydraulic brakes. y*AIMING: Never inhale dust from broke linings. Aiteiloi duit when inhaled can be injurious to Do not blow out dust with an air line. A cleaner equipped for this purpose, brush ,, reg should be carefully used la remove any Any dust should be contained in a sealed bag disposal. CAJT SPOKE WHEELS ewnovel tali* the rehicle until the tire clears the floor and install safety stands. Remove the tire and rim assembly by removing the damps and nut. j iemove the cast spoke wheel and drum assembly trom the front or rear axle. 1 Remove the drum from the cast spoke wheel by removing the nuts, bolts and washers, s Check the drum for damage or wear and repair or replace if necessary If a new drum will be installed, remove the protective coating with a degreaser, NOTE: Replace the drum with the same type and ' "trie Failure to do'so will affect vehicle performance. Replace east drums with cast drums. Replace centrifuse drums only with centrifuse > 'drums. . . ,. . t Uwullction ^ 1. Assemble the drum to the cast spoke spider. Tighten the null to 299*352 N-m (220-260 ft-lbs). 2. Assemble the cast spoke spider ond drum assembly to the front or rear axle. Adjust the wheel bearings and the axle shaft installation, if necessary, per the appropriate Section in Group 11 3. Install the tire and wheel ossemoly on the cast spoke wheel. Refer to Section 11-01, Wheels, Rims ond Tires for the procedure. 4. Tighten the front and rear wheel clamps to 299-352 N-m (220-260 ft-lbs|. DISC WHEELS--OUTBOARD MOUNTED DRUMS Removal 1. Raise the vehicle until the lire clears the floor and instoll safety stands. Remove the nuts retaining the tire ond wheel assembly to the hub (Fig. 6). 2. Remove the drum from the hub. 3. Check the drum for domoge or weor and repair or replace as necessary. If a new drum is installed, be sure to remove the protective coating with degreaser. - NOTEj Replace drums with drums of the same type. Failure to do so will offeet vehicle "track and performance. Replace cost drums only with cast drums. Replace centrifuse drums only with ''-centrifuse drum*.' * * ... Check wheel grease seals for leakage. If the hub Islremoved from the axle, install new wheel grease seols. ' i Ii H i t PRODUCED BY FORO U-0M9 General Hydraulic Brake Service 12-01-19 i i Insert the line trough iti appropriate ribbed hole 8. Release the screw bar, and flared line Inspect the in the bar assembly until the end ol the line sticks flare for cracks or poor flare form, and repeat the out about os far as the thickness of the adapter process if the flare is not correct. above the bar, or even with the bar, depending on : the tool used. 9. Repeat 5teps 3 through 6 at the opposite wheel cylinder. t fit the adapter onto the line and slide the bor into the yoke Lock the bar in position with the line beneath the yoke screw. BRAKE HOSE ^ Form the single flare by tightening the yoke screw securely. Replace a flexible brake hose if if shows signs of 4. Release the icrew and remove the adaptor. softening, cracking or other damage. y. Form the double flare by fighening the yoke screw again, with second adaptor fitted, depending on the tool used. When installing a new broke hose, position the hose to avoid contact with other vehicle parts. OVERHAUL WARNING: Never inhale dust from brake linings. Asbestos dust whan inhaled can be injurious to health. Do not blow out dust with an lr line. A vacuum cleaner equipped for this purpose, brush or rag should be carefully used to ' ..remove any dust. Any dust should be contained in o sealed bag for disposal. ' ' Removal of dust and dirt from brake assemblies , . should be done by using the Rotunda broke vacuum ' 'model 34-0009) or Rotunda brake parts washer (model . , 650016) or on equivalent. Brake assembly dust and dirt 1' * thould not be removed by either blowing off with on , sir gun or vacuuming with a standard industrial vacuum '. cleaner because a health hazard from breathing in . * asbestos dust may develop. Also, any machining done on brake finings or pods should be done using properly " - eihauit ventilated equipment. Also, any mochining -r don* on brake linings or pads should be done using '' property exhaust Ventilated equipment. BRAKE. DRUM REFINISHING Minor scores on a brake drum can be removed with fine emery doth, provided the emery is thoroughly (leaned off the drum after the operation. A