Document MoYqakNdaNw8m1YNE9Jpy9Ea

007389 Inter Ollics Ford Part* and 5rviea Division June 1, 1991 Hr. H. H. Esmbsrg Subject: EFA/OSHA Asbestos Exposure Program As requested, 'we hare relieved the attached slide-tape script and (2) bro chures regarding asbestos poisoning and sake the following comments: , There is an inconsistent between the two brochures in the mention of brake vacuums. In the slide-tape script, pages TO, 11 and 12 refer to using a industrial or shop vacuum. Further emphasis for a shop vacuum designed for asbestos usage or a efficient* filtering and dis posal system, like that mentioned in the larger brochure would be appropriate. - . One popular brake cleaning method the program does not address is the coffee can method. This method is simply using a coffee can filled with parts cleaner solvent from the ports washer and brushing off the brake assembly holding the can under it. Because technicians are paid by the job (flat rate), cleaning a brake with a vacuum is not always dons, even If the garage has the equipment; it becomes awkward, time consuming and costly. Brake washers are fine, but they are a fairly new product and there are few in use in the field. The coffee can method is used by technicians who are aware of asbestos poisoning but ' don't have the sophisticated equipment or take the time to use it. This paper should address this method and its* safety impact in areas such as solvent disposal (Do you pour down the drain or put it bask in the parts washer"). , Consider suggesting to Mr. Guimonda that the brochure and slide-tape refer to people who work on oars aa technicians, rather than mechanics. TM3 is a practice adopted by Ford and G.H. which technicians prefer. In the area of program effectiveness, the brochure suggests (pg. 7*0 displaying a poster to remind people of the dangers of asbestos poison ing. Because it is not readily available, the EFA might consider making a poster available including it with the distribution of brochures. A poster hrmg in the garage area might prove to be the most effective reminder of the dangers of asbestos poisoning. There are currently (b) four class action suits pending against Ford Kotor Company for asbestos poisoning by former Ford dealer technicians, 1 suggest you review this material aid your prepared response to iPA/OSIEA with Wanda Jones (xk2k'J$) to assure it doss not adversely effect those lawsuits. D. E. Sctivonk PRODUCED BY FORD 12-01-23 General Hydraulic Brake Service 12-0 ^ 1 Remove the tine end mipcct the flsre for cricks or poor (Ure form. If the Here it not correct, cut U off end repent the procat. The finished flare must be squire with the line, free of cracks and have a smooth mating surface to ensure a leakproof connection- flaring a Lina (Flaring-Bar Typa) Refer to Figs. ! 5 and 11 t Cut off and straighten the required length of line. (A hue otitmg tool will simplify making a clean and square cut). 2. Square off the ends of the line with a file, and chamfer the end of the line to he Bared. 1 Insert the Itne through its appropriate ribbed hole in the bar assembly unal the end of the hue socks out about u far as the thickness of the adaptor above the bar, or even with the bar, depending on the tool used. 4. Fit the adaptor onto the line and slide the bar into the yoke. Lock the bar in position with 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 iigheamg the yoke screw again, with second adaptor fitted, depending on the too! used. 8. Rekasc ihe screw bar, and flared line. Inspect the flare for cracks or poor flare form, and repeat the process if the flare s not correct. 9. Repeat Steps 3 through 6 n the opposite wheel cylinder. FIG. 17 Lna Ronng (Flaring Bor Type) MAKE HOSE Replace a fleaible brake hose if u shows signs of softening, cracking or other damage. When installing a new brake hose, position the hose to avoid contact with other vehicle parts. REMOVAL AND INSTALLATION BRAKE DRUM A Remove the front wbeel-to-hub bearing cone and roller assembly, and All Vohidos thru 9000 Sorioa Use the following service procedures far both hydraulic and air brakes. Since the F-lOO thru F-3J0, E-1QO-E-350 and Branco rear drums, and the P-JGO (front and rear) procedures apply to hydraulic brakes only, they are covered m Fart 12 02. FRONT BRAKE DRUM retaining nuts (or no and tire attaching nuts). Remove the wheel (or nm and ore) from the hub and drum. 3. Remove the brake drum retainers and attaching bolu. screws or bolts and frrrrr 6. Remove the brake drum from the hub. 7 Cheek die drum for damage or wear, the bearing adjusting nut On all other axles, install the outer bearing cone and roller and flat washer on ihe spindle. Install the adjusting nut. 11. Install the wheel endure on the bub Then the clamps (if applicable) and ihe