Disc Ford Crown Victoria I

DESCRIPTION & OPERATION

The dual hydraulic brake system is a conventional pedal-actuated system with a master cylinder, pressure control valve, proportioning valves, brake calipers or wheel cylinders, brake hoses and lines. Hydraulic brakeline routing is diagonally split from front to rear (left front to right rear, and right front to left rear).

BLEEDING BRAKE SYSTEM

MANUAL BLEEDING

Note. Check fluid level in master cylinder frequently during brake bleeding sequence.

Non-ABS

1. Clean dirt from master cylinder fluid reservoir filler cap area. Fill reservoir with brake fluid. If master cylinder is known or suspected to have air in bore, bleed master cylinder first. To bleed brake system, release vacuum from power unit by depressing brake pedal several times.
2. Install clear vinyl bleed hose onto first bleed valve to be serviced. See the «BRAKELINE BLEEDING SEQUENCE»(/ford/crown-victoria/i-1992-1997/remont/mechanical-hydraulic/#disc) table. Place other end of hose in clean transparent container.
3. Partially fill container with clean brake fluid so end of hose is submerged in fluid. Open bleed valve 1-2 turns. Have an assistant slowly depress brake pedal through its full travel.
4. Close bleed valve and release pedal. Pump pedal several times to push air toward wheel cylinders. Repeat procedure until flow of brake fluid is clear and shows no sign of air bubbles. Proceed to next bleed valve.
5. Check brake pedal for firmness. If brake pedal feels "spongy", repeat bleeding procedure. Top off brake fluid reservoir.

BRAKE LINE BLEEDING SEQUENCE

1. Release all vacuum from power unit by depressing brake pedal several times. Clean dirt from brake fluid reservoir cap and surrounding area, then remove cap. With pressure tank at least1/2 full of brake fluid and charged with 10-30 psi (.70-2.10 kg/cm 2 ) air pressure, connect tank to master cylinder using proper adapter(s).
2. Attach bleed hose to first bleed valve to be serviced. See the «BRAKELINE BLEEDING SEQUENCE»(/ford/crown-victoria/i-1992-1997/remont/mechanical-hydraulic/#disc) table. Place other end of hose in clean transparent container. Partially fill container with clean brake fluid until end of hose is submerged in fluid.
3. Open release valve on pressure bleeder. Open bleed valve 1-2 turns, noting fluid flow. When fluid flowing into container is clear and free of bubbles, close bleed valve securely.
4. Finish bleeding system in same manner using correct sequence. Remove pressure tank from master cylinder and check master cylinder reservoir fluid level.

BRAKE PRESSURE CONTROL VALVE

Note. Ensure suspension is at proper riding height. Vehicle must be placed on drive-on type hoist or alignment machine. Failure to comply could affect proper operation of braking system.

Scheme 1

Scheme 2

BRAKE PEDAL HEIGHT

1. Measure distance between center of brake pedal pad and floor. If measurement is not within specification, go to next step. See the «BRAKE PEDAL HEIGHT SPECIFICATIONS»(/ford/crown-victoria/i-1992-1997/remont/mechanical-hydraulic/#disc) table.
2. Check brake pedal for missing, worn or damaged bushings and/or loose retaining bolts. If components are okay, ensure brake pedal, brake booster and/or master cylinder components are correct for vehicle application.

BRAKE PEDAL HEIGHT SPECIFICATIONS

PARKING BRAKE

Note. The parking brake is not adjustable.

REAR BRAKE SHOES

1. This adjustment should be made only after replacing brake lining or if brake applications are insufficient to actuate automatic adjuster. Remove wheel. Remove brake drum.
2. Use a brake drum diameter gauge to determine brake drum diameter and proper shoe diameter. Hold automatic adjusting lever out of engagement while rotating adjusting screw.
3. Adjust brake shoes to fit gauge. Rotate gauge around shoe to ensure proper fit. Install brake drum. Install wheel. Check brake operation by making several stops from varying forward speeds.

