brake FORD CAPRI 1974 Workshop Manual

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View o f frOll t undo. body (2 _8 injection)
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Exhilllsl sys/t'''' {,uIII II'Pol Clutch c.,hI,· ,w'/mi!lJt'f g.li/l:( Od /rU,H Cd,llIdy" Brake c.l/,/uN OWkt· fie.d)l" "yllt,IIII,,; hese
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7 8 9
F,QII! SIl$/lellSIOII {""Ie t 'ollitolmm Tr,lt'1!. (0(/ emf IMII/mlll RulJ/"" IJdfows Pt)Wf!( s/f!f!,lIIg !leal
'0 Fam l SI",,,II.\I." " .l(
" f)1II d}d{.~
" r.", .., Sump "" ,h,,,,, Iduy , ., U!lIIOIII 1m,,...
'" " S(.JI/"', 11/(1/01' lV/,'/w/11
16 SMile, "'''IQI 17 Fuel !ct-" ,1m/te/llm ,)'pes /8 M,1"'1.1I,!",,,v ox 19 Plopell,·, _,,,,,11
20 MUI"'('''', ("IIYllle IC,ll) 21 511<:1:1/"""</'" cdhle
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Chapter 6 Manual gearbox and automatic transmission 123
When towing a vehic le wIth automl11ic uansmission it is impoltllllt to observe the precautIons gIven til ,he 'Jading and Towing' se<:,ion at the Iront 01 the manual. Due to the complexity of the au'oma',c tran smission unit. If performance IS not up 10 s tandard, or overhaul is necessary, it IS impera tive that this be left to the locallllain agents who will have the special equipment for fault diagnosis and rectiflcallon. The content of the following sections is thereforc confined to supplying gener", Informl11ion 1'Ind any service information and ins t.uc tion tha i cnn be used by the owner.
19 Routine Illilinte,wno
At the i!lle.vnls SI)CClfiecllll Iho ROllllne Milintennnce seCIlOll in the I.onl 01 th e Illanllal cnllY Oul Ihe follOWIng p'ocp.dwe
Luuricow selector link'1[}() , Applv the h;rrldh.,lke th(:n J,lck \lp the front of Ihc Cill ,'lid Support
,n nxle Slnnds
2 Orlthe Irnkn!JCs at cndl end 01 Ihe genrsh ,h rml on the Icfl·hnnd "le 01 Ihe Iransnll~s,on lowel the cnr \0 Iho wound,
Check /mn.Wllissioll fluid level 4 Elrlll!! the engIne and trnnsnllSSlon to nOllllal ope.IlIUl!IIp.llIperillllfe
and I)alk tho vehlchl on le vel grOllnd 5 Wi,h Ihe engIne idllll(l. move tht: 1.,lnsnllSj"on St:leclt>r lev!]r through ill! pOSlllons 1!lIee lImes. Ihen onuaue '1" ,11111 wall for ;rt lea~t one minute. 6 With ,he engine 51111 idling, wllhd.ilW Ihe lr.1nSnllSSIOll d,psllck.
