Document gaVgkKbGG4r2w8Q3YqL6O4ooJ

Inter Office Ford Pam and Service Division Wt H, 1975 Mr, H, B. Lick Central. Medical Services Bldg. Boom 210 Rouge Plant cc Mr. S, Keoleian Mr. R. L, Peaker As discussed during our recent phone conversation, ve here reviewed the contents of our current service mmrnalg for mention of cautions regarding brake repair. We are not currently providing a procedure for raaoval of dust from the brake drums or brake 1 f.ni ng area. I hare noted on the attached copies of our shop manual, the locations that should Include a caution regarding asbestos particles. If you will, provide some suggested copy for a caution, ve vill Insert it in the next printing. We vill also incorporate this caution in all future texts, such as training urnmn-lq and video tapes, that pertain to the areas where asbestos dust may be considered harmful. Attachments 105479 007894 PRODUCED BY FORD I X-V I-U nyoruum. jeivue* U-01 1Z REMOVAL AND INSTALLATION brake drum removal and INSTALLATION THROUGH 1000 SERIES * U'c tin Fi4h*wmg mn pnKedurc* for b*uh huiuulu amj air hr.ikrv iuu*c Ibr I 1M0 ......... .. 1 HO I Hin c iMi rear drums Mroni' iii ihe I**W1 4tX) (front and rtjif jiul ihr 4-whvcl drive Jfiini brake dtum frH riiuits apply to hyjrnuhi hrikiK mil}, iht> tire enteral in Pan 12 \)2 FRONT BRAKE DRUM 1 Raise the vihnli mini iht lire Hears llit flour and nrmwe the wheel and tire frorr the huh Loosen the brake vhnt adjuMmp s*w& tinTiI rhr sUms no lunger tniish ihe brake drum Rrniovir the gu ate sup anti Ihc jtjskut lit equipped) from ihi hub 2 C^n vehn lev uilh 4 000 through T+flTlCl lb ,ntd 1ft [TOO 20 000 111 from Jules, rrmnu ihc vivner pm, ariiiiMinp nut ami flat *j%tur Imiti the spindle On m Indus tMLit * oesn, 11 mn nr 1 |h axlr^ remove the lock nm, tiimpkd washer locking ring, nod aiioistm^ nui *iml pin assembly 3 Remote tin. outer hearing ciw and toller .issimhly PuH the huh and drum assembly oft lhe wheel spindle 4 Hemove the Inmi w Ut d*tn-hub retaining nuts fur rim and nr? atlaiJnng mow Remove Iht wheel (or nm and lire1) from ihc huh and drum 3 Ri move the brake drum retainers and attaching holts, screws, or holts and JiUjs 6 Remove the brake drum from the huh 7 Cheek the drum for damage or wear, and repair nr replace d necessary If a neu. drum will he installed he sure In remove lhe protective coating wnh deg reaver tmiafl new greiwif rnatner senls whenrTt r a wheel ami hub is remom d. H PI i,i (h> brake ihtriii Ui ih> Im* itnJ iiimiII 1 III MJinus aini r tuning h*ll> wkws in Kills t-eiii null ^ Insult ihi huh amt drum mi tin wheel sptn/Jlr Keep the hub ft mprrd art )he spindle Tti prevent rfam/igc to the crtise retainer or the spindle threads JO On vehicles mtb 4,000 thnmfch 7,(100 fh ami 1H.ODO lb. frtirtt avlis. instill fhrouiii hcarmfc. com anilrolhr jnd liu. fTal UiOkhct on the spnnfti IrMai! the adjusting nut On >ehieU*s with 0.01)11 11,000 nr lS.Ofil) Ih front axles install flic iMttr-i hmriMC s'Uu nnl roller jss^mhlv mil tin biannc. idpisring nut amt pm awnihU 11 lioi ill the wheil amJ rifi ,m iln hub T hen install the d unps lit applicable) ,nuf (hi. whirl si ltd thus 32 VMub ntiiMng ihi whsfij mrqut rhe* idpiMing mit to spt tifu ai inn AJuist wheel bearings as drswnhcd i Oroup 11 !1 liisnll the dimpled washir with iht ihmpie imlracd in nm if the hH,*s m i Itit ail ] us ling nul Instill flit h*k mr jtid iiirque In sperificaiton Hind the dimpled washer m.t a ftji uf ths Iis k nul 14 tnsmtl fhc gasket (if equipped) and the gTiusc tap, end nnque ilu* whuH stud nuis in spectfuAtum Install ihe hub tap Of eqinppedl and adiusi the hrako as described m Una Pari REAR BRAKE DRUM E2S0-E350, F250-F350, P350-P400 1 Raise iht vehicle and insult safety stands. 