Ford Falcon. Manual — part 76

206-06-24 Hydraulic

Brake

Actuation 206-06-24

DISASSEMBLY AND ASSEMBLY

Electronic Throttle Control Module

1. Refer to Section 310-02.

Dual Master Cylinder

Disassembly
Main Bore

Item

Description

Item

Description

16

Primary piston

1

Reservoir cap

17

’O’ Ring

2

Reservoir seal

18

Differential switch assembly

3

Reservoir

19

Proportioning valve assembly

4

Reservoir retaining screw

20

Prop housing sleeve

5

Reservoir seal

21

’O’ Ring

6

Circlip

22

’O’ Ring

7

Fast fill valve

23

End plug

8

’O’ Ring

9

Master cylinder body

1. Clean the outside of the master cylinder and

remove reservoir cap. Pour out and discard any

10

Secondary spring

brake fluid that remains in the cylinder.

11

Secondary piston assembly

2. Unscrew reservoir-to-body retaining screw located

12

Secondary piston stop pin

at base of reservoir.

13

Cup retainer

3. Separate, by hand, the plastic reservoir from the

14

Primary cup

body. Remove the reservoir sealing grommets.

15

Recuperating guide

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206-06-25 Hydraulic

Brake

Actuation 206-06-25

DISASSEMBLY AND ASSEMBLY (Continued)

4. Invert the cylinder so that the reservoir wells face

3. Remove the valve sealing ‘O’ ring from bottom of

down. Depress the primary piston with a rod of

reservoir port. The by-pass bleed groove allows

wood dowel until fully bottomed in the bore. The

fluid to by-pass the ball valve. This ensures that a

secondary piston stop pin should freely fall out; if

fluid passage is maintained between the brake

not, remove with long nose pliers.

pressure circuit and reservoir in the Brakes Off

position.

CAUTION: Slowly return pistons to avoid

primary piston from sringing out of the bore.

5. Carefully remove primary piston assembly from

main bore of master cylinder.

6. Remove secondary piston and return spring by

using compressed air or lightly tapping the open

end of the cylinder bore squarly onto a soft piece

of wood.

7. Separate the secondary return spring from the

secondary piston locating spigot.
NOTE: The caged spring on the secondary piston

has been set to a pre-determined length. DO NOT

attempt to adjust the screw or remove the caged

spring. If cups are damaged or badly worn, the

complete seconary iston assembly MUST BE

Item

Description

REPLACED (as supplied in repair kit).

1

Circlip

8. Remove the seal retainer from the primary piston

2

Fast fill valve

by using a small screwdriver to carefully pry apart

3

O-Ring

the seal retainer legs.

4

Master Cylinder Body

9. Remove the recuperating guide and seal from the

primary piston.

Pressure Differential Switch Assembly (Non ABS

10. Remove the O ring from the other end of the

only)

piston taking EXTREME CARE not to damage the

1. Remove end plug and ‘O’ ring from master

piston.

cylinder body.

Fast-Fill Valve

2. Remove electric switch from master cylinder,

1. Using suitable circlip pliers, remove circlip

ensuring the electrical earthing spring remains on

retaining the fast-fill valve in the primary reservoir

the switch plunger.

port of the master cylinder.

3. Remove the proportioning valve assembly by

2. Face reservoir port down to allow the valve to fall

gently bumping the master cylinder body against

out. If valve is stuck in position, lightly tap cylinder

a piece of wood to dislodge the proportioning

on piece of wood to assist valve removal.

valve assembly. Do not damage the assembly by

attempting to pull it out with pliers.

4. Spring must remain attached to switch plunger.

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206-06-26 Hydraulic

Brake

Actuation 206-06-26

DISASSEMBLY AND ASSEMBLY (Continued)

1. Assemble the large ‘O’ ring onto the end of the

Proportioning Valve (Non ABS only)

primary piston.

DO NOT disassemble the proportioning valve

NOTE: All hardware must be correctly installed

assembly. The valve is serviced only as a complete

and torqued to specification.

assembly.

2. Install primary seal onto the end of the primary

piston, with sealing face away from guide already

assembled. The primary seal can be identified by

the 6 shallow grooves around the seal’s outer

surface.

3. Assemble the cup retaining ring onto the primary

piston. Using a small screwdriver clip the retainer

legs into the groove on the piston. Care should be

taken to avoid damage to the piston or seal.

Secondary Piston

Item

Description

1

End plug

2

’O’ Ring

3

Proportioning valve assembly

4

Master cylinder body

Assembly

1. Extreme care must be taken to avoid damaging

O-Rings when inserting proportioning value.

Item

Description

2. Before assembly, lubricate internal ports and

1

Secondary spring

master cylinder bore with recommended brake

fluid from a sealed container. Prior to assembly,

2

Secondary piston

ensure primary piston (without seals) is free to

move full piston stroke in the large bore.

Primary Piston

Item

Description

1

Master cylinder body

2

Secondary piston stop pin

Item

Description

3

Secondary piston assembly

1

Cup retainer

1. Assemble the small end of the secondary piston

2

Primary cup

spring over the end of the secondary piston. This

3

Recuperating guide

should be a slight interference fit.

4

Primary piston

5

Large ’O’ Ring

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206-06-27 Hydraulic

Brake

Actuation 206-06-27

DISASSEMBLY AND ASSEMBLY (Continued)

2. To assemble the secondary piston assembly into

the body, align the slot in the secondary piston

with the reservoir wells. This must be done so that

the stop pin can be inserted into the master

cylinder body.

Master Cylinder

protrude more than 6 mm above the bottom of the

Item

Description

well.

1

Fast fill valve

2. Insert the primary piston into the main bore and

2

Circlip

against the secondary piston. Then carefully push

3

’O’ Ring - Larger

both pistons down the bore until the primary

piston is flush with the bore opening.

4

Primary piston

3. Stroke pistons and check primary piston fully

5

Split line

returns to end of bore at end of each stroke.

6

’O’ Ring

Ensure movement is not sticky.

7

Primary cup

Differential Warning Switch Section (Non ABS

8

Secondary cup - ’L’ Type

only)

9

Secondary piston

1. Before assembly, lubricate small bore master

1. Carefully insert the secondary piston, (caged

cylinder and proportioning valve with clean brake

spring end last), through the large bore and into

fluid from a sealed container.

the smaller bore until the spring “bottoms”. Ensure 2. Ensure spacer and ‘O’ ring are over proportioning

the secondary spring is not dislodged from the

valve spool, if they were removed, and check that

piston assembly during this operation. Fully stroke

spacer and ‘O’ ring are installed around the right

the secondary piston using a soft dowel and while

way.

held at the bottom of the bore install the piston

stop pin. The piston pin should easily fit in through

the larger hole of the 2 holes in the secondary

reservoir well. The top of the stop pin should not

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