Wipe it dean, reinsert II, wilhd •• 1W 11 for Ihe second !line nnd read off the levol. 7 Two tv pes 01 automatic transnllssion fluid a.e nvarlilblc (sec SpccifiCiltions 10' tv,>c numbe.s) .1nd It is ImpO,I,ln , Ihilt IheV 'lIe nOI mixed. The colour 01 the dipstick. 10' flUId level checklllg denotes which fluid tvpe to use , 8 If a tlr1nsnllssion requlII"U 1,1ter tvpe fluid IS I'lled 10 " to'<lue COIlVOIlr!r preViously used w<lh oarl.er tVI}e fluid, or vice vr:&#39;.~iI, the compollellt~ shOuld Ire Ilushed 10 ,1IIoi(1 mlxinu o f the two Ill/Ids
COllsult your I'ord dealer rI thIS cond,t ron arIS&#34;~ 9 If III)r.CS~.1rv IOp·up with til'.! spec.rlled orl, thr ough tire drpSlrck tube. 10 tire MAX m, uk, The '1"<rlllrty leqlm ed 10 r,IIS!] tile level !rOllr 'V1IN In MAX IS approxlmatt:lv 0 3 Illre (05 pIIIl)
Adjust Iront brake /)(In(/ '" ApplV Iho handb."ko tholl lack 1'1) th'.! ',ollt 01 the ca. and sUPPO.I axlo stands 11 D,sconnoC t the downshIft ca!)le at Iho t'.1nsmISSlon 12 Slacken Iho brnke band adJusto, sClew locknut and unSClew the
adjus'or screw n lew h,fIlS . 13 Tlghlolllhe adJuslo, sOcw to 14 Nm (10 Ihl II) IISIilU a SUItable lo,que wrcnch From Ih,s poSlllon slaCken the adJusle r screw bv exact Iv I'll \Urns (pre·1983 models) or 2 Iwns ( 1983 and late,
model), Ihen tighten Ihe locknut Wllhoul diSlUrblllg Ihe pOsition of Ihe adjuster sc,ow .
14 R econnec t the downshift cable and lowe' Ihe car 10 Ihe ground.
20 Automalic transmission -removal (HId refining
If l)Osslble, ,aise the car on a hOlsl o. place it over an inspectIon pit. Alternatively, it WIll ho necessary 10 Jack up Ihe car to obtain the Illaximum possible amount of wOlking room undernealh. 2 Place a large d.ain pan benealh the transmiss.on sump (011 pan)
Ihen. working horll the ,car, loosen the a!laching boilS and allow ,he lIuld to drain. nemove all thO bohs excep t tho two I.onl ones to draIn as mIlch fluid as pOSSIble, th on temporarilV .efit Iwo bolls at th e re,1I 10 hold it in place . 3 Remove tho Slilrte. moto. as desc.ibed in Chapter 12 . • jWhero apphcable, rernove the access cover Dnd ad3pto, plale bolts,
Ie the engine untrl the to.qu e converter drain plug is visible, then
unsc.ew Iho plug and d.ain Iho Ihud Into a suit3ble con winer. Refl! and l'Uh ten Iho plug.
Fig. 6 .25 Checkill{J tho au tomatic transmission lIuid lovel (Soc 19)
Fig. 6.2 6 FrQ,1 bn'ko band adjustment (Sec 19)
A Arllf/SICI sc/t'w a Locknut
C Downslu/t Icvel D Downs/u/t c.lblc
Fig. 6.27 Torquo convorter to driveplato boll -arrowod (Sec 20)
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procarmanuals.com

1 Chapter 8 Rear axle 133
Fig. 8 .1 CrOSS-Sl!ction o f cnrlv rCilr ;1xlo (Sec 1)
A Fixed /ellglh SIJ.1C(!f B Pinion slum
2 Routino mnintcnoncc
C Dd1clCII1.11 S/II"'$
At lhe uHerv"ls specIfIed 111 the HOlltmc M.111l1cn;mc c SCCllon III the 110111 0 1 the mnnu;1I c""y oul the following p,uccdw(!.
