Ford Fiesta (1989-1995). Manual — part 43

wheel cylinder and backplate. Take great care
not to inhale the dust, as it may contain
asbestos.
4 If required, remove the hub from the drum
as described in Chapter 10.

Inspection

Note: If a brake drum requires renewal, BOTH
rear drums should be renewed at the same
time to ensure even and consistent
braking. New brake shoes should also be
fitted.
5 Clean the inside surfaces of the brake drum
and hub, then examine the internal surface of
the brake drum for signs of scoring or cracks.
If any deterioration of the friction surface is
evident, renewal of the drum is necessary. To
detach the hub from the drum, refer to
Chapter 10.

Refitting

6 Check that the automatic brake adjuster is
fully retracted, then refit the drum/hub to the
axle. Tighten the retaining bolts to the
specified torque.
7 With the brake drum refitted, refit the
roadwheel. Fully depress the brake pedal
several times, to actuate the rear brake
adjuster and take up the adjustment. Check
that the rear wheels spin freely when the
brakes are released, then apply the
handbrake, lower the vehicle and tighten the
wheel nuts to the specified torque.

6

Rear brake shoes - renewal

2

Warning: Drum brake shoes
MUST be renewed on both rear
wheels at the same time -
NEVER renew the shoes on only

one wheel, as uneven braking may result.
Also, the dust created by wear of the
shoes may contain asbestos, which is a
health hazard. Never blow it out with
compressed air, and don’t inhale any of it.
An approved filtering mask should be worn
when working on the brakes. DO NOT use
petroleum-based solvents to clean brake
parts - use brake cleaner or methylated
spirit only.
1 Remove the rear brake drum with reference
to Section 5.
2 Note the fitted positions of the springs and
the adjuster strut.
3 Depress the cups holding the brake shoes
in position and rotate them through 90° to
release them from the locking pins (see
illustration). Carefully remove the cups and
springs, then withdraw the locking pins from
the rear of the brake backplate.
4 Lift the shoes from their lower pivot and
remove the lower pull-off spring (see
illustration). Note that on some models anti-
rattle shims may be fitted between the brake
shoe and the lower pivot (see illustration). If

fitted, remove the shims and store them
safely.
5 With the shoe assembly pulled away from
the wheel cylinder, disengage the handbrake
cable from its operating lever on the trailing
shoe (see illustration).
6 Remove the upper pull-off spring, noting
the method of location.
7 Release the automatic brake adjuster cam
and pawl, then remove the adjuster strut
which is held in position by spring tension
(see illustrations).
8 Using a screwdriver, lever off the spring clip
securing the handbrake operating lever to the
trailing shoe and separate the assembly (see
illustration).

Braking system 9•5

6.4b Arrangement of brake shoe anti-

rattle shims - where fitted

A Shims

C Lower pull-off spring

B Lower pivot

D Brake shoes

6.5 Disengage the handbrake cable from

its operating lever on the trailing shoe

6.4a Detach the lower pull-off spring

6.3 Depress and turn the cups securing

the brake shoes

6.8 Lever off the spring clip securing the

handbrake operating lever to the trailing

shoe

6.7b Detach the adjuster strut

6.7a Release the automatic brake adjuster

cam and pawl

9

1595Ford Fiesta Remake

9 Detach the automatic brake adjuster
cam in a similar manner to that described
in the previous paragraph, noting its
orientation.
10 Clean the adjuster strut and its associated
components.
11 Clean the backplate, then apply a little
high-melting-point grease to the shoe contact
points on the backplate and the lower anchor
plate (see illustration). On models so
equipped, refit the anti-rattle shims to the
brake shoe lower pivot on the backplate
ensuring that they are securely located.
12 Fit the handbrake operating lever to the
trailing shoe, using a new spring clip.
13 Fit the automatic brake adjuster cam to
the leading shoe, using a new spring clip.
14 Apply a small amount of high-melting-
point grease to the automatic brake adjuster
cam and pawl contact faces, and where
the cam and handbrake operating lever
sweep across their respective brake shoes.
Do not over-apply, as this may result in lining
contamination in use - a thin smear will
suffice. Take care not to allow any grease to
contact the brake linings.
15 Fit the adjuster strut to the trailing shoe,
securing with its spring, then connect the free
end of the strut to the automatic brake
adjuster cam. Fit the upper pull-off spring
between the tops of the two brake shoes.
16 Reconnect the handbrake cable to its
operating lever.
17 Position the brake shoes onto the
backplate so that their upper leading edges
rest against the wheel cylinder pistons, and
their lower leading edges engage either side
of the lower pivot. Fit the lower pull-off spring
into its locating slots at the bottom end of
each brake shoe.
18 Insert the brake shoe locking pins through
the rear of the backplate, then relocate the
springs and cups. Depress and turn the cups
through 90° to secure.
19 Check that the brake shoes and their
associated components are correctly refitted,
then refit the brake drum with reference to
Section 5.
20 Repeat the procedure on the remaining
rear brake.