badly scored, rough, or out-cf-rouno drum should be ground or fumed on a drum lathe. (Refer la the lathe manufacturers instructions.) Do not remove any more material from the drum than is necessary to provide a tmaolh surface for the brake shoe contact. Brake drum maximum broking surface diameter is shown on each h*oke drum (Fig. 13). Brake drums which exceed the maximum braking surfoce diameter shown on the brake d'um, either through wear ac refuushing, mutt h "placed. The maximum braking surface diameter 'Pacification, which is shown on each brake drum (Fig. 13), allows for a 1.52mm (0.060 inch) machining cut m>tr the original nominal drum diameter plus .762mm 10 030 inch) additional wear before reaching the drum^Kord diameter. fRONT DISC BRAKES Remove the shoe and linings as described In Section 12-24 Disc Brakes--Light and Heavy DufySliding Caliper. 2=5, RA*t DRUM . rr^tCAt iu"unnL ^ * FIG. 13 Rear Brake Drum Maximum Inside Braking Surface Diameter Marking location--E-100--E-350, Bronco, and F- , . 100--F-350 , . .. . . 2. Measure the thickneii of the brake lining. If the lining thickness at any point on the assembly is less than ,794mm (1/32 inch) above the backing plate or rivets, or if the lining shows evidence of broke fluid or oil contamination that is cousing a broke pull, .replace all,,four shoe and lining assemblies. 3. To check rotor runout, first eliminate the wheel bearing end play by tightening the adjusting nut. Then check to be sure the rotor can still be rotated. 4. Gamp a dial indicator to the spindle so the stylus contacts the rotor approximately one inch from the outer edge. Rotate the rotor and take an indicator reading, if the leading txteeds .254mm (D.SMO inch) total lateral runout within o six inch radius on the indicator, replace or re-surface the disc brake rotor. The following requirements must be met when ra-eurfacing disc brake rotors. Use o disc brake lathe to re-finish the disc broke rotors. (Follow the manufacturers instructions.) No more than ,508mm 10.020 inch) of material may bo machined equally off each surface (A and B, Fig. 14|. If rotor thickness falls below the minimum shqwn on each rotor, it must be reploced. 005240 hhuOUCEO By Fono I 12-J1'25 general hydraulic brake service 12-01-25 HAT WARMER INBOOJfl HUB MjT N801T1 4 8100 TIGHTEN NUT TO J4J J71 H m 1100*200 II n\ ARTM hub is StATCP UTSUINPG-1S1P0E*CAIAL0H0UNtOITNSUTSAUIMSBPATCOTOL WflNCH FOR REMOVAL OB INJTAL LAHON OF HUS NUT AFTER nUT IS rSOLOPTO0y*lOOORIlVFEOSRHMARnTutUSCINOGLLATOROINLTAOS >N. OlCATSO IN THIS FIGURE 7h( NUT MUST NOT SPUT QB CRACK WH(N STAKED IP NUT IS SPLIT OB CRACKCO AFTER STAK ING rr MUST s< R6M0VI0 ANO BKPLACSO with NEW. UNUStO NUT NOTE REMOVING OB MOVING A HUS NUT AFTER 1TAKING requires THE NUT 0 replaced with a new HUT t6ChcPAsBtBaIkCiAnTgEOtoFoRlOCMaAnN l&IITfO HARDENED CRaHdISiuEsL oTnMITChOiBCBHCICSTEL TIP Wiu, PREVENT IMPROPER TSfTMAPKTINGTO0S0TAnKoEtWAITTH A SHARP E0O8O TOOL PAOIUS 11mm $ a$ I 00 IN S oil fabricate tool AS ABOVf FIG. 11 Hub Nut Installation MS ft 7 A Refer to Section 11-12, Front Hubs for nut tightening procedure. 5. Be sure vehicle Is centered on hoist before servicing any front end components, to avoid bending or damaging rotor splash shield on full right or left wheel turns. 6.' Riding of brake pedal (common on left-front applications) must be avoided. 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 -. ..................................... t S. Do not attempt to clean or restore oil or greasesoaked brake linings. When contaminated lin ings are found, brake linings must be replaced In complete axle sets and the rotor braking sur faces wiped clean. 9. Do not lubricate caliper slide pins. 10. Calipers must be Installed with bleed screws in an upward position lor proper bleeding of air from brake system. Drum Brakes ' .' 