02-02-08
Brake System
02-02-08
Tool-HRE-8650
JUST SET TO DRUM
DIAMETER HERE . . .
FIND CORRECT BRAKE
SHOE DIAMETER HERE
H1416-A
FIG.
7
7—Adjusting Brake Shoes Using Tool HRE-8650
BOOT
BOOT
PISTON
. BLEEDER .
CYLINDER
SCREW RETURN SPRING PIST0N
H1385-B
FIG. 72—Brake Wheel Cylinder—Typical
DISASSEMBLY
1.
Remove the links and the rubber
boots from the ends of the brake cyl-
inder. Remove the pistons, cups, and
return spring from the cylinder bore
(Fig. 12).
2.
Remove the bleeder screw from
the cylinder.
INSPECTION
1.
Wash all parts in clean brake
fluid. Dry with compressed air.
2.
Replace scored pistons. Always
replace the rubber cups and dust
boots.
3.
Inspect the cylinder bore for
score marks or rust. If either condi-
tion is present the cylinder bore must
be honed. However, the cylinder
should not be honed more than 0.003
inch beyond its original diameter.
4.
Check the bleeder hole to be sure
that it is open.
ASSEMBLY
1.
Apply a light coating of heavy-
duty brake fluip! to all internal parts.
2.
Thread the bleeder screw into the
cylinder and tighten securely.
3.
Insert the return spring, cups,
and pistons into their respective posi-
tions in the cylinder bore (Fig. 12).
Place a boot over each end of the cyl-
inder. Bleed the brake system.
HYDRAULIC LINE REPAIR
Steel tubing is used throughout the
brake system with the exception of the
flexible hoses at the front wheels and
at the fear axle housing brake tube
connection (Figs. 17 thru 21).
Always bleed the applicable pri-
mary or secondary brake system after
primary or secondary brake system
hose or line replacement. Centralize
the pressure differential valve after
bleeding the system.
BRAKE TUBE
REPLACEMENT
If a section of the brake tubing be-
comes damaged, the entire section
should be replaced with tubing of the
same type, size, shape and length.
Copper tubing should not be used in a
hydraulic system. When bending
brake tubing to fit underbody or rear
axle contours, be careful not to kink
or crack the tube.
All brake tubing should be double
flared properly to provide good leak-
proof connections. Clean the brake
tubing by flushing with clean brake
fluid before installation.
When connecting a tube to a hose,
tube connector, or brake cylinder,
tighten the tube fitting nut to specified
torque with Milbar tool 1112-144 or
equivalent.
BRAKE HOSE
REPLACEMENT
A flexible brake hose should be re-
placed if it shows signs of softening,
cracking, or other damage.
When installing a new front brake
hose,
position the hose to avoid con-
tact with other chassis parts. Place a
new copper gasket over the hose fit-
ting and thread the hose assembly into
the front wheel cylinder. Engage the
opposite end of the hose to the brack-
et on the frame. Install the horsesho-
e-type retaining clip, and connect the
tube to the hose with the tube fitting
nut (Figs. 17 thru 21).
A rear brake hose should be in-
stalled so that it does not touch the
muffler outlet pipe or shock absorber.
Thread the hose into the rear brake
tube connector. Engage the front end
of the hose to the bracket on the
frame. Install the horseshoe-type re-
taining clip, and connect the tube to
the hose with the tube fitting nut.procarmanuals.com
TUBE ASSEMBLY-2B255
VIEW IN CIRCLES V
FUEL LINE
CLIP (4 REQUfRED)
PART OF AXLE ASSEMBLY
HOSE ASSEMBLY-2A448
FRAME
TUBE ASSEMBLY-2267
CHECK BRAKE HOSE
CLEARANCE TO ALL
COMPONENTS IN
METAL/METAL JOUNCE
AND METAL/METAL
REBOUND.
CLIP (3 REQUIRED)
TUBE ASSEMBLY-2267
BRAKE BOOSTER-2B195
HOSE-2A047
TUBE ASSEMBLY-2B255
TUBE ASSEM3LY-2420
[
TUBE-2263-C *
TUBE ASSEMBLY BRAKE TUBE
2268 ASSEMBLY
2267 R.R. BRAKE TUBE
ASSEMBLY
TUBE ASSEMBLY
2263
VIEW IN CIRCLES X
COVER-2A487
PEDAL PAD-2457
BRAKE PEDAL-2455
USE EXISTING NUTS
TUBE ASSEMBLY
2325r
TUBE ASSEMBLY
2264 L.H. 2263 R.H.
TUBE ASSEMBLY
2B171-C R.H.
23218-C L.H.
BOLT-381877-S2
(3REQUIRED)
CLIP-382088-S2
(3 REQUIRED)
ALL CONNECTIONS, TUBES, MASTER
CYLINDER AND FITTINGS MUST BE
FREE OF FLUID LEAKAGE WHEN
CHECKED AFTER ROAD TEST.
TUBE ASSY.-2A040
TUBE ASSY.-2B253
PRESSURE IMPULSE
VALVE
ALL BRAKE LINES, FITTINGS AND
FLEXIBLE HOSES MUST BE KEPT FREE
OF FOREIGN MATERIAL BEFORE
AND DURING ASSEMBLY OPERATIONS.
TUBE ASSEMBLY
2B255
PROPORTIONING
VALVE-2B328
GASKET-2149
(4 REQUIRED)
#LUBRICATE PIVOTS
CLIP-381799-S2
2REQUIRED
180°APART
BE LEAKPROOF
TUBE ASSEMBLY-2B255
6
w
Q
7T
3
CHECK BRAKE HOSE
CLEARANCE TO ALL COMPONENTS
IN METAL/METAL JOUNCE
METAL/METAL REBOUND AND FULL
INSIDE AND OUTSIDE TURNS.
BOLT
2 REQUIRED
TUBE ASSY. -2264
BRACKET ASSY.-2B328
O
6
H 1540-C
FIG. 20—Service Brake System—Thunderbird, Continental Markprocarmanuals.com
