1996 Ford Thunderbird Brake Service (ONLINE REPAIR MANUALS)

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...

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...

Capri

Rear braking is provided by self-adjusting, single piston, floating caliper disc brakes, Fig. . The caliper slides on two hollow, stainless steel guide pins in bushings.

One guide pin is secured to the anchor bracket by a bolt. The other guide pin is held in position by the caliper retaining bolt.

The disc pads are held in the anchor bracket by two retaining clips and a "V" spring. The caliper must be removed to replace the disc pads.

During normal operation, hydraulic pressure from the master cylinder pushes the piston forward and applies pressure on the inboard brake pad. This pre...

Master Cylinder Overhaul

Disassemble

• Clean outside of master cylinder thoroughly. Drain brake fluid from master cylinder.
• Remove stop bolt and pressure control valves, if equipped.
• Using a screwdriver, carefully pry up on reservoir and remove it from master cylinder body.
• Remove fluid control valve, if equipped.
• Depress primary piston and remove snap ring from retaining groove at open end of bore.
• Remove primary and secondary piston assemblies from master cylinder. If secondary piston does not come out, apply air pressure to secondary outlet port to remove.

Inspection

When disassembled...

Remove wheels and inspect brake disc, caliper and linings. The wheel bearings should be inspected at this time and repacked if necessary. Do not get any grease on the linings.

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

Should it become necessary to remove the caliper when installing new parts, clean all parts in alcohol, then wipe dry using lint-free cloths. Using an air hose, blow out drilled passages and bores. Inspect dust boots for punctures or tears. If punctures or tears are evident, install new boots during assembly.

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