Disc & Drum Ford LTD Crown Victoria I

BRAKE BOOSTER - BENDIX SINGLE DIAPHRAGM

The power brake booster is a self-contained, vacuum/hydraulic unit which uses engine manifold vacuum and atmospheric pressure to provide its power.

Vacuum power unit contains power piston assembly, which houses control valve, reaction mechanism and return spring. Control valve consists of air valve, floating control valve assembly and push rod. Reaction mechanism consists of reaction plate and levers. A vacuum check valve is mounted in front housing for connection to vacuum source.

DISC BRAKES - SINGLE PISTON

Note. Ford Motor Co. models use Bendix, Kelsey-Hayes and Teves disc brake calipers.

The disc brake assembly consists of a rotor, a single-piston caliper, 2 shoe and lining assemblies, a splash shield and an anchor plate. The cast iron rotor has cooling fins between the 2 braking surfaces. Brake linings rivet to the brake shoes and insulator gaskets bond to the back of each brake shoe.

All models use a sliding caliper that slides on 2 locating pins. Locating pins on Ford Motor Co. models attach caliper and combination anchor plate and spindle.

DRUM BRAKE AUTOMATIC ADJUSTER

Adjuster uses movement of rear (secondary) shoe during reverse brake application to turn brake adjusting screw. Screw is rotated a small amount to maintain proper lining-to-drum clearance.

DRUM BRAKES - SINGLE ANCHOR

Unit consists of a backing plate, 2 brake shoes, return springs, hold-down spring assemblies, self-adjusting components, and a wheel cylinder. Automatic adjuster consists of a cable (with spring hook and anchor fitting), cable guide, adjusting lever, lever pivot and adjusting screw (star).

MASTER CYLINDER - BENDIX/DELCO-MORAINE

All master cylinders are dual-piston, single-bore assemblies. When the brake pedal is depressed the master cylinder primary piston moves forward. Under normal conditions, the combination of hydraulic pressure and the force of the primary piston spring move the secondary piston forward at the same time.

When the pistons have moved forward so that their primary cups cover the by-pass holes, hydraulic pressure is built up and transmitted to the front and rear brake assemblies.

Some master cylinders have a residual pressure valve installed under tube seat insert in drum brake outlet. This valve keeps a small amount of pressure in drum brake systems and prevents air from entering system.

BRAKE SYSTEM BLEEDING

Hydraulic system bleeding is necessary any time air has been introduced into system. Bleed brakes at all 4 wheels if master cylinder lines have been disconnected or master cylinder has run dry. Bleeding can be accomplished by using pressure bleeding equipment or by manually pumping brake pedal and using a clear bleeder hose.

SERVICING METERING VALVE

1. On disc brake equipped vehicles, the metering section of combination valve must be held open before pressure bleeding.
2. Hold metering valve open while pressure bleeding front brakes. To loosen front mounting bolt and install pressure bleeding tool on combination valve, valve stem should be fully extended or depressed.

Note. Never reintroduce brake fluid that has been drained from hydraulic brake system or that has been allowed to stand in an open container for an extended period of time. Also, do not use fluid that contains a petroleum base. Petroleum based fluids will cause swelling and distortion of rubber parts in hydraulic system.

BENCH BLEEDING MASTER CYLINDER

Note. Bleed tubes must have a residual pressure check valve installed to keep tubes from siphoning brake fluid.

1. Master cylinder must be bled before bleeding entire system. Master cylinder bleeding may be done on vehicle. Preferred method is to bleed master cylinder on bench. If master cylinder has a bleed screw, bench method should still be used. When master cylinder is installed on car, use bleed screw as a final check for trapped air.
2. Place master cylinder level in a vise. Attach bleeding tubes to cylinder. Fill reservoirs with fluid so that ends of tubes are covered (Scheme 2) Tubes attached to disc brake outlets must have residual pressure valves installed over ends. This will keep tubes from siphoning.
3. Stroke piston in bore with a wooden stick or dowel until bubbles no longer appear at ends of tubes. Remove tubes and plug the master cylinder disc brake outlets to keep fluid from draining.

Scheme 2

MANUAL BLEEDING

Note. Ensure that fluid level in master cylinder is adequate at all times during bleeding procedure.

