Document Lgq0Bq7jyzXDn3BBV1BZJkZqg

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 19 7 7 1977 19 7 0 1978 1979 1980 1930 19 80 19 80 1980 1981 19 91 1981 19 B1 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/He avy T ruck BCE Fairmont/Sephyr T-Bird/Cougar5 BCE Pinto/Bobcat Mustang/Capri Granada/Monarch/ Versailles BCE Ford/Ma retry Lincoln Continental/ Continental/Mark VI BCE Lincoln BCE Escort/Lynx BCE Light Truck BCE Medium/feeavy Truck BCE Courier BCE 12-01-0 8 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 D E E D 12-01-23 D 12-01-20 12-01-22 12-01-27 12-01-10 12-01-24 . 12-01-6 305222 E E F E E A PRODUCtU BV FORD 105579 WARNINGS IN SHOP MANUALS Page 2 1982 1982 1982 1982 1982 19 82 Lincoln Town/Mark VI Ford/Mercury BCE Lincoln Continental T-Bird/XR-7 Fairmont/Zephyr Granada/Cougar Mustang/Capri BCE Escort/Lynx BCE t 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 f *BCE - Body, Chassis, Electrical i 005223 PRODUCED BY FORD ! \ 1 ( I i 4, r r I 12-01-03 ` General Brake Service 12-01-03 l 'V ^ ,, n. _ * * * be inspected for near or damage 9. On floating caliper tvpe disc brakes, ihe caliper assembly must be removed from ihe spindle prior to re moval of ihe shoe and limns assem blies. . 10. On floating caliper ivpe disc brakes Ihe calipers must not be inter changed from one side to the other Yrhen the caliper is installed on iu 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 properIv. 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 - j, - DRUM BRAKES " replacement of the retracting and hold-down springs is strongly recom mended 0'trtita led springs lost their pull and could-cause the new lining to wear prtmaturelv. if they are not re. placed. If the brake drums are heat spotted, indicating a overheated con dition. they should be replaced. 5 If the vehicle has 30 000 or more mi!es of operation on the brake lin ings or signs of overheating are pres ent when relining hrakes. the wheel cylinders should be disassembled and inspected for wear and entrance of din into the cylinder The cylinder cups should be replaced, thus avoiding future problems. 6- Inspect all other brake parts and replace any that are worn or dam aged _ 7. Inspect the brake drum and, if necessary, refinish Refer to Part 12-02 for refimshmg 1. Remove the wheel from the drum, and remove the drum as out lined in Part 12-02 aX Brush all dust from the backing plates and interior of the brake drums. Jr* Imped the brake shoes for ex cessive lining wear or shoe damage ff tne lining is worn within 1/32 inch of _ the rivet heads''or if the shoes are damaged, they must be replaced Re place. any luiiog ihat had been .con taminated with oil grease or brake fluid, ' Replace lining in axle sets. Prior to replacement oT lining, the arum diameter should be checked to determine if oversize linings must be installed. 4. Cheek the condiuon of brake shoes, retracting springs, ho Id-down springs, and drum for signs of ov erheating If the shoes have a slight blue coloring, indicating overheating. BRAKE BOOSTER , ,, ' iP v ` ' Check the booster operation as noted in Pan 12-01 Power Brake Functional Test. If the brake booster is damaged or inoperative replace it with a new booster The brake boost er is seriiced only as an assembly. HYDRAULIC LINES' ' Steel tubing ts used throughout the brake system with the exception of the flexible hoses at ihe front wheels and at the rear axle housing, brake tube connection Alwavs bind the applicable pri mary or secondary brake system after primary or secondary brake system hose or line replacement. Centralize the pressure differential valve after bleeding the system. ` BRAKE TUBING 1 t.1 V If a section of the brake tubing be comes damaged, the entire* section should be replaced with tubing of (he same type. sue. shape and lenglh. Copper tubing should not be used in a hydraulic system. When bending brake tubing to fit underbody or rear axle contours, be careful not to kink or crack the tube. i All brake tubing should be double flared properly to provide good leak proof connections. Clean the brake tubing bv flushing with clean brake fluid before installation. . , When connecting a tube to a hose, tube connector, or brake cylinder, lighten the lube fitting nut to speci fied torque with Milbar Tool 1112 144 or equivalent. _ BRAKE HOSE | B" *t ^ ` , A flexible hrake 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 fil ling 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 clip, and con nect the tube to the hose with the tube fitting not, 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 horse shoe-type re taining dip, and connect the tube to the hose with the tube fitting nut. 005224 t ii i l t ii i i 1 005225 12-QM9 ft 6. Clean all parts in clean isopropyl alcohol, and inspect the parts for chipping, excessive wear or damage. When using i masttr cylinder repair ldt. Install all the parts supplied. 7. Be sure that all recesses, openings and internal passages are open and clean Place all pans on a clean pan or paper. 1, Inspect the master cylinder here for signs of etching, pitting, scoring or rust. If necessary to hone the master cylinder bore to repair damage, do not exceed allowable hone specifications. Assembly 1, Dip all parts except the master cylinder body in clean bralte fluid (ESA.-M6C25-A) Ford Part Ho. CEAZ-19S42-A or DOT-3 equivalent. 2. Carefully insert the complete secondary piston and return spring assembly in the master cylinder bore frV, 23). General Hydraulic Broke Service J Install the primary piston assembly at the master cylinder bore. ' 4 Depress the primary piston and install the snap ring is the cylinder bore groove. 5. Install the push rod, boot and retainer an the push rod, if so equipped Install the push rod assembly into the primary piston. Make sure the retainer is properly seated and holding the push rod securely, fi Position the inner end of the push rod boot (if so equipped) in the master cylinder body retaining groove. 7 Install the secondary piston stop bolt, if used, with an O-nng if screw is on bottom outside of master cylinder casting 8 install the bleed sciew (if so equipped) Install the gasket (diaphragm) in the master cylinder filler cover Position the gasket as shown in Fig 23 Make tore the gasket Is securely seated. 12-01-29 Install the cover and gasket on the master cylinder and secure the cover into position with the retainer Typical CLEANING AND INSPECTION e* i .r : 1 ' .' i DISC BRAKES ' Front wheel bearing end play is sets. Prior to replacement of lining, 1. Remove the wheel and are from the hub and rotor - r ' " ' ` 2. Inspect brake sboes and lining for wear. If the lining is worn, to within ' * 1/8 inch of the 'hoe, replace all (d) ` shoe limns assemblies (complete axle set) m* trout or rear wheels as - tpprejjnie ' 3. Ytsuafl check the caliper, K the caliper housing is leaking, it should be replaced. If a seal is leaking. the callper must be disassembled and new- installed. If a pistcm is taxed hi? " the bore, a new caliper housing required. Refer to Part 12-20 for d* * rake rotor resurfacing procedure. __ ` ,, ' j- critical and must be within .specifications. - - Be sure the vehicle is centered on the hoist before servicing any front cod components, to'avoid bending or damaging the rotor splash shield on full right or left wheel toms. Riding of the brake peoal (common on left-foot applications) must be avoided during vehicle operation. The wheel and are must be removed veptrately from the brake rotor, uniur drum brakes where the wheel. Ore and drum can be removed as a Do not attempt ti clan or restore oil or grease-soaked brake linings. When contaminated liningsare (bund, brake finings must be replaced is complete ibe drum diameter should be checked to'determine that'the brake drum braking surface diameter is within specification If (he braking surface diameter exceeds specification, the drum must be replaced. Check the condmon 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 hoid-down springs should be replaced Overheated springs lose their pull and could cause the new lining to wear premacureiv, if not replaced. If the brake drums are beat spotted, indicating an overheated condition, they should be replaced. 