1. Remove wheel and tire assembly and drum assembly from spindle. ' 2. Remove drum assembly from spindle. Use an Industrial vacuum cleaner to remove all dust . from backing plates and Interior of the brake - drums. . '.. . , WARNING: Dust and dirt conditions present on wheel brake assemblies and rotors and drums, may contain asbestos libers that can represent a poten tial health hazard when made airborne by cleaning with compressed air. All wheel brake assemblies should therefore be cleaned only with a vacuum cleaner suitable lor use with asbestos libers. This type of vacuum cleaner is available through the Rotunda Dealer Equipment Catalog. Dust and dirt Irom the vacuum cleaner should be disposed of in a manner that prevents dust exposure. Any service done on brake linings, pads, rotors and drums, should be dona using properly exhaust ' ventilated equipment -- 005241 produced by ford . ijiBisriTir \\ i'v ) MUTUAL 21040 Grrenficld Rml, IVtroil, Michican 48207 Tel. (313) GGG-2325 December 29, 1975 Fc.jl Dialer novelopmont C'alci chip Presidents P.T-f.ro tn iVhestos Dust ' f.*'a licit ,s. rads and clutch assemblies ore mile nf osbestos, which has long i . v ..i<i.d as a material prcjuclr.g a l.~:01.1 in the health of those v.ho 1n- .( via <':st In excessive cisur.ts over n 1r,.g i'i Ind of tl.-a. During the last i w i* hrmvcr, aU'cnilcn lies h:*n tern".I on the ('.-.vclap.r.ant of cancer of t'.a lc.r and other body aicas following c;.|u'.uri: to ashrstGs dust. An r.lcrL mr.rcrnlng the potential health l.icnl for persons exposed to asbestos *ii ] t! i servicing of renter vc.lilclo Lrrl.s .u I rlutr.h assemblies v.as Issued by 1 " I .ti .nl Intitule for Ucciirjtlr.irl f; I iv m | llrallli on August 0, 1575. i p !l u< I iV.r cases of re re ra.r.lkilirl ( 'is l.i per .r.ns who i.ero crpluyed In .1. , ti....Uli.g Lrdc servicing, ll.1t i.u r.j.r of ra.,c.:r In the cir .h,a.io ... .if- Ir.g or slo -.*.oh crut:: 1 In lflrh >' f il:s In the general papulae:. ' c I t c. a st". , If C32 csl.catos ixrl.crs fi r. I Hr* .12 (1 out of 20) had died of {Me l\ : cf r:.nc:i\ Achactcs also carrrs Imp rnirer; and an asbestos worker i.'.a is 50 times r.:ore likely to g-L lung r.:u:.c;\ l.'.a full extent of asbestos-related disease in birl.e servicing personnel Is not I... .1 laca.ice this group has never before icm c, slrcallcally studied. Excessive i\:l. ccr.ec..1. ctior.s censured et opercl lew?, r,,,ii rs hi .'".-nut of cutc-cbHc drua Lein ctar '.lies, grinding of used tntrl. hrnlc linings, bevelling of r.re; truck h. 'lirieg:, end arcing of revi auto Lir.ha 11nii i(:, together vilth rr.e:jthal lal 1 ..: in fi.scns so employed, affirms tlu nrtcsslly for effectively controlling t.'.a crpcsuic. At present via do not have complete Information nn Imw mur.h exposure, if any, can I 7 talcratcd; and so It Is Important to elIn. I unto exposures v.hcnr.vcr possible and.. r.1i.l,.i1ze the aw which cannot be eliminated. Uceinmicnilcd practices are listed below. I'rr.r Kesplrstnr: . EXHIBIT J 9^), , 4 .-.aYi 1 M.--2.1-B533S. During brake servicing, an air purlfylnn respirator, either single use or ultli replaceable particulate flllcrs(s), ns npp. t. i| .liy tlio flatfansl-Institute for Cccui'alliral Safety and I'calth hicibll shnuM i y i.in during all prncedi.as staitii... with the ic.oval of the v l.rels ;'I h.rluclb.g runs:. lily. Ihirlr.g r.an- tr.l cl ii l * h servicing, turh n r..s|ha1nr 'l.mlii is i.-,i n dm Ini) teacval aid cleat,It.g of ilia clutch, pleasure piste ni"l I'Mr.lug sc.rbly and di.rlug in stallation of the new clutch assembly. Ibis should also include any arcing or riveting operations. . 002809 U&IBT1 H I'TL'aL INSURANCE COMFANY LJDEUTY MUTUAL Kill IT INHUMAN. I li.MI'AN* U.II-.UTY UFC AdflURANCE COMPANY <} BOSTUl iii.mk Dll'ii ib. ii...n<. 1. EQUAL OPrullTUHITY L.im.VUU) PRODUCED BY FORD The sticky note shown below was written by Barry Castleman and attached to the page immediately following this one along the right margin at the spot marked on the Xnext page with an s fa INDUSTRIAL HYGIENE AUDIT OF OHIO TRUCK PLANT 6-8 June 1983 An industrial hygiene audit was conducted at Ohio Truck Plant on June 6-8, 1983. The purpose of this audit was to evaluate environmental conditions, work practices, and processes in the plant that could adversely affect employee health or con tribute to worker discomfort. Mrs. Nancy Lutz, Plant Safety Engineer, very cooperatively assisted during this audit. Elements of the audit included appraisal of general plant and process ventilation, chemical handling practices, air quality, hearing conservation, respiratory protection, corrosive chemical vision conservation practices, illumination, skin protection practices, sanitation, and heat stress protection. Overall, the plant's industrial hygiene programs are excellent. Noteworthy are the local exhaust ventilation systems and control of employee exposures to