PROPORTIONING VALVE

Install pressure gauge in front caliper bleed valve and rear caliper/wheel cylinder bleed valve opposite front gauge. This ensures pressure gauges are connected to same hydraulic circuit. Depressing brake pedal, apply 1000 psi pressure to front brake system. Check pressure at rear pressure gauge. See PROPORTIONING VALVE TEST SPECIFICATIONS table. If pressure is not as specified, replace proportioning valve. Repeat procedure on remaining hydraulic circuit.

PROPORTIONING VALVE TEST SPECIFICATIONS

REMOVAL & INSTALLATION

Removal

Raise and support vehicle. Remove front wheels. Disconnect and plug brake hose from caliper. Mark caliper for right or left installation reference. Remove flex brake hose from caliper. Remove caliper locating pins. Remove caliper. Note position of brake pads, shims and anti-rattle springs (if equipped) and remove components.

Installation

Apply high-temperature grease to guide pins and insulators. Install brake pads. Ensure brake pads are installed correctly. If new brake pads have been installed, seat brake caliper piston in caliper bore. To complete installation, reverse removal procedure. Refill and bleed system. See BLEEDING BRAKE SYSTEM .

1. Remove brake master cylinder cap. Remove brake fluid until reservoir is half full. Raise and support vehicle. Remove wheels. Disconnect flexible brake hose from caliper. CAUTION: When removing brake caliper, DO NOT pry against plastic caliper piston.
2. Plug brake hose. Remove caliper locating pins. Using a rotating motion, remove caliper and anchor plate. Remove brake pads. Retract piston in caliper bore. To install, reverse removal procedure. Bleed brakes. See «BLEEDING BRAKE SYSTEM»(/ford/crown-victoria/i-1992-1997/remont/mechanical-hydraulic/#disc__bleeding-brake-system) .

Remove brake caliper. See REAR BRAKE CALIPER & PADS . Remove caliper anchor plate (if equipped). Remove rotor retaining nuts and rotor. To install, reverse removal procedure. Bleed brakes. See BLEEDING BRAKE SYSTEM . The parking brake is not adjustable.

Disconnect brake fluid level indicator connector. Disconnect hydraulic-brake lines from master cylinder. Remove master cylinder attaching nuts and remove master cylinder. To install, reverse removal procedure. Bleed brake system. See BLEEDING BRAKE SYSTEM .

1. Disconnect negative battery cable. Remove air cleaner (if necessary). Disconnect manifold vacuum hose from booster check valve. Disconnect brake lines from master cylinder. Remove master cylinder-to-brake booster nuts. Remove master cylinder.
2. From under dash, remove brakelight switch wiring connector. Remove brakelight retaining pin. Slide brakelight switch off brake pedal pin just enough for outer plate of brakelight switch to clear pin. Remove brakelight switch from pin. DO NOT damage switch during removal.
3. Remove booster-to-dash panel retaining nuts. Slide booster push rod, bushing and inner nylon washer off brake pedal pin. From under hood, move booster forward until booster studs clear firewall. Rotate front of booster inward (toward engine) and remove booster by raising until clear.

To install, reverse removal procedure. Bleed brakes. See BLEEDING BRAKE SYSTEM .

Disassembly

Remove caliper. See FRONT BRAKE CALIPER & PADS under REMOVAL & INSTALLATION. To remove caliper piston, place shop towels in the caliper and apply air pressure to the brake hose bore. Remove dust boot. (Scheme 3) Being careful not to scratch caliper bore, remove piston bore seal.

Inspection

Clean all metal parts with isopropyl alcohol and dry with compressed air. Replace components if worn, pitted or scored.

Reassembly

Apply a thin film of clean brake fluid to the seal, bore and piston. Install piston seal and dust boot in caliper bore. Spread dust boot over piston and install piston squarely into caliper bore. To complete assembly, reverse removal procedure. Bleed brakes. Refer to BLEEDING BRAKE SYSTEM .

Scheme 3

REAR BRAKE CALIPER

Raise and support vehicle. Remove brake caliper. Refer to REAR BRAKE CALIPER & PADS under REMOVAL & INSTALLATION. To remove caliper piston, place shop towels in caliper and apply air pressure to brake hose bore. Remove dust boot. Being careful not to scratch caliper bore, remove piston bore seal.