1 Inspect all other brake parts and DISC BRAKE SERVtCT PRECAUTIONS ' -. >>. t. -Crease cr any other foreign material axle sets. > 'i t L , i * 4 t *m 'w'1, * -cfjRUM BRAKES - - t1* mtui oe kept off the linings suriace* I. Remove the wheel from the drum, Of the rotor, and external surfaces of ani remove the dium as outlined in the hub during service operations. In _ -+ Fart 12-OZ. handling the rotor and caliper f 2. Use an industrial type _______o_ Tl, assemblies, avoid deformation of the I eteanei to repiove all dust from I brake rotor and ntr ting or scratching I the backing 'platei and interiorof ^ of brake hntngs. *- the brake ddrruamasv. 2.. If k caliper ptston is removed for any Inspect the brake shorn for excessive reason, the piston sea! must be lining wear or shoe damage. If the replace any that are worn or damaged. ' Inspect the brake drum and, if necessary, refmish The maximum inside braking surface diameter is shown on each brake drum I Fig. 23). If the maximum inside braking surface diameter shown on the drum is exceeded either by wear or refinisbmg, the drum must be replaced. Refer to Fart 12-02 for refimshing. * replaced. - X During removal and installation of a brunt A worn within 1/32 inch of the rtvet heads or tf the shoes are BRAKE BOOSTER wheel assembly, exercise care not to damaged, they must he replaced. Check the booster operation as noted . interfere with and damage the caliper Replace any lining that had been under Power Brake Functional Test If splash shield or the bleeder screw contaminated with oil, grease or the brake booster is damaged or fitting. brake fluid. Replace lining in axle inoperative, replace u with a new booster. /? 7 7 Co*'-n/.* - ri PRODUCED BY FORD s > ?-' - -art- 12-01-22- General Hydraulic Brafce Service* 1 t &. Remove the'line and inspect the flare - for cracks or poor flare form If the , fine ts not correct, cut 11 off and repeat the process, The finished flare must he square with the Ime, free ofcracks and have a smooth mating surface to ensure a J , leakproof connection. - Flanng a Line (Flaring-Bar Type) ir 'r C ? * - Refer to Figs. 15 and H * * 1, Cat off and straighten the required *. ' length of line (A line cutting tool will . .-.simplify tanking a clean and square ' * cut). y-- ':y 1 - .j ' " I. Square off the ends of the line with a file and chamfer the end of the lute to be flared. u' -- 3. Insert the line through its appropriate ribbed bale in the bar assembly until - -the jnd of the line stick* out about as Tar *s the thickness of the adaptor above the bar, or even with the bar, depending an the tool used. - 4 Fit the adapior onto (he line and slide the bar into ihe yoke Lock the bar in position with the line beneath the yoke screw 5 Form the single flare by tightening the yoke screw securely. 6 Release the screw and remove the adaptor 7 Form the double flare by tigheaing the yoke screw again, with second adaptor fitted, depending on the ted used. S Release the screw bar, and flared iinc. Inspect the flare Tor cracks or poor flare form, and repeat the process if the flare is not correct. 3. Repeat Steps 3 through 6 at the ' opposite wheel cylinder. " ' Replace a Flexible brake hose if a shows signs of softening, ackin[ other damage. When installing a new brake Wt. position the hose to avoid contact Tilt v other vehicle pans. 1 11 CD 04 04 in S3 <3 REMOVAL AND INSTALLATION, BRAKE DRUM . Alt Vehicles thru 9000 Serin* Use the followtng service procedures .for both hydraulic and air brakes. Since the F-100 thro F-350, E-100-E-350 and Bronco teas drums, and the P-500 (front ' ,r and rear) procedures apply to hydraulic brakes only, they are covered in Part 12 1 - OXj - _> , j -- - - - . ' .FRONT BRAKE DRUM 1. Raise the vehicle until the tire dean the floor and remove the wheel and tire from the hub. Loosen the brake shoe adjusting screw until the shorn no longer touch the brake drum. Remove the grease cap and the gasket fif equipped) from the bub. 2. On vehicles with 9,000 lb front axles and hydraulic brakes, remove the locknut, locking nng, 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 nm and tire) from the hub and drum 5. Remove the. brake drum retainers and ' attacJwng'bolu, screws, or bolts- and nuts. 6. Remove the brake drum,-from the " huh. ` ' ', ' 1 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 1 wheel and hub is removed. S. Place the brake dram to the bub and install the retainers and retaining bolts, screws, or bolts and nuts. 9 Install the hub and drum on the wheel spindle. Keep the hub centered on 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 cone and roller assembly, and the bearing adjusting nut On j]J other axles, install the outer bcannj cone and roller and flaL washer on the spindle. Install the adjusting nut. 'IT Install the wheel and tire on'the"hub. ' Then install the clamps (if applicable . and the. wheel stud nuts. . .., . . 12. While rotating the wheel, tighten thr ' adjusting nut to specification Adjust wheel bearings as described in Group 11. 13 On vehicles with 9000 !b front salt and hydraulic brakes, install Ihe dimpled washer with the dimple indexed in one of the holes in the adjusting nut. Install the locking nng lock nut and tighten 10 specification. Bend the locking nng over a fiat of the lock nut. 14 Install the gasket (if equipped! nd the grease cap, and tighten the whed stud nuts to specification. Install the hub cap (if equipped), and adjust the brakes as described un this Part. OVERHAUL An industrial type vacuum cleaner ai place ofcompressed air, is recommended to remove any dust and dirt present on brake lutings, pads, rotors and drums ect, when performing wheel brake repairs , Also, any machining done on brake finings or pads should be done using properly exhaust vtatilaied equipment. BRAKE DRUM REfWJSHJNG 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 emery ts 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 any more material from the drum iha n neemsary to provide a smooth surface for the brake shoe contact Brake dm maximum braking surface diameter " shown on each brake drum (Fig I'l Brake drums which rsceed the maxima braking surface diameter shown on IT n 77 c ^ "s /*?&*** / JL. s l - O / - Z i PRODUCED SV FORD 12-01*32 " 9 Generof Hydraulic Broke Service ' 12-01 -32 , installed, If a piston is seized m the bore, a new ' caliper housing is required. >, , . - Refer to Pari 12-20 for disc brake rotor resurfacing procedure. . - , .. ' *. ' f 005227 DISC BRAKE SERVICE PRECAUTIONS 1.- Grease or any other foreign material must be kept off the linings surfaces of the rotor, ond external surfaces of the hub during service operations in handling the rotor ond caliper assemblies, avoid deformation of the brake rotor and nicking or scratching of brake linings. ` 2. If a caiiper piston is removed for any reason, the piston seal must be replaced. _ , 3. During removal ond installation of a wheel ' assembly, exercise care not to interfere with ond , damage the caliper splash shield or the bleeder ' screw fitting. 