Document MMYeY2yEaYrRb1YnY3pqXVb0k

FILE NAME: Ford (FD) DATE: 1975 July 11 DOC#: FD129 DOCUMENT DESCRIPTION: Internal Letter to Medical Services RE Contents of Service Manuals RE Brake Repair with Attachment Inter O ffice Ford P a ru and Service D>vision Ju ly 11, 1975 Mr. H. B. Lick Central Medical Services Bldg. Roan 210 Rouge P lant cc Mr. S. Keoleian Mr. R. L. Peaker As discussed during our recent phone conversation, we have reviewed the contents o f our current service manuals fo r mention o f centions regarding brake rep air. Y/e are not currently providing a procedure fo r removal of dust from the brake drums or brake Tin-ing area. I have noted on the attached copies o f our shop manual, the locations that should include a caution regarding asbestos p a r tic le s . dust may be considered harmful. Attachments KNCAD'lyonnc, .H I. exhibit f e La. ,X K I 007894 PRODUCED B Y FORD IX-Vi i - J x nyuiuuin. oiu*.e jeiu.e 12-01-12 REMOVAL AND INSTALLATION BRAKE DRUM REM OVAL AND IN 3 7 A L L A T IO N T H R O U G H 1000 SE R IE S ' Usr IIn- following service prm.cdurc for both h sdiu uli. and air brain's hun'C 1hr 1 -1<X1 itn.Miirli I "(1 |- -IIXI-C-IMI rear ilruins. Ilrou. . nr Ilie l' -lsn-41'O iftoni and ri-ji i jiul 1hr 4 . wheel drive Ironi brake ilium prix-riluics appls in hyOraulix hraks-s mils, the) are ensereti in Can 13-113 FRONT BRAKE DRUM I R.iisr Ilie srhit'le uulil ihi* lire clears Hit- flmir and remote ihe wheel and lin- fmrr Ilie hub Loosen Ihe brake sluic adjusting s. revi uni il ihr slims nu longer lunch ihe brake drum R rnim r ihe gicusc cap ami Ihr gasket HI equipped! frurn ihe hub : On vehicle' with 4.000 through 7.000 lb ami Ki.lOR 3(1.000 lb [ruin axles, rrmiiss ihr enuer pm. uil lusting nul. and n.il j 'lu r Inuii the spindle On xeiiicLs m ill .u i*i. il.n o n nr i i .r t o lb .n Ir s . re inns e Ihe lock m il. dimpled soxlirr. locking ring, and adiiisiui)! nui and pin a'scinhh .1 Rcmusr lilt nuler hearing enne and inller assemhlt Cull the huh and drum astcinbls nfV ihe wheel spindle 4 Rrm uvc ihr Ironi wlieel-ln-huh retain in g nu Is (or rim and lire uiiaclunp mils) Remove the wheel (nr rim and lire) from ihe huh and drum 5. Remove the brake drum retainers and ailnchiiig bolls, screws, ur bolls and nuls 6. Remnse the brake drum from ihe huh 7 Check the drum for damage or wear, and repair or replace il necessary If a new drum will he insiallrd. be sure in remote (tic proiccli'c coaling wuh degreaser Install new grease r r lm r r r rids whcnrvi r n wheel and hull is rnniusrd. K IM.nr ihr brake ilium In lie* hu1' .luil insiall IIn' reiaim-'s and r in n iiip b.-Its s. ti ws. hi b-'li- am! nul si Insiall lin* huh and drain .m ihr wheel spimllr Keep ihe hub renterrd on Ihe spuidlr In p rn e n l dumnuc m Ike crease retainer or the spindlr threads. |0 ( hi vehicles with 4,000 ihrmigh 7,1X10 Ih. and 111.000 Hi. front n i t s , msi.dl the mm*i bearing cum' and ril|rr and ills* Hal wjalici on ihe sp'inlle Insiall the asljiisimg nut. O n vrhirles wilh P.OIItl. 11.000 nr 15.0011 In. front axles, insiall the mm-i bearutc mne .ind.roller assemhls. aod lie l.':innc n,1 (listill); nul and pm jssenihls I | Ill-lull die wheel and 1in mi ihr hub I lien insiall the s'l.nnps III apphsalilel ami ihe wheel s l u j mils I ' While rnt.itiiip the wheel, torque the ad iiisimp nul to spi'eifi. in mu Adlust ' Wheel hearings as di-serihcd m G r o u p I I 1.1 Install the dimpled washer wilh ills dimple indexes! in one o f tin* holes in llie ailjii'lmp mil. Insiall the h s k mo and lorquc In specifiealiiui Heriil ihe dimpled washer liter a flal ol ihe hs k nul 14. Install the gasket (if ctpiipped) and Ihe preaisc cap, and lorque ihe wheel slud nuts to specification Insiall ihr huh cap (if equipped), and adiusi ihe brakes as described in tins Carl R EA R BRAKE DRUM E250-E350, F250-F350. P350-P400 0. R e m o t e th wtuel and tire a< an assemh ls l.oo>, . rIti l ' n l c shne adiuslini' s, n ss mod | In- slioes io longlT Inni II i h ' 111 A i diluii 1 K eniote ila ie.u ; xI sli.i!' rei.uninp liuls. adapoTs a sii. si.all, and gre 5w' si'.ll 4 Keniote ilio ssl'tsl Is.irinp loekn il. liw.lt wasber. and ndiusiinp nul. 1)n I ' S" and I - IMI seliis l"x. irmi've 'he l.