Disc & Drum: Other Ford Thunderbird X

BLEEDING BRAKE SYSTEM

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 bleeder hose onto first bleeder valve to be serviced. See «BRAKELINE BLEEDING SEQUENCE»(ref-44055-S21783793682001011500000) . 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 bleeder valve 1-2 turns. Have an assistant slowly depress brake pedal through its full travel.
4. Close bleeder 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 bleeder valve.
5. Check brake pedal for firmness. If brake pedal feels "spongy", repeat bleeding procedure. Top off brake fluid reservoir.

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

BRAKELINE 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 bleeder hose to first bleeder valve to be serviced. See «BRAKELINE BLEEDING SEQUENCE»(ref-44055-S21783793682001011500000) . 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 bleeder valve 1-2 turns, noting fluid flow. When fluid flowing into container is clear and free of bubbles, close bleeder valve securely.
4. Finish bleeding system in same manner using correct sequence. Remove pressure tank from master cylinder and check fluid level of master cylinder reservoir.

MASTER CYLINDER PUSH ROD

1. Normally, brake booster-to-master cylinder push rod should never require adjustment. If brake booster is suspected of having an improper push rod length, check and adjust push rod length as necessary. Go to step 2).
2. Make push rod gauge according to specified dimensions. (Scheme 9)or (Scheme 10). Remove master cylinder from power brake booster (without removing hydraulic lines) and set aside. Support master cylinder to prevent damage to hydraulic lines.
3. Start engine and place gauge over push rod. (Scheme 11) Adjust push rod nut to provide light tension of about 5 lbs. (2.3 kg) against gauge. Reinstall master cylinder.

Scheme 9

Scheme 10

Scheme 11

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 «BRAKE PEDAL HEIGHT SPECIFICATIONS»(ref-44055-S22118551722001011500000) .
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

Cougar & Thunderbird

Release parking brake fully. Place transmission in "N" and raise vehicle on hoist. While supporting tensioner, remove retaining clip. (Scheme 12) Tensioner spring will automatically take up any cable slack and preload parking brake cables. Reinstall retaining clip. Lower vehicle and check parking brake operation.

Scheme 12

Mark VII & Mustang

1. Ensure parking brake is fully released. Place transmission in "N". Raise and support vehicle. Tighten cable equalizer adjusting nut until rear wheel brake drag is felt when spinning rear wheel by hand.
2. Loosen cable equalizer adjusting nut until rear brakes are fully released. Spin rear wheels and ensure there is no brake drag. Lower vehicle and check parking brake operation.

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 tire and wheel assembly. Remove brake drum assembly.
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 drum assembly. Check brake operation by making several stops from varying forward speeds.

1. Raise vehicle, and 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 10-12 INCH lbs. (1.1-1.4 N.m).
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.

REAR BRAKE CALIPER