DEMO - 1972 Ford Truck Shop Manual Vol 1-5

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Copyright © 2011, Forel Publishing Company, LLC, Woodbridge, Virginia

All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoever without written permission of Forel Publishing Company, LLC. For information write to Forel

Publishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192

1972 Ford Truck Shop Manual EAN: 978-1-60371-080-0

ISBN: 1-60371-080-9

Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192

Email address: [email protected] Website: http://www.ForelPublishing.com

This publication contains material that is reproduced and distributed under a license from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is

allowed without the express written permission of Ford Motor Company.

NNoottee ffrroomm tthhee PPuubblliisshheerr This product was created from the original Ford Motor Company’s publication. Every effort has been made to use the original scanned images, however, due to the condition of the material; some pages have been modified to remove imperfections.

Disclaimer

Although every effort was made to ensure the accuracy of this book, no representations or warranties of any kind are made concerning the accuracy, completeness or suitability of the information, either expressed or implied. As a result, the information contained within this book should be used as general information only. The author and Forel Publishing Company, LLC shall have neither liability nor responsibility to any person or entity with respect to any loss or damage caused, or alleged to be caused, directly or indirectly by the information contained in this book. Further, the publisher and author are not engaged in rendering legal or other professional services. If legal, mechanical, electrical, or other expert assistance is required, the services of a competent professional should be sought.

FOREWORD

This manual is divided into five volumes: 1. Chassis; 2. Engine; 3. and 4. Electrical andBody; 5. Maintenance and Lubrication. These volumes should provide Service Technicianswith complete information covering normal service repairs on all 1972 model trucks built bythe Ford Companies in the U.S. and Canada. As changes in the product occur, thisinformation will be updated by Technical Service Bulletins that will supersede theinformation in the manual.

Information in each volume is grouped by system or component plus "General Service" partwhich contains information common to several similar components.

The table of contents on the first page of each volume indicates the general content of thebook and provides a handy tab locator to make it easy to find the first page of each"Group." That page will contain an index to "Parts" and the first page of each "Part"contains a detailed index which gives page location for each service operation covered. Pagenumbers are consecutive in each "Part."

To make reference easier, information has been broken down into smaller units so thatessentially there is now one "Part" for each component or system. Group numbers indicatethe volume in which the group may be found.

EXAMPLE: 11-02-7

Volume 1 - Group 11; Part 02; Page 7

The descriptions and specifications in this manual were in effect at the time this manual wasapproved for printing. The Ford Companies reserve the right to discontinue models at anytime, or change specifications or design, without notice and without incurring obligation.

Service Publications

10-02-1 Identification Codes 10-02-1

mamm iiilii•ilfililiM

JHB9KHH••lililiflllil

iBiiiiiiliiii

GROUP

10GENERAL INFORMATION

VEHICLE CERTIFICATION LABEL

The Vehicle Certification Label (V.C.Label) is attached to the rear face of thedriver's door.The upper half of the labelcontains the name of the manufacturer,the month and year of manufacture andthe certification statement. The V.C. La-bel also contains the Vehicle Identifica-tion Number.

The remaining information codes onthe V.C. Label are the same as the TruckRating Plate Codes (Fig. 1). Vehiclecodes shown on the Truck Rating Plateare explained in the following para-graphs.

RATING PLATE

Figure 1 illustrates a typical TruckRating Plate. On light and medium cowland windshield vehicles, the Rating Plateis mounted on the right side of the cowltop panel under the hood. On strippedParcel Delivery vehicles, the rating plateis placed in an envelope and included inthe Boxed Items parts. On Bronco mod-

els, the plate is mounted on the insidepanel of the glove compartment door. Onall other vehicles, the Rating Plate ismounted on the rear face of the left frontdoor.

Vehicle Identification NumberThe identification number is the first

line of numbers and letters appearing onthe Rating Plate (Fig. 1). The first letterand two numbers indicate the truckmodel and series (the letter prefix identi-fies the type of body or cab nd the num-bers are the first two numbers of a truckseries). The letter following the truck se-ries code designates the engine identifica-tion code. The letter following the engineidentification code indicates the assemblyplant at which the vehicle was built. Theremaining numbers indicate the consecu-tive unit number. The charts that followlist the various vehicle identificationnumber codes.