-sl-me ss Jg nm1 admsimp nul 5 Ri moti' (he liuti and diu m fmm ihe alle h R e n o o , ilo- hi al i d r u m -lo -li ih c u m i n i - rew. boli, or bolli aiti iinis Riiiiosi' iln luakr dium from die I. ni* ~ I S s 1 die iiit iM loi d minse or wr ir. III.I U | ` in "i ' 'l'ij il imi i*ss.iri Ilo nm m.n limi I" A i ili uni* lo a braki ig suri.n e dium-o'i eli.nei than me musinom i iltu'in I'r sbowil un ihc drum li . i ness illuni stili he trislall il. rem oti ihe p io i s - lis e cuanng w th di ere *r |n\* ili ile t i '* " iptnincr srils h e n n r r wIn ri nini ludi is remm si. h l' osinoli I I I bt.lki' d u m i lo ihe I uh and instali ili. .ituii'liinu h i i 'ws. bo Is, or N'hs and uiiis b Cosinoli tlie hnb "il ilrum. a.s an assembli. ou th a.xle and Stari th adjustinp imi 10 A J p i s i th whe 'l b r m n g nut, and instali tlie licei buanng lock washe> unii 1k L. nul 11. InsUi!! j n c * scai 'W mi scal. ad e sbafi and piskct. siuO adapters. and auadnnf: nyis 12. I n a i a l i i he e l i c c i a n d Hrc *s an 1 Raise the vehicle and install safety .stands. l Aditivi the br.ikc' '`hin-^ Frmnv ihc u f e i y vtiint.N .*itd U'v-CT the '-'`-i'jiclc. OVERHAUL { ' BRAKE D R U M REFIN ISH IN G E100-C300. F100-F350. P350- J>^00. U100 * Minor a brake drum can be rrm*''rd vwnH line i*nu*ry cloth. provided ihe cmrrv iv ihoroughly clrancd nil the drum after the ppcMtum A h a d 1> u n r e d . r o u g h , or mitof*round drum should be ground or turnnl on 3 drum lathe. D o not remove any more maternal fmm the drum than is nei*r<^ary hi provide a tmOOth SUrfiCf for 1he brakr shoe contact. Brake drum matmum braking surface diameter ts shown on rach brake ilrtim (I ig |t rjk r ilruniN which ca crcd the min im um hrakiuy- sotlacr diameirr shown mm tlu* hr;iki* drum, etthrr through wrar nr rrlin ish in g. must hr rcplacrd THr masitnum braking surface dtamcirr sjn-rificaimn, which is shown nn each hrakr drum (Fig. IK), allows lot a OOrO utrh machnnng rut over the original nnimnal drum diameter plus 0.0.H1 inch ad d itional wear before reaching the drum-discard diameter. F IG . IB Broke Drum M oiim um Inside Broking Surface Domr M arking Location 007895 PP-ODUCED B Y FORD 12-01-13 General Hydraulic ftrake .Servir 12-01-13 FlG . 19 B 'o k r Drum M nu Tiu m Broking Surface CiQmeter M arking lo c o n o n --* Typical Med iu m ---Hrov y TrucW Sho*n ' O n all vehicles SOO ami up Scries hra\\ i n n .U , the maximum braking Mkflavf dianuter spe ilk atum. whi.h is sh'wn mi each bt akc drum, allows fur 0 null inch m ai Innin g . ui over the oriemal iiiinm ul drum diameter. plus U U h M n r h additional skf*ui before the ilium mu>i I** replaced Afirr icfmishmg the brake surface runout must not exceed O f T f L i n r h t o t a l iml>> j i u r r e a d i n g , measured Irom the hear me cup Un 5fX) and ttp Series heavy trucks, if the drum dtametet is less ihan 0 0JOiiu li nsrrsi7c .tier rrftn'^hmp. install standard linings on ilie h u k r assemblies. If the diameter is over O oW inch, install ovrrM?e or slummed linings BRAKF. SHOE AN D BAND R E IIN IN G 1. H m i n s e the nvets holding the old lining and remse the lining 2. Clean the shoe or hand thoroughly with cleaning fluid. especially tin* nm surfaee Vrpe 'he shoe or hanJ dry and reinse all lines or tough sjsoi . from the sb*x* Du not use shoes with elongated rivet holes. 3. tin servir* hi.ike *hr*k the inside dinmrtn ol tle h i;d t Jrum 4 Position a m*w hmitg i. lit** sh** oi band Install nm* rise.s. lvgni.ing with the nsr t holes near the enter of the .shoe (In som e veh icles, the primary lining is shorter than the secondarv li nin g If this wondltnn exists, postn mi i h** shoiier (prirnurvj lining in line with the he**l end ol the .slave Do nnl let brake fluid, nit, nr grease touch the brake lining. U a brake lining kit is used in replace the nrn linings, follow the instructions in the kit and install ail the parts provided. 3 r h e V the vlrarjnw C hetwren ihr Itnno .mil shiv nm I he lining must .rji %m;*lv aKiiin1 the nm will: not m p if than fi 110^ meh srp iratton N-twccn .on two m ets H oid\ the ln ti*i*s nc r. '*!, ed nu *hn*sr:\n otgl* on h-M h i.jk cs with I* .1 .i>iv |ji < pins. [he hi ,tkr hi*'tgs tn.io l* k.mi gr-Mind I' t'lit mch .it il*r *;uK i*e lining* nr.