wheel stud nuts. 11 While rotating the wheel, tighten the adjusting nut to specification Adjust 1 Raise the vehicle until the ore dean the floor and remove the wheel and and repair or replace if necessary If a new drum will be installed, be sure wheel bearings as described in Group It. j i nre from the huh. Loosen the brake shoe adjusting screw anal the shoes no longer touch the brake drum Remove the grease cap sod the gasket (if equipped) from the hub 2. On vehicles with 9,000 lb front axles to remove the protective costing with degreaser , Install aew grease retainer seals whenever wheel and hub is removed. S. Place the brake drum to the bub and install the retainers and retatmng 13 On vehicles with 9000 lb front axle and hydraulic brakes, install ihe dimpled washer with the dimple indexed in one of the holes in the adjnsung nut. Install the locking ring lock nut and tighten to specification. and hydraulic brakes, remove the locknut, locking ring, dimpled washa bolts, screws, or bolts and nuts. Bend the locking ring over a flat of the and adjusting nut On all other axles, 9 Install the hub and drum on the wheel lock nut. remove the eoner pin, adjusting nut spindle. Keep the hub centered m the 14 Install the gasket (if equipped) and and flat washer from the spindle. 3. Remove the outer bearing cone and spindle to prevent damage to the greens retainer or the spindle threads, the grease cap. and tighten ihe wheel stud nuts lo specification. Install the i t roller assembly Pull the hub and drum assembly off the wheel spindle. 10 On vehicles with 9.000 lb front sxla and hydraulic brakes install the outer hub mp (if equipped), and adjust the brakes as described in this Put. OVERHAUL An industrial type vacuum cleaner m BRAKE DRUM REFINISKtNQ an s drum lathe Do not remove an? place of compressed air, is recommended E-100-E-J5D, F-IOO--P-SSO, U-100 mote material from the drum than is to remove any dust and dirt present on Minor scores on a brake drum can be necessary to provide a smooth surface for i brake linings, pads, rotors and drums ect, removed with fine emery cloth, provided the brake shoe contact Brake drum when performing wheel brake repairs. the emery is thoroughly cleaned off the maximum braking surface diameter u Also, sfty machining done on brake drum after the operation. shown on eseh brake drum (Fig limngs or pads should be done using A badly scored, rough, or out-of Brake drums which exceed the maximum properly exhaust ventilated equipment round drum should be ground or turned braking surface diameter shown on ihe 007390 PRODUCED BY FORD 13-01.23 fT MCPMOMAEN 1MII FIG* 15 Ur FSanflQ Soqutno Genera! Hydraulic Broke Service 13-01-22 w C0ND9tHAT10n SOU0I.C *L**I 7 Form the doubts ftits by tighemng the yoke screw (gam. with second adaptor ruled, depending on the too] used. 8. Release the screw bar, and flared !me Inspect the Hare for cracks or poor flare form, and repeat the process if the flare is not correct. 9. Repeat Steps 3 through S at the .opposite wheel cylinder BRAKE HOSE Replace a flexible brake hose if it shows signs of softening, cracking or other damage. When installing a new brake hose, position the hose to avoid contact with other vehicle parts. FtG. 14 Un* Raring (Spfit Dim Typ*} FIG. 17 Un* Flaring (Raring Bar Type) REMOVAL AND INSTALLATION BRAKE DRUM 4. Remove the from wheel-io-hub the bearing adjusting nut. On all \ All VhidM thru 9000 Series retaining nuts (or run and tire attaching nuts) Remove the wheel other axles, install the outer bearing cone and roller and flat washer nn the Use the following service procedures (or run sad ore) from the bub and iputdle. Install the adjusting nut JCs for bach hydraulic and air brakes. Since the F-ICO thru F-350, E-100-E-35G and drum. J. Remove tbe brake drum retainers and 11. Install the wheel and tire on the hub. Bronco rear drums, procedures apply to reaching bolts, screws or bolts and Then install the damps (if applicable) hydraulic brakes only, they are covered nuts. and the wheel stud nuts. in Part 12-01. 6. Remove the brake drum from the 12. While rotating the wheel, tighten the FRONT BRAKE DRUM hub. 7. Check the drum for damage or wear, adjusting nut to specification. Adjust wheel bearings as described tn Croup 1. Raise the vehicle until the ore dean the floor and remove the wheel and and repair or replace if nm-tury If a new drum will be installed, be sure H bra from the huh. Loosen the brake to remove the proteenve coating with 13. On vehicles with 9000 lb front axle shoe adjusting screw until the shorn pH5JuT and hydraulic brakes, install the no longer touch the brake drum. Install new grease retainer seals dimpled washer with the dimple Remove the grease cap and the gasket whenever a wheel aad beb la removed. indexed in one of tbe boles