Vehicle Data

The Vehicle Data appears on the Rat-ing Plate on the two lines following the

identification number. The first three dig-its under W.B. designate the wheelbasein inches, the one or two letters underCOLOR identify the exterior paint color(two letters designate a two-tone). Theletter and three digits under MODELdesignate the truck model within a series.The letter and numerals under BODYdesignate the interior trim and body type(the letter identifies the interior trimscheme and the numerals identify thebody or cab type). The transmission in-stalled in the vehicle is identified underTRANS by either a numeric or alphabeti-cal code (if two symbols appear, the firstidentifies the auxiliary transmission, if soequipped, and the second symbol identi-fies the main transmission). A letter anda number or two numbers under AXLEidentify the rear axle ratio (when re-quired, a letter is also stamped behind therear axle code to identify the front axlecapacity). The maximum gross vehicleweight in pounds is stamped under MAX.G.V.W. Following MAX. G.V.W., thehorsepower rating of the engine with

RATING PLATE

SEE OPERATORS MANUAL FOR EQUIP REQ D FOR MAX GVW & LOAJM:APACITIES

F25 YL M40000WARRANTY VOID IP LOADCAPACITY EXCEEDED

f WARRANTY NO ADEQUATE TIRES REQ D FOR AXLE LOADINGSW.B. COLOR MODEl BODY TRANS

ME F250

t A T .M A X G V W I B 1 C F R T NET M P

<b( ? ) TRUCK SERIES CODE

( T ) ENGINE CODE

( T ) ASSEMBLY PLANT CODE

( T ) CONSECUTIVE UNIT NO

(s) RECOMMENDED MAX, GROSSv - ^ VEHICLE WEIG+HT

K44

4100

( T ) WHEELBASE

Q EXTERIOR PAINT CODES

© MODEL CODE

© CERTIFIED NET HORSEPOWER

M40000MANUFACTURED BYFORD MOTOR COMPANY

08/71 THIS VEHICLE CONFORMS TO A L L A P P L I C A B L EFEDERAL MOTOR VEHICLE SAFETY S T A N D A R D S INEFFECT ON DATE OF MANUFACTURE SHOWN ABOVE.AS A P P L I C A B L E ( C E R T I F I C A T I O N COVERSONLYF O R D - B U I L J PORTI ON OF VEHICLE) OR (MADE INCANADA). •'•'""'•

F25 YL M40000 131 F250 [38 373

WARRANTY VOID IF LOAD CAPACITY EXCEEDED SEE OPER MAN.FOR EQUIP. REQD FOR MAX. GVW & LOAD CAP. ADEQUATE TIRESREQ'D FOR AXLE LOADING. M a d e i n U S A

VEHICLE CERTIFICATIONLABEL

]]) SPECIFIED RPM

TRANSMISSION CODES

( j j ) DISTRICT/SPECIAL ORDER CODES

(u) REAR AXLE CODES

BRONCO, ECONOLINE AND 100-6000 - ( l l ) FRONT AXLE CODES (IF SO EQUIPPED)TRIM CODE; 700-9000 SERIES - FIRST W

CHARACTER IS CAB TRIM, SECOND ISSEAT TYPE, AND THIRD IS BODY CODE

W1017-D

FIG. 1 Typical Truck Rating Plate and Vehicle Certification Label


which the vehicle is equipped is stampedunder CERT. NET H.P. and the rpmrequired to develop the given horsepoweris stamped under R.P.M. Two-digit num-ber is stamped under D.S.O. to identifythe district which ordered the vehicle. Ifthe vehicle is built to special order(Domestic Special Order, Foreign SpecialOrder, Limited Production Option, orother special order), the complete ordernumber will also appear under D.S.O.The charts that follow list the variousvehicle data codes.

W.B. (WHEELBASE)The wheelbase in inches is entered in

this space.

