lock FORD CAPRI 1974 Repair Manual

•
Chapter 8 Rear axle 139
ci,cumS«"Ulces mny only one pmt of the two be renewed. fnspect the dllfe,enti,ll pinions nnd side gems for signs of pitting. score mMks. Chipping nnd general wem. Obtain new gears as necessa,y . Inspect the th,ust washers lor signs of weM or deep sco,ing. Obwin new thrust wnshe,s as necessary. Once the pinion o il senl has been disturbed it must be discMded and a new one obtained. 20 When new pnrts have been obwined ns required. reassembly cnn begin. First lit the thrust washers to the side gems and place them in position in the differential housing. The ground side of the thrust washers IllUSt lace the side gC.Jrs. 21 Place tile thrust wilshers behind the dillelentini pinion genrs i1nd mesh these twO Oems with the Side gears through the tWI) ilpertores in the lilllerentlill housing. Milke sure they ilre diametlicilily opposite 10 each other. RO«l!e the clillerent'i11 pinion gears through 90' so brinUlI1\j them into line with the pinion genr shnlt bore 111 the housinlt 22 Insert the pinion genr shnft with the lock In!) p'n hole III line with the pill hole. 23 Usinu leeler 1),IU!Jcs. measure the en{lll(",t 01 ench s,de Be,,,. II the speclficd h\Jure IS excecrt"d. IU!W tl"u~t washlllS mu"t he olJt,uned
-omnlllie the a~~el)lhly ,lg,llll ,trld ht new thll,st wa:,lu'<IS . Lock the P""O" near shalt U~I&#34;\I the pill whn:h should hc wpped hilly h01)1I, UStrlO n SlIlIah l" d,a",,:ter parallel pill pUIH.:h. Peen ()V,,' thc ()I the p", hole to stop the pill WOlklll!J liS wily out t." The tlowllwhcui m;,y next I,,, Idllted F,,~t heat 11 101 nppro~I&#39; ","lllly 10 nHIHltc~ III 1I0111IIIJ W,lter Wipe the ,,,nl"IIJ l aces 01 the c,ownwhuui ,Ind dllferuntlal houslI'U ;,nd. II OliOlnal p,lItS ,lie l,utnU used. plate the Clownwlll!cl tnto p(l~ltton With the prev,oll~ly m,llie marks nhOllud Relit the elO1ot IHlllS th;11 sucule the ,;r()wllwlwel ,trld tighten Ihese III a I"og'esslve and dla\lunill rlt"nner to the spe.:,fled torquc. 26 PI<lce the Shlill packs b<ltk III thell Oll!)lnal foiled pOSition on the differential housing be<lrlllU IOC<lllon USllllJ .1 p,cce of sUlla!Jle diameter tube ve,y c,1refully ftt tim d ifferential housln!J bearlllgs with the smaller dlnmeter 01 the taper outw,Hds The hearing t,lge must nut in nny wny be dilrllnged. 27 PI,1ce the shims hehllld the hcnd of the pinion geM nn[1. using ,I
suilahle dinmetci tul!c . cmclully lit the larg"r ti!per rollI)' benllll\) onto Ihe pillion shafl. The lar\ler dlilllleter 01 the be,lllllU !\lust be nex110 the pInion head
28 Using soitable diameter tubes. fit the two Wper roller bearing cones into the finnl dlive housing. making sure that they ale litted the correct way round. 29 Slide the shim and spncer onlO the pinion shalt and insert inlo t he final drive housing. 30 Relit the second and smaller diameter wper loller bea,ino onto the end of the pinion shaft lind 101i0w Ihis Wilh a new oil seal. Sefore Ihe senl is nctually fitted. apply some grense to the inner Ince between the two lips of the seal. 31 Apply n little jOinting compoond to the outer Ince of the seD I. 32 Using n tuhulilr dllft 01 suitable dinmeter, carefully drive the oil seal into the fillal (hive housinlJ. Make quite sore thnt it is lilted squarely and flush with the housinU. 33 Refn the drive pinion IInnge nnd hold securely in n bench vice. It II fixed lenIJth spncCl is Itlted. fit ilnd tighten the pinion nut 10 the spec ,lied lorque. If a collapsihle spnce r is f,tte d. follow the prOCedlHe