in the (if equipped) From the hub. 2. On vehicles with 9,000 lb front axis 8. Place the brake drum to the hub and install the retainers and retaining adjusting nuL Install the locking nng lock mu and tighten to specification. and hydraulic brakes, remove tbe bolts, screws, or bolts utd nuts. Bend the locking nng over a flat ofthe locknut, locking nng, dimpled washer 9. Install the hub and drum hi the wheel lock nut. and adjusting nut. On all othe sals, spindle. Keep the hnb cratered on the remove the cotter put, adjusting nut spindle to prevent damage to tbs 14 Install the gasket (if equipped) and and flat washer from the spindle. grease retainer or the spindle threads. the grease cap, and tighten the wheel 3. Remove the outer bearing cone and 10. On vehicles with 9,000 lb front axles stud nuts to specification Install the roller assembly Pull the hub and and hydraulic brain install the outer bub cap (if equipped), and adjust the drum assembly ofT the wheel spindle. bearing acne and roller assembly, and brakes as described m this Part OVERHAUL An industrial type vacuum cleaner tn place of compressed air, is recommended to remove any dust and dirt present on brake linings, pads, rotors and drums ect, when performing wheel brake repairs. Also, any machining done on brake lintugs or pads should be done using properly exhaust ventilated equipment * 007391 PRODUCED BY FORD 13-01-18 General Hydraulic Brake Service 12-01-18 5. Form the single flare by tightening the yoke scow securely. 6. Release the screw end remove the adopter. 7. Form the double flare by Hghening the yoke screw again, with second adapter fitted, depending on the" tool used. 8. Release the screw bar, and flared line. Inspect the flare for 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 shawt signs of softening, cracking or other damage. When installing a new brake hose, position the hose to avoid contact with other vehicle parts. OVERHAUL iM Removal of dust and dirt from brake assemblies uid be done by using the Rotunda brake vacuum ((model 34-0009) or Rotunda brake parti washer (model (650016) or an equivalent. Brake assembly dust and dirt I should net be removed by either blowing off with an air gun or vacuuming with a standard industrial vacuum cleaner because a health hazard from breathing in] asbestos dust may develop. Also, any machining done on brake linings or pads should be done using properly exhaust ventilated equipment. Also, any maehining done on brake linings or pads should be done uiing properly exhaust ventilated equipment. BRAKE DRUM REFINISHING -------- V Minor scares on a brake drum can be removed with fine emery doth, provided the emery is thoroughly dearmd off the drum after the operation. A badly scored, rough, or out-of-round drum should be ground or turned on a drum lathe. (Refer to the lathe manufacturers instructions.} Do not remove any mare materia! from the drum than is necessary to provide a smooth surface for the brake shoe contact. Brake drum maximum braking surface diameter is shown an each brake drum (Fig. 13). Brake drums which exceed the maximum braking surface diameter shown on the brake drum, either through wear or refinishing, must be replaced. The maximum braking surfoce diameter specification, which is shown on each brake drum (Fig. 13), allows for a 152mm (0.060 inch) maehining cut aver the original nominal drum diameter plus ,762mm (0.030 inch) additional wear before reaching the drum- discard diameter. FRONT DISC BRAKE5 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 lining thickness at any paint on the assembly is less than .794mm (1/32 inch) above the backing plate or rivets, or if the fining shows evidence of brake fluid or oil contamination that is causing o brake pull, replace all four shoe and fining assemblies. 3. To check rotor runout, first eliminate the wheel bearing end play by tightening the adjusting nut. Then check to be sure the rotor can stilt be rotated. 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 KHAKI DHIH - TTHCKI FIG. 13 Rear Brake Drum Maximum Inside Braking Surface Diameter Marking location--4-100 E 350, Bronco, and F100 F 350 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 mutt be met when re-surfacing disc brake rotors. Use a disc brake lathe to re-finish the disc brake rotors. (Follow the manufacturers instructions.) No more than -508mm (0.020 inch) of material may be machined equatly off each surface (A and B, Fig, 14). If ratar thickness falls below the minimum shown on each rotor, it must be replaced. 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 ta B0 micro inches. When the runout chock Is finished, adjust the bearings at described in Fart 11-10, Wheel Hubs and Bearings--Front (except Front Whoa) Drive) to prevent bearing failure. 