4. Front- wheel bearing end play Is critical and must " be within specifications. " 5.' ' Be sure' the vehicle is centered on thehotsf bafare servicing any front end components, to ovoid bending or damaging the rotor splash shield on fuil 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 the brake rotor, unlike drum brakes where the wheel, tire and drum con be removed as a unit. Do" not,attempt to clean or restore oil or grease-, soaked brake linings. When contaminated linings _ are found, brake linings must be replaced in complete axle sefs, ' ` ' ' m. . i 1 f" -* 9. On Fairmonl/Zephyr anly, always replace rubber . cqliper insulators and plastic sleeves when replacing linings. Do not lubricate the slide pins. not replaced. If the broke drums are het spotted, indicating an overheated condition they should be replaced. '' 5. Inspect oil other brake parts and replace any that are worn or damaged. ,. 6. inspect the broke drum and, if necessary, refinish The maximum inside braking surface diameter is shown on each broke drum (Fig. 33). |f maximum inside braking surface diameter shown on the drum is exceeded either by wear or refinuhing, the drum must be replaced. Refer to Port 12-02 for refimshing, BRAKE BOOSTER ' ~ Check the booster operation as noted under Power Brake Functional Test if the brake booster is damaged or inoperative, replace it with o new booster. The brake booster is serviced only as an assembly, including the check valve. ' BRAKE TUBING ' If a section of the brake tubing becomes damaged,, the entire section should be replaced with tubing of tha same type, sixe, shape and length. Copper tubing should not be used in a hydraulic system. When bending brake tubing to fit underbody or rear axle contours, be careful not to kink or tract the tube." HYORAUUC LINES * - " Double wall steel tubing is used throughout the brake system with the exception of the flexible hoses at the fj-ont wheels and^ot.the rear axle housing brake tube_ connection. " " " ' * - < * " Always bleed the applicable primary or secondary brake system after primary or' secondary brake system hose or line replacement. Centralize the pressure differential valve after bleeding the system. DRUM BRAKE5 1. Remove the wheel from the drum, ana remove the drum as outlined in Part 12-02. Use an industrial vacuum cleaner to remove all dust from the backing plates and interior of the brake drums. Inspect the brake shoes far excessive lining wear or shoe damage. If the lining is worn within 1/32 inch of the rivet heads or if the shoes ore 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 broking 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 o 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 lo wear prematurely, if All brake tubing should be double flared properly to provide good leakproof connections. Cleon the brake tubing by flushing with dean brake fluid before installation. When connecting a tube to a hose, tube connector, or brake cylinder, tighten the tube fitting nut to specified torque with Milbor Tool 1)12-144 or equivalent. _ BRAKE HOSE A flexible brake hose should be replaced if it shows signs of softening, cracking, or other damage. When installing a new front brake hose, position the hose to avoid contact with other chassis parts. On oil vehicles except Foirmont/Iephyr, place q new copper gasket over the hose fitting and ihread the hose assembly into the front wheel cylinder or caliper. Fairmont/Zephyr front hose does not require a copper 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 af twisting Install the horseshoe-type retaining clip, and connect Ihe tube to the hose with the tube fitting nut. 197f Cer s/e. yj f \ PRODUCED BY F=ORD 12-01-20 General Hydraulic Broke Service 12-01-20' OVERHAUL *''' ` Removal of dust ond dirt from brake assemblies I should be done by using the Rotunda brake vacuum J [model 34-0009) or Rotunda brake parts washer (model 650016) or on equivalent Broke assembly dust and dirt j should not be removed by either blowing off with on 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 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 1 BRAKE DRUM REFINISHING " ' Minor scores an a brake drum can he removed with fine emery cloth, provided the emery is thoroughly cleaned off the drum after the operation. A badly seared, rough, or out-of-round drum should be ground or turned on a drum lathe (Refer to the lothe manufacturers instructions.) Do not remove any more moferiol from the drum than is necessary to provide a smooth tvrface for the brake shoe contact. Brake drum maximum broking surfoce diameter is shown on each broke drum [Fig 13). Brake drums which exceed the maximum braking surface diameter shown on the broke drum, either through wear ar refmishing, must be replaced. The maximum braking surface diameter specification, which is shown on each broke drum [Fig. 13), ollows for a 1.52mm (0 060 inch) machining cut over the original nominal drum diameter plus 762mm [0.Q30 inch) additional wear before reaching the drum- discard diameter. ' fluid' or oil contamination that is causing a fanjk pull, replace all four shoe and lining assembl'ist,* 3, To check rotor runout, first eliminate the wheel bearing end play by lightening the od|ustmg nut Then check to be sure the rotor con siill be rotated." 4. Camp a dial indicator tq the spindle so the sty!w contacts the rotor approximately one inch from the outer edge Rotate the rotor and take an indicator reeding If the reading exceeds .254mm [0 010 inch) total lateral runout within a six inch radius cn the indicator, replace or re-surface the disc brake rotor. The following requirements mutt be met when re-surfacing disc brake rotors. Use a disc brake lothe to re-finish the disc brake rotors. [Follow the manufacturers instructions.) No mare than 50Smm (0 Q20 Inch] of matenol may be machined equally off each surface [A ond B, Fig. 141. If rotor thickness foils below the minimum shown on each rotor, it must be replaced 005228 FIG. 13 Rear Brake Drum Maximum Inside Braking Surface Diameter Marking Location--E-100--E-350, Branco, and F100--F-350 FRONT DISC BRAKES 1. Remove the shoe and linings as described in Part 12-24 Disc Brakes--Light and Heavy Duty-- Sliding Caliper. 2. Measure the thickness of the brake lining. If the tining thickness at any point on the assembly is less than 794mm [1/32 inch) above the bockmg plate or nvets, O' if the lining shows evidence of brake i<jrfc i.(+r />4.ca J-4^, iwiiidncd isniis inatnocwi* ((XCCPT A-TOtf JSQQJfJbQ CVWR WITH POWftR BRAKES! H3H5*kG FIG. 14 Disc Brake Rotor Service Limit* The finished braking surfaces of the rotor must be fiat and parallel within 0.025mm (0 001-inch), lateral runout must not exceed 0 D76mm (0 003 inch) total indicator reading, and the surface finish of the braking surfaces must be 16 to BO micro inches. When the runout cheek is finished, adjust the hearing* a* described in Part 11-10, Wheel Hubs ond Bearings--Front [except Front Wheel Drive} to prevent bearing failure. 5. Check the ralor for storing. Remove minor scares with a fine emery doth. If the rotor is excessively scored, re-finish or replace the rotor if necessary. i-i^c , i -- or- 2 e PRODUCED BY FORD 005229 f f*flT 12-01 GENERAL HYDRAULIC 8RAKE SERVICE 12-01-27 . Be sura vehicle is centered on hoist before ser1 vicmg any front end components, to avoid ben ding or damaging rotor splash shield on full nght 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 me wheel, 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 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 trghtemng pro cedure. 4 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 5 Ora 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 . r_ an upward position for proper bleeding of air . , from brake system. Dmm Brakes . 4* 1. Remove wheel, tire and drum assembly from ` 'spindle. ,: T- Brake Tubing -' * ' I- A *" * .