check oil FORD CAPRI 1974 Repair Manual

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r'9' 8.11 Differential ClOsing and bCiHillU C Fig. 8 .1 3 Removing tholockinu pin IrOtlllh c pinion goar shaft (Sec 8)
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~i9. 8.1 5 Checking tho d iff erential sid e gear ontilioal (Sec 8)
Fig. 8.12 RClll ovin!J the differential assemhlv (Sec 8)
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fig . 8 .1 4 Oiffercntiill cOIllI)oncnlS (Sec 8)
Fig. 8.1 6 Chocking the crownwheel and pinion backlash (Sec 8)
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Chapter 8 Rear axle 139
ci,cumS«"Ulces mny only one pmt of the two be renewed. fnspect the dllfe,enti,ll pinions nnd side gems for signs of pitting. score mMks. Chipping nnd general wem. Obtain new gears as necessa,y . Inspect the th,ust washers lor signs of weM or deep sco,ing. Obwin new thrust wnshe,s as necessary. Once the pinion o il senl has been disturbed it must be discMded and a new one obtained. 20 When new pnrts have been obwined ns required. reassembly cnn begin. First lit the thrust washers to the side gems and place them in position in the differential housing. The ground side of the thrust washers IllUSt lace the side gC.Jrs. 21 Place tile thrust wilshers behind the dillelentini pinion genrs i1nd mesh these twO Oems with the Side gears through the tWI) ilpertores in the lilllerentlill housing. Milke sure they ilre diametlicilily opposite 10 each other. RO«l!e the clillerent'i11 pinion gears through 90' so brinUlI1\j them into line with the pinion genr shnlt bore 111 the housinlt 22 Insert the pinion genr shnft with the lock In!) p'n hole III line with the pill hole. 23 Usinu leeler 1),IU!Jcs. measure the en{lll(",t 01 ench s,de Be,,,. II the speclficd h\Jure IS excecrt"d. IU!W tl"u~t washlllS mu"t he olJt,uned
-omnlllie the a~~el)lhly ,lg,llll ,trld ht new thll,st wa:,lu' suilahle dinmetci tul!c . cmclully lit the larg"r ti!per rollI)' benllll\) onto Ihe pillion shafl. The lar\ler dlilllleter 01 the be,lllllU !\lust be nex110 the pInion head
28 Using soitable diameter tubes. fit the two Wper roller bearing cones into the finnl dlive housing. making sure that they ale litted the correct way round. 29 Slide the shim and spncer onlO the pinion shalt and insert inlo t he final drive housing. 30 Relit the second and smaller diameter wper loller bea,ino onto the end of the pinion shaft lind 101i0w Ihis Wilh a new oil seal. Sefore Ihe senl is nctually fitted. apply some grense to the inner Ince between the two lips of the seal. 31 Apply n little jOinting compoond to the outer Ince of the seD I. 32 Using n tuhulilr dllft 01 suitable dinmeter, carefully drive the oil seal into the fillal (hive housinlJ. Make quite sore thnt it is lilted squarely and flush with the housinU. 33 Refn the drive pinion IInnge nnd hold securely in n bench vice. It II fixed lenIJth spncCl is Itlted. fit ilnd tighten the pinion nut 10 the spec ,lied lorque. If a collapsihle spnce r is f,tte d. follow the prOCedlHe
g iven in Section 7 paragraph 14. setting the pinion turning to'que to hetween 25 nnd 2.7 Nnt (1.810 2 0 Ihf It) which includes 0.2 to 0.<1 Nm (0.15 10 0.30 Ibl It) lor the ndriitional friction of the new oil senl II new hea,inns h~ve heen filted. logether With n li~e(l len(Jth SP,lCer. check thm the tOrlllllg torque is bel ween the limits just stmed. If not. a longer or shorter spilcer must he I,tted until the setting IS correct 34 Fit the healing cones to the cf,fierenllal houslIlg heallll(Js and carefully ease the housing Into posilion in the finill drive housmg 35 Relit the be,IIII'!J CilpS in thell originnl pOSitions. Srnc,ll n httle JOlntmg compound on the threilcfs 01 each cnp secuIII'O bolt nnd fit 11110 position. When ,111 low halts have bcen rein ted tiUhten these up in a (h"IJonal and progresSive milnne, to the speCi fied torque. 36 I I pOSSIble. 1Il00nt n dlnl in(licntor onu(Je so thnt the probe IS resting on one of the teeth of the crownwheel and determine the backlash hetween the clownwheel and pillion. The bileklash may be vMicd by elecreasll'\) the thickness of the shims bellind one beilling nnd incrensing the thickness of shirns behind the othcr. thus moving the crownwheel ;nlO or out ofmcsh as requi,ed. The tOt.llthlckness 01 the shims must not be chnn\)ed. 37 The hesl check the do·it·yourself owner cnn make to aSCerta", the correct meshinu of the crownwheel ilnd pinion is to smear ,I htt le engineer's blue onto the crownwheel and pinion iJnd then lot"te the pinion. The con1 COlleCI 100110 CO"t.1ct
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t Heavy conWCl 0" huel. at 100lh !,leu Move p'",on lowa,ds crownwhcd u:.!:.crt:1 3nd c,ownwhuel towards p,n,on
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l ' Fig. 8.17 CrownwheeJ and pinion setting chart (Sec 8)
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) Chapter 9 Braking syste m 143
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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
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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 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
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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
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)
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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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Chapter 10 Suspension and steering 161
fig. 10.11 Drivebelt [ldjustlllent pulley holts on 3.0 litre models -arrowed (Sec 2)
2 Routine maintenance
At the "*',vals spec ,f,ed III the Routine MainhHlance $()(;t,on in the front of til() manunl c,lIIy out the 101l0wlIl\j p,o(;cdures.
