Document V39GGGRLwweZx4VQzN4BgB704
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V.V 1 rp | . vf
srs maintenance
9-9
^ C5 brake drum and brake assembly repair
front brake drum
REMOVAL and installation
rimovai
j. Knur the car so that the wheel
isilr-'r of ihi floor. Remote the hub cap. "neel.
.m.l hearing dust cap. Remote the roue' pm. nut. and washer
j. pull the brake drum approxini.iu-K two inches forward and push n.icrl. into position Remove the wheel
and withdraw the brake
drum If the brake drum will not come
of insert a narrow screw driver through the brake adjusting hole in the earner plate, and disengjpe the adiuvung lever from the adjusting screw \\ hile thus holding the adluvtinc lever away from the adjust ing screw, back of! the adiustine screw with the brake adjusting tool (Fig 51. Back ofl the adjustment only if the drum cannot be removed. Be vcr> careful not to burr, chip, or damage the notches in the adjusting sriew; otherwise, the self adjusting mechanism will not function prop erly.
INSTALLATION
1. Remove the protective coating from a new drum uah carburetor decreaser
2. Make sure that the grease in the hub is clean and adequate
3. Place the brake drum over the spindle and into position With the smaller diameter of the wheel bear ing pointed inward, place the bear ing over the spindle and push into position, followed by the washer and retaining nut
4. Adjust the wheel bearing
REAR brake drum
removal and installation
RtMOVAl
J- Raise the car so that the wheel I'* of int* floor
* Remove the hub cjp and wjiccl Renos o the three T innernia" nu'.s no remove the brake drum
_ll the brake drum will not come t>". invert a narrow screwdriver in-oi'gh the brake adjusting hou* in m. c i-ricr plate unJ Jisenj.g.* tnc 'viii'vtinj icve: tront the .ovv.ing
W r,',e thus bolding me ad"`viT'.' lever awav from the adjust-
v.tew. nack ofl the adjusting
Adjustment
screw with the brake adjusting tool (Fig. 5). Back off the adjustment only if the drum cannot be removed. Be vtrj careful not to burr, chip, or damage the notches in the adjusting screw; otherwise, the self adjusting mechanism will not function prop erly.
INSTALLATION
1. Remove the protective coaling from a new drum with carburetor degrcascr.
2. Place the drum over the brake assembly and into position Install the three Tmnerman nuts and tighten securely.
3. Install the wheel
BRAKE DRUM REFINISHING
Minor scores on a brake drum can be removed with a fine emery cloth. A drum that is excessively scored or shows a total indicator runout of over 007 inch should be turned down Remove only enough stock to eliminate the scores and true up the drum The refinished diameter must not exceed .060 inch oversize
If the drum diameter is less than .030 inch oversize after rcnnishtng. standard linings may be installed. If the drum diameter is between .030 inch and 060 inch oversize, shimmed linings or oversize linings must be installed
After a drum is turned down, wipe the Tcfimshed surface with a cloth soaked in elejn denatured alcohol If one drum is turned down, the op posite drum on the same a\lc should also be cut down to the some size.
BRAKE SHOE AND ADJUSTING SCREW REMOVAL AND INSTALLATION
REMOVAL 1. With the wheel and drum re
moved. install a clamp over the ends of the brake cylinder as shown in Ftg. 6
2. Contract the shoes as follows: a. Disengage the adjusting lever from the adjusting screw by pulling backward on the adjusting lever (Part 9-1, Fig )) b. Move the outboard side of the adjusting screw upward and back off the pisot nut as far as it will go 3. Pull 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 (he hole. 4. Remove the automatic adjuster spring and adjusting lever (Part 9-1, Fig 1) 5. Remove the secondary shoe to anchor spring with the tool shown in Fig 6 Wuh the same tool, remove the primary shoe to anchor spring and unhook the cable anchor 6. Remove the anchor pin plate 7. Remove the cable guide from the secondary shoe (Part 9-1. Fig 1) ' 8. Remove the shoe hold-down springs, shoes, adjusting screw, pivot nut and socket 9. On rear brakes, remove the parking brake link and spring Dis connect the parking brake cable from the parking brake lever 10. After removing the rear brake pnmarv shoe, disassemble the park ing brake lever from the shoe by remov ing the retaining dip and spring washer (Pari 9-1, Fig 1>
FIG, 6--Rctrocting Spring Removal
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8003 0574
nt-m
PRODUCED BY FORD
SCF-FORD-0303
9-10 GROUP 9-BRAKES
CKANING AND INSPICTION
1. Wash all ihe pans except the brake shoes in a cleaning fluid and dry with compressed air.
2. Brush all dust from the earner plates and interior of the brake drums.
3. Inspect the brake shoes for ex cessive lining wear or shoe damage. If the lining is worn to within laa inch of the rivet heads or if the shoes arc damaged, they must be re placed. Replace any lining that has been oil saturated. Replace lining in axle sets. Prior to replacement of lining, the drum diameter should be checked to determine if oversize or shimmed linings must be installed.