* "i, 1 ** * 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 m a hydraulic system. When bending brake tubing to fit body contours, be careful not to kink or crack tube. ., 7 Use an industrial vacuum cleaner to remove all ' dusf 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 line. A rtcuum cleaner equipped for this purpose, brush or rtg should be carefully used to remove any dust. Any dust should be contained in a sealed bag for 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 orJshoe damage. It lining is damaged or worn within 102 Inch of the rivet heads on riveted lin ings or within 0 060 inch of the shoe on banded finings, 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. , Ail 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 tube to a hose, tube connec tor, or brake cylinder, tighten the tube fitting nut to specified torque with the DS1L-6GG-A inch-pound torque wrench. Uf , , e,siy *C -A , ,, *4 - - - f* <*T * ' PRODUCED BY PORD ^lEMOVAl AND INSTALLATION .. '?g*?S&!` p,pipp'"i ''i"' I*-: AW*AVRe,NeINGd:uNsfev~ehreinhianlheadleudst cfaronmbebriankejulir,,;ynn9(<J* Wth. Do not blow out dust with an oir ? *^<vum*clean*erb'eqcuaiprepfeudllyfoor stehdis topurrepo"soev u'TM' Jl *^t. Any dust should be contained in a sealed baa aii^osoie ( CAST SPOKE WHEELS ILxncrrtl > Raise the vehicle until the tire clears the floor and mitoll sofety stands. Remove the tire and nm assembly by removing the clamps and nut. 3 temove the cast spoke wheel and drum assembly (ram the front or rear axle 3 Remove the drum from the cast spoke wheel by removing the nuts, bolts ond washers. 1 Check the drum for damage or wear and repair ar reptoce 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 'siie1.-Failure to da so will affect vehicle- performance. Replace cast drums with cast drums. Replace.centrifuse drums only with ceritnfuse -i*; drums. .. . t i * .. , 2. Assemble the cost spoke spider and drum assembly to the front or rear oxle. Adjust the wheel bearings and the axle shaft installation, if necessary, per the appropriate Section in Group 11, 3. Install the tire and wheel assembly on the cast spake wheel. Refer to Section 11-01, Wheels, Rims and Tires for the procedure. 4. Tighten the front and rear wheel clamps to 299-352 N-m {220-260 ft-lbsj. DISC WHEELS--OUTBOARD MOUNTED DRUMS Removal 1. Raise the vehide until the tire clears the floor and install safety stands Remove the nuts retaining the tire and wheel assembly to the hub {Fig. 6). 2. Remove the drum from the hub. 3. Cheek the drum for damage ar wear and repair or replace as necessary. If a new drum is installed, be sure to remove the protective coating with degreaser. NOTE, Replace drums with drums of the same type. Failure to do so will affect vehicle track ond performance. Replace cast drums oniy with cast drums. Replace centnfuse drums only with `*i'`centrifuse drums. -' -> '>*- -1 5* 005230 ' '/ff-j' 7*f<rt//tfy ' 75-Hi k SMf /*?*** d `' *' * * /i xeai.ipmmjyi.i m fin i m nmiff<i*nr^rTnnirr v i irpr-mnw "ih^h i ........... aim PRODUCED BY FORD U-Ol-19 General Hydraulic Brake Service 12-01-19 . 1/tjerf the line through its appropriate ribbed hole * in the bar assembly until the end of the line sticks out about as far as the thickness of the adapter above the bar, or even with the bar, depending on the tool used. fit the adapter onto the line and slide the bar into the yoke, lock the bar in position with the line beneath the yoke screw form the single flore by tightening the yoke screw securely. ^ Release the screw and remove the adaptor. 7 form the double flare by fighemng the yoke screw ogoin, with second adaptor fitted, depending on the too! used. B- Release the screw bar, and flared Sine. Inspect the flare for cracks or poor flore form, and repeat the process if the flare is not correct, 9. Repeat Steps 3 through 6 at the opposite wheel cylinder. i BRAKE HOSE Replace a flexible brake hose if it shows signs of softening, cracking ar other damage When installing o new brake hose, position the hose to avoid contact with other vehicle parts. OVERHAUL 005231 WARNING; N ever inhale dust from brake lirtings. Asbestos dust when inhaled ean be injurious to health. Do not blow out dust with an .air line. A vacuum cleaner equipped for this purpose, brush or rog should 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 should be done by using the Rotunda brake vacuum Irnodel 34-0009} or Rotunda brake parts washer [model tSOOl-6) or an equivalent. Brake assembly dust and dirt should not be removed by either blowing off with on oir gun or vacuuming with a standard industnai vacuum cleaner because a health hazard from breathing in nibestos dust may develop Also, any machining done on brake linings or pads should be done using properly exhaust ventilated equipment. Also, any machining done an brake linings or pads should be done using properly exhaust ventilated equipment. 13 Rear Brake Drum Maximum Inside Braking Surface Diameter Marking location--E*i00---350, Branco, and F- , ,, 100--F-350 .... 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 :hau"tr- be ground or turned on a drum lathe. [Refer to the lathe V'anufaelurers instructions.! Da not remove any more *olerial from the drum than is necessary to provide a smooth surface for the brake shoe contact. Brake drum xixjmum braking surface diameter is shown on each Noke drum (Fig. 131. Broke drums which exceed the maximum braking surface diameter shown on the brake d'vm, either through wear or refinishlng, must be 'placed. The maximum braking surface diameter specification, which is shown on each brake drum (Rg, 13}, allows for a 1 32mm (O.OdO inch) machining cut ^er the original nominal drum diameter plus .762mm 10.03(3 inch} additional wear before reaching the drum- discard diameter. _ ,, ttONT DISC BRAKES ' ' "* " 1- Remove the shoe and linings as described in Section 12-24 Disc Brakes--Light and Heavy Duty-- Sliding Caliper. "2." 'Measure the thickness af the brake lining. If the " lining thickness at any paint 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 causing a brake pull, replace all four shoe and lining assemblies. 3. To check rotor runout, first eliminate the wheel bearing end play by tightening the ad|usting 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 reading exceeds .254mm (0.010 inch) total lateral runout within a six inch radius on the indicator, replace or re-surface the disc broke ratar. The fallowing requirements must be met when re-surfacing disc brake rotors. Use a disc broke lathe to re-finish the disc brake rotors. (Follow the manufacturers instructions.! No mare than .508mm (0 020 inch) of materia! may be machined equally off each surface (A ana B, Fig. 14}. If ratar thickness falls below the minimum shown on each rotor, it must be replaced. sdc.fr '`fe'ytrtc? * SaJ^ r`/2 -- t f PRODUCED BY FORD tf-qi-gg. GENERAL HYDRAULIC SRAKE SERVICE 12-01-25 005232 HUB NUT NBOl 714-S100 TIGHTEN WUT TO }*3 ^ n$o-ico lb*ft> after hub is sbatsd USING SPECIAL HUB INSTALLS TOOL TBlf \ 104-4, DO HOT USE IMPACT WKSMC* fl REMOVAL Oft (NSTAU LAT10N OF HUB NUT AFTER UT IS TORQUES OEFQflW NUT COLuW INTO SLOT OP ORfveSHAFT USING TOOL AS IN. OICATEO IN THIS FIGURE. TNI NUT MUST NOT SPUT OR CftACIt WHIN STARED if NUT IS SPUT OR CRACKED AFTER STAX wa rr must be removed and replaced WITH new UNUSED nut VW K note removing on Mavcvc * KCfQ NUT after staking REQUIRES THE NUT BE NLMACEO WTH A HEW WIT - " * - THf STAKING TOOL CAN ie fabricated from an EXISTED HAflCtNEO CHISEL. THE CORRECT RADIUS QN THE CHISEL TIP WILL PREVENT IMPROPER STAXflWL OO NOT AT TEMPT TO STAKE WITH A CHAAft EDGES TOOL ^ j RADIUS Y $ MM t iS I 09 IN OU FABRICATE TOOL .* *s**?*. . f' ''1 WtMi FIG. 11 Hub Nut Installation a... *^wj u i Refer to Section 11-12, Front Hubs for nut lightening procedure ' .