1974 FORD CAPRI ECO mode

) Chapter 9 Braking syste m 143
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Fig. 9.1 DU

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.00 Chapter 9 Braking system
PR IMARY CUP
SeCONDARY J CUP _ RETA INER SCREW
INTERMEDIATE RING
SECONDAR Y CUP)
STOP WASHEP. WASHE R
PRIMARY ~ (''''')
CUP PISTON ~lJ ~
SPRIN\G SEAT T 1 WAStE:~L~\C Q I~
PRl~lARY CUP ./
SPRING OISC I -1 '" "'~'f" SPRING i SEAT L ,:-\,/(.'.~·, J ' '
RETAINER • \ . '0 I)J-'0'.'.)'. ',:.,' "'f
I -, " ,O"'j')'" I' . I r -h" .
l J i\\"\" ,jl;
~G«1N w: 1 vl";';':' ~ .. '
" r • • {l"t:';" ,: .• ,-; \{. . ' SNAP . \J, ~;'. PISTON RING
--
1\-\1 ijM:\'.' ,J , ~1.1"9 _ ·S TOP SCREW .....
--
SEAL ','
-'---
WASHEA
---, ,

/ /
SECONDARY CUP
Fig. 9 .9 EKplodcd view of tho Teves (ATE) master cylinder (Sec 11)
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F ig 9.10 The Tavos (ATE) maste r cylinder pisto ns as sembled ready fo r reliUing (Sec 11)
12 Pressure di Herent;al switch -desctilHion. removal and refitting
E,lrly mOdels were filled with a pre ssure diHerent ial switch to illurnin~to ~ wolfning l igh t on the in stru men t pilnel in the event 01 a drop in preSsure in eithe/the Iron t 0/ rear hydraul ic circui ts . The switch ir- "'rporates 1I piSton which is kept 'in b alanco' if the pres sures in tho I. and roar ci,cui ts are equal. Howeve/, rl there is a pressure drop in
one circuit. t he pisto n is displaced and the switc h con tacts close .
2 The switc h is loca ted on tha lowe, left .hand side of the eng ine comp,Htrnent and a lthough it was once possible \0 obtain new in ternal
seals these are no longer available. Th e switch may be renewed alone (without Iho hyd,au lic body) by disconnecting the wiring and unsc rewing it .
3 To rernovo the hydraulic body. first tigh t
en a piece 01 polythene shoetinu bene ath th e brako Iluid reservoir fillor cap 10 reduce th a loss 01 fluid .
4 D isconnec t the swit ch wiring.
5 Unscrew the fi
ve union nuts thon disconnec t and plug the pipes.
6 UnSCfew the mouming bolt and romove the unit.
7 Relillin g is a reversa l of removal. but on comple tion bleed the hydraulic system as described in Section 15 .
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Chapter 9 Braking syste'm 153
3
Fig, 9 .13 Foothr 1
Spring clips 7 Clip 2 Washer 8 Bushes 3 Shafl 9 Clevis " in , Spacer 10 Rdl/fn sp,illY
5 Bushes /I Rub/u."r P,lI/
6 Pl1d;1I
172 Stop lilOlP switch iHld witi:lg plug
18 Handbrake -adjustment
)Jack up the ,e 6
11
Early (1974/1975) models 2 loosen the locknul on the end 01 the primMY c b,acket. Tighten the Jocknut.
3 Loosen the locknul on the IIgill·hnnd end 01 the secondnry cable then IUfn the adjustment le"ule until Fig. 9.14 Handbrake primary cable adjustment nut an d locknut (arrowed) on early models (Sec 18)
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procarmanuals.com

)4 Chapter 9 Braking system
Fig 9 .16 H an dbrak8 cable adjusting nul (A) on later models (Sec 18) ~'9. 9 .15 Handbrako secondary cable adjustment fonu le and lockn u t (arrowed ) on early models (Soc 18)
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Fig. 9 .17 Hnndhrnke operating lover n n d (llwtment (ldjuSlment gn p ·A' on later models (Sec 18)
'-iller mode!!s 4 LO(:,'I" trw r.al,lo .1dlUS1Cf lust forWi1f(1 01 the 10." axle dillCrcntinl , ;;.~.IIl!J (,.holn). then Sflp,l'ate Ihe ndjus\ing nul and sio eve usinIJ II se.ewtl""cr ["n,'IIO lhe keyed sleove in the bracket.
