Document NGNM7LLp2LqoLRkRVODqvXrR8

I . I BRAKE SYSTEM |0(o ) L I f' ^ 1 T, C Orr\ t r ai H ' Jacu d .t AHe* ? u. 1- Hold the from and rear p:Mon plates together and install the six piston plate capscrews. Leave the screws loose. 13 Insert the rubber reaction disc in the recess at the center of the front piston plate. Use care not to lose the reaction disc out of the piston before the ]>ush-rod is installed. PISTON EXPANDER RING, FELT, AND RETAINER (Refer to Figure 2-13.) 1. Place the assembly ring oscr the piston packing Turn the pision assembly upside down and assemble the expander ring against the inside lip of the leather packing. (Sec Figure 2-16.) 2 Saturate the felt in vacuum cylinder oil and assemble it in the expander ring. ? Assemble the retainer ring over the bosses on the rear piston plate making certain the retainer is an chored in all six grooves of the piston plate Tighten securely the six capscrews in the from piston plate. VACUUM CYLINDER, POWER PISTON, AND END PLATE (Refer to Figure 2-12 ) 1. Attach the vacuum hose to the vacuum piston and align the hose to lay flat against the piston. Apply a thin coal of vacuum cylinder oil to the bore of the vacuum cylinder. - Remove the assembly ring from the vacuum piston Attach the air filter and air cleaner cover w'tih screws. Insert the short end of the vacuum lube and plate through the gasket and attach the tube and plate in the position shown with screws. 3. Install the end plate assembly over the valve oper ating rod and attach the vacuum hose to the tube attached to the end plate Before proceeding fur ther. make certain the reaction disc is in place in the front piston plate. Fig. 2-17. Backing OB Brake Ad|i>ttment--(91-2410) 4. Center the small diameter end of the piston return spring in the vacuum cylinder. Center the vacuum piston on the spring, and align the end plate to the scribe marks 5. Compress the spring and install two attaching screws at opposite sides to hold the end plate and cylinder together Install the balance of the screws and tighten them uniformly. " 6 Dip the rubber dust guard in alcohol and assemble it over the end of the valve rod and the scalloped flange of the end plate SPECIAL SERVICE AND REPAIR OPERATIONS BRAKE LINING, WHEEL CYLINDER, AND DRUM Brake Lining REMOVAL 1. Remove the wheel from the brake drum, then re move the brake drum. Refer to the removal procedure 1-I.AIN'IIKK'SkXTIIIIIT H>-786 8f'03 0666 PRODUCED BY FORD SCF-FORD-0307 a-10 of the broke assemblies in this section of the manual. If it becomes necessary to back of! the brake adjust ment in order to remove the drums or because of dragging brakes, use an ice pick or small screwdriver to move the adjuster lever of! the adjusting screw while the adjusting screw is backed oft. (See Figure 2-17.) ~ 2. REAR BRAKE ONLY: Move the parking brake operating lever forward and lift out the parking brake cable. 3. Contract the shoes as follows: a. Disengage the adjusting lever from the adjusting screw by pulling backward on the adjusting lever. b. Move the outboard side of the adjusting screw upward and back up the pivot nut ns far as it will go. 4. Pul) the adjusting lever, cable and automatic adjuster spring down and toward the rear to unhook the pivot hook from the large hole in the secondary shoe web. I)o not attempt to pry the pivot hook out of the hole. 5. Remove the primary shoe to anchor spring and spacer plate first. (See Figures 2-18 and 2-19 ) Remove the secondary shoe to anchor spring and unhook the cabie anchor. 6. Remove the shoe guide plate. 7. Remove the cable guide from the secondary shoe 8. Remove the shoe hold-down springs, shoes, adjust ing screws, pivot nut. and socket inspection Examine the brake linings for wear, if the lining face has worn to within inch or less from the rivet heads, replace the linings Either linings or lined shoes are sup plied for service. However, the installation of factory-lined shoes w'ill give more satisfactory results 1,'ndcr no cir cumstances replace one lining only, or one wheel set. Both front wheel sets or both rear wheel sets should ANCHOR PLATE PRIMARY RETRACTING SPRING SECONDARY RETRACTING SPRING LINING CABLE GUIDE fiL. ASS Y SHOE AND LINING ADJUSTER IEVER HOtE COVER BACKING PLATE SPRING SOCKET THRUST WAHER tAAD5J*2U;;WSTING SPACER SHIM BRAKE SHOE .................... _______ ____________ J A_________I ANCHOR PLATE r~ 3 CABLE BRAKE SHOE .....-HiA?'