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2-20
GROUP
2-BRAKES
Fig. 23-Brake Installation
the primary and secondary outlet
ports of the master cylinder.
Remove the wires from the warning
light switch.
Remqve the secondary piston
stop bolt from the bottom of the
primary
reservoir. Refer Fig. 25.
2. Remove the two nuts and two
lock washers attaching the master
cylinder to the brake booster assem-
bly.
3. Slide the master cylinder for-
ward and upward from the vehicle.
INSTALLATION
1.
Position the master cylinder
assembly over the booster push rod
and onto the two studs on the booster
assembly (Fig. 23).
2. Install the attaching nuts and
lock washers and torque them to
specifications.
3. Install the front and rear brake
tubes to the master cylinder outlet
fittings.
4. Fill the master cylinder with
the specified brake fluid to within
: inch of the top of the dual reser-
voirs. Use Motorcraft Brake Fluid.
·Do not m1x low
temper~ture
brake
fluids with the specified fluids for the
disc brake system.
5. Bleed the dual master cylinder
and the primary and secondary brake
systems. Refer to Hydraulic System
Bleeding, Page 2-3 for the proper
procedure. Replace the wires on the
warning light switch.
7. Operate the brakes several
times, then check for external hy-
draulic leaks.
BRAKE BOOSTER
REMOVAL
1. Working from inside the ve-
hicle below the instrument panel,
disconnect the booster push rod from
the brake pedal assembly. To do this
proceed as follows:
Remove the hairpin retainer from
the brake pedal pin and then remove
the booster push rod and the nylon
spacer and bushing off the brake
pedal pin (Fig. 23).
2. Open the hood and remove the
master cylinder from the booster. It
is necessary to disconnect the brake
lines. Care should be taken that the
brake lines are not deformed. Perma-
nent deformation of brake lines can
lead to tube failure.
·
3. Disconnect the manifold vac-
uum hose from the booster unit.
4. Remove the booster to dash
panel
attaching
nuts
(Fig. 23).
Remove the booster assembly from
the dash panel, sliding the push rod
link out from the engine side of the
dash panel.
INSTALLATION
1. Mount the booster and bracket
assembly to the dash panel by inser-
ting the push rod or push rod link in
through the hole and boot in the dash
panel. Install the bracket to dash
panel attaching nuts (Fig. 23).
2. Connect the manifold vacuum
hose to the booster.
3. Install the master cylinder and
torque the attaching nuts to speci-
fications.
.
4. Working from inside the ve-
hicle below the instrument panel,
connect the booster push rod link to
the brake pedal assembly. To do this,
proceed as follows:
·
Install the inner nylon spacer, the
booster push rod, and the bushing on
the brake pedal pin. Secure these
parts to the pin with the hairpin
retainer.
BRAKE PEDAL
REMOVAL
ALL
MODELS
1. Remove the hairpin retainer.
Slide the master cylinder or booster
push rod and the nylon spacer and
bushing off the brake pedal pin
tFig. 23).
2. Remove the circlip type re-
tainer from the brake pedal shaft,
then remove the shaft, the brake
pedal and the bushings from the
pedal support bracket.
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