4. Inspect all other brake parts and replace any that are worn or damaged.
5. Inspect the brake drums and. if necessary, rcftmsh as outlined in this section
INSTAUATION
1. Before installing the rear brake shoes, assemble the parking brake lever to the secondary shoe and se cure with the spring washer and re taining clip.
2. Apply a light coating of hightemperature grease at the points where the brake shoes contact the carrier plate
3. Position the brake shoes on the earner plate, and install the hold down spring pins, springs, and cups On the rear brake, install the parking brake link and spring Connect the parking brake cable to the parking brake lever (Part 9-1, Fig 1)
4. Install the anchor pin plate on the anchor pin Place the cable anchor over the anchor pin with the crimped side toward the carrier plate
5. Install the primary shoe to anchor spring with the tool snown in F ig 7
FIG. 7--Rclrntling Spring
6. Install the cable guide on the secondary shoe web with the flanged hole fitted into the hole in the secondary shoe web Thread the cable around the cable guide groove (Pan 9-1. Fig. 1)
It is imperative that the cable be positioned in this groove and not be tween the guide and the shoe web.
7. Install the secondary shoe to anchor spring (Fig. 7).
Be certain that the cable end is not cocked or binding on the anchor pin when installed. All parts should be flat on the anchor pin. Remove the brake cylinder clamp.
8. Apply high-temperature giease to the threads and the socket end of the adjusting screw 1 urn the ad justing screw into the adjusting pivot nut to the limit of the threads and then back ofl '4 turn.
Interchanging the brake shoe ad justing screw assemblies from one side of the car to the other would cause the brake shoes to retract rather than expand each time the automatic adjusting mechanism operated To prevent installation on the wrong side of the car, the socket end of the adjusting screw is stamped w-iih an R or L (Fig 8) The adjusting pivot nuts can be distinguished by the number of lines machined around the body of the nut. Two lines indi cate a right hand nut, one line indi cates a left hand nut.
9. Place the adjusting socket on the screw and install this assembly between the shoe ends with the ad justing screw nearest the secondary shoe.
10. Hook the cable hook into the hole in the adjusting lever from the backing plate side The adjusting levers are stamped with an R or L to indicate their installation on a right or leu hand brake assembly (F-ig SI
FiQ. 8--Adjusting Strew ond levir
ider.i'.i'ui.on
11. Position ihe hooked c-o
the adjuster spring into the i^ree < :n the prinurv shoe vveb. jrJ
r.ect the loop end oi tne vrnr. -0
the adjuster lever hole
''
12. Pull the adjuster lever. ca-;e
and automatic adiuster spring celn and toward ihe rear lo engage --f
pivot hook in the large hole In -"f
secondary shoe web (Part 9-1 f 2 ll '
13. After installation, eheo, -etion of the adjuster by pull na
-ection of the cable between cable guide and the jdiustine ie.e-
:oward the secondary shoe web ;_r enough to lift the lever past a tec a an the adjusting screw wheel y-.e
ever should snap into posit-on -en;nd the next looth. and release
the cable should cause the aeiur.espring to return rhe lever -o -s
original position This return act an ot the Icycr will turn the ad:us -g screw one tooth
If pulling the cable does not p-> Jucc the action described or ii :-e
lever action is sluggish instead o; positive and sharp, check the po sition of the lever on the adiust.r.g screw-toothed wheel XX'nh the bra.e :n a vertical position (anchor at tne
topi, the lever should contact the acusting wheel 'i.. inch rplus or mm.-
--c inch) above the centerline ot re screw' If the contact point is cc.c this centerline, the lever will not levts
on the teeth in the adjusung screw wheel, and the screw will not c-e
turned as the lever is actuated bv tr.e Cjble
To determine the cause ot :r > condition
a. Check the cable end niunj`
Ine cable should completely HI or extend slightlv beyond the cr.mrec
section of the fittings If it does not
meet this specification, possible ua~ -
:;e is ind'eated and it>e rjM;
r,v should be replaced
b. Check the cable lengtn T.-.e
cable should measure 11 h I'C-et us or minus 1 *S- tnent t:~"' ' end ol the cable anchor to tne on.' the cable hook
c. Check the cable guide tor uar-ae The cable groove s.nomd be r.
ai lo the shoe c~ ana tr.e
.; the giikie shoun1 !". t .rjr` "t web Repl.i.e Ha a:-.- ` -OU s damage
d. Check the pvoi hxv " " '
a' lie h.Vk >, . - .