Clean all parts with isopropyl alcohol and dry with compressed air. Lubricate piston with clean brake fluid. Replace components if worn, pitted or scored.

Lubricate seal, dust boot, piston and bore with clean brake fluid. Install new piston seal in bore groove. Install dust boot in piston bore. Spread dust boot over piston and seat in piston groove. Install piston. To complete assembly, reverse disassembly procedure. Bleed and adjust brakes as necessary. See BLEEDING BRAKE SYSTEM .

MASTER CYLINDER

Note. On ABS-equipped models, master cylinder is NOT serviceable. If master cylinder is defective, replace master cylinder assembly.

1. Clean outside of master cylinder. Remove fluid reservoir cap. Remove brake fluid level indicator. Drain all brake fluid from master cylinder. Clamp master cylinder in vise at mounting flange. Remove plastic reservoir and seals. (Scheme 4)
2. Remove stop bolt and pressure control valve from master cylinder. Press primary piston inward and remove snap ring. Remove primary and secondary piston assemblies from master cylinder. If piston is difficult to remove, apply compressed air to secondary outlet port to aid in piston removal.

Scheme 4

1. Wash master cylinder body, bore and piston assemblies with denatured or isopropyl alcohol. Inspect piston assemblies and return springs. Replace pistons if scored, worn, cracked or broken. Replace springs if broken, bent, collapsed, distorted or fatigued.
2. Inspect cylinder bore for scoring, corrosion or wear. Aluminum body of master cylinder is anodized. Some wear on anodized surface, as evidenced by lighter areas, is normal. Aluminum master cylinders may not be polished, but must be replaced.

1. Coat bore of cylinder and piston assemblies with clean brake fluid. Install secondary and primary piston assemblies into bore. Press primary piston inward and install snap ring.
2. Install pressure control valve and stop bolt. Lubricate reservoir seals with clean brake fluid and install in master cylinder. Ensure seals are properly seated. Place reservoir on hard surface and install plastic reservoir with a rocking motion. Fill reservoir with clean brake fluid and bleed brakes. See «BLEEDING BRAKE SYSTEM»(/ford/crown-victoria/i-1992-1997/remont/mechanical-hydraulic/#disc__bleeding-brake-system) .

1. Raise vehicle. Refer to Section 00-02. Disconnect front parking brake cable and conduit from parking brake rear cable and conduit at connector.
2. Disconnect parking brake cable retainer spring at frame (dual exhaust only).
3. Disconnect parking brake rear cable and conduit LH from parking brake rear cable and conduit RH at parking brake cable adjuster (2B599).
4. Release parking brake rear cable and conduit RH tabbed conduit retainer from frame using a 13 mm box-end wrench.
5. Remove cable retainer from LH shock bracket, wire retainer on LH axle bracket, and disconnect parking brake rear cable and conduit from retainer on RH axle shaft (4234) by removing bolt and retainer.
6. Remove cable retaining E-clip and cable eyelet from rear parking brake cable (2A637). Pull parking brake rear cable and conduit out of rear wheel disc brake adapter (2C220) boss.
7. Remove parking brake rear cable and conduit(s) from vehicle.

1. Insert parking brake rear cable and conduit through mounting boss and connect it to rear parking brake cable.
2. Push rear parking brake cable through mounting boss and install retaining clip.
3. Attach rear parking brake cable RH to axle retaining clip, through wire retainer and LH shock absorber plastic loop. Press tabbed retainer into crossmember hole until locked into place.
4. Route rear parking brake cable LH under RH cable between stabilizer bar stud and shock absorber. Connect RH cable end to equalizer bracket assembly (part of rear parking brake cable LH).
5. Connect parking brake rear cable and conduit connector to front parking brake cable and conduit.
6. Lower vehicle. Check operation as outlined.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS

See also:
• ANTI-LOCK BRAKE SYSTEM
• COMPUTER RELEARN PROCEDURES
• BRAKELINE BLEEDING SEQUENCE
• BLEEDING BRAKE SYSTEM