MAX. G.V.W. LBSThe maximum gross vehicle weight in

pounds is recorded in this space.

CERT. NET H.P.

The certified net horsepower at speci-fied rpm is marked at this location.

SPECIFIED RPMThe rpm required to develop the certi-

fied net horsepower is marked at this lo-cation.

D.S.O.If vehicle is built on a D.S.O., F.S.O.,

L.P.O. (special orders) the complete or-der number will be reflected under theD.S.O. space including the Districi; CodeNumber.

MODEL DESIGNATION (FIRST 3 CODE SYMBOLS

WARRANTY SERIAL NO. LINE)

u

U-14

U-15

E

E-11

E-12

E-13

E-14

E-15

E-16

E-21

E-22

E-23

E-24

E-25

E-26

E-27

E-28

E-29

E-30

E-31

E-32

E-33

E-34

E-35

E-36

E-37

E-38

E-39

Bronco

U-100 (Pickup) 4 x 4

U-100(Wagon)4x4

Econoline

Basic Series

100 Series

E-100 Club Wagon

E-100 Custom Club Wagon

E-100 Chateau Wagon

E-100 Regular Van

E-100 Window Van

E-100 Display Van

200 Series

E-200 Club Wagon


E-200 Chateau Wagon

E-200 Regular Van

E-200 Window Van

E-200 Display Van

Bus Models

E-200 Standard

E-200 Custom

E-200 Chateau

Camper

300 Series

E-300 Club Wagon


E-300 Chateau Wagon

E-300 Regular Van

E-300 Window Van

E-300 Display Van

Bus Models

E-300 Standard

E-300 Custom

Chateau

F

K

Pick-up

F-10

F-11

F-25

F-26

F-35

F-50

F-60

F-61

F-65. F-66

K-60

K-61

K-70

B

J

B-50

R fin

R R1

B-70

B-75

J-70

P

G

P-35

P-40

P-50

P-60

G-50

M-35

M-40

M-50

Chassis

Cab

F-17

F-18

F-27

F-28

F-37

Conventional

Conventional

Basic Series

F-100

F-1'00 4 x 4

F-250

F-250 4 x 4

F-350

F-500

F-600

F-600

F-600 4 x 4

F-6000

F-6000

F-7000

Bus

Bus

B-500

B 600

R Rnn

B-700

B-750

B-7000

Parcel

Parcel

P-350

P-400

P-500

P-600

P-5000

M-350

M-400

M-500

(Gas)

(Diesel)

(Diesel)

(Diesel)

(Diesel)

(Gas)

(Diesel)

(Diesel)

(Gas)

(Diesel)

(DSO)

(Diesel)

(DSO)

(DSO)

(DSO)

F-70

F-75

F-80

F-81

r-aUK-80

K-81 • ' r '

K-90

N-60

N-61

N-70

N-75

N-80

N-90

R-60

R-61

R-70

R-80

R-81

R-90

S-80

S-90

W-90W-90

C-60

C-61

C-70

C-75, C-76

C-80

C-90

D-60

D-70

D-80

T-80

T-90

U-80

U-90

L-80

L-90

Q-80

Z-90

X-90

F-700

F-750

L-800

L-800

L-aUuL-8000

L-8000

L-9000

LN-600

LN-600

LN-700

LN-750

LN-800

LN-900

LN-6000

LN-6000

LN-7000

LN-8000

LN-8000

LN-9000

LNT-800

LNT-900

LNT-8000LNT-9000

C-600

C-600

C-700

C-750

C-800

C-900

C-6000

C-7000

C-8000

LT-800

LT-900

LT-8000

LT-9000

CT-800

CT-900

CT-8000

W-9000

WT-9000

(Diesel)

Cias)

(Diesel)

Cias)

(Diesel)

(Gas)

(Diesel)

(Gas)

(Diesel)

(Gas)

(Diesel)

i Diesel)

CW1168-A

10-02-3 Identification Codes T 0-02-3TRUCK SERIES CODE, MODEL CODE,HEAVY AND EXTRA HEAVY TRUCK

