Document NEnoz3Nk3aVEQj2MBnO56yeGb

I Intar Office Ford Piru and Service D vinon JWj- n, 1975 Mr. H. B. Lick Central Medical Services Bldg. Rocm 210 Rouge Plant cc Mr. S. Eeolelan Mr. R. L. Peaker As discussed during our recent phone conversation, ve have reviewed the contents of our current service for mention of cautions regarding brake repair. Ve are not currently providing a procedure for removal of dust from the brake drums or brake n "g area. I have noted on the attached copies of our shop manual, the locations that should include a caution regarding asbestos particles. If you will provide same suggested copy for a caution, ve will insert it in the next printing. Ve will also incorporate this caution in all future texts, such as training mmnala mil video tapes, that pertain to the areas where asbestos dust may be considered harmful. N Attachments 007894 SCF-FORD-1269 PRODUCED BY FORD I 4L*V i-U sje.ieiui nygiuunv 0'u*e ocu.e u-m i2 REMOVAL AND INSTALLATION BRAKE DflUM REMOVAL AND INSTALLATION THROUGH 1000 SERIES * Use tin* fallowing servile procedure* fur Huh htdf iuh and air hr.itrv ihr | WX | no i no C-1M1 rear drums Hmi. . m J* iso ln() (fn*m and fun jml ihr 4.wind tinsc brake ilium pfisTilmcs applt in hydmuln. hrikes mils, tin.) are covered m r.tn FRONT BRAKE DRUM I R.usr llie vihul until ihs lire clears ilit A'*ir and nmse (he wheel and tin* fr<*rr 1 be huh Loosen ihr brake shoe JdjusMnp s*rew until ihr slnws n lunger much the brake drum Kmimr ihr grease cap and thcpaskcl lil *quippedl fmm ihw hub ? On sehn les wnh 4 OOU through 7,000 lb mat UillYI :nOOO 1b front unit;*, rminvi the timer pm, adjusting nul .mil n.ti wjsiur (rum the spindle On si-IulLh *uii Mum n nm ,ir nrxjo lb ttlr- ri'imne the lock nut thmpkd ^ashrr lotking ring. unO adliisung nui anti pin assembly .1 Remove (Ik outer hearing emu and Miller usvemblv Pull the hub and drum assembly "O' the wheel spindle 4 Remove ihr lrmi wht`cl*iohuh rrininmg nuts (or rim and lire aiiatiunp nut\) Remove Ihr whirl for nm and lire) from (he huh and drum 5 Remove i We hrake drum retainers and attaching bolts, screws or bolls and nuts 6 Remove the brake drum from the hub 7 Cheek the drum for damage or wear, and repair or replace if neccuary If a new drum will be installed, be sure m remove the protective coating with drprea^r Install new greusr rri*M*ir sents whcnrvt r a wheel nmt hnh is rammed. K I'l.nr lh*a brake ilium in lie' bn1' mil inviilt llu mid n inning K hs * < as or N<h un' mu. u Install tin* hub ami drum >m die stkvl vpimllr Keep ihr hub rt nirrrd nn the spinrfir In pfhcni dumnue i the crease retainer or (hr spindle threads. in Mu vehicles wilb 4.000 through 7.000 lh. and Ift.QOO lb. fn.nt asks, tnsi ill the uii*`t bearing entn and rulbr jnJ llie H.ii wjahet itn the spunlle Install the adjusting nm On vehicles with 4,011(1, 11,000 nr iS.OOn 11,. front otlcs. install the nuim he trine v'ir and rnlier nocmhls and llu U:nrine adjusting nut and pm j*wMtihl\ I I ln* d! tin* whci) and lift ui iltr huh I hen install the J.nnps til a|'|'liuhlt*l .nul the wind MuJ mils I? Vklnle mnimp (hi wind tnrqni the u/ljusimg nul In sfvufi. at ion Adnisl a liccl N.armgs as dt*>snbcd mi Group II 1.1 Install the dimpled washr with flu tiimpie imlracd m tne of ihr ht'l.s m the adjusting nu( fnstnff rhr hs L me jnd torque in specification Mend the dimpled washer user a Out ol the 1<s k nm 14. Install the gasket (if equipped) and Ihc prcu.sc tap. and torque the wheel stud nuiv to specification in>tail the huh cap (if equipped). and udiusi ihc brakes as described in this Part REAR BRAKE DRUM E25&.E350, F250-F350, P350.P400 1 Raise the vehicle and mstull safety sunds. 2 Remote th, hnl nod tire ai jn 4v>iMihlv I him, lh, bnkc shoe 4t1|llsllRf sp- nrt"| I In* shoes u longer Inn, h lh In d, 0111111 I Romoi, do fi.o m) *1i it' rvf.nnmp mils adipors asli sl.jti and grr k al 4 Ktnt.isr the svbi^l N mnp lex.Vnat. I<*k aoj idfnsimp nul On I mil I - iso uln* h*v. rrmosr `he I'^kmi. ** )^* .in*1 jt|i*i>iing nut ** K<mior llu hub and drum from the aslr h Kini"i. ib, b,^t, drumio*h h tetainm, -..tews b>di. ,* Kills aid unis kiinosi tlu hukr dium fn m die l.uh " ( * i. k Oi, ,in mi i.it mtipi or wr u, and m p .......... |`lj il n< vrss.ifs IX, nm m u linn h *1, di nn>s ni a hraki ig sorti. Ji un i-, ctiaui than tne m.istninm i{ii*o,i r s),,,wit un the drum Ram.