Ford Courier 1974 76 Brake Repair Guide

DESCRIPTION

Courier dual brake system consists of a dual master cylinder, combination valve, system failure warning light, two single piston hydraulic cylinders (front wheels) and two dual piston hydraulic cylinders (rear wheels). All lines are connected to both master cylinder and combination valve. Both front and rear brakes operate same (pressurized brake fluid forced to wheel cylinder). Front cylinders however, expand each shoe individually and rear dual piston cylinders expand both shoes equally.

ADJUSTMENT

PEDAL FREE PLAY

Fig. 1 Front Brake Assembly Exploded View

Loosen lock nut on master cylinder push rod at clevis. Turn push rod in or out to obtain .12-34" (3.0-8.6 mm) free play, measured at pedal pad. When clearance is obtained, tighten lock nut.

BRAKE SHOES

All shoe to drum adjustments must be made with brake shoes at normal room temperature. Turn lower wheel cylinder ratchet to expand brake shoe locking it against drum. Back-off ratchet 5 notches or until drum rotates freely. Repeat procedure for upper wheel cylinder.

Fig. 2 Rear Brake Assembly Exploded View

PARKING BRAKE CABLE

NOTE - Service brakes must be properly adjusted before adjusting parking brake. Adjust length of cable at equalizer so that rear brakes are locked when parking brakes lever is pulled out five to ten ratchet clicks (1 5/8-3 1/2"). After adjustment, apply and release parking brake several times, and make sure wheels rotate freely when parking brakes is released.

COMBINATION VALVE

Combination Valve Reset - Place ignition switch in the on position. Depress brake pedal and piston will center itself. This will cause brake warning light to go out.

HYDRAULIC SYSTEM BLEEDING

NOTE -  Front and rear hydraulic systems are individual systems and are bled separately. Bleed longest line first on individual system being serviced.

Manual Bleeding - 1) Attach a bleeder tube to right rear lower brake cylinder, and immerse opposite end of tube in a container partially filled with brake fluid. Open bleeder screw 3/4 turn, push brake pedal through full travel, close bleeder screw, and return pedal. Continue operation until air bubbles are no longer seen in discharged fluid.

2) Repeat procedure at upper right rear wheel cylinder, and at wheel cylinders on left rear brake. If primary system is to be bled, repeat procedure at each right front wheel cylinder and each left front wheel cylinder. When bleeding operation is completed, fill master cylinder reservoirs to within 1/4" of top of reservoirs.

Pressure Bleeding - Attach a suitable pressure bleeder to master cylinder, with approximately 10-30 psi (.7-2.1 kg/cm2) air pressure in tank. CAUTION - DO NOT exceed 50 psi (3.5 kg/cm2). Follow manufacturers recommendations when installing bleeding equipment. Perform bleeding operation in same sequence as manual bleeding.

REMOVAL & INSTALLATION

BRAKE DRUM

Removal - Remove tire and wheel. Remove brake drum attaching screws and install them in tapered holes in brake drum. Turn screws in evenly to force drum away from wheel hub. Lift off drum.

Installation - Align attaching screw holes with ones in wheel hub. Transfer screws to retaining position and tighten evenly. Install tire and wheel.

BRAKE SHOES

Removal - Remove tire, wheel and brake drum. Remove brake shoe return springs, withdraw shoe retaining pin and spring. Disconnect handbrake link and cable from lever. Lift out brake shoes.

Installation - Reassemble handbrake. Position new brake shoes to backing plate with slots toward wheel cylinders. Install retaining springs and clips. Replace brake drum and adjust brakes.

WHEEL CYLINDER

Removal - With brake drum and shoes removed, disconnect hydraulic line from cylinder. Remove stud nuts and bolt which retain cylinder to backing plate and remove cylinder.

Installation - Reverse removal procedure, adjust brake shoes and bleed hydraulic system.

MASTER CYLINDER

Removal - Disconnect all brake lines and remove two mounting nuts and lockwashers. Lift off cylinder by pulling out and up to clear push rod.

