1990 Ford Thunderbird Brake Service (ONLINE REPAIR MANUALS)

Never use copper tubing as a replacement for steel tubing. Copper tubing is subject to fatigue cracking and corrosion which could result in brake system

Steel tubing is used to conduct hydraulic pressure to the brakes. All fittings, tubing and hose should be inspected for rusted, damaged or defective flared seats. The tubing is equipped with a double flare/inverted seat or I.S.O. flare to insure more positive seating in the fitting. To repair or reflare tubing, proceed as follows:

DOUBLE FLARE/INVERTED SEAT

• Using the tool shown inFig. or equivalent, cut off the damaged seat or da...

DISASSEMBLY

Except Capri, Festiva, Tracer, Scorpio, XR4Ti, Probe & 1991 Escort

• Remove caliper assembly from vehicle as described under "Caliper, Replace."
• Position fiber block and shop towels between caliper piston and caliper housing, then apply compressed air to caliper brake line fitting bore to force piston from caliper.
• Remove dust boot from caliper assembly,Figs. and .
• Remove piston seal from cylinder and discard.

Festiva

• Remove brake pads and caliper as outlined previously.
• Remove bleeder screw, drain remaining fluid from caliper, then reinstall screw.
• Remove dust boot retaining r...

BRAKE DRUMS

Any time the brake drums are removed for brake service, the braking surface diameter should be checked with a suitable brake drum micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If the braking surface diameter exceeds specifications, the drum must be replaced. If the braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. Mi...

After performing any service work, obtain a firm brake pedal before moving vehicle.

MARK VII

CALIPER, REPLACE

Removal

• Raise vehicle and support on safety stands, then remove tire and wheel assemblies.
• Disconnect fitting on rear brake tube from hose end fitting at frame mounted bracket and plug end of brake tube to prevent loss of fluid and entry of dirt. Remove horse shoe retaining clip from hose fitting and disengage hose from bracket.
• Disconnect parking cable from lever,Fig. , using care to avoid kinking or cutting cable or return spring, then remove retaining screw from cal...

REMOVAL

Except Capri, Festiva, Tracer, Scorpio, XR4Ti, Probe & 1991 Escort

• Remove brake fluid until reservoir is half full.
• Raise and support front of vehicle, then remove wheel and tire assembly.
• Remove caliper locating pins.
• Lift caliper assembly from adapter plate, then remove outer shoe from caliper assembly.On some models, slip shoe down caliper leg until clip is disengaged.
• Remove inner shoe and lining assembly.On some models, pull shoe straight out of piston. This should require a force as high as 20-30 lbs.
• Suspend caliper from inner fender housing with wire to avoid damaging brake ...

The caliper assembly consists of a pin slider caliper housing, inner and outer shoe and lining assemblies and a single piston,Figs. and . The caliper slides on two pins which also act as attaching bolts between caliper and the combination anchor plate and spindle. The outer brake shoe and lining assembly is longer than the inner brake shoe and lining assembly. Inner and outer shoe and lining assemblies are attached to the caliper by spring clips riveted to the shoe surfaces. The inner shoe is attached to the caliper by installing the spring clip to the inside of the caliper piston. T...