2 Remove ih shul and iue as an jvsrmhlv I m>>, fin brake shne adruMinf s^i vv nno| ihr siir>rs ui longer Imu li 11 h *ki iltiim 1 Ki.ni'Oi iIn rl i* r\l ihd1 ret iimng mils oilaptj rs avis slalL, Jiul gre se jJ 4 Kmiovr (Ik wIhl! Fm ttmg loiknit, U\k w.ishrr, and nt|iv|ing rtui On 1 vchu lr*s rrmovp 'he liskim. wi Jj. iiv.1 adMivimg nut *i K< move tin. huh and drum from 'he avie h Ken*"*'1 il*i bi,i11 drum-fo-h ih utjinini s.nws KMi. <f boll* aid uuiv Klihovl ilu Inakr ijium fn m lire huh " t 1 . k thi itr* rn f,n ihnng< or we if, an>1upmiM pla Hititimsary 1>h nm m u Imu b1 iL iliums in -) hraki ig Mir I t-i. dim* i*i i: 11 Hi i than me frr.itffrmnr r flwiivf? tin f'te drum Jf i m,'1 il*nm will be mvljll d. rerrnm rhs prolsklivc uialtng w th k grr '* r 1 n\*nM re" mi1**! rpfmner sells whenever n wlrrrl nmf Imh ivremov si V Pi*Miion ili. iki, dnmi to ilu. 1 uh and imm ill 11k ill u him. n tews, bo is, rT K'll^ and miiv 4 Piisiiinn lilt, hub o*d drum as an asM*mMv .in tin. a\k and Star! the JiljuMinr mil 10 AdivM ihi wlvl heinng nut, and mvutl tlii, who.1 bt^inng lock wa.shcl and lo* k nut J) In>uJ] j nr* uaJ ml seal, a vie shafl and gasket, siud adapters, and auaihing nuiv 12 lnsiall ihe wHcl! and tire as it) assembly H Ad iiivi thi brake sluice Rrmnve ihe safe1> stands ami lower ihc vehicle OVERHAUL XA f BRAKE DRUM RE FINISHING ' EIQOE^aO. F1U0F3S0. P350- ^00, U10G ' 1 Minor srnrr^ on a hrakf drum can he rrm.ivrd *ilh jim inury ciolh prmidol the rnrn is thomuphl) drai.nl oil tin.' drum jfu' ths xpciatnui A hadls scored, rough, or nui-of-mumi drum should he ground at turniil on 3 drum Ini he Do not remove an) more ttiatcnnl from (he drum (hart ii neif*tar7 In prrmdc a emnoih surface for (he brakr shoe cnnlact hrjlte drum maximum braking surface diameter u shown on eaih hrake drum (lip (Ul Hr air ilnims. ,1m li Cisrisl lliriiuaimutii HraLiuf: surtnLr dmmetcr slioan mi the brake dTum rillirr thiough *ra; nr rrlinishinp, must be repiaird The mnannum braking surfuse liiainrirr s|irurteaMOft, which is shown on rich hrjko itniin (Fig Id. alhtws lor a fllbiO mrh mm hitting out over the origins) nominal drum diameter plus Otl'O imh addiiuinal wear before reaching the dnim-ducard dumeter FIG 18 broke 0o,rn Maaimum Inside Braking Surface Diameter Marking Location 007895 PRODUCED BY FORD 12-01-13 G*nrraJ Hydraulic Brake Service 12 01-13 FlG )9 Broke Drum Minimum Rroktriq Surface Ciormrler Marking location--Typical Medium --Heavy Truck Shown F On jII vehicle^ ^Hfl anil up ^erus hens IrmAs the niasimum braking surij*c ilianii ict spci, ilu* limn, whivli is shown rm u.jt buke drum, allows for 0 inch imji laitiin|* ui over Die miuinal mintuuil ij'um JumtLcr plus 0 ijlfMnrh addu mtj il wsji before the iliurn musr lv riphted After rcfimshing Lhe. brake suffice runout musi not exued 0 fi"0 me >i tui.il nuiu acl>f reading. meaMituI Irorn the hc<mii? mp U ^rKT and up Vm*- ham trucks tf ih<. drum dmmriej o Um Jh*in OtHOuuli nvrrsivi Uiir nfurshinp,. install strnvLiiJ Iminps nti tin hi At* assemblies If thL ihameur is river 0 uW nn.h* msull nvrrsuc or shimmed liftings BRAKF SHOE AND BAND REUNING 1 Kmintc the rivets holding the old Uiunq and ruruui the lining 2 Clean tin. slow tir band thnruuphly unh cleaning riunl espanlh ilu nm surfai i ^Aipr *l.c. k. or h,uiJ drs and ri Miivu ;ift bin v or louph spoi. ftotn the livx [)n not uu* shoe* with rintiftnied met hole* 3 On u rvit " In iLi i h^* l, the inside ihamtin ut ilu hr.dt, drum 4 Position .i rim hump < i. Hi** sho oi band Irjsj,]l) nrw me s K*gim mp with the rivet holes iilmi thi amcr nf the *hoe On smm, vehicles, th< primary lining is shorter than the secondary lining Tf iftis u*ndiiiflii r*nls position Ibr* shmicr | prim irs | lining tti Inn unh ihi luH md ol ihe shoe 1>o not let brake fluid, nil. or prase touch the brake lining If a brake lining kit is nted in replace the vnm lining, follow the instructions in the kit And install til tbr parti provided 5 Chet k rhe Uoiranvc hiruren rhe Itmrik mil shiv rim Ihe lining muM wji sm,lk aK.imO the itin with mu more ihan ftMFH-uiih "fpiruion hrtvvieii ins luo rivets H mils ihe linmi v nr r phn ed on dim sri\o mjh Huh ii hi.ikrs wult til. I ouh> i p.nv.ihpht ikr liT<'tgs tn i*i 1* urn ground Pfttli mth 'ii ihe '_u|v 111.