air borne contaminants. Exposures to overspray mist and solvent vapors in paint booths were controlled as was exposure to fine-wire welding fume and gases. Deficiencies in some industrial hygiene programs were noted, however, and should receive attention. Ventilation Vhereas overall plant ventilation is excellent, a slight negative pressure condition exists. While insignificant during warm months when large doors are open, this could be a problem during winter leading to breathing zone air quality problems. Plant engineering should assure provision of sufficient makeup air to balance all supply and exhaust systems to within ten percent of each other. Sodium hydroxide mist was extremely irritating to eyes and respiratory tract on the catwalk in the Caustic Building. The two aide draft local exhaust systems were inoperative at the lye tank. These should be repaired and the caustic tank enclosure immediately designated a respiratory protection area. All employees in this enclosure must wear respirators approved for alkaline mists and must be included in a comprehensive respiratory protection program in compliance with OSHA standards and Company guidelines. The enclosure must be appropriately posted. Asbe stos/Silica Sand blasting of brake drums at the Trailer Maintenance Building presents potential exposures to airborne asbestos fiber and respirable silica dust. Steel shot or glass beads should be considered as substitutes for silica to eliminate risk of silicosis. An air-supplied abrasive blasting helmet must be provided to control exposure to a&Lustoa fiber and dust. A vacuum sweeper approved for asbestos fiber should be purchased to remove residual asbestos from truck trailer brake drums before new brake shoes are installed. This vacuum sweeper should be made available to maintenance personnel who repair and install new brakes in the hi-lo and fork truck vehicle maintenance area. Employees must be instructed not to use compressed air wands to blow residual asbestos dust and fiber off brake shoes and drums. Wet methods, vacuuming, respiratory protection, and ventilation must be used to control exposure to asbestos. Brake maintenance employees should be on the asbestos medical surveillance program. Illumination Illumination was marginally acceptable in several areas in the north end of the plant. Much daytime illumination in this area comes from skylights. Illumination is considerably less on the night shift. Steps should be initiated to clean and maintain existing lighting fixtures and to consider installation of additional luminaire a. PRODUCED UY FORD 912741 Ohio Truck Plant -2- 6-8 June 1983 The area behind the lye tanka in the Caustic Building waa poorly illuminated. Since there are tripping hazards here and employees must periodically enter this area of corrosive and slippery chemicals, better illumination i3 indicated. Sanitation Overall plant sanitation and hygiene is excellent. No deficiencies other than minor housekeeping were noted in cafeterias, food preparation areas, canteens, locker rooms, and washrooms/toilets. The nuisance odor condition associated with cigarette butts, food, waste, and oil discarded into trenches around production equipment should be addressed by a periodic maintenance cleaning schedule. At the least, this condition is visually unaesthetic and is an employee concern as expressed by the UAW Health and Safety Representative. The food storage refrigerator in the Power House should be relocated away from the chemical storage area. Free-standing water in the Trailer Maintenance Building should be controlled to eliminate a slipping hazard and harborage for mosquito and insect larvae. Flying insects in the plant were not a problem, and we see no compelling need for installation of more electronic bug killers. Hearing Conservation There was inconsistent use of hearing protectors in designated hearing conserva tion areas. All employees must consistently wear approved muffs or plugs at these locations. A variety of protectors should be made available including an approved earmuff and at least two types of earplugs. The Power House generator area should be designated a hearing conservation area and appropriately posted. Some metal finishers at F-26, for example, were not wearing protection. They must constantly use hearing protection equipment. The paint pot block house must