1974 FORD CAPRI brakes

Chapter 9 Braking system
Fault rflnunosis -hrnking sys tem Foothrnk.c I)(!dnl -removal .1nd refluing From m ake caliper -overhau l .. Front blake cillipCf -removal ;1nd 'Cl,UUl\1 .... ______ ._ .................... . Front brake discs -inspection, ,enlov,,1 and rcl,!\in(J Front disc pilds -renewal , ....... _ ...... .. General description ..... .... ........ . ............ . H andb Spcci/ic:ltions
Syste m type
I=rOl1t brakes ~c tt,ickncss :
Now ....................................... .
Min rmum.
Oisc fun ·out (ma~inlum including hub).
Mini'l1ulll disc pad lining Ihickness
Re ar brakes MInimum bfake shoe lining thickness.
Torque w re nch settings Caliper ....... ................. ................................... . Brake disc .................... . Backpl"te ........................... .................... .......... ................ .... .. .. .......... . Hydraulic unions. Bleed screw (ma~) .... Aecuf>Cfaling valve 'Clainel (Gi,ling)
Gonoral description
23
16
5 ,
G 3 1 18 20 19 14 15
Oisc brakes aro f;tted 10 Iho front wheels and drum brakes to the lea. wheels. Tho cable or cablo and rod opelilled handbrake oper:11es independently on the real wheels. A vacuum sorvo unit is fiued
" "tween the mastel cytinde. and loolbrake pedal to provide assistance 'en the pedal is depressed.
T he hy,aulic circui t is split frOnt and rear. Undel normal conditions
M,lSIC' cylinder -ove.hilul Milsle. cylinder -removill ilnd .e liuing . P.eSStue d,ffcrenliill swit c h -desoiplion .• e m ov,,1 and .el,ning P,essure ,educing valve · description. relllovill ilnd .er,llonu
Reil' i),lGkplilte · ,emov"r ilnu refining Hei!( i)r"ke shoes -renewal ....... .................. .............. . . Routine m"intenance ........ . ................. .
SlOp·lilmp switch - removal. re/rUlng and ildJustmcflI . Vilcuum servo unil _ description . Vncuum servo unil -rcrnovnl nod rcfiUing Wheel cylindcr -rcmovnl. ove.haul and ref'lIing
11 10 12 13 ,
7 2 17 21 22 8
Dlml hyd'i1ulic cif cuit. snlol Ironl i1nd rCilr WIth IlreSSU,e reducing v:llve in reil r ci.cui t on Iiller models. DISC I,onl brilkes i1nd self·ndjust illu rca .
(!rum brilkes. all wilh servo aSSIstance. Calrle or c.,blc .1nd rod operated handbrake on rear l)f"k es
12 .7 mm (0.5 in) 11.4 rnm (0.45 in) 009 nlln (0.0035 in) 3 .0 mm (0.118 in)
1.5 mm (0.059 in)
Nm 471068 41 1046 271031 71010 10 491062
Ibl It 351050 301034 20 to 23 5 to 7 7 36 to 46
both ci.cuilS operale in unison. howeve •. in the event of faIlure o f one circui t Ihe lemaining ci.cui l will p procarmanuals.com

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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
I
J
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Index
A
Accelerator cilble removal ilnd refining -14 shnft ilnd pedal removal and refining -75 Air cleaner removill Jnd ref,nrng cal buren or mod cis -68 fuel injecllon models -80
P rnator .,rushes inspecllon. removal and refilling Bosch -202 Femsa -203 Lucas - 202
dismantling and rcassembly -203
removal and refining -201 Antifreeze mixture -60 Automatic transmission descrip tion -122
B
downshift cable removal. refi11ing and adjustment -121 extension housing oil seal renewal -121 faull diagnosis -127
maintenance. routine -123
removal and refOlting -123
selector mechanism ildjustment - 126 rcmovill. overhaul ilnd refl11lng -125 speclflf:iltions -103 SI.1r1er IIlh'bilm/reVerse lamp switch remov Bilttery clrilrgmg _ 201 description and testing -200 removal and rcfll\lng -201 Big-end bearings -37. 52 Bleeding the hydr centre console -189