* i i m U.I to lie. hi .ik e *ho FRONT DISC BRAKES I K . m>*v i : h*- slon. and Inn: ' a J*-ns i iN il in I'.! t l .*24 2. Measur1; the thickness of the h u kr limni; If the lining thickrus, a: ai> j'i11 : oi* *he .issiiiihlv is 1*> il..m 1* 2 Ifl iu.h above tht asking plate " rivets or if the lining *Lo* > e men, . uf brake loud of oil sontamii.ai *n that is earning .1 brass pull. ript.we .dl tour shoe and lining assemblies .1. Chevk .-aliper I* spuntl- m .i.lnug holt torque il -ZMMMi I.- .'V ' I ,i)m>v(. I'Vr*11 ( 1 k U 1 lorqu* them to vpe ifn .non it required 4 l o he k toiof runout, fust eliminate the wheel hearing end plus lv nghtenmg the adjusting nut I hen Ju \ k to lx* sure the mior .an still K* 1<t.iied 5. (/lamp 3 dul indicator to the sptnrt! so lie vtvlus con tacts 1lie rom r app n\iinulel) I inch limn tltr mner cdg.* Rotate the rotor and take an indicator rending If the reading exvccds 0 Ul')-im .h total la lft.il runout within 3 su inch radius on the inch. ator. replace or resurface the eti b rak e ro to r T h e fn lln w ing rn jn 1remenIv must he met when resurfacing disc brake rotors. I se R o t u n d a D i s v Ilf a l e Helimshutg Lathe, Tool i*Kl - 1 l i in tcfitmh the disc brake rotors Follow the step-by-step irsiirlai mg instructi*nis that some with the 1**0 ! Ni m ore th an 0 .0 3 0 m elt ol material tvas h*` machined '*quall\ ol* each surface ( *\ and 11. H g H rotor thickness lallv below the minimum shown on each rotor, it must hr replac'd 1 he finished braking surf-ires of the rornt must be flat and parnlUt within Mn l .m h. lateral runout must not r .e r d li ui) t-in. h total indteatnr re.iding, it iJ the surface finish of the hr..king vurUkrs must he lt> to HU n:: m in h*s " hi n thi runout rhcck is finished, iljiivr rhi harmg.s ns drsiribcd in Puri 11Hl.tu present hrsrng failure. (> 1 In wk tlr rotor lor sum mg Remove eimor v ues vuti. a fmr emerv cloth I' thr ioi,ir is e u e -v o c i) seoied. u t u u d i 1 nulim ed in Step 5 or repl.ur trie mtor if necessary 7 ( );*V 1hr *.a!iper If t is rrackrd or shows anv signs if leakage, replace it If the aliper is leaking aeiuitc the losi b*Mr. rcin>vc ami repair >< X ( he k nruke hoses lot signs nl * 1.1. king, leaks or abrasion Replace them if necessary BRAKE CYLINDER 1 L' lean all brake cyhndei m clean isopiopv l ulsohvd I iop**rt all p ans f**r wear or dam age t he k rlu* tvlm dcr Is. *re t.H rusi. s . . *ft .** .iher damage He su it the hl-.eder s rew passage tv Iran and open K ep i.u e all pans that aie worn or dam aged 2 If dirt is found in any part of the hydraulic system, flush the entire svstem with clean isopropyl akohol. M ASTER CYLINDER l ("lean all master cylind er parts in U.m isopropvl alcoho l, and inspect i I m- pnris lor wear or d.imnee Replace tloMn tf req uired NNhen '".aster p>tinder rrp uir k it is used, follow the in structions in the k it and install all nf the parts provided. 2. Make su!e that till ports and vents in the mnste* cvhnilcr arc |>cn and free *l fo ifigi, matter 3 On a sm ile brake svstrm master cv ltn d e i. chfk k the spring valve Iro ricd to the front end of the piston) ..... _ [ Tn_ Mi**MI'V W* i'n * n* > -I . : ! M I M M I I* I I. I II A , -- 1 .1 .N i i A ISt_M It t***1J 'i1 3 - m '-'-'rn o M n . ~ ' FIG. 20 Due Broke Rotor Service limits U ' - -T im . too i o 007896 PRODUCED B Y FORD 12-02-9 Drum Brokns-- Single Cylinder, Dual Piston 12. 07-9 screw n*'ide the hnlr in expand the brakes shun until they drajr against the brake drum and l<xk the drum F IG . I I Becking O ff B 'ak Adjustment-- F 100-250, E 100-150, with Rear Drum Broket !-oosen the adjusting screw until a slight drag is nutrd (Fig 111 1 When the shoes arc against ihr drum, loosen the a d ju stin g screw an FIG . 1? {ponding Brake r.hcet-- F 250-350, E 750 350 Rear, and P-350-400 additional 10 to 12 nntrhrs so that the drum roi.ues free!