wheel FORD CAPRI 1974 Owner's Guide

) Chapter 9 Braking system 145
/ll.Iid reservoir tille , cap \0 help roduce any fluid loss. 4 Where a rigi d brake line is connec ted \0 the calipe r, comple tely unscrOw the union nUl . Where Iho flex ible hose is connected directly \0 Ihe caliper. loosen only .he union (lnd unscrew Ihc caliper f.om Ihe
hose later. S Prise back the laus on the locking plale and unscrew Ihe mouming boilS (photo). The cJliper may now be wit hdrawn ove r th o disc and where neCessary unscrew ed from Ihc flex ible hose, 6 Refilling is a revCfsal of fernOv;!I, but lit a new locking plate and
l ighten the mouming bol ts \0 the specified torque. Bend the Inbs \0 Io<:k I he boils. On comple tion bleed the hydwulic system wit h
reference \ 0 Sec tion 15.
5 Front brake caliper -ovorlulU l
1 With the c~liper removed . cle~n away all external dlr1. 2 Where applicable, prise out the dust cover cirClips <Jou wleilse the
dust covers from the external ~onular groove. : lIr"ct the pistons: keeping them idenhlied side lor s.de. If nt .... "ss"ry. use low [lir P"CSSlU(! frOill a foot pump to lorc e the pistons
IrOIl' lho bores. 4 nove tho dust covers Irom the pistons or bores as apphc<Jblo. 5 Prise tho pisto n seillinU rings from tho hores tnkino Cilre not to scratch the bore suri<Jce. 6 It is impOrliln1 liw i tho twO h<Jlves olthe caliper are not separated under any circumstanr:es . If hydr.1ulic lIuid lenks ,l,e evident from tho join!. the ca liper must be ronewed complete. Thoroughly wash all p.1,t5 in methylated spi ri ts. or c lean hydraulic lIuid. DUling reassemhly. new rubbe .. seals must be lilted. These should bo weiliubricilted. wrth clean
hydrau lic Uuid . Inspect the piSlons and bores for signs 01 weilr . score markS. or damage and il evident. new par ts should be obtained !Cady for lilting. or a new ca lipe r obtained. 7 R eassem ble tho components using a reversal of th n disnwn tling procedure. but before inserting the pis tons dip them in clen n hydrnulic fluid to assist entry through the seals. On comple tion press the pistons fully into the bores.
45 Front brake caliper mounting bolts (arrowed)
6 Front brake discs -in spection. re rnovnl and refitting
Apply the hilndlxake then jn ck up the hom of the car and support on :1xle st:1flds. Remove the Iront roadwheels . 2 Rotate the disc by hand and examine il lor deep scoring, grooving or cf1lcks. light scoring is normal, but if excessive the disc must be
renewed.
3 SCrJpe <Jway any loose rus t fro m the oute r edge of the disc, lhen mensu.e the disc thickrless using a micrometer or cnlipe rs. If less lhan the minimum specified thiCkness rhe disc mUSI be renewed.
RUEO '.(RlW
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4IOUf llltlGOOLI tCCKltlG PLATE
R( 1 Altl{R RltlG
BRAKE (VLIHOER PISTO'l
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Fig. 9.3 EKp loded view of the front brake calipe( on fater models (Sec 5)
RING
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procarmanuals.com

Chapter 9 Braking system
4 Note that in order to m,lintOIll even braking both discs should he renewed ill the sal1 1 e lime
5 T o remove il dl~c. first remove the tHlb as described in Chllpter 10 . 6 Prise lip th(J locklllU I"hs. unscrew the fOlll bolts. and remove the disc from Ihe huh.
7 Clcilll the Illllirnu !ilces of the disc and hub then locale the diSC on the huh and allgel the holt holes.
8 InScrt new holt~. tOI){)ther w rth new locking plates. and tiuhten them to the specrfre(1 torque_ loc k b y bending the tabs. 9 Th e huh Illily now he ref Illed with reference to Chapter 10.