RECOMMENDED GROSS VEHICLE WEIGHT

SERIES

LT-8000

LTS-8000

LNT-8000

CT-8000®

L-900

LN-900

C-900

LT-900

MODEL CODE

U-813

• U-814

Y-800Y-801Y-802Y-803Y-804

Y-805Y-806Y-807Y-808Y-809Y-810Y-811Y-812Y-813Y-814Y-815Y-816Y-817

W-800W-801W-802W-803W-804W-805W-806W-807W-808W-809W-810

Q-8000-801Q-802Q-803Q-804Q-805Q-806F-900F-901F-902F-903F-904F-905F-906F-907F-908F-909F-910F-911N-900N-901N-902N-903N-904N-905N-906N-907N-908N-909N-910C-900C-901C-902C-903C-904C-905C-906C-907C-908C-909C-910C-911C-912C-913T-900T-901

GVW( lbs . )56,000

62,000

39,00027,00042,00043,00046,00050,00050,00052,00054,00056,00056,00058,00060,00062,00064,00043,00042,00039,000

39.00027,00042,00043,00045,00046,00050,00050,00054,00043,00042,000

43,00027,00039,00045,00049,00041,00051,00025,50024,00027,50029,00030,00031,00032,00033,00034,00035,00033,00027,50025,50024,00027,50029,00030,00031,00032,00033,00034,00035,00031,000.27,O0ti20,00024,00026,00027,50030,00031,00032,00032,00033,00034,00034,00036,00031,00039,00027,000

SERIES

LT-900

LTS-900

LNT-900

CT-900

L-9000

LN-9000

W-9000 ®

LT-9000

MODEL CODE

T-902T-903T-904T-905T-906T-907T-908T-909T-910T-911T-912T-913V-900V-901V-902V-903V-904V-905V-906V-907V-908V-909V-910V-911V-912V-913V-914V-915V-916V-917S-900S-901S-902S-903S-904S-905S-906S-907S-908S-909S-910S-911S-912S-913

L-900L-901L-902L-903L-904L-905L-906L-907L-908L-909L-910L-911L-912K-900K-901K-902K-903K-904K-905K-906

R-900R-901R-902R-903R-904R-905

Z-900Z-901Z-902Z-903

U-900U-901U-902U-903

GVW(lbs.)

41,00042,00043,00045,00046,00050,00050,00054,00056,00060,00043,00046.00039,00027,00042,00043,00046,00050,00050,00052,00054,00056,00056,00058,00060,00062,00064,00042,00043,00039,00039,00027,00041,00042,00043,00045,00046,00050,00050,00054,00043,00042,00039,00046,000

39,00027,00030,00041,00043,00045,00047,00049,00049,00051,00039,00043,00041,00027,50024,00032,00034,00035,00032,00034,000

27,50024,00032,00034,00035,00035,000

32,00026,00034,00036,000

43,00027,00045,00046,000

SERIES

LT-9000

LTS-9000

LNT-9000

WT-9000 ®

B-700

B-7000

B-750

® Spec.al Order.

MODELCODE

U-904U-905U-906U-907U-908U-909U-910U-911U-912U-913

Y-900Y-901Y-902Y-903Y-904Y-905Y-906Y-907Y-908Y-909Y-910Y-911Y-912Y-913Y-914Y-915Y-916Y-917Y-918

W-900W-901W-902W-903W-904W-905W-906W-907W-908W-909W-910

X-900X-901X-902X-903

B-700B-701B-702B-703B-704B-705B-706B-707B-708B-709

J-700J-701J-703J-704J-705J-706J-707J-708J-709

B-750B-751B-752B-753B-754B-755B-756

GVW(lbs.)50,00050,00054,00056,00060,00043,00045,00052,00056,00062,000

43,00027,00046,00050,00050,00052,00054,00056,00056,00058,00060,00062,00064,00043,00046,00050,00066,00068,00070,060