} wiihnul ding IF the drum docs not rotaie f/rely. remoe llir heel anil drum, and hlow mu mis dust and dirt frnm the linings Using sand pnprr. rrmnsr any rust from the pmnls where the shoes luush ihc hacking plate Apply a light m atin? of high temperature grease ( C 1 A / . - I P J O 0 - B ) H u not get the lnlincant on the linings 4 In s u ll Ihe wheel and drum , and iJlu s t the shoes Install the adjusting hole rover on ihe hrakr hacking plate 5. Chcsk. and adjusi the olher ihrcc brake assemblies b Apply ih>-brakes If the pedal travels more than halfway in the floni, there is inn much clearance between ihe brake sh.ms and the drums Repeal Steps 2 and ahive 7, W hen all h rjk r shoes have hern properly adjusted, lower Ihe vehicle ntnl ro-jd lesi in shesk brake operation I'erlorm Ihe road li-sl only wlu-n Ihr brakes will apply an j the vehicle can be: safely stopped REMOVAL AND INSTALLATION BRAKE DRUMS Front Broke D rum -- P-350-400 Srrios Hemoral 1. H:usc die vehicle until the tire clears the tlnor 2. R r m m c the whcrl cover or hub cap and *hrcl Scaring du.st cap Remove the cotter pin. nut lock, nut, and washer. 3. Pull Ihe brake drum Approximately two inches forward, then push it back into position. Remove the wheel bearing and pul! off the brake drum. If she brake drum will is,. come off. insert a narrow screwdriver through ihr biakr adpistmg hole in the earner plate. and disengage the adjusting lever from the adjusting screw. \k hale holding tli*` ad justing lever from the adjusting sciow, l>ovcn the ad lulling screw wuh ih* brake adjusting tool (Fig 11) laonsen the adjusting screw only if the drum runnut be removed. i)o not hnrr. chip, nr damaci' the notches in the adjusting screw nr the self adjusting mrihmiism will not function propcrlv If the adjusting sere* u loosened, check to be sure the adjusting lever is still properly seated in the shoe web. JastttHation 1 II ihr hull nnrt drum *sscmOI> "dl replaced, remove ihe protective coating from a new drum with caib u fcto r drgreascr Install new hearings and a new grease retainer Pink the wheel hcanng. install the inner hearing cone and roller as.svmbl\ in the inner tup. and install . the new grensc retainer as described in Part 11*10. I f the original drum will be msiallrd. be sure the grease in the hub is clean and adequate. . 2. Install the drum assem bly, outer wheel bearing, washer, and adjusting nut as described in Pan 11-10. 3. Adjust the wheel hcanng. install the nut lock and cotter pin. and grease cap 4. Install ihr whcrl and huh cap. If the adjustm ent screw was loosened. atl|uM the brake as described in this Pan REAR DRAKE D R U M -- F-100, F-250 (UP TO 6900 G .V .W .) , E-100-150 A N D U-100 Remntul I R.itse the ' chicle so the wheel is clear of ihe Ainu 2. Remove the huh cap and wheel and lire assembly Remove the three retaining nuts and remove the brake drum If hr brake drum w ill not come nIT. tn-t-ri .*fro** screwdriver through the brake a d ju stin g hole tn the hacking plate, and disengage the adtusting lever frnm the adjusting strew While holding the adjusting lever awuy from the adjusting screw, loosen the adjusitng strew with the brake adjusting tuol (Tig 11). Loosen the Adjusting screw only if the drum cannot be removed. Do not burr. chip, or d am age the notches in the adjusting screw nr the srlf edjnsting mechanism will not function property. I f the a d ju stin g crew was lo o sen ed , check to be sure the adjusting lever is still properly sealed in the shoe web. JaftJiU.it inn 1. Remove the protective coaling from a new drum w ith carb uretor ilrptcaser 2. Adjust the brakes as described in this I'nit t Install the drum 4. Insi.ill dir brake drum retaining nuts and rghicn s t u r d y Install the wheel on tin* rule shall flange studs ngatnsi die (itum. am! nuque the retaining nuts to spcedicalion REAR D RAKE D R U M -- F-750 (A D O V E 6900 G .V .W .) 330, E-250-E-350, P-350. P-400 Remora! I Raise the vehicle and install safety stands 007897 PRODUCED B Y FORD 12-02-8 Drum Brakes-- Single Cylinder, Dual Piston C-< \ 12-02-8 5 z F IG . 10 F-ICO-E-35C 3<ole Sy ilem 007898 prod u ced b y ford ,1 2 -0 n -3 Drum Brakes-- Dual Cylinders. Puoi Fl>l0n>. 12-00-3 rcaaoyal an d in stallatio n r,P A I-E SH O E S A N D A D JU S T IN G SCREW P-BOO S e rie s-- Roar Remoral |. Raise the vrhicle until the tires clear the floor. R en in the wheel and tire assembly, and remove the drum or hub and drum assembly Mark the hub and drum to aid assembly la lie sme position. 2. C la m p the brake cy lin d er boots against the ends of the cylinder and remove the brake shoe retracting springs using Tool 30.1J-N (Tift. i). 