** tl'iimwiUhi rristall U. remmt (Ik pioUvii'i mannf w lh tli err *s. r Ins* di ncM Km *% irimncr srds w hrnnrr wl* rl nml Imh is remm si b Pisiinui If w *'.iku ifrum O* (hi I uh and install lit. attai limp m u*ws. bo U, or K'h> and itnn 4 PoMimti ilie loib i*d drum, as in assemMt mi the ask and Start the adjusimj* mil )0 Adnisl thi wht't betrinp nul, and mstull tin wliui I branny lock wvheY am) hs k mil I) Install j new tear n<U oil seal, isle shaft and p.iskit, stud adapters, and anachinp nuis 12.lnsial1 the w hcsl and lire ai an asse rnhli I' Adttisi llu hrakc stuns Remove (he vafei) stands -mj lower the /.Hide s OVERHAUL `BnAKE DRUM REFINISHING E100 C300. F100 F350. P350- ^00. U100 4"* Minor sn>re% on a brake drum can be removed with Inn emery cloth, provided Ihc rmrrs is thoroughly dratted oil the drum sfu' ths opcraumi A badls scored, rough, or nut<of*rouml drum should he ground or lurnnl on a drum lathe Do nut remove any more matrna) fiom ihe drum than o <-<ury to protide a smooth surface for the brakr .shoe contact. Brake drum maaimum braking surface diameter is shitwn nn ruch hrakr drum ffip |U) Iti jkr drums win, U cx*n*d the iiuumuiui hrakuip sin lace dtameirr shown on the hrakt drum either ihrMUgh wear or ref wishing, must he replaced The maximum braking surfase diamcirr sfin*ific*inn, which is shown nn each hrakr drum fTig. 18). allows lor a HotO mrh mmhmmg rut over the original nominal drum diameter plus 0.010 imh addmonal wear before reaching the drum-discard diameter. FIG. 18 ftroke Dn^ Monmwm Iniide broking Swrlocr Otoml,r Mofkmg Locohon 007895 PRODUCED BY FORD 12-01-13 CenrraI Hydroulic Broke Scmr 12 01-13 FIG 19 Broke Orom Mmimum Broking Surfote Ciomefer Marking locotion-- Typical Medium Heavy truck 5hon * On jII vehicles *00 anti up Scries brass triiyks. the ntaumunt braking Mtfljsf diann ter spewfn.Hunt, vthivli is 'h'*xn rm u.'li bulf drum, allows for 0 inch iiiji , ut oscr the oricin.it nominal d*um Jumetcr. plus 11 tiUMnrh .tildiiioii it neat before I he illnm itiiN r placed Afirr ufintshmg the brake surface /imou> must mu exu'vd On'O.imli ioi.il imh 4ior reading, measured lnm (He hcarno* sup On *tt) and up Sern** bs*j\> trucks, if tbs drum (h.inu'ici is less Mian Ofil(V unb oseism* a'ur tefin'diinp. install kiandard linings on the Inakr assemblies If ihi dumetcr is over OirtO inch, install overM/c or slummed linings BRAIfF. 5H0E AND BAND RLINING I. Ktmove the rivets holding the old bump ami remote the Immg 2 Clean the s)>nr ur hand thnr*>ughly with cleaning flout. cspivialW tin nm surfan* "ipe 'he shm. or band drs and riinotk all lnii*s or tough spot, from I lie slitn On not use shoes with rlnnjtmcd nct holes. 3 tin m mt lu.iLe hr. V, the inside diameter ot tin ht.de Jfum 4 Position a m*w bmuf i. lli* shv oi band Install nrw nse.s. Ivpmi my with the ntri boles neat ihi enter "f the shoe (In some si.im.les, tbe primary lining is shorter than the secondary lining If ihi%. wondihnn exists, poMhtMi ih >h.>n,r |pnrn.trs j lining m bur with the luv*J end <>J I he shoe Do not let brake fluid, nil, nr gffUt touch the brake lining. If a brake lining kit Is usrd In repUer the *nrn lining'. follnw the instructions In the kll and install all the parts provided. 3 f'hci k the wlraramc hitwren ihr linou i*ol tins nm 1 he lining must vrji <*m;!s .iK.nn.t Mic mn s* ill: n.<i more thin fiMfl*iuih sfpir,itun N-iwyen iro in rocts H onls the luioies nr > p'.iiiil on lm*sii\o met' 1 tl v it *1 Hi.lies Stub l'. 1 ou In t* ns the hi iki luo'tgs in oi u* iam gr Mind Mrifn iikh .n Mir * m|s 1111 i'u lutings nr. nsifi.1 to Mu hl.lkl silt* FRONT DISC BRAKES t K.uifit *h s||.