1. Fill master cylinder with clean brake fluid. Install bleeder hose to wheel assembly being serviced. Submerge other end of hose in clean glass jar partially filled with clean brake fluid.
2. Depress brake pedal slowly through its full travel and hold. Open bleed screw 3/4-1 turn. Close bleed screw. Release brake pedal. Repeat procedure until brake fluid shows no signs of air bubbles.

PRESSURE BLEEDING

1. To prevent dirt from falling into reservoir, clean master cylinder and cover/diaphragm assembly, With pressure tank at least 1/3 full, connect to master cylinder using adapters.
2. Install bleeder hose to wheel assembly being serviced. Submerge other end of hose in clean glass jar partially filled with clean brake fluid.
3. Open release valve on pressure bleeder. Open bleed screw 3/4-1 turn. Close bleed screw when brake fluid is clear and free of bubbles. Bleed remaining wheel assemblies in sequence and in same manner. Remove pressure bleeding tool.

BLEEDING PRESSURES

BLEEDING PRESSURES

BLEEDING SEQUENCE

If vehicle is equipped with power brakes, exhaust vacuum reserve from power unit by depressing brake pedal several times. Bleed master cylinder before bleeding wheel assemblies. Bleed wheel cylinders or calipers in the correct sequence.

BLEEDING SEQUENCE

BRAKE BOOSTER PUSH ROD

Note. Some Ford boosters use factory adjusted or non-adjustable push rods. Do not attempt to adjust this type of push rod.

1. Make push rod gauge according to specified dimensions. (Scheme 3)and (Scheme 4). Remove master cylinder from power unit without removing hydraulic lines and set aside.
2. Start engine and place gauge over push rod. Adjust push rod nut to provide light tension of about 5 lbs. (2.3 kg) against gauge. Reinstall master cylinder. (Scheme 4)
3. With engine idling and master cylinder reservoir cover removed, observe fluid surface when brake pedal is applied rapidly. Movement of fluid surface in forward reservoir indicates properly adjusted push rod. If fluid surface movement did not occur, push rod is adjusted too long and procedure must be repeated to prevent brake drag.

Scheme 3

Scheme 4

DISC BRAKES

Disc brakes are self-adjusting. Caliper piston seal retracts brake lining lightly touches rotor.

DRUM BRAKE SHOES

Note. This adjustment is made only after brake lining replacement or if brake applications are insufficient to actuate automatic adjuster.

1. On all models with 7" brakes, use a measuring tool to determine drum diameter and proper shoe diameter. Hold automatic adjusting lever out of engagement while rotating adjusting screw. Adjust brakes shoes to fit gauge. Rotate gauge around shoe to ensure proper fit.
2. Complete adjustment by applying brakes several times while backing vehicle, with forward movement after each application. Use a minimum 50 lbs. (22 kg) pressure on non-power brakes and 25 lbs. (11 kg) on power brakes.

Scheme 5

Scheme 6

PARKING BRAKE - RWD MODELS

Release parking brake fully. Place transmission in "N" and raise vehicle on axle type hoist. Tighten adjusting nut against cable equalizer or cable adjusting rod until rear brakes drag. Loosen adjusting nut until brakes turn freely, without drag. Tighten lock nut to 7-10 ft. lbs. (10-14 N.m), if equipped. Lower vehicle and check brake operation.

STOP LIGHT SWITCH

Switch is mechanically actuated by brake pedal, mounted on master cylinder push rod. It is not adjustable. If switch remains on, check for binding linkage.

VACUUM PARKING BRAKE RELEASE

1. Visually check operation of brake linkage as pedal is depressed and when manual release lever is activated. CAUTION: Air pressure should never be applied to vacuum system as diaphragm in vacuum motor may be damaged.
2. Ensure a minimum of 10 in. Hg. is available at all points where vacuum is applied. Start engine and let idle. Place transmission in "D" and observe that lever moves upward and parking brake releases. If it does not release, check for proper vacuum in system and replace components as necessary.