3. Rem ove ihc hrnkc bhue guide bolt cotter pin, nut. washer, and bolt from .b o th shoes, and remove the shoes from the hacking plate 4 Rem ove the vlam p-lype adjusting wheel lock from the anchor pm support, and unthread the adjusting screw and wheel assembly from the ' anchor pin support. Instillation . ] L uh ricair all points where brake shoes contact other brake assembly parts wuh high temperatute grease (C1AZ-I95W -U). 2. Thread the adjusting screw and wheel assembly inm'lhc anchor pm support and insiail the dam p-type adjusting wheel luck. Thread the adjusting wheel into the support so the brake shoe rests against the adjusting wheel end. 3 P U r e the brsVe hue a * a' nM l ^ c hacking rime, .m a t the ends ,n the brake rvhndcr lin k '. and install the shoe guidr K ill. ashcr. and mu (nig 4 ). Finger tighten the nut. then In.wen it one lull turn and install the cotter pm. 4 Install the rciracting spring' using ' Tool 20J N (Fig 5)5 Remse the cylinder clumps, install ' the drum or the huh and drum assem bly, and in stall the wheel assembly Align the marks on the hub and drum for proper Installation. 6. Adjust the brakes, and lower ihc vehicle 600-900 SERIES-- REAR-- W A G N E R R\emRoa*,vmc! ihc vehicle until the t .r c.l r,, the floor. Remove the wheel, and lire assembly, and the drum or huh and drum assembly It may be neers-u.ry to loosen the a.ljustmg wheels slightly 111 free the grooved drums Du not loosen Ihc adjustment so much that ad lusting wheel jam s against Ihc ft tenon nng on the adjuster screw or damage m the ring may result M a rk the hub and drum to aid assembly In the same position. Re sure there is no vacuum In the system before DBA* l SMU disconnecting the bydrr>"l'c I1- ' '.ivprl! vacuum in the s y ir m t) P " '1-'" no brake pedal with Ihe r-'-n r 2 U nhook the anion..-.lie .id iu slrr springs ( lig 21- Rei-'. - c lnn? adjuster link hy piw'iin? l-'ck the adjusting wheel r in k s '-""I l|,r,r slots align with the hnk 1 '" out Ihe links and slide die I'u-' ks from the anchor pm cra-ks Remove the short links by m in i'"? 'hr 'ic h o r cranks until Ihc link hook - dear die eccentrics on thr shoe chs Then remove the smaller hooks from the cranks . 1 Spread die anchor C'-mV (.-washers and remove die c u n ts <" unnecessary in rrm o.c d--- udtnstnig wheel cranks) If shot - " id be 'dm ed. remove adjuster rcc-iurns l"-m l ie shoe webs by unscrewing dieir sell lapping screws 4 Remove the shoe rru .lion springs by sliding the looped s 'd > 'd ' l,c T11" Remove the shoe hold-down lock wires, castellated nuts, and plntn washers, and lift the shoes off the backing plate. 5. Unthread the-ad lusting screw and adjusting wheel fmni each of the anchor supports. Installation l. Insert the adjusting wh-cls m the anchor support slots and dueod.ii the adjuster screws from the vh-- sit e. with the friction ring end loss aril the sh o e. Fsir new lin in g s , loo sen adjusters, but do not '-- ( l,,'n f* r enough to jam the adjusting wheels. F IG . A Two Cylinder Broke-- Reor-- R-500 FIG. 5 Rebooting Spring Rtplocim ent-- Typicol 007899 PRODUCED B Y FORD i H BA *> C AiSCwOlT FIG . 2 Two-Cylinder Broke Shoe [Wogner]-- Rear _:7 Mirjt.B FIG 3 Hydroutic Brake A iiem bly (KUey-Haye) 007900 PQ PRODUCED B Y FORD  12-08-9 Drum Brakes-- Dual Cylinders, Duel Pistons 12-0B-9 C-Sorios R cm orsJ 1. Remove the brake pedal retracting spring (Figs. 9 and 11). 2 Remove the brake master cvltnder push rot 'C'*rn(nc bolt nut. bolt, and nylon bushings. 1 Remove the brake }>cdal bumpcr-io- brackct retaining nut Remove the bolt and bumper 4 On models with a single hydraulic brake system, remove the masicr cylinder push rod by pulling up the tab on the push rod K-it. and pulling thr push rod and bool Irom the cylinder 3 Remove the nut from the bolt, slide the bolt to the right and remove the brake pedal assembly, sleeve, and hushing , 6. Rem m c ihc bushings from the pedal assembly insInJUfton 1 Coat all bushings and the pedal shaft, uith a small amnuni of l.ubnpljte *r an equivalent lubneant. Position the nylon bushings in the brake pedal shaft bore 2. Position thr brake pedal assembly, slcrse, and hushirw m the rnl*d support hrai