41,00027,00045,00046,00050,00050,00054,00043,00043,00041,00046,000

41,00032,00045,00049,000

20,50017,00021,00022,50023,00024,00025,50023,00023,00022,000

20,50017,00022,50023,00024,00025,50023,00023,00022,000

22,50017,00023,00024,00025,50023,00023,000

CW1177-B


ENGINE CODES BRONCO-ECONO-CLUB WAGONS-PARCEL-SCHOOL BUS LT & MED TRUCKS

Code

FG

AG

ABGYH

BBCDE

UV

AB

K

1

23485

Gas

Gas

Gas

Gas

(600 Series)

Diesel

Gas

Diesel

(Detroit)

Gas

CID

Engine

170-1V302-2V

240-1V302-2V

240-IV300-IV302-2V360-2V390-2V

300-IV300-1VH.D.

330-2V330-2V H.D.

361-2V

522 (V 150)522 (V-175)

240-1V300-IV

353N

240-IV300-1V H.D.

302-2V330-2V H.D.

360-2V361-2V

Heavy and Extra Heavy Truck-Series 700 through 9000LN 500-9000 and C-500-900

Code

A

BCD

Cylinders

6

688

Engine C.I.D.

240-1V

300-IV330-2VM.D.330-2V H.D.

Cyl.

68

68

66888

66888

88

66

3(DSO)

668888

Gas

Consecutive Unit Numbers-The starting serial number M40000 will be used for all the 1972 Trucks.

1971 CALENDAR YEAR

August (1971 Model)

August

September

October

November

December

M20,000 thru M29,999

M40,000thruM59,999

M60,000thruM79,999

M80,000 thru M99,999

N00,000 thru N 19,999

N20,000thruN39,999

ASSEMBLY PLANTS CODE LETTERS

Code Assembly Plant. Ontario Truck. Mahwah

LorainKansas City

. Michigan Truck

Heavy and Extra Heavy Truck-Series 700LN-500-9000 and C-500-900

CodeEFHKLUW9X

1

345

BCDEFGJKLMNPQR

T

uVWXYZ

1234567

89

Cylinders

888888888

6888

Through 9000

Engine C.I.D.361-2V391-4V401-4V477-4V534-4V330-2V H.D.361-2V534-4V391-4V

240-1V330-2V M.D.330-2V H.D.361-2V

903 Cummins-V903-320636 Caterpillar-V8-225855 Cummins NTC-270

903 Cummins-V903-270855 Cummins-NHCT-270903 Cummins V903-290855 Cummins-NHC-250855 Cummins-NHCT-270855 Cummins-NHCT-270855 Cummins-NTC-260855 Cummins NTC-280855Cummins-NTC-300855 Cummins-NTC-320855 Cummins-NTC-335568 Detroit 8V-71N522 Caterpillar V8-150522 Caterpillar V8-175855 Cummins-NTC-290927Cummins-N927

927 Cummins-N927927 Cummins-N927

855Cummins-NH-230426 Detroit 6-71N638 Caterpillar 1674573 Caterpillar-V8-200855 Cummins NHCT-270568 Detroit 8V-71N568 Detroit 8V-71NE318 Detroit 6V-53N555 Cummins V-8

Gas

LiquidPropane

Gas(DSO)

GasLow

Compression

Diesel

1972 CALENDAR YEAR

January

February

March

April

May

June

July

N40,000thruN59,999

N60,000 thru N79,999

N80,000thruN99,999P00,000 thru P19.999

P20,000 thp. P39,999

P40,000 thr. P59.999

P60,000thr. P69,000

ASSEMBLY PLANTS CODE LETTERSCodeNP

SV

Assembly Plant. . Norfolk. . . Twin C ties.. San Josfi. . . Allen P;rk. . . Kentucky Truck

AUXILIARY TRANSMISSION CODE

CODE

9

34

DESCRIPTION

Spicer 5831D

Spicer 7231B

Spicer 7231D

Heavy and Extra Heavy Truck-Series 700 Through 9000LN 500-9000 and C-500-900

CODE

5

6

8

DESCRIPTION

Spicer 8341C

Spicer 8031C

Spicer 7041

CODE

C

D

DESCRIPTION

Fuller 3K6EiFuller 4E7E.

