Document 6bXN6EpqxkpDpd6GxEbzYLevd

Intar Offica Ford Part* and Sarrtca Dlvlmlon 29, 1981 ) i i Mr. M. E. Hamburg cc Mr. G. G. CHckard Mr. E. J..Riley Subject: EPA/OSHA Asbestos Exposure Program for Brake Mecbaalcs Raf: 1. EPA letter of 4/27/81 2. A. B. M. Houston letter of 5/21/81 We have reviewed the EPA letter and attachments and also Mr. Houston1 a letter and offer the following comments: 1. The Training and Publications Dept, has published warnings In the brake section of the Car and Truck Slop Manuals regarding the health hazard of air blowing asbestos dust and recearniended the use of proper equipment for dust removal. Copies of this information are attached for your use. 2. The Training and Publications Dept, has had no brake training programs in recent years because there has been so new tech nology on brake service requirements. Accordingly, we have not published training information on asbestos dangers and handl1ng procedures. Attachments E. F< Prlebe i; 1 \ l i + 007386 SCF-ALLF-08540 PRODUCED BY FORD 12-C7-20 Generol Hydraulic Brake Service 12-01-20 REMOVAL AND INSTALLATION 'RAKE DRUM . VEHICLES THRU 3000 SERIES Use the following service procedure] for both nydrautic and oir broke*. 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 adjuiting screw until the shoes no longer touch the brake drum. Remove the grease cop 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 broke 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 cooling with 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 ond retaining bolts, screws, or bolts and nuts. 9. Install the hub ond drum on the wheel spindle. Keep the hub centered an the spindle 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 eone and roller assembly, ond the bearing adjusting nut. On all other axles, install the outer bearing cone and roller ond flat washer on the spindle. Instoll the odjusting nut. 11. Install the wheel and tire an the hub. Then install the clomps (if applicable) and the wheel stud nuts. 12. While rotating the wheel, tighten the adjusting nut to specification. Adjust 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 cop, ond 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. OVERHAUL __ ' Removal of dust and dirt from brake assemblies should be done by using the Rotunda Brake Vacuum (340009) or equivalent or Rotunda brake parts washer (model 650016) or equivalent. Broke assembly dust and dirt should not 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 dene \ on brake linings or pads should be done using properly 1 exhaust ventilated equipment. j ' BRAKE DRUM REFINISHING Minor scores on o brake drum can be removed with fine emery cloth, provided the emery is thoroughly cleaned off the drum after the operation. BRAKE DRUM REFIMISHING Minor scores on a brake drum can be removed with fine emery doth, provided the emery is thoroughly cleaned off the drum after the operation. A badly scored, rough, or out-of-round drum should be ground or turned on a drum lathe. Do not remove orv more material from the drum than it necessary to ide o smooth surface for the brake shoe contact. ,okt drum maximum braking surface diameter it shown on eoch broke drum (Fig. 10). Brake drums which exceed the maximum braking surface diameter shown on the broke drum, either through wear or refiniihing, mutt be replaced. H1US.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 brake drum, allows for 0.060-inch machining cut over the original nominal drum diameter, plus 0.030lneh additional wear before the drum mutt be replaced. After refinishing the broke surface runout must not exceed 0.070-ineh total indicator reeding, measured from the bearing cup. 007387 PRODUCED BY FORD 007388 4 tl I u llyilldlillu Brake* (Tenet *1 Seivli.e 12 0 1 -22 icomptete axle sell on from wheels as required. The rubber caliper 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. Refer to Part 12*20 for disc brake rotor resurfacing procedure. Service Precautions 1. Grease or any other foreign matenal must be kept off the lining surfaces of the rotor and external surfaces of the hub dunng 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 from end components. 6. Riding of the brake pedal (common on left-loot applications) must be avoided during vehicle operation. 