_jpj * PRIMARY RETRACTING SPRING SECONDARY RETRACTING SPR'NG Fig 2-19 Freni vVFyel Broke Anembly- (61 LM-24.S? j 8003 0567 PRODUCED BY FORD LRAKE SYSTEM 8005 0568 2-1 1 Fig. 2-20. Puton Retaining Clomp Installed--(91-2403) be replaced if one wheel set requires replacement. I>o not turn down the linings. The lining radius is ground to specification and should not be changed. If 24,000 miles of operation are on the brake linings or if leaks or signs of overheating are noted, it is recom mended that the wheel cylinders be disassembled and in spected The cylinder cups should be replaced upon dis assembly. If the wheel cylinders do not require attention, install a Wheel Cylinder Piston Clamp, Tool LM-119, to hold the piston in place. (Sec Figure 2-20.) INSTALLATION 1. Before assembly, clean the backing plate -md apply high temperature lubricant COA7.-I9584-A spar ingly to the shoe bosses 2. If the wheel cylinder was serviced, remove the re taining clamp and install the connecting links. 3. Position the brake shoes on the backing plate and install the four hold-down spring pins, springs and cups. On the rear brake, install the parking brake link and spring Connect the parking brake cable 4 Install the shoe guide plate on the anchor pin. Place the cable anchor over the anenor pin with the crimped side toward the backing plate 5 Install the secondary shoe to anchor spring 6 Install the primary shoe to anchor spring and the spacer plate. (Refer to Figure 2-19.) Install the cable guide on the secondary shoe web. Thread the cable around the cable guide grove. It is imperative that the cable be positioned in this groove and not between the guide and the shoe web. He certain that the cable end is not cocked or binding on the anchor pin when installed and that all parts arc flat on the anchor pin. ". Apply door lock lubricant I wi;h flake graphite added) to the threads anJ socket end of the ddiusting screw. S Turn the adjusting screw ir.to the adjusting pivot nut to the limit of the thread' and tnen bjek off a turn. CAUTION: 7he brake shoe udimtnu; tcrew assem- blu'f mmt not be interchanged trom one tide of the car to the other side. Interclumgmt; the adlusting iWH i would came the brake shoes to retract, rather than e.xpand. each time the automatic adlusting mech anism operated. 9 Install the thrust washer and ad lusting socket on the screw and install this assembly between the shoe ends with the adjusting screw nearest the secondary shoe 10 Hook the cable hook into the hole in the adjusting lever from the backing plate side 11 Place the adjuster lever pivot hook in the large hole in the secondary shoe web (Refer to Figure 2-19.) 12 Position the hooked end of the adjuster spring into the large hole in the primary shoe web. and install the loop end of the spring to the ad luster lever. 13 After installation, the action of the adjuster can be checked by pulling the section of the cable be tween the cable guide and the adjusting lever toward the secondary shoe web far enough to lift the lever past a tooth on the adjusting screw wheel The lever should snap into position behind the next tooth, and release of the cable should cause the ad juster spring to return the lever to us original posi tion, w'hich will turn the adjusting screw one tooth (revolution) If pulling the cable docs not produce the action described, or if the lever action is sluggish instead of positive and sharp, check the position of the lever on the adjusting screw' toothed wheel With the brake in a vertical position (anchor at the top) the lever should contact the adjusting wheel inch (plus or minus N't,, inch) above the centerline of the screw. If the contact point is below this centerline, the lever will not lock on the teeth in the adjusting screw w'heel, and the screw will not be turned as the lever is actuated by the cable. To determine the cause of this condition: a. Check the cable end fittings The cable should completely fill or extend slightly beyond the crimped section of the fittings If it docs not meet this specification, possible damage is indicated and the cable assembly should be replaced b. Check the cable length 1 he cable should meas ure 11 Vb inch (plus or minus ',.4 inch) c. Check the cable guide for damage T he cable groove should be parallel to the shoe web. and the body of the guide should lie flat against the web. Replace the guide if it shows damage d Check the pivot hook on the lever The hook surfaces should be square with the body of the lever