^ - , / 5. Be sure vehicle ts centered on hoist before servlctng any front end components, to avoid bending or damaging rotor splash shield on full rfght 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. ,, __ _( ^ 8. 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. Drum Brakes `- ' - 1, Remove wheel and tire assembly and drum assembly from spindle. " 2. Remove drum assembly from spindle Use an industrial vacuum Gleaner 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 fibers 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 for use with asbestos fibers. This type of vacuum cleaner is available through the Rotunda Dealer Equipment Catalog. Dust and dirt from the vacuum cleaner should be disposed of m a manner lhal prevents dust exposure. 10. Calipers must be installed with bleed screws In ft Any service done on brakB linings, pads, rotors . an upward position tor proper bleeding of air V and drums, should be done using properly exhaust from brake system. \ ventilated equipment V c'^-r/tr ,/T-Svn, ^oe/^ '' C4&SFS _ %/t ' ^ /i -C/- S produced by ford 12-0T-Q8 General Brake Service 12-01-08 be insoected for wear or damage 9. On floating caliper type disc brakes, the caliper assembly must be removed from the spindle prior to re moval of the shoe and lining assem blies 10- On floating caliper type 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 sad spindle, she bleeder screw wilt point to the rear of the vehicle If a caliper is installed on the wrong side of the vehicle, it is noi possible to bleed the system properly II. Do not attempt to clean or restore oil or grease soaked brake bnmgs When contaminated linings are found, brake linings most 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 all dust from the backing plates and interior of the brake drums 3''Inspect the'brake shoes for ex cessive lining wear or shoe damage If the lining is worn within 1/32 inch of the rivet heads1 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 Fnor to 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 blue coloring, indicating overheating. * replacement of ihe redacting ana hold-down springs is strongly recom mended Overheated springs losr tneir pull amt could cause the new lining to weal prematurely, if they are not re placed. 1! the brake drums are heat Spotted, indicating a omheaied con dition. thev should be replaced. S* If the vehicle has 30 OOQ or more miles of operation on the brake lin ings or signs of overneatmg are pres ent when relming brakes, the wheel cylinders should be disassembled and inspected far wear and entrance of dirt into the cylinder The cylinder cups should oe replaced, thus avoiding future problems 6 Inspect all other brake parts and replace any (hat are worn or dam aged 2 Inspect the brake drum and, if netessary. refimsft Refer lo Pan 12-02 for refinishing BRAKE BOOSTER ' Check the booster operation as noted in Part 12-01 Power Brake Functional Test If the brake booster is damaged or inoperative replace it with a new booster The brake boost er is serviced only as an assembly HYDRAULIC LINES Steel tubing is used throughout the broke system with the exception of the flexible hoses at the front wheels and at the rear axle housing brake tube connection Always bleed the applicable pri mary or secondary brake rrstera after primary or secondary brake smem hose or line replacement. Centralize the pressure differential valve after bleeding the system J BRkKE TUBING If a section 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 hv drautie system. When bending brake tubing to ht underbody or rear axle contours, be careful not to kink or crack the lube Aft brake tubing should be double flared properly to provide good leak proof connections Clean the brake tubing by (lushing with clean brake fluid before installation When connecting a tube to a hose, tube connector, or brake cylinder, tighten the tube fitting nut to speci fied torque with Milbar Tool 1112[44 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 wiih other chassis pans place a new copper gasket over the hose fit 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 clip, and cons, nect the 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 an the frame Install the horseshoe-type re taining chp. and connect the tube to the hose with the tube fitting nut. 005233 T PRODUCED BV FORD 005234 12-0 >-29 General Hydraulic Brake Service 12-01-29 6. Clean ell parts ui clean isopropyl alcohol, and inspect the parts for chipping, escessve war or damage When using a Blaster cylinder repair Ut, install all the parts supplied. 7 Be sure that all receaes, openings and internal passages are open and clean. Place all parts an a clean pan or paper g. Inspect the master cylinder bare for signs of etching, pitting, scoring or rnsL If accessary _ta hone the master cylinder bore to repair damage, do not exceed allowable hone specifications. Aaembij 1. Dip all parts except the master cylinder body in clean brake fluid (ESA-M6C25-A) Ford Part No C6AZ-I95+2-A or DOT-3 equivalent. 2. Carefully insert the complete secondary piston and return spring assembly in the master cylinder bore (Fig 22) '3. Install the primary piston assembly in , the master cylinder bore. ` 4 Deprtss the primary piston and install the snap nng in the cylinder bore greove. 3. Install the push rod, boot and retainer , on the push rod, ifso equipped. Install the push rod assembly into the primary piston Make sure the 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 the secondary piston stop bait, if used, with an 0-nng if screw is an bottom outside of master cylinder casting. 8. Install the bleed screw (if so equipped) Install the gasket (diaphragm) m the master cylinder filler cover. Position the gasket as shown in Fig 23 Make sure the gasket la securely seated. 9 Install the cover and gasket on the master cylinder and secure the cover into position with the retainer Snm Al-v Pll-ra nunc FIG. 24 Removing Snap Ring-- Typical CLEANING AND INSPECTION DISC BRAKES t. Remove the wheel and Ore from thebub and rotor. 2. Inspect brake shoes and lining for wear If the lining is worn to within " 1/TTmch of the shoe, replace ail (4) shoe and Lining assemblies (complete axle set) on front or rear wheels as appropriate. J, Visually check the caliper If the eahpcr housing is leaking, it should be replaced. If a seal is leaking, the g-ltper must be disassembled and new wl< installed. If a piston is seized m the bore, a new cahper bousing is required. Refer to Part 12-20 for disc brake: rotor rerarfaciag procedure^ a-- DISC BRAKE SERVICE* PRECAUTIONS - '- 'll, Grease or any other fonagir materialmust be kept off the linings surfaces ' of the rotor, and external surfaca of the hub during semen 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 far any reason, the piston seat 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. 4. Front wheel bearing end play is 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 tight 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 ore must be removed separately from the brake rotor, unlike drum brakes where the wheel, ore and drum can be removed as a unit. 8. Do not attempt to dean or rmiorc oil ,, or grease^soaked brake linings. When contaminated linings are found, brake bungs must be replaced in complete axle sets. - DRUM BRAKES. , . *- 1 Remove the wheel from the drum, and remove the drum as outlined in Part 12-02. 2- Use an inoustnal type vacuum cleaner to remove all dust from the backmg plates and ulterior of the brake drums. 