Installation - Position master cylinder to mounting studs while guiding push rod into contact with cylinder piston. Tighten mounting nuts, connect hydraulic lines, bleed hydraulic system, and adjust brake pedal free play.

COMBINATION VALVE

Removal - Disconnect warning light wire. Disconnect hydraulic lines from combination valve. Remove bolt mounting valve assembly and take off combination valve.

Installation - To install combination valve, reverse removal procedure and note the following: Bleed hydraulic system and reset piston in valve.

OVERHAUL

Fig. 3 Disassembled View of Courier Front Wheel
Cylinder

Disassembly - Remove piston, adjusting screw, and boot from cylinder and separate. Using compressed air applied to fluid inlet, place cylinder face down and blow out piston cup, cup expander and spring.

Cleaning & Inspection - Wash all parts in sopropyl alcohol. Examine cylinder bore, piston and adjuster for wear or damage. Check clearance between cylinder bore and piston; if greater than .006" (.15 mm), replace parts as necessary.

Reassembly - Apply clean brake fluid to cylinder bore, piston, and new piston cup. Install return spring in cup expander, then install return spring, cup expander and cylinder cup into cylinder with flat side of cup outward. Install boot to piston with small lip of boot in groove of piston, install piston into cylinder, and install larger lip of boot in cylinder groove. Install adjusting screw in piston assembly.

REAR WHEEL CYLINDER 

Fig. 4 Disassembled View of Courier Rear Wheel
Cylinder

Disassembly - Remove piston, adjusting screw, and boot assemblies from each end of cylinder and separate parts. Press in on either piston cup and force out piston cups, expanders, and return spring.

Cleaning & Inspection - Wash all parts in isopropyl alcohol. Examine cylinder bore, pistons and adjusters for wear or damage. Check clearance between cylinder bore and pistons, if greater than .006" (.15 mm), replace parts as necessary.

Reassembly - Apply brake fluid to cylinder bore, adjuster and cylinder cups. Position return spring in cup expanders, place cups against expanders, and install into cylinder bore with flat side of cup facing outward. Install boot to piston into cylinder, and install larger lip of boot into cylinder groove. Install adjusting screw into adjuster.

MASTER CYLINDER

Disassembly - Remove two screws attaching reservoir to cylinder body, and lift reservoir from grommets. Remove cylinder dust boot and primary piston stop ring. Withdraw stop washer, primary piston assembly and return spring. Remove secondary piston stop screw and "O" ring, and remove secondary piston and return spring. Remove outlet port fittings, gaskets, check valves, and check valve springs.

Fig. 5 Courier Master Cylinder Assembly

Cleaning & Inspection - Clean all parts in isopropyl alcohol CAUTION - DO NOT use mineral based solvents. Check all parts for wear or damage, replace parts as necessary.

Reassembly - 1) Dip all parts except body and reservoir in clean brake fluid. Insert check valve springs and check valves, into cylinder outlets and install gaskets and fittings. Install secondary return spring on secondary piston assembly and install into cylinder bore, spring end first.

2) Install primary piston return spring to primary piston assembly and insert into cylinder bore, spring end first. Install stop washer and stop ring. Install secondary piston stop bolt. Install grommets into cylinder body, position reservoir to body, and install and tighten attaching screws.

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Triumph 1974 Models Wheel Alignment Guide

TRIUMPH SPECIFICATIONS AND ADJUSTMENTS

TIRE INFLATION (COLD)

Before attempting to check or adjust wheel alignment, make sure tires are properly inflate. Refer to manufacturers specifications in owners manual.

CASTER

All Models - Caster angle is not adjustable. If caster angle is not to specifications, inspect suspension system for wear or damage and repair or replace components as necessary.

CAMBER

All Models - Before adjusting camber angle, inspect suspension for wear or damage and repair or replace components as necessary. To adjust, raise vehicle and support chasis on jack stands. Loosen nuts securing lower control arm bracket to chassis. Add shims equally to increase camber angle. After each adjustment is made, tighten bracket to chassis, remove stands and measure camber angle.

