FORD CAPRI 1974 Workshop Manual
Manufacturer: FORD, Model Year: 1974, Model line: CAPRI, Model: FORD CAPRI 1974Pages: 205, PDF Size: 43.75 MB
Page 151 of 205
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.00 Chapter 9 Braking system
PR IMARY CUP
SeCONDARY J CUP _ RETA INER SCREW
INTERMEDIATE RING
SECONDAR Y CUP)
STOP WASHEP. WASHE R
PRIMARY ~ (''''')
CUP PISTON ~lJ ~
SPRIN\G SEAT T 1 WAStE:~L~\C Q I~
PRl~lARY CUP ./
SPRING OISC I -1 '" "'~'f" SPRING i SEAT L ,:-\,/(.'.~·, J ' '
RETAINER • \ . '0 I)J-'0'.'.)'. ',:.,' "'f
I -, " ,O"'j')'" I' . I r -h" .
l J i\\"\" ,jl;
~G«1N w: 1 vl";';':' ~ .. '
" r • • {l"t:';" ,: .• ,-; \{. . ' SNAP . \J, ~;'. PISTON RING
--
1\-\1 ijM:\'.' ,J , ~1.1"9 _ ·S TOP SCREW .....
--
SEAL ','
-'---
WASHEA
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SECONDARY CUP
Fig. 9 .9 EKplodcd view of tho Teves (ATE) master cylinder (Sec 11)
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F ig 9.10 The Tavos (ATE) maste r cylinder pisto ns as sembled ready fo r reliUing (Sec 11)
12 Pressure di Herent;al switch -desctilHion. removal and refitting
E,lrly mOdels were filled with a pre ssure diHerent ial switch to illurnin~to ~ wolfning l igh t on the in stru men t pilnel in the event 01 a drop in preSsure in eithe/the Iron t 0/ rear hydraul ic circui ts . The switch ir- "'rporates 1I piSton which is kept 'in b alanco' if the pres sures in tho I. and roar ci,cui ts are equal. Howeve/, rl there is a pressure drop in
one circuit. t he pisto n is displaced and the switc h con tacts close .
2 The switc h is loca ted on tha lowe, left .hand side of the eng ine comp,Htrnent and a lthough it was once possible \0 obtain new in ternal
seals these are no longer available. Th e switch may be renewed alone (without Iho hyd,au lic body) by disconnecting the wiring and unsc rewing it .
3 To rernovo the hydraulic body. first tigh t
en a piece 01 polythene shoetinu bene ath th e brako Iluid reservoir fillor cap 10 reduce th a loss 01 fluid .
4 D isconnec t the swit ch wiring.
5 Unscrew the fi
ve union nuts thon disconnec t and plug the pipes.
6 UnSCfew the mouming bolt and romove the unit.
7 Relillin g is a reversa l of removal. but on comple tion bleed the hydraulic system as described in Section 15 .
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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
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
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
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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
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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
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
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
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
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Chapter 9 Braking syste'm 153
3
Fig, 9 .13 Foothr
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
11
Early (1974/1975) models 2 loosen the locknul on the end 01 the primMY c
3 Loosen the locknul on the IIgill·hnnd end 01 the secondnry cable then IUfn the adjustment le"ule until
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)4 Chapter 9 Braking system
Fig 9 .16 H an dbrak8 cable adjusting nul (A) on later models (Sec 18) ~'9. 9 .15 Handbrako secondary cable adjustment fonu le and lockn u t (arrowed ) on early models (Soc 18)
I
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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) 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
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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
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Page 158 of 205
rhapter 10 Suspension and steering
F
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
Steering column -rCmov
Steeling wheel -rCfllov
Wlleels nlld lyres -uencrill CilfC and maintenance ...................... .
17 10 9
" 2 19 13 12 ,.
" 21
Independent. MacPherson strutS with Integral telescopic shock
ab sorbers
Rack and
pinion 3.36 SAE 90 EP gea r oil 0.15 IlIre (026 pint)
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)8 Chapter 10 Suspension and steering
Power steerin g gear Type .. Steer ing wheel turns (lock to lock) lubrican t Iype, Lubricant capacity . Fluid Iype .
Fluid cilpacily: Sepilrilte reservoir . Integli!1 reservoir .
Front wheel alignment C",nbc, M;lXll11um dlffcrence side \0 side C
195/50VR15: Up 10 3 pe.sons . Morc th(ln 3 persons.
Torque wrench settings Fran! SIIS{!cl!siotJ Stlut upper 1110untrng . P,ston rod nut Suspen Sion ')~",{Jont St;rhiliscr birr mount"'lt . Stab iliser h;rr to track control ,)In,
Track cOIHlol ~rrn p,vot
,H'o1( slIspCIlsion od abso,bcr lower mountH'g .ock absorber upper mounting Stabillser bar to axle .. St;rl.lIlIscr har 10 underbody
U ·bol . Sprinu I.ont mount"'g . Spring rear sh;rckle
SINNing Steering gear (m~nual) Track rod end uall,oint Coupling shaft to pinion. Coupling shah t o column . Steering wheel.
Steering column.
Roa(/wiJec/s Wheel nuts/holts: Conicall;rce . FI(lt face.
General description
, -'The flonl suspension is of Independen t MacPherson Strut Iype incorpotating inleglal telescopic shock ~bsorbers and a stabilisel b~r. The ,eal suspens ion is o f semi ellip tic leaf spring·with· 'l ive ' axle Hydrau
l
ic assisted rack tlnd pinion 3.25 SAE 40 oil 0.20 litre (0.35 pint) AulOm
1- 0 ' 30' I" O· I l' O' O ' 45' 01070 nun (0 !O 0 28 ",)
185170HR13. 185/70VRI3. 205/60VR13 o. 195f50VR15 Front Rear
23(1.6) 23 (1 6) 28 (20) 28 (20)
2<1 (1 7) 28 (2.0) 28 (20) 32 (22)
28 (20) 28 (2.0) 32 (22) 32 (22)
26 (1 8) 26 (1.8) 32 (2 2)
32 (22)
N'H Ibl It
20 to 2<1 151018 40 to 45
30 to 33 <11 to <18 30 to 35
28 to 33 21 to 211 21 to 61 15 to <15 25 to 30 18 to 22
53 to 63 39 to 11 13 27 to 33 20 to 2<1 40 to 50 301037 35 to 41 26 to 30 25 to 36 181027 35 to <11 26 to 30 11 to 14 8 to 10
20 to 24 15 to 18 24 to 30 18 to 22 16 to 20
12 to 15 231030 17 to 22 27 to 34 20 to 25 17 to 20 13 to 15
85 to 115 63 to 85
115 to 140 85 to 103
type, incorporating telescopic shock absorbers and ;l stabdiser bill. The steering is of rack and pinion type, but may be either m(lnual or power·assisted . The steering wheel incorporates 11 convoluted cam which is designed to collapse rn the event 01 (In accident to prevent
injur y to Ihe driver. It is not reco mmended that the power steering gear is dismantled on Ihis work is best entrusted to a specialist.
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Page 160 of 205
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Fig . 10.1 Front suspension and steering components (Soc 1)
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