Ford Falcon. Manual — part 74

206-06-16 Hydraulic

Brake

Actuation 206-06-16

GENERAL PROCEDURES

Adjustable Brake Indexing

Brake Hose Replacement

1. Refer to Section 310-02.

A flexible brake hose should be replaced if it shows

signs of softening,cracking,leaks or abrasion.

System Bleeding

When installing a brake hose,position the hose to

avoid contact with other chassis parts.

1. Refer to Section 206-00.

Brake hoses should be installed as shown on the

Power Brake Booster Testing

installation drawings.

1. Check the hydraulic brake system for leaks or

Hoses must not be twisted.

insufficient fluid.

New copper gaskets must be installed in all applicable

2. With the transmission in neutral, stop the engine

locations.

and apply the parking brake. Depress the brake

Brake Tube Replacement

pedal several times to exhaust all vacuum in the

system.

If a section of the brake tubing becomes damaged,the

3. With the engine shut off and all vacuum in the

entire section should be replaced with tubing of the

system exhausted, depress the pedal, and hold it

same type,(special doublewall steel tubing conforming

in the applied position. Start the engine. If the

to specification ASTM-A 254-6T),size,shape and

vacuum system is operating, the pedal will tend to length. Copper tubing should not be used in a

fall away under foot pressure and less pressure

hydraulic system.

will be required to hold the pedal in the applied

Brake lines should be installed as shown on the

position. If no action is felt, the vacuum booster

installation drawings.

system is not functioning.

Use Special Tools when bending brake tubing to fit

4. Remove the vacuum hose from the brake booster underbody or rear axle contours.Be careful not to kink

check valve connection. Manifold vacuum should

or crack the tube.

be available at the check valve end of the hose

All brake tubing should have the ends formed identical

with the engine at idle speed and the transmission

to the existing ends (using Special Tools)to provide

in neutral. Be sure that all unused vacuum outlets

leak-proof connections.Clean the brake tubing by

are properly capped, hose connectors properly

flushing with clean brake fluid before installation.

secured, and that vacuum hoses are in good

condition. When it is established that manifold

vacuum is available to the booster, test the check

valve and replace if necessary. With the engine

shut off disconnect the vacuum hose from the

check valve. Connect a piece of tubing to the

check valve and blow into the check valve. No air

should pass through the valve. Connect the

vacuum hose to the booster and repeat Step 3. If

no downward movement of the brake pedal is felt,

replace the brake booster.

5. Operate the engine a minimum of 10 seconds at

fast idle. Stop the engine and let the vehicle stand

for 10 minutes; then, depress the brake pedal with

approximately 80 N force. The pedal feel (brake

application) should be the same as that noted with

the engine operating. If the pedal feels hard (no

power assist), replace the brake booster.

NOTE: If the brake pedal movement feels spongy,

bleed the hydraulic system to remove air from the

system.

Hydraulic Line Repair

Always bleed the applicable primary or secondary

brake system after hose or line replacement.
Install the lines and retaining clips as shown on the

illustrations.

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206-06-17 Hydraulic

Brake

Actuation 206-06-17

REMOVAL AND INSTALLATION

5. Dislodge brake booster pin clip by pulling rear and

Brake Box Assembly

upward.

Removal

WARNING: Wait at least one minute after

disconnecting the battery ground cable before

disconnecting any electrical connector.

CAUTION: Battery must be disconnected

prior to removing brake box assembly.
NOTE: This is not a dealer serviced item Pedal box

must be replaced if brake pedal requires replacement

because this is a safety critical assembly.

NOTE: There are four variants of the pedal box, which

include three variants to the brake pedal. Removal

and replacement is similar for all Pedal Boxes.

Removal of Pedal Box Assembly is required to service 6. Remove

rotator

de-coupler.

components.

7. Undo four brake booster mounting bolts.

NOTE: The steering column must first be removed to

allow removal of the pedal box.

1. Remove the lower dash panel.

8. Disconnect booster rod from brake pedal by

sliding the booster rod toward the passenger side

of the vehicle.

2. Remove side kick panel (Refer to Section

501-12).

3. Remove steering column (Refer to Section

211-04).

4. If Pedal Box is adjustable then drive brake pedal

down to lowest position as shown.

Item

Description

1

Pin Clip

2

Rotator De-coupler

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206-06-18 Hydraulic

Brake

Actuation 206-06-18

REMOVAL AND INSTALLATION (Continued)

9. Lightly pull brake pedal away from floor until clear 12. Unbolt steering intermediate shaft and pull

of booster rod.

forward (away from firewall).

10. If the vehicle has a manual transmission then

13. Disconnect connectors C-317 and C-379 from

undo two clutch master cylinder bolts.

pedal box assembly.

11. Disconnect accelerator electrical connection.

14. Remove fuse box out of the way.

G22120 en

206-06-19 Hydraulic

Brake

Actuation 206-06-19

REMOVAL AND INSTALLATION (Continued)

2. Ensure yellow plastic clip is in place and not

15. Undo two nuts holding pedal box to body.

damaged during assembly.

WARNING: The yellow plastic clip is part

of the pedal anti-intrusion system and MUST

be refitted if the brake booster rod has been

detached from the pedal shaft.

16. Carefully remove Pedal Box Assembly by pulling

from the points shown on the diagram.

3. Check that the rotator de-coupler is correctly

positioned on the pedal pin. The decoupling

mechanism must be correctly positioned as

shown, with 1-2 mm clearance between the lower

end of the de-coupler blade and the rotator

de-coupler.

WARNING: After any service procedures

that involve removal of the pedal box. It is

important to check that the breakaway

components have not been dislodged.

WARNING: Do not apply loads on the

accelerator, brake pedal or accelerator when

removing the pedal box assembly from the

vehicle. Loading pedals during installation or

removal can misalign or damage components.

WARNING: Remove and install pedal box

carefully and ensure that fingers are not pinched

in the process.
Installation
1. Install components in reverse order.

Item

Description

1

De-coupler Blade

2

Rotator De-coupler

G22120 en