Check fcar axle oil level 1 Jilek lIlllhc IvaI of the Cil! ;uHf suPPOtl on axle ~I&#34;nds T o C!lSI'''') li1,'l Ihe Cilr is lellel ;,150 I<lo k III) Ih e IrOnl of th e cm Allefll;. \,vcly . OSI110n Ihe en, ovcr ;m IIlSIJO:ction ,)11 or all .;)mps J. Usmg;J 51111<11110 sqll1lrO key, llrlSe.cw the hiler plu\) I.om Ihe 't·h;md Side 01 tho d'lfcruntinl housmu. USIng a 'mger Or., )llceO 01 bent mowl .otl. check Ihat the OlliS level WIth the b0110111 01 tho f ,lIe . 1)lug hole O f il n>i!xnmun ul 100 mill (0 39 Ill) belo w the holo 4 II necessmy top Ull wllh I he euoree! \)I;lde 01 011 ;IS !Jlvcn '" 'Rceommcmlt'd !"brle,',,'s ImrllhUfls' 00 no! ovcllill thc .em ,nle. o th e.wise thc 011 will ove.he;ll ;111(1 he IO~1 Ihl oUll h Ih e b.e;Ith e. vent 5 Rcht ilnd tiuhten thu hUu. plu\1 Ihen lowe. Ihe eM 1 0 the lJ'ound
3 R e<lr <1)(10 - relllov,,1 ,\Il d refilting
Jack up the le,lI olth e cm ;Jnd sUPPOl1 wllh axl a stan ds 0' hl oc ks
posi tioned lIancnlh the sid(Hllemhe.s . Cho ck thc tronl wheels and rcmove the .ear wheelS . 2 Mark thc p.ol>elle. sh;J1! ilnd .eil' <ule drivc ft3!111cs in .elallon .0 ench olhcr. 3 Unscrew the Iou. fI,lIlge boilS while holding the sh M , wilh a mewl
ha. insc<led through the universal 10Ini. o r by applylllg lhe hJ'ldhrake lower the 'eM 01 th e p.opelle. shafl.
4 D is connect the h,mdlllilkc ti.lIle and. whe.e .1pphC;Jblc. tha
t'ansverse ,od from the .ea. (Ide wl,h refalCnce 10 Chal >!el 9
5 CI<lmp Iha fle~lble hr<lke hosa t o the re<lr a~lc then unsc.ew 'he nuts and disconnec t II /.om the IIgid tJ'ilke pipe all(i ;J~le hrnckel. It a ho se clamp is not av allahle. lig hlen a piece of polythene sheel lIenealh the laSle r cyl inde f till> 10 reduce any fl u id loss and also plug the disco nnecte d hose 6 Jack up the ,ca. ilxle a few Inc heS Ihen unsc.ew and rem ove the sh oc k ab so,be, lowe. moun.,n g lIo115. Prise Ihe shock abso,lIers horn lhe b.ack (lIS on Ih e rca. aKle.
COUAPS'8ll -----i--i!~e&#34;&#39;.!i SPACH'
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Fig. 6 .2 Cross·sc ction of I"ter rear Ilxle (See 1)
Fig. 6.3 Removing the rear ax le fillo r 1)lug (Sec 2)
Fig. 8.4 Flexible brake hose connection to the .ear axle­arrowed (Sec 3 )
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1
134 Chapte r 8 Rea r axl e
FiO. 8.5 Discorlllccti!l9 the rcar sI"biliser Iwr (Sec 3)
7 U~&#34;&#39;!I u"ps (FlU 8 5) I)UU rile s1.1h,l,s(lI b.ll 10 lilt:! lCol. while unstocwIIlIJ the mOlllllnlU I)oIIS from the Ie;)' ;l~II!. flcl110vc the C!JIllI'S 8 W,lh the rC:II Ildc sUlt,lbly SUIlI>o.ICd. lIIlSCICW rhe nulS hom the hallom 01 the U-bolts i1rld reOlOlle rhe lowel S I)llrlU p l;lrcs .. ",t! 1115 .. 1<11015. 9 Wllh rhe help of an asslSlilnt. hft the rem a~lc over the &#34;~<lr ~p&#39;!I1\1s iUld withdraw i t from undcr the CilL 10 To refit the ICtllr axle, lirst cher.k Ihal the upper insul<l ,ors ;lnd 1",lCkclS a.e correctly located on the springs. 11 Wllh rhe help of an assistant hft the rear ;'!Kli! into 1)05'1'011 on the W:1r 5Il flrl!JS. 17. COIIIWC l rhe IUOI)clle. shall 10 Ihe dflllc flanUc with rile IlfClllous ly 111;1,1 " "'o1rks :11111110<1. ,1nd loosely fll the four bOl ts. tOljclhe. W Ith new hl':kw;,s he.s
