1989 FORD FIESTA lug pattern

11 Brake pedal-to-servo cross-link - removal and refitting
3
Removal
1Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Disconnect the cross link pushrod from its
brake pedal location by removing the retaining
clip on the brake pedal, noting the bush fitted
in the pedal.
3 Disconnect the wiring multi-plug from the
fluid level warning indicator in the master
cylinder reservoir filler cap, then remove the
filler cap. Note that the filler cap must not be
inverted. The brake fluid should now be
removed from the reservoir.
4 Identify each brake pipe and its connection
to the master cylinder. Unscrew the fluid pipe
to master cylinder union nuts and disconnect
the pipes. On models equipped with anti-lock
brakes, disconnect the modulator return
hoses from the brake fluid reservoir, collecting
fluid spillage from the hoses in a suitable tray.
The modulator return hose unions should be
disconnected by first pushing the hose into
the reservoir, then retaining the collar against
the reservoir body whilst withdrawing the
hose. Note that the modulator return hoses
are colour coded - the left-hand modulator
has a black return hose and connector, and
should be fitted to the forward section of the
reservoir, whilst the right-hand modulator has
a grey return hose and connector, and should
be fitted to the rear section of the reservoir.
5 Disconnect the vacuum hose from the
servo unit by carefully levering between the
hose connector and the servo housing collar
with a screwdriver.
6 Lift up the flap of sound insulation on the bulkhead, in the passenger side footwell, to
expose the servo mounting bracket retaining
nuts, and remove them
(see illustration).
7 Remove the four nuts securing the servo
unit to its mounting bracket assembly.
8 Pull the servo/master cylinder assembly
forward and remove the inner servo support
bracket.
9 Remove the spring clip and clevis pin
securing the servo actuating rod to the cross
link, then lift out the servo/master cylinder
assembly.
10 Remove the two nuts on the right-hand
side of the pedal box assembly to free the
cross link right-hand support bracket, then
withdraw the link from the vehicle (see
illustration) .
Refitting
11Refitting is the reverse procedure to
removal, ensuring that the brake pedal
pushrod grommet is seated correctly in the
bulkhead and that the pushrod itself locates
through the brake pedal before securing the
servo operating link support brackets. Ensure
correct location of the pushrod bush in the
brake pedal.
12 Bleed the complete brake hydraulic
system in accordance with Section 13 or 14
(as applicable).
12 Hydraulic pipes and hoses -
renewal
2
Note: Before starting work, refer to the
warning at the beginning of Section 13
concerning the dangers of hydraulic fluid.
1 If any pipe or hose is to be renewed,
minimise hydraulic fluid loss by disconnecting
the wiring multi-plug from the fluid level
warning indicator in the master cylinder
reservoir filler cap, then remove the filler cap.
Note that the filler cap must not be inverted.
Place a piece of plastic film over the reservoir
and seal it with an elastic band. Alternatively,
flexible hoses can be sealed, if required, using
a proprietary brake hose clamp; metal brake pipe unions can be plugged (if care is taken
not to allow dirt into the system) or capped
immediately they are disconnected. Place a
wad of rag under any union that is to be
disconnected, to catch any spilt fluid.
2
If a flexible hose is to be disconnected,
unscrew the brake pipe union nut before
removing the spring clip which secures the
hose to its mounting (see illustration). Where
the other end of the hose is connected
directly to the brake caliper, disconnect it by
unscrewing it from its tapped hole.
3 To unscrew the union nuts, it is preferable to
obtain a brake pipe spanner of the correct size;
these are available from most large motor
accessory shops. Failing this, a close-fitting
open-ended spanner will be required, though if
the nuts are tight or corroded, their flats may be
rounded-off if the spanner slips. In such a case,
a self-locking wrench is often the only way to
unscrew a stubborn union, but it follows that
the pipe and the damaged nuts must be
renewed on reassembly. Always clean a union
and surrounding area before disconnecting it. If
disconnecting a component with more than
one union, make a careful note of the
connections before disturbing any of them.
4 If a brake pipe is to be renewed, it can be
obtained, cut to length and with the union
nuts and end flares in place, from Ford
dealers. All that is then necessary is to bend it
to shape, following the line of the original,
before fitting it to the car. Alternatively, most
motor accessory shops can make up brake
pipes from kits, but this requires very careful
measurement of the original, to ensure that
the replacement is of the correct length. The
safest answer is usually to take the original to
the shop as a pattern.
5 Before refitting, blow through the new pipe
or hose with dry compressed air. Do not
overtighten the union nuts. It is not necessary
to exercise brute force to obtain a sound joint.
6 If flexible rubber hoses are renewed, ensure
that the pipes and hoses are correctly routed,
with no kinks or twists, and that they are
secured in the clips or brackets provided.
7 After fitting, bleed the hydraulic system as
described in Section 13 or 14 (as applicable),
wash off any spilt fluid, and check carefully for
fluid leaks.
Braking system 9•9
12.2 Prising out a spring retaining clip from a rigid pipe/flexible hose support bracket11.10 Exploded view of brake pedal-to-
servo cross link and its retaining brackets11.6 Servo mounting bracket retaining nuts
A Inner section retaining nuts
B Outer section retaining nuts
9
1595Ford Fiesta Remake
An ideal way to remove fluid from the master cylinder
reservoir is to use a clean
syringe or an old poultry
baster.
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