*t ihi killings ,i- iisiti I n> ilu biAr shin FRONT DISC BRAKES . I KiUio\i Jh sliov and luitr-qv ^ ih*s* nl> d m I' n l 1J 3*1 1, Mt.i.ur- the thitkw~o of ihe hukc linmv, If ihe Immii ihuknvs* a' ,im p*i ` on ilii .issindds is lo' th m n ^|0 nil.L jnm, th< ija^kni). f I m o* riviis or if the lmu(! slw*ws om- in. ill hr ikr Inrnl nr i'll voni llltlh <i* *n tlm * i Mining ibrakv pull ill inur shoe ind lining ussinihhis T Oiivk jlip<; In sprnilh mi Imp Silt Idfqlll il 2^1 'Mj 1 3'i'l 'Mj llmst i \ ^ j lnrijm tlusn m sprt ifk iiion il tu|uired 4 ]otIkik iiU'f fuiiout First cliriim Hi ilu w In 11 end pin*. Is iiphlinmp Ilu adjusiiu^. nut 1 lien ifin k to hcsuti the rotor an miu K ml ikd 5 ( lamp a dul tnihvaior to thi spmdl sn lie sislus mntavls the riiior jpp mini.lids I iiKh !rfnn ihr mm r pilpe Kntali. the rotor and lake m imluiun rradm^! H thi. n Hliug CXi .C(ls ft Uhl-iLh iota! Uii r 11 runon i wnhin 3 \u inch rashusno i hi* inch aitir repijicor rpsurf ill ihw rli . h r >i k r r n I n r The fnllnwinu roqtiirrmefits must hf mi t when re^urfaemu ditr brake rnr\ l si K n t u ii il a Dim Jl r j v i` UUniislime Lithe, Tool HU Uuli SI in refimsh lln disc hraki r>*urs i nllnst ihe* * icp*l*y slip rmurta; mg msiriutMh`1 lh,ii vniw* mlh lln tool So mnrt film 0 030 m< Ii ol maiirul nw> nut Jm*illyiialh oil crji.li viirfue 1% md It I ig -('l U rmur llmkiu\s tails bilusx tbe AW OMJ'S O", I (nil im i ' * ntinimum ihnwn on each rotor, 11 mini tit repLud 1 he finished braking ^urfires of the roinr mu*! be Hat and parallil within H'til *nih laieral ninoui musi not e',cfd titiflt.j^h Kua) inriicainr ri irIm^ jnd itu surfjie Finish of ihu hr kmc ^uriaies must he 1ft tn 80 n i so iru ht*s ^ tin ilu runout eheek is finished* ftdjmi rbi h irtttttt as described in I'an ll-UJ.to prevent hrsr-nR failure* <p * lu,.k tIf rnur lor mump Rcmcne muuir * sre* with a Fine emcrv ilnih I1 ltii roii-f is fXii**M>c|v scntfd is.iim.| j| a* nuiitncd in Step 5 or n*pi,u t tne mlnr if nciev*3r> 7 f 1j>* k the t-aliprr If n is rtacked or shows gm signs of leakage rcpIaLeil Jf rhe vahpef is leaking around the iluvi Nvit, r-muve ami repair it X C Jiei k nr tike hospv Im sipns rr iti king kaks nr abrasion Replace tin m if iixi^sar> BRAKE CYLINDER 1 l ban all brake cvhud* f pari* m clan isoprops l aLohol f n*pt \ i ait puns for uia* isr danuiTL t hnk rlu* (.vhndtf h*n 1 u rusi s.iirt* oi jiibei damage 1U sine ihi N.Ldir ssrew passage Li i Iran and open Kepl.ut all pans that in worn m CdruvsiJ 2 If chri is fouriJ in ans p.ol of the hydratihs system, flush ihe enlire sssieni wiih clean iviprnp)l akoliol MASTER CYLINDER l {'lean all master ishnder parts in t-ii m tsopropsl aUohul. and mspett iln piris lor utar or it imaec Hrplate th-rn if required NNhcn a '-ifliter rs Under rrpuir kit is used, follow the instructions tn ihv kit and inslali ail n( the parts provided 1 M ike suk that .ill pom and vents m tin m.isii* l sluulcr arc ojko and free ot fnrvipji m ii ier 1 On a sm^li brake sssirm mssicr ssluuUi thesk tht spring salve tmiud to iht from end iWihe puionl I ' l| ^li'.r l'f .'4| tv ) tl I V. illMIMH OV4 OA IHH I 1A irm.li i.. tx t-VV**"' S 'SV"v'SsrSsS^VKSvMi **l'*- 't ?0 wn h JSU '____ ^- . ^ // ^ J ' f IM IJ50 l Q FIG 20 Due Brake Rotor Service Umitt 007896 PRODUCED BY FORD 12-02-9 Drum Brakes--Single Cylinder, Dual Piston 13-03.9 screw 'DMfie l he hole in ejpand the brakes shoes until thev drag against the hrake drum and lock the drum FIG 11 Becking Off Brake Adjunmeni*--F 100-250, E 100-150. with Rear Drum Brakes laxnen the adjusting screw until i slight drag is nuied (Ktg 1 0 3 When Ihr shows arc against ihr drum, loosen lhe adjusting screw an FIG 13 Expanding Brake f>hocs--F 250 350, E 750 350 Rear, end P 350 AQO triditinnal tO to 12 nntrhrs so lhat the drum rni.ues freely withmil dtag IF the drum does not ratsle Freely. rrmo*n ihr w heel and drum, and blow mil ini dust and dirt From thr finings Using sand paper, rrmnvr any nisi from the points w here ihr shoes touch ihe hacLmg place Applv a light mating of high temperature grease (ClA/.