7

Rear wheel cylinder -
removal, overhaul and refitting

3

Note: Before starting work, refer to the
warning at the beginning of Section 13
concerning the dangers of hydraulic fluid.

Removal

1 Remove the brake drum as described in
Section 5.
2 Using a suitable hose clamp, isolate the
relevant rear brake unit by clamping its
flexible brake hose.
3 Disconnect the brake pipe at the wheel
cylinder union, and fit a blanking plug to the
brake pipe to prevent dirt ingress.
4 On all models except Courier, drill out the
pop-rivets securing the brake backplate to the
axle flange, and withdraw the backplate
assembly with the brake shoes in situ. Note
that it is not possible to remove the backplate
completely as the handbrake cable will still be
attached to the brake shoes.
5 Expand the brake shoes by pulling their
tops away from the wheel cylinder. The
automatic brake adjuster will hold the shoes
clear of the wheel cylinder for ease of
removal.
6 Remove the single bolt securing the wheel
cylinder to the brake backplate, and withdraw
the wheel cylinder (see illustration).

Overhaul

7 Clean any heavy dirt or grease deposits
from the external surfaces of the wheel
cylinder, then pull off the dust-excluding
covers (see illustration).
8 The pistons and seals will probably shake
out. If they do not, apply air pressure from a
foot-operated tyre pump to the brake pipe
connection to eject them.
9 Examine the surfaces of the pistons and the
cylinder bores for scoring or signs of metal-to-
metal rubbing. If evident, renew the complete
cylinder assembly.
10 If the cylinder is to be renewed, note that

three sizes are used across the Fiesta range,
dependent on specification. Ensure that the
new cylinder obtained is of the correct size to
maintain the rear braking balance.
11 Where the pistons and cylinder bores are
in good condition, discard the rubber
seals and dust excluders and obtain a repair
kit.
12 Any cleaning of the components should
be done using clean hydraulic fluid or
methylated spirit - nothing else.
13 Reassemble by dipping the first piston in
clean hydraulic fluid, then manipulate its seal
into position using fingers only. Ensure that
the seal is fitted correctly with its raised lip
facing away from the brake shoe bearing face
of the piston.
14 Insert the first piston into the wheel
cylinder from the opposite end of the cylinder
body. With it located in position, fit a dust-
excluding cover to it.
15 Fit the seal to the second piston, as
described in paragraph 13, then insert the
spring to the wheel cylinder, followed by the
second piston. Take care not to damage the
lip of the seal when fitting to the wheel
cylinder - additional lubrication with clean
hydraulic fluid and a slight twisting action
may help. Once again, only fingers should be
used.
16 Fit the dust excluding cover to the second
piston.

Refitting

17 Refitting is the reverse sequence to
removal. When refitting the backplate, locate
it in position and temporarily insert the
hub/drum retaining bolts to ensure correct
alignment. Now secure the brake backplate
using new pop rivets. Release the automatic
brake adjuster so that the brake shoes are
brought into contact with the wheel cylinder,
before refitting the hub/drum assembly as
described in Section 5.
18 On completion, bleed the brake hydraulic
system as described in Section 13 or 14 (as
applicable).

