Ford Thunderbird 1967 - Page 32

PART
2-2-Brake
System
2-25
to
the
piston
or
bore,
rotate
the
piston
with
the
tool
while
pulling
it
outward
at
the
same
time.
Be
careful
to
avoid
scratching
or
damaging
the
outside di
ameter
surface
or
dust
boot.
Such
dam
age
causes
poor
sealing.
If
a
piston
is
so
completely
seized
in
the
cylinder
bore
that
it
can
not
be re
moved
with
the
special
tool,
force
the
cylinder
out
of
the
bore
by
positioning
two
screwdrivers
in
the
piston
dust
boot
retaining
groove
and
prying
outward.
To
prevent
cocking,
tap
the
end
of
the
piston
lightly
around
the
circumference
with
a
hammer,
while
the
prying
force
is
being
applied.
Be
careful
to avoid
damaging
the
dust
boot
retainer
in the
caliper
housing
(Fig.
22).
If this
meth
od
of
removal is
used,
the
pistons
must
be
replaced.
Remove
the
dust boots
from
the cal
iper
assembly.
9.
Remove
the
rubber
piston seals
from
the grooves
in
the cylinder
bores
by
carefully
inserting
the point
of
a
small
knife or other
pointed
instrument
under
the
seal and
raising
the
seal
up
far
enough
to be pulled
out
with the
fingers.
CLEANING AND
INSPECTION
Clean all
metal parts
with
alcohol
or
a
suitable
solvent
(Fig. 22).
Use
clean,
dry,
compressed
air
to
clean out and
dry
the
grooves
and passage
ways.
Be
sure that the
caliper
bore
and
compo
nent parts
are
completely
free of
any
foreign
material.
Check the
cylinder bores
and pistons
for
damage
or
excessive wear.
Replace
the
piston
if it
is
pitted, scored,
or
the
chrome
plating
is worn
off.
ASSEMBLY
1.
Clamp
the
caliper
in
a vise and
secure it
by
the
mounting
flange on
the
inboard housing.
2. The
new
caliper seals
must be
flat round
and not twisted when
setting
freely
on a
clean
surface. Discard
any
new
seals
that have been
deformed
in
shipping
or
storage.
Installation
of
deformed seals
may
result in
seal
leakage.
3.
Apply
a film
of clean
brake
fluid
to
new
caliper
piston
seals
and
install
them
in
the
grooves
of
the
cylinder
bore.
The seal
should
be
positioned
at
one
area in
the
groove
and
gently
worked
around. Do
not
re-use the
orig-
nal
seals.
4.
Install
the new
dust
boots
by
seating
the
boot
flange in
the
outer
caliper
bore
groove.
Position
in
one
area and
gently
work
around
until
fully
seated. Do
not
reuse
the
old
dust
boots.
5.
Coat
the
outside
diameter of
the
pistons with
brake
fluid
and
install
them
in
the
cylinder
bores so
that
the
open
end of
the
piston
and
the
boot
re
taining
groove
face
out of
the
bore.
Spread the
dust
boot
over the
piston
as
the
piston is
being
installed.
To
avoid
cocking,
locate
the
piston
squarely
in
the
bore and
apply
a
slow
steady
pressure.
If a
piston
will not
easily
go
all
the
way
into
the
bore,
remove
it
and
thoroughly
inspect the
cylinder
bore,
the
piston seal and the
installation
of
the seal.
If the
piston still
will not go
in
with bore in
good condition and
the
pis
ton
seal
properly
installed,
use the
tool
shown in
Fig.
23.
Rotate the
piston with
the
tool while
pushing
it inward at the
same
time.
Seat the dust
boots
careful
ly
in the piston
groove,
be sure that
each boot
is
fully
seated in
their
groove.
6.
Install the
external transfer
tube.
7.
Install the flexible
brake
hose to
the caliper.
8. Install
the
caliper
assembly
on
the
spindle,
and install
the
shoe
and lin
ing
assemblies
and
the
splash
shield as
outlined
in
Section
2. Check
the
caliper
for
fluid leaks
under
maximum
pedal
pressures.
Do not
move
the
car
until
a
firm
brake
pedal is
obtained.