5. Check the rotor for iconng. Remove miner scores with a fine emery doth, if the rotor is excessively scored, re-finish or replace the rotor if necessary. 6. Greek the eafiper. If it is crocked or shows any lign* of leakage, replace It, If the caliper is leaking around the dust boot, remove and repair it. 7. Greek brake hoses for signs of cracking, leaks or ' abrasion. Replace them, if necessary. 007392 J PRODUCED BY FORD 007393 PART 12-01 GENERAL HYDRAULIC BRAKE SERVICE 12-01-27 . Be sure vehicle Is centered on hoist before ser vicing any front end components, to avoid ben ding or damaging rotor splash shield on full right or left wheel turns. 6. Riding of brake pedal (common on left-front ap plications) must be avoided during vehicle operation. 7. The wheel and tire must be removed separately from the brake rotor, unlike drum brakes where the wheel, tire and drum can be removed as a unit. i 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. 10. Calipers must be installed with bleed screws In an upward position for proper bleeding of air from brake system. Drum Brakes 1.Remove wheel, tire and drum assembly from spindle. 2. Use an industrial vacuum cleaner to remove all dust from backing plates and interior of the brake drums. WARNfNG: Never inhafe dust from brake lin.ZingDs. Asbestos dust whan inhaled can be Injuriou)Us1 to health. Do not blow out dust with an air lina. A vacuum cleaner equipped for this purpose, brush or rag should be carefulty used to remove any dust. Any dust should be contained in a sealed bag for disposal. 3. Inspect brake shoes for excessive lining wear or shoe damage. If lining Is damaged or worn within 1/32 inch of the rivet heads on riveted lin ings or within 0,060 Inch of the shoe on bonded linings, they must replaced. Replace any lining that has been contaminated with oil, grease, or brake fluid. Replace lining in axle sets. Prior to replacement of lining, drum diameter should be Checked to determine that brake drum braking surface diameter is within specifications. If braking surface diameter exceeds specifica tion, drum must be replaced. 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 tightening pro cedure. 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 oniy as an assembly, In cluding the check valve. Brake Tubing If a section of brake tubing becomes damaged, the entire section should be replaced with tubing of the same type, site, shape and length. Copper tub ing should not be used in a hydraulic system. When bending brake tubing to fit body contours, be careful not to kink or crack tube. Hydraulic Lines Double wall steel tubing Is used throughout the brake system with the exception of the flexible hoses at the front and rear wheeis. 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. Ail brake tubing should be property 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. (Jch- EajUtJ-J PRODUCED BY FORD 12-4 Broking System 12-4 007394 A--Platon Homing B--Brake Fluid C--Platon D--Inner Brake Ped F--Brake Disc E--Pad Housing {Anchor Bracket) 6--Outer Brake Pad FF1205--2A FIG. 5 Sectional View of Front Caliper Simultaneously, the transverse cable is placed in tension by the equalizer causing the actuating lever on the right hand brake assembly to activate the brake shoes [Fig. 10). BRAKE SERVO The Brake Servo, if installed, is of the suspended vacuum type. With the engine funning, vacuum is supplied to the Servo unit through a nerwehim valve. Both sides of the chamber diaphragm in the Servo are subjected to equal vacuum. Initial movement of the brake pedal admits atmospheric pressure to the rear of the diaphragm, resulting in a pressure difference which causes the diaphragm to move forward. The brake pedal effort is assisted and reduced by the movement of the diaphragm. GENERAL NOTE Every 40,000 km (34,000 miles), brake cylinder Malt, flexible beset and hydraulic fluid should be replaced. Brake system components must be kept dean ef any foreign matter. If necessary, any hydraulic components should be washed in elean brake fluid, industrial alcohol or methylated spirits to remove any foreign matter and dried with a elean non-fluffy doth. Do not us a mineral base fluid such as petrol or paraffin. Brake fluid mutt not be allowed to come into contact with brake pads/shoet or with disc or drum surfaces. Due to the complexity of braking systems, when replacing or overhauling components, care must be taken to ensure that only correct parts ore installec. Any brake fluid accidentally spilled onto a painted surface must be cleaned off immediately using cold water to prevent damage to paint-work. ____ WAANINGt Care should be token to ovoid in rhaling dust from brake linings. Asbestos dust when Inhaled may bo Injurious to health. Do not blow out dust with an air lino. A vacuum