3. Inspect the brake shoes for excessive lining wear or shoe damage. If the bung is worn within 1/32 inch of the rivet heads or if the shoes are damaged, they must be replaced. Replace any lining tbift baa 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 sb ght blue coloring, indicaimg overheating, the retracting and hold-down springs should be replaced Overheated springs lose their pull and could cause the new lining to wear prematurely, if not replaced. If the brake drums sit heat spotted, indicating an overheated condition, they should be replaced. 5. Inspect all other brake parts and replace any that are worn or - dunageei '* * ^ S. laipect the brake drum and, if " necessary, refimsh The maximum Inside braking surface diameter is shown oo each brake drum (Fig. 23V. If the maximum inside braking surface diameter shown on the drum is exceeded either by wear or reftnishing, the drum must be replaced Refer to Part 12-02^ for rebus hut g. BRAKE BOOSTER Check the booster operation as noted under Power Brake Functional Test, ir (he brake booster is damaged or inoperative, replace it with a new boaster PRODUCED BY FORD 4". A I 12-01-22 General Hydraulic Brake Service I?-01-21 8, Remove the line and inspect the flare for cracks or poor flare form If the flare is not correct, cut it off and , repeat the process, " The finished flare must be square with the line. Ares of cracks and have a smooth mating surface to ensure a leakproof connection. Flaring a Line [Flaring-Bar Type) Refer to Figs. 1J and 17 1 Cut off and straighten the required length ofhnt (A hne cutting tool will simplify making a clean and square cut) 2. Square offthe ends of the line with a file, and chamfer the end of the line to be flared, ' 3 Insert the Uiie through its appropriate ribbed hole in the bar assembly until the end of the line sticks out about sa , far as the thickness of the adaptor above the bar, or even with the bar, depending on the too! used ' 4 Fit the adaptor onto the line and slide the bar into ihe yoke Lock the bar m position with the line beneath the yoke screw 5 Form the single flare by tightening the yoke screw securely fi Release the screw and remove the adaptor 7 Form the double flare by ughcmng the yoke screw again, with second adaptor fitted, depending on the tool used S Release the screw bar, and flared line. Inspect the flare for cracks or poor Hare form, and repeat the process if the Hare is not correct. 9 Repeat Steps 3 through fi at the ' opposite wheel cylinder Replace a flexible brake hose if* shows signs of softening, cracking or other damage. When installing a new brake hose, position the. hose to avoid contact wei' other vehicle parts. _ REMOVAL AND INSTALLATION BRAKE DRUM .,, 4 Remove the front wheel-to-hub bearing cone and roller assembly, and All Vehicles thru 9000 Sena* ' retaining nuts (or nsi and tire the bearing adjusting nut. On ill Use the following service procedures attaching nuts) Remove tbe wheel other axles, install the outer bearing lor both hydraahc and air brakes. Since (or nrn and Ore) from the hub and ` cone and roller and flat washer on Ihe the F-IQO thru F-3JQ, E-10O-E-3J0 and_ Bronco rear drums, and the P-500 (front -- and rear) procedures apply to hydraulic brakes only, they are covered in Part 12- ' OJL , ,` drum. S Remove the brake drum. irUtneis and . " ' attaching bolts, screws or bolts and ' ` 11 nuts. fi. Remove the brake drum from the, t, bub, * `` ' spindle. Install the adjusting nUL Install the wheel and'Ure on the huh.' Then install the damps (if applicable) and the wheel stud nuts. , 12. While rotating the wheel, nghten the ^ FRONT BRAKE DRUM '1 7 Check the drum for damage or wear, adjusting nut to specification. Adjust 1. Raise the vehicle until the tire clean the floor and remove the wheel and and repair or replace if necessary If a new drum wtU be installed, be sure wheel bearings as described in Group II. Un from the hub. Loosen the brake shoe adjusting screw until the shorn 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 hunt axles and hydraulic brakes, remove the locknut, locking ring, dimpled washer and adjusting hul On all other axles, remove the cotter put, adjusting nut and fiat washer from the spindle. 3 Remove the outer bearing cone and to remove the protective coating with degreases Install new grease retainer seals whenever a wheel and hub is removed. S Place the brake drum to the hub and install the retainers and retaining bolts, screws, or baits and nuts. 9 Install the hub and drum an the wheel spindle. Keep the hub centered on the spindle to prevent damage to the - grease retainer or tbe spindle threads. 13 On vehicles with 900C lb from ask and hydraulic brakes, install the dimpled washer with the dimple indexed in one of the boles m the adjusting nut Install tbe locking ruig lock nut and tighten to speafianccL Bend the locking ring over a flat of the lock nut. 14 Install the gasket (if equipped) *nd the grease cap, and nghten the whed stud nuts to specification. Instill tbe roller assembly. Pull the hub and 10 On vehicles with 9,000 lb front axles hub cap (if equipped), and sdjusi the drum assembly off the wheel spindle. and hydraulic brake: install the outer brakes as described in this Part- OVERHAUl An industrial type vacuum clatter in place of compressed air, is recommended to remove any dust and dirt present on brake linings, puds, rotors and drums eel, when performing wheel brake repairs. Also, any machining done on brake linings or pads should be done using property hn!tt ventilated equipment. BRAKE DRUM REFINISHING E-100---E-35Q, F-100--MSB, U-1D0 Minor scores on a brake drum can be removed with fine emery cloth, provided the emery ts 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 T more material from the drum than necessary to provide a smooth surface the brake shoe contact. Brake draw maximum braking surface diatneier 11 shown on each brake drum (Fig I'- Brake drums which exceed the msxin11**" braking surface diameter shown on * 005235 ' * of ,, r * 5\ 12-61-32 ` f- Generd Hydraulic Brdte Service- 12-01-32. .J installed If a piston ii seized In the hors, fl new - caliper-housing is required. -- - - - Refer to Part 12-20 for dl*e brake rotor resurfacing procedure. DISC BRAKE SERVICE PRECAUTIONS 1, Grease or any other foreign material must be kept 1 off the linings surfaces of the rotor, and external surfaces of the hub during service operations In handling the rotor and caliper assemblies, ovoid deformation of the broke rotor and nicking or scratching of brake linings, - - - - " 2. ` If o'catiper pisfoms removed for cny 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, ^"* * 4. Front wheel bearing end play is critical and must be within specifications. 5 Be sure the vehicle is centered on the Hoist before servicing any front end components, to avoid bending or damaging the rotor splash shteid on fufl right or left wheel turns. d. Riding of the broke pedal (common on (eft-foot applications) must be avoided during vehicle operation. 7. The wheel and tire must be removed separately from the brake rotor, unlike drum brakes where the ' wheel, tire and drum can be removed at a unit, 8. Do .not attempt to clean or restore-oil oe greasy- ,,, soaked brake linings. When contaminated linings are found, brake linings must be replaced in complete axle sets. 9 On Fairmant/Zephyr only, always replace rubber caliper insulators and plastic sleeves when replacing linings. Do not lubricate the slide pins. not replaced. If the brake drums are heat spotted, indicating an everheated_conditiofl they should be replaced. * - *' 5, Inspect all other brake parts and replace any that are worn or damaged 6, Inspect the broke drum and, if necessary, reftnish. The maximum inside braking surface diameter is shown on each brake drum (Fig. 23). if the maximum inside braking surface diameter shown on the drum is exceeded either by wear or refim thing, the drum must be replaced Refer to Part 12-02 for refinishing. BRAKE BOOSTER ' , ' Check the booster operation as noted under Power, Brake Functional Test If the broke booster is damaged or inoperative, replace it with a new booster The brake booster is serviced only as an assembly, including the check valve. - BRAKE TUBING , If a, section of the brake tubing becomes damaged,, the entire section should be replaced with tubing of the same type, sue, shape and length. Copper tubing should not be used in a hydraulic system. When bending brake tubing to fit underbody or rear axle, contours, be careful not to kink or crack the tube. r ' -* i I HYDRAULIC LINES Double wall steel tubing is used throughout the brake system with the exception of the flexible hoses at the front wheels find at the rear axle housing broke tube, connection. _ - lj!