7. The wheel and bre 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 any oil or grease-soaked brake linings. When contaminated lining; 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 Irom brake assemblies f should be done by using the Rotunda brake I vacuum (model 340009) or Rotunda brake parts I washer (model 650016) or equivalent. Brake I assembly dust and dirt should not be removed by blowing oft with an air gun because a health hazard from breathing asbestos dust may develop. __ j 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 damaged, they must be replaced. Replace any lining that has been contaminated with oil. grease, or brake fluid. Replace lining in axie sets. Prior to replacement ol lining, the drum diameter should be checked to determine that the brake drum braking surface diameter is within specification by using the Rotunda brake drum micrometer (model 100010) or equivalent. If the braking surface diameter exceeds specification, the drum must be replaced. 4. Check the condition of brake shoes, retracting spnngs, hold-down springs, and drum lor signs of overheating. It trie shoes have a slight blue colonng, indicating overheating, the retracting and hold-down springs should be replaced. Overheated springs lose their pull and could causa the new lining to wear prematurely, It not replaced. If the brake drums art heat spotted. Indicating an overheated condition, they should be replaced. 5. Inspect ail 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 dnjm is exceeded either by wear or refinishing, the drum must be replaced. Refer to Part 12-02 for refinishing. FIG, 21 Location ol Brake Drum Maximum Inaide Surface Marking* Braka Booater 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 ea en assembly. Including the check valve. PRODUCED BY FORD 007389 Infer Office Ford Parti and Service Division June 1, 1981 Mr. M. H, Hamberg Subject: EPA./0SHA Asbestos Exposure Program As requested, 'we hare reviewed the attached slide-tape script and (2) bro chures regarding asbestos poisoning and make the following comments: . There is an inconsistency between the two brochures in the. mention of brake vacuums. In the slide-tape script, pages 10, 11 and 12 refer to using a industrial or shop vacuum. Further emphasis for a shop vacuum designed for asbestos usage or a efficient*filtering acd dis posal system., like that mentioned in the larger brochure would be appropriate. ,- . One popular brake cleaning method the program does not address is the coffee can method. This method is simply using a coffee can filled with parts cleaner solvent from the parts washer and brushing off the brake assembly bolding the can under it. Because technicians are paid by the job (flat rate), cleaning a brake with a vacuum is not always done, even if the garage has the equipment; it becomes awkward, time consuming and costly. Brake washers are fine, text they are a fairly new product and there are few in use in the field. The coffee can method is used by technicians who are aware of asbestos poisoning but ' don't have the sophisticated equipment or take the time to use it. This paper should address this method and its1 safety impact in areas such as solvent disposal (Do you pour down the drain or put it back in the parts washer?). . Consider suggesting to Mr. Cuimonda that tbf brochure and slide-tape refer to people who work on cars as technicians, rather than mechanicstm < la a practice adopted by Ford and G.M. which technicians prefer. , In the area of program effectiveness, the brochure suggests (pg. 7*0 displaying a poster to remind people of the dangers of asbestos poison ing, Because it is not readily available, the EPA might consider making a poster available and including it with the distribution of brochures. A poster Vmvig in the garage area might prove to be the ao3t effective reminder of the dangers of asbestos poisoning. There axe currently (4) four class action suits pending against Ford Motor Comoany for asbestos poisoning by former Ford dealer technicians. I suggest you review this material and your prepared response to nPA/OSfiA with Wanda Jones (i42476) to assure it does not adversely effect those lawsuits. D, E. Schvonk PRODUCED BY FORD n \ N* 12-01-22 General Hydroufic Brake Service 12-01-22 1 t. Remove (he line and inspect (he Here for cracks or poor Here form. If (he (lire is not correct, cut it ofT and repeat the proem. The finished flare must be square with the line, free of cracks end have a smooth matin[ surface to ensure a leakproof connection. Flaring a Una (Flaring-Bar Type) Refer to Ftp. 13 and 17. 1. Cut off and straifhten the required Itruth of line. (A line eultini tool will simplify making a clean and square cut). 2. 