Document DMnopBpGzjgL6MyvMbGJx0aGQ

FILE NAME Ford FD DATE 1949 DOC FD219 DOCUMENT DESCRIPTION Brake Manual . - SERVICE ,sHuUleid SUD qx oe6p6t 9109 Y wnuod DOKLET UL MECHANICS (iL! ADIANS NO MECHANICS BDIANaS PASENGR SoINvHOa s7yvud WW dils) PASENGER ON CAR 1708 au0j PASENGER CAR b-Z29 wg LISEHXS S.4LNIV 1d FOREWORD ae HERE IS a grim reminder of the grave responsibil ity that you as a Ford Service Mechanic must assume Automobile brake safety de- pends often on your alertness in spotting the symptoms of brake trouble You have an opportunity to do this on the many cars that pass through your service department To neglect this duty or to fail to follow through when you do find evidence of brake trou- ble may have consequences as tragic as those - this newspaper headline In this booklet you will see examples of the major brake trouble symptoms proper diagnosis and the procedures for correcting the troubles The methods are factory approved and broken down to simple detail Following them will help Fordyou maintain the high standards which have made Friendly Service a watchword among Ford owners everywhere This booklet is the fifth of a series Keep it The complete set will become your personal Ford Service reference library Additional copies of this and booklets on other subjects may be obtained from your Ford Dealer PLAINTIFF'S EXHIBIT 672-2 Low Pedal Reserve This is the most common trouble symptom brake pedal goes down too far when you step on it Obtain customer permission to remove a wheel and drum for inspection when low pedal reserve is discovered Drums should be perfectly round and free of score marks STEP ON IT i ON command No that's not a accelerator order nor is it a commacndommand to push the accelerator pedal to the floor board like a racing car driver Step on it is your slogan- e : your key to the best method for uncovering brake trouble oe symptoms hi - The brake pedal will tell you almost everything there is to . know about the condition of a car's brake system And it is : almost impossible to work on any car for any reason without having something to do with the brake pedal It is easy to : reach All you have to do is Step on " Linings should be clean and free of grease or fluid PLAINTIFF'S EXHIBIT 672-3 Lining Wear If there is less than 2 of lining above the rivet heads linings should be replaced Fill Cylinder Fluid level should be up to within quarter inch of the master cylinder filler neck be r ee Lining Con- tact Measure the thick- ness of the lining at both ends of the shoe to determine whether the lining has been making proper contact with the drum Check Cables Parking brake cables should have no slack Don't adjust cables too tightly If the inspection shows that drums and linings are in good condition A MINOR ADJUSTMENT . . should be sold bring pedal reserve up to safe driving standards Expand Shoes With the adjusting tool expand the brake shoes until it is barely possible to revolve the wheel by hand PLAINTIFF'S EXHIBIT 672-4 Back Off Shoes Turn the adjusting screw back approximately 14 notches or until the wheel turns freely ' . BRAKE SHOE REPLACEMENT linings LININGS are worn on one wheel at least replace Ion opposite wheel so that brakes will engage and hold equally Check Travel If pedal + can be depressed more than ' half the total distance to the toe board brakes must be readjusted to reduce lining clearance : i Disconnect Springs The tool shown a brake retracting spring remover and replacer is specially designed to do this job quickly and safely UNEVEN NOISY GRABBY BRAKES Tbrake TROUBLE Symptom usually indicates badly worn Tbrake linings First all four wheels and drums should be removed for close examination of linings and drums Remove hold down pins cups and springs ( i PLAINTIFF'S EXHIBIT 672-5 Disassemble Shoes Move the anchor pin ends of the shoes together to relieve lension On the adjusting