for proper pivoting Repair the hook or replace the lever if the hook shows damage c See that the adjusting screw socket is properly seated in the notch in the shoe web 14 After completing the installation of the adjuster and testing the action of the adjuster. inst.ill the drum on the spindle or axle shall. Remove the adjusting hole PRODUCED BY FORD 2-12 . cover from the backing plate Turn the adjusting screw upward from the baching plate side to expand the shoes. Use Adjustment Tool 201S-A. Expand the shoes until a slight drag is fell during drum rotation. Remove the drum and while holding the adjusting lever aw'ay from the adjusting screw, back off the adjusting screw -VS of a turn. 15. Install the brake drum. Id. If the brake cylinder was serviced, bleed the cylindcr (See "Hydraulic System Bleeding", which tollows in this section.) 17. Install the wheel and tire assembly. Torque the wheel nuts to 75-85 lbs. ft. 18. Install the hub cap. 19. Lower the car to the floor Drive the car in reverse, and apply the brakes five or six times while the car is moving rearward This action will operate the ad justers if additional brake shoe expansion is required to bring the brakes into proper adjustment The "Diagnosis and Test rrocedtires" area at the end of this section contains a "Brake System Service Cheek List" which should be reviewed to insure the rclining and repair operations have been done correctly. Front Wheel Cylinder REMOVAL (Sec Figure 2-21.) 1. Disconnect the hydraulic hose from the tubing at the frame. 2. Remove the capscrews which secure the cylinder to the backing plate Remove the cylinder unh the hydraulic line attached. Remove the hydraulic line 3. Remove the boots, pistons, cups and spring irom the cylinder. CLEANING AND INSPECTION 1. Place all pans, except the cylinder casting, in alcohol Clean the cylinder walls with alcohol. 2 Fxannne the cylinder bore A scored bore nuv be honed providing the diameter is not increased more thjn 0 005 inch beyond the orgirul di.inwicr of 1 ' inch. Replace worn or damaged parts with the re pair kit. CAUTION. Clean hands with soap and water, not cleaning fluid or kerosene, before handling replace ment parts. 3. Clean the hose: then, wipe the threads and sealing surface clean in order to obtain a leak-proof con nection. INSTALLATION 1. Install the hose on the cylinder L.ubricate the wheel cylinder walls and cups with brake tluid 2. Install the spring, cups, pistons, and boots in the cylinder housing 3 Install the Piston Retaining Cljmp. Tool 1M-119 (Refer to Figure 2-20 ) l. Attach the cylinder to the backing plate Torque the capscrews to 11-19 lbs. ft 5 Connect the hydraulic hose to the hydraulic line at the underbody Rear Wheel Cylinder REMOVAL (Refer to Figure 2-21 ) I. Disconnect the hydraulic line at the wheel cylinder Do not pull the metal line away from the cylinder. Pulling Ihc line out of the cylinder connection will bend the metal line and make installation difficult. The line will separate from the cylinder when the cylinder is removed trorn the backing plate 2 Remove the two capscrews securing the hydraulic wheel cylinder to the backing plate Remove the cylinder. CLEANING AND INSPECTION For inspection and repair, follow Step 3 of "Removal" through Step 3 of the Installation" inclusive, under "Front Wheel Cylinder". The original diameter of the rear wheel cylinder is :'l,. inch. f q ?*) Wh<* Cfiiiocr Asscntbly-tl-?OG6 8003 0569 PRODUCED BY FORD BRAKE SYSTEM 2-13 INSTALLATION' 1 Wipe the end of the VyJrauhe line to remove any foreign matter. Piacc me hydraulic cylinder in posi tion. Enter the tubing into the cylinder and start connecting the nut. 2. Secure the hydraulic cylinder to the brake backing plate with two capscrews and complete the tightening of the tubing nut. Torque the capscrews to 11-19 lbs. ft. Brake Drum E.xantine the brake drum for the following wear condi tions. a SCORED SL'Rl ACT. \ isually check and grind, if necessary. The inside diameter of the drum must not exceed 11.122 inches. To remove more material would seriously aflcct the strength of the drum. If it is necessary to turn down one drum to 11.122 inches, turn down either both front or both rear and use the oversire linings in axle sets. Do not shim linings. b. OUT-OF-ROUND. If erratic brake action is noted when brakes arc road tested, check for an out-of-round drum condition Use an arbor and dial indicator gauge or equivalent for making the check. There