k**t. shdi* thr Kill i** th`* It[i and install (lie nut 1 <nque thr nu. to specification J. On model' with .t single Im lnoihc brake system. install thr push n*l and bool in lit** ni.i'U'i vslimier 4 (hi models with .i simile hvdfuulic brake sistcm . install tlir p r jjl bumper b o h . bum per, and nut Tighten the nui sit ureU 5. Install the nyl*n bushings in thi push rod bore, and install tin post- uhJ eccentric boil and nut 6. Install the pedal rrir.vliny spring 7. On models with a sutglr hvdr.iulw brake system, jdiust the hr.ike {fd.il fm *.tra v e l to .1/ lb to * S im lt Torque thr crccn lfiv N d i nut to specification co*1, r v a --iR- ecu *.* M G . H Single Mmter Cylinder ond Broke Pedol Init oil a Ion-- C*Senei OVERHAUL X BRAKE WHEEL CYLINDER DisJL'tsrmhly l With the w herl cylinder remitted, remove the rubber hoots from the ends nf the brake cylinder. Remove 4lie pistons, cups, ami piston tnurn spring from the cylinder (Fig. 12) F IG . 12 Double Servo Broke* Cylinder 2. Rrmove the bleeder screw from the cylinder. . A ssem bly \ Coat all biake cylinder parts with clean ritrn heavy duly brake fluid C b A 7 - l<?S4.'-A 2 Install the bleeder screw (I ig 12) in the brake cshndrr. 3 flare the piston return spring, cups, and pistons m the cylinder bore, and install i b v it and link over eawii end of the cylinder. C lam p the brate cylinder pistons against the ends o f the cylinder When using a brake cy llo d rr repair kit follow the Iflstmrlioot (a the Wit ajid inatal) ail of the p&ru provided. M ASTCR CYLINDER Single Brako Systom PisAMcmbh I Remove the master cylinder Clean the ouiside of the master cvhnder. and remove the tiller cap and y.askrt J'our out any brake fluid left in the cylinder anil reservoir. O n CScres vehicles. I Fig l . remove the bo!i> that hold the iV.mder b s u on tin. m - *s,ir and remse the et Ties' down on the pivi-m to corrpresv tlie m u m spring. jn J remove the snap n rr Remove the piston, pnm.uv cup. piston ftlier. return spring, ches k vj|v,,\ ann check valvr veal C>n vehicles with a I'amr^n-nunled m ruum brake lioustcr. the ebrek valve is in stallrd in th* booster instead uf in the muster cylinder. VAL Vi Si Al / ( c,,> \ i . ip Ip / I,. `H| 9 /At VI ! 6e wSr * r . ... F"- . -W f . >> ------ - 5 0 ,/k ' Rt 1OHM / y '0 ) l>u* uu Mil * \ jr>> 'V m m a p i 9>r L i v A - .s r M tu . -- F IG , 13 C Series Broke M aster C ylin d er-- Disassem bled Htisr-e 007901 PRODUCED B Y FORD Z Connect the hr.ikp hydraulic system linr' in the diiTrf rn iiil valve issemhiy i i i J tighten th** lulx- nuis so*urcl> 3. Cnnnrut the shell-wire connector to tjr hi aVc warmup lamp ^^t*ch M ake xurr thr plndic lugs on thr ronnretor hold the connector securely to the iwiteh. 4 Rlecd the brakes and c r n in li/ c the pressure d iltrrc n lia l valve a' descnhcd in th*' Pan BRAKE PEDAL ASSEM BLY L-. LN-. and L T -So ries Remora! 1. R cinm c the stoplight switch from the pedal bracket. 2. Remove the hrnkc master cylinder push uxt holt nut. and nylon hushing 3. Remove thr nut from the prda! shall. Slide the shaft in tbclrthand remove the brake pedal and sleeve 4. Rem ove.the bushings from the pedal. Instillation 1. Cnai all bushings and f hc pedal shaft with 3 small amount o f L uhnplate or an equivalent lubricant. 2. Position the nylon bushings in the brake pedal 'halt bme. 3 Position the brake |cri.il assrmhly and 'Ireve in the p^dal support bracket Slide the pula! 'h a il through the sleeve and pedal and secure with the nut lorcim the mil to specification 4. position the nylon bushings in the bore of lhe push r>d Connect the push rod to the brake pedal w ith the bolt and mu 3 Adju st thr hr.ikr r r"dl frrr travrl to 3 / |b in 3/R-inch lo rq u e the eccentric bolt nut to sp'-niw ation b. Instnll Ihr slop light ' * h Mi in the pedal l r.iri t-l as far lit -' p") blc Pull the ptdal t.' Ms iu a l ir .t return p n u im n tu p f opctl> tesel the slopilfht switch P-500 Series R cm nm f 1 O j v n the front cover am! ihsennncit thr tianvnov-.rm yenr'h th rxj' flout the shift levers l\umn the u wis so maximum working sp.ue i' available at the pedal supjHttt hrurkcr 2. R e m o v e the pedal p a d ' fro m the clinch and h m le pedal (Pig 10! 