1991 Ford E-250 Econoline Brake Service (ONLINE REPAIR MANUALS)

SERVICE BRAKE

The hydraulic drum brakes are self-adjusting and require a manual adjustment only after brake shoes have been relined or replaced. The adjustment is made as follows:

• Determine inside diameter of brake drum using brake adjustment gauge, Fig. .
• Reverse tool and adjust brake shoes to fit the gauge. Hold automatic adjusting lever out of engagement while rotating adjusting screw to avoid damaging screw slots.

PARKING BRAKE

REAR WHEEL MOUNTED

Foot Operated Control

• Position parking brake pedal to fully released position, then grip tension limiter housing to prevent automatic a...

This brake booster is a hydraulically operated booster, receiving its power from the power steering system, Fig. . The power steering pump provides fluid pressure to operate both the brake booster and the power steering gear. This fluid pressure provides a variable power assist that is regulated by brake pedal applic...

EXCESSIVE PEDAL TRAVEL

• Worn brake lining.
• Shoe and lining knock back after cornering or rough road travel.
• Piston and shoe and lining assembly not properly seated or positioned.
• Air leak or insufficient fluid in system or caliper.
• Loose wheel bearing adjustment.
• Damaged or worn caliper piston seal.
• Improper booster pushrod adjustment.
• Shoe out of flat more than .005 inch.
• Rear brake automatic adjusters inoperative.
• Improperly ground rear brake shoe and lining assemblies.

BRAKE ROUGHNESS OR CHATTER; PEDAL PUMPING

• Excessive lateral runout of rotor.
• Rotor excessively out of parallel.

EXCESSIVE P...

The hydra-boost power brake booster is serviced as a unit.

REMOVAL

• With engine off, depress brake pedal several times to discharge the accumulator.
• Remove master cylinder from brake booster and position up and out of the way. Do not apply booster with master cylinder removed.
• Disconnect three hydraulic lines from booster, then disconnect input pushrod from brake pedal assembly, Fig. .
• Remove booster mounting nuts, then remove booster from vehicle. Do not carry booster by the accumulator and be careful not to drop booster on the accumulator. The snap ring on the accumulator shou...

Two warning lamps are located on the instrument panel to alert the driver to a system malfunction. The red brake warning lamp is used to indicate conventional brake system malfunctions such as low fluid level, parking brake applied and low vacuum conditions (diesel engines only). The yellow anti-lock system warning lamp is used to indicate proper warning lamp circuit operation (2 second illumination with ignition On or engine cranking). If yellow lamp comes on while vehicle is being driven, it is alerting the driver of an anti-lock system malfunction and yellow lamp can...

BRAKE LININGS

Remove both front wheels and inspect the brake discs, calipers and linings. (Wheel bearings should be inspected at this time and repacked if necessary).

Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective shoe and lining is worn or damaged. Inspect and, if necessary, replace rear brake linings also.

If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.

BRAKE ROUGHNESS

The most common cause of brake chatter on disc brakes is a variation in thick...