-I9JW B| Do not get the lubricant on the linings 4 Install Ihe wheel and drum, and adiusi the shoes Install the adjusttng hole cover on the hrakr hacking plate 5 Check and adjust the other three hrakc assemblies 6 Apply thr brakes. IF the pedal travels more than halfway tn the flocu there is too mstch clearance between the brake shoes and tlir drums Rrpcat Sleps 2 and ' above 7 Win n al) hrakr shoes have been properly adjusted, lower the vehicle stnl road Itsi to theik brake i prraimn 1'erlnrnt the road test only when the brakes will apply and the vehicle can be wFels stopped REMOVAL AND INSTALLATION BRAKE DRUMS Front Braktj Drum--P-350-400 F-ria* /Femora/ .1 K use llu vehicle unit! the tire clears the llonr 2 Kmto'c thr wherl enver or hub Lap and wh-cl bearing dust rap Remove the emtet pm. nut lock, nut, and washer 3 Pull ihe brake drum approximately two tnt hes forward, then push it bask into position Remose the wheel bcanng Jiir) pull ulT the btake drum If the htjk c drum will tint come off. insert a narrow s^rewtlnser through rhi bial r ,|J lusting holt in (he earner plait* and ihstng.ige ihr sdiusiu.g lever front ihr ad just mg strew 'Mule holding ill.- iiljitsting lrv< r from the adpistiiip siitw loosen (he adluviing screw with the brake adjusting looI (Tig 111 truism the adjusting screw uniy if the drum runnel he removed Da nut hurr chip, nr damapt the natrhei in the adjusting screw or the self adjusting ntcilmnum will not fiinetinn pruprrlt If Ihe adjusting screw was loos, nrd, rheek to be lure the adjusting lever is still property icalrrt in the shoe web ItuiHilunan I II ihr hub and drum assemhls will he repjatrd, remove the protective coating from a new drum with cjthutitur dcgrciser Install new hearings and a new grease retainer I'jik the whrcl hearing install the inner hearing cone and roller assembh tn ihe inner cup, and install Ihe new grrise retainer us ilrstnhed in Pan 11-10 If ihe original drum will be installed, be sure the grease tn the hub ts clean and adequate . 2 Install the drum assembly, miter wheel bcanng. washer, and adjusting nm as desenbed in Part 11-10 3 Adjust the wheel hearing, install the nut lock and stiller pin. and grease Up 4 Install the wheel and huh cap If thr adjustment mrev was Inosencd atlpist the brake as described m this Part REAR DRAKE DRUM--F-100, F-250 [UP TO 4900 G.V.W.), E-100-150 AND U-100 /femora/ 1 Raise the ' clusle so the wheel is clear nf jhe floor 2 Rrmovr the huh cap and whpcl and lire asLrmhlv Krmovc the three reuinmg nuts and remuse the brake drum If the brake drum will nttt come ulT timer a nnrrnw verewdrver through the brake adjusting hole in the hacking plate and disengage ihe adtusting teser frnm the adjusting strew While holding thi idjusting lever away from the adjusting wrc loosen ihe adjusurg srrew with the hrukL adjusting tuol iFtg ID Loosen the adjusting screw only if rhe drum eannat be retnoyed Do not burr, ch'p. nr damage the notches in Ihe adjuring screw nr the self adjusting mechanism will not function properly. If Ihe adjusting serrw was loosened, check tn be sure the mljusting lever is still properly seated in the shoe web Jafiiiihtion 1 Krmovc the protective coaling from i new drum with carburetor tlrpicavrr 2 Adjust the brakes as described in this 1`nit s Install the drum 4 luvt.ill thr brake drum retaining nuts and t jtluen securely install Ihe wltesl on the axle shalt ilanpe studs against Ihe drum anil torque ihe retaining nuts nr specification REAR DRAKE DRUM--F-7SQ (ABOVE 4900 G V W.) 350, E-250-E-35Q, P-350, MQ0 /femora/ l Raise Ihe vehule and install safety stands 007897 PRODUCED BY FORD 12-02-8 Drum Brake}--Single Cylinder, Dual Fulon \ 5s r /wi\ ' i -/ \ \ ! r\'\ i , FIG 10 E ICO E-35C Srnltci SyJlem 007898 PRODUCED BY FORD I2-T1-3 Drum Brakes--Dual Cylinder!, Dual Pistons n-oc-3 REMOVAL AND INSTALLATION rRrA!'E SHOES AND ADJUSTING SCREW P-500 Sana*--Rear Remord 1 Raise Ihe i chicle until the urea clear the floor Remove the wheel end lire assembly, and remove the drum or hub and drum asiemblj Mark the hub and df-m to aid assembly is the same pusiltnn. 2 Clamp the brake cylinder boot! against the ends of the cylinder and remove the brake shoe retracting springs using Tool 201J-N (Tig 5) 3 Remove (hr brake shite guide bolt toner pm, nut. washer, and boll from both shoes, and remove the shoe* from the backing plate 4 Remove the slump-type adjusting wheel Irak from the anchor pin support and unthread the adjusting srrrw and wheel assembly from the anchor pin support. IostaJlattan l Uubneatr all points where brake shoes contact oilier buke assembly parts with high temperatute grease IC1A2 I93TO-U) 2. Thread the adjusting srrew and wheel assembly into the anchor pin support and install the damp type adjusting wheel link Thread the adjusting wheel into the support so the brake shoe rests a gam*! the ad lusting wheel end 3 Place the brake shoe against the hacking plate insett the ends w the brake cylinder links, and install the shot jtuirir holt washer and nut (Fig 4) Finger tighten thr nut, then loosen it one lull turn and insult the colter pm 4 install rhe retracting springs using Tool IQJ5 N (Fig, 5) 3 Remove the cyftntier clamps, install the drum or the huh and drum assembls, and install the wheel assembly Align Ihe marks on Ihe hub end drum for proper installation. 6 Adjust the brakes, and lower the vehicle 600-900 SERIES--REAR--WAGNER Remont t Raise the vehicle umtl the tires clear the flcHir Remove the wheel, and tirr assembly and Ihe drum or huh and drum assembly It may be nesronrv to loosen the adjusting wheels slightly to free Ihe grooved drums Go not loosen (he adjustment so much that adjusting wheel jams against Ihe friction ring on the adjuster screw or damage to the ring mas result Mark the bob and drum to aid assembly In the same position. Re sure there is no vacuum in the system before disconnecting the bydrmd'r !' s t.spell vacuum In the system ty pr|*i''s rtusro on bnke pedal with (he ndne 1T 2 Unhook the atitnm'.tis adjuster springs (1 tg 2) Rrim sr fish long adjuster link by pooling Vs.I the adjusting wheel crv-'Vs until ihcir slot* align with Ihe link luvt-s lift out the link* and shde the hooks from the anchor pin cranks Frnmve the short links by rotating rlie "ichor cranks until tt>e link huokv clear the eccentrics on the sh<" <schs Then remove the smaller hook* from the cranks. 3 Spread llte anchor crank <. -washers and remove the sinni* {it is usually unnecessary In remove th udlusnng wheel cranks) U shm - will b< m lined, remove adjuster res nit ni-s hem the shoe webs bi unscrewing thetr jclftapptng screws 4 Remove the shor rm ..den spnnps by sliding the I. roped ends * 1! the pm* Remove the shoe hold-down Sock wires, castellated nu's and plain washers, and lift the shoes oft the backing plate 3 Unthread the adiusiing -ircw and adjusting wheel front nib of the anchor supports. Insitltttron I Insert the adjusting wtoets in the anchor support 'lois and lined in rhe adjuster icre*s from the sh - side, with the fncnrm nnc end loi ird t/ie shoe For new linings, loosen adjusters, but do not I-"-in them far enough to jam the adjusting wheels FIG 4 1 o Cylinder Broke--B ftor--P-5Q0 FIG Retracting Soring Replacement--Ty pitaI 007899 PRODUCED BY FORD L H C ASStMttl T FIG 2 Two-Cylinder Brake Shoe [Wogneri--Rear FIG, 3 Hydraulic Broke Aiembly [Kley-HoyMl 007900 PRODUCED BY FORD 12-08-9 Drum Brakes--Dual Cylinders, Duo! Pistons 12-08-9 C-Senas RcmartI 1 Remove the brake pedal retracting spring (Figs b and tl) 2 Remove (he brakr masier eslrnder push rod 'k entnc boll nut, bolt, und nylon hnshingv 1 Remove ihc brake jiedal bumper-ttibracket retaining nut Remove the halt and bumper 4 On modtls ssiih a single hydrautn, brake system, remove ihe master cvlinder push rod hi pulling up the lab on the push rod h.u, and pulling I he push rod and bunt Irnm the cylinder J Remove the nut from Ihe bolt, tilde the boll to the nghi and remove the brake pedal assembly, sleeve and hushing , 6 Remove the bushings from the pedal assembly hulullttinn 