FRONT WHEEL BEARINGS

1. Raise and support vehicle. Remove wheel cover and grease cap. Remove cotter pin and nut lock. Loosen adjusting nut 3 turns. Rock wheel, hub and rotor assembly in and out several times to push brake pads away from rotor.
2. Tighten adjusting nut to 17-25 ft. lbs. (23-34 N.m) while rotating wheel assembly. Loosen adjusting nut 1/2 turn, then retighten to specifications. See «TORQUE SPECIFICATIONS»(/ford/ltd-crown-victoria/i-1983-1991/remont/mechanical-hydraulic/#disc-drum__torque-specifications) .
3. Reinstall nut lock on adjusting nut and insert new cotter pin. Install grease cap and wheel cover. Lower vehicle. Before driving vehicle, pump brake pedal to restore normal brake pedal travel.

LATERAL RUNOUT

1. Tighten wheel bearing adjusting nut until all end play is removed.
2. Mount a dial indicator on a pedestal stand or on axle spindle with indicator pointer contacting center of braking surface.
3. Turn rotor 1 revolution, checking indicator reading as rotor moves. If runout is excessive, replace or resurface rotor as needed.

PARALLELISM

Measure rotor thickness at four or more points, at equal distances from edge of rotor. If rotor does not meet specifications, replace or resurface rotor as needed.

DISC BRAKE SHOE & LINING INSPECTION

Inspect condition of lining any time wheel is removed. Replace lining if worn to less than 1/8" (3.18 mm) thick.

DRUM BRAKES

Note. When servicing brake parts, do not create dust by grinding or sanding brake linings or by using compressed air. Use water dampened shop towel to remove dirt and dust from brake parts during disassembly.

Cleaning

Clean all parts except the brake lining and the brake drums with brake cleaning solvent. To remove brake fluid contamination, clean all parts except the brake lining with denatured alcohol. Contaminated brake lining must be replaced.

Inspection

1. Pull back the wheel cylinder dust boots and check for evidence of leakage. If evidence of leakage is noted, the cylinder should be disassembled, inspected and overhauled.
2. Polish the brake support plate ledges with fine emery cloth and inspect them for grooves that could restrict shoe movement. If grooves exist after polishing, the support plate must be replaced.
3. Inspect lining wear pattern. If wear across the width of the lining is uneven, the drums should be checked for distortion, the shoes for correct positioning, and the support plate for distortion.
4. Inspect all springs for evidence of overheating and fractures. Self-adjusting cables should be inspected for kinks, fraying, or elongation of the eyelet. Inspect adjuster screws for freedom of rotation, and adjuster lever for wear and distortion.
5. Replace defective brake parts.

Removal

1. Working in engine compartment, disconnect battery and remove master cylinder from booster. Set it aside without disturbing hydraulic lines. It is not necessary to disconnect brake lines, but use care to avoid kinking them.
2. Disconnect manifold vacuum hose from booster check valve. Working inside vehicle, below dash, remove stoplight switch connector. Remove switch retaining pin.
3. Slide stoplight switch off of brake pedal pin just far enough for outer plate of stoplight switch to clear pin, and then remove switch from pin. Avoid damaging switch during removal.
4. Remove booster-to-dash panel attaching nuts. Slide booster push rod, nylon washers, and bushing off brake pedal pin. Remove booster assembly from dash panel by sliding push rod out through engine side of dash panel.

Installation

To install, reverse removal procedure.

Scheme 7

DISC BRAKE CALIPER

Caliper removal and installation procedures are same as brake shoe assembly replacement, except brake hose needs to be disconnected. See DISC BRAKE SHOE & LINING .

DISC BRAKE SHOE & LINING

Note. Replace shoes and linings on both sides of vehicle to maintain equal braking action.

1. Remove enough brake fluid from master cylinder to prevent overflow when piston is pushed into caliper. Raise and support front of vehicle and remove front wheels.
2. Be careful not to pry directly against plastic caliper piston. Remove caliper locating pins on RWD models. NOTE: If caliper end retainer is loosened more than 1/2 turn, brake fluid may leak into parking brake mechanism chamber. If this happens, remove end retainer and clean parking brake mechanism chamber.
3. On all models, lift caliper assembly from anchor plate and rotor. Support caliper assembly with wire to prevent damage to brake hose. Remove outer shoe. Remove inner shoe and anti-rattle clip or spring.
4. On RWD models, remove and discard locating pin insulators and plastic sleeves. DO NOT reuse these parts.