5 T 11m Ihe lldlu sling nul unlot all c.,l>lo slilc k is eliminated and a cleiuallr.e of I 0 '0 1 5 mill (0.039 to 0.059 in) exists at tho handb'Jke ope.aling 10l'm .. butment points (Fig. 9.17) Temporarily apply the holn(i!),,,kc 10 cnUage t he ilujus\ing nut with the sleeve then recheCk the ildJuSlmcnt.
All models 6 Lower Ihe r.'lr In the ground.
1 9 H ,1"dbrako lover -removal and refilling
Chock till) front whecls then lack l'P thO tcat 01 t he Cllt and SUllport on ilxlc swnds . Rclc~!se the halldbmko . 2 Whete applicahle remove the centre console with reference to Chapter 11.
3 Disc;onnecl the l>fiOlilJy cable from the lower end of t he h andbrilke
lever beneath the etlr . On early mooels baek all the cable adjustmen t
and unhook the c lev is (photo). On lale r m odels remove the splil pin and withdtaw the clevis pin (photo). <1 Remove the SCHlWS and withdraw the gaiter over the top 0 1 th e lever.
S Unbol t the hanrlhtake lever Irom the lIoot. 6 Relinin g is a revetsal 01 removal, but check the handbHlke
ildjustment as desClibed in Section 18 .
19 .
3A Prim ary cable connection to
handbtake lever (early models) 19.39 p.ima.y cable connection 10 handbrake leve r (Iale. models)
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156 Chapter 9 Brakin g syste m
Secondary cc1ble (early models) 5 Loosen 1I1c lock.nut ~nd unscrew the adju stment ferrule from the right-hand rear clevis.
6 Remove the split pin and clevis pin securing the secanda.v caulo \0 the left-hand Icar operating le ve l. 7 htrac the clip, remove the clovis pin. and withdraw the pullcy wheel from the lever on the Ical a~le. 8 Remove Ihe cable from the lever.
Transverse rod (later models) 9 Disconne ct the cable from the righi-hand rear opCfating Icvcr by
removing the split pin and clovis pin. to Uncl.p the cable hom the 'Hlnsvcrse rod . 11 Remove Iho spli, pin and clevis pin securing the fod 10 the Icft·h~nd le;!1 operating lever . 12 Slide the transverse rod Irom the guide on the rOM axle . 13 Check thO {luide bush lor wear and dama ge and renew It il necessary by prising il oul and pressing a new bush irllo POSilioll.
All models 14 Refining is a r e versa' of removal. but lubr icllto the lin kage as )scflhed in Section 2, and atljl' stthe cable as (fescri bed in Section 18.
21 VilCUUrll sorvo unit -dosCrilHion
A vacuum servo unit is linod Into the lir,lk e hydrallirc cil cu il. 111 series with I he 111,1S ler cylinde f. to provide assiswnco to the dllver whlln Ihe brake pedal is depressed . Thi s reduces the eHolI le{luired try the driller to oper,lIe the brakes, under all brak ing condi tions .
This unit operates by vacuum, obtained from Ihe indu ction mnni rold and comprises basicall y iI booster diilphragnl and check lIallle . The servo unit and hydraulic master cylinder are connected
t o gether so that th e serllO unit piston rod acts as the master cylrnder pUShrod. The driller's b rilking ellon is trilnsmitted through allot her PIi ShlOd 10 the serllO unit piston and ils built-in COmrol system . The scrllo unll pislon docs not fit tightly inro the cylinder. but has a strong ,lltl flhril!Jlllto ke el) liS edges in COllst ilnt COntaCI with I he cylinder Willi_
23 rilult diagnosis -hrilking system
~ylllptom
-'ceSSllle ped,,1 u;tllel
nrakcs pull 10 ono Side
Or;tke ludder
E~cessive eHor l to stop car
so ensuring an i1inigh t seal between the two parts, The fo rward
chamber is held undelllaCUUm condi tions cleilted in the inle t manifold of the engine and during periods when the brake pedill is not in use, the controls open a passtlge 10 the rear ch ambe ., so placing it under lIacuum conditions as well. When the b.ake pedal is dep.essed. the lIacuum pass.Jge to the rear chamber is CUI oH and the chamber expos ed to atmospheric pressure. The consequent rush 01 ail pushes
the servo piston lorward in tile lIacuum chamber and operates the main push rod to the m.Jster cylindcl. The controls are designed so that assistance is given under all condllions. When the brakes are 1'101 requ ired, vacuum in the rear chamuer i s .e -es tabl ished when the br.Jke ped.J1 is released . All air Irom the atmosphe.e entering tho rear ch.Jmbe. is passed through II sma ll air trlter. Und er normal opcr.Jting cond itions tho IIflC(IUm serllO unit is lIery relraule and does not require ollerhaul e~cepl at IIcry high mile,1geS. In this case it is far bcner 1 0 o bta in a serllice e~hange uni l. r,1the, than rcp;ti . the o,igi'lo11 unit . Although inlernal components we,e once .Jv'lIlaule 10 ' ovcrhauling purposes this service has no w been
d,scont,nue(t .