TOE-IN

All Models (Front) - Set front wheels in straight ahead position. If adjustment is necessary, loosen steering link (tie-rod) lock nuts and gaiter clips. Rotate adjusting sleeves equal amounts until correct toe-in is obtained. Tighten lock nuts and recheck toe-in.

Spitfire (Rear) - If toe-in is not to specifications, loosen bolts holding strut front support. Adjust as necessary by adding or removing from the shims fitted between support and body. Tighten bolts and recheck toe-in.

TR6 (Rear) - If toe-in is not to specifications, loosen bolts and nuts securing trailing arm outer bracket to chassis. Add or remove shims between chassis and bracket to obtain correct toe-in. Tighten bolts and recheck toe-in. NOTE - Drive vehicle forward or backward before rechecking rear toe-in.

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Audi S90 100 1970 73 Brake Repair Guide

Models Covered

• S90 (1970-72)
• 100 (1970-73)

DESCRIPTION

Brake system is hydraulically operated, utilizing a tandem master cylinder and Teves T 51/349 power brake unit. Front disc brakes consist of rotors attached to transmission output flanges, and two-piston calipers attached to transmission. Disc pads are equipped with a ceramic transmitter-type wear sensor. Transmitter is mounted on cross spring and will break when contact is made with pad plates, interrupting control circuit and causing indicator light on instrument panel to be activate. Rear brakes are leading-trailing shoe/drum type, using a dual piston wheel cylinder. Parking brake is cable actuated, operating secondary shoes of rear brake assemblies.

ADJUSTMENT

NOTE - Adjustments or readjustments should be carrier out on cold brakes. However, brakes must be warm when testing. Instrument panel trim must be removed to adjust master cylinder push rod free play.

MASTER CYLINDER PUSH ROD FREE PLAY

Check brake pedal free play by measuring distance between master cylinder push rod and master cylinder piston. This measurement should be .039" (1.0 mm), which would give free play of .20" (5.08 mm) at brake pedal. If necessary to adjust, loosen lock nut on push rod and turn push rod until correct clearance is obtained. Tighten lock nut and again measure pedal free play at brake pedal.

FRONT DISC BRAKES

Front disc brakes are self-adjusting, therefore, no adjustment in service is required.

REAR DRUM BRAKES

Raise and support rear of vehicle release parking brake. Using a 17 mm wrench, tighten eccentric adjusters until wheels can no longer be turned by hand. Loosen eccentric adjusters until wheels are just free to turn.

PARKING BRAKE

Raise and support rear of vehicle and adjust rear brakes. Lift parking brake lever until it engages third ratchet stop. Adjust nut at equalizer until rear wheels are just free to turn. When parking brake lever is pulled up one additional notch (to fourth ratchet stop), rear wheels should be locked.

HYDRAULIC SYSTEM BLEEDING

Fill master cylinder reservoir with brake fluid and maintain level throughout bleeding operation. Attach a hose to bleeder screw, and immerse opposite end in a container partially full of brake fluid. Open bleeder screw approximately one-half turn, depress brake pedal, close bleeder screw, and slowly return pedal. Continu operation until air bubbles are no longer seen in discharge fluid. Bleeding sequence is left-rear, right-rear, right-front, left-front.

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS

Removal - Remove lock clips. Pull out retaining pins so they project into openings in side members. NOTE - Do not remove rubber grommets from side member holes. Using a suitable extractor tool (SB-3), remove disc pads from caliper.

NOTE - Disc pads can be removed on right side only after removing front exhaust pipe.

Installation - Press both pistons into caliper bores.

NOTE - Fluid level in master cylinder reservoir will rise.

Siphon sufficient fluid to prevent reservoir from overflowing. Ensure pistons are in correct alignment in bores using suitable tool (B-5). Install disc pads in recesses of caliper, slide in retaining pins, and install lock clip. Pump brake pedal several times to position disc pads. Bleed hydraulic system if necessary.

