Ford Falcon. Manual — part 75

206-06-20 Hydraulic

Brake

Actuation 206-06-20

REMOVAL AND INSTALLATION (Continued)

Brake Pedal Adjustment Motor

6. Remove motor, ensure inserts remain in place.

Removal
1. Remove pedal box assembly from car Refer to

Section 206-4.

2. Remove Accelerator assembly Refer to Section

310-02

3. Rotate cable connect plug anti-clockwise and pull

plug out of motor as shown.

Installation
1. Install components in reverse order.

Brake Pedal Motor Cables

Removal
1. Rotate cable connect plug anticlokwise and pull

plug at motor end as shown.

4. Remove gear box assembly from pedal box.

2. Disconnect plug at brake pedal end as shown

using pliers.

5. Remove two screws holding motor to pedal box.

Installation
1. Install components in reverse order.

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206-06-21 Hydraulic

Brake

Actuation 206-06-21

REMOVAL AND INSTALLATION (Continued)

Brake Pedal Control Switch (where

Brake and Cruise Pedal Switch Setting

fitted)

Removal

Removal

1. Remove switch assembly from mount by rotating

to release.

1. Undo three screws underneath the lower shroud.

Move the steering column adjustment lever about

half way through its travel. Gently spread the

lower shroud to clear the key illumination ring.

2. Pull plunger out to the full extension.

Item

Description

1

Screw

2

Adjustment lever

2. Slide the shroud down and rearwards, ensuring

the adjustment lever passes through the aperture

in the lower shroud. Unclip the wire harness for

the adjustable pedal switch.

3. Refit the switch by holding brake pedal down and

reinserting switch in to housing and rotating to

lock into position.
NOTE: Hold brake pedal down while fitting switch.

3. Remove pedal adjust switch from the shroud by

deflecting the steel retaining clips and pushing the

switch outwards.

Installation
1. Install components in reverse order.

NOTE: Ensure the steering column adjustment

lever passes under the pedal switch wire harness

when installing the lower shroud.

4. Release brake pedal gently so it returns to the

relaxed position. Lightly (less than 80N) pull brake

pedal rearwards to ensure pedal fully returns

switch. This will push the plunger in and correctly

set the switch.

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206-06-22 Hydraulic

Brake

Actuation 206-06-22

REMOVAL AND INSTALLATION (Continued)

Brake Pedal Pad

Power Brake Booster

Removal

Removal

1. Remove brake pad by peeling rubber from the

1. Remove nuts attaching master cylinder to booster

pedal plate.

tie rods and remove master cylinder.

2. Disconnect vacuum hose from vacuum check

valve.

6 Cylinder

Installation
1. Install components in reverse order.

NOTE: Heating the pad will assist replacement.

8 Cylinder

Accelerator Pedal Pad

Removal
1. Remove accelerator pad retention clip on the

back of the pad by inserting a small screwdriver

and prising the pedal pad over the tang of the

pedal blade. Slide the pad from the blade.
NOTE: If the pad is to be discarded, the plastic

can be broken away to simplify removal.

3. Disconnect pushrod (part of valve assembly) from

brake pedal.

4. Remove nuts from booster tie rods and remove

booster.

5. Remove four nuts securing booster to firewall and

pedal box.

6. Remove

assembly.

Installation

Installation

1. Attach booster to dash panel/pedal box with nuts.

1. Fit new pad by pushing onto pedal blade until the 2. Attach push rod (part of valve assembly) to brake

pad clips over the retaining tang.

pedal.

3. Connect vacuum hose to vacuum check valve.
4. Attach master cylinder with nuts to booster front

shell.

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206-06-23 Hydraulic

Brake

Actuation 206-06-23

REMOVAL AND INSTALLATION (Continued)

3. Slide the master cylinder forward and upward

Dual Master Cylinder

from the vehicle.

NOTE: Special rubber components are used in this

Installation

master cylinder, therefore the cylinder must be

1. Position the master cylinder assembly over the

repaired using only genuine kits. These kits include

booster push rod and onto the two studs on the

new rubber components. Ensure all sections of the

booster assembly.

cylinder are repaired. For cleaning of internal parts of

2. Install the attaching nuts and torque to

master cylinder use clean brake fluid or methylated

specification.

spirits.

3. Install the front and rear brake tubes to the master

The split point pressure of the proportioning valve is

cylinder outlet fittings. Connect the warning light

stamped on the end face of the master cylinder body,

switch.

and it is most important that, should a cylinder need

replacing an identical cylinder be used.

4. Fill the master cylinder with the specified brake

fluid to the level marked on the side of the dual

When removing the master cylinder from the booster,

reservoirs. Use Motorcraft approved Brake Fluid.

care must be taken not to disturb the pushrod and not

Do not mix low temperature brake fluids with the

to depress the brake pedal after the cylinder is

specified fluids for the disc brake system as

removed. Failure to observe this caution may result in

specified in Section 206-00.

the output rod becoming dislodged inside booster.

5. Bleed the brake system. Refer to Hydraulic

Removal

System Bleeding in this section for the proper

1. Remove the brake tubes from the outlet ports of

procedure. While bleeding brake system, check

the master cylinder. Disconnect the plug from the

the brake failure warning light operates and

warning light switch.

resets.

2. Remove the two nuts attaching the master

6. Operate the brake several times, then check for

cylinder to the brake booster assembly.

external hydraulic leaks.

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