1994 Ford Crown Victoria Brake Service (ONLINE REPAIR MANUALS)

BRAKE ROUGHNESS

The most common cause of brake chatter on disc brakes is a variation in thickness of the disc. If roughness or vibration is encountered during highway operation or if pedal pumping is experienced at low speeds, the disc may have excessive thickness variation. To check for this condition, measure the disc at 12 points with a micrometer at a radius approximately one inch from edge of disc. If thickness measurements vary by more than ...

CAPRI

Removal

• Raise and support vehicle, then remove wheel and tire assembly.
• Using chisel, unstake and remove halfshaft nut and washer. Discard nut and washer.
• Remove brake pads and caliper from steering knuckle as described under "Brake Pad Service."
• Support caliper with wire strung from coil spring. Do not disconnect brake line from caliper.
• Using tie rod end separator tool No. T85M-3395-A, or equivalent, disconnect tie rod end from steering knuckle.
• Remove ball joint pinch bolt, then separate control arm from steering knuckle.
• Remove steering knuckle to strut assembly bolts.
• Using knuck...

FRONT & REAR SPLIT SYSTEMS

When the brake pedal is depressed, both the primary (front brake) and the secondary (rear brake) master cylinder pistons are moved simultaneously to exert hydraulic fluid pressure on their respective independent hydraulic systems. The fluid displacement of the master cylinder is proportioned to fulfill the requirements of each of the two independent hydraulic brake systems, Fig. .

If a failure of a rear (secondary) brake system should occur, initial brake pedal movement causes the unrestricted secondary piston to bottom in the master cylinder bore. Primary p...

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 failure.

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

• Cut off the damaged seat or damaged tubing.
• Ream out any burrs or ...

On vehicles equipped with anti-lock brakes refer to appropriate "Anti-Lock Brakes".

PUSHROD

Proper adjustment of the master cylinder pushrod is necessary to ensure proper operation of the power brake system. A pushrod that is too long will prevent the master cylinder piston from completely releasing hydraulic pressure, eventually, causing the brakes to drag. A pushrod that is too short will cause excessive brake pedal travel and cause groaning noises to come from the booster when the brakes are applied. A properly adjusted pushrod that remains assembled to the booster with which is was ...

On vehicles equipped with anti-lock brakes refer to appropriate "Anti-Lock Brakes".

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 hydr...