13 I O.:.lt!"! the ul~&#34;&#39;&#39;&#39;&#39;o.s 1m!! lowe. SP""1J pl~ws all the sp rin!jS thclI "1 Ihn 1)·llo\1s. W!IClhc. wilh Il/!W sld/.locklll\) lIutS T'!Jhlf:l1 thc IHII S l"o!Jlnsslvuly 10 Ihe spo{;lf ,/!(IIOIQUC. III 1')<;,lIe Ihc CI;1I1IP~ 011 liIe Slilhd,scr bilr "'0\I1111\1 tubhers tlrCII pull 1 hili IlltO poslllon WIllI thl) grips <l1l(1 fIt the mountlllll bolts. TIUhtell .Il hl>l1~ 10 the S IICclllI .. '(l toIlIUI) . • ,. j<lck up the reM a~l{l ,1S neceSSilry and push the shock <lhso<be .s
, Ihe" I/.ac ket s. In se'l Ihe nloum"lU bolts and tlghlel1 the nUI S. H i Ilelll Ihe lIexll/le b.,lko hose and lIuhten the nuts. 17 Rel1lovc the hoso cl,lrn p or polythene sh eet then blcL,{/ Ihe hr<lke s n~ d(!sCllhed ill Ch<lpWr 9
t 8 nelll t he h<llldhr<lke c,1blc and. where <lpphcllhle. the tr~&#34;sverse lad II) thfl ICi"lI n K le WIth referen ce to Chapter 9 . 19 T,ohtell Ihe dllve ""nne·to·propeller shall holls to lhe speCIfI ed to.que. 20 R el'l the .ear wheels "nd lowe. the car to the ground. 21 Check Ihe .en. aKle 0,1 level <lnt! top up II 'Hlcessi"lIy .
1 AxleshMt -removal ilnd refilting
Chock Ihe front wheels then jack up the re,lr of the c~r ilnd support with onle stilnds. Remove the .ear wheel 2 Ilelea se the hilndb.nke and .emove Ihe brake drum.
3 USIng a socket through the special holes in the drive lI.::tnge. unsc'ew the bollS secu.ing the b.::tckp late and bearing ,el.::tinor to tho a~le cilSln g (pholo). 11 Withdraw tho a~leshnft. together with the bearing. " it is tight due 10 tho oulor Ir<lc k seizing in the casing tcmporarily refil Iho wheel .::tnll Iwll on the wheel. If Ihis is unsuccessfu l. use n slide hammer allached
1 0 the dtive lIange. or ,1Iternil1ively sc rew two long baits th.ough Ihe jng al diametlicaUy opposite pOInts (FIg. 8 .7) and lighten them I,·...r<jressiv ely un!11 the be.::tring is freo . 5 To .e"l the a~leshafl. IU$I w ipe clean Ihe bcallng .(!(:ess in the casing and al>ply a liule Illhium based glease both 1 0 the casing and bear ing outer !rack . F
ig. 8
.6 RelHoving t h o Mdeshalt .e l'l ining hoits (Soc 4)
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Fig 8 .7 U sing long bolls to ""ithdra"" tho a~leshaft (Sec 4)
cd
procarmanuals.com

·0 ) Chapter 8 Rear axle
crowllwh(lcl teeth. Refer to Fig 8.' 7 where the corrcCl100l h paltcrn is shown, Also shown arc incorrec t loorh patterns ilnd the method of oi11<lining the conect pattern, Obviously th,s will ll1ke time and further dismilntllllQ but will be worth ,I. 38 Refit the brilke b<lckplilles followed by the rCM cover (Section 6) ,1rld ilxleshMts (Section 4). 39 ReI,t the (C,lr ilxlc (Section 3),
9 Wheel stud -renewal
Chock the IrOllt wheels then lilck up the ,eaf of the Cill ilnd sUPPor! will> ilxlc S1<Jnds. Remove the reM wheel. 2 RcicilSC the h;mdhr,1kc ilnd remove the brake drum. 3 Apply p(Hl Clrminu 00110 the slud to be removed ilml allow it to sO<lk lor $cvC"illm,nutes.