FRONT DISC BRAKE CALIPER & ROTOR

Removal - 1) On vehicles equipped with automatic transmission, disconnect steering damper from its bracket and move out of way. On all models, depress brake pedal approximately 1.2" (30.48 mm) and hold in this position by using suitable pedal support. Disconnect temperature transmitter wire from connector (near transmission)

2) On automatic transmission equipped vehicles, disconnect hydraulic line at union on transmission, EGR line at exhaust pipe, and exhaust pipe from hangers. On all models, disconnect and remove front exhaust pipe and shield from manifold, and drive shaft at stub axle.

3) Remove ball joint mounting bolts, pull wheel downward, and swing out steering knuckle after prying it off ball joint. Remove disc brake pads, leaving spring and wire in vehicle. Remove EGR filter from oil  pan. Remove caliper mounting nuts, then remove caliper and rotor from stub axle. NOTE - If necessary, pry engine assembly to one side to ease removal.

Installation - To install, reverse removal procedure, tighten caliper mounting bolts securely, and bleed hydraulic system.

REAR BRAKE DRUM

REAR BRAKE ASSEMBLY

Removal - Raise and support vehicle, remove wheel and tire assembly. Pry off dust cap, remove cotter pin from hex nut, and remove nut. Remove brake drum making sure that retaining washer and wheel bearing do not fall out.

Installation - To install, reverse removal procedure adjust brakes, and adjust wheel bearings. See Wheel Bearing Adjustment in WHEEL ALIGNMENT Section.

REAR BRAKE SHOES

Removal - With brake drum removed, remove retaining spring for brake shoes. Remove shoes as an assembly by disconnecting spring at bottom, pulling shoes back from wheel cylinder, and disconnecting parking brake cable.

Installation - To install, reverse removal procedure and not the following: Make sure long ends of retainin clip and spring are installed on secondary shoe and parking brake lever. Ensure brake shoes are correctly positioned on wheel cylinder pistons.

REAR BRAKE WHEEL CYLINDER

Removal - With drum and shoes removed, depress brake pedal approximately 1.4" (35.56 mm) and hold in this position by using suitable pedal support. Disconnect remaining hydraulic line and cylinder mounting nuts. Separate master cylinder from power unit, taking care not to lose "O" ring installed between units.

Installation - To install, reverse removal procedure, adjust brakes and bleed hydraulic system.

MASTER CYLINDER

Removal - Disconnect hydraulic line at rear of master cylinder. Depress brake pedal 1.2-1.6" and hold in position using a suitable pedal support. Disconnect remaining hydraulic line and cylinder mounting nuts. Separate master cylinder from power unit taking care not to lose "O" ring installed between them.

Installation - To install, reverse removal procedure and bleed hydraulic system.

POWER BRAKE UNIT

Removal - Siphon brake fluid from master cylinder reservoir and disconnect hydraulic lines. Loosen hose clamp and disconnect vacuum hose from power unit. From inside vehicle, remove trim below instrument panel as necessary. Disconnect push rod form brake pedal, remove power unit adapter attaching nuts, and remove power unit and master cylinder from engine compartment as an assembly. Separate master cylinder and adaptor from power unit.

Installation - To install, reverse removal procedure and note the following: Be sure to install "O" ring between master cylinder and power unit. Install adaptor to power unit so that center punch mark on adaptor is located on lower right hand side facing engine. To complete installation, adjust pedal push rod free play and bleed hydraulic system.

Check Valve Replacement - A vacuum check valve is locate in vacuum line between intake manifold and power it. To remove, loosen hose clamps, separate vacuum hoses from check valve, and remove check valve. To install, reverse removal procedure and not the following: Check valve is stamped with the word "MOTOR" and an arrow. End of valve in which arrow points must be connect to shorter hose from intake manifold.

OVERHAUL

FRONT DISC BRAKE CALIPER

FRONT DISC BRAKE CALIPER ASSEMBLY

Disassembly - Remove disc pads. Pry out retaining ring and remove dust seal by hand. Place a small block of wood in caliper cavity, and remove piston by applying compressed air to fluid inlet. Remove remaining piston in same manner. Remove seal from caliper bore using a piece of wood or plastic. NOTE - Do not use hard or sharp tools for this purpose. Do not separate caliper halves.