*c and linn C' *v i iK tl m I* u i t34 1 Measure the ihiykiu-o* of the hi.iki linmjl If the lining thulmsi at ant poo' oi* 'he .issitiihls is It * M. o' i J |fl nulj jHisi tin ij.islmf.jl.Mi m roiis or if the lining d.ow unfit, ol brakr loud *r oil wontumti. o mi lii.K is t mrmg a hraU pull, npiuw ill lour shoe md lining assimhlus \ Clicsk ahper to xpindb* mi lung Kill torg.u tl I I Mt ,i)m ts i r,k** i M . \ U i 1 or ijin llit in i< * spei ifn nion it ie|mred 4 1 o > lit* k iMor nuuMii, fust cliium.ite ilu wbeil hearing end plav it figbteiooc Mic adjusting uni i ben vbii k to lx* suit the rotor .an still W* O'l.iUd 5 l Uiup a dial milieator to the sjMnrtl so be sislus t'liitaeis ihe rotor app osmulcl) 1 rush limn thr tuner nig' Hoiatc the romr and take an imiie.iior reading If thv re.rdoig cis.'fils n UIM-iim.Ii total lateral runout tsuhin a six inch radius mt the imh. ator. replace or resuK.u e tin. th * brake mi or Thr fnl Inning reijMirmienis must be met when rcsurfaeirg ilxr brake rotors I s Kolurtdu Drs* II rale Kc'lmislung Lobe, Tool f'KI Mntoll to icfinish Mie disc brake rotors hollo* the Mep>b)*>iep resiirlaimg instructions vli.it tome wtih the loot Si more fiian 0 O'fl mrh ol m.Hcn.il ivas K* niarhimil **uiiall\ ott each surface and II. I:ip i**l II roior tliiekncss (alls bslow the * **. `S' 'S* V* '* | 11*11 INI J ` * mmimum shn*n on each rotor, it ttni'i l rrpla*'il 1 he finished hraktng surfircs or thr roii'i must be flat and paralbl xuhm M'itl *m h lateral runout must not r.er1 I'MCll.insh total indicator le.nbu,:. jnj the suKjsc finish of th. br..kmg surfaips imiM he In in Ml) n ro mv f***s "bin tin runmii check is finished, iljtist ibi hi irimcs >*' drunbed in I'urt I Mil tv prevent hearng failure t t l.iik Mo rotor l*r sii.nnp Kcniosr minor s* *rrs uitl a fmr emrrs ibuh I' th* toior is csie'siifls scoicd isimisb >i a* outlined m Sirp 5 ur repine t*ic rotor f ncipssjpy 7 f h*s V ihi ijliprr If t rscraikrdor slums jm signs *f leakage replace it If thr ijlipsr is leaking ariuiiC the dust N*r. remove ami repair u X ( hci k nr.ikf hoses lot signs ol iii. km? leaks or abrasion Krplacr tin in if ruxessir> BRAKE CYLINDER I L'U.m all brake svbmlt i parts in clean isopiops l aliolud Iiopei i all pans f,r ssear or danuee t lu* k Mn* islmricr l-wre I u rusi s r* . . .il*er dinupe He sutr Mu* M.idrr rew passage is Iran and open Kepla* i all pans that arc worn or Uanugui 3 If dirt is fouuj in ans part of the hydratdn, v>sicm. flush thr enure sssitnt with clean tsoprnp)! akoitnl MASTER CYLINDER 1 Oran nil master csltndcr parts in i ban isopropyl alcohol, and mspevl Mm p ms lor wear nr damnec Replace tb'*m if required kkhen i easier r> linder repair kit Is used, follow the instructions in the kit u\d install ill nf the part' provided. 2 Make suiv that :dl pons and vents in tin- rmtsie* ssfnuler arc open and free d fiui-igr, mailer 3 fn a s111111 brakr system mnstcr v*s Ionic i. sbesk Ihe spring salve Irtsnvd to the front cud of the piston) . ......................... ..,i jt;. > n . M, VIMMII" |iy I ll*. . I.IS * Nl l '1^ ISw" M |V* | nt ti hU* li* ''"isv" \ ------ " -- ' . (O) , |- j W ,^-=1.. ' j J+ 'Tipomoio FIG. 20 Due Brok Rotor Service Limdi 007896 PRODUCED BY FORD  12-07-9 Drum Brake's---Single Cylinder, Dual Pijtoi 12-07-9 screw -nside the hole in expand the brakes shoes unlit ihrr drag against the brakr drum and lock ihe drum FtC. It Bockmg Oft B-ote Ad|u*lmcnl---F 100-250, E 100-150, -iih fleai Drum Broket [.omen ihe adjusting xerrw until a Jiphi lira* is nmed (Hi* III 5. When ihe shoo are agatnsi ihr drum, loosen the adjusting screw an FIG 17 {spending Broke Shccx--F 250-350, E 750 250 Rear, and P 350-400 additional 10 to 12 nmrhrj so that the ilnim nn.net freely wiihnut ding If the drum does nm rotaie freely, remove the wheel and drum, and hlow mil nuv duxi and dirt from the linings Using sand paper, rrmrnr any rui (mm thi points * here ihr shoes touch ihr hacking plaic Apply a light mating of high temperature g.-easc (Cl A/ lumn fi) I in nnt get the lubricant on the lining* 4 Insijll the wheel and drum, and adtuxt ihr shoes Install the adjusting hole rover on Ihe hrslr hacking plate 5 Chesk and adjust the other three brake axv.