7 ReM hrake shoes -rt)rlewal
Check the front wheels th!:n lilck up the rem of the CM lind support on ,1~le stands. Rel(,a5e Ihe handbr,lke lind femove the reM roadwh~~els
2 Unsr",w th" I"ake drum lewinrnu scrow then t.1p off the ,IIurn \Jsing ;I ~&#34;It f.lced milliet (photos) 3 Barsh away all dust I.orll the brilke shoos, backplate ilnd drum, ",killfl can' ""I /0 11111""., II ;I S 1/ is iHjmiaus to "e,11Ih Del&#34;&#34;~~ ,,;och shoe hold-down sprrng (photo) ,lnt! rOt,lte the sprrn!! ",w"nIlH w.r~I&#34;&#34; th,ou!lh 90" , to rhsengage ,t from the pm sel:rr",d 10 Ihe had' pt. 'I" 1.,11 ,"wily 1Ill! w;'shel and spm}!J
Early moth'ls (iippmxilllawly pm Df!c()tllbcf 1974) 5 Eas,) .. ad} shoe loom ,t~ loc;rllol1 slor III the lixed pivot nrrd tllen detach th,-othe! &#39;~nd 01 ea(.11 shoe f,om the wheel cylind'lr, 6 Note whld, W.1Y fOwul and IIltO which holus in the s hoes tlH~ two retracting sP""Hs Ill. 7 lift ,lway t ho two brake shoes "nd retracting springs. 8 TUf(lthe self- ad lust'ng ratchot wheetum,1 it alJuts the shoulder on t he s lot head bolt.
FiO_ 9.4 Renr brake shoo components Oil e,lrly moclnfs (Sec 7 )
I Pili 'm froft! dowII sWIIIII 2 Buc/."liTlt! J B&#39;,l~&#39;l! shot's <1 II,-IIIrflHiiAe opcra/jllY h-v", 5 lIo/d d"wII slNil/ys
Lawf lII oduls
6 fir"",,:, (/",,1 r:lJvlH 7 IId;III1I1'!IIII.llr!S 8 flNr;Il:IIl'!! .,'I,"IIIIS 9 WI",,:II:yllJldl!l
fJ N Ole the local,on of the shoe 1"lpacl,no sprrll!ls nrld thell unllook tlwm \lSUl!l a s(;lewrh,vef or SUil;!tJle plo~&#34;s. Remuv,) th" lorw,lrd shoe Unhuok tho small pelurn spring loom the reill shoe and then rumuve the shoe lenvinlJ the adJus!Cr in pos,tiol} (ph o tos)_ 10 Tu remove tim adjuster unit. del<J~h the hllluH)p,lke cahte or pod <It the clevis (Jlmer side of backpl.1ll)) <lnd withdp,lW the adJl,stef
'nech<lnism (photos)
7.2A Re<lr t,r<lko shoes With (IrUIll removed (eilr ly models) 7.2B Rear brake shoes with drum removed (Iatc! models) 7.4 Brake shoe hold down sprinO
cylinder (later models) 7.98 Brake shoe attachment to anchor ( later models) 7.10 Halldbr~ ke tra nsverse rod connection to opera ting lever on backp!ilte (Jrlowed)
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Chapter 9 Braking system 147
Br;'lke IlIlInU
Wheel Adjustment
"m
cylinder --·-·_.L
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• shoe hold down spring/pin
Br.lke shoe
Fig. 9
.5 Rear brake shoe components on later m odels (Sec 7)
All models 11 Check the wheel cylinder lor leaks and lor Ioee moyemen t of the
piston(s). Apply a hule brake urease to Ihe shoe contac t points on the
backpla te. wheel cylinde r, anchOr and sell-adjusting mechanism. On
early models check th<lt the wheel cylinder is free \0 moye up <lnd down in the backplate <lnd "pply <l hule brake grease to the sliding Surfaces .
12 Fit the new brilke shoes using a reyers .. 1 01 the remoyal procedure,
but check that the self-.. djusting mechanism is set to the minimum
posi tion belore refilling the drum .