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 appropriate ribbed bole in the bar assembly until the end of the line socks out about u fsr as the thicknos of the adaptor above (he bar. or even *ruh die bar, depending on the tool used. 4. Fit (be adaptor onto tbc line and slide the bar into the yoke. Lock the bar in petition with the line beneath the yoke screw. 3. Form the single flare by tightening the yoke screw securely. 6. Release the screw and remove the adaptor. 7. Form the double flare by lightning the yoke screw again, with second adaptor fitted, depending on the tool usedL L Release the screw bar. and flared line. Inspect the flare for cracks or poor Qarc form, and repeal the process if the flare is not correct. 9. Repeat Steps 3 through 4 at the oppaste wheel cylinder. FIG. 17 Lin* Flaring (Flaring Bor Typel BRAKE HOSE Replace s flexible brake hose if u shows signs of softening, cracking or other damage. .When installing > new brake hose, position the hose to avoid contact with other vehicle pans. REMOVAL AND INSTALLATION BRAKE DRUM All Vahiclaa thru 9000 Sanaa Use the following service procedures for both hydraulic and air brakes. Since the F-100 thru F-3J0. E-IOO-E-33C and Bronco rear drums, and the P-300 (front and rear) procedure apply to hydraulic brakes only, they are covered in Part 12 in. FRONT BRAKE DRUM 1. Raise the vehicle until the tire dears the floor and remove the wheel and ore from the bub. Loosen the brake shoe adjusting screw until the shoes no longer touch the brake drum. Remove the grease cap and the gasket (if equipped) from the hub. 2. On vehicles with 9,000 lb front uics and hydraulic brakes, remove tbe locknut, locking ring, dimpled washo' and adjusting out. 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 ore) from the hub and drum. 3. Remove the brake drum retainers and attaching bolts, screws or bolts and nuts. 6. Remove the brake drum from the bub. 7. Check the drum for damage or wear, and repair or replace if neccsaary. If a new drum will be installed, be sure to ranerve the protective coating with dcgreascr. , lastall sew grease retainer seals whenever wheel and hub is removed. g. Place tbc brake drum to tbe hub and install the retainers and retaining bolts, screws, or hula and nuts. 9. Install the hub and drum on the wheel spindle. Keep the hub eestcred on the apindle to prevent damage to the greaae retainer or the spindle threads. 10. On vehicles with 9.000 lb front aales and hydraulic brakes install the outer bearing cone and roller usenbly. 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 nuL 11. Install the wheel and tire on the hub. Tam install the clampi (if applicable) and the wheel stud nuts. 12. While rotating the whceL tighten the adjusnng nut to specification. Adjust wheel bearings as described in Group 11. 13. On vehicles with 9000 lb from axle and hydraulic brakes, install the dimpled washer with the dimple indexed in one of (he holes in the adjusting nut. Install the locking ring lock out and tighten to specification. Bend the locking ring over a Oat of the ' lock out. " --- 14. Install the gasket (if equipped) and the grease cap. and tighten the wheel stud nuts to specification. Install the hub cap (if equipped), and adjust the brakes as described in this Part. OVERHAUL An industrial type vacuum cleaner in place of compressed air, a recommended to remove any dust and din present an brake linings, pads, rotors and drums eet, when performing wheel brake repairs. Also, any machining done on brake linings or pads should be done using properly exhaust ventilated equipment. BRAKE DRUM REF1NI3HINQ E-100--E-350, F-100--F-350, U-100 Minor scores on a brake drum can be removed with fine emery doth, provided the eatery is thoroughly cleaned off the drum after the operation. A badly scared, rough, or aut-ofround drum should be ground or turned oa t drum lithe. Do not remove tt mote material from the drum than * necessary to provide a smooth surface for the brake shoe contact. Brake drum maximum braking surface diameter is shown on each brake drum (Fig- f'*- ake drums which exceed the maximum iking surface diameter shown o" '"e 007390 producedbyford I ft 12-01-22 General Hydraulic 5roVe Service 12-01-22 o zF*0MMnn'LAtAoe*t*sC HAST 0*1 MATIon SiNCLC *IAM FIG. Una Haring Saquanc* w MDCOO-UNBOLE0H^AUAAATC10M 7. Form the double (lire by tighenmg the yoke icrew again. with second adaptor Hiicd. depending on the tool used. S. Release the screw bar. and flared line. Inspect the (lare Tor cnclu or poor dare form, and repeat the process if the dare is not correct. 