1 Cnat all hush mgs and t he pedal shaft ilh a small amount of 1 uhnplale nr an equivalent lubnrant Position the nylon bushings in Ihe brake pedal shaft bore 2 Position ihe brake pedal assemhlv slertc, anil lnishirit m ihe prilil support hrail'l slide [hr Kilt t" the lor and install the out 1 mque thr nu. It' spot rficai ion J On models tih ,i single hsdiaulie brake system, nistvll the push rod and hosU tit ill- m isiet Lslmil-r 4 On models with a sinek hv.lrjulu. hrake sssiem insi.ill the pedal hnniper holt hnrnpir and nut Tighten the nut sssurels 5 Install the ns Ion hiishui|is in thi push rod horn and install tin pus)' nul cnmtrtc bolt and nur b Install thi prtla! retr.-suing ,p>ing 7 On models ssith a single htdraulis brake system adiust thr hr.ike |sda1 fri i travel to it in to < msh Torque 1 hi eseenlrii hull nui to spcitfitjlinn i>EDo arrur-isti BBL1 'M Htau-b HG 11 Single Mmler Lyhnder and Brake Pedul installation--C Senes OVERHAUL BRAKE WHEEL CYLINDER DtfavrrmWi l With the sshcr! cylinder removed, remove the rubber hoots from the ends of the hrake lylmdir Rrmtne the pisions. cups, and piston mum spnng from the cylinder (Fig 12) C vt'NDl r .< n * ny-ON MASTER CYLINDER Single Qrako System Disxkiembli 1 Remove thi master cylinder Clean the outside of the masiu tslinder, and riniosc tin. tiller Cjp and j'usku I'our out tins hr,lit fluid left in ihi cylinder sod resinrm On C-Serirs vehicles, llig !'> rctnuve the balks that hold tin ft -- ` i -*,i islinder tvsis nil ihi ns imir and rimosr thi , > I u Puss dovn on thi piston to g,impress (In mum spring and remove the 'imp nrr Hrmove the piston, prim in tup pision filler, return spring, chet k sals; and check salvr seat (In vehtrlrs with frame nnunlrd vacuum broLi lu<ustcr the ehrrk valve is installed in IF- boulter insu.nl of in Use mailer cylinder I PI T 1 III I MIS y. AAj_, ptiioH unit, i i,r ^vir eooi E iHssin n s - v mots b FIG 12 Double Servo Broket Cylinder 2 Remove the bleeder screw from (he cylinder Axirmbl) 1 Coat ill hiake cylinder parts with clean citra heavv dun brakr fluid ' tbA.7-1`1'4' * 2 Instill thr hlredcr it rev (I ig 12 V in the brake cs Linder J riaee Ihe piston return spring cups, and pistons in the cylinder hare and install * boot and link over esth rnd of the erlinder CUmp the brase rylitulrr pistons against thr ends of the cylmdrr When using brake cylinder repair kit folio* the Instructions in the kit and install ail of the parts provided. ,-i Hu-- l er t a SKI MKl - FIG 13 C Saties Brake Mailer Cylinder--Diianembled H11IU 007901 PRODUCED BY FORD 2. Courted the brake hydraulic system line* In the diFTrrnntial waive assembly fid tiplnrn thr* tube mils so urel) 3 tnrmn.t the shell wire ermiieunr tn llm hr at * warning Umip^wUth Make * aujt the ploillr Ihk^ n thr runnertor hold the eotmeeuif arsurHy In ihc witch 4 Bleed the brakes and rmtrahrc the pressure differential valve as de-tnhrd in thrs firt BRAKE PEDAL ASSEMBLY L, LN . and LT Sane* RcmorMf 1 Remove theslop light switch from the pedal bracket 1. Remove the hmke master cylinder push icxi bolt nut and nylon hushing 3 Remove the nut from the praial shaft Slide ltic abaft tr the lelt/and remove the brake pci Lai and sleeve 4 Remove ihc bushings from I he pedaL Jn&LillattPir I Cnar ail bushings and the pedal shaft vwitii a small amount of Luhnplute or in equivalent lubricant 2. Position the nylon bushings tn the hr ile pedal 'haft bora 3 Position the brake jicdal assrmhly and sires* in the p^djl support bratkri Slide the pedal shaft through I lie sIlivc and ped *1 ami M.ure with the nut Torqm the mil lit spt-ufkanon 4 position the nvlim bushings m the bore nf ihc push rod Council the push rod in the hrAc ptdal with the bolt nnsJ run 5 Adjust the hnirc pnial fire iravrl to VI ft m l/fl-inch 1 nrqur the ecrentns holt nut to sp^rthr alum t Install the >Uip light swiIlIi in Ihe peiUl Lrurlit as for m i* possible Pull the pi did ti> in (italic-1 return position lo pmpeilv icscl the stoplight switch P-500 Senea Remorai 1 itp^n the fronl cover and discount t the tianvnusM ui jrt'*',shilt rwis fmm the shift levers J\isih<m the intis so maximum working spue i- available at the pedal sup]xm hr n Let 2 Rctnnvt the pedal pad* from the dutch and brake pedal if tg 10) 3 Remove ihe screws i hat hold the floor covers at ihe steering column and remove the covers t/nlauh The engine sOver assemhlw and open 4 Rimnve ihe floor pljl retaining screws Remi>ve ihr aculemior pedal from tlu acLtrUntnr liiikige and remove the floor plait 5 Hiscnnuri,t the iluich and brake pedal retmcimg springs 6 loosen the pednf support brisket damp bolt Kmim*, die mircr pins and rlrsis pms from the dnuh md brake pedals 7 Turn ih^ front whet Is .ill the w,i\ to the left TTuimgii the left front frndcr Jipr in, rrmovi llje loiknif pin fmm the clutch pedal and ramose tin* pedal Bush the peJ.il shaft lm* ini the centerline of the nJmlr l nm inside the cab, slide (lie pedal shaft M FIG '0 Sroke Pednl and Related Parts--P-500 and clutch pr'lul levci tiwlirnght tnd nil nf the stippnH bucket Remove the hrakr pedal ftom Hi* Sup| nrt htaikci ftrmmc the biHnnps ftiim ih^ p*iial and the pedal support h:a in 1 (\u; ad hushing and the pnlnt shaft with ,i small smoinii of lubrirint I S \ MFC TmB or ryui\fl[-TTi Im'til now hushmgs m j**d*J suppem hmikit amt the h^kc jv<h! 2 Position the hr ike pedal in the support bmihet and duJ^ rhe pedal shall and dutch twiht lever thfough the bracket mil p< InL 3 Thrmigh the left fouo fcmJrT apron, install the rluidi imIH on the si aft and secure ft wiili a new cnlier p*n 4 Pi^sitton ihc climb 'od on 1 h Uu^ch pedal lcsrr, install Mir cl-vis pm und sei un* ii with i nrw cotter pm 4 Position ih* hid* ni'ster tybrnlcr push revhn Ihr rr ik t*eiUl inmall'he drvo pm, and scluic it with a new uu,r pm b Insi ill the clutch and brake pedal KirArnng springs 7 ii h il-* hi iU i^dal iRnr*si the stop, **1 |usi die Viki win mi i%lui<Tpr push nvj in rise 0 ft? h* 0 2 * inch Ire*" play measured *t snort hire nf prd.il pad hv Inft push n il t nnlJH t.S pistrm |lininf tin Jims pm iniin Mu push rod md inrii 1 iir rod until ihc siirtnud firr irtiwi] is nbtaimd 7 u him thr i4i*i mu and msull ckn* pm liter ad|UMmuu B Series Rettwvfff 1 Krnisfthi stop lirEu sssiuh frnm the jwcilal hi jkl cl 11 o M 2 Rcm'>wi the rn.m,ii r bp master iWhnJcr push mil *vnl hu^hmg 3 Rrmosf Mu* i lip fion I h- portal thnft Slidt the shift to tin. kit and renu ve the hnkc pisl.il Hfiiit'u* Mu biiwlun^s Iron* Ihe pedal IltttMiljttHUI 1 f oai iH hushing* mil the I'fdnl shaft with a -null aruoimt id Luhaplalc or no u,im ilcni hibiunm 2 Insijll rhr nvlon huMiings in the Hrjk* f> iml di ift Nu 1 T'usm, n In t^nki i mI il *ls cmhly in ltu Mippoil Ui ktt ^liUr the pcsJul sh''i ihrom 11 ihc p^ilal and seem* stub the rrfuioi'v Hip 4 r.feitio'i ihc nvlnn hu-hmv in the bnre of the push nxl in ivnnblc Mic broke pedal wuh the rlcs pu1 3 InsLall the sinphrhi win h in ihc pedal hmrkrt a% Inr >n as possible Pull the pedal io us furthest return posthon to properly reset the stoplight switch 007902 PRODUCED by ford l?-09-1 Drum Brake*--Duel Cylinders, Single Piston (Wagner) 12-09-1 PART 12-09 Drum Drakes -- Dual Cylinders, Single Piston (Wagner) Applies To GOO Thru 9Q0 Senes Trucks COMPONENT INDEX Page i I COMPONENT INDEX BRAhfc BACKING *'L ATE Removal and lusinll.itinn BRAKE DRUMS Rt ntui'iil and liistJluime SHAKE MASTER CYLINDER Removal and fnst.ill, ;ujii Disassembly and Assembly Inspection and Repair , . , (j'J 2 _ no 1 , . 'j fl'i 3 ji' 0'! l, j I uo 5 ( l.R.M E SHUI't R'`Tt ' ll inrl lilll, i'hIi t(, IJIU1 c v.HbEL CYLINDER r iniwpl and Hstjlta'.i n H Msr"tTt|)w and Assumli.v. # LVturiLATlQNS Pace ! 