Ford Falcon. Manual — part 62

206-00-10

Brake System — General Information

206-00-10

DIAGNOSIS AND TESTING (Continued)

Pressure Differential Valve (where fitted)

To Centralize
After any repair or bleeding of the brake systems the

pressure differential valve will centre itself

automatically when pressure is applied to the brake
pedal. The warning light switch is self setting.

Item

Description

1

Reservoir Cover

2

Diaphram

3

Reservoir Chamber

To Check Fluid Level

To check the level of the brake fluid in the master

cylinder, visually inspect the fluid level in the

transparent plastic reservoirs, without removing the

reservoir cover.
The fluid level should be within the maximum and

minimum marks on the Right Hand side of the

chamber. The fluid level will decrease gradually as the

linings wear. Any rapid change in fluid level should be

investigated immediately.
To reduce the possibility of fluid contamination, the

reservoir cover should be removed only when

absolutely necessary. To remove the cover, first clean

all dirt from around the cover. Refill to the maximum

level mark.
Prior to installing the master cylinder cover ensure

that the diaphragm gasket is correctly positioned in its

original form in the reservoir cover.
The cover should be fitted so that lettering on cover is

the correct way when viewed from the right hand side

of vehicle.
Use only the specified brake fluid or equivalent.

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206-00-11

Brake System — General Information

206-00-11

GENERAL PROCEDURES

Repeat this procedure at the wheel

Hydraulic System Bleeding

cylinder/caliper on the opposite side. Refill the

1. When any part of the hydraulic system has been

master cylinder reservoir after each wheel

disconnected for repair or replacement, air may

cylinder/caliper is bled and install the master

get into the system and cause spongy pedal

cylinder cover and diaphragm seal.

action. Bleed the hydraulic system after it has

If the front brake system is to be bled, repeat

been properly connected to be sure that all air is

steps 1-5 at the left front brake caliper and

expelled. Press the pedal several times and check

ending at the right front brake caliper.

for leakage.

Be sure that the caliper pistons are returned

2. The hydraulic system can be bled manually or

to their normal positions and that the pad

with pressure bleeding equipment.

assemblies are properly seated by depressing

3. Bleed the longest line first on the individual

the brake pedal several times until normal

system being serviced.

pedal travel is established.

NOTE: Clean all dirt from the master cylinder

System Pressure Bleeding

reservoir cover before removing the cover. The cover

should be fitted so that lettering on cover is the

1. The bleeder tank should contain enough new

correct way when viewed from the right hand side of

Brake Fluid to complete the bleeding operation.

the vehicle.

Never exceed 340 kilopascals pressure.

Do not mix low temperature brake fluids with the

2. The tank should be charged with 70 to 200

specified fluid. Never re-use brake fluid which has

kilopascals of air pressure.

been drained from the hydraulic system.

WARNING: Ensure the adaptor is

When the bleeding operation is completed the

clamped securely to reservoir before applying

reservoir should be filled to the MAX FLUID LEVEL

pressure.

mark on the R.H. side of the reservoirs. Be sure the

diaphragm type gasket is properly positioned in the

3. Install the pressure bleeder adaptor tool to the

master cylinder cover and is positioned in the

master cylinder and attach the bleeder tank hose

configuration as shown in Section 206-06 prior to

to the fitting on the adaptor.

installation. If brake fluid is split on the paintwork the

4. Master cylinder pressure bleeder adaptor tools

affected area must be washed with water

can be obtained from the various manufacturers

immediately.

of pressure bleeding equipment. Follow the

instructions of the manufacturer when installing

Manual System Bleeding

the adaptor.

If the rear wheel calipers are to be bled,

NOTE: When bleeding brakes do not pump the pedal.

position a ring spanner on the bleeder fitting

1. The front and rear hydraulic brake systems are

on the left wheel caliper. Attach a bleeder

individual systems and are bled separately.

tube to the bleeder fitting. The end of the tube

During the complete bleeding operation, DO NOT

should fit snugly around the bleeder fitting.

allow the reservoir to run dry.

Open the valve on the bleeder tank to admit

To bleed the rear brake system, position a

pressurised brake fluid to the master cylinder

suitable ring spanner on the bleeder fitting on

reservoir.

the wheel cylinder/ caliper. Attach a drain tube

Submerge the free end of the tube in a

to the bleeder fitting. The end of the tube

container partially filled with clean brake fluid,

should fit snugly around the bleeder fitting.

and loosen the bleeder fitting.

Submerge the free end of the tube in a

When air bubbles cease to appear in the fluid

container partially filled with clean brake fluid.

at the submerged end of the bleeder tube,

Route the tube upwards from the nipple to the

close the bleeder fitting and remove the tube.

container, which should be positioned higher

Repeat steps 3 to 7 at the right rear brake.

than the nipple. Loosen the bleeder fitting

approximately 3/4 of a turn.

Repeat steps 4 to 7, starting at the left front

caliper and ending at the right front caliper.