9. Repeal Steps 3 through 6 at the opposite wheel cylinder. IRAKI HOS Replace a flexible brake hose if it shows signs of softening, cracking or cthff damage. When installing a new brake hose, position the hose to avoid contact with Other Vehicle parts. FIG. 16 Una Flaring (Split Dl* Typa) FIG. 17 Una Raring (Flaring Sar : t Type) \ k 4Q > ,<3-' REMOVAL AND INSTALLATION BRAKE DRUM All Vahid** thru 9000 Saris* Use the following service procedures for both hydraulic and air braises. Since the F-100 thru F-350. E-lOO-E-330 and Bronco rev drums, procedures apply to hydraulic brakes only, they are covered in Pan 12-01 FRONT BRAKE DRUM t. Raise the vehicle until the tut clean the door and remove the wheel and tire from the hub. La<wm the br-ke shoe adjusting screw until the shoes no longer touch the 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 brakea, remove the locknut. locking ring, dimpled washer and adjusting nut. On all other axles, remove the cotter pin.'adjusting out and flat wisher from the spindle. 3. Remove the outer bearing cone and roller assembly. Pull the hub and drum aitrrnSly 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 bub and drum. 3. Remove the brake drum retainers and attaching bolts, screws or holts and outs. 4. Remove the brake drum from the huh. 7. Cheek 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 sew greast retalaer seals whenever s wheel sad hub is removed. I. Place the brake dram to the hub and install the retainers and retaining bolts, screws, or bales and nuts. 9. Install Use bub and dram on the wheel spindle. Keep the bah watered o At spindle to prevent damage tn the grease reveller or the spindle threads. 10. On vehicles with 9,000 lb front sales and hytinulic brakes install the outer bearing cone and roller assembly, and the bearing adjusting nut. On ill other sales, install the outer bearing cone uid roller and flat washer on the spindle. Instill the adjusting nut. 11. Install the wheel and tire on (he bub. Then install the clamps (ifapplicable) and the wheel stud nuts. IZ. While routing the wheel, tighten the adjusting nut to specification. Adjust wheel beanop as described in Croup 11. 13. Ou vehicles with 9000 lb front isle sod hydraulic brakes, install the dimpled wa-her with the dimple indexed in one of the holes in the adjusting nut. Install the locking ring lock nut and tighten to specification. Bend the locking ring over a Oat ofthe lock nuL Id. Insult the gasket (if equipped) and the grease cap, and tighten the wheel stud nuu to sjxcifieanon. Install the hub cap (if equipped), and adjust the brakes ss described in (his Psrt. An industrial type vacuum cleaner in place of compressed sir, ts recommended to remove any dust and din present on L brake linings, pads, reton and drums ect when performing wheel brake repairs. Also, any machining done on brake 007391 linings or pads should be done using 1 properly exhaust ventilated equipment. PRODUCED BY FORD i i < ( 12-01-18 General Hydraulic Brake Service 12-01-18 5. form the single Hare by tightening the yoke icrtv securely. 6. Release the icrtw and remove the adaptor. 7. Form the double flare by fighening the yoke screw again, with second adaptor fitted, depending on the'tool used. 8. Release the screw bar, and flared line. Inspect the flare for crocks or poor flare form, and repeat the process rf the flare it not correct. 9. Repeat Steps 3 through 6 at the oppotite wheel cylinder. BRAKE HOSE Replace a flexible broke hose if if shows jjgns of softening, crocking or other damage. When installing a new broke hose, position the hose to avoid eontoet with other vehicle parts. OVERHAUL I Removal of dust and dirt from brake assemblies khould be done by using the Rotunda brake vacuum nmodei 3X0009) or Rotunda brake parts washer (model 1650016) or an equivalent. Brake assembly dust ond dirt /should not be removed by either blowing off with an air 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 broke 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 REFINISHING -------- Minor scores on o brake drum can be removed with Tint emery doth, provided the emery is thoroughly cleaned off the drum after the operation. A badly scored, rough, or out-af-raund drum should be ground or turned on o dram lathe. (Refer to the lathe manufacturers instructions.) Do not remove any more materia) from the drum than is necessary to provide a & C-V"~ smooth surface for the brake shoe contact. Brake drum maximum broking surface diameter is shown on eoch brake drum (Fig. 13). Brake drams which exceed the maximum braking surface diameter shown on the brake drum, either through wear or refinishing, must be replaced. The maximum broking surface diameter speufication, wVch is shown on each brake drum (Fig. 131, allows far a 1.52mm (0.060 inch) machining cut over the original nominal drum diameter plus ,762mm (0.030 inch) additional wear before reaching the drum- discard diameter. FRONT DISC BRAKES 1. Remove the shoe and linings os described in Port 12-24 Disc Brakes--light ond Heavy Duty-- Sliding Celiper. 