Specifications
GROUP
2-Brakes
VACUUM
TUBE-2420
SHAFT
STANDARD AUTOMATIC
TRANSMISSION
TRANSMISSION
FIG.
30-Vacuum
Brake
Booster
Installation
-
Mustang
and
Cougar
using a master cylinder repair kit,
install all the parts supplied.
2.
Check all recesses, openings and
internal passages to
be
sure they are
open and free of foreign matter. Use
an air hose to blow out dirt and clean-
ing solvent. Place all parts on a
clean pan or paper.
3.
Inspect the master cylinder bore
for signs of etching, pitting, scoring
or rust. If it is necessary to hone the
master cylinder bore to repair dam-
age, do not exceed allowable hone
specifications.
ASSEMBLY
1.
Dip all parts except the master
cylinder body in clean Rotunda Extra
Heavy Duty Brake Fluid.
2.
Install the seal and pumping
cup on the secondary piston (Figs. 28
and 29). Install the protector and
brake master cylinder primary cup
on the secondary piston: then install
the primary cup retainer and sec-
ondary piston return spring on the
secondary piston. Care must be taken
to assure the protector is installed.
3.
Carefully insert the complete
secondary piston and return spring
assembly in the master cylinder bore.
4.
Install the primary piston and
return spring assembly in the master
cylinder bore.
5.
Install the push rod retainer on
the push rod,
if
so equipped. Install
the push rod assembly in the cylinder
bore. Make sure the retainer is prop-
erly seated and holding the push rod
securely.
6.
Depress the primary piston and
install the snap ring in the cylinder
bore groove.
7.
Position the inner end of the
push rod boot (if so equipped) in the
master cylinder body retaining
groove.
8.
Install the secondary piston
stop bolt and gasket in the bottom
of the master cylinder.
9.
Install the bleed screw (if so
equipped). Install the gasket (dia-
phragm) in the master cylinder
filler
cover. Position the gasket as shown
in Figs. 28 and 29. Make sure the gas
ket is securely seated.
10.
Install the cover and gasket on
the master cylinder and secure the
cover into position with the retainer.
DISC BRAKE CALIPER
.
DISASSEMBLY
Do not remove the bridge bolts that
hold the two halves of the caliper to-
gether.
The
two caliper housings are
shown separated in Fig.
31
for illus
tration purposes only.
1.
Remove the caliper assembly
from the vehicle as outlined in Section
2.
2.
Remove the two attaching bolts
and the caliper clips (Fig. 31).
3.
Remove the two shoe and lining
assemblies.
4.
Remove the flexible brake hose
from the caliper.
5.
Remove the external transfer
tube.
6.
Clamp the caliper in a vise and
secure it by the mounting flanges on
the inboard housing (Fig.
.32).
7.
Remove the four pistons from
the cylinder bores with the special tool
shown in Fig. 32. The caliper pistons
must be removed prior to removal of
the dust boot. As the piston is with-
drawn from the caliper, spread the
dust boot back over the piston. To
prevent cocking with consequent dam-
age 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 diameter surface or dust
boot. Such damage causes poor seal-
ing.
If a piston is so completely seized
in the cylinder bore that it can not
be removed 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
be-
ing applied. Be careful to avoid dam-
aging the dust boot retainer in the
caliper housing (Fig. 32).
If this
method of removal is used, the
pistons must
be
replaced.
8.
Remove the dust boots from the
caliper 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 instru-
ment 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 brake
fluid or a suitable solvent (Fig. 32).
Use clean, dry, compressed air to
clean out and dry the grooves and
passageways.
Be
sure that the caliper
bore and component parts are com-
pletely free of any foreign material.
Check the cylinder bores and pis-
tons 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.