,I PU.lSS Or dllvc the wheel SlUt! through t he axlestwft /I;)n9c. 5 Clc<lll the hole III the flan!)!} then ,nsert the new stud f'0111 iJehind and nloHIl Ihe splines W'lh those milde hy the o"oonal stud,
" 1',,11 tho slUd lully "'to Ihe lIan!)c "s"'\.1 ~ wheel nut ~nd wilsho,s as ,own III Fill . 818 ., neht the IHilke (hum ,11ld ,e~, wheel then lowel the eM 10 the
IUlld
10 lillli ted-slip diffc ronli"l-\.Ien er,,1
The IIllllwd·shp (I,fle,ent,,,1 's f,tled to 2 8 Spec,,,1 modl:ls ""d Its "';1111 purpose is to il,event wheef SPIll 01 the IIlsule ,ea, wheel when dnvin(l round bends or oul of l>emls w ith lull enOl/Ie powe, applied.
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ll. 8.19 Cutaway view o f the limited·slip differential (Sec 10 )
A Crowf!whecl /J fJ'{""I!/IIi,,/ carrier r: PIllIOII ue .. " /J $h .. ,{1 r fhlll.I'IIIII!llill",,,,II/,1C<.'S r Uukr IJ{;,I<.-((III """Ht'nll,,1 ,;,/1 IIf,'1 ) (; 1"111:1 I"a/(: ((III axle .<ll/mt'S) If Elld (."ov,:, .J /lIII}S/ ",:,slwi
K Suit.' !I''""'' I. /lIIIHI IIII!/-I" 1M S,IIIIIII woIsl".:,s
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F ig . 8.18 U sinll 11 wheel nut 10 pull il slud in to lhe ilJ(le
flonge (Sec 8)
Under these cond,tlons thNe I S il weiohttriln~IN 1 0 lilo oulslde wheel. ,111d lho deS'Bn of the standJIl1 (hlf(:relll,al is such Ihal all ,1dvmse I(uque con 110 ajlpl".:d 10 l11e Ills, de wheel ca"slIlII wheel ~pln, The l,lll ,W<I·slop <IoIf'''''''!I,,1 lIS(:~ lllUI1I·plol1C r.IUlches In r.oumerar.1 wheel Spill and Ihe ",UI &#34;I~n h"s" hllllll:l IWllel,t in lh.1llhc r.ar r.all pull ilway I)lOr(, jJIlSII,vo.:iy "" ~I,pp(:ty ~&#34;,Iac(,s. The 1ll"lt, 1,lall' (.I " tl'hos ,lre 1'0,Uleclctl hVlwevn Ihe ,1xle~haI15 anti two Ih""1 &#34;&#34;~IS wh,ch suppOltlhe pinion (Ieil' sholis til speCial sqllare CU1'Ollts (F'(I B 1!) Wh .. ;n power ,s ,1pphed. !he Shilfts force the th'lIst
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
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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.
procarmanuals.com

) Chapter 9 Braking syste m 143
2
Fig. 9.1 DU<lI linc hydn.ulic brnke circuit (Sec 1)
1 2 Fron! br,)k(1 disc ,1nil c<1IijJ~&#39;f M,lS/IH cylinder and I/uid resefvoir 3 V,KIIUIn sClva unit 5 ReM drum brake 4 Prcss1ltc (h!fetcH/i.)1 wi/filing swi/cl!
2 ROlltine maintenance
Al III<, u,h!lvals speClficed in the Routine M<JinlellilllCC sectIo n in the frOllt of tlw 11,;)1111<11 Colny oul the lollowlIl(J procedures
Check hrilke fluid Ivvel 1 CI",<;k 110.11 Ilw hrake thud )"vcl in the reselvoir is .1, or nc." lhe 1Il,,~i&#34;&#39;lI&#39;&#34; ',,,10k The ,c~;cr\loi( is localed on the master cylinder on the nghl-hillld sule 01 the IJulkhead III the cl1uine cOIllpnnlllCII!. SliUht Va-"I,ulls of I"vel Will occur ilccordlfl!) to the wear ollhe II/<l ke linings. If lI,v(!1 (hops wW ;1,ds the ""Ilimlllll mn,k the cornplclC hydraulic system should he Chec ked lor le<lks,
2 ·'h tim cm rnlsed. c,lIe1l1lly inspect illl the hydraulic pipes. hoses ;lnt. .. ,lions lor chJlmg. c'ilcks. Illilks ilnd corrosion.
2.4 ;-.-
uejJ.es~ the rubue' membrJne to check the fluid low level
Warning IrUht
3 To top up the fluid unscrew the fill er cap whrle holding the c,lhle connector sWtionar y. and add brake lIuid ns necessJr y. R efit the cnp on completion. 4 When checking the brnk e fluid level it is n good practice to also check the low level wnrning light With the hnndbwke rele<lslId and the iunition switched on. depress the rubber membr<lrlC on the rIl511'VOII hi ler C<ljJ (phOto) If the wilrning light filils to came on check the bulb ill1d <lssocimed circuit.
Check disc p<1d and rear bwke shoe linings 5 Jnck up the Iront nnd rem of the Cilr nnd support all il xle stands,
Re leuse the hilndb'<lke. 6 Although i t is pOSSible to check the Iront disc pari 1illillUS with <l mirror and torch. it is recommended thnt the front wheels <lre Illst
,emoved. 7 Mensufe the thickness 0 1 lining on e<lch disc p<ld <lIlt! If ,lilY IS less thnn 3 .0 mm (0,1 18 in) renew the complete set of front [Jose pnds 8 II the ren, b'nke h<lckplntes incorporn\(! inspection hOles. remove the rubher plugs nnd check thnt the thickness of the hmn\js IS not less
thnn 1 .5 mm (0.059 in)
Fig. 9.2 Handbr a ke lin k ag e lubrication points (arro\Ncd) on early models (Sec 2)
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procarmanuals.com

144 Chapter 9 Braking systom
9 II there Dre no inspec tion holes, remove the wheels and drums In inspect the linings . 10 Where any lining is less Ih,111 the nllnimufll thickness, renew Ihp. complete SCI 01 re,ll b,~ke shoes. 11 Refi ' the drums lind wheels as necessary then lowe. tho em \0 thl) 9lOund.
Ch eck operation of servo lIoil 12 Visually inspCCllhe vaCUUll1 hose IClIding hom the inlet mlllllfolll Of air box 10 the servo unit fOf dc\c,iOf1l1lon and security. 13 Wit h the engine Slopped. dCI).es s the bra ke pedal several ,imes to dissipate t he VOC U\Ull hoUl the sorvo Imit. 14 Depress the b'i1kc 11Cdll1 wilh moderate pressure then Sin' I the
cnU illC . As the V<leuum bwlds up. the l)Cdal should move sh Utl1ly IOw ;uds the floo. indlc;uulg that Ihe $Crvo is p.ovidlllg .esis tilnCfl
L ubrietl!£! /wndbh7ke linkage 15 Jilck up Ihe .eolf of Ihe Colf illid SIIIIPOII on ilxle Slilnds . 16 Oltthe prim,uy eil!>le connOChon to the boltom of Ihe halldh&#39;;,~&#34; level. 17 011 1974/1975 models. u,ease Ihe pflmolfy callie whe,e II p;,sses over Ihe pulley wheel. ,111(1 0,1 Ihe pull ey ilnd lever pivot pO"'IS . 18 On lillCr models grease Ihe 1,i1nw c.se rod SUI)I)Olt hC;lfinU 19 011 the clcv is IIUIS i1I the w", l>olckpl" ,es. 20 lower thc cm !O the gr ound
R/mew fhe /)rilke I/Ilid 21 lJIucd Ihe hyd.; ."loc sySle m as d"scllherl III Seelloll 15 ilUOwnl! II",
Ihe new h ,,,k\) Ih"d to COnlph: lely 1,lIlhe C:"CUtt he"I!1 bled . 22 AI Ihe sanl\) I"ne rcn,uve Ihe 'Ci" ",ake \I'lOn,s alld check tho wlu,,,1
cylonclers 10' leak"IJe.
3 Front disc pl1ds - renewal
Apply t
he handbr<lke then Jack U') Ihe Ioonl of the Cill <lnd supporl on <I~le s tandS.
I
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2 RemOV(l Ihe hont wheels.
3 It Ihe fhnd level in the maste' cylondel reservoir is high. when the pistons l1re moved into thei, respecI,ve bo,es to accommodate new pi1ds. thO leyel could rise sulticienlly fo, Iho fluid 10 oyerflow. Place ilhsoruent clOlh .1round the reSe,yO". o. syphon a Imlo Ituid oul. so 1)'Cven tUlg Pil"ltwOlk <lilmage UCUlIl caused by the hydraulic lIuid . 4 Usmg iI 1)11" of tong·no~ed pile,s. exl,aCt the two smiltt clips Ihat
hOld the m;"n ,clalfl,ng pins in plilce (photo) 5 RemOYfl Ihe m"in le tainm g pin~ which ,un through Iho c.lliper and the mel,, 1 h.,r. krnn of th o pads and Ihe ShUllS. 6 The flll ;t, o n l),le1S cil n now bo removed from the cahper. If they prnv!! \III1ICIIII to ,emove by Iland . II pair of long·nosed pi ie,s can be lIscd Lill :Iway the shims and tens.on sPflnus (whe,e lilted) (phoIOS). 7 Ca.eh,liy clcall Ihe .ecesses in the cahl>Of in which Ihe h,ction pads :md ShUllS he. and Ihe exposed faces 01 caCh pis ton. rem oving allu3ces 01 d"t 0' rllst 8 Us",u a p,nte 01 wood. e.l,eh,lIy rUlI,1et Ihe pis tons. n 1'1,11;\1 IhH t&#34;,&#39;~e p"d tens,on SI""'U" Oil Ihe hr~ke 1)o1ds i1fl<l shims ililfl locale mlhe t,lhpCf . NOle Ihi11. whe,e ,11)I)hcal)le. the affOWS on the ~hUllS m&#34;~1 I<le.: Ihe lo,w.,rd rOIi1UOII 01 Ihe iron! wheels (photo). 10 ,,,,,Crlthe maon p;,(1 Ictitlll,nU prlls. tIIilklt1IJ ~&#34;,e th,11lhe 1i1nus of the IUII51(1I1 SP"II\j" .lIe under Ihe rCtallllll\ J pins Secure Ihe pillS with Ihe ~&#34;,,,II w,w d,l's 11 R&#39;·IM~<lt (hf! I" ocl,tlu,e on the .emil"' .. ,\! hom bri1ke then ,cl,t the ....heels <llIti lowe, Ihe Cilr 10 Ihc U,ou'HI 12 To co,,,,(;l ly ~eill t hc p'stons. 1l'''''))lhe !,,;.ke pedal suveral tim cs ",,<I j,n:,lIy top "p Ihe hydri1uh c Ih"d level in Ihe m.1ste, cylinde.
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<1 F rollt brake caliper _ rcmoy'll iltld refitting
1 nemove the f,on! disc pads i1S tie sc"lJc(/ in Section 3. 2 1111 'S Itll,,,,d,,(1 10 lit ncw Ci1tiper pistoll s "nd/o, seals. dep,ess the tH.1k'J Iwel,,1 10 hlUlU the pistons i"to COI11i1ct with thO (fisc and <lssist ~&#34;hs<:qllc&#34;l H:fllOV<l1 of the p'stons. ) FII a h{JS(l ciilt1lp 10 the lteK'ble hose ICi1d,llg \0 thc c'l hpcr. If a hose dallip 's not ilYil,li1bto. tighten" p,ece of l)Qlylhelle she"t beneath the
3 .4 A pad .et<llnn1U pin and clo,) (ilffOWt:d) 3 6A Ret1lovinU a d,sc pad 3.6B The two disc pads remOved
.>.6C Disc pad and shim 3.9A T he shim allow must lace tho forwa,d rotation o f Ihe f.ont wheel
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3 .9B Fitting the tenS ion springs
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灲潣慲浡湵慬献捯m

) 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.
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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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