2. Measure the thickness of the brake lining. if the lining thickness at any point on the assembly is less thon ,794mm (1/32 inch) above the backing plate or rivets, or if the lining shows evidence of broke fluid or oil contamination that is causing a brake pull, replace all four shoe and lining assemblies. 3. To cheek rotor runout, first eliminate the wheel bearing end play by tightening the adjusting nut. Then check to be sure the rotor con still oe 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 toke an indicator ^=5, IRAKI DRUM - rvnCAl FIG. 13 Rear Brake Dram Maximum Inside Braking Surface Diameter Marking location--E-100 -- 350, Branco, and F- 100--F-350 reading. If the reoding exceeds ,254mm (0.010 inch) total lateral runout within a six inch radius on the indicator, replace or re-surface the dise brake rotor. The fallowing requirements must be met when ra-surfadng disc brake rotors. Use a disc brake lathe to re-finish the disc brake rotors, (Follow the manufacturers instructions.) Mo more than .50Smm (0.020 inch) of material may be machined equally off eoch surfoct (A ond B, Fig. 14). If rotor thickness falls below the minimum shown on eachrdfor, it must be rep^-vd. The finished braking surfaces of the rotor must be flat and parallel within 0.025mm (0.001-inch); lateral runout mutt not exceed 0.076mm (0.003 inch) total indicator reeding, and the surface Finish of the braking surfaces must be 16 to 80 micro inches. When the runout check is finished, od|ust 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 scorei with a fine emery doth. If the rotot Is excessively scored, re-finish or replace the rotor if necsssory. 6. Check the caliper. If it is cracked or shows any signs of leakage, replace it. If the colipet is leaking around the dust boat, remove ond repair It. 7. Check brake hoses for signs of cracking, leoks or abrasion. Replact them," if necessary. ' 007392 J PRODUCED BY FORD i I 007393 PART 12-01 GENERAL HYDRAULIC BRAKE SERVICE 12-01-27 5. Be 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 left wheel turns. 6. 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 from the brake rotor, unlike drum brakes where the wheel, tire and drum can be removed as a unit. A. Check condition of brake shoes, retracting spr ing, holddown springs, and drum lor signs ol 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 not 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. B. 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 tor proper bleeding of air from brake system. Drum Brakes 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 the 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 tint. A vacuum cleaner equipped for this purpose, brush or rag should be carefully used to remove any, dust. Any duet should be contained In a ssalad bag tori' disposal. } 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 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 tion, 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 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 fit 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 leakproof connections. Clean brake tubing by flushing with clean brake fluid before installation. When connecting a tuOe to a hose, tube connec tor, or brake cylinder, tighten the lube fitting nut to specified torque with the D81L-600-A Jnch-pound torque wrench. PRODUCED BY FORD 12-4 Braking System 12-4 037394 A--Piston Housing 8--Brake Fluid C--Piston 0--Inner Brake Ped F--Brake Disc E--Pad Housing (Anchor Brackst) Q--Outer Brake Pad FF1205--2A FIG. 5 Sectional View ot Front Caliper Simultaneously, the transverse cable it placed in tension by the equalizer causing the actuating lever on the right hand brake assembly to activate the brake shoes [Fig. 101- BRAKE SERVO The Brake Servo, if installed, is of the suspended vacuum type. With the engine running, vocuum is supplied to the Servo unit through a non-retum valve. Both sides .of the chamber diaphragm in the Servo are subjected to equal vocuum. Initial movement of the brake pedal admits atmospheric pressure to the rear of the diaphragm, resulting in a pressure difference which causes the diaphragm to move forward. The brake pedal effort is assisted and reduced by the movement of the diaphragm. GENERAL NOTE Every 64,000 km (36,000 miles), brake cylinder teals, flexible hoses and hydraulic fluid should be replaced. Brake system components must be kept dean of any foreign matter. If necessary, any hydraulic components should be washed in clean brake fluid, industrial alcohol or methylated spirits to remove any foreign matter and driod with a deon non-fiuffy doth. Da not us a mineral base fluid such as petrol or paraffin. Brake fluid mutt not be allowed lo came into contact with brake pads/shoet or with disc or drum surfaces. Due to the complecity of braking systems, when replacing or overhauling components, care must be taken to ensure thot only correct parts are installec. " u"' ----. --. Any brake fluid accidentally spilled onto a painted surface must be cleaned off immediately using cold water to prevent damage to paint-work. ____ WAXNINOt Car* should be taken to avoid li*-\ haling dust from brake finings. Asbestos dust ) when Inhaled may be Injurious to health. Da not blow out dust with an air 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 a sealed bag for disposal. JACKING THE VEHICLE Before commencing any repain that involve jacking tha vehicle It Is essential that the vehieis jacking instructions contained in Section 11, General Description, are followed. /?7 * PRODUCED BY FORD 007395 t "i i:1; 1 ' .i f. 12-01-20 General Hydraulic Brake Service _'2-Ol-20 . 6. Install the bleed screw (rf so equipped). Install me gasket (diaphragm) in the master cylinder filler cover. Position the gasket as shown in Fig. 17. Make sura the gasket Is securely seated. 9. Install the cover and gasket on the master cylinder and secure tne cover into position with the retainer. CLEANING AND INSPECTION Disc Brakes 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 1/8 inch of the shoe, replace all (four) shoe and lining assemblies (complete axle set) on front or rear wheels as ' required. The rubber caliper insulators and the plastic sleeves must be replaced when linings are replaced. 3. ' Visually check the caliper. If the eaJiper 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. Reler to Part 12-20 for disc brake rotor resurfacing procedure. Service Precautions 1. Grease or any other foreign 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 cafipet piston vs removed tor any reason, the piston seal must be replaced. 3. During removal and installation of a wheel assembly, exercise care not to. interfere with and damage toe caliper splash shield or toe bleeder screw fining. 4. Front wheel bearing end play is critical and must be within specifications. 5. To avoid bending or damaging toe rotor splash shield on full right or left wheel turns, be sure toe vehicle is centered on toe hoist before servicing any Iron! end components. 6. Riding of toe 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 toe wheel, tire, and drum can be removed as a unit 8. . Do not attempt to clean or restore any oil or grease-soaked brake linings. When contaminated linings are found, brake linings must be replace in complete axle sets. * 9. Always replace rubber caliper insulators ana plastic sleeves when replacing linings. Do not lubricate the slide pins. Drum Brakes 1. Remove the wheel from the drum, and remove toe drum. Part 12432. ___ 2. Removal of dust and din from brake assemblies should be dons by using the Rotunda brake vacuum (model 340009) or Rotunda brake parts washer (model 650016) or equivalent. Srakel assembly dust and dirt should not be removed by/ blowing off with in nr gun bcciuie i health hi:ira\ ^ from tareithing ubenoi Suit miy ievtloo 3. Inspect toe brake shoes for excessive lining wear or shoe damage. If toe lining is worn within 1/33 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. Pnor to replacement ol lining, toe drum diameter should be checked to determine that the brake drum braking surface diameter is within specification using toe Rotunda brake drum micrometer (model 100010) or equivalent. It the braking surface diameter exceeds specification, toe drum must be replaced. 4. Check the condition of brake shoes, retracting springs, hold-down spnngs, and drum for signs at overheating. II the shoes have a slight blue coloring, 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, It not replaced. If the brake drums art heat spotted, indicating an overheated condition, they should be replaced. 