3. R emove I he screw s that hold the floor covers at the steering col um n, and rem ove the covers l n l a u h the engine over assembly and open. 4. Kt-mnvp the floor pin t: retainin g screws Remove ihr .iLvilernior pedal fr om the a c ce le r at o r link pe and remove the Hoot plate 3. P t^ c o n t ir c i the c l u t c h and brak e pedal rriruetmg springs 6. L oos en the pedal support bracket cl amp bolt Remove thr cotter puts ami rlrvts pin> from thr clutch md brake pol.ils 7. Tun the front wheels .ill the way to the left Through the left front fender apron, rrm m r the lixkinp pm from the . clu t ch p c d j l j n J rrm ove tin* pedal. Push the pcJu l shaft toward Ihr rcnterline of the cinch- I tom inside the cab. slide the pedal shaft nu**' i*;>.v \ &> . -- ih A*/ . . . . 4* w . ^2' y I #1f M I* 1*1 ' S* / u* * I t ..b ; r r . *muw 1*1* 4i n.| Ii tin n * ris*. n *v.. i*, c t x ^ a I . a - ... 'I A 1 U-& - . ^ U A tt ? . *r*< *' / .. *I *. i / i ^ * .1 . ,,<aSB i . 's o .v ' ^ . ! 7 - * ^ Jst,u*i I Cm............. y/ x \ 1,Av"A' * m i - ''l I'a'. . . if ;v i \' Hrp'.A**''.. /`*..v wvAt /** x tu* INI. fK *;>' FIG . 10 Sfoke Pedal ond Related Parti-- P-500 n n j rluieh p -ll 1r\c> toihenght md ruf of the Mippmt 1't-n.kr! Remove Ihr brake pi dal l*om '** sup| ort bracket Rrmmc the bn-hmps hum t h ' prdal and the pedal support b;a. kt j ln*(K/Ututn l l \ u : ail bushing, and the pedal shaft v5h a small stnount of hibrtr int I S \ M lt'7'.-fl nr ruuoal-nt Ins'all nev htixhtngs in ,l*'* p-N support bracket an.l the bfkc jv ,M 2. P osition the brave pedal n the support bracket and did'* the perial shad and iluieh j-.d.-il lever through ihe bracket .ml p* dal 3. Through the left ftom fimlrr apron, install the Mutch |m ( 'I on the si afi and secure it with :t new colter p*n .4. P.Tsijimi he clutch :t\l * rb clu.ch pedal lever, install ihr clevis pin and s m ir f it with a kw .otier pn 4 Position 111- hi .*! inkier cylinder push rod in the ni.ikr* |v U I msl.ill ' he clevis pm. and scwuic M with a new cotter pm t Install ihr dutch and brake pedal iviraennc springs 7. "* uli the hr.d t )- d.il .t.:i,,'t the stop, adjust the N .d c vlmdrr push nvt to u\r 0 in t- (J I-t im h itr- plav mrtoureJ at v.rnirt line of pulal pad hi lore push ri*d iim tm ts piston R< nv\r tin* vIf'ts pin limit tin* push rsj ud turn the ruJ until Ihe sp en t tt d fire tr1v**I is nhu um d . 7 thr tut: mil atJ .stall clevis pm alter adjustment B .S eries flrm i'o/ l R r*> " r ihr stop lirb' vwitwii from the pcil.il biasl et 1 *r f ' 2. R en vui the rrt:i*MT I'P. master eshnder push tmI mul ht/dnng. 3. Rrmove thr clip font 'hr pedal shaft. Slide the shall to the lull ami remove the brake pedal 4 Rrju.s* thr bushings Uuni the pedal Installation 1 Coat .ill hushing' ami thr pcln! shift with a small amount of Lubriplatc or an fipnvalent lubni-mt 2 Install thr nvlon bu'im tg' 'he br jk.* p oal shaft *'* .1 I'o m ii, n *hr >' r:ki. t-*ihl ns-rmhly in the psdal sitpp'il bt:t'kel ^hdr the pedal shaft thrum *' the prtlal and sccuo* with Itie rrtrumri' rhp 4 P*sitnui the nvlon huslunv in thr bore of the push rod to ls.rnihlc the biakc pedal wuh the elrv* pu* 3 Install thr sinpluht 'w-t*.h in the pedal brarket as Inr in as possible. Pull the pcdftl tn it' furthest rctum p o sitio n to p ro p e rly reset the stoplight switch. 007902 PRODUCED B Y FORD 12-09-1 Drum Brotes-- Dual Cylinders Single Piston (Wngner) 12-09-1 PART 12-09 Drum Brakes - Dual Cylinders, Single Piston (Wagner)________ _ ------------------ Applies To COOThru Q00 Seiius Trucks_________ __________________ COMPONENT INDEX BRAs.fc BACKING 'LATP " Pape " i T 1 COMPONENT INDEX SHOE Removal and Inyinlltilnin . . . BRAKE DRUMS J2 Rria \.il -tP.'l l;ist;.i,,ili-'i. . .. R'tmuval and ItisUil'uli'm............................... OU-l IJliAl.C V.HLEl CYLINDER BRAKE MASTER DYUNOEH i` meval mil I.mstu'-'n'.-i.n.............................. Disassembly and Assembly............................ no 3, 1, 01) it 1 1 Inspection and Repair.................................... 