CW1169-B


EXTERIOR PAINT COLOR CODES

Code

2

M

C1

T

J

E

N

B

7

W

6

Q

K

9

Color

Maroon

White

Spec. White

Calypso Coral . . .

Candyapple Red .

Rangoon Red . . .

Med. Blue Metallic

Platinum

Lt Blue

Med. Blue

Med. Blue Metallic

Bright Med. Blue .

Lt. Yellow Green

Med. Ivy Green . .

Prime

M-30J/M-32J Spec. No.

3059-A

1619-A

1525-A

1730-A

2008-A

1515-A

5087-HS

921-A

.. . . 3029-A

2098-A

5108-HS

5004-A

5060-A

3151-A

M6J-102B (red)

M6J-103B (gray)

Code

Z

3

F

P

LR

svD

Y

G

H

W

5

0

R

Color

Lt. Copper Metallic

Med. Bright Aqua

Lt. Green

Med. Green Metallic

Dk Green

Lt. Aqua

Med. Turquoise

Dk Green

Lt. Yellow

Med. Mallard Green Metallic . . .

Med. Goldenrod Yellow

Chrome Yellow

Med. Beige

Lt. Ginger Metallic

Brt. Yellow

Med. Metallic Green

Med Metallic Ginger

M-30J/M-32J Spec. No.