^ < tlx"
i'K*
v.*.-
f pi^Onrj in * i* xk*
8003 057* PRODUCED BY FORD
PART 9-2-r-\t SYSTEM
IE:,`.'-CE
v -i i
lever if f hook shows
t. s- ihat the adjusting screw .-I." " proper!) sealed m the notch inih. shoe web.
adjustment
-j,. h'draulic service brakes sire v! '.,!"ii%unp and require a manual /.u.-tmont only after the brake
... m- been rcltncd. replaced, or t:.- ihe length of the adjusting ,,..rew has been changed while per-
some other service oper, V*
1. After the shoes have been in stalled or the adjusting screw has m.- turned, install the drum We Mire thai all excess grease, oil. and o.he: lorcipn material are wiped ofi the carrier plate and drum
Retort installing the brake drum on the front wheel spindle, wipe the spinJIe completely free of grease In stall the urum carefully so that the grease sol retainers within the hub will not be damaged.
2. Remove the adjusting hole cov er from the earner plate and. front tne earner plaie side, turn the adtuvttnc screw upward to expand the shoes (Fig 9) Fxpand the shoes un til a slight drag is felt when the drum is rotated.
3. Remove the drum. While hold ing the adjusting lever out of en gagement with the adjusting screw, back oft the adjusting screw 3/a of a turn with the fingers If finger move ment will not turn the screw, free it up otherwise, the self adjusting lever w ill not turn the screw. Lubricate the screw with oil and coat with wheel bejring grease
FIG. 9-Exponding Broke Shoes
Anv other adjustment p-nruluri may cause damage tn the ndlusting screw with consequent self adjuster problems.
4. Apply a small quantity of hightemperoture gtcase to the points where the shoes contact the carrier plate, being careful not to get the lubricant on the linings Install the wheel and drum.
5. Install the adjusting hole cover on the brake earner plate.
6. When adjusting the rear brake shoes, check the parking brake cables for proper adjustment Make sure that the equalizer lever operates freely.
7. After the brake shoes have been properly adjusted, check the operation of the brakes.
BRAKE SHOE REllNiNG
Brake linings that are worn to within Vis inch of the rivet or have been saturated with grease or oil should be replaced Failure to re place worn linings will result in a scored drum. When it is necessary to replace linings, they must also be re placed on the wheel on tiic opposite side of the car.
Inspect brake shoes for distortion, cracks, or looseness If this condition exists, the shoe should be discarded. I)o not repair a defective brake shoe.
1. Wash the brake shoes thor oughly in a clean solvent Remove all burrs or rough spots from the shoes
2. Cheek the inside diameier of the brake drum. If the drum is less than 030 inch oversize, standard lining may be installed. If the diam eter exceeds .030 inch, oversized or shimmed lining should be in stalled
3. Position the new lining on the shoe Starting in the center, insert and secure the rivets, working alter nately towards each end Install all parts supplied in the kit Ford re placement linings are ground and no further grinding is required when the original drum diameter is main tained.
4. Cheek the clearance between the shoe and lining The lining must se.it tighilv against the vhoc with not
more than 0 005-inch clearance be
tween any two rivets.
BRAKE CYLINDER
REPLACEMENT
REMOVAL
1. With the wheel tn a raised po sition. remove the wheel and the drum
2. Pljcc a clamp over the ends of the brake cvhndcr as shown in Fig 6
3. Remove the brake shoe assem blies. following procedures outlined in this section
4. Disconnect the brake line from the brake cvhndcr To disconnect the hose at a front cvhndcr. loosen the pipe fitting that connects the oppo site end of the hose to the brake tube at a bracket on the frame Remove the horseshoe-tv pe retaining clip from the hose and bracket, dis engage the hose from the bracket, then unscrew the entire hose assem bly from the front brake cylinder.
At a rear cylinder, unscrew the pipe fitting that connects the tube to the cvhndcr Be sure the engine is stopped and there is no vacuum in the booster system before discon necting the hydraulic lines.