arc various commercial devices available for restoring drum roundness, most of which are equipped with necessary gauges A variation of more than 0 007 inch from round warrants attention. HYDRAULIC SYSTEM BLEEDING When any part of the hydraulic system has been open to the atmosphere or disconnected for repair or replace ment. air may get into the lines and cause lack of brake application or spongy pedal action. Bleed the hydraulic system after it has been properly connected to be sure that all air is expelled from the brake cylinders and lines. The hydraulic system can be bled ..lanually or with pressure bleeding equipment However, pressure bleeding equipment ts preferred Manual Bleeding 1. Till the brake master cylinder with brake fluid. 2 Position a -1b inch box wrench on the wheel bleeder fitting Install a bleed tube on the fitting Submerge the end of the bleeder tube in a clean glass jar partially filled with fluid. Start at the right rear brake bleed fitting 3 Open the bleeder valve approximately Vi turn 4 Depress the brjkc ped.il slow Is and close the bleeder valve, then, allow the pedal to return to the normal position Repeat this pumping action until all evidencc ol air buboies has ceased, and the fluid enter ing the glass jar is clear During this bleeding process, the master cylinder reservoir must be kept at least half full of brake fluid. 5 Repeat the bl.vJing pr*svd..fv . ..si. wr.ee1 cylinder Proceed from me ieft rear to tne ngr.t front, to the left front 6 When the bleeding operation is complete, check the fluid level in the master cylinder Fill to within Vi inch from the lop of the reservoir Pressure Bleeding 1 Connect the pressure bleeder tank to the master cylinder, replacing the master cylinder cap with the special adapter cap. Too! 21fl2 2 Open the valve in the pressure tank supply line Start at the right rear brake bleed fitting 3. Position a inch box end wrench on the wheel bleeder fitting in.siui. m. o.eed tune on tne fining Submerge the end of the bleeder tube in a clean glass jar partially filled with fluid 4 Open the wheel cylinder bleeder valve approximately Vi turn 5 Allow the hydraulic fluid to bleed into a glass jar until all air bubbles have disappeared and the fluid is clear 6. Close the bleeder valve. 7 Repeat the procedures at each wheel cylinder, pro ceeding to left rear, right front, then left from 8 When the bleeding is complete, check the fluid level in the master cylinder reservoir. Fill to within Vi inch from the top of the reservoir ADJUSTMENTS PARKING BRAKE Check the parking brake cables when the brakes are fully released If the cables are loose, adjust them as follows: J. Fully release the parking brake pedal 2. Raise the car. 3. L oosen the parking brake cable at the equalizer lever 4 Depress the parking brake pedal R5 inches from its normal released position 5. Adjust the cable until a slight drag is felt when turn ing the rear wheels 6 Tighten the locknut on the equalizer rod 7 Release the parking brake and check to make sure that the brake shoes return to the fully released posi tion 8 Depress the parking brake pedal two inches Under normal conditions, this will satisfactorily hold the vehicle SERVICE BRAKE The hydraulic service brakes are self-adjusting and require a manual adjustment only after the brake shoes have been relined, replaced, or when the length of the adjusting screw has been changed while performing some other service operation The brake drums should be at normal room tempera ture when adjusting the brake shoes li the shoes arc ad justed when the drums arc hot and expanded, the shoes may drag when the drums are cool and contracted After adiusting. cheek the parking brake adjusimen; 8003 0570 PRODUCED BY FORD tiHAKE SYSTEM 2-15 ncr'K to restore c funenvy and periortnance that has been io^t due to went, corrosion, deterioration. or maladjust ment* It is seldom advisable to attempt an improvement in brake performance by correction of one or two items only During normal brake operation, changes in various component parts take otnee gradually, thereby reducing their cfhcicncv below recommended specifications. Last ing brake efhcicncv and nerfornijnce is assured by fol lowing definite and thorough testing, inspection and, repair procedures The following "Brake System Service Check List" items should be reviewed prior to. during, and after servicing of the brake system. This will insure that all repair work has been performed correctly and completely, thus reducing service complaints upon com pletion cf a specific rcpc.r operation. Brake System Disassembly 1. In order to avoid damage to wheel bearing grease seals, always remove the front wheels from the drums before the drums arc removed from the spindle. The spindle should be wiped free of grease. Dam aged seals can allow some of the wheel bearing grease to escape onto the brake drum, resulting in brake pull and grab. 2. Check the condition of the brake shoes, retracting springs, and drum for signs of overheating. If the shoes have a slight blue coloring, indicating over heating. replacement of the retracting and hold down springs is strongly recommended. Overheated springs lose their pull and could cause the new lining to wear prematurely, if they arc not replaced. 3 If the car has 24,000 or more miles of operation on the brake linings or signs of overheating are present when rclimng brakes, the wheel cylinders should be disassembled and inspected for wear and entrance of dirt into the cylinder. The cylinder cups should be replaced, thus avoiding future problems Brake Shoe or Lining Replacement 1 Factory lined shoes give better results than shoe linings rivet mounted at the dealership. However, if rivet relincd shoes arc to be used, be sure all the rivets are secure. Do not "turn down" the linings of factory lined shoes. The lining radius is ground to specification at the factory and should not be changed. 2 Lining replacements (primary and secondary) should always be made in axle sets to prevent brake pull. Oversize linings should always be used when the drums have been ` turned" oversize. Broke Drums 1 Brake drums should be "turned" only if the braking surface h.is been d imaged o: if the out-of-round ipJic.iiion cueeils 0 inch Use care in handling drums. Dropping a drum on an edge can pro duce an ou!-of-round condition. There is no real advantage t' t ihi-v vi - ata -orv. . drum if the brake sjriace is wiihin sp^c.r.c.-.ions and is not dam aged, or in; out-of-round indication does not exceed 0 007 inch 2. If the drums do require 'Turnm/. do not exceed a drum diameier of 11 122 inch Always turn both front or both rear drums to the same diameter if any one drum requires turning. Make sure the surface of the drums is good. Assembly of Brakes 1. When installing the brake shoe.- always piacc the parts on the aner.or pin in the following order. (Refer to Figure 2-19 ). First - Brake shoes Second -- Shoe guide plate Third - Acustcr cable eye. with the crimped side toward the backing plate Fourth - Secondary shot retracting spring. Fifth -- Primary shoe retracting spring Failure to place the parts on the anchor pin in the above order can result in incorrect operation of the self-adjuster due to interference of the adjuster cable with the secondary shoe retracting spring. 2. The front wheel brake shoe retracting springs arc 114 lb springs and are colored red The rear brake shoe retracting springs are "7.1 lb springs and are colored purple He sure the springs arc in the correct location to avoid unequal braking. 3. High temperature lubricant COA7-19584-A, or a flake graphite lubricant should be applied sparingly to the backing plate ledges at the points of shoe contact This permits the shoes to move easily. 4 Lock lubricant, with flake graphite added, should be used to lubricate the adjuster screw. The thrust washer should also be lubricated with this mixture 5. Test the self-adjuster action by pulling the cable (between the cable guide and the adjusting lever) toward the secondary shoe web far enough to lift the liner past a tooth on the adiusting screw wheel The lever should snap into position behind the next tooth Release of the cabie should cause the ad juster spring to return the lever to its original posi tion which will turn the adiusting screw one tooth of a revolution). * 6 To adjust the brakes after installing the shoes, a Install the drum, then, remove the adjusting hole cover from the backing plate, b Turn the adjusting screw- upward from the back ing plate side to expand the shoes Use Adjust ment Tool 201S-A Expand the shoes until a slight drag is felt during drum rotation c Remove the drum, and while holding the ad justing lever off the ad'usting screw, back off the adjusting screw 3j of a turn CAUTION. Failure to use tnt abo\e adjustment pro cedure con domain' the oa'nis'im; siren resiiliini; in selj-adjiisu r problems;. 8003 0571 PRODUCED BY FORD