-mhhex b Apply th- hrakei If the pedal travels mtirc than halfway in the floni. there is too m.icli elear.inec hrrvsern the hrakc sh.x-s and ihr drums Kr)icai Steps 2 and ' tbove 7. Wh,n all hrjk- shoes have hern properly adjusted, lower the vrhtcle nnd road li'i l" ihrsk brake i prraiion Perform I he road lexl only when the brake* will apply anj the selnclc can be xdfcls stopped REMOVAL AND INSTALLATION BRAKE DRUMS Front Brnka Drum--P-350-400 .^_prno * Hcmotil 1. Hmsr the vehicle unlit the lire clears the llnnr 2. Hrminc Ihr wherl enver or hub cap ' and wheel bearing dust rap Remnve ihe cotter pin. nut lock, nut, and washer 3 Pull Ihe hrakc drum approximately two inches forward, then push it back into position. Remove the wheel beanng and pull ofT the btake drum If the hral.s drum will in. ;pmr o(T. insert a narrow x*rrtxdnxer through thr biakr adinsiing hole in Ihr earner plair. and disengage the adjusting jrxer fn-m rise- adjusting Ssreu kk lulc holding 111-- adjusting Irsrr from the adpisting ss-tew loosen Ihe adlu-ling screw with the brake ad|ii*nug tool If-ig 11) I amsrn thr adjusting screw unly if thr drum runnuf hr rcmnicd. Du nut hiirr. chip, nr damact Ihr notrhci In the adjusting sert-w nr the self adjusting mrihnmini will nni (nnetinn proprrls If the adjusting xerrw <u Inns.-nrd, check to be sure Ihe adjusting Irvcr is inti properly iratrd in the shoe web. Ituinlltuon I II ihr huh and drum ssxctpMs --ill hv replaced. remose ihe proieClive coaling from a new drum with caihuietor drgrenscr Install new hearing* and * new grease retainer I'ask ihe wheel hearing install ihe inner hearing cone and roller axssmhli in the inner sup. and install . (he net* grrtsc retainer as rlrscrrhed in Pan II-10. IT the original drum will be inxuilrd. be sure the grease in the hub IS rlrnn and adequate . 2. Install ihe drum assembly, miter wherl bearing, washer, and adjusting nut .x described in Pan 11-10, 3 Adjust Ihr wheel beanng. install thr nut lock and coilrr pin. and grease cap ` 4 Install the wherl and huh cap If Ihr adjustment screw was loosened, ail|iim the brake ax described In this Pan REAR BRAKE DRUM--F-100, F-250 (UP lO 6900 G.V.W.), -100-150 AND U-100 Btmmul I Raise the ichicle so the wheel is clear nf ihe floor 2. Rrmovr ihr huh rap and wheel and tire assembly Remove the three retaining nuix and remove the brake drum If 'hr brake drum will nnt come ofT. m* ri n im*-- *ere-- driver Ihrourh the brake adjusting hole in the harking plaic ami disengage Ihe ailiusting lexer from the adjusting screw While holding thi adjusting lever away from the jdjusiinj* screw, loosen the adjusting srrrw with Ihe brake adjusting tool (Tig II) l-oostn Ihe adjusting screw only If Hie drum cannot be removed Do nnt burr ch'p. nr damage the notchrs in the rtjuding screw ne the irlf adjusting mechanism will nnt fnneunn properly. If Ihe adjusting acre* seat Inoaened, rbeck to be sure the adjusting lever u sull properly seated In the shoe eh. Jn.i1iLll.Uinn ~~ 1 Remove the protective coating from a new drum with carburetor ili-pi easer 2 Adjust the brakes as described in this I'm i l Install (he drum 4 Install Ihr brake drum retaining nuts and i glucn si.urcly Install the hcxl on the axle shall ftanpu slud* against (lie rliuni anil loiqur ihe reiaimng nuts to specification REAR DRAKE DRUM--F-250 (ABOVE 6900 G V.W.i 330. E-250-E-350. P-350. P-400 Rcmrtftl \ the vehude and UUlfcll wfctTf standi 007897 PRODUCED BY FORD 12-02-8 Drum Brolei--Single Cylinder, Duol Piiton 12-02-8 FIG. 10 C ICO E-35C 3/oV S il. mr 007898 produced by ford Drum Brakes--Duol Cylinder!, Duel Pistons 12-00-3 RCMOYAl AND INSTALLATION r.PAI'E SHOE! AND ADJUSTING SCREW P-600 Sarios--Rear Remora! 1, R.nst the vehicle until the tiro dear the floor Remove the v heel and tire assembly. and remove the drum or hub and drum iiiernbfj Mirk the hub ind drum Is aid assembly la the lime putilina. 