5035-HS

5006-A

5058-A

3462-HS

1237-A

3066-A

.- 5054-A

5005-A

3439-A

5019-HS

3492-A

1526-A

3569-A

3516-HS

3470-A

5187-HS

5186-HS

CLUB WAGON INTERIOR TRIM CODES

13,14,15 Lt. Gray/Black Vinyl

23, 24, 25 Lt. Blue/Med. Blue Vinyl or Cloth and Vinyl

33, 34, 35 Lt. Ginger/Med. Ginger Vinyl or Cloth and Vinyl

43, 44,45 Lt. Green/Med. Green Vinyl or Cloth and Vinyl

ECONOLINE INTERIOR TRIM CODES

1,11,12 Lt. Gray/Black Vinyl

2, 21, 22 Lt. Blue/Med. Blue Vinyl

3, 31, 32 Lt. Ginger/Med. Ginger Vinyl

4 ,41 , 42 Lt. Green/Med. Green Vinyl

26, 27, 28 Lt. Blue/Med. Blue Vinyl

36, 37, 38 Lt. Ginger/Med. Ginger Vinyl

46, 47,48 Lt. Green/Med. Green Vinyl

B, B1 Lt. Blue/Med. Blue Vinyl

C, C1, C2 Lt. Ginger/Med. Ginger Vinyl

D, D1, D3 Lt. Green/Med. Green Vinyl

LIGHT AND MEDIUM TRUCK TRIM CODES

4,4B,4C,43, D, DB, M3, MB, UB Black Vinyl

M, U Black Cloth and Vinyl

2, 23, B, K3 :. Lt. Blue/Med. Blue Vinyl

2, 23 Med. Blue Cloth and Vinyl

KB, SB, 2B, 2C, BB Black with Blue Vinyl

5, 53, E, N3 Red/Dk. Red Vinyl

N, V Dk. Red Cloth and Vinyl

5B, 5C, EB, NB, VB Black with Red Vinyl

6, 63, F, 03 Lt. Green/Med. Green Vinyl

0, W Med. Green Cloth and Vinyl

6B, 6C, FB, OB, WB Black with Green Vinyl

3, 33, C, L3 Pastel Parchment Vinyl

L, T Light and Pastel Parchment Cloth and Vinyl

3B, 3C, CB, LB, TB Black with parchment Vinyl

BRONCO INTERIOR TRIM CODES

3, 34 Pastel Parchment Vinyl

HEAVY TRUCK TRIM CODES

4, D, D3, DC,43,4C,4A,4B,41, 42, D2 DB, 46, D6, 4F, DF Black Vinyl

B2 Lt. and Med. Blue Vinyl

E2 Red and Dk. Red Vinyl

F2 Lt. Green/Med. Green Vinyl

C2 Pastel Parchment Vinyl

BB Black with Blue Vinyl

EB Black with Red Vinyl

FB Black with Green Vinyl

CB . Black with Parchment Vinyl

11 . Med. Gray Vinyl

11 Lt. Gray Vinyl

12, A2 Lt. and Med. Gray Vinyl

13,1C,A3, AC, 14,1D,A4, AD, 15, IE, A5, AE Med. Gray Vinyl

A2 Gray Multicolor and Lt. Gray Vinyl

G4, G5, G7, GD, GE, GG Ginger (Saddle) Vinyl

CW1170-A


RATING PLATE "BODY" TYPE CODE

ECONOLiNE-VANS & CLUB WAGONS

CUSTOM

BCD

STANDARD

1234

CAB/TRIM

GRAY/BLACKBLUEGINGERGREEN

VAN SEATS

1 STATIONARY PASSENGER2 FLIP PASSENGER6 DELUXE DRIVER7 DELUXE DRIVER & DELUXE STATIONARY

PASSENGER8 DELUXE DRIVER & FLIP PASSENGER

WAGON SEATS

3 FIRST&SEC0NDR0W-5PASSENGER4 FIRST, SECOND & THIRD ROW - 8 PASSENGER5 FIRST, SECOND, THIRD & FOURTH ROW -

12 PASSENGER

LIGHT & MEDIUM TRUCK-

CUSTOM

BCDEF

RANGER

KLMN0

100 Thru 6000 and Bronco

RANGER XL!

STuVW

STD.

23456

COLORCAB/TRIM

BLUEPARCHMENTBLACK

REDGREEN

H.D. VINYL BRONCO REAR SEAT STD. SEATS

BENCH SEATFOAM CUSHIONBRONCO REAR SEAT

03456789

BODY TYPE

PARCELFLARESIDE PICK-UPSTYLES.IDE PICK-UPPLATFORM STAKEWINDSHIELDCOWLCHASSIS CABPLATFORM

HO BlackVinyl

AB__-_--

Seat Codes

Driverw/Companion

__CDEFG ©H

SingleDriver

__345678

FullWidth

12__-_--

Description

Full WidthFull Width-CustomL-S UnisonL-S No. 675Bostrom WestccasterBostrom T-BarNational Cush-N-AireBostrom Level Air

(D w/Lear Siegler companion seat.

FRONT AXLE CODES

LIGHT AND MEDIUM TRUCKS

CODE

ABCDKL

5,000 Ford5,5006,0007,0003,500 DANA6CFHD3,000 DANA 44 LOCK

CODEManual

123456

Power

JKLMN_

Medium & Heavy Trucks (Except F-B-500-600, 6000)

Description

5000 Ib.5500 Ib.6000 Ib.7000 Ib.9000 Ib.12,0001bCenter Point

CODEManual

789_-_-

Power

P_RSTUZ

Description

12,0001b.12,0001b. Stee- Ease15,0001b.16,0001b.18,0001b.20,000 Ib.DSO Front Axli

111210

14151617212223242341

BOSTON

BUFFALOMFW YORKPITTSBURGHNEWARKPHILADELPHIAWASHINGTONATLANTACHARLOTTEMEMPHISJACKSONVILLELOUISVILLECHICAGO

4243AC

47485253545556575871

CLEVELAND

MILWAUKEEINDIAKIAPDI 19CINCINNATIDETROITDALLASKANSAS CITYOMAHAST. LOUISDAVENPORTHOUSTONTWIN CITIESLOS ANGELES

DISTRICE CODES

72 SAN JOSE

73 SALT LAKE CITY74 9FATTI F75 PHOENIX76 DENVER83 GOVERNMENT84 HOME OFFICE RESERVE85 AMERICAN RED CROSS89 TRANSPORTATION SERVICES87 BODY COMPANY90's EXPORT

FORD OF CANADA

MERCURY RETIONS

A1 CENTRAL

A2 EASTERN

A3 ATLANTICA4 MIDWESTERN

A6 WESTERN

A7 PACIFIC

12 EXPORT

FORD REGIONS

B1 CