FORD CAPRI 1974 Workshop Manual

·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 9 Wheel stud -renewal
Chock the IrOllt wheels then lilck up the ,eaf of the Cill ilnd sUPPor! will> ilxlc S1 ,I PU.lSS Or dllvc the wheel SlUt! through t he axlestwft /I;)n9c. 5 Clc " 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.
F i
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 . K Suit.' !I''""'' I. /lIIIHI IIII!/-I" 1M S,IIIIIII woIsl".:,s
)
i
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 procarmanuals.com

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 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 , , ,
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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 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 procarmanuals.com

) Chapter 9 Braking syste m 143
2
Fig. 9.1 DU

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 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';,~" 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 I
I .
. ~ .. " ,) •. :Y.
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 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",'~e p"d tens,on SI""'U" Oil Ihe hr~ke 1)o1ds i1fl '''~'''''''" ;,S n,~:"sS,l'y
<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 3 .4 A pad .et .>.6C Disc pad and shim 3.9A T he shim allow must lace tho forwa,d rotation o f Ihe f.ont wheel
'-.. ~
, .
3 .9B Fitting the tenS ion springs
.--.::.:.:; .
....... . ~,'
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 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 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 RUEO '.(RlW
--
1-""£0""""" ~Plf'l ~-____ ttIP
BI"'~( ".",~"" PI~I()'
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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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 ~"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""~~ ,,;och shoe hold-down sprrng (photo) ,lnt! rOt,lte the sprrn!! ",w"nIlH w.r~I"" 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! '~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',l~'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~"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 'nech 7.2A Re 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)
,
j
procarmanuals.com

Chapter 9 Braking system 147
Br;'lke IlIlInU
Wheel Adjustment
"m
cylinder --·-·_.L
-::'~~:.J/
I
'j
~
l
~
• 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 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 '
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 4 On pre Oecembe r 1974 models remoye the split pin and clevis pin Irom the handb rake leyer 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) 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.
i.
i I
II
j
I ;
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 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 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'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
procarmanuals.com

1 Chapter 9 Braki ng system 1 49
,1 M aste r cylinder -overhaul
With tho m 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 spnJlg
9 Dotach lhe villve space ,. tilking c 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 .opair kit of seals. 14 Di p Ihe piston and seills in hydrilulic Iluid then reassemble Ihe m 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 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 ;.
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