13 Finilily apply lhe loo tbrake firmly several times. On later models this will actua1e the self-adjus ting mechanism; however. on e<lrly models, re le<lse the footbr<lko then <lpply the hondbrake seyerill times until the ra tche t is heard to s top turning.
'
Wheel cylinder _ remo yal. oyerhaul and re fitting
Remove lhe rear urake shoes as described in Section 7.
2 Fit a hose clalllp to the fle~ible hose leading to the reaf br .. kes. If a hose ci<lmp is not <lyail<lble, tig hten a piece 01 polythene sheet beneath the Iluid reseryoi r hiler cap to help reduce any lIuid loss. 3 Unscrew the union nut(s) connecting the rigid b rake line(s) to the re<lr 01 the wheel cylinde r.
4 On pre Oecembe r 1974 models remoye the split pin and clevis pin Irom the handb rake leyer <lnd pull 011 the rubber dUSI cover. Pull oul the two U·shaped plates and withdraw the wheel cylinder. NOle that
the spr ing plate is inser ted from the piston end 01 the wheel cylinder.
5 On I.ller models unbolt the wheel cylinde r from the backplate .
6 To dismantle thO wheel cylinder, remoye the clip where fitted then
prise the rubber boo t(s) from the cylinder body.
7 Extr.lct the piston( s) <lnd separa te the rubber boot(s)
8 Remoye the piston return spring .
9 Prise the seal(s) from the piston(s) , 10 Clean all thO compo nents in methylated spirits or clean hydraulic fluid then inspec t them for wea r and damage. Check the cylinder bote and piston{s) 10f scoring and corrosion. and il eviden t renew the
complete w heol cylinder. If the components are in good condition
ob tain a repair kit 01 seals.
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procarmanuals.com

)8 Chapter 9 Braking system
8
Fig. 9 .6 Rear wheel cylinder component s on "",I y models (Sec 8)
I Cft,} 2 Rubber hoot 3 Pis/oil
5 Relmll SfJflflY 6 Blcell screw 9 Scff ",',uSilll!! wtdll.:/ 10 At/jlls/my boof
4 Seal I Retaming JlI,~tcs II Ullfufb,;,Ac oj/cUlling level 8 Wheel cyhirdcr body
11 Dip the piSlOn(s) and plSlOn SC<lr(s) in hydrauhc flUId then reassemble the wheel cylinder In rcversc orde . to d,srnanthn\J. Not(! Iha the seal lip must lace into the cyhnder
12 Rein the wheel cyhnder using il f(lversal of Ihe fcmOy.1. procedure. Note lhal on (l,lIly models t he sel l.,ldrusI1I19 .atchet is handed -RH thread on the RH side. and Lit thread on thc LH SIde. 13 On cOlllpletion bleed the hydraulic syslCHll ;'IS described in Section 15.
9 ROilr backl}lato -rClllovn! (IIHI mfittillg
Remove th ... wheel cylllllier ~s <Iescllhed in Section 8. 2 Remove the ~KleslHlit (h~lfsll.1II). wllh reh,rel1ce 10 Ch,lpler 8. Ihen pll the h.1ckpl,11C.
Thoroughly cle,ln the b~ckpl.1te ~nd Jxll) casing Ihen relit the h .. 1ckplJte with reference to ChJpter 8 Jnd Section 8 01 this CIl.1pler.
Fig. 9.7 Re .. r whoel cylinder components on lilter models (Sec 8)
1 Rubber boots 2 Se'lls 3 PiS/OilS 4 Re/vm spring
5 Wheel cylinder body 6 Bleed screw 7 OVSI cover
1 0 MJsle r cylinder -rcmov;11 Jnd refitting
P lace a ~wllcIH&#39;hJe COI11~lIler benem h Ihe mJ$le f cylinde r 10 cmch ,1ny spIlled Ihud ... Mil also place ~on,e cloth on Ihe surrounding hodywork ;lml componems 2 Disco"nect Ihe wirinlJ lrom the low tluid winni,,!) sw,tch on the ,evelvoir 1,lh.1I r:ap (photo).
