1974 FORD CAPRI brake

) Chapter 9 Braking system 145
/ll.Iid reservoir tille , cap \0 help roduce any fluid loss. 4 Where a rigi d brake line is connec ted \0 the calipe r, comple tely unscrOw the union nUl . Where Iho flex ible hose is connected directly \0 Ihe caliper. loosen only .he union (lnd unscrew Ihc caliper f.om Ihe
hose later. S Prise back the laus on the locking plale and unscrew Ihe mouming boilS (photo). The cJliper may now be wit hdrawn ove r th o disc and where neCessary unscrew ed from Ihc flex ible hose, 6 Refilling is a revCfsal of fernOv;!I, but lit a new locking plate and
l ighten the mouming bol ts \0 the specified torque. Bend the Inbs \0 Io<:k I he boils. On comple tion bleed the hydwulic system wit h
reference \ 0 Sec tion 15.
5 Front brake caliper -ovorlulU l
1 With the c~liper removed . cle~n away all external dlr1. 2 Where applicable, prise out the dust cover cirClips dust covers from the external ~onular groove. : lIr"ct the pistons: keeping them idenhlied side lor s.de. If nt .... "ss"ry. use low [lir P"CSSlU(! frOill a foot pump to lorc e the pistons
IrOIl' lho bores. 4 nove tho dust covers Irom the pistons or bores as apphc hydrau lic Uuid . Inspect the piSlons and bores for signs 01 weilr . score markS. or damage and il evident. new par ts should be obtained !Cady for lilting. or a new ca lipe r obtained. 7 R eassem ble tho components using a reversal of th n disnwn tling procedure. but before inserting the pis tons dip them in clen n hydrnulic fluid to assist entry through the seals. On comple tion press the pistons fully into the bores.
45 Front brake caliper mounting bolts (arrowed)
6 Front brake discs -in spection. re rnovnl and refitting
Apply the hilndlxake then jn ck up the hom of the car and support on :1xle st:1flds. Remove the Iront roadwheels . 2 Rotate the disc by hand and examine il lor deep scoring, grooving or cf1lcks. light scoring is normal, but if excessive the disc must be
renewed.
3 SCrJpe RUEO '.(RlW
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1-""£0""""" ~Plf'l ~-____ ttIP
BI"'~( ".",~"" PI~I()'
4IOUf llltlGOOLI tCCKltlG PLATE
R( 1 Altl{R RltlG
BRAKE (VLIHOER PISTO'l
(l001
Fig. 9.3 EKp loded view of the front brake calipe( on fater models (Sec 5)
RING
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procarmanuals.com

Chapter 9 Braking system
4 Note that in order to m,lintOIll even braking both discs should he renewed ill the sal1 1 e lime
5 T o remove il dl~c. first remove the tHlb as described in Chllpter 10 . 6 Prise lip th(J locklllU I"hs. unscrew the fOlll bolts. and remove the disc from Ihe huh.
7 Clcilll the Illllirnu !ilces of the disc and hub then locale the diSC on the huh and allgel the holt holes.
8 InScrt new holt~. tOI){)ther w rth new locking plates. and tiuhten them to the specrfre(1 torque_ loc k b y bending the tabs. 9 Th e huh Illily now he ref Illed with reference to Chapter 10.