Push the brake pedal down slowly through its

full travel. Close the bleeder fitting, then return

When the bleeding operation is completed,

the pedal slowly to the full release position.

close the bleeder tank valve and remove the

Wait 5 seconds then repeat this operation

tank hose from the adaptor fitting.

until air bubbles cease to appear at the

Be sure that the caliper pistons are returned

submerged end of the bleeder tube.

to their normal positions and that the pad

When the fluid is completely free of air

assemblies are properly seated by depressing

bubbles, close the bleeder fitting and remove

the brake pedal several times until normal

the bleeder tube.

pedal travel is established.

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206-00-12

Brake System — General Information

206-00-12

GENERAL PROCEDURES (Continued)

Remove the Pressure Bleeder Adaptor Tool.

2. No brake pedal clearance adjustment is required

or provided for. With the brake master cylinder

Service Precautions

outlet lines disconnected and the brake pedal fully

depressed, the centre of the top surface of the

1. Do not attempt to clean or restore brake fluid, oil

brake pedal pad should be 25 mm from the floor

or grease soaked brake pads. When

surface.

contaminated pads are found, brake pads must

3. If the pedal height is below specification make the

be replaced in complete axle sets.

necessary repairs.

2. Check the brake hoses for signs of softening,

cracking, leaks or abrasions. Replace them if

necessary.

3. If the vehicle caliper parts show signs of

overheating are present when relining brakes, the

wheel calipers should be disassembled and

inspected for wear and dirt and an overhaul kit

installed, thus avoiding future problems.

WARNING: Under no circumstances

should compressed air blow off be used to

clean brakes and associated components.

Breathing in dust from the pads is a health

hazard. Remove dust and dirt with the rotunda

brake vacuum (4-0009) or equivalent or the

rotunda brake parts washer (65-0016) or

equivalent.

Caliper

4. If a piston is removed from a master cylinder or

1. Check the caliper attaching bolts torque. Torque

caliper for any reason the piston seals must be

them to specification, if required.

replaced.

2. Visually check the caliper. If the caliper housing is

All foreign material must be kept off braking

leaking it should be replaced. If a seal is leaking

surfaces and associated components.

the caliper must be disassembled and new seals

Handling of components should be done in a

installed. If a piston is seized in the bore and upon

way to avoid deformation, nicking or

disassembly is found to be scored it must be

scratching of brake pads or braking surfaces.

replaced. If the caliper is found to be distorted or

damaged or if the cylinder bores are excessively

Changing Brake Fluid

scored or worn replace the caliper assembly.

Refer to Warning under Service Precautions.

NOTE: Do not allow the reservoirs to empty.

3. Wash all parts with methylated spirits and dry with

1. If this procedure is adhered to, air will not enter

compressed air or lint free cloth.

the system and the time taken to change the fluid

4. Blow out the caliper bore and all drilled passages

will be kept to a minimum.

with compressed air.

Proceed in the same manner and order as for

5. Inspect the piston for scoring, pitting, corrosion or

bleeding the system using a transparent bleed

areas where the chrome plating has worn off. If

tube attached to a bleed screw and a glass

any damage is present replace the piston. Black

jar. Refer to Brake Bleeding in this section.

stains, caused by the seal, will do no harm.

Pump out most, but not all, of the fluid in the

6. Inspect the caliper bore for scoring, pitting,

reservoirs.

corrosion or damage and replace the caliper if any

Top up the reservoirs with new unused fluid.

of these factors are present. The caliper must not

Ensure the reservoirs are kept topped up.

be honed.

When new fluid is seen in the transparent

7. Inspect all other components and replace if wear

tube, continue to bleed for two full strokes of

or damage exists.

the pedal and close the bleed screw.

8. The calipers must not be interchanged from one

Repeat the procedure at each bleed screw in

side to the other. When the caliper is installed on

turn.

its proper side the bleeder screw will be at the top

Top up the reservoir and road test vehicle.

of the piston bore.

9. Refer to Section 206-03 or Section 206-04 for

Brake Pedal Clearance Check

detailed Caliper replacement information.

1. The brake system is designed to permit full stroke

of the master cylinder when the brake pedal is

fully depressed.

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206-00-13

Brake System — General Information

206-00-13

GENERAL PROCEDURES (Continued)

Brake System Leak Check

1. Check the brake fluid level. If the fluid level is

below the MIN line on the brake master cylinder

reservoir add the necessary amount of High

Performance SUPER DOT 4 brake fluid meeting

Ford Specification ESA-M6C25-A or SUPER DOT

4 equivalent.

2. Inspect the (1) brake line nuts and the (2) brake

master cylinder reservoir for fluid leaks.

3. Inspect the brake lines and hoses for fluid leaks.
4. Inspect the rear disk brake caliper for leaks.
5. Inspect the front disk brake calipers for leaks.
6. If a hydraulic leak is detected, refer to Section

206-06.

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