3 UIlSI:f(lW lill) reservoir 1011111 cap and dr"w out the flui(1 using J syphon or sucl'o" l(,be <1 Unsocw ("u un'on Illl(S IOnd rlist:onncct Ihe b,ake lines. 5 Unscrew lOud r emove (ill) nlolUwng nulS and washers Jnd lilt the mnster cyl",du' hom Ihe Siuds Oil Ih e servo lmll. G Empty llin tlu,d 11010 llie con l,urlcr Jnd remove the master cylinder
from Ihe enU",e comp(lrtmeni. Io1k,ng cllre nOI 10 spill Iluid on the bodywolk. 7 HeliuinU 's II ,eve'slIl of removJI. but on completion bleed the hydraulic syslem IIS (Iescribed In Section 15.
10.2 Disconne cting the low lIuid warning switch wiring
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)
Chapter 9 Braking system
,,-
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: ~~ 11111JIII/IIIJ II /I /III Ii hIIllllIlIlIllllIlll 11111#111111 III! -------
8
9
Fig. 9.11 Exploded view o f Iho pressure d ifferenti<ll switch (Sec 12)
I Fron( /)',l/a.' inlet ullioll 2 W ,)Silms 3 Pj~(UflS
J Pressure reducing vulve -description. remalln' nnd refitting
<1 SCi/Is 5 W,If/ll//y $wl(ch (j [lid ilIIIY
All models from ~pproxirniltely 1978 me lilted with il pressure ,educing valve in the rC~f hydraulic Cifelli!. The IInlve is IOCillCd on the lower Icft- hJrHJ side of the engine compn((mcnt (phOIO) ,mel 11 effectively limIts the hrakin\1 force DV<J,lilblc \0 the Ie ... wheels dUring hCilvy bri'Jking to prevent reM wheel locking, 2 Checking of the vnlvc requires the use of a pressure IJ<luge and .. therefore, Ihis work should be Cilrricd out by il Ford U~r~Ue. 3 To remove the valve, first tightell a piece of polythene sheellnu bene;]1h the brake fluid reservoir fdler c~p to reduce the loss of fluid.
4 Unscrew the twO union nuts then disconnect ~nd pluU the pipes .
5 Unscrew the mounting bolts ,md remove the unit.
6 Refitting is a reversal of removal, but on completion bleed the
hydraulic system as descrihed in Section 15.
1 4
Hydraulic pipes and hoses -removal and refittin g
7 8.1/1 8 Body 9 R(lb/w( cover
First wke meilsures to reduce the loss 01 hydraulic fluid. If ~ rig id
pipe downstream of a fle~ible hose is being removed fit ~ hose clamp to
the hose . If this is not possible tighten a piece 01 polythene sheetinu
beneath th e livid reservoi r filler cap. 13
.1
Rear brake pressure reducing valve
2 To femove a figid pipe, unscrew the union nutS;]1 each cnd and release the pipe from the retaining ctrps. wh(Jre /riled.
be retained as a gUide.
151
)TO remove 11 fle~ible hose, lirst disconnec t the rigid pipes IN u"screwing the union nuts then unscrew the nuts securing the hose to
the 1l10unting brackets .
4 RiUid brake pipes arc normally made up from straight pipe using special bending <.rnd flare· forming lools. The old pipe should therefore 5
Refitt ing
is J revNsal o f removal, but make sure thJtlle~ible hoses
arc positioned clear of suspension or steering cOlilpo rwnts which
could chafe them. Finally bleed the hydrauhc system as deSCribed in Section 15.