22 Vacuulll servo unit _ remOlla l MId re filtillg
I RemOIlO the master cylinder as desc.ihed In Section 10. 2 D,scolllwc l thc vacuum hose from the non·return lIalve on the serllo \lI1it. 3 Work i,,!) insido thc cal. remOlle th e lower l;t cia panel below the stccring column. 4 E~tractlhc clip and l)ul1 outlho clellis pin attaching Ihe push.od to the l ootu .ake ped;t!. 5 Unsc.ew the nuts securing thc mount ing b.ack.et to the bulkhead.
then withdraw thc serllo unit and bracket from the engine COlllp,lJtlnen t, 6 UnSClew th e nuts ar1(1 serlar,lle the braket 110m the SCIIIO uni, . 7 netrning IS;t rell e.sal 0 1 remOllal w ith leference .Jlso 10 Section 1 0 when retrumg Ihe master cylrnder.
Renson(s)
RC.Jr blake self adju sting mechanism faulty All i n hydrilulic system
WOIll or cont,llllina led /rnin{Js Seized Caliper or wheel cy linde r
E~cessille run-out or distortion of discs o. drums
Worn Of cont aminated linings Brake backplate or caliper l oose WOIll suspensio n bailloints
SerllO unit faulty
Worn or conwmin.Jted linings
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)76 Chapter 11 Bodywork and fitting
General description
The body is of all-s teel welded construction with impact ilbsorbing hont Dnd rear sections . Anli-burSllocks nrc lilted 10 the doors, ilnd the
t ailgDte is supponcd by \J 2 Routine nwintenancc
AI the in1erVills speCIfIed in the Routine M"IIl\cnilnCe section in the front 0 1 the nl Check seal bellS 1 ThorouUh1y check nil sent hellS 101 frayu10 . cu\s, iheck and lubricafe bonnet and door locks 2 011 the bonnet lock ilnd sillety c~tch ilnt! check thilt they oper~lle correctly. 3 011 illl the (Ioor check strilps ilrld lock hilrwls 4 011 the luel 1IIIer CilP hlnw:! ilnd lock
Check underbody protective coatiog 5 W,th the CM supponed on i1xle stilnds. check the cond,tlon 01 the un(lelbody protcctivc coating. i1nd wherc neceSSilry clean w 3
M,,;ntcll The gorH)! ose solids which lIl.1y have stllt:k to the vehIcle. It is i",portant 10 Ilush these oU in such a way ilS 10 prevent \}lIt 110m scratching Ih(l Irni sh . T11e wheel arches o1I1(f unded'nrne need w~lshln9 in the s;rrne
Wily to remove any aCCUIllUI,lted mud whIch WIll retillll mOlslu re f or inspection. Periodically, except on vehicles w'lh iI wax· bnsed underbody protec tive cO After w 4 Mnintenllnce -upholstery MId eMpets
Mats and C 5 Minor body dnnl rhe phOlo{Jr.1phic SCl/rICIICCS 011 P,IflcS 174 ilfld 175111051'.11" Ihe OIWfil/iofl$ d"lo1Ifcd ill Ih" 101i0willY suh·SCC(IOII$. Note: Fo, mon' (il-1,1iIL'd ili/OlilialiOIl 01/)01/1 I}odywork fCfwir. Ihe U"ylll:s P"hlislllilY Group pu/)/ish II book by Lilli/say POller c!llIed The C,If lJodywork H"II,11f Mill",al flII:~ lIIeorpor"ll!s ;lIlo,,,,,l(ioll on sllcli Repair of minor scratches it) bodywork II the scratch is very superllclill, MId docs not penetrilte 10 the Illelill 01 the hodywork, repnir is very simple. LIghtly rub the area 01 the scratch with a pilintwork renoviltor, or il vcry line CUtlll'\} p pa il11work by rubbing Ihe sC/Dtch men w ith iI pilintwork renovator or a
very line culling pils te. Finally, opply wax polish. WhNe the scrotch has penctrDt(ld right through to the metill of the bodywork. causing the mowl \0 rust. iI d ifferent repa ir lechnique is
