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duriq
removal.
2 .. Remove about 2/3 of the total
brake fluid capacity from the
mas-
ter cylinder
~eservoir
which serves
the disc brakes. Do not drain the
reservoirs
completely.
3. Disconnect the brake hose
from the caliper. Cap the hose fitting
to prevent brake system contamina-
tion and loss of brake fluid from
the
master cylinder. Mark the left and
right caliper assemblies with chalk
prior to removal from
the
vehicle.
. 4. Remove the caliper locating
pms and lower stabilizer attaching
bolts and discard the stabilizer. Refer
to Fig.
8.
·
Lift
the caliper from the
anchor plate Fig. 11.
INSTALLATION
S. Position the caliper assembly
over the rotor with
the
outer brake
shoe against
the
rotor braking surface
during installation on the anchor
plate to prevent pinching the piston
boot between the inner brake shoe
an~
the
piston. Verify that
the
correct
caliper
1S
assembled on the correct
anchor plate as marked during dis-
.
assembly.
8. Position the new stabilizer.
Apply methylated spirits on the
locating pins and attach the stabilizer
to
the
caliper. Be sure the
locating
pins
~
free
of on,
grease
and
dirt.
T1ghten
,
the caliper locating
pins
finger
tight.
Warning: When ever the caliper
is removed, it is mandatory that
a new stabilizer, stabilizer locat-
iq pins
and insulator
bushes be
fitted.
7. Install the stabilizer to anchor
plate attaching screws. Finger tight.
8. Remove the cap from the
brake hose fitting. Install a new
copper washer on each side of the
hose fitting and install the brake hose
on the caliper. Tighten the clutching
screw to 27-32 lbs.
ft.
torque.
t.
Bleed the brake system.
CAUTION: DURING BLEED-
ING OPERATIONS THE BRAKE
WARNING
LIGHT
SWITCH
MUST BE REMOVED FROM
THE MASTER CYLINDER TO
AVOID
DAMAGE
TO
THE
SWITCH.
Replace the w&ming light switch
on completion of bleeding
o~tion.
10. Fill the master cylmder as
required to within one quarter inch
of the top of the reservoir.
11. With moderate pressure appli-
ed to the brake pedal torque the
stabilizer attaching screws to 8-lllb.
PART
2-2-BRAKE SYSTEM
ft.
and the caliper locating pins to
25-35 lb.
ft.
12. Install the wheel and tyre
assembly and tighten the wheel nuts
to 70-115lbs.
ft.
torque.
DISC BRAKE CALIPER ASSEMBLY
REMOVAL P.B.R.
(1)
Remove about 2/3 of the total
brake fluid capacity from the mas-
ter cylinder reservoir which serves
the disc brakes. Do not drain the
reservoirs completely.
(2)
With vehicle raised evenly on a
hoist or jackstands, remove the front
wheels-
Note
If
more than one brake requires
service, work on only one brake at a
time, however, shoe and lining as-
semblies must always be replaced in
both brakes.
(3)
Locate brake line and wipe
area around fitting at
·
brake with a
clean cloth to remove dirt and grease.
Remove hose and place dust cap over
end fitting. Insert dust cap into in·
let hole of caliper.
(4)
Remove the two anchor bolts
which hold the caliper anchor plate
·
to the steering spindle, remove the
two bolts and lift the caliper
·
·and
anchor plate assembly from the
spindle.
INSTALLATION
(1)
Position caliper correctly over
disc and slide straight into position
until anchor bracket bolt holes align
with their respective holes on the
steering knuckle.
(2)
Instal the lower bolt fmger
tight. Instal the upper bolt and torque
to specification. Torque the lower
bolt to specification. Safety wire both
bolts.
Be
_
s ure specified wire wraps
are made and sharp wire ends
point
away from brake hoses.
(3)
Loosen the bleeder screw. Re·
move the plugs from the fluid in·
sert hole in the caliper and the brake
hose and insert fitting into hole and
tighten.
(4)
Bleed the system. Allow the
caliper to fill with brake fluid. After
all
air bubbles have
.
e scaped, and fluid
runs clear from bleeder, close the
bleeder screw. Replenish the brake
fluid in the master cylinder.
(S)
Pump the brake pedal several
times to actuate the piston seals and
position the hose and pad assemblies.
(6)
Check for fluid leakage at all
connections under
maximum
pedal
pressure.
(7)
Instal wheel and tighten wheel
nuts to 70-115 lbs ft Torque.
2-19
(8)
Remove jackstands or lower
hoist.
(9)
Road test the vehicle and
make several heavy 40 - 0 m.p.h.
stops to wear off any foreign material
on the brakes and to seat the shoes.
(The vehicle may pull to one side
on the
f~rst
application after service.
This
is normal until shoes are seated).
DUAL MASTER CYLINDER -
DRUM BRAKES
REMOVAL
1.
Remove the hairpin clip from
the brake master cylinder push rod
pedal pin.
2. Slide the master cylinder push
rod and the nylon spacer and bushing
oft' the brake pedal pin.
3.
Remove the brake tubes from
the primary and secondary outlet
ports of the master cylinder.
4. Remove the nuts and lock-
~ashers
that secure the master cyl-
mder to the dash panel and lift the
cylinder forward and upward from
the vehicle.
INSTALLATION
1.
Position the boot on the push
rod and secure the boot to the master
cylinder. Carefully insert the master
cylinder push rod af?-d boot through
the dash panel openmg and position
the master cylinder on the panel.
2. Install the nuts and lock
washers at the dash panel and torque
them to specification.
Coat the nylon bushings with
SAE lOW oil.
3. Install the inner nylon
spacer
the
~aster
cylinder push rod, and th;
bushmg on the brake pedal pin.
Secure these parts to the pin with the
hairpin clip.
4. Connect the brake lines to the
master cylinder leaving the brake line
fittings loose.
5. Fill the master cylinder with
the specified brake fluid to within
~
inch of the top of the dual reser-
voirs.
Use Motorcraft Brake Fluid
or equivalent for all drum brake
applications.
6. Tighten the brakeline fittings.
Bleed the dual master cylinder and
the primary and secondary brake
systems. Refer to Hydraulic System
Bleeding,
Page
2-3
for
proper
procedure.
7. Operate the brakes several
times, then check for external hy-
draulic leaks.
DUAL MASTER CYLINDER -
DISC BRAKES
REMOVAL
1.
Remove the brake tubes from
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