be made a mandatory hearing conservation area and so posted. Although exposures are brief in this area, the noise intensity is extreme and poses a risk of noise-induced hearing loss. Generally, hearing conservation areas should be more clearly posted and designated. Respiratory Protection Employees use appropriate and approved respirators for air contaminants to which they are exposed; however, a serious deficiency exists because many do not use both straps on the half mask respirators. This prevents an effective face-to- mask seal. This should be corrected by management enforcement and education and training sessions. The paint residue removal area at the Caustic Building lye tanks must be designated as "Respiratory Protection Required". Written programs must be established for all respiratory protection areas in compliance with OSHA standards. Paint sprayers leave their respirators on work surfaces adjacent to the booths. This must be corrected by providing an hygienic storage ar^a for each painter's respirator'. - ' * "* -- Vision Conservation Employees use inappropriate eye protection when handling or working near corro sive chemicals. Eye protection of choice is the chemical splash goggle which is superior to a face shield for vision conservation. Employees must he instructed to wear goggles where splashing of corrosive chemicals could occur. These areas should be 90 designated. The chemical eyewash fountain and shower in the Caustic Building must be relocated on the catwalk midway between both lye tanks. Consideration should be given to installing an emergency eyewash fountain near BB-21, A-22 or A-21. It must be emphasized that eyewash fountains are secondary to consistent use of splash goggles in vision conservation areas. Employees who handle strong acids, alkalieB, oxidizers, corrosion inhibitors, microbiocides, and scale removers must wear splash goggles. We see little need for face shields in chemical handling areas at Ohio Truck Plant. PRODUCES BY FORD 012742 Ohio Truck Plant - 3- 6-8 June 1983 Air Quality Other than caustic miat at the lye tanka, no obviouB air quality problems were noticedl It iB advisable, however, to document exposures to solvent vapors in the paint kitchen. Arrangements will be made to have plant personnel conduct this monitoring this winter when doors are closed. Air sampling is also recom mended to document solvent vapor exposures of maintenance employees who clean paint sludge filters in the basement at C-37- Skin Protection There is no evidence of excessive dermatitis at Ohio Truck Plant in spite of potential contact with a wide variety of dermal irritants and sensitizers. Several paint sprayers complained, however, that even two pairs of green gloves do not prevent paint from penetrating through to their skin. As a result, they wash their hands with paint thinner at the end of the shift. They believe that white cotton gloves which had been provided to them previously are superior to the present gloves. The plant should select a glove to assure that painters do not have to resort to the use of solvents to clean their hands. Non-silicone based barrier creams should also be considered. Although the solvent they use is not appreciably akin absorbed, it can dissolve protective oils and lipids from the skin and pave the way for an industrial dermatosis. Chemical Storage Greater attention by means of educating and training lift truck operators is required to assure that incompatible chemicals are not stored together. For example, drums of concentrated sulfuric acid were stored next to drums of aqueous ammonia. Drums of sodium nitrite, a strong oxidizer, were stored next to readily oxidizable materials. Inadvertent drum rupture aB might occur during a fire or from impaling by or dropping from a fork truck could produce a chemical emission emergency. Ergonomics The BAO ergonomics task force should consider the potential for chronic hand/ wrist musculoskeletal and neurological trauma in sealer application employees. Heat Stress No significant heat stressful work environmental conditions were observed. The Industrial Hygiene Services Section will, as requested, assist in implementing these recommended industrial hygiene programs at Ohio Truck Plant. Roge? Wabeke, Supervisor Industrial Hygiene & Toxicology Department Employee Health Services 3b PRODUCED BY FORD 012743