2. Clamp the brake cylinder boots ayamM the ends of the cylinder and remove the brake shoe reiractinj springs using Tool 20IJ-N (Tig }). } Remove I hr brake shoe guide bolt colter pin, nut, masher, and boll from both shoes, nnd remove the shoes from the hacking plate 4 Remove the clump-type adjusting whrel loik from the anchor pin support and unthread Ihr adjusting srrrw and wheel assembly from the anchor pin support lastaJIatiun I Luhncair all points where brake shoes soniact other biuke assembly pans will high lemperatutc grease ICIAZ-I959H-U). 2. T bread the adjqatmp screw and wheel assembly into the am hot pm support and install the clnmp type jdjustmg wheel link. Thread the adjusting wheel into the support so the brake shoe rests against the adjusting wheel end. 3 Plant the brake shoe against the hacking plate imril thr ends >n Hie bruit rvluidcr link-, and install the shm guidr hsdt usher, ami mu fFig 4). Finyrf tighten thr nut, then Irvisen it one lull turn ind install Ihc collet pm 4. Install the rriracling springs using Tool 201! hi (F,g J) J Remose the cylinder clamps, install the drum or Ihe huh ind drum asiemblr. and install the whrcl uscmbly Align Ihe marks on the bub and drum far prnper Installation. 6 Adjust the brakes, and lower the vehicle 600-900 SEBIES-- REAR--WAGNER Remora! I. Raoe Ihc vehicle until the tires clear the floor Remove the wheel, and lire assrmhls. anil Ihe drum or huh .mJ drum assembly It may be nesrsmrs to loosen tine ask passing wVirrVs slights-, to free Ihe grooved drums Du not loosen the idjusimcnt so much that udlusting wheel jams against Ihc fiicnnn nng on thr adjuster screw or damage to the ring mas result Mark the bob and drum la aid uscmbly in the same position. Dr sure there is no vacuum In the system before on**i uss disconnecting tbr bydrlu * !.ipr(! isruum In the syMrn b) Kgro 00 brake pedal with Ihr r^nr oft. 2 Unhook thr anion**.lu ndjmtrr spnnjA (fig 2) Rom*c rvh long adjuster link hy pfwtitnr l\.k thr adjusting whrcl **.! (I-rir slots align with the hnk I*`**Sa l iff out the links and tittle the h*k* from ihr jnchor pm cracks the short links by r*innf tl.r anchor cranks unit! the link hue*1** ilc-'r the eccentrics on thr <h**e wchs Then remote (he smaller hooks (runt the cranks ,1 Spread the anchor cii*V (.'*:thers and remove ihr unntj <u i i'miuII) unnecessary in rrmn*c ***' adi*itg wheel cranks) If Wnx . I'hnnt. remove adpivter rct'iorns l m the shoe webs bs unscrewing (hear self* upping screws 4 Remove the 'hr* rru .tn*n springs by sliding the h^ped vi d '5 the pins Remose ihe vkwus bold<iowu lock, wires, castellated nut*. nnd plain % ashen, nnd lift the shoes off (he backing plate 5 Unthread the sdiuump and adjusting wheel finm each of (he anchor supports Installation 1 Insert the adjusting wh-el* in the anchor support slots and tlnml in the adjuster screws from the h* * snle. with the fnetton rm end toward the shoe. For new lining*, loosen adjusten, but di> mt h%*b*n th*m far enough to jam Ihr adjusting wheels. ANUeOrTtft*'* PIC. 4 Two Cylinder ftroko--flor--P`300 n mi ( FIG. A Retracting Spring Replottmtni--Typical 007899 PRODUCED BY FORD FIG. 3 T-o-Cylind.r Broke Shoe (WognerV--Rear FIG. 3 Mrdw"c Brake A.mbly |K.U.r-Hay..| 007900 PRODUCED BY FORD ) 12-08-9 Drum Broke*--Dual Cylinder*, Dual Pistons C-Serloi Fcmartl 1 Remove the brake pedal retracting spring (Fife. <> and II). 2 Remove (he brake mailer cshndrr push rivl "i.Tnmc boll nul. bolt, und nylon bushings 1 Remove ihe hrile pedal bumper-io- brackcl retaining nut Remove the boll and bumper 4 On models uh a ample hydrauliv brake lystem. remove the master cylinder push md by pullinc up the lab on Ihe push md b,-i|. and pulling lhr push rod und bom Irnm the cylinder 5 Remove the nut from Ihe boll, slide the holi in the nglit and remove ihe brake pedal assembly, sleeve, and hushing , 6 Remove ihe bushings from the pedal assembly Imtulhhnn I Cmt all bushings and ihe pedal shaft uiih a small amnuni of l.uhnpljtt or an equivalent lubneani Posninn ihe nylon bushings in Ihe hiakr pedal shaft bore 2. Potiunn (hr brake prd.it assrnihlv. alcrve, ami liuihin. m thr rrilil support brat * I vhdr ihr Ism i ill lull and install llic nul 2 r.iquc ll'r nu. lo spcsificition } On modrlv uh ,r suipl* Its sii niiltr brake sysimi msull llir push nal and Pool in ih- luoin vslinil-r 4 On models with a smelt hs.lruulii brake stsiem. inslull llir prjal huniprr boll, bumper and itul Tighten Ihe mu aw urelv i Install the nsl.m htohiugs m thi push rod bore anil innall tin push i.sj ccreniric boll and nul 6. Iniiall the pedal rrlr.ivliny spring 7. On model' with a imylr hwlr.iuln. brake system, jdiusi the brake j-i'al frer-ltavrl In *< I b lo * iih It Tmquc Ihe ciicuiriv bolt nut lo pet iris al inn 12-0B-9 Intiollahon--C-Senet OVERHAUL BRAKE WHEEL CYLINDER DisA\xrmhl\ l Wiih the ssherl cry tinder remitted, remove the rubber hmttt from ihe ends nf the brake cylinder Rrtnme 4lie putnns, cups, amt pKtnn imurn vpnng from the cylinder (Kig. 12) ftiit'ifr i r \ >1001 Cvi'NDti m* .-.j *vdn MASTCR CYLINDER Single Qrako Systom OitMsscmbf 1 Remove ihe masicr cylinder C Iran the outside of Ihe master cslmiter, and remote Ihr Idler cap and y.askit I'our out ans brake fluid left in ilie cylinder mil rewrtnir On C-Srriri vehicles, t l*ij! I *. xcourse the boll' that hold tin* ivhmlcr on iIk t* *vnir and nnuttr lIk , I et I'ms* *%n tin the pisi*m to C irrpris^ iHc mum spring, jnJ frmmf the sn.ip nrr Krmi*c the piston, pnmirs cup. piston filler, return spring, chci k s j|v: jnn check saUi* seat On vehicle* with p I'aerrTmuntrd mruum brakr lt*MHicr. the check valve iv Insulin* in th- booster instead of In the mailer cylinder. I fa l *t ill I *MN pision . 4N0i u*' booj FIG. 12 Double Servo broket Cylinder 2. Remove the bleeder terew from the cylinder . AssrmbJj t Coil ill hi ike cylinder part* %ith clean rttra hravy duly brake Hunt l*bA7*19W; A ' ' 2 Instill thr Herder s*.rc (I ijt 1?) in the brake cstmdrr J rtifc the pisum return spnn* cups, and ptstun* m ihe cylinder hire, and install ib^i md link **ver each rnil nf the cylinder Clamp the brtte cyliniirr pistons ajitnM the ends of the cylinder Whco usint brake cyllodrr repair kit follow the iBStrurtloo* le tba kll amd Inauil all of ibe pans provided. t 6U* M| /hi V* AV "s" ni 1 v*i <* j \^ l + I* ^<1 dj. - ------ - 9 V ~L y |u/ \ l ivntp U JU* l,.hf HUU N'J I \ t * 'W +* `L ' MM** S V *"V Mil ' **' FIG. 13 C S.ri.i Broke Moiltr Cylinder--Ditonembled stna; e 007901 PRODUCED BY FORD 2. Connect the hr,ikp hydraulic system Imp' in lh differential salve assembly and tighten ihi* tul* iiu<n c> urcl) 3 Innttru the shpll-uirc roniieiinr to thr hi aV r skiriiMip lamp switch Make aurr (hr pbsllr lugs on the ennnector hold the runncctur securely In the iwhrh 4 Hfpcd thr brakes and eentrih/c the pre^'ure differential vahe a* devnhrd in ih s Pm BRAKE PEDAL ASSEMBLY L. IN*, and LT-Sonna Remora! 1 Rcmnvc ihestophghJ switch from the pedal bracket 2. Remove the brake master cylinder push tod holt nut. and nylon bushing .1 Remove the mil from the pedal shall. Slide llie shaft In the Inl and remove the brake pedal and sleeve 4 Remove.(he bushings from the pedal. JnSLallatwn t Cnat all bushing and *he pedal shaft with s small amount of l uhnpluic or an equivalent lubncant. 2 Position the nylon bushings tn the brake pedal 'hall hme 3 Position the brake pedal asjrmhly and *ti*e*e tn the p**dal support bracket Slide the pedal shaft through the sleeve and ped il ami semre with the nut lorqm the mil to uprvifu'Jiinn 4, Position the nslott bushings tn the bore of the push rod (Tunnci f the push rod tn the hnkc pedal with the bolt and mil 3 Adjust I hr hnkr pp-did frrr travrl to 1/lh to 1/R-tncli fnrque the ecrentm boll nut to ep^rtlw otton 6 Insinll I he stop light swiuh in the pedal I r.id t*< as far in .i possible Pull the pdn| to us Itinhc*! rnurn position in pfopeth level the stoplight switch P 600 Sorias Rcmnr*! 