9•6 Braking system

7 .7 Exploded view of rear wheel cylinder

components

A Dust cap

E Piston

B Bleed screw

F Seal

C Wheel cylinder

G Spring

D Dust-excluding cover

7.6 Rear view of brake backplate

A Wheel cylinder-to-brake backplate

retaining bolt

B Wheel cylinder brake pipe connection
C Bleed screw

6.11 Brake shoe contact points on brake

backplate (arrowed)

1595Ford Fiesta Remake

8

Rear brake backplate -
removal and refitting

3

Removal

1 Remove the brake drum/hub assembly as
described in Section 5.
2 Remove the rear brake shoes as described
in Section 6.
3 Compress the three retaining lugs, and
release the handbrake cable from the
backplate by pushing it back through the
plate (see illustration).
4 Using a suitable hose clamp, isolate the
relevant rear brake unit by clamping its
flexible brake hose.
5 Disconnect the brake pipe at the wheel
cylinder union, and fit blanking plugs to
prevent dirt ingress.
6 Drill out the pop-rivets securing the
backplate to the rear axle, and remove the
backplate (see illustration).
7 Remove the single bolt securing the wheel
cylinder to the brake carrier plate, and
withdraw the wheel cylinder.
8 If required, remove the handbrake
adjustment plunger from the backplate by
gently prising the spring off, over the plunger
abutment, then withdraw the plunger from the
brake shoe side (see illustration). Remove the
plunger collar from the rear of the backplate.

Refitting

9 Locate the wheel cylinder in positionand
securely tighten the retaining bolt.

10 If removed, refit the handbrake
adjustment plunger to the backplate.
11 Place the backplate in position and
temporarily insert the hub/drum retaining
bolts to ensure correct alignment. Now secure
the brake backplate using new pop rivets
12 Refit the handbrake cable, and ensure
that the retaining lugs are secure.
13 Connect the brake pipe to the wheel
cylinder and remove the brake hose clamp.
14 Refit the rear brake shoes as described in
Section 6.
15 Refit the brake drum/hub as described in
Section 5.
16 On completion, bleed the brake hydraulic
system as described in Section 13 or 14 (as
applicable).

9

Master cylinder - removal,
overhaul and refitting

3

Note: Before starting work, refer to the
warning at the beginning of Section 13
concerning the dangers of hydraulic fluid.

Removal

1 Disconnect the wiring multi-plug from the
fluid level warning indicator in the reservoir
filler cap, then remove the filler cap from the
reservoir. Note that the filler cap must not be
inverted. The brake fluid should now be
removed from the reservoir.
2 Identify each brake pipe and its connection
to the master cylinder. Unscrew the fluid pipe

to master cylinder union nuts and disconnect
the pipes. On models equipped with anti-lock
brakes, disconnect the modulator return
hoses from the brake fluid reservoir, collecting
fluid spillage from the hoses in a suitable tray
(see illustration). The modulator return hose
unions should be disconnected by first
pushing the hose into the reservoir, then
retaining the collar against the reservoir body
whilst withdrawing the hose. Note that the
modulator return hoses are colour coded - the
left-hand modulator has a black return hose
and connector, and should be fitted to the
forward section of the reservoir, whilst the
right-hand modulator has a grey return hose
and connector, and should be fitted to the
rear section of the reservoir.
3 Unscrew the mounting nuts and withdraw
the master cylinder from the servo unit.

Overhaul

4 With the master cylinder removed, empty
any remaining fluid from it, and clean it
externally.
5 Withdraw the brake fluid reservoir from the
top of the master cylinder by pulling and
rocking it free from its retaining seals (see
illustration).
6 Extract the reservoir seals from the top face
of the master cylinder (see illustration).

Braking system 9•7

8.8 Handbrake adjustment plunger

A Plunger B Spring C Collar

8.6 Drilling out a pop-rivet securing the

brake backplate to the axle flange

8.3 Compress the retaining lugs (arrowed),

and release the handbrake cable from the

backplate

9.5 Removing the brake fluid reservoir

from its seals in the master cylinder

9.2 Modulator return hose connections at

the brake fluid reservoir

A Return hoses B Collars

9

1595Ford Fiesta Remake

9.6 Brake fluid reservoir seal

An ideal way to remove fluid
from the master cylinder
reservoir is to use a clean
syringe or an old poultry
baster.