g iven in Section 7 paragraph 14. setting the pinion turning to'que to hetween 25 nnd 2.7 Nnt (1.810 2 0 Ihf It) which includes 0.2 to 0.<1 Nm (0.15 10 0.30 Ibl It) lor the ndriitional friction of the new oil senl II new hea,inns h~ve heen filted. logether With n li~e(l len(Jth SP,lCer. check thm the tOrlllllg torque is bel ween the limits just stmed. If not. a longer or shorter spilcer must he I,tted until the setting IS correct 34 Fit the healing cones to the cf,fierenllal houslIlg heallll(Js and carefully ease the housing Into posilion in the finill drive housmg 35 Relit the be,IIII'!J CilpS in thell originnl pOSitions. Srnc,ll n httle JOlntmg compound on the threilcfs 01 each cnp secuIII'O bolt nnd fit 11110 position. When ,111 low halts have bcen rein ted tiUhten these up in a (h"IJonal and progresSive milnne, to the speCi fied torque. 36 I I pOSSIble. 1Il00nt n dlnl in(licntor onu(Je so thnt the probe IS resting on one of the teeth of the crownwheel and determine the backlash hetween the clownwheel and pillion. The bileklash may be vMicd by elecreasll'\) the thickness of the shims bellind one beilling nnd incrensing the thickness of shirns behind the othcr. thus moving the crownwheel ;nlO or out ofmcsh as requi,ed. The tOt.llthlckness 01 the shims must not be chnn\)ed. 37 The hesl check the do·it·yourself owner cnn make to aSCerta", the correct meshinu of the crownwheel ilnd pinion is to smear ,I htt le engineer's blue onto the crownwheel and pinion iJnd then lot"te the pinion. The con1<lct lIlil,k should nppenr rl\fht ill the Iluddle oJ th..,
COlleCI 100110 CO"t.1ct
_
t Heavy conWCl 0" huel. at 100lh !,leu Move p'",on lowa,ds crownwhcd u:.!:.crt:1 3nd c,ownwhuel towards p,n,on
.~\;!~&#34; •. ,;.';,;,"",.,=,"--
l ' Fig. 8.17 CrownwheeJ and pinion setting chart (Sec 8)
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Chapter 8 Rear axle 141
lings apm! and compress the clutch plntes. The nction is varinble. depending on the power npplied. so tlMt under full power the dIfferential will lock completely nlld full torque will be appl;ed to both
11 Fa ult diagnosis -rear axlo
Symptom
NOIse
"Clonk· Oil nccelera tlon nnd deceh:ontlun
,... Ilenka\Je
)
renr wheels . Under coasting or overrun conditions the differential will operate as a normal stnndard unit. The unit incorpora tes four different;nl pinions <IS <lgninst the two pinions lilled to standard units.
Roason(s)
Worn axleshaft bearing Insufficient luhricant
Worn dlfferentinl houSIng bearings Worn crown wheel and pinion Incorrect crown wheel nnd pinion mush
Worn 1I. leshalt splrnes Excessive crownwheel nluJ pinIon bncklnsh
Pm ion oil senl Icnkrng ReM cove r gasket leaklllg 011 seal on <lxlesh<lfl bearing leakIng
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procarmanuals.com

Chapter 9 Braking system
Fault rflnunosis -hrnking sys tem Foothrnk.c I)(!dnl -removal .1nd refluing From m ake caliper -overhau l .. Front blake cillipCf -removal ;1nd 'Cl,UUl\1 .... ______ ._ .................... . Front brake discs -inspection, ,enlov,,1 and rcl,!\in(J Front disc pilds -renewal , ....... _ ...... .. General description ..... .... ........ . ............ . H andb<ake - adjus tment ................ ................................... ___ __ ...... . Handbrake cable(s) and rod -removal and rcfiuing . Handbrakc lever -removal and refilling ........ ........... ..... ..... ......... . Hydraulic pipes and hoses -removal and refiUing . Hydraulic system -bleeding . . .............. .
Spcci/ic:ltions
Syste m type
I=rOl1t brakes ~c tt,ickncss :
Now ....................................... .
Min rmum.
Oisc fun ·out (ma~inlum including hub).
Mini'l1ulll disc pad lining Ihickness
Re ar brakes MInimum bfake shoe lining thickness.
Torque w re nch settings Caliper ....... ................. ................................... . Brake disc .................... . Backpl"te ........................... .................... .......... ................ .... .. .. .......... . Hydraulic unions. Bleed screw (ma~) .... Aecuf>Cfaling valve 'Clainel (Gi,ling)
Gonoral description
23
16
5 ,
G 3 1 18 20 19 14 15
Oisc brakes aro f;tted 10 Iho front wheels and drum brakes to the lea. wheels. Tho cable or cablo and rod opelilled handbrake oper:11es independently on the real wheels. A vacuum sorvo unit is fiued
" "tween the mastel cytinde. and loolbrake pedal to provide assistance 'en the pedal is depressed.
T he hy,aulic circui t is split frOnt and rear. Undel normal conditions
M,lSIC' cylinder -ove.hilul Milsle. cylinder -removill ilnd .e liuing . P.eSStue d,ffcrenliill swit c h -desoiplion .• e m ov,,1 and .el,ning P,essure ,educing valve · description. relllovill ilnd .er,llonu
Reil' i),lGkplilte · ,emov"r ilnu refining Hei!( i)r"ke shoes -renewal ....... .................. .............. . . Routine m"intenance ........ . ................. .
SlOp·lilmp switch - removal. re/rUlng and ildJustmcflI . Vilcuum servo unil _ description . Vncuum servo unil -rcrnovnl nod rcfiUing Wheel cylindcr -rcmovnl. ove.haul and ref'lIing
11 10 12 13 ,
7 2 17 21 22 8
Dlml hyd'i1ulic cif cuit. snlol Ironl i1nd rCilr WIth IlreSSU,e reducing v:llve in reil r ci.cui t on Iiller models. DISC I,onl brilkes i1nd self·ndjust illu rca .
(!rum brilkes. all wilh servo aSSIstance. Calrle or c.,blc .1nd rod operated handbrake on rear l)f"k es
12 .7 mm (0.5 in) 11.4 rnm (0.45 in) 009 nlln (0.0035 in) 3 .0 mm (0.118 in)
1.5 mm (0.059 in)
Nm 471068 41 1046 271031 71010 10 491062
Ibl It 351050 301034 20 to 23 5 to 7 7 36 to 46
both ci.cuilS operale in unison. howeve •. in the event of faIlure o f one circui t Ihe lemaining ci.cui l will p<ovide adequate bfaking 10 SlOp Ihe car in an emergency. late. models incorporate a pfessure reducing valve in Ihe r(la. hydraulic Cifcu il to prevent rca, wheel locking during heavy braking . When working on the bo"aking system. remembef Ihat blake fluid is loxic and will also damage painlwo.k. II spilt II should be washed away immediately with cold water.
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) 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
--
1-""£0""""" ~Plf&#39;l ~-____ ttIP
BI&#34;&#39;~( &#34;.&#34;,~&#34;&#34; PI~I()&#39;
4IOUf llltlGOOLI tCCKltlG PLATE
R( 1 Altl{R RltlG
BRAKE (VLIHOER PISTO'l
(l001
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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1 Chapter 9 Braki ng system 1 49
,1 M aste r cylinder -overhaul
With tho m<lster cylinder removed (SeClion 10) clean the exterior sudaces.
Girling type 2 Removo the SCleW$ and withdraw rhe fluid reservoir. twisting i as necesS,,'y from Ihe end seal. 3 Remove the twO seals afler cdraC ling the circlip ovor Ihe cnd seal. <1 Using II hOKagon key. unscrew Ihe relainer and hit oUllhe primary
recuperating valvo. Oepress Ihe primll'y piston during Ihis procedure. 5 Exl.;'!ct Ihe primary and secondary pistons. IOgether wi,h their associated components. noting Ihe order of lemOlln l. H nccessary top Ihe master cylinder on a block of wood or use air pressure from il foot pUIllP through the inlel porlS. G Separate rhe primmy ,10d secondary l)is10 11S irani lha intermediilte
sprinu . Uso tho !inUe.s 10 remove tile Ulilnd seDI from the primil'Y
r""' lon .
The secondil'y piSlon assembly should ho sOfh"ated by lilting the u"mblo leaf ove , Ihe shouldered cnd 01 tho viston . Using the lingo,s.
rr 'wo the se<ll from Ihe second,lfy I).ston . l ,opross Iho sccondilry sprinH. illiowinn Ihe vDlve stern 10 slide throu!Jh the keyholo in tho thimble. thus releasing tho tension on Iho
spnJlg
9 Dotach lhe villve space ,. tilking c<lre of the spring washer which win he lound IOCille(1 under tho villve he<l(!.
Teves (ATE) type 10 Dopress Ihe primary piston, thon oxtrnCtlhe circlip from the mOUlh of th o c ylindo r and also unscrew Ille SlOp screw. 11 Extract the primary piston componen ts noting Ihe order 0 1 removal. followed by Ihe secondary piston componenlS. If necessary top the
master cylinder on a block of wood or use air pressure from a 1001 pump through tho inlet ports. 12 Prise the seals from the pistons, nOling which way round they are lilled. then il necessary remove tho springs and seals. The prima ry
pis ton spring is retained by a screw.
Both types 13 Clean all tho components in melhylated spirits or brake fluid then
inspec t them for wear and damage. Check the cylinder bore and pistons for scorinu and corrosion. and if eviden t renew the complete nI<lster cylinder. If the componen ts are in good condition obtain a
.opair kit of seals. 14 Di p Ihe piston and seills in hydrilulic Iluid then reassemble Ihe m<lster cylinder in revorse order to dismantling. Make sure that Ihe seals a ro assemble d tho COffect way round as previously noted. Note thaI the secondary seals may be idontif ied with a silver band. On Iho Girling Iype make sure Ih<lllhe shim on Iho end valve is fined with liS
convex side against Ihe shoulder nange. Belore refiuing the fluid reservoi r on lhe Girling type ch ock that the recupera ling valve is open wllh Ihe prim<lry piston released, and closed when I he piston is
depressed.
1
2~
3~
13
1
2
3
4 5 6
7 8
R
22
21
Fig. 9
.8 Exploded view 01 the Girlin g master cylinder (Sec 11)
Filler cap 9 Seal 16 Secondary piston
Seal 10 MaSler cylinder body 17 Seal
Seal !Clainer
11 WiJslrer 18 Rell11i1er
Fluid reservoi r 12 Reservoir relaining screw 19 Spring
Seal
1 3 Seal 20 Spring fl/Miner
Relainer
14 Primary piSlon 21 Valve
Primary fCCllpCfaling valve
15 Spring 22 Seal
Circlip
10
!
" 1 ,
1
I
!
!
I ,
J
,[
1
I
I
; .
!I ' i ;.
procarmanuals.com

-
)
Chapter 9 Braking system
,,-
")_'J ,
: ~~ 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
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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 .
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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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)4 Chapter 9 Braking system
Fig 9 .16 H an dbrak8 cable adjusting nul (A) on later models (Sec 18) ~&#39;9. 9 .15 Handbrako secondary cable adjustment fonu le and lockn u t (arrowed ) on early models (Soc 18)
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Fig. 9 .17 Hnndhrnke operating lover n n d (llwtment (ldjuSlment gn p ·A' on later models (Sec 18)
'-iller mode!!s 4 LO(:,'I" trw r.al,lo .1dlUS1Cf lust forWi1f(1 01 the 10." axle dillCrcntinl , ;;.~.IIl!J (,.holn). then Sflp,l'ate Ihe ndjus\ing nul and sio eve usinIJ II se.ewtl""cr ["n,'IIO lhe keyed sleove in the bracket.
5 T 11m Ihe lldlu sling nul unlot all c.,l>lo slilc k is eliminated and a cleiuallr.e of I 0 '0 1 5 mill (0.039 to 0.059 in) exists at tho handb'Jke ope.aling 10l'm .. butment points (Fig. 9.17) Temporarily apply the holn(i!),,,kc 10 cnUage t he ilujus\ing nut with the sleeve then recheCk the ildJuSlmcnt.
All models 6 Lower Ihe r.'lr In the ground.
1 9 H ,1"dbrako lover -removal and refilling
Chock till) front whecls then lack l'P thO tcat 01 t he Cllt and SUllport on ilxlc swnds . Rclc~!se the halldbmko . 2 Whete applicahle remove the centre console with reference to Chapter 11.
3 Disc;onnecl the l>fiOlilJy cable from the lower end of t he h andbrilke
lever beneath the etlr . On early mooels baek all the cable adjustmen t
and unhook the c lev is (photo). On lale r m odels remove the splil pin and withdtaw the clevis pin (photo). <1 Remove the SCHlWS and withdraw the gaiter over the top 0 1 th e lever.
S Unbol t the hanrlhtake lever Irom the lIoot. 6 Relinin g is a revetsal 01 removal, but check the handbHlke
ildjustment as desClibed in Section 18 .
19 .
3A Prim ary cable connection to
handbtake lever (early models) 19.39 p.ima.y cable connection 10 handbrake leve r (Iale. models)
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