7 ReM hrake shoes -rt)rlewal
Check the front wheels th!:n lilck up the rem of the CM lind support on ,1~le stands. Rel(,a5e Ihe handbr,lke lind femove the reM roadwh~~els
2 Unsr",w th" I"ake drum lewinrnu scrow then t.1p off the ,IIurn \Jsing ;I ~"It f.lced milliet (photos) 3 Barsh away all dust I.orll the brilke shoos, backplate ilnd drum, ",killfl can' ""I /0 11111""., II ;I S 1/ is iHjmiaus to "e,11Ih Del""~~ ,,;och shoe hold-down sprrng (photo) ,lnt! rOt,lte the sprrn!! ",w"nIlH w.r~I"" th,ou!lh 90" , to rhsengage ,t from the pm sel:rr",d 10 Ihe had' pt. 'I" 1.,11 ,"wily 1Ill! w;'shel and spm}!J
Early moth'ls (iippmxilllawly pm Df!c()tllbcf 1974) 5 Eas,) .. ad} shoe loom ,t~ loc;rllol1 slor III the lixed pivot nrrd tllen detach th,-othe! '~nd 01 ea(.11 shoe f,om the wheel cylind'lr, 6 Note whld, W.1Y fOwul and IIltO which holus in the s hoes tlH~ two retracting sP""Hs Ill. 7 lift ,lway t ho two brake shoes "nd retracting springs. 8 TUf(lthe self- ad lust'ng ratchot wheetum,1 it alJuts the shoulder on t he s lot head bolt.
FiO_ 9.4 Renr brake shoo components Oil e,lrly moclnfs (Sec 7 )
I Pili 'm froft! dowII sWIIIII 2 Buc/."liTlt! J B',l~'l! shot's <1 II,-IIIrflHiiAe opcra/jllY h-v", 5 lIo/d d"wII slNil/ys
Lawf lII oduls
6 fir"",,:, (/",,1 r:lJvlH 7 IId;III1I1'!IIII.llr!S 8 flNr;Il:IIl'!! .,'I,"IIIIS 9 WI",,:II:yllJldl!l
fJ N Ole the local,on of the shoe 1"lpacl,no sprrll!ls nrld thell unllook tlwm \lSUl!l a s(;lewrh,vef or SUil;!tJle plo~"s. Remuv,) th" lorw,lrd shoe Unhuok tho small pelurn spring loom the reill shoe and then rumuve the shoe lenvinlJ the adJus!Cr in pos,tiol} (ph o tos)_ 10 Tu remove tim adjuster unit. del 'nech 7.2A Re cylinder (later models) 7.98 Brake shoe attachment to anchor ( later models) 7.10 Halldbr~ ke tra nsverse rod connection to opera ting lever on backp!ilte (Jrlowed)
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Chapter 9 Braking system 147
Br;'lke IlIlInU
Wheel Adjustment
"m
cylinder --·-·_.L
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I
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• shoe hold down spring/pin
Br.lke shoe
Fig. 9
.5 Rear brake shoe components on later m odels (Sec 7)
All models 11 Check the wheel cylinder lor leaks and lor Ioee moyemen t of the
piston(s). Apply a hule brake urease to Ihe shoe contac t points on the
backpla te. wheel cylinde r, anchOr and sell-adjusting mechanism. On
early models check th 12 Fit the new brilke shoes using a reyers .. 1 01 the remoyal procedure,
but check that the self-.. djusting mechanism is set to the minimum
posi tion belore refilling the drum .
13 Finilily apply lhe loo tbrake firmly several times. On later models this will actua1e the self-adjus ting mechanism; however. on e '
Wheel cylinder _ remo yal. oyerhaul and re fitting
Remove lhe rear urake shoes as described in Section 7.
2 Fit a hose clalllp to the fle~ible hose leading to the reaf br .. kes. If a hose ci 4 On pre Oecembe r 1974 models remoye the split pin and clevis pin Irom the handb rake leyer the spr ing plate is inser ted from the piston end 01 the wheel cylinder.
5 On I.ller models unbolt the wheel cylinde r from the backplate .
6 To dismantle thO wheel cylinder, remoye the clip where fitted then
prise the rubber boo t(s) from the cylinder body.
