brake FORD CAPRI 1974 User Guide

Chapter 9 Braking syste'm 153
3
Fig, 9 .13 Foothr 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 6
11
Early (1974/1975) models 2 loosen the locknul on the end 01 the primMY c 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 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) ~'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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) 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 F ig. 9. 18 Handbra ko components on Iille r models (Sec 20)
•
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
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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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162 Chapte r 10 S uspension and steering
)
Fin· 10.6 Front
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Y 6
hub cOnll)oncnts (Sec 3)
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1 0,1 seal 7 Diller be,?li/!{J Iwck 2 IIIlIcr bcaring wee 8 GUiN Iwmitlfl filct' 3 Inner bemiJlg /I,?ck 9 ThlllS! wilslwf 4 Screw 10 NIII 5 Disc 11 Sf"il (lin 6 H", 12 01151 C.1jJ
4 Remove the split pin frorn the nul rC\;linCf and undo the adluS\ing nul from the stub a xle. 5 Wilhd,nw the thr ust washer and the outer tapered he,..ing. 6 Pull off the complete hub ;111(1 disc ilsscrnbly ffOIl11hc s tuh tlXlc. 7 To refit locale the huh tlSscmb ly on the stub il~lc <'Ind slide on the outer hc"rinu nnd II11 II) while IIngurs ~"d Ihun1l),
1 0 Rei" the nut ret;)u)Cr SO th~t the spill pUl holes ~re ~lIg"ed. Fit a
v split pin 4 Front hub be 1 Remove Ihe Iront hub as described in Section 3.
2 Cmelully prise out the gre.lse senl Irom the b~ck 01 the hub 4
Scoop out the grease 110m inside the huh imd wash clea". S Drive the new bearing tr 5 Working the
glease well into th e beiu ings. lully p 5
Front Suspension strut _ renl0v

Chapter 10 S uspension and steering 163
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Fig. 10.7 Coil spri n g compressor lOo ls (Sec 6 )
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FiU. 1 0 .8 C o rn pressi nu the frOllt Goil spring ( S ec 6)
~ " / ron t stobiliser bar clamp mountrng
2 Mount the strut firmly i n ~ vice .
3 Fit t he spring compressor tool(s) to the coil spring and compress the spring until it is juSt clear of the upper mounting. Milke sure tho t the
1001 is f ully engilged with the spring.
4 Prise off Ihe plastic cap then unscrew Ihe pis ton nut ~nd remove
t he cranked
retoiner .
F ig . 10 .9 CU\·
ilWilY view o f th e front coil spring nnd strut mountin g compo nents (Sec 6)
A Shack absorbfN pis/ull B 51,,11
5 Remove Ihe upper 1110unling lollowed by Ihe corl spring. rebOllnd
rubber and lowe r sprrnU seal. G The coil springs are colour· coded ,1nd II a new sprong 's being I,!led
il muSI hilve the same colour code.
7 Ref itting is a reve,sal 01 removal. but il Will be neceSS nlll _ using locking fluid on its thre nul until Ihe weighl of Ihe car is on the suspension and. when l ightening il. posilion the cranked retainer wIth ilS twO ears al 90' to
lhe centre.line of Ihe CM. Where the p iSlon rod incorpor crrmp the nut
II~nge into the 5101
7 F ront stabiliser bar -removal Apply t
he hand brake then Jack up the front of the car and supporl
on axle stands. Remove Ihe fronl roadwheels.
2 Working under Ihe CM at the Irani. knock back the loc king tabS on the four baits securing tile two f,ont ct~mps Iha t hold the swb,hser ba r
t o the frame and then undo t he four bol tS and remove lhe clampS rubber insulJtors (phOIO). 3 Remove the split pins 110m the cJstellated nu ts rewin in g the stabiliser bar to the Irack control arms, then undo Ihe nu ts and pull off
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