1 t)p^-n thr front cover nml discnnncvf the tiaiisnuv.ini /i^shtM rinjs fium the shift lever* the nxj> to maiimum working spue is available at (be pedal lupimii br.u lct 2 Remove the pedal p.nls from the chiich and hraie ptdal if ig I CM 3 Remove theset exs that hold the floor covers at the sircrttijt column, and remove the covers t nlault the engine wiver assemble and open. 4 Hi movr the floor plat retaining screws Remove the aw iterator pedal from tin arcclir nor hnk ige and rrmove the Hoot filait 3. PiscnnnrtM the ilutch and brake pedal retracting springs 6 l.uosen the pedal support bracket clamp Kilt llmiotk thr toner pins ami clevis pm> from the vhmh md brake pril.il' 7. Turn the front whcils dl the w,t\ to the left Thnnifh thr Irtt front fender apr in. remo\i thr linking pm from the clinch pedal and rcmmc tin* pedal Push thr pedal shaft tmird the centerline of ihc vclmb I nm inside the cab. slide the jvcd.il shaft MW<ml*,(.'1* \ % ------1-- l 1 Ill'll 1 * !* l*|* . ,, e r*. "ii v iv,'.'.V '1 rr 1 ' 'ijk .-.u-,-- fr x-c '^ m>.i S-iiC, I. IV .fi , \ 'V-j 1 !L. \ \ \ Ki.. f *.< l*-` N IV^V. / * &-T>X^f"1 "*^J111 ' * .i l . ui IVI \ >>| >. H***L1 I IX' ** *"* B,< \........ ... HG 10 tok Pedal and Related Pam--P-500 and rlnieh p** 1*1 Irsci to thr nghl tnd ut of the suppfMt hi ndrt Remove the hrikr pdal loni i* sup| nrt hraikn Rrmme the Imdunps Jiont the pi dal and the pedal support h. a. Vu Jn*tKfUtutn 1 t'.u: .id hushintt> jr.l the pedal shaft vijh a snull stnonnt of hibrir int I s \ Mil 7'..ft nr ruuo.il rt Ins*&II nr* hu-hings in '*** j**H*1 support bra. Vit and the h* *kc |*<ld 2. Position the hrui pedaf in hc mppori hrailei .mil slid" rhe yvdal shah and duirh rtl.il le'er thruugh the bracket .ml p* *Jal 3 Through Ihi lefl fti'iu finder apron, instal* the rlu* h |\dd on the si aft anil serurr it w*h :t new colter p*n 4. Pinion ihe cluti It .t\l Hi clu.ch pedal lever, install the c!**i\ pm and srs ure it with a nrw ^mirr pm 4 Position ilr bill* nr'icr tylmdcr push roil in the oi.|xlul mvi.dl *he ilrvis | m. nnd scwuie n with a new inner pm b Inst dl the clinch and brake pedal iitrarnnc springs 7 'V iHi il** hr d i [-d.il ic.u ' the stop ad him the N it i* i slmi'rr puih nut in mr Out |.* (J M niih hr** plav mr.ourrj at vetoei Imc t'l P'dat pad In lin puvh red i out,it Is piston ltm"w* tin thvis pm Iioiii tin push rod md turn thr ruJ until the spreund fire trawl is ohminid. 7 ii hie'i thr urn mu and mMall lUvis pm .liter inljiiMmuil B Sonos Renwwtt I Hr*n nr llir stop lirh* swiuh from the fxaJ.il husl et tin* M 2. Rcnvni the rnao*M*p l*i*. matter cvltnder push rol iml I'idnng 3. Rrmine dir rli| fiom ih^ I'edal shaft Shdc the sh.Vi to the lilt and remt vt the hnkr psl.sl 4 Kritunr thi hiisiuugs Itunt the pedal Intttllatum 1 (`oat t! hushings vul thr pnla! thafl with a small unionist H Luhriplateor an iqttisnlcnl Inbiusnl 2 Insuil tUr tivlon hu'imigs in the br jk. p uni sh tfl Nx .t n *lu (*r.ks rdd a.s*rmhfy in I'm f\Jal siippnt lua-ksl ^hdr Ihc ped.d vh M ihrom ' the p'-dal and sreui** sub the ret imr* fl'P 4 r<ritum the nvlon hyvhuiv m the bore of thr pudt rixl to ts.rnhlc the bioke pedal with the rlr\ . pn* 3 Install the sinphiln swit'h tn the pedal br*rkrt as br tn as possible Pull the pcdnl tn its furthesi return pnnitutn to properly reiel the iiophght switch. 007902 PRODUCED BY FORD n-09-i Drum Brakes--Duo! Cylinders, Single Piston (Woqrter) U-09-1 PART 12-09 Drum Drakes -- Dual Cylinders, Single Piston (Wagner) COMPONENT INDEX BRAht BACKING "l ATP Applies To GOO Thru 900 Set res Trucks Page ' \ COMPONENT IN0EX 1 i;h-m E^Hur, Removal a id luMniimum . . brake drums 0J2 `.f / .C .. f,` R' -i-t .,1 tmi Inst,.p.di it . R'-mu.-nl and liibUilluii'to .. . 0*3 1 BRAKE MASTER CYLINDER Removal and lnsi.i!l..:um......................................... Disassembly and Assembly .. . M3 IV)!, , llliAl C v.HLEL CYLINDER i` mi'inl mil i.-istc'ir..i n 0 ,.ib"ip.I'i/ and Assemli.y. , . . Insoeciion and fleouif................................................ 