FRONT DISC BRAKE CALIPER ASSEMBLY

Cleaning & Inspection - Clean all parts in alcohol only. Check cylinder bore and piston for damage. NOTE - Do not machine caliper bore or piston. Parts are serviced by replacement only.

PINION INSTALLATION

Reassembly - Coat all parts with ATE brake cylinder paste (or equivalent), reverse  disassembly procedure, and note the following: Use new seals, dust boots, and retaining rings when reassembling. When installing piston, make sure machined surface of piston face makes a 20° angle to wall of caliper bore (see illustration). Install disc pads after caliper has been installed on vehicle.

REAR WHEEL CYLINDER

Disassembly - Thoroughly clean outside of cylinder. Remove end caps, piston and seal assemblies, and spring. Remove dust cap and bleeder screw.

AUDI MASTER CYLINDER
(COMPONENT PARTS)

Cleaning & Inspection - Clean all parts in alcohol only. Check all parts for rust, corrosion, and damage. Check cylinder bore and piston for wear or damage. Cylinder bore should not exceed .6287" (16.00 mm) and piston diameter should not be less than .619" (15.74 mm). NOTE - Manufacturer recommends replacing rubber components on each disassembly.

Reassembly - Reverse disassembly procedure and not the following: Apply a thin coat of ATE brake cylinder paste (or equivalent) to all parts during assembly.

MASTER CYLINDER

Disassembly - Remove reservoir, brake light switch, circlip and dismantle cylinder. To extract piston, unscrew stop screw.

Cleaning & Inspecting - Clean all parts in denatured alcohol. Inspect bore and piston for rust or wear and replace any parts out of tolerance. It is advisable to always replace rubber parts.

Reassembly - Preassemble pistons and coat cups with ATE brake cylinder paste (or equivalent). Insert assembly into cylinder bore, install stop screw and circlip. Install brake light switch and resrevoir.

NOTE - Models without power brake servo differ slightly. Primary piston desgin is somewhat varied. Piston is equipped with only on secondary boot. There is no air compensating bore. Brake light switch location is different.

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Plymouth Cricket 1971 72 Brake Repair Guide

DESCRIPTION

Cricket disc brakes are hydraulically operated. Brake assembly consists of a rotating disc attached to hub, caliper mounted to stub of axle carrier, a disc, a cylinder on each of caliper housing, a piston, a pair of brake pads between disc and pistons retained by pins and spring clips. Rear brake drum incorporates a primary and secondary brake shoe. Rear brakes are operated by a double-acting wheel cylinder. A separate handbrake automatically adjust rear brake lining. Master cylinder and power brake unit supply needed hydraulic pressure to operated brake system. A brake warning light is activated if either system loses hydraulic pressure.

ADJUSTMENT

Disc Brakes - No adjustment required.

Drum Brakes - No adjustment required.

Handbrake - Only required adjustment when cable becomes stretched. On sedan models only, remove cable yoke from lever. Set both adjusters in released position and rotate sleeve of adjuster. Yoke must fit freely into lever.On station wagon models only, disconnect left-hand cable at yoke. vertically position bellcrank on right-hand brake rod and center hole in operating lever 3/4" to rear of a line parallel to axle. With bellcrank in position and without pulling on left cable, position yoke on left-hand lever.

BLEEDING SYSTEM

Bleed rear brakes first beginning with left side. With pressure on pedal, open bleed fitting and push pedal its full travel. When pedal is fully depressed, close fitting and let pedal return to fully released position. Move forward and repeat procedure starting on right side.

REMOVAL & INSTALLATION

POWER BRAKE UNIT

Check Valve Replacement - Press down on valve and turn on-third turn counterclockwise. Remove valve by pulling and applying side pressure. Install new "O" ring. Lubricate new grommet, place in front shell and push in new check valve. Press hard to seat "O" ring and turn one-third turn clockwise engage retaining tongs.

