air condition FORD SIERRA 1987 2.G Braking System Workshop Manual

neck with a rubber band, or by refitting the
cap. This will reduce the loss of fluid during
the following procedure.
3Disconnect the flexible fluid hose from the
rigid brake pipe under the wing of the vehicle,
or alternatively unscrew the flexible hose from
the union on the caliper. Take care not to twist
the hose, and plug the open ends to prevent
fluid loss and dirt ingress.
4Remove the disc pads.
5On models fitted with Girling calipers (1.3
and early 1.6 litre models) (see illustration),
unscrew and remove the bolt from the lower
caliper guide pin, while holding the pin
stationary with a spanner, then remove the
caliper.
6On models fitted with Teves calipers (later
1.6, 1.8 and 2.0 litre models) (see
illustration), remove the caliper from the
vehicle.
7If required, the caliper carrier bracket can
be unbolted and removed from the hub
carrier.
Overhaul
8Brush away all external dirt and dust, but
take care not to inhale any dust as it may be
injurious to health.
9Pull the dust-excluding rubber seal from the
end of the piston.
10Apply air pressure to the fluid inlet union,
and eject the piston. Only low air pressure is
required for this, such as is produced by a
foot-operated tyre pump. Position a thin piece
of wood between the piston and caliper body
to prevent damage to the end face of the
piston in the event of its being ejected
suddenly.
11Using a suitable pointed instrument, prise
the piston seal from the groove in the cylinder
bore. Take care not to scratch the surface of
the bore.
12Clean the piston and caliper body with
methylated spirit and allow to dry. Examine
the surfaces of the piston and cylinder bore
for wear, damage and corrosion. If the piston
surface alone is unserviceable, a new piston
must be obtained, along with seals. If the
cylinder bore is unserviceable, the complete
caliper must be renewed. The seals must be
renewed regardless of the condition of the
other components.
13Coat the piston and seals with clean
brake fluid, then manipulate the piston seal
into the groove in the cylinder bore.
14Push the piston squarely into its bore.
15Fit the dust-excluding rubber seal
between the piston and caliper, then depress
the piston fully.
Refitting
16Refit the caliper and where applicable the
carrier bracket by reversing the removal
operations. Tighten the mounting bolts to the
specified torque.17On P100 models, when refitting the
roadwheel align the previously made marks
on the roadwheel and wheel stud.18On completion, bleed the front brake
circuit.
Braking system 10•9
10
6.6 Exploded view of Teves front disc caliper
A Guide bolts
B Caliper carrier bracket
C Caliper retaining clipD Disc pads
E Dust-excluding seal
F Piston sealG Piston
H Caliper
6.5 Exploded view of Girling front disc caliper
A Caliper
B Guide pin and dust
bootC Piston seal
D Piston
E Dust-excluding sealF Disc pads
G Caliper carrier bracket

Specifications. To do this, fix the measuring
equipment, and rotate the disc, noting the
variation in measurement as the disc is
rotated. The difference between the minimum
and maximum measurements recorded is
known as disc run-out.
5Mark the position of the brake disc in
relation to the drive flange and on Saloon,
Hatchback and Estate models, remove the
retaining screw or spire washer(s), as
applicable, and remove the disc. On P100
models, also mark the position of the wheel
adapter plate in relation to the disc and drive
flange, then unscrew the five retaining nuts
and remove the wheel adapter plate and disc.
6Refitting is a reversal of removal, but when
refitting ensure that the mating faces of the
disc, drive flange and on P100 models the
wheel adapter plate, are clean. Align the
marks made on the disc, drive flange, and
where applicable the wheel adapter plate,
during removal. Refit the disc caliper and
carrier bracket.
Rear disc
7Chock the front wheels, loosen the relevant
roadwheel nuts, then jack up the rear of the
vehicle and support on axle stands.(see
“Jacking and Vehicle Support”).Remove the
roadwheel and release the handbrake.
8Detach the handbrake cable from the
retaining clip on the lower arm.
9Unscrew the two caliper carrier
bracket-to-hub carrier bolts and remove the
caliper assembly. Support the caliper on an
axle stand to avoid straining the flexible hose.
10Proceed as described in paragraphs 3
and 4.
11Mark the position of the brake disc in
relation to the drive flange, remove the
retaining spire washer(s), and withdraw the
disc.
12Refitting is a reversal of removal, but
ensure that the mating faces of the disc and
drive flanges are clean, and align the marks
made on the disc and drive flange during
removal.
1Whenever a brake drum is removed, brush
out the dust, taking care not to inhale any, as
it may be injurious to health.
2Examine the internal friction surface of the
drum. If deeply scored, or so worn that the
drum has become ridged to the width of the
shoes, then both drums must be renewed.
3Regrinding is not recommended as the
internal diameter of the drum will no longer be
compatible with the shoe friction material
contact diameter.
Saloon, Hatchback and Estate
models
1Chock the front wheels, loosen the relevant
roadwheel nuts, then jack up the rear of the
vehicle and support on axle stands (see
“Jacking and Vehicle Support”).Remove the
roadwheel and release the handbrake.
2Remove the retaining spire washer(s) from
the wheel stud(s) and pull off the brake drum.
If the drum will not pass over the shoes, it is
possible to release the automatic adjuster
mechanism by inserting a screwdriver through
the small hole in the drum and pressing down
on the ratchet.
3Remove the brake fluid reservoir cap and
secure a piece of polythene over the filler
neck with a rubber band, or by refitting the
cap. This will reduce the loss of fluid during
the following procedure.
4Unscrew the union nut and disconnect the
fluid pipe from the wheel cylinder (see
illustration). Plug the open ends of the pipe
and wheel cylinder to prevent fluid loss and
dirt ingress.
5Pull the tops of the brake shoes apart so
that the self-adjuster mechanism holds them
clear of the wheel cylinder.
6Unscrew the two retaining bolts from the
rear of the brake backplate, and withdraw the
wheel cylinder and sealing ring.
7The wheel cylinder can now be dismantled
as follows.
8Prise the dust-excluding rubber seals from
the ends of the wheel cylinder, and withdraw
the pistons and central spring, identifying the
pistons so that they can be refitted in their
original positions.
9Prise the seals from the pistons.
10Clean all the components in methylated
spirit and allow to dry. Examine the surfaces
of the pistons and cylinder bore for wear,
scoring and corrosion. If evident, the
complete wheel cylinder must be renewed,
but if the components are in good condition,
discard the seals and obtain a repair kit.
11Dip the new seals in clean brake fluid and
fit them to the piston grooves, using fingers
only to manipulate them. Ensure that the seal
lips face into the wheel cylinder.
12Carefully insert the pistons and central
spring into the cylinder, and fit the
dust-excluding rubber seals. Ensure that the
pistons are fitted in their original positions.
13Wipe the brake backplate clean, then fit
the wheel cylinder together with a new sealing
ring, and tighten the securing bolts.14Reconnect the fluid pipe to the wheel
cylinder and tighten the union nut.
15Using a screwdriver, push the
self-adjuster toothed quadrant fully towards
the backplate to its initial setting.
16Further refitting is a reversal of removal,
but on completion apply the footbrake several
times in order to set the brake shoes in their
normal positions, and bleed the rear brake
circuit.
P100 models
17The procedure is as described in
paragraphs 1 to 16 inclusive, but with the
following differences.
18Before removing the roadwheel, mark its
position in relation to the brake drum.
Similarly, mark the position of the brake drum
in relation to one of the wheel studs. Align the
marks when refitting.
19The wheel cylinder is secured to the brake
backplate by a circlip instead of the two bolts
used on other models (see illustration).
Saloon, Hatchback and Estate
models
1Remove the rear brake shoes.
2Disconnect the handbrake cable from the
backplate by extracting the U-clip.
11Rear brake backplate (drum
brakes) - removal and refitting
10Rear wheel cylinder (drum
brakes) -removal,overhaul
andrefitting
9Brake drum -inspectionand
renewal
10•12Braking system
10.4 Fluid pipe union (1) and wheel cylinder
retaining bolts (2)
10.19 Wheel cylinder securing circlip
(arrowed)
Caution: Refer to the
precautions in Section 1.
Caution: Refer to the
precautions in Section 1.