demister
noules reOlov description _ 174
doms-178.180. 18210 185 face level vents removal and refItting -197 facia panel -188 fuel filler flap -188 heater -192 to 194. 196 10 ) bodywork and under/rame _ 176 routine _ 116
uphOISlCry
and carpets -176 mirrors
-
192 open rem quarter glass assembly
removal and refitting -186
re~r qllMlcr trim panel removal and refitting -185 repi'lir millor damaue -178 minor damage -176 sent belts -191 seats -192 sunroof-189la 191 lailgate -180. 187. 188 torque wrench scuings -173 windscreen -180 Bodywork repair sequence (colour) -174, 175 Bonnet release c p ipes c
Camshaft (3.0 litre engine) retitting -54 removal -50 Camshaft and camshaf t bearings examination and renovation 2 _8 litre engine -35
3 .0 litre engine -51 Camshah and front intermediate plate (2.8 litre engine) refilling -41 Capacities. general -6 Carburetlor (Weber) aulomat ic choke
adjustment -71 removal. overhaul and retitting -71
dismantling and reassembly -69 general -68 idling adjustment -73
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rernoy .. ' and refl Uing -69 spcc,'iC d'ilUlinU 59
(IlIvchells
G3 e~p:mSloll I nnk 6<1 Ian hub l)()nllllH (30 hilI] 1110<1111,;) 64 f~ull (II;)Ul1osl~ 65
flll".U -
60 lIush"'9 59
",nmlen,lncc. roullllC 59
'ild,nlOr
GO speclficn llon5 57 lem,)er;!lurc unuuc Sf:n(Ie. unil -134 IhcrmOSl<11 -61 10Htlle wrench selll ngs 57 VISCOUS drlv\! 11'111 -63 W1)ler IWIllP 61 Crankca se ventiln tion system 2.8 tol'c engine -39 3.0 rillC engine 53 Cranksh1)ft 2.8 li l.e engine examinat ion nnd rcnoviuion -37 refilling -<10
3 .0 til.e cn gine examination lind renOV1'l110n -52 Crankshilft and main bearings (3.0 litr o engino) removal -51 Crankshllft pulley refitting (2.8 hIre engine) -44
removal ( 3 .0 litre engine) -50 Crankshaft r ear oil seal (3.0 litre engine) .efllling - 55 .emova l -51 Cylinder bores ~xaminalion and .enovation -36. 51 Indo r heads 2.8 titre engine dismanll ing .• cnova lion and .eassembl y -35
Index
D
refining - 45
3.0 litre engin e
. eassembly -55 refining -55 .emoval wilh engIne -49
removal wil h engine in car -49
Decarhonising -52 Dimensions. vehicle _ 6 Dim-dip lighting system _ 226 Disc br1lke s scc Front disc brakes Distributor overhaul 2.8 hlle engIne -93 3 a !r1l0 cng,ne -92 rcmoval and r efIlling _ 90 Doors eXle.io. hllndle ,emoval and refilling - 183 lock 1Issernbly removal and .efilling -184 pillar swi lc h -224
priVill e lock ,ernovill and ref'lIing -185 fnllics tracing nnd feCllik al ion -178 remOle conlroi hnndle removal and refilling -180 Hlmoval and rell\1l11g _ 185 Irim j>ilnel removal and ,efi ning _ 182 window Irnm c
moul(II ng nnd door wealhcrSlrips
removal and refining -185 rcmoval and relining -185 wmdow glass removal and retilling - 184 window regulnlor nssembly
r emoval and relilling -183 Drivebelt s .emov,,1 ilnd refil ling -63 Drum brakes sce Renl drum brakes
E
Eloc triclIl.system -198 e/ seq Electrical systcm altell11110, -201 10 203
ilu xiha.y driving "ghl -212 bmlery -200. 201 bulbs -199.21310217 ciga. IighlOf -225
clock -223
d escrip llon -200 dim-dip ligh ling syslem -226 laull diilgnOSIS -19. 233 ""sher unils and rel1lys -225
fuse s -199. 220
headligllls -211 10213 horn -220
inSI.ument clUSler -22 1 inSI.ument vollage .egula lor - 226 Inmp5 -21410217 mninlenance. fOUline w 200 mobite r"dio equIpment - 226
precautions - 200
rildio /casse tte player -226 specif ications - 198