Check lyres for illflalioll, wear and conditioll 1 Check [lnd If necessary adjust the tyre pressures .
2 Check [III t yres for WC[lr and condition with referenc e to Section 21
Check power steering pump drive belt tensiof) 3 Check thm the deflection of the drivebelt m,dway ulon!) its lonyest nlll between upper pulleys is approxirn 1110tler;lle th"'''h pressure . 1 If "dl"~t"'e"l ,s necuss;uy. loosen the ,dler pulley bracket bolt~. re'posll'o" tlH~ IIIilcket then rc·t'Uhten the bolts On 30 htre llIodels the III[lck"t t"u~t he pivott:!! .1tound the end holt. whmeas on 2.8 litre ,,'odds the b';'eket mllst I", ,"oved wllh"l Ihe elonu"t<:d bolt holes
(photo).
Clwck puwer steering fluid levef (lnd hydraulic huses II pOSStble the level should be checked w,th the Buid [It nOll1lal
uper,\!mg tClIll)Cr[lture . 6 On c;lrly modcls unscrcw the wing nut nnd relnove Ihe rese,voir cover ilild uaskel. The flu,d should be up 10 Ihe MAX level mark on the
reservo". 7 On later models, wrn tht! hiler C lll.Jrk on the d'pstick.Js applicable (photo).
Fig. 10. 5 Topping·up the power steering reservoir on early models (Sec 2)
8 Whele nec.ess.1'y ~dd Ihe ~pccilled lIU1d to bring Ihe level up to the
correct ,nilrk. 9 ChC(;k the hydr[luhc hoses for comJit,on and security.
Check steerinfj ,-md suspension components 10 n,ll$O tilt) front ilno reM 01 the Cill or position over an inspeclion pn. 11 Check the SleetinlJ wck and t'e 'rods for d[lm3ge und weM. Also check the wek HJbber bellows and track rod end rubber bOOIS for spfilS
ilnd leilk[lge. 12 Chec k the front ,md reilr suspension components lor d"m.Jge [lnd wear. In particuf;lr check the front suspension tr.Jck control Mm ilrod stahiliwr r"bber mounling bushes. Usc a lever to check that there is no excessive we[lr III the Iron I slispenSlon lower IJ[ll lJoints which Me
"'\()\JIill wnh the track conlrol ilflllS . 13 Check the operat,on of the I,ont ;IIHt rear shock absorbers This is
be st ilchievcd with thO} Cilr on the \lfOlind by depressing euch corner of the ca' 1111\I1. On 'ele[lsil\ljthe C()"H~r helllU checked Ihe body should ,,~c thell s"llie IIlIl11ed,mely on ,t~ way down. II there nrc sever.J1 ()sclll;ot'ons the sho(;k absorber IS weilk nnd should be renewed.
3 Front hub _ removal. refitliny and bearing adjustillent
Apply the h[llldhr[lke then Jilek tip the front 01 the cm ilnd support
on axlt! standS Remove til(! rOildwhecl 2 Rernove the front ul;lke CJllper With ,elerence 10 Ch.Jpter 9. Whele the flex,ble br[lke host! is connecte(t dueclly to the cililper ther e IS no need 10 disconnect the hose i1S thO} caliper can be suspcnded by wire
aWily from the diSC. 3 By calelul 1 centre of the huu (phOIO).
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Adjusting the power Sleering pump drivebelt tension on the 2.8 litre engine
2.7 Powcr steeling filler c.Jp/d,pstlck for the 2.8 hIre engine
3.3 Removing the dUSI cap from the front
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