required. Remove any loosc rus t fronl the bottom 01 the scra tch with a penknile. then apply rUSI inhibiting paint 10 prevent the lormation 01 rust in Ihe future. Using n rubber or nylon appliCiltor fill the scratch with bodystopper paste. II requ ired. this paste Ciln be mixed with cellulose thinners to provide a very thin paste which is ideal for filling narrow scratches. Before t he stopper·paSI(l in the scratch hardens. wrilp il piece 01 smooth COllon rJg i1round the lOp 01 J linger. Dip the finger in cellulose thinners and then quickly sweep it i1CIOSS the surlace of the 5topper-pJste in the scratCh: this will ensure tha t the surfilce 01 the stopper,pilste is slightly hollowed. The scratch can now be p Repair o f dents ill bodywork When deep denting 01 the vehicle's bodywork hilS taken plilce. the
first wsk is to pull the dent out, untrl t he affected bodywork almost
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17 8 Chapter 11 B odywork and fitting
If the owner is renewing ~ complete component himself. he will be left with the problem of IlIldmg a sUI1 6
Major u o d y damage - repair
Where serious danHlge has or.cur",d or la,ue aWroperly and. secondly. nneven slresses w,1I be Impos".r nil tli,! S1o:"rmu. (!n\l'n(~ nnrt
Ir 7 Door r The most common C (,1)
Loose door or window winde, ",,,,dft,!; (Ii) Loose 0' lIIiS.lliUned d(Jo, lock c(lillj/olJC!lJl~ (c) Loose or worn relllOle con/iol ""."/."";",i$III
2 It IS quite possrule 10' r,rllies 10 he the ",suit of" [O,,,lrrllirl,Orl 01 111<.1 atrove laullS. so a c;,r(:/ul <.1xanrrrr;riron should he rn",h, 10 ilCIl'UllU1e III<, exact CillrSf:! 3 If cd\Jes A and B (FIIJ . 11 1) should I", p,Hirl l,,) ,md "an he d1ecked by slrrnm\J a torch tlrrou\jh Ihe dOllr \Jap lrom "iJovo 'Irld Irelow the strrker • Cheek the ..
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7 .3 Door striker plate
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(.'----+"<, --'-1 ------<0
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F i!J.1l.1 A lignin!J the s triker 10 lock support plnte (Sec 7)
Edyes A and lJ shoold be 1'.1(.lllel
A
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F ig 11.2 Lock claw·to·striker cleiHance (Sec 7)
A -70,11111 (028111)
5 Wrlh t he lock in the open positron. check the lock cl milterral on Ihe siroker POSI ,lnd cheding Its hergllt n!tar gently closll1g the doo •. The striker plale call be reposnroned verlrC d lmensron. bw t~ke Colle 10 not to dislurb any prevrous milral se1\lI1gs 01 Ihe pl,lte.
8 Bumper s -removal nnd refitlin g
FrOIll bumpN 1 D,sconnect the u<.rttery earth lend. Also where necessary dis connect the IIldrC 3 Renlove the fOI" bumper rewining screws (pholo) nnd hit away the bumper. On Imer models drser1!lage the bumper corner sectiOns f,om the body side clips as the I)umper IS wnhdrJwn. <1 Refrl1ing r$ the reverse 01 the removal p.ocedure. but do nOI fully truhlCn Ihe uolts unlrl tire bumper is correclly aliUned .
Rear bUll/pel 5 Open the lJ.tgate. Ihen rernOve the mal ilnd the sub·floor. G Remove the Jack ilnd washer water reservOIr (where applrcable) . 7 Remove the two nuts. Sp",l(J wilsher and 11m wilshers. procarmanuals.com