speedomeler cab le -226 Slmte . mOlOr -207 swi tches -223 10 22 5 lailgall) wash er -217 laHgme wipef -217 to.que wrench sell ings -199
w indscree n washer -219 windscreen wiper -21810 220 wi.ing diagrams -235 10 249
25'
Ii
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inlet manifold - 83
main system components remova l and refilling -80 m~intenilnce, routine -79
specificiltions -67 to rque wrench settings -67 Fuel pump carburettor system cleaning - 68 re moval and refilling - 68
testing -68
fuel inject ion system removal and refining -80 Fuel system (carbureUor) accelera tor cable -74
accelerator shah and pedal - 75 air cleaner - 68
carburetlor -66, 68 to 73
description -67 e~ haust manifold - 76 lault diagnosis -85 luel pump -68 fu el wnk -73, 74 fu el lan k fille r pipe -74 fuel tank sender unit -74 inle l manifold -75 mainte nance, routine -67 specifiCiltions -66 torque wrench senings - 67 Fue l tank cleaning and repai r -74
filler pipe removal and re fi\ling .-74 remova l and refilling -73
sender uni t removal and ref il\in g -74 Fuel tank sender unit (fuel injection models) -83 Fuses
G
general -220 specifica tio ns - 199
Gearbo~ see Manual gearbO K Gudgeon pins - 37. 52
pdbrake adjus tment -153 cable(s} and rod removal and refilling 155 lever removal and refitting -154
warnin g hght switc h -225 Headlights alignment - 212 assembl y: removal and refilling ~ 211 bulbs renewal-2 13 Heater assembly: diSI11(lntting and reassembly 8ehr - 19 4 Smiths standard and heavy duty -196 assembly: removal and ret.tting -193 contlols
adjustmen t -192 removal and refilling ~ 1 93 water valve (heavy dUly heater)
removal and re fitting - 193 History o f tho nlodal-5 Horn faul t tra cing . remova l and refilling -220 Hubs, front
bearings renewal -162 removal. ret lu in g and bearing adjustment -16 1 Iraulic systam (brakes) bleed ing - 152 pipes and hoses removal and refilling -151
Index
Ignition switch and lock -224 Ignition system -87 el seq Ignition sys tem amplrlier module (2 .8 l i\(e mode ls)
r emova l and refilling - 94
condenser (3. 0 litre models) -90 COntact bre aker points (3.0 litre models) - 89
description -88
dis tributo r -
90. 92. 93 fau lt diagnosis -96
firing order -87 mainteMnce. routine -88
spare plugs - 91. 95 speci fications -87
t im ing -94
torque wrench settings -87 In strument cluster ill umina tion switch -224 removal and refitting _ 221 Instrument voltage regulator removal and refilling -226 Interior lamp and bulb
removal and refilling -217
J
Jacking -7
L
lubricants and fluids recommended - 17 lubrication chart - 17 lubrication system
M
2.8 litre engine -39 3.0 litre engi ne -53
Main and big·eOld bO(lrings e~amination and renovation -37, 52 Main bearings (3.0 litro engine) removal - 51 Maintenanco , routine bodywork and fillings d oor ch ec k straps security check - 16 locks, door chec k Straps. tuellilte r C upholstery and carpets - 17 6 windsCtee n illld windows cleilning - 16 braking system
h andbrake linkage lubricat ion -16, 144
h ydraulic fluid levul check /lap up - 16 . 143 hydraulic flu id renewal -16. 144
line s and hoses check -16
pads ilnd shoes we." check -16 , 14 3 servo check -16 . 144 vacuum hose check -16 Clutch adjustment chock -16, 98 cooling syslem
coolan l leve l chec k/top up -16, 59 coolant renewal -16, 59 drivebelt condl tion/wnsion check -16, 59 leaks check - 59 electrical system
ballery elec tro lyt e leve l cheek /top up - 16. 200 equ ipmen t opera tio n check -16. 200 headlamps cleaning -16
253
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