- *i i Always bleed the applicable primary or secondary brake system after primary or secondary brake system hose or line replacement. Centralize the pressure differential vaive after bleeding the system. L \ } C I DRUM BRAKES 1. Remove the wheel from the drum, and remove the drum as outlined in Part 12-02. 2. Use an industrial vacuum deaner to remove ail dust from the backing piates and Interior of the brake drums. . 3. Inspect the broke 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 ail, grease or broke fluid. Replace lining in axle sets. Pnor to replacement of lining, the drum diameter should be checked to determine that the brake drum braking surface diameter is within ipedfication. 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 shoei have a slight blue coloring, indicating overheating, the retracting and hold-down springs should be replaced. Overheated springe lose their pull and could cause the new lining to wear prematurely, if All brake tubing should be double flared properly to provide good leakproof connections Gean the broke tubing by flushing with clean brake fiutd before installation. When connecting a tube to a hose, tube connector, or brake cylinder, tighten the tube fitting nut la specified torque with Milbar Tool 1112-144 or equivalent. , BRAKE HOSE A flexible broke hose should be replaced if it show* signs of softening, cracking, or other damage. When installing o new front brake hose, position the hose to ayoid contact with other chassis part*. On all vehicles except Fairmant/Zephyr, place new copper gasket aver the hose fitting and thread the hose assembly into the front wheel cylinder or caliper. Fairmant/Zephyr front hose does not require a copper gasket and is reusable. Engage the opposite end of the hose to the bracket an the frame. The white stripe an the hose should show no evidence of twisting. Install the horseshoe-type retaining clip, and connect the tube to the hose with the tube fitting nut. *** 005236 . 1-kuu^cO BY FORD 12-01-20 General Hydraulic Brake Service 12-01-50 OVERHAUL Removal of dust and dirt from broke assemblies should be done by using the Rotunda brake vacuum (mode! 34-00091 or Rotunda brake parts washer (model 650016) 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 cleaner because a health harard from breathing tn 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 a brake drum can be removed with fine emerv doth, provided the emery Is thoroughly deoned off the drum after the operation. A badly scored, rough, or out-of-round drum should be ground or turned pn a drum lathe. (Refer to the lathe manufacturers instructions.) Da 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. 13| Brake drums which exceed the maximum braking surface diameter shown an the broke drum, either through wear or reflnishing, must be replaced The maximum broking surface diameter specification, which ts 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 reaching the drumdiscard diameter. - BRAKE DRUM -TVMCJU. fluid or oil contamination that is causing q brak* pull, replace all four shoe and lining assemblies, 3 To check rotor runout, first eliminate the whe*} bearing end play by tightening the adjusting nut Then check to be sure the rotor can still be rotate^ 4 Clamp o dioi indicator to the spindle so the stylu, contacts the rotor approximately one inch from th, outer edge Rotate the rotor and take an indicolev reading. If the reading exceeds .254mm (0 Oig inch) total lateral runout within a six inch radius an the indicator, replace ar re-surface the disc brat* rotor. The following requirements must be met when re-surfacing disc brake rotors. Use a disc brake lathe to re-finish the disc brake rotors, (Fallow the manufacturers instructions.) No mare than 508mm (0.020 inch) of material may be machined equally off each surface [A and B, Fig. 14) If rotor thickness falls below the minimum shown on each rotor, it must be replaced. rLi f-SI ISmrt II IS INCH! '0 00-0 SOBnit. 10 OSH IMCHi MINIMUM OVERALL 2 ff7rewn (TI WlfCtDKFINiSCSHE} 34 Afenm I0JS INCH! O 0O l-SCEmm [Q Q30 IHT** MINIMUM OVERALL thickness n 120 r ^ ~ P 23014 * 4) AMD F 2 ABOVE TOO 3Wf 14 X 2) E 23WS0 30 Z2mm11 1M IkChi 0 00 0 SOWn ICL0 INCHI P 100 4600/4700 CVWH WITH POWER BRAKE! 005237 FIG. 13 Rear Brake Drum Maximum Inside Braking Surface Diameter Marking Location---E-100---350, Branco, and F100--F-350 FRONT DISC BRAKES 1. Remove the shoe and linings os described in Fort 12-24 Disc Brakes--Light and Heavy Duty--Sliding Caliper. 2. Measure the thickness of the broke lining. If the lining thickness at any paint on the assembly is less than .794mm (1/32 inch) above the backing plate ar rivets, or if the lining shows evidence of brake 'EXCEPT P 100 4MV4300CVWR WITH POWER BRAKES) H2Q0 *6 FIG. 14 Disc Brake Rotor Service limits The finished braking surfaces of the rotor must be flat and parallel within 0.025mm (0 001 -inch); lateral runout must not exceed 0.076mm (0.003 inch) total indicator reading, and the surface finish of the braking 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 and Bearings--Front (except Front Wheel Drive) to prevent bearing failure. 5. Check the rotor for scoring. Remove minor scores with a fine emery doth. If the rotor is excessively scored, re-finish or replace the rotor if necessary- PRODUCED by FORD ^JLRT 1201 GENERAL HYDRAULIC BRAKE SERVICE 12-01-27 - ^ sure vehicle is centered on hoist before ser vicing} any front end components, to avoid ben ding or damaging rotor spiash shield on full right or left wheel turns. . flying of brake pedal (common on left-front ap plications) must be avoided during vehicle operation. ; The wheel and tire must be removed separately irom the brake rotor, unlike drum brakes where me wheel, 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 slight blue color ing, indicating overheating, retracting and hold down springs should be replaced. Overheated springs lose their pul! 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. t 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 3 0o not lubricate caliper slide pins. ip Calipers must be installed with bleed screws in , ,an upward position for proper bleeding of air 1 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 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 lor 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 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 surface diameter is within specifications, tf braking surface diameter exceeds speclficalion, 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 Tubfng . tf a section of brake tubing becomes damaged, the entire section should be replaced with tubing of the same type, size, shape and length Capper 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 ime replacement. Centralize pressure differential valve after 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 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 PRODUCED BY FOF 13-10-4 Broke Drum 12-10-4 |M0VAL and installation rfc* fcflowmg apply to vehicles equipped with either at trd;oullc brakes. WAlNfNfl; New inhale du*t from brake lining*. AjAetlot dust when inhaled can be injurious to i**itf\. Da not blow out dust with on air hna. A rwvuin cleaner equipped For this purpose, brush ff reg should be eorefully used to remove any Any dust should be eontotned in o sealed bag Sw disposal. CAST SPOKE WHEELS ' tone the vehicle until the tire dears the floor and (nfoll safety stands. Remove the tire and rim assembly by removing the damps and nut. J Remove the cost spoke wheel and drum assembly bant the front or rear axle 1 Remove the drum from the cast spoke wheel by removing the nuts, bolts and washers. 