1. Tighten caliper end retainer. Seat piston in caliper and install caliper.
2. Install new locating pin insulators and plastic sleeves. Make sure insulator flanges straddle caliper housing holes.
3. Install anti-rattle spring on inner shoe and install shoe in caliper. Shoes are marked for left side (LH) or right side (RH) use. Install outer shoe wear indicator (if equipped) toward front of vehicle.
4. Install wheels, lower vehicle and fill master cylinder with fluid. Pump pedal several times to seat shoes and check brake operation.

1. Raise and support front of vehicle and remove front wheel. Remove caliper assembly and support out of way to avoid damaging brake hose.
2. Remove grease cap from hub, then remove cotter key, nut lock, adjusting nut and thrust washer from spindle. Remove outer wheel bearing, then pull hub and rotor from spindle.

1. Remove drum, releasing brake adjustment if necessary. Install clamp over wheel cylinder pistons. Remove shoe-to-anchor springs and unhook cable eye from anchor pin. Remove anchor pin plate.
2. Remove hold-down springs, shoes, adjusting screw, pivot nut, socket and automatic adjuster. Remove parking brake link spring and retainer. Disconnect parking brake cable from lever. After removing secondary shoe, disassemble parking brake lever from shoe by removing retaining clip and spring washer.

1. Assemble parking brake lever to secondary shoe and secure with spring washer and retaining clip. Lubricate brake shoe contact points. Position shoes on backing plate and install hold-down springs.
2. Install parking brake link, spring and retainer. Back off parking brake adjustment and connect cable to brake lever. Install anchor pin plate. Place cable eye over anchor pin with crimped side toward drum.
3. Install primary shoe anchor spring. Install cable guide on secondary shoe web with flanged hole fitted into hole in shoe web. Thread cable around anchor guide groove; NOT between guide and shoe web. Install secondary anchor spring. All parts should be flat on anchor pin.
4. Lubricate threads of adjusting screw and turn screw into pivot nut to limit of threads. Back off 1/2 turn and place socket on screw end. Install assembly between shoe ends with adjusting screw toothed wheel nearest secondary shoe.
5. Install cable hook in adjusting lever. Position hooked end of adjuster spring completely into large hole of primary shoe web. Connect loop end of spring to adjuster lever hole. Pull adjuster lever, cable and adjuster spring down and rearward, engaging pivot hook in large hole of secondary shoe web.
6. Ensure shoes are seated and centered on backing plate and that automatic adjuster is operating. Install drums, adjust and bleed brakes. Check for proper brake operation before moving vehicle.

To install, reverse removal procedure and adjust wheel bearings. See appropriate article in the SUSPENSION section.

1. On power brake systems: Disconnect brake fluid level indicator and brake warning switch leads, if used. Disconnect hydraulic brake lines. Remove master cylinder attaching nuts and remove master cylinder.
2. On manual brake systems: Disconnect negative battery cable and warning switch lead, if used. Disconnect hydraulic brake lines. Remove push rod at brake pedal and remove stop light switch, if used. Remove master cylinder attaching nuts and remove master cylinder.

1. Bleed master cylinder and reverse removal procedure, to complete installation. Bleed hydraulic brake system. See «BRAKE SYSTEM BLEEDING»(/ford/ltd-crown-victoria/i-1983-1991/remont/mechanical-hydraulic/#disc-drum__brake-system-bleeding) .
2. Check master cylinder compensating ports. Remove master cylinder cover and observe brake fluid. A slight surge or small spurt should appear in one or both reservoirs upon brake application. If no spurt appears, push rod may be improperly adjusted.
3. Adjust push rod at brake pedal, on manual brakes. Push rod should have a slight amount of play when brake pedal is released. On power brakes, see «BRAKE BOOSTER PUSH ROD»(/ford/ltd-crown-victoria/i-1983-1991/remont/mechanical-hydraulic/#disc-drum__brake-booster-push-rod) under ADJUSTMENTS.

1. Raise and support vehicle. Remove wheels and brake drums. Remove housing cover and drain lubricant. Remove differential pinion shaft lock bolt and pinion shaft.
2. Push axle toward center and remove "C" locks. Remove axles being careful not to cut axle seal. Using a slide hammer and puller, remove bearing and seal as a unit.

1. Lubricate bearing with rear axle lubricant and install with a driver. Install seal. If seal becomes cocked during installation, remove it and replace it with a new one. Insert axle in housing with care to avoid damage to oil seal.
2. Install "C" locks and push shafts outboard to seat locks in counterbore of differential side gears. Install pinion shaft lock bolt. Install carrier housing cover with a new gasket or a bead of silicone. Fill differential with proper lubricant and lower vehicle.