5. Remove the brake cylinder re taining bolts and lock washers and remove the cylinder Remove the clamp from the cylinder
INSTALLATION
1. Insert the cylinder into the opening on the carrier plate and in stall the retaining bolts and lockwashers Install a front wheel cylin der with the inlet toward the rear of the car
2. On a front cylinder, install a new copper gasket over the hose fit ting Screw the hose assemblv into the cylinder. Engage the opposite end of the hose to the bracket on the frame, install the horseshoe-type re taining clip, and connect the brake tube to the hose with the pipe fitting nut T ightcn the nut with Milbjr tool 1112-144 until the tool `clicks" at 12 ft lbs
On a rear cylinder, connect the tube to the cylinder by tightening the pipe fitting nut to the cylinder. Tighten the nut with Milhar tool 1112-144 until the tool 'clicks" at 12 ft lbs
3. Install the links in the ends of the brake cylinder, install tbs vhoc and adjuster assemblies jnd adjusl the shoes as outlined in this section
PRODUCED BY FORD
y-i/ GROUP 9-BRAKES
FRONT MAXI CYLINDER
shaft into the hoiis.nc so t^jj splines engage ihe d t'crcntial s
gear with the hearing ..ner -he. onto the retaining bc.t* -no .gjj
Ihe carrier pljte Install the retain' nuts through the access hole :n i axle shaft flange
BOOT
CUP
REAR BRAKE CYLINDER
Position a new front carrier nl
to the wheel spindle and install (
retaining bolts and nuts
2. Install the brake snoe ar.d a
eoor
juster assemblies and the bra^ c inder as outlined in this section l
a rear brake conneci the carki brake cable to the lever
3. Conneci the brake l.ne to t brake wheel cv tinder Ten
the wheel and brake drum
PISION FIG. 10--front ond Reor Broke Cylinders
PISTON
HI152.A
4. Install the brake drum and wheel and bleed the brakes as out lined in this section
BRAKE CYLINDER OVERHAUL
It is not necessary to remove the brake cylinder from the carrier plate to disassemble, inspect, or hone and overhaul Removal is necessary only when the cylinder is damaged or scored beyond repair
DISASSEMBLY
1. Remove the links and the rub ber boots from the ends of the brake cylinder. Remove the pistons, cups, and return spring from the cylinder bore (Fie 10).
2. Remove the bleeder screw from the cylinder.
INSPECTION
1. Wa-n all pans in e'ean de natured cicchci and dr a :h com pressed air
2. Check all internal pans for ex cessive wear or damage If anv of the infernal parts require replacing, all
should be replaced.
3. Inspect ihe cylinder bore for
score mars-s or rust If either condi tion is present, the cv liruier bote musi be honed However, the cylin der should not he honed mure Ilian .003 inch beyond itv original diam
eter.
-t. Che.\ :1'; Meed'." >ure;\ il .yen
ve be
ASSEMBLY
1. Apply a coating of heaw-dutv brake fluid to all internal parts
2. Thread the bleeder screw into the cylinder and tighten securely
3. Insert the return spring, cups, and pistons into their respective po sitions in the cylinder bore (F ig 10) Place a boot over each end of the cylinder.
BRAKE CARRIER PLATE REPLACEMENT
REMOVAL
1. Remove the wheel and brake drum Disconnect the brake line from the brake cylinder.
2. Remove the brake shoe and adjuster assemblies and the brake cylinder as outlined in this section On the rear wheels, disconnect the parking brake lever from the cable
3. If the rear carrier plate is being replaced, rotate the axle shaft so I*'?' the hole in the axle shall flange lines up with the carrier plate retaining nuts and remove the nuts Pull the axle shaft assembly out of the hoik ing with tool 423.5N and a slide hammer (Part 6-1, Fig 3), then re move the carrier plate
If the front carrier plate is being replaced, remove the holts and nuts that secure the plate to the iron; wheel spindle anil remove the pl-ite
INSTALLATION
1. Position a new rear :a:ner
p! u* on the rvumi"g bolts .r. :uc
iv!e ions ng 'tinge I-sert
as'.*
4. Adjust the brake shoes ai bleed the brake system as outlined this section
HYDRAULIC SYSTEM BLEEDINi
When any part of the hydraul system has been disconnected fc repair or replacement, air may gi into the lines and cause spongv tied action Bleed the hvdraulic svstei after it has been properlv connectc to be sure that all air is expelled ttor ihe brake cylinders and lines
The hydraulic system can be ole manually or with pressure bleedin equipment
MANUAL BLEEDING
Bleed the longest lines first Kect the master cylinder reservoir fillci with new heavy-dutv brake fluid dur ing the bleeding operation
Never use brake fluid which ha1 been drained from (he hydraulic sys tem.
1. Attach a rubber dram tunc tc the bleeder screw at the brake cvlrndcr that is tocaied ihe lamest trom
' *Mer c u-J.*.- The end of the tube Should lit snugly around the bleeder screw.
2. Submerge the tree e*o o; the ij-e in a container p. ` - M cc with clean brjke fluid, i.u ..vvc-r :r-" bleeder screw
3. Push the brake pedal down vlowlv by hand, allowing it to re -m vio v I' to the lull.-rcie i-eu ro-.- on Rape il 'hiv oper.i.cii in ..." *- ' Mev ce ixe to Jppo if it .' ."ie'r-" end O! ihe tube
4. 'A hen ihe . e\i v - """ - !:..c air ru'vx , ve ' . ' ' --
1 6003 0577
PRODUCED BY FORD