screw spring The adjusting screw assembly will then slip off Install adjusting screw and adjusting screw spring Use replacement shoes furnished by an authorized Ford reconditioner : MADE RIGHT FIT RIGHT LAST LONGER INSTALLING REPLACEMENT SHOES Check Shoe Position Primary shoe to front secondary shoe to rear Lubricate all points of i contact between brake shoes and other parts CAUTION Oo Do not get grease on linings a on PLAINTIFF'S EXHIBIT 672-6 Install hold down pins cups springs and retracting springs Free Play Adjustment If brake pedal free play is less than quarter inch -- -- more than half inch ad- just the eccentric bolt at the rear of the master cylinder Grind Linjngs Perfect drum mating results when the brake linings are accurately ground in place to match the inside diameter of the drum Fill Master Cylinder MAJOR ADJUSTMENT TH PROCEDURE automatically follows brake shoe replacement Also make a major adjustment when a minor adjustment fails to restore proper pedal reserve Wedge secondary shoe forward with a 0.010 feeler gauge The 0.010 feeler is inserted between lining and = drum through lining clearance slot then moved up to wedge shoe forward 10 PLAINTIFF'S EXHIBIT 672-7 Expand the shoes Use adjusting tool to turn adjusting screw to point where the primary shoe is secure against the drum and the secondary shoe snug against the feeler gauge BLEEDING THE HYDRAULIC SYSTEM Bleeding eliminates air pockets in the system This procedure also follows wheel und master cylinder work Illustrated here is the pressure tank system of bleeding a method requiring the work of only one auechanic Attach pressure tank hose to master cylinder Back Off Shoes Re- move feeler gauge and back off shoes until a clearance of 0.010 may be obtained at points one and half inches from each end of the seconda" srhoye If proper clearance cannot be obtained by this procedure an anchor pin adjustment is necessary Attach hose to wheel cylinder bleeder valve Remove Slack from parking brake cable Nut adjustments at points A and B permit easy take up of slack CAUTION Stop when slack is out otherwise you might cause brakes to drag Start pressure tank Close the bleeder valve when bubbles no longer appear in fluid in jar holding end of bleeder tube Sn PLAINTIFF'S EXHIBIT 672-8 SPONGY PEDAL ACTION PEDAL action means that air has entered the SPhyOdraulic system One place air can enter is at the wheel cylinder rubber piston cup Here's how this happens MYDRAULIC | LEAKS Symptom Symptom NO BRAKES t Inspect hydraulic lines for breaks or cracks HEN EXCESSIVE lining clearance exists and the parking brake is pulled up air is sucked in past the wheel cylinder rubber piston cup Find out the cause of the excessive clearance Correct it Bleed the system | Inspect master cylinder : for breaks or cracks in the housing or at line connec- tionts ions . i | ! | 1 1 | PLAINTIFF'S EXHIBIT 672-9 Inspect wheel cylinder assembly for worn rubber piston cup or threaded bleeder screw GREASE LEAKS AND FLUI LEAKS BOTH NECESSITATE LINING REPLACEMENT THE LUBE MAN PLAYS A KEY PART IN UNCOVERING OTHER BRAKE TROUBLE 7 ; SYMPGTREAO SE OM R FLSUID LEAKS IR ARSE fen Check brake drums and -- backing plates for signs of grease leaks Causes of Grease Leaks Worn grease seals too much lubricant in differential wrong lubricant in front wheel bearings 17 PLAINTIFF'S EXHIBIT 672-10 ROAD TEST THE CAR FTER COMPLETING any brake repair or adjustment procedure road test the car This is the final proof of how well and completely you've done your work REMEMBER THIS the brake pedal is as dumb as an onion it won't tell you a thing unless you... STEP ON IT PLAINTIFF'S EXHIBIT 672-11 SALON le 2b-29 LISHXS S.d51LNIV SaLON MUSTHANICS SERVICE FORUM FORD MUSTHANICSMUSTHANICS SERVICE FORUMFORUM COMPLIMENTS OF YOUR HEADQUARTERS FOR FRIENDLY SERVICE AND GENUINE FORD PARTS Re LITHO IN U.S.A. PLAINTIFF'S EXHIBIT 672-13