1996 Ford Thunderbird Brake Service (ONLINE REPAIR MANUALS)

Master Cylinder Reservoir

Brake fluid level in the master cylinder reservoir should be between 0.16 inch below the MAX line and the MAX line on the reservoir. If brake fluid is low, the red "Brake" lamp will illuminate. Fill reservoir with brake fluid C6AZ-19542-AA (ESA-M6C25-A) or DOT-3 equivalent.

Brake System Bleed

The master cylinder and hydraulic control unit must be bled using ABS test adapter tool No. T90P-50-ALA, or equivalent. If this procedure is not followed, air will be trapped in the hydraulic control unit which will eventually lead to a spongy brake pedal.

To bleed the ma...

Warning Lamp Diagnosis

The anti-lock brake system uses two warning indicators to alert the driver of malfunctions in the system.

The red "Brake" warning lamp will come on for only two reasons:

• If brake fluid level in master cylinder reservoir falls below level determined by set point of fluid level switch.
• If parking brake is applied.

The amber "Check Anti-Lock Brake" lamp will come on for numerous reasons. It warns the driver the ABS has been turned off due to a symptom existing in the system. Normal power braking remains but the wheels may lock during a panic stop while the warning...

Removal

• Raise and support rear of vehicle, then remove tire and wheel assembly.
• Remove brake drum.
• Install suitable wheel cylinder clamp over ends of wheel cylinder to retain pistons in bore.
• Disconnect parking brake cable from parking brake lever.
• Remove two brake shoe hold-down retainers, springs and pins, Fig. .
• Spread brake shoes over piston shoe guide slots, then lift shoes, springs and adjuster off backing plate as an assembly.
• Remove adjuster spring.
• Remove retracting springs to separate shoes.
• Remove parking brake lever retaining clip, spring and washer.
• Remove lever from pin.

Instal...

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 inspect for this condition, measure the disc at 12 points with a micrometer at a radius approximately one inch from the edge of the disc. If t...

Pressure bleeding is recommended for all hydraulic brake systems. Ensure all dirt and contaminants are removed from master cylinder area prior to removing reservoir cap.

To prevent air from the pressure tank getting into the lines, do not shake the tank while air is being added to the tank or after it has been pressurized. Set the tank in the required location, bring the air hose to the tank, and do not move it during the bleeding operation. The tank should be kept at least one-third full.

On vehicles equipped with disc brakes and master cylinders without proportioners or press...

Vacuum Assist Diaphragm Type

The vacuum assist diaphragm assembly multiplies the force exerted on the master cylinder piston in order to increase the hydraulic pressure delivered to the wheel cylinders while decreasing the effort necessary to obtain acceptable stopping performance.

Vacuum assist units get their energy by opposing engine vacuum to atmospheric pressure. A piston, cylinder and flexible diaphragm utilize this energy to provide brake assistance. The diaphragm is balanced with engine vacuum until the brake pedal is depressed, allowing atmospheric pressure to unbalance the u...