09-1 j (JtJ1 ] j ' 11 u n*n5 1J ) 03 9 ! ADJUSTMENTS BRAKE SHOE ADJUSTMENT Adjust tht brake shnes when the brake drum* are ji normal room teuiperatute IT lbs shoes are adjusted when the dmtm are hot and expanded, they ma> dtajt as the drums ctxil and coni rati Brake adiustmcnt re csiahlishm the ticakt- hnirip M'*drum cUarjiiLC and compensatri for nnnnal lining wear hollow ihe adjustment procedures below SELF ADJUSTING BRAKES--SOO'500 SERIES Manually adjust i*n-e)lituier front brakes using the hcx*h$ad ^clMnckmg i.am jd)u<tm Subsctjucni .id niMmciit is automatic I nr tninunl adiuslment 1 Raise ihe \rht.lc and ihcik (hr front brain for drag h\ totsting the u heels 2 Adjust one shoe hs mutiny the wheel forward *htlc tummg the cam hei- htad fnrwvd Tapanri the shoe unit) a Ithi fr ig is fi |i i*n the druni Do not appJs furtr an Ihr he*- head earn, nr the autnmattc adjuster pans mtij be (itmnirctt. I nosen the adjimmeni until the wheel turns intis Adjust the other cam m the samr manner ^ Ad|usi the orher front wheel brake using ihr proerdure above 4 Appls the htakes and recheck the adjustment REMOVAL AND INSTALLATION y 'tRAKE DRUMS THROUGH 900 2. Remove both brake shoe retracting SERIES Pernor*! ind [nitaJiMtinn Service pro1 edures fur these models ire described in 1*311 12-01 springs (Tig h 3 Rcroovi the C-washers a-nd flat washers Trom the hold-down studs Lift the shoes ofT the harking pkitc it, To remote the adjuster assembly BRAKE SHOPS AND ADJUSTING MECHANISM 600-900 Serial from the shot, unhook the vu-djte sprint; frnm the wedge and the coil spring from the shoe web Work the coil spring cnT the levet ptvrti pm and Jlcinont l Ruse the vehicle until the tires dear Ihe floor Remove the wheel and lire aJssemhlj Remove the ditim or the hub and drum assemhl) Mirk the hub ind drum to aid assembly In the slide Jhe sprint: honk from the plug Sever pm Pull l hr .id just er lever fiotit the hack of the shoe and remove the plug, wedge washer, wedge, and wedge guide insrslUtion some posttinn 1 To install the adjuster assembly, fspell all vacuum in the sysiem position the wedge guide with us pm before disconnecting the hydraulic in the hole provided in the brake shoe lines Pspell sicuum in the system by Place the wedge guide on Ihe side of pit> King down on brake pedal when the brake shoe larthcst awaj frum the engine is o(T earner plate. Position the wedge on the shoe web with us serrated edge resting against the serrations on the wedge guide 2. Insen ihc dnim contact plug so us head is tlirouph the hole in the brake shoe and lining and us shank rests over the wedge anil wedge guide 1 he plug must be installed from the inside of the brake shoe J From the opposite sidr or the shoe install the shoe aduivtment lever, guiding the pm min thr mating hole of the comas t plug Install the washer over the wedee mi ihe lever pivot pm A Position Ihr U-hook uf Ihe adjuster torsion spring an the plug Irver ptn Attach one end of the wedge spring lti the hook, and install the coded pnrtton of the inninn spring over the lever pivot ptn Install the outer end of the toriinu ipnng over the edge of the shoe web 007903 PRODUCED BY FORD 17-00-17 Drum Brafc^--Ducal Cylinders, Dual Putorw 12-08-12 tb f rnnpfs rise tfinnp so>! mctatl llif iem,utiiii imp nur tud spill waslicf til, til. pi*h*t) Si up li*l 17 Muir the pjsuvi siiip ml initi the w^nrtfiary piMnn ami the siwp ruu if* prt*.: 1* Mvlr tin. eml fnp .mil [wvttm as< nibls uUn ih ifumct i\li Ifi lmn .muI 4 h h ili rniJ >|* ml** |l* maMir r>Jmdcr body TnfL|uc ihc .ip to 15 Kt 20 ft Ih |V Install washers on thr tri nn*T\ and pU^? ill** ru j frTi m thr TTH'vmi.np hnlrs ul [Hr km iuni 20 Pln-r the rubN r wathci' aiu) 1> nmti tn Oir rt'litiiM fs 21 Install lIu rc'-t'v nr u<*d i"t.nneT tsutnhlv i*i` I he nu'i r^l'inJ* i*t anil torque th< retainers to 15 10 20 U !h 2J J{pp* u tr (Hr and check. valves m i Hi" rmil.i pHiru uf thu cylinder 2' Kfpfrui, ifr rrirtjt s and secondary j>ir i *f* mil n'cqur tn l' to 20 fl-lb 74 I i\i t.l Dip nnniririnji senl tw thr ft ito *if fNr rtintJif t slimier liitutl the iiU'1 .jp iml pjskn SPECIFICATIONS SPTcn it Tbnnut i'*in . * 1 * * * -ji n TORQUE UIMTS - HYDRAULIC 7Uf 1UTJ IfT LU' hill u '- n . t i i 'T* ' *r BfUftl DRUM RtMtA LIMHJ lllUlt LtTH[- ^4* - ' * -- I *j -*I * t *Mii - I - i %. *4.* - '*** I I'mjlli'i". % + Tm4 Sii flLhi *> _! jty K 007904 PRODUCED BY FORD