7 Extr.lct the piston( s) 8 Remoye the piston return spring .
9 Prise the seal(s) from the piston(s) , 10 Clean all thO compo nents in methylated spirits or clean hydraulic fluid then inspec t them for wea r and damage. Check the cylinder bote and piston{s) 10f scoring and corrosion. and il eviden t renew the
complete w heol cylinder. If the components are in good condition
ob tain a repair kit 01 seals.
i.
i I
II
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1 Chapter 9 Braki ng system 1 49
,1 M aste r cylinder -overhaul
With tho m Girling type 2 Removo the SCleW$ and withdraw rhe fluid reservoir. twisting i as necesS,,'y from Ihe end seal. 3 Remove the twO seals afler cdraC ling the circlip ovor Ihe cnd seal. <1 Using II hOKagon key. unscrew Ihe relainer and hit oUllhe primary
recuperating valvo. Oepress Ihe primll'y piston during Ihis procedure. 5 Exl.;'!ct Ihe primary and secondary pistons. IOgether wi,h their associated components. noting Ihe order of lemOlln l. H nccessary top Ihe master cylinder on a block of wood or use air pressure from il foot pUIllP through the inlel porlS. G Separate rhe primmy ,10d secondary l)is10 11S irani lha intermediilte
sprinu . Uso tho !inUe.s 10 remove tile Ulilnd seDI from the primil'Y
r""' lon .
The secondil'y piSlon assembly should ho sOfh"ated by lilting the u"mblo leaf ove , Ihe shouldered cnd 01 tho viston . Using the lingo,s.
rr 'wo the se spnJlg
9 Dotach lhe villve space ,. tilking c Teves (ATE) type 10 Dopress Ihe primary piston, thon oxtrnCtlhe circlip from the mOUlh of th o c ylindo r and also unscrew Ille SlOp screw. 11 Extract the primary piston componen ts noting Ihe order 0 1 removal. followed by Ihe secondary piston componenlS. If necessary top the
master cylinder on a block of wood or use air pressure from a 1001 pump through tho inlet ports. 12 Prise the seals from the pistons, nOling which way round they are lilled. then il necessary remove tho springs and seals. The prima ry
pis ton spring is retained by a screw.
Both types 13 Clean all tho components in melhylated spirits or brake fluid then
inspec t them for wear and damage. Check the cylinder bore and pistons for scorinu and corrosion. and if eviden t renew the complete nI .opair kit of seals. 14 Di p Ihe piston and seills in hydrilulic Iluid then reassemble Ihe m convex side against Ihe shoulder nange. Belore refiuing the fluid reservoi r on lhe Girling type ch ock that the recupera ling valve is open wllh Ihe prim depressed.
1
2~
3~
13
1
2
3
4 5 6
7 8
R
22
21
Fig. 9
.8 Exploded view 01 the Girlin g master cylinder (Sec 11)
Filler cap 9 Seal 16 Secondary piston
Seal 10 MaSler cylinder body 17 Seal
Seal !Clainer
11 WiJslrer 18 Rell11i1er
Fluid reservoi r 12 Reservoir relaining screw 19 Spring
Seal
1 3 Seal 20 Spring fl/Miner
Relainer
14 Primary piSlon 21 Valve
Primary fCCllpCfaling valve
15 Spring 22 Seal
Circlip
10
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procarmanuals.com

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)
Chapter 9 Braking system
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: ~~ 11111JIII/IIIJ II /I /III Ii hIIllllIlIlIllllIlll 11111#111111 III! -------
8
9
Fig. 9.11 Exploded view o f Iho pressure d ifferenti I Fron( /)',l/a.' inlet ullioll 2 W ,)Silms 3 Pj~(UflS
J Pressure reducing vulve -description. remalln' nnd refitting
<1 SCi/Is 5 W,If/ll//y $wl(ch (j [lid ilIIIY
All models from ~pproxirniltely 1978 me lilted with il pressure ,educing valve in the rC~f hydraulic Cifelli!. The IInlve is IOCillCd on the lower Icft- hJrHJ side of the engine compn((mcnt (phOIO) ,mel 11 effectively limIts the hrakin\1 force DV 4 Unscrew the twO union nuts then disconnect ~nd pluU the pipes .
5 Unscrew the mounting bolts ,md remove the unit.
6 Refitting is a reversal of removal, but on completion bleed the
hydraulic system as descrihed in Section 15.