4 Check the drum for damage or wear and repair or replace if necessary If a new drum wili be insta(led, remove the protective coating with o degreaser. NOTE: Replace the drum with the same type and - ' 'trie. Failure to do"so will affect vehicle performance. Replace cast drums with cast drums. Replace eentrifuse drums only with centrifuse y- drums, - , . ^ * ,, - ; tneulletioit ,, L Assemble the drum fa the cast spakespider. Tighten the nuts to 299-352 N m (220-260 ft-lbs). 2. Assemble the cast spoke spider and drum assembly to the front or rear axle Adjust the wheel bearings and the axle shaft installation, if necessary, per the appropriate Sedion in Group 11 3. Install the lire and wheel assembly on the cast spoke wheel. Refer to Section 11-01, Wheels, Rms and 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 I Raise the vehicle until the tire dears the floor and Install safety stands. Remove the nuts retaining the tire and wheel assembly to the hub (Fig 6). 2. Remove the drum from the hub. 3. Check the drum for damage or wear and repair or replace os necessary If a new drum is installed, be sure to remove the protective coating with degreaser. NOTE, Replace drums with drums of the same type. " Failure to do jo will effect vehicle`track and . performance. Replace cost drums only with cast drums. Replace centrifuse drums only with `h- 'centrifuse drum*. Check wheel grease seals for leakage If the hub Itrbntoved from the'axle, instoll new wheel grease seals. ` 4 Brake Drum Mounting* 005239 -ilxxeU-*- wysei 4UL,j in ^Kegit< pwrmrws li ipf PQ aveqpen T3P ' PRODUCED BY FORD j 2-0 T-T 9 General Hydraulic Brake Service 12-01-19 [,,rt the line through its appropriate ribbed hole 1 in the bar assembly until the end af the line stick* out about as far as the thickness of the adapter above the bar, or even with the bar, depending on the tool used. A pt the adapter onto the line and slide the bar into the yoke Lock the bar in position with the line beneath the yoke screw. form the single flare by tightening the yoke screw tecurely. 4 Release the screw and remove the adaptor. 7 Form the double flare by tighemng the yoke screw again, with second adaptor fitted, depending on the tod used. S. Release the screw bar, and flared line. Inspect the flare far cracks or poor flare form, and repeat 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 signs af softening, cracking or other damage. When Installing a new brake hose, position the hose to avoid contact with other vehicle parts. OVERHAUL WARNING; Never inhale dust from brake linings. Asbestos dust when inhaled can be injurious to health. Do not blow out dust with an sir line. A vacuum cleaner equipped far this purpose, brush or rag should be carefully used ta . remove any dust. Any dust should be contained a sealed bag for disposal. Removal of dust and dirt from brake assemblies diodd be done by using the Rotunda brake vacuum 'model 34-0009) or Rotunda brake parts washer [mode! 6J0Q16) or an equivalent, brake assembly dust and dirt should not be removed by either blowing off with an oir gun or vacuuming with a standard industrial vacuum cleaner because a health hazard from breathing in asbestos dust may develop. Also, any machining dane on brake finings or pads should be done using properly eihaust ventilated equipment. Also, arty machining done on brake linings or pads should be done using property exhaust ventilated equipment. BRAKE DRUM REFINISHING Minor scores on a brake drum con be removed with fine emery cloth, provided the emery is thoroughly cleaned off the drum after the operation. A badly scared, rough, or out-of-round drum should bt ground or turned on a 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 far the brake shoe contact, drake drum maximum braking surface diameter Is shown an each broke drum (Fig. 13). Brake drums which exceed the maximum braking surface diameter shown an the brake drum, either through wear ar refinishing, must be 'tplaced. The maximum braking surface diameter `pacification, which is shown an each brake drum (Fig. 13), allows for a 1.52mm (0.060 inch) machining cut *tr the anginal nominal drum diameter plus 762mm 10 030 inch) additional wear before reaching the drum^seard diameter. **ONT DISC BRAKES L Remove the shoe and linings as described In Section 12-24 Disc Brakes--Light and Heavy Duty-- Sliding Caliper. BRAKE - rfPtCAL U, HlflGB-lft FIG. 13 Rear Brake Drum Maximum Inside Braking Surface Diameter Marking Location--E-tCO--E-350, Bronco, and F- , . 100--F-350 , ,, , 2. 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 hacking plate or rivets, ar if the fining shows evidence of broke fluid or oil contamination that is causing a brake pull, replace all four shoe and lining assemblies. 3. Ta check rotor runout, first eliminate the wheel bearing end play by tightening the adjusting nut. Then check ta be sure the rotor can still he 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 reading exceeds .254mm (0 010 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-surfaang disc brake rotors. Use a disc brake lathe to re-finish the disc brake rotors. (Follow the manufacturers instructions.) Na more than JOSmm (0 020 inch) of material may be machined equally off each surface (A and B, Fig. 14). If rotor thickness falls below the minimum shown qn each rotor, it must be replaced. 005240 hhuOUCED BY FOSO 12-01-25 GENERAL HYDRAULIC BRAKE SERVICE 12-01-25 hub nut flit 17 7 4 S1 DO TIGHTEN NUT TO 7*1 J71 N [1BO-JOO LB-fTl AFTER HUB IS SEATED USING SREOAL HUS INSTALLER TOOL TB1P 11 OA*A 00 NOT USE IMPACT WHENCH FOR REMOVAL OR INSTAL LAT1DN OP HUB NUT AFTER NUT IS TGRQUED DEFORM NUT COLLAR INTO SLOTT OF ORIVESHAPT USING TOOL AS INDJCATSD IN THIS FIGURE THE NUT MUST NOT SPUT OR CRACK WHEN STAKED IP NUT IS SPUT OR CRACKED AfTER STAR. ING IT MUST BE REMOVED ANO REPLACED WITH NEW UNUSED NUT wm REMOVING OR MOVING a HUB NUT 4,cTfl JTAK1NG RSOUIRES THE NUT BE REPLACED WITH A NEW NUT THE STAKING TOOL CAN BE FABNCATtO FROM AN EXISTED HARDENED CHISEL. THE CORRECT Radius on the chisel tip WILL PREVENT IMPROPER STAKING DO NOT At TEMPT TO STAKE WITH A SHARP EDOBO TOOL KAOIIJS I I MM IS I BS IN ; Dt| FABRICATE TOOL AS ASDVE FIG. 11 Hub Nut Installation :v MT37 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, , . , 8. Do not attempt to clean or restore oil or greasesoaked brake linings. When contaminated lin ings are found, brake imrngs 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 m 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. s . . , (i , ' WARNING: Dust and -dirt conditions present on wheel brake assemblies and rotors and drums, may contain asbestos fibers 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 for usa with asbestos fibers. This type of vacuum cleaner is available through the Rotunda Dealer Equipment Catalog, Dust and dirt from 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 ba done using properly exhaust ventilated equipment 005241 PRODUCED BV FORD