7 Using a suitable socket, firmly press the
primary piston into the master cylinder until
the secondary piston retaining pin becomes
visible through the secondary piston reservoir
opening. Remove the retaining pin using
needle-nosed pliers or similar tool (see
illustration).
8 Remove the primary and secondary pistons
by shaking or gently tapping the master
cylinder (see illustrations).
9 Examine the piston and cylinder bore
surfaces for scoring or signs of metal-to-metal
rubbing. If evident, renew the master cylinder
assembly as a complete unit.
10 Cleaning of components should be done
using clean brake hydraulic fluid or
methylated spirit - nothing else.
11 Obtain a master cylinder repair kit, and
brake fluid reservoir seals.
12 Having dipped the secondary piston
assembly in clean hydraulic fluid, insert it into
the master cylinder. Note that the seals on the
secondary piston have raised lips which face
away from each other, towards the extremities
of the piston (see illustration). A slight
twisting action will assist insertion.
13 Using a suitable socket bar extension, or
similar tool, press the secondary piston into
the master cylinder to enable fitting of the
secondary piston retaining pin.

14 Dip the primary piston assembly in clean
hydraulic fluid and, using a similar twisting
action to that used for the secondary piston,
insert it into the master cylinder. Note that
both the seals fitted to the primary piston
have raised lips that face the same way -
towards its captive spring.
15 Insert new brake fluid reservoir seals to
the master cylinder then, using a similar rolling
action to that used to remove it, fit the
reservoir to the master cylinder.
16 It is recommended that a small quantity of
fluid is now poured into the reservoir and the
pistons depressed several times to prime the
unit.

Refitting

17 Locate the master cylinder to the servo
unit, having fitted a new dust cover as
applicable. Refit the two spring washers and
nuts, then tighten to the specified torque.
18 Remove the blanking plugs fitted on
removal of the unit, then reconnect the brake
pipes, tightening the unions securely.
Additionally, on vehicles equipped with anti-
lock brakes, reconnect the modulator return
hoses to the brake fluid reservoir in
accordance with their colour coding (see
paragraph 2), pushing the hoses firmly into
the reservoir body then levering out the collars
to retain.

19 Refill the brake fluid reservoir with fresh
fluid of the specified type, then bleed the
braking system in accordance with Section 13
or 14, as applicable.
20 On completion, ensure that the brake fluid
level is up to the MAX mark on the reservoir
before refitting the reservoir cap and the
warning indicator wiring multi-plug.

10 Brake pedal -

removal and refitting

1

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
2 Remove the clip securing the brake servo
operating link pushrod to the brake pedal,
noting the bush fitted in the pedal, and
disconnect the brake stop light switch wiring
connector. Release the brake stop light switch
in a clockwise direction, and extract it from
the pedal bracket.
3 Remove the C-clip from its pedal shaft
location, at the right-hand side of the brake
pedal, to allow the shaft to be withdrawn
towards the centre of the vehicle.
4 As the pedal shaft is withdrawn, remove the
brake pedal from the servo operating link
pushrod. The brake pedal spacer can now be
slid off the shaft if required, and the brake rod
bush removed.
5 Prise the bushes out from both sides of the
brake pedal, and renew as necessary.

Refitting

6 Prior to refitting, apply a small amount of
molybdenum disulphide grease to the pedal
shaft.
7 Refitting is the reverse sequence to
removal, ensuring that the brake rod bush is
located correctly, and that the pedal shaft “D”
section locates into the pedal box right-hand
support.
8 When refitting the stop light switch, insert
the switch into its retainer, press it lightly
against the brake pedal until all free play is
just taken up, then turn the switch clockwise
to secure. Reconnect the switch wiring
connector.

9•8 Braking system

9 .12 Exploded view of master cylinder components

A Brake fluid reservoir
B Reservoir seals
C Secondary piston retaining pin

D Master cylinder
E Secondary piston
F Primary piston

9.8b . . . followed by the secondary piston

assembly

9.8a Removing the primary piston

assembly from the master cylinder . . .

9.7 Removing the secondary piston

retaining pin

1595Ford Fiesta Remake