Filter Replacement - Disconnect operating rod from brake. Remove four nuts from mounting studs. Detach four-way connector from inner fender shield. Pull whole unit forward enough to reach filter. NOTE - Do not lose spacers. Remove filter diaphragm plate and press new filter into neck of diaphragm

LINING REPLACEMENT (DISC BRAKES)

REAR BRAKE ASSEMBLY

Removal - Withdraw retaining pin and clips. Lift out pads and clamping clips.

Installation - Install new pads by opening bleed screw, pushing piston to bottom of bore and closing bleed screw. Secure new pads with new retaining clips and pins. Pump pedal to reposition pads.

LINING REPLACEMENT (DRUM BRAKES)

Removal - Remove countersunk screw and lift off brake drum. Remove hold-down springs and clips. Pry shoe away from backing plate and lift off shoes.

Installation - Transfer lever stop clip to new shoe. Screw adjuster to forked end of push rod. Position rear shoe in wheel cylinder and handbrake assembly. Insert push rod into female adapter and position primary shoe in forked end of push rod and wheel cylinder. Install springs, clips and pins. Screw adjuster into operating position.

BRAKE ROTOR (DISC)

Removal - Remove brake caliper complete with pads. Remove dustcap, cotter pin, plain nut and washer. Lift-off complete hub assembly.

Installation - Install hub assembly complete with inner bearing and grease seal. Insert outer bearing, plain nut and washer. Adjust wheel bearing to specifications. Install cotter pin and dust cap. Fit caliper and pads to rotor.

FRONT BRAKE ASSEMBLY

BRAKE CALIPER

Removal - Drain brake fluid through bleed screw and remove metal brake line. Remove two mounting bolts and lift off whole caliper assembly. NOTE - Do not split caliper in two.

Installation - Reverse removal procedure.

MASTER CYLINDER

Removal - Disconnect brake lines, detach push rod from foot pedal (models without power brakes) and remove mounting bolts to lift off cylinder.

TANDEM MASTER CYLINDER

Installation - Reverse removal procedure.

POWER BRAKE UNIT.

Removal - Disconnect operating rod from brake pedal. Disconnect brake lines and vacuum hose. Remove mounting nuts and washers. Lift off power brake unit and master cylinder as a unit.

Installation - Reverse removal procedure. NOTE - Ensure spacers are replaced in original position.

OVERHAUL

BRAKE CALIPER

Disassembly - Remove brake caliper and pads. Place a clean rag between pistons and blow compressed air into inlet connection forcing piston from cylinder. Using a suitable tool (probe or equivalent) pull piston from bore. NOTE - Avoid damage to annular groove.

Cleaning & Inspecting - Clean all parts in approved grade brake fluid or alcohol. Inspect both bores and pistons for grooves or score marks.

Reassembly - Lubricate cylinders with brake fluid and position sealing rings in grooves. Insert piston fully into cylinder and replace dust boot, retaining ring and brake pads. Install caliper. NOTE - Ensure all shims have been installed. Reconnect brake line and bleed system. 

MASTER CYLINDER

Disassembly - Remove reservoir and compensating valve. Separate piston and intermediate spring. Lift leaf of spring, retainer and remove spring and center valve sup-assembly. Remove spring, valve spacer, and spring washer from valve head and stem. Remove seals from secondary pistons and pry out baffle.

Cleaning & Inspection - Clean all parts in approved grade brake fluid or alcohol. Examine both bore and pistons for pits or score marks.

Reassembly - Lubricate all parts before installation . Position valve seals in valve head, position spring washer so flare is away from stem shoulder; install valve spacer legs first. Attaching spring retainer to valve stem, keyhole first. Slide secondary spring over spring retainer, position sub-assembly on secondary piston. NOTE - Spring must be compressed while leaf of spring retainer is pressed behind head of piston. Fit intermediate spring into position. Insert piston assembly into bore, valve end first. Press primary piston down to fit, compensating valve assembly. Fit seal, screw in compensating valve and tighten. Install reservoir and refill.

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