cleaner equipped for this purpose, brush, or rag should be carefully used to remove any dust. Any dust should be containod In a sealed bag far disposal. JACKING THE VEHICLE Before commencing any repairs that involve jacking the vehicle it it essential that the vehicle jacking instructions contained in Section 11, General Description, are fallowed. PRODUCED BY FORD 12-01-W Generel Hydraulic Brake Sendee 12*01.20 8. install the bleed screw fif so equipped). Install the gasket (diaphragm) in the master cylinder filler cover. Position the gasket as shown in Fig. 17. Make sure the gasket Is securely seated, 9 Install the cover and gasket on the master cylinder and secure the cover into position with the retainer. CLEANING AND INSPECTION Disc Brakes 1 Remove the wheel and tire from the hub and rotor. Z inspect brake shoes and lining for wear. If the lining is worn to within 1/3 inch of the shoe, replace all (four) shoe and lining assemblies (complete axle set) on front or rear wheels as required. The rubber caliper insulators and the plastic sieaves must be replaced when linings are replaced. ' 3. Visually check the caliper. If the caliper housing is leaking, it should be replaced. If a seal is leaking, the caliper must be disassembled and new seals installed If a piston a sacred in the bore, a new caliper housing is required. Refer to Part 12-20 for tse brake rotor resurfacing procedure. Service Precautions 1 Grease or any other foreign material must be kept off the lining surfaces of the rotor and external surfacas of the hub dunng service operations. In handling the rotor and caliper assemblies, avoid deformation of the brake rotor and nicking or scratching of brake linings 2 If a caliper piston is removed for any reason, the piston seal must be replaced. 3, During removal and installation of a wheel assembly, exercise care not to interfere with and damage the caliper splash shield or the bleeder screw fitting. 4 Front wheel bearing and play is critical and must be within specifications. 5. To avoid bending or damaging the rotor splash shield on full nght or left wheel turns, be sure the vehicle is centered on the host before servicing any front end components. 6. Riding of the brake pedal (common on left-foot applications) must be avoided dunng vehicle operation. 7. The wheel and ore must be removed separately from the brake rotor, unlike drum brakes where the wheel, bre, and drum can be removed as a unit 8. Do not attempt to clean or restore any oil or grease-soaked brake linings. When contaminated linings are found, brake finings must be replaces in complete axle sets. 9 Always replace rubber caliper insulators anq plastic sleeves when replacing linings Do not lubricate the slide pins. Drum Brakes l. Remove the wheel from the drum, and remove the drum, Part 12-02. __ p-- Removal of dust and dirt from brake assemblies should be done by using tne Rotunda brake vacuum (model 340009) or Rotunda brake pans washer (model 650016) or equivalent. Brake/ assembly dust and dirt should not be removed by[ Wowing off with *n air gun because a haalth haiard( | from breathing asbestos dust may develop 3. Inspect the brake shoes for excessive lining wear or shoe damage If the lining is worn within 1/3; inch of the rivet heads or if the shoes are damaged, they must be replaced Replace any lining that has been contaminated with oil, grease or brake fluid. Replace lining in axle sets. Prior to replacement of lining, the drum diameter should be checked to determine that the brake drum braking surface diameter is within specification using the Rotunda brake drum micrometer (model 100010) or equivalent If the braking surface diameter exceeds specification, the drum must be replaced. 4. Check the condition of brake shoes, retracting spnngs, hold-down spnngs, and drum for signs of overheating. If the shoes have a slight blue colonng, indicating overheating, the retracting and hold-down springs should be replaced Overheated springs lose their pull and could cause the new lining to wear prematurely, if not replaced. If the brake drums are heat potted, Indicating an overheated condition, they should be replaced. 5. Inspect all other brake parts and replace any that are worn or damaged. 