Ford Falcon. Manual — part 77

206-06-28 Hydraulic

Brake

Actuation 206-06-28

DISASSEMBLY AND ASSEMBLY (Continued)

3. Insert proportioning valve (capped end first) into

Item

Description

bore, EXTREME CARE should be taken when

4

master cylinder body

inserting valve to ensure ‘O’ rings are not

1. Carefully install the valve ‘O’ ring in the bottom

damaged. If ‘O’ rings are damaged the master

shoulder of the primary reservoir port.

cylinder will not function correctly and will leak

brake fluid. The proportioning valve assembly

2. Fit the fast-fill valve, ensuring the rubber base

must be bottomed in the bore of the master

with 6 dimples if faced downwards, and secure

cylinder.

with circlip.

4. Assemble a new ‘O’ ring onto the end plug, and

Reservoir

screw end plug into body. Tighten end plug to

25Nm-30 Nm.

Electrical Switch (Pressure Differential)

1. Lightly smear reservoir bores and grommets with

clean brake fluid.

2. Carefully assemble grommets into reservoir bores

1. Before installing the electrical switch, ensure

to locate against the shoulder in each bore.

earthing spring is installed on switch plunger as

3. Assemble reservoir into grommets.

shown in diagram.

4. Push on reservoir to align the retaining screw hole

NOTE: Electrical spring must remain firmly

in the reservoir and cylinder body. Then assemble

attached to the plunger. Small end of spring may

retaining screw, and tighten to 4-5 Nm. Screw

need to be closed down to give required

should just protrude from hole in the master

attachment.

cylinder body.

2. Assemble electrical switch to the master cylinder

NOTE: Both reservoir and master cylinder holes

by hand. Tighten to a torque of 2 Nm. (DO NOT

must be aligned to avoid cross threading.

OVER TIGHTEN.)

Assemble new reservoir seal into reservoir cap.

Fast-Fill Valve

5. Lubricate inside of reservoir lips with clean brake

fluid to accept reservoir cap seal.

6. Push cap and seal assembly onto reservoir and

secure by pressing clip at each end to locate on

reservoir lugs. Caps should be fitted so that

lettering on cap is correct way up when viewed

from side of vehicle.

Item

Description

1

Circlip

2

Fast fill valve

3

’O’ Ring

G22129 en

206-06x-1

Hydraulic Brake Actuation — Load Proportioning Valve (1 tonne option)

206-06x-1

SECTION : 206-06x Hydraulic Brake Actuation —

Load Proportioning Valve (1 tonne option)

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

DESCRIPTION AND OPERATION

Hydraulic Brake Actuation — Load Proportioning Valve . . . . . . . . . . . . . ..206-06x-2

REMOVAL AND INSTALLATION

Load Proportioning Valve . . . . . . . . . . . . . . . . . . . . . . . . . .206-06x-3

206-06x-2

Hydraulic Brake Actuation — Load Proportioning Valve (1 tonne option)

206-06x-2

DESCRIPTION AND OPERATION

Hydraulic Brake Actuation — Load

Proportioning Valve

Refer to Section 206-00.

G45290 en

206-06x-3

Hydraulic Brake Actuation — Load Proportioning Valve (1 tonne option)

206-06x-3

REMOVAL AND INSTALLATION

Installation

Load Proportioning Valve

1. Installation is the reverse of the removal

procedure. Once installed, bleed the brake

Removal

system. Refer to Hydraulic System Bleeding in

The Load Proportioning Valve is located on the

Section 206-00.

chassis rail above the rear axle.

NOTE: The load proportioning valve is a

non-serviceable component and must be replaced

if faulty.

1. Remove all the brake tubes from the load

proportioning valve.

2. Loosen the strap attaching the nut.

3. Support the strap and remove any force from the

bracket, remove strap attaching nut.

4. Release strap support and remove load

proportioning valve fastening nuts.

5. Remove

assembly.

G45291 en