BRAKE BOOSTER

Note. If brake booster is damaged or inoperative, replace it with a new booster. Do not attempt to disassemble booster as it is serviced as a complete assembly only.

Disassembly

With caliper assembly removed from vehicle, pad interior of caliper with shop cloths. Apply compressed air to caliper inlet port to remove piston. If piston is seized, lightly tap around piston while applying air pressure. Remove dust boot from caliper. Using a plastic or wooden tool to prevent scratching caliper bore, remove piston seal from caliper groove.

Scheme 8

Scheme 9

Cleaning & Inspection

Clean all parts with denatured alcohol or clean brake fluid and dry with compressed air. Clean out and dry all grooves and passages with compressed air. Inspect piston and caliper bore for wear, pitting, scoring, nicks or corrosion. Replace components as necessary.

Reassembly

Apply a film of clean brake fluid to new piston seal and dust boot and install into caliper bore. Coat piston with clean brake fluid and install into caliper bore. Seat dust boot in piston groove. Spread dust boot over piston.

1. Clean outside of master cylinder. Remove caps or cover/diaphragm assembly. Remove brake fluid level indicator, if used. Pump and drain all brake fluid from master cylinder.
2. Clamp master cylinder in vise by mounting flange. Remove plastic reservoir and grommets on two piece master cylinders.
3. Discard reservoir assembly used on Ford diagonal split master cylinder. Remove fluid control valve using a 12mm socket on Ford diagonal split master cylinder. (Scheme 10)
4. Remove push rod, if used. Press primary piston inward and remove stop bolt, if used. Press primary piston inward and remove snap ring. Remove primary piston assembly. Apply compressed air and remove secondary piston assembly.

Scheme 10

Scheme 11

1. Wash master cylinder body, bore and piston assemblies with denatured or isopropyl alcohol. Inspect piston assemblies and return springs.
2. Replace pistons if they are scored galled, worn, cracked or broken. Replace springs if they are broken, bent, collapsed, distorted or fatigued.
3. Inspect tube seat inserts in outlet ports. Replace if they are cracked, scored, loose or cocked. If removal kits are not available, replace by using one of the following methods.
4. On Bendix: Remove worn tube seat inserts using an easy-out. Thread easy-out firmly into tube seat insert and tap out.
5. On Delco-Moraine: Drill a 13/64" (5.1 mm) hole through tube seat inserts. Place a heavy washer over outlet and thread a 1/4-20 x 3/4" screw into tube seat insert. Tighten screw until tube seat insert is unseated. Remove check valve and spring from drum brake outlet, if used.
6. Inspect cylinder bore for scoring, corrosion or wear. Aluminum master cylinders are anodized. Wear on the anodized surface, as evidenced by lighter areas, is normal and not detrimental.
7. Use crocus cloth to polish out light corrosion on cast iron master cylinders. Replace master cylinder if bore does not clean up using crocus cloth. Aluminum master cylinders may not be polished and must be replaced.
8. Inspect compensator and by-pass ports at bottom of reservoir. If they are plugged or dirty, clean them using brake cleaning solvent and compressed air only.

1. Install check valve and spring in drum brake outlet, if removed. Using a spare tubing nut, press tube seat insert into place, if removed. Turn nut until tube seat insert bottoms. Remove nut and inspect outlet for burrs or shavings.
2. 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. Press primary piston inward and install stop bolt, if used. Install push rod, if used.
3. Install fluid control valve using a 12mm socket on Ford diagonal split master cylinder.
4. Lubricate grommets with clean brake fluid and install in master cylinder making sure that they are properly seated. Place reservoir on hard surface and install plastic reservoir with a rocking motion on two piece master cylinders.
5. Fill reservoir with clean brake fluid and bleed master cylinder.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS

DRUM BRAKE SYSTEM SPECIFICATIONS

DRUM BRAKE SPECIFICATIONS (CROWN VICTORIA, GRAND MARQUIS, TOWN CAR)

See also:
• TORQUE SPECIFICATIONS
• DISC BRAKE SHOE & LINING
• BRAKE SYSTEM BLEEDING
• BRAKE BOOSTER PUSH ROD