5. Inspect alt other brake parts and replace any that are worn or damaged. . _ 6. Inspect toe brake drum and. if necessary, refinish. Refer to toe Rotunda Catalog Wheel Service, for a descnpbon of toe various types of brake lathes available. The maximum Inside braking surface diameter It shown on aech brake drum (Fig19|. If the maximum inside braking surfacs diameter shown on toe drum is exceeded either by wear or refinishmg, toe drum must be replaced. Refer to Pan 12-02 for refinishing. Brake Booster Check the booster operation as noted under Power Brake Functional Test. If the brake booster damage or inoperative, replace it with a new booster. The bra* booatsr Is serviced only as an assembly. .Including ths check valve. 4 PRODUCED BY FORD 007396 12-01-20 General Hydraulic Brake Service 12-01-20 OVERHAUL Removal of dust and dirt from brake assemblies should be done by using the Rotunda Brake Vocuum (340009) or equivalent or Rotunda brake parts washer (model 6.50016) or 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 because a health hazard from breathing asbestos dust may develop. Also, any machining rinne on brake linings or pads should be dene using property exhaust ventilated equipment. BRAKE DRUM REFIN15HING 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 REFINISHING 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. A badly scored, rough, or out-of-round drum should be ground or turned on o drum lathe. 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 is shown on each brake drum (Fig. 9). Brake drums which exceed the maximum braking surface diameter shown on the brake drum, either through wear or refinishing, must be replaced. . MIOt-IA FIG. 9 Brake Drum Maximum Braking Surface Diameter Marking Location--Typical Medium Heavy Truck Shewn On all medium and heavy trucks, the maximum braking surface diameter specifications, which it shown on each brake drum, allows for 1.52mm (0.060 inch) machining cut over the original drum diameter, plus 0.762mm (0.030 inch) additional wear before the drum must be replaced. After refinishing the brake surface runout must not exceed 1.77mm (0.070 inch) total indicator reading, measured from the bearing cup. On medium and heavy trucks, if the drum dia meter is less than 0.762mm (0.030 inch) oversize after refinishing, install standard linings on the brake as semblies. If the diameter is over 0.762mm (0.030 inch), install avenixe 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 deoning fluid, especially the rim surface. Wipe the shoe or band dry and remove all burrs or rough spots from the shoe. Da not use shoes with elongated rivet holes, a bent or worn shoe web or rim. 3. On service brake, check the inside diameter of the brake drum. 4. Position a new lining on the shoe or band. The primary and secondary linings ore marked. Install new rivets, beginning with the rivet holes near the center of the shoe. On some vehides, the primary - lining is shorter than the secondary lining. If this condition exists, paiition the shorter (primary) lining in line with the heel end of the shoe. Do not let brake fluid, oil, or grease touch the brake lining. If a brake lining kit is used to replace the wom linings, follow the instructions in the kit and install all the parts provided. 5. Check the clearance between the lining and shoe rim. The lining must seof snugly against the rim with not more thon 0.127mm (0.005 inch) separation between any two rivets. If only the linings are replaced an duo-servo single anchor brakes with fixed anchor pins, the brake linings muit be cam ground 0.25mm (0.010 inch) at the ends after the linings are riveted to the brake shoe. BRAKE CYLINDER 1. Clean all brake cylinder parts in dean isopropyl alcohol or the Rotunda brake parts washer (model 650016) or equivalent. Inspect all parts far wear or damage. Check the cylinder bore for rust, scores, or other damage. Be sure the bleeder screw passage is clean and open. Replace all parts that are wom or damaged. 2. If dirt is found in any part of the hydraulic system, flush,the entirejystem wiih.tLran.iispropyl "leohol. MASTER CYLINDER 1. Clean all master cylinder parts in elean isopropyl alcohol or the Rotunda brake parts washer tmodel 650016) or equivalent, and inspect the parts far wear or damage. Replace them if required. When a matter cylinder repair kit it used, fallow the Initmctlont In the kit and initall all of the partt provided. 2. Make sure that all ports and vents in the master cylinder ore open and free of foreign matter. 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 are open, replace the piston. 4. Inspect the cylinder walls for scores or rust. Remove scores and rust or obtoin a smooth wall surface by honing the cylinder walls, but not more thon 0.076mm (0.003 inch) of material. Remove any 75c;- < /9 PRODUCED BY FORD