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152 Chapter 9 Braking system
)
OIOIN -.1
(2 ~i MMI __ J-j -I , h= .. OJ"N , r-t1 8 7MH)
Fig. 9 .12 Modified screVlldrivcr f o r CC01t;llisillg {he IHcss urc different;", switch pisto n (SIlC 15 )
15 Hydraulic systerll -hfccdiliU
The correct functioning 01 the bfl,kc hyd,~ulo<.: sy Stem IS only possible aile! removal of all ai, from the components ilnd CIICUI1. Ihis is ilchieved by bleeding the system. Note \h<ll only etc;on IInus.:d tUilke fluid, which hilS renlilincd unshaken 10/ at least 24 hours, l11uSl he used. 2 IIlhcf(l is any POSSibIlity 01 jncolfI~cl flUId havU\g bee n usc\ 1 III the sys tem. the brilkc hnes "nd component s must be compll!lely flushed wllh IInconl,lrll'Jlilled fluid ,mel new seals hned \0 the componCllIs. 3 Never reuse lJ<ilke fluid which hi'S been bled Irom Ihe syswrn . " DUJmU tlHI prm:edure. do nul illiow Ihe level of br(lke fluid 10 lhup IIlure th,]I hilifway Ilown the .ese.voll 5 Uclorl! Sla rtlnu wmk. chock Ih<1l illl I)II)OS imd hoses ale socllfe. UIHons IIUht allli bleed screws closed. T"ke U,eal Cilre not to .. lIuw hr"ke flUId to come inlO COn1ilCt wllh the cal pil;ntwork, othe.wlse the ~h WIll 1)0 scrlously do1"'ilued . W<lsh 011 any spilled lIuld .Icrlr;llely wilh cold wawr. G If the hydraulic SYSlem h<ls only heen Ihl.t;"lIy (hsconneclCd .md ~ ble l)reC"utions were laken 10 prevent fuuher loss of fluid. Ihen il shlll/id only he nccessmy 10 hleed the hfllke conce.nCl!. or Ihill pill I of the ci,cull 'downstreDrll' frorn where the work look !}Iace 7 Where a I),es su.e dlf!e,enlial SWlich is !I!wd (Section 12) it will 1)0 I1ecessnry lor an asslstanl to hold the mtemal pistun in the cen tral positIon du.ing Ihe bleeding opcf1llion. otherWise " WIll be dlfficuJ t to uelthe warning h\)htto go out ilnd stay oul A screwdllver mOdIfied as shown in Fig . 9.12 should lJe inselted through thO baso 01 the hydrauliC body after removing the ,ubber cover.
8 II possible, one 01 the DIY brake bleedIng k'ls avaIlable frorn ncccssory shops shoul d be used, paltlcul1\lly tho typo which p,essulisos the system. as they \)rea tly simphly the task and leduce the risk 01 expelled air and lIuid being drawn back rlI10 the systelli. Whell.! ono of these kilS is being used, follow Ihe milnlliacturer's instructions concerning its operiltion. 9 If a brake bleedmg ki t is nOI being used, the sys!Cm may be blcd in the COllVCntlOllill Wily ilS lollows: 10 Ohlain a cleill1 glass Iilr. a suililble lel1glh 01 pillstic or rubbe. tubin g willch IS a 1Ight fll over the bleed sc rews. a tIn of the speciflod hrake lIuld ~nd the help of an ilssis tant. 11 Depress the b.ake pedal seve'<lltimes to dlssipille any vacuumlrom tho servo uni •. 12 Clean Iho area around the bleed screw ilild remove Ihe rubbor dust COlD (photo). If the complele ~ystem is 10 he bled. stalt at the 1I{JllI·hand Iront bl(lke 1: I the tuhe to the bleed screw, inse" Ille 111)0 end of the tube into
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15 12 Ruhhe. (i'lsi C,lP 011 Ironi brake Cilllper
tht!
J;II ill111 porn 111 sull,c.(,:nt hrilkc lIuld 10 keep Ihe end 0 1 Ihe tube ,"uhml!r!Jed . Opel1the IJIL'Cd screw hall a ilIOn anti hnve your ilSSlstilnt dnp,nss IIII! IHilk e pedal In the flOOr and then relColse il. Tlghton Ihe billed ~r.rew ill Ihe end 0 1 cilch downstoko to prevent Ihe e_I)OJled <IiI ;111(1 fhud lroml)Olnu drllwn IhlCk IntO the system Repeatlhe puxodure IInt,1 clean blake fluili. fICO from all buhhles, ell" be sccn emcrging hUln the rube. then hllally lighlen the bleed screw . ..,,,,ove the tuho illld ,elll the dust Cilp . Remember to check the hwke flun! level 111 the IflSCIVOII pellod,cillly and keel) II lopped tip III !lepeat Ihe procedure 011 Ihe left-hand 1,0111 "rake 1"lIowell hy Ihe Jelt-hand rca. hr;lke. Note thai there '5 110 hleed screw on the IIUhl ·h lll1( llI!ar iI'ilk,] as the flUId ,s supplred dlll:l;tlhr{lII!11i Ihe wheel ,:ylnldl!r to Ihe l"'l ·hilllll,c." h •• ,ke When cOllipleted. rec heck Iho flu.d l"vl·1 Ul the leSl!rVUIf. lUI' IIp If n(,:ccssil'y ;Inl ,01,1 the cap .
1 5 D,'press the hlake pcllal sevel,,1 I""es, It should feci 111111 <llIti free ito", 'SPUIIUIIICS5' whIch would ",lflcHte ill( IS slllI presenl 111 the
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16 Foolbrake pod,,1 -removal and .elillinll
Wo.kll1g InSide Ihe CM, ,emove the lower In c. a I","el below the 511,."," Ill!! C()IUIllIl 2 F.xlrilct the chI' ilnd pull out the clOVIS pIn "t1achlng thc servo pushrO<i 10 the 1)(1(1011 3 Unhook the rei"," Sl)ring. 1 Hemove lhe SpIIIIg c!rp and slide the pedal from the shah. 5 Clea" the cmllllOIIcnts ehen ex1lmrno them lor wea, and damage.
Th o bushes may be renewed separately if neCeSSilry by driving thel11 hom the pcdaL G Rehlllng.s a reve,sal 01 ,emoval. but lubrIcate Ihe bushes, sh<lll and devls pIn wllh a !rille grease .
17 Stop lamp switch _ removal, refilling aile! il(ljuslmenl
WOlking inSldc the car. remove the lower I"cia p"nel bolOw the slcCllng cOl ullin. 2 D,sconnoct the wiling plug, unscrew the locking nut and detach the swiech (photo).
3 Refilling is il revers<ll 01 lemov<ll, bUI adjust the Jlosition 01 Ihe switch so Ihal when Iho 100lbr;lke pedal is al Ihe reSt pOSlilon the switch is depressed hatl it s 10tal travel <1 On completioll, check Ihat the swiech operales correctly.
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Chapter 9 Braking syste'm 153
3
Fig, 9 .13 Foothr<lke pedal cOlllponents for automatic transmission models (Sec 16)
1
Spring clips 7 Clip 2 Washer 8 Bushes 3 Shafl 9 Clevis " in , Spacer 10 Rdl/fn sp,illY
5 Bushes /I Rub/u."r P,lI/
6 Pl1d;1I
172 Stop lilOlP switch iHld witi:lg plug
18 Handbrake -adjustment
)Jack up the ,e<lf 01 the CM ,HJd suppOrt on axle stands. Chock the hont wheels. Fully mleJse the Iwndb'Jke level .
6
11
Early (1974/1975) models 2 loosen the locknul on the end 01 the primMY c<lble then tum the <ldJustment nut unt,1 the levC! 'S Just clem 01 the slap on the feaf axle
b,acket. Tighten the Jocknut.
3 Loosen the locknul on the IIgill·hnnd end 01 the secondnry cable then IUfn the adjustment le"ule until <III cahle slack is Illst eliminated M<lke SUIC Ih<l the ope"ltlng levefs on the b<lckplatcs remain on their stopS (ie lully ,eleased).
Fig. 9.14 Handbrake primary cable adjustment nut an d locknut (arrowed) on early models (Sec 18)
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) Chapter 9 Braking syste m 155
20 Hllndbrake ctlble(s) and rod -removal and refitting
I Chock the hon wheels Ihen jack up Ihe rea, ollhe car and support on a~le stands. Release tho handbfilke .
p,imary cable 2 Disconnect \heCllble flom Ihe lower end of Ihe handbrilke lever. On
c1'IIIy mOdels back 011 the cable ad,ustment and unhook the clevis . On latcr models remove the split pin and withdraw the clevis pin. 3 On early models, unscrew the locknut and adjustme nt nut hom the rOlll end 01 Ihe cable. disconnect the cable Irom Ihe lever, and withdraw it Irom the underbody guides and pulley.
4 On l<ller mode ls remOve the clevis pin securing Ihe cable to the right· hand reil< operating lever, unclip the cable from Ihe transverse rod, then withdraw the cilblc 110m the unde rbody guides and bracke t.
F ig. 9. 18 Handbra ko components on Iille r models (Sec 20)
•
I HaN/brake lever 2 Clevis pin lIml chi) 3 Prif!!lIfY clIble
4 Gllidc 5 Clevis {lin illld r:hiJ 6 TWf/sveISC lOti
3
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,
156 Chapter 9 Brakin g syste m
Secondary cc1ble (early models) 5 Loosen 1I1c lock.nut ~nd unscrew the adju stment ferrule from the right-hand rear clevis.
6 Remove the split pin and clevis pin securing the secanda.v caulo \0 the left-hand Icar operating le ve l. 7 htrac the clip, remove the clovis pin. and withdraw the pullcy wheel from the lever on the Ical a~le. 8 Remove Ihe cable from the lever.
Transverse rod (later models) 9 Disconne ct the cable from the righi-hand rear opCfating Icvcr by
removing the split pin and clovis pin. to Uncl.p the cable hom the 'Hlnsvcrse rod . 11 Remove Iho spli, pin and clevis pin securing the fod 10 the Icft·h~nd le;!1 operating lever . 12 Slide the transverse rod Irom the guide on the rOM axle . 13 Check thO {luide bush lor wear and dama ge and renew It il necessary by prising il oul and pressing a new bush irllo POSilioll.
All models 14 Refining is a r e versa' of removal. but lubr icllto the lin kage as )scflhed in Section 2, and atljl' stthe cable as (fescri bed in Section 18.
21 VilCUUrll sorvo unit -dosCrilHion
A vacuum servo unit is linod Into the lir,lk e hydrallirc cil cu il. 111 series with I he 111,1S ler cylinde f. to provide assiswnco to the dllver whlln Ihe brake pedal is depressed . Thi s reduces the eHolI le{luired try the driller to oper,lIe the brakes, under all brak ing condi tions .
This unit operates by vacuum, obtained from Ihe indu ction mnni rold and comprises basicall y iI booster diilphragnl and check lIallle . The servo unit and hydraulic master cylinder are connected
t o gether so that th e serllO unit piston rod acts as the master cylrnder pUShrod. The driller's b rilking ellon is trilnsmitted through allot her PIi ShlOd 10 the serllO unit piston and ils built-in COmrol system . The scrllo unll pislon docs not fit tightly inro the cylinder. but has a strong ,lltl flhril!Jlllto ke el) liS edges in COllst ilnt COntaCI with I he cylinder Willi_
23 rilult diagnosis -hrilking system
~ylllptom
-'ceSSllle ped,,1 u;tllel
nrakcs pull 10 ono Side
Or;tke ludder
E~cessive eHor l to stop car
so ensuring an i1inigh t seal between the two parts, The fo rward
chamber is held undelllaCUUm condi tions cleilted in the inle t manifold of the engine and during periods when the brake pedill is not in use, the controls open a passtlge 10 the rear ch ambe ., so placing it under lIacuum conditions as well. When the b.ake pedal is dep.essed. the lIacuum pass.Jge to the rear chamber is CUI oH and the chamber expos ed to atmospheric pressure. The consequent rush 01 ail pushes
the servo piston lorward in tile lIacuum chamber and operates the main push rod to the m.Jster cylindcl. The controls are designed so that assistance is given under all condllions. When the brakes are 1'101 requ ired, vacuum in the rear chamuer i s .e -es tabl ished when the br.Jke ped.J1 is released . All air Irom the atmosphe.e entering tho rear ch.Jmbe. is passed through II sma ll air trlter. Und er normal opcr.Jting cond itions tho IIflC(IUm serllO unit is lIery relraule and does not require ollerhaul e~cepl at IIcry high mile,1geS. In this case it is far bcner 1 0 o bta in a serllice e~hange uni l. r,1the, than rcp;ti . the o,igi'lo11 unit . Although inlernal components we,e once .Jv'lIlaule 10 ' ovcrhauling purposes this service has no w been
d,scont,nue(t .
22 Vacuulll servo unit _ remOlla l MId re filtillg
I RemOIlO the master cylinder as desc.ihed In Section 10. 2 D,scolllwc l thc vacuum hose from the non·return lIalve on the serllo \lI1it. 3 Work i,,!) insido thc cal. remOlle th e lower l;t cia panel below the stccring column. 4 E~tractlhc clip and l)ul1 outlho clellis pin attaching Ihe push.od to the l ootu .ake ped;t!. 5 Unsc.ew the nuts securing thc mount ing b.ack.et to the bulkhead.
then withdraw thc serllo unit and bracket from the engine COlllp,lJtlnen t, 6 UnSClew th e nuts ar1(1 serlar,lle the braket 110m the SCIIIO uni, . 7 netrning IS;t rell e.sal 0 1 remOllal w ith leference .Jlso 10 Section 1 0 when retrumg Ihe master cylrnder.
Renson(s)
RC.Jr blake self adju sting mechanism faulty All i n hydrilulic system
WOIll or cont,llllina led /rnin{Js Seized Caliper or wheel cy linde r
E~cessille run-out or distortion of discs o. drums
Worn Of cont aminated linings Brake backplate or caliper l oose WOIll suspensio n bailloints
SerllO unit faulty
Worn or conwmin.Jted linings
I
J
procarmanuals.com

rhapter 10 Suspension and steering
F<lull (haOl1osls suspension ilnd steeling FIonl co,1 spOI"g remOIl,, 1 imd .ehIlOllO . FrOln huu ,el11ova', .chuing and ue,lrIng adruSl!llcnl FrorH hub bC;1II1195 -rencw,,1 .... ....... , .. . F,onl st<llJilis. b,ll -,clllolli,l imd .eliulI19 ..... FIOn! suspcnSIOIl strut -,01ll 01l<11 and .efottlng F.onll.ack comrol arm -.emoll;! 1 <lnd rellUlng F'aln wheel alignment and Mooring angles Genc.al description ...... ,...................... .._ ... . Power steelin\) -bleedmg ......... _ ...... _ .0_''', .. _. __ POWIJ• sleeri llU gear -removal <lnd refining,
Specificatio n s
Front suspension
Rear suspension
, . , enflg gear (manual) Type ................... ....................•................ Steeling whecl turns (lock to lock) .. . LUbrican t type ............. ................. ...... . lUbricant capacity _ ............................. .
" G 3 ,
7 ,
• 20 1 15
"
Powel stCCIlIlg Ilump .. remOllal ,111(1 fcllting RCiU leill SI)II119 . emoval. bush renewal .1nd Iclottlng Flo;"), shock iJbSOfOO' removal ,m(/ felUtlng , ............... , Rein sl<lluhscr bar rcmoval and rcfruing
ROlltlllc m"IIH ennncc .
Steering column -rCmov<ll. ovcrhnul <lnd rctrtllng
Slecrong gear (manual) -overhaul and adJustmcn t .. Steeling ge'lf (manu"l) -removal and relrn ing •...•.•...
Steeling wheel -rCfllov<l1 <lnd rctilling ...
Track rod and baliJoll1l -renewal
Wlleels nlld lyres -uencrill CilfC and maintenance ...................... .
17 10 9
" 2 19 13 12 ,.
" 21
Independent. MacPherson strutS with Integral telescopic shock
ab sorbers <lnd stabiliser bar
Seml·elllpliC leaf springs with flgld <lxlc. t clescopic shock abSOrbers
and stabiliser bar
Rack and
pinion 3.36 SAE 90 EP gea r oil 0.15 IlIre (026 pint)
i
i.
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I (
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:~
I:
II
procarmanuals.com