00 5 1 j ';HLL iriCAT IQNS . . Page 09 1 U-1 00 2 j 00 5 .i 02 fj ADJUSTMENTS BRAKE SHOE ADJUSTM ENT A d ju st the brake shoes when the brake drum s arc at n orm al room tcmpcraiute If the shoes are adjusted when the drums are hot and eipandcd. thc> mas dtag as the drums cool and contrail Brake ailiustment re-establishes ihr btakc lining-to-drum ctearance and compensates fur normal lining wear. hollow Ihe adjustm ent procedures below: SE L F A D JU ST IN G B R A K E S -- 600-900 S E R IE S Manually adjust two-cylinder front brakes using the hex-head. sell-locking cam adjusters Subsequent .idm 'imcm is automatic. Fur manual adjustment 1. Raise the si-ht.le and chctk the front hrakes for drag by to ta lin g the w heels. 2. Adjust one shoe by rotating the whcrl forward while turning the cam hex- head forward Expand the shoe until a light l-ag is |,-It ,.ii the drum Do nut apply r i n - o i u Inree on the hex- head earn, or the aiunmatic adjuster parts mil) be rt-imnecd. I nosen the id jn stm cn l until the wheel turns freclv. Adjust the other cam in the samr manner. J . Ail lust the other front wheel brake using the proerdure above a Apply the hiakcs and rccheck the adjustment. - REMOVAL AND INSTALLATION y 2. Remove both brake shoe retracting b R A K E D R U M S T ',.R O U C !`. 900 spring' (Pip- H. SERIES 3. R e m o te the C -w :ixhcrs and flat R cm art/ and nirtdlttinn washers from the hold-down studs. Service procedures for these models Lift the shoos nfT the hacking plate. are described in Part 12-01 4. T o remove Ilie adjuster assembly BRAKE SHOES AND ADJUSTIN G M ECH ANISM from Ihe shoe, unhook the wedge spring from the wedge and the coil spring from ihr shoe web. Work the 0 00 -9 00 Sarioa end spring off ihr levn pivot pm and Rem oral 1. Raise the vehicle until the tires clear the floor Uetnnve the wheel and tire ft.sAcmhl) Kcnvivc the drum or the hub and dnti assembly M a r k Ihe hub and drum to aid assembly in the asme position. F.xpell all vacuum in the system before disconnecting the hydraulic lines Rxpe!! vaettum tn the system by pushing dnwn on brake pedal when engine is ofl. slide the spring hook from the plug lever pin. Pull th< adjuster lever fiom the hack of thr shoe and remove the plug, wedge washer, wedge, and wedge guide. JnstxJUtion 1. T o install the adjuster assembly, position ihe wedge guide with its pin in Ihe hole provided m the brake shoe PlllCC Ihe wedge guide on the side o f the brake shoe larilirst away from the earner plate. Position the wedge on the shoe web with us serrated edge resting against ihe .serrations on the wedge guide 2. Insert the dnim contact plug so its head is ihrnurh llic hole in the brake shoe and lining and its shank rests liver the wedge anti wedge guide 1 he plug must he installed from the inside of the brake sh-v 3. From the opposite side of the shoe, install thr shoe adjustment lever, guiding the pin inlo thr mating hole of the eontaei plug. Install the washer over the ivedce on die lever pivot pm 4. Position Ihr U-hixik of the adjuster torsion spring on the plug Irver pm. Attach one end nf the wrrige spring to the hook, and tnsiall the coiled portion nf the torsion spring over the lever ptvtsl pm Install the outer end nf the torsion spring over the edge of the shoe web. 007903 PRODUCED B Y FORD U -O S-12 cyfindrr body T l M " " P ' 5 <.' - i -- ih' rtm.iinin? snap n n l ,l.v pi-si-u S,'T 17 Sh.li- ihc pi- 11' '1 - ll p .nniiary pi't,in *,lJ 1 |n(|l , hr _ . 7 ............- - ;,;;;;: t r c m i' T i and p l a f f " ,i: ri', J ,n r r 111 :n mr bm.Minthmr*n M- h N* - - a ,"l*rc 1^ n J O r .rnn.tis. ,, s:;;:;:;TM :- ;riMi /.vrr.;:. Ihr rrtamrrs ........ ; ,,i,i,k,.t,<i in .i .t.. . .......................,.....,.....m... a. .s. .rir. f . - . - ' " " j ' -- ... ...i - 'na' ,,r , ,, , t inrquc Ihc rc u m c n lo U to 20 K n -'a ,c ih r .p '" 'it' "d vjlv<* *" III |hr mill. I putt nf 'h i c>Itndcr. I 'f.- b , c III- rn n a :> and 'ondary .mil iniqur In I.' til 20 M b , J | .ls , ,;i .),, ni.miitinK <ral on the ` ,.| Ihr Iiia'ti r ulim lcr ln-tall Ihc lilt*.I ..ip >ml l" ' VlM SPECIFICATIONS s u c h -c lonnut T0H0U11 . " i n - H t o - a u u c j u . t m i n j t w _ _ . * ----- -- iHiftdS* ^ __ . _ . -- --------- . ',****" * ,*gal HUM H W l l i a m t l " 1 ' 1 " ' * 1 , ------- ................. ................................. -- ------------------------------------------- _ 7 . ' _ - ' " " M ' " ------------_ , . . ' . - -- ----- 007904 RQ produced by ford