boot FORD CAPRI 1974 Workshop Manual

Chapter 9 Braking system 147
Br;'lke IlIlInU
Wheel Adjustment
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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.
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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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)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 11 Bodywork and fitting 189
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32 8A I&#39;,,~c 0111 Ihe alp 32 an ali(I ,(,mo .. c the console screw 329 Removing the hnndbrake lever boot find be~el
Fig.n.la C lock ro:.,,"ov<ll tools (Sec 32)
1 () "'I!! (0 If; "') /J IOO",m (()/I() III)
32 Centre cOIl~ole·· fUIllUV,,1 ,,,,d refiUinu
IJasic tYlle '.111 Ihe caqll:l 110m ;!lolllni the r'OIlI of t im t:()Il~()lo, thun push the " .J <llld hel..,1 out of Ihe hUlls&#39;&#39;&#39;~J DlsCO""CCI the dock 1r~<](ls 2 Remove 11", two SCI(lWS il( Ill(.' reiH cnd ,inti two (I101e hom the clock emt. to 1!.,lu<lst: Ihe cOllsol", 3 rlell10vc the \lP;" l<:vcI ~&#34;(lh, or T·h""dln 1 Lilt 0/11110 consul" As dpphcilhlc. !(:r!'UVC the clock 11l0llrlll1l!) pl<lIC screws "ud/or UCilrstuft lever hoot 5 flchtl;nu 15 the reverse of the 'clllov,,1 1110<:odlllO.
Gfli,1 type (also Il((ed fa I(I/ef nVI)-Glli" modrds) 6 Lift the Cil'PCl hom ;"oulld the IrOll1 oj the console 7 F,.brIC<lte twO sm~11 h",cke!s f,om 1 5 ""n (0 06 ,n) sheet sleel (sce Fig . 11.18) ,1I)d ,nsel1 (hese hel"nd (he IJlilck hewl to ,emove the clock Disconnect the w,,,ng. 8 Remove the two console ,etammg 5c,ews. then prIse oul the Cflp in hOIl! 01 the gearshift lever ~n(f rcmove the screws heneilth (photOs). 9 Cilrefully p,,~e the h;Ul(llJrilkc lever hoot ilnd belel ;)ssembly from tlie conSOle ;)nd remove II (photo). 10 Cnwluily PrlSC out the Gellire pflilel cover hom behind lhe gear lever. 11 Lilt up the cenlle il&#34;llfe~1 and remove lhe screw hom the bottom of the comp,lrtmen1 12 Remove the ;)rrn(CSI h"'\Je screws and place the ;)"nrest in the comp;),tment 13 Remove thc lwo screws ,I[ the hont end 01 Ihe iI&#34;,&#34;e~t rUSC out the cap at the r"ar 01 the console and remove th e scre w • Ca(elully lilt Oli! the 'eilr seCllon. I,onl s(:ctlon and console COlllpilftmcnt 16 Remove the he,ll "'5ul"tll1g pad Irom bene,l1h the consola Cornpnrtment ilr..,a
17 As appliCill)le. remove lhe eleeuical connector from Ihe base 01 cilch senlhelt s(;llk and rcmove the stn lk ".lI1g boll th,ouOh the top of thc consolc. Rcmove the stnlk ilssell1hly thrOuoh tlHl II1SIdc console suppo,!. 18 Pull the cMpet awny hom the SIdes of the 5UPPO,1 assen,bly. then detilch the support hy removIng (he eluht S!)CUW1!J screws. 19 Hefil!lnU is bilS'C,1I1y Ihe reV«($e ollhe !«Illoval procedlHe. hUI Illst ensure lh,11 illl Ihe splle nuts ilre corrCClly loenled on Ihe brflCke(s. Tluhten tile sefllhelt SliIlks to the specilied IOlque.
33 Sunroof piln el -ndjustments
Gap adjustment 1 When closed. a Unp of 5 8 10 6.9 mm (0.2310 027 "') should eXI~t hetwecn thc slIn(oof and (h e CM rool. II;) vmyl roof cover IS lilted. Ih,s gap should he reduced by 1 .78 mm (0.07 Ill). If adlllst'!\(Jnl IS requued. pwceed ns detaIled below. 2 With the sunrool hall open. remove (he sunrool heildhlunll hnlne 3 Close the sUllfool. then pull Ihe hei!dhnll1H hOIll (he Ie." and remove ,I. 1 To ndlust the hOnl 01 the sumoo!. loosen the front Uu,de relillnu1U screws. then whIlst p,essu1!J (he Uuitles IIlwilrds. lighten thc screws. 5 To ;)d,ustthe rear. loosen (he twa h.II1!) screws nt eneh Side of the ,1dlustinU hnsc. thcn p,ess (he reilr shdes mw,uds ,1"d t'Uh!Cn . 6 F,t the hCildllmn(J and hemU",,,,U h,,,ne 7 lithe ild)lIsunenl is slill Incorrect. ,emove (he we,l\hel$I"p from Ille rool panel ;)11(1 hend ,IS mountll1g lIange as necessary
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FiU 11.19 Sunroof controllllechanism (Secs 33. 34 and 35)
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