Ford Thunderbird 1967 - Group 2: Brakes; Part 2-1: General Brake Service

2-1
akes
GROUP
2
PART
2-1
PAGE
General
Brake
Service 2-1
PART
2-2
Brake
System
2-8
PART
2-3
Specifications
PAGE
2-26
PART
2-1-Genera/ Brake
Service
Section
Page
1
Diagnosis
and
Testing
2-1
Brake
Systems
Tests
2-1
Road
Test
2-1
Disc
Brake
Trouble
Symptoms
and
Possible
Causes
2-3
Drum
Brake Trouble
Symptoms and
Possible
Causes
2-4
2
Common
Adjustments
andRepairs
2-5
Parking
Brake
Linkage
Adjustment
2-5
PAGE
Section
Power
Brake Master
Cylinder
Push Rod
Adjustment
2-5
Hydraulic
System
Bleeding
and
Centralizing
of the Differential Valve
2-6
3
Cleaning
and Inspection
2-7
Front Brakes
2-7
Rear Brakes
2-7
Booster
Unit
2-7
DIAGNOSIS
AND
TESTING
BRAKE
SYSTEM
TESTS
BRAKE
FLUID
LEVEL
AND
HYDRAULIC SYSTEM
Always
check
the fluid
level in
the brake master cylinder
reservoirs
before
performing
the test
procedures.
If the fluid level is
not
within 1/4
to 1/2 inch of the
top
of
the
master
cylinder
reservoirs,
add
Rotunda
Brake Fluid
Extra
Heavy Duty
C6AZ19542-A
(ESA-M6C25-A).
The
disc brake
extra
heavy
duty
brake fluid
is
colored
for
identification
purposes. Do not mix low
temperature brake fluids with
the
specified brake
fluid.
1.
Turn the ignition dual
master cylinder
brake system
switch to the ACC
or ON
position.
If
the light
on the brake
warning
lamp
remains
on,
the condition
may
be
caused
by
a defective
switch,
grounded switch
wires or
the
differen
tial
pressure
valve
is
not
centered.
Centralize the
differential pressure
valve
as
outlined
under
Bleeding
the
Brake
System
in
this section of the
manual.
If
the
warning
light
re
mains
on,
the
condition
may
be
caus
ed
by
a
defective
switch,
grounded
switch
wires
or the
differential
pressure
valve
is
not
centered.
Centralize the dif
ferential
pressure valve
as outlined un
der
Bleeding
the
Brake
System in this
section
of
the
manual.
If the
warn
ing
light
remains
on,
check the switch
connector and
wire
for
a
grounded
condition
and
repair or
replace the
wire
assembly. If
the
condition of
the
wire
is
good,
replace the
brake
warn
ing
lamp
switch.
2.
If the
brake
warning
lamp
does
not
light when
a
pressure
dif
ferential condition
exists
in the
brake
system,
the
warning lamp may
be
burned
out,
the
warning lamp
switch
is
inoperative
or
the switch
to
lamp
wiring
has an open
circuit.
Check
the
bulb
and
replace
it,
if required.
Check the switch
to
lamp
wires for
an
open circuit and repair or
replace
them,
if
required.
If the
warning
lamp
still
does
not
light,
replace the
switch.
BRAKE PEDAL FREE
HEIGHT
AND TRAVEL
MEASUREMENTS
With
the
engine
running
for
full
power
brake
operation,
measure
the
brake
pedal free
height,
and check
the brake
pedal
travel
with the
use
of the Brake
Pedal
Pressure
Gauge,
Tool
WRE-500-50
as
follows:
Brake
Pedal
Free
Height
Measurement
1. Insert a
slender,
sharp
point
ed prod
through the carpet and sound
deadener
to the dash panel metal and
measure the
distance to the brake
pedal
(Fig. 1).
2. If
the
position
of the pedal is
not
within
specification,
check
the
brake pedal
linkage for
missing
bushings or
loose
attaching
bolts
and
replace
them,
if
required.
3.
If
the
pedal free
height
is still
out
of
specification,
check
the
brake
pedal booster
or
master
cylinder
to
be
sure the
correct
parts
are
installed.
Replace
the
defective
parts
as
neces
sary.
Brake
Pedal Travel
Measurement
1. Install a
Brake Pedal Effort
Gauge
on
the
brake
pedal pad
(Fig. 2).
2.
Hook
a steel
measuring
tape
to the brake pedal
as shown in
Fig.
1. Measure and
record the
distance
from the
brake pedal
free height
po
sition
to the
reference
point,
which is
at the
six
o'clock
position
on
the
steering
wheel
rim.
3.
With
the steel
tape
still
hooked
to the brake
pedal
depress
the
brake
pedal
by
pressing
downward
on
the
brake pedal
effort
gauge.
Apply
a
50 pound
load
to the
center
of
the pedal
by
observing
the
pressure
gauge,
and
measure
the
distance
from
the
brake pedal
to
the fixed
ref
erence
point on
the
steering
wheel
rim
parallel
to the
centerline
of
the
steer
ing
column.
4. Tie
difference
between
the
brake
pedal
free
height and
the
depressed
ped
al
measurement under
a
50
pound
load
should
be within
the
specified
max
imum
pedal
travel
service
specification
Bin
Fig. 1.
5. If
the
pedal
travel
is
more
than
the
specified
maximum
shown,
in
Fig.
1,
dimension
B,
make
several
sharp
re
verse stops
(equivalent
to 50
pounds
pedal
pressure)
with
a
forward
stop
be
fore
each. Move
the
vehicle in
reverse
and
forward
for
a
distance
of
approx
imately
ten
feet;
then
apply
the
brakes
sharply
and
hold
the
brake
pedal
down
until
the
vehicle
is
completely
stopped.
This
will
actuate
the
brake
self-adjusters.
If
these
stops
do
not
bring
the
brake
pedal
travel
within