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10•10 Braking system
18.5 Hydraulic unit pump mounting bolt
18 Hydraulic unit pump and
motor - removal and refitting
1 Remove the accumulator (Section 17).
2 Disconnect the high pressure hose from the
pump. Be prepared for fluid spillage.
3 Disconnect the low pressure hose from the
pump. Allow the fluid to drain out of the
reservoir through the hose.
4 Disconnect the multi-plugs from the
pressure switch and the pump motor.
5 Remove the pump mounting bolt (see
illustration).
6 Pull the pump and motor assembly off the
mounting spigot and remove it.
7 Recover the mounting bushes and renew
them if necessary.
8 If a new pump is to be fitted, transfer the
pressure switch to it, using a new O-ring.
9 Commence refitting by offering the pump to
the spigot, then reconnecting the low pressure
hose.
10 Refit and tighten the pump mounting bolt.
11 Reconnect the high pressure hose, using
new sealing washers on the banjo union.
12 Refit the accumulator, using a new O-ring.
13 Reconnect the multi-plugs and the
battery.
14 Refill the reservoir, then switch on the
ignition and allow the pump to prime itself. Do
not let the pump run for more than two
minutes - see Section 3. Check for leaks
around the disturbed components.
15 Bleed the complete system (Section 2).
19 Hydraulic unit pressure
switch - removal and refitting
Note: To remove the pressure switch from the
hydraulic unit in situ, Ford tool No 12-008, or
equivalent, will be required. The switch may be
removed without special tools after removing
the hydraulic unit complete (Section 16) or the
pump (Section 18).
1 Disconnect the battery negative lead.
2 Depressurise the hydraulic system by
pumping the brake pedal at least 20 times, or
until it becomes hard.
3 Disconnect the multi-plug from the switch,
then unscrew and remove it.
19.4 Refitting the pressure switch
Hole (arrowed) in sleeve must face pump motor
4 When refitting, use a new O-ring on the
switch. Position the plastic sleeve so that the
hole in the sleeve is facing the pump motor
(see illustration). Tighten the switch.
5 Reconnect the multi-plug and the battery.
6 Bleed the complete system (Section 2).
20 Hydraulic unit hoses -
removal and refitting
1 There are two hoses on the hydraulic unit.
The low pressure hose connects the reservoir
to the pump inlet; the high pressure hose
connects the pump outlet to the booster and
valve block.
2 To remove either hose, first disconnect the
battery. Depressurise the hydraulic system by
pumping the brake pedal at least 20 times, or
until it becomes hard.
Low pressure hose
3 Have ready a container to catch spilt fluid.
Remove the spring clip and pull the hose off
the pump inlet. Allow the contents of the
reservoir to drain out of the hose and into the
container.
4 Pull the hose off the reservoir and remove it.
5 Refit by connecting the hose to the reservoir
and pump inlet. Secure the hose to the pump
with the spring clip.
6 Refill the reservoir, reconnect the battery
and bleed the complete system (Section 2).
Check for leaks.
21.3 Undoing a rigid pipe union nut
Flexible hose locknut is just above
20.9 Fitting new sealing washers to a banjo
union
High pressure hose
7 Remove the banjo bolts which secure the
hose. Be prepared for fluid spillage.
8 Remove the hose and recover the sealing
washers.
9 Refit by reversing the removal operations,
using new sealing washers on both sides of
each union (see illustration).
10 Reconnect the battery and bleed the
complete system (Section 2). Check for leaks.
21 Brake pipes and hoses -
inspection, removal and refitting
1 Periodically inspect the rigid brake pipes for
rust and other damage, and the flexible hoses
for cracks, splits or "ballooning". Have an
assistant depress the brake pedal (ignition on)
and inspect the hose and pipe unions for
leaks. Renew defective items without delay.
2 Before removing any pipe or hose,
depressurise
the
hydraulic
switching off the ignition and pumping the
brake pedal 20 times, or until it becomes hard.
3 To remove a flexible hose, first undo the
union nut which secures the rigid pipe to it.
The use of a split ring spanner, sold for this
purpose, is recommended (see illustration).
Be prepared for hydraulic fluid spillage, and
take precautions to keep dirt out.
4 Having disconnected the rigid pipe, release
the hose from the bracket by removing the
locknut and washer (see illustration).
21.4 Removing a flexible hose from its
bracket
system
by
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