1 4
Hydraulic pipes and hoses -removal and refittin g
7 8.1/1 8 Body 9 R(lb/w( cover
First wke meilsures to reduce the loss 01 hydraulic fluid. If ~ rig id
pipe downstream of a fle~ible hose is being removed fit ~ hose clamp to
the hose . If this is not possible tighten a piece 01 polythene sheetinu
beneath th e livid reservoi r filler cap. 13
.1
Rear brake pressure reducing valve
2 To femove a figid pipe, unscrew the union nutS;]1 each cnd and release the pipe from the retaining ctrps. wh(Jre /riled.
be retained as a gUide.
151
)TO remove 11 fle~ible hose, lirst disconnec t the rigid pipes IN u"screwing the union nuts then unscrew the nuts securing the hose to
the 1l10unting brackets .
4 RiUid brake pipes arc normally made up from straight pipe using special bending <.rnd flare· forming lools. The old pipe should therefore 5
Refitt ing
is J revNsal o f removal, but make sure thJtlle~ible hoses
arc positioned clear of suspension or steering cOlilpo rwnts which
could chafe them. Finally bleed the hydrauhc system as deSCribed in Section 15.
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152 Chapter 9 Braking system
)
OIOIN -.1
(2 ~i MMI __ J-j -I , h= .. OJ"N , r-t1 8 7MH)
Fig. 9 .12 Modified screVlldrivcr f o r CC01t;llisillg {he IHcss urc different;", switch pisto n (SIlC 15 )
15 Hydraulic systerll -hfccdiliU
The correct functioning 01 the bfl,kc hyd,~ulo<.: sy Stem IS only possible aile! removal of all ai, from the components ilnd CIICUI1. Ihis is ilchieved by bleeding the system. Note \h 8 II possible, one 01 the DIY brake bleedIng k'ls avaIlable frorn ncccssory shops shoul d be used, paltlcul1\lly tho typo which p,essulisos the system. as they \)rea tly simphly the task and leduce the risk 01 expelled air and lIuid being drawn back rlI10 the systelli. Whell.! ono of these kilS is being used, follow Ihe milnlliacturer's instructions concerning its operiltion. 9 If a brake bleedmg ki t is nOI being used, the sys!Cm may be blcd in the COllVCntlOllill Wily ilS lollows: 10 Ohlain a cleill1 glass Iilr. a suililble lel1glh 01 pillstic or rubbe. tubin g willch IS a 1Ight fll over the bleed sc rews. a tIn of the speciflod hrake lIuld ~nd the help of an ilssis tant. 11 Depress the b.ake pedal seve' ,; , .'
'\'~!.; .~ . .,.
15 12 Ruhhe. (i'lsi C,lP 011 Ironi brake Cilllper
tht!
J;II ill111 porn 111 sull,c.(,:nt hrilkc lIuld 10 keep Ihe end 0 1 Ihe tube ,"uhml!r!Jed . Opel1the IJIL'Cd screw hall a ilIOn anti hnve your ilSSlstilnt dnp,nss IIII! IHilk e pedal In the flOOr and then relColse il. Tlghton Ihe billed ~r.rew ill Ihe end 0 1 cilch downstoko to prevent Ihe e_I)OJled 1 5 D,'press the hlake pcllal sevel,,1 I""es, It should feci 111111 sy~IC'"
16 Foolbrake pod,,1 -removal and .elillinll
Wo.kll1g InSide Ihe CM, ,emove the lower In c. a I","el below the 511,."," Ill!! C()IUIllIl 2 F.xlrilct the chI' ilnd pull out the clOVIS pIn "t1achlng thc servo pushrO Th o bushes may be renewed separately if neCeSSilry by driving thel11 hom the pcdaL G Rehlllng.s a reve,sal 01 ,emoval. but lubrIcate Ihe bushes, sh 17 Stop lamp switch _ removal, refilling aile! il(ljuslmenl
WOlking inSldc the car. remove the lower I"cia p"nel bolOw the slcCllng cOl ullin. 2 D,sconnoct the wiling plug, unscrew the locking nut and detach the swiech (photo).
3 Refilling is il revers procarmanuals.com