00 5 |j ;PLUri:ATlQNS Pace 03 1 | 00 1 012 03 5 03 fj J ADJUSTMENTS BRAKE SHOE ADJUSTMENT Adjust the brake shoes when ihe brake drums are ai normal room lcni|irratutc If the shoes are adjusted when the drums are hot jnd expanded, they may dug as the drums coni and contrast Brake atliusrmcnt re-establishes (hr btikc linuty-tn-drum clearance and compensates fur normal lining wear hollow Ihc adjustment procedures below SELF ADJUSTING BRAKES--600-900 SERIES Manually adjust two-cylinder front brakes using the hci-head sell locking cam adjuster* Stihu-tjuriil .idi'iMmcm is automatic. l;or manual adiosinn-m 1. Raise the irltt.le and chci k llir front brakes for drag hy totaling the w Itcrls 2. Adjust nnc shoe hi rotating the wheel forward while turning the cam hex- head forward Txpanri the shoe until a light I* is is l> It on the drum Dn mil tooli r>n-*nr Inrre on the beshead ram, nr the iionmatic adjuster parts maj he dammed. I nosen the adjustment until the wheel turns frrcls. Adjust the ntber cam in the ttmr manner, J Ailtusl the other front wheel brake using ihe procedure above A Appli thr hiakrs and rccheck the adjustment REMOVAL AND INSTALLATION ^RAKE DRUMS 7..ROUC:: 900 I Remove both brake shoe retracting str.iEs Demortl and latttlltlinn Service pro- edurcs for (hear models ire described in Part 12-01 springs (Tip. It J. Remote rite C-wnshcr* and flat washers from Ihc hold-down studs. Lift the *hi n(T the hacking plate. A. To remote ihc adjuster jssrmhly BRAKE SHOES AND ADJUSTING MECHANISM 000-900 Sorioa from the shoe, unhook thr wcJge spring fmm the wedge and the eotl spring from tltr shoe web Work the end spring ofT tltr levrt pivot pm and .fiemorj/ 1. Raise the vehicle until the tires clear thr floor Remove the wheel and tire asxrmhl) Run-ive the drum nr the hub and drum assembly Mark Ihc slide the spline 1-n.ik from tile ping le*rrptn Pull lh* adjuster lever finni the hack of the shoe and remme the plug, wedge washer, wedge, and wedge guide. hub and drum to aid assembly in the Intttllthon same position. I. To install rhe adjuster assembly, F spell all vacuum in the system position Ihe wedge guide with us pin before disconnecting the hydraulic in Ihe hnle provided in the brake shoe lines F.spell vnemim in (be svslem hy Place the wedgr guide on the side of pushing Jown on brake pedal when the brake shos- larthest away from the engine u oH earner plate. Position the wedge on the shoe weh with its serrated edge resting against the serrations on th; wedge guide 2. Insert the drum contact plug so us head is thrmirh the hnle in the brake sh.se and lining and its shank rests over the wedge ami wedge guide Ihc plug must he installed from the inside of the brake sh-w 3. From the opposite sidr of the 'Hoc. install the shoe adm-micn! lever, guiding the pin tnin the mating hnle of the contact plug. Install the wxslu-r over the wcdcc nn the lever pivot pin 4. Position I hr tt-himk of the adjustrr torsion spnnf on the plug Irver pm. Attach one end nf the wrrige spring to the hook, and install the coiled portion of the torsion spring over the lever pivot pin Install ihc outer end of the torsion spring o*er the edge of the shoe web 007903 PRODUCED BY FORD 17-00-17 Drum BraVr^--*Ouol Cylinders, Dual Pnloni 12-08-12 It ( nm press the spline sml install the rem<mm<p wap nnp md spin waMtcr in. th; pis|i*(i s'*p i<I 17 Shle the piston stop irvl into ihr u .unitary piston and **#*|TJ|Ct* the ijp ntu in it\ primt 1 sh*)r Jlii pml rap mul pi*mn a<wnhh im. ih* inasici *vhr.ln Kmi ami itit /*.) >\ n mjsu t tylmdrr body Torque the %.ip t* 15 in 70 ft fh 1^ (n >t a (I suishfM u |)ir rv-rr \ *n t rmiii'Ti ami p(jcr l he ft u nrr<* in ihr mmiJ)tiij holes u| (hr rvs.'rv*u 20 J'l.ui ihr ruhl* r *isliei* and O nnp i*t Ihr fHiiiiM'tv 21 Install ()k re-#*\.*`r ,im1 i-i.nncr aswiutiU nr the m.i*i i.vhiij* Kt. anil torque Ihe retainers to 15 to 20 It th 22 Krp` u c ihr pnnpA and chrel valves m thr m.tl I pun* tif itn t)tinder 2' I'rphu tli and scvOndary pf . f.s mil iinqur in p to 20 Mh 2J l tsi .J *h, niuunnnp *rnl on Ihr Him **f `hr tna^fu ulimlrr In.tall (tic hit. ..tp tm( jiish*t SPECIFICATIONS imcipc lonouc viv, ii , 79*9Vl UNITS-NYDJUtrilCTVIf SUTJinilH 007904 PRODUCED BY FORD