6 Inspect the brake drum and, if necessary, rgfinish Refer to the Rotunda Catalog Wheel Service, to a desorption of the vanous types of brake lathes avaiiabla The maximum Inside braking surface diameter Is shown on each brake drum (Fig. 19). if the maximum inside braking surface diameter shown on the drum is exceeded either by wear or refinishing, the drum must be replaced Refer to Part 12-02 tor refinishing Brake Booster Check the booster operation as noted under Power Brake Functional Test If the brake booster is damaged or inoperative, replace it with a new boaster. The brsk* booster Is serviced only as an assembly, 'Including the check valve. Co produced BY FORD 12-01-20 general Hydraulic Broke Service 12-01-20 OVERHAUL Removal of dutt and din from broke assemblies should be done by using the Rotunda Brake Vacuum (340009) or equivalent or Rotunda brake parts washer [model 650016) or equivalent. Brake assembly dust and ' dirt should not be removed by either blowing off with an air gun or vacuuming with a standard industrial vacuum because a health hazard from breathing asbestos dust may develop. Also, any machining rinne on broke lining) or pads should be done using properly j exhaust ventilated equipment. I BRAKE DRUM REFINISHING ^ Minor scores on o brake drum can be removed with fine emery cloth, provided the emery is thoroughly cleaned off the drum after the operation. BRAKE DRUM REFINISHING Minor scores on a broke drum can be removed with fine emery doth, provided the emery is thoroughly cleaned off the drum after the operation. A badly scored, rough, or out-of-round drum should be ground or turned on o drum lathe. Do not remove any mere material from the drum than is necessary to provide a smooth surface for ttie broke shoe contact. Broke drum maximum braking surface diameter is shown on each brake drum (Fig. 9). Brake drums which exceed the maximum braking surface diameter shown on the broke drum, either through wear or refmishing, must be replaced. BRAKE SHOE AND PARKING BRAKE BAND REUNING 1. Remove the rivets holding the old lining and remove the lining. 2. Gean the shoe or band thoroughly with deoning fluid, especially the rim surface. Wipe the shoe or bond dry and remove all burrs or rough spots from the shoe. Da net use shoe* with elongated rivet holes, a bent or wont shoe web or rim. ' 3. On service brake, check the inside diameter of the broke drum. 4. Position a new lining on the shoe or band. The primary and secondary linings are marked Install new rivets, beginning with the rivet holes near the center of the shoe. On some vehides, the primary lining is shorter than the secondary lining. If this condition exists, position the shorter (primary) tiring in line with the heel end of the shoe. Do not lot brake fluid, oil, or grooso touch the brake lining. Jf a brake lining kit is used te replaco the worn linings, follow the instructions in the kit and install all the parts provided. 5. Cheek the clearance between the lining and shoe nm. The lining must seat snugly ogainst the rim with not mare than 0,127mm (0.005 inch) separation between any two rivets If only the linings are replaced on duo-servo single anchor brakes with fixed anchor pins, the brake liningi must be cam ground 0.25mm (0.010 inch) at the ends after the linings ore riveted to the brake shoe. BRAKE CYLINDER 1. Cleon all brake cylinder parts in dean isopropyl alcohol or the Rotunda brake parts washer (model 650016) or equivalent. Inspect all parts for wear or damage Check the cylinder bore tor rust, scares, or other damage Be sure the bleeder screw passage is dean and open. Replace all ports that are worn ar damaged. 2. if dirt is found in any part of the hydraulic system, hush the entire system with dean isopropyl alcohol. FIG. 9 Brake Drum Maximum Braking Surface Diameter Marking Location--Typical Medium--Heavy Truck Shewn On all medium and heavy trucki, the maximum braking surface diameter specifications, which is shown on each brake drum, allawi far 1.52mm (0.060 inch) machining cut ever the original drum diameter, plus 0.762mm (0.030 inch) additional wear before the drum must be replaced. After refinishing the brake surface runout must not exceed 1,77mm (0.070 inch) total indicator reoding, measured from the bearing cup. On medium and heavy trucks, if the drum dia meter is less than Q.762mm (0.030 inch) oversize after refinishtng, install standard linings on the broke as semblies. If the diameter is over 0.762mm (0.030 inch), install oversize or shimmed linings. MASTER CYLINDER 1. Gean all master cylinder parts m dean isopropyl alcohol or the Rotunda brake parts washer [model 650016) or equivalent, ond inspect the ports for wear or damage. Replace them if required. When a master cylinder repair kit it used, follow the instructions in the kit and install all of the parts provided. 2. Make sure that ail ports and vents in the master cylinder are open and free of foreign matter. 3. On a single brake system master cylinder, check the spring valve (riveted to the front end of the piston) If it is loose or has moved to the piston ports an open, replace the piston. 4. inspect the cylinder waits for scores or rust. Remove scores and rust or abtam a smooth wall surface by honing the cylinder walls, but not more than 0.076mm (0.003 inch) of material. Remove ony 007396 it PRODUCED BY FORD