1991 Mercury Capri Brake Service (ONLINE REPAIR MANUALS)

• Remove wheel, drum and brake shoes.
• Disconnect hydraulic line at wheel cylinder. Do not pull metal line away from cylinder as the cylinder connection will bend metal line and make installation difficult. Line will separate from cylinder when cylinder is moved away from brake backing plate.
• Remove screws holding cylinder to brake plate and remove cylinder.

OVERHAUL

• Referring toFig. as a guide, remove boots, pistons, springs and cups from cylinder.
• Place all parts, except cylinder casting in clean brake fluid. Wipe cylinder walls with clean brake fluid.
• Examine cylinder bore. A scored ...

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...

BENDIX, TEVES & DOUBLE DIAPHRAGM BOOSTER

On Bendix, Teves and Double Diaphragm Booster type power brake units, overhaul is not required. If it has been determined that the brake booster is defective, replace power brake unit as an assembly. In some instances, the only service required is replacement of the check valve and grommet and pushrod adjustment.

SINGLE DIAPHRAGM BOOSTER

Disassembly

• Remove brake booster from vehicle.
• Place front shell of booster in a vise.
• Remove clevis from valve rod and plunger assembly.
• Remove dust boot from rear shell,Fig. , then place alignment marks on fron...

Whenever new brake components are installed in the hydraulic system, it is recommended that the entire hydraulic system be thoroughly flushed with clean brake fluid.

It may sometime become necessary to flush out the system due to the presence of mineral oil, kerosene, gasoline, etc., which will cause swelling of rubber piston cups and valves so they become inoperative. The procedure is as follows:

Flushing is ...

DESCRIPTION

These units are of the vacuum suspended type. Some units are of the single diaphragm type,Fig. while others are of the tandem diaphragm type,Fig. . Both single piston and double piston or split system type master cylinders are used.

The vacuum suspended diaphragm type units utilize engine manifold vacuum and atmospheric pressure for its power. It consists of three basic elements combined into a single power unit. The three basic elements of the single diaphragm type are:

• A vacuum power section which includes a front and rear shell, a power diaphragm...

Complaints about power brake operation should be handled as if two separate systems exist. Check for faults in the hydraulic system first. If it is satisfactory, start inspecting the power brake circuit. For a quick check of proper power unit operation, press the brake pedal firmly and then start the engine. The pedal should fall away slightly and less pressure should be needed to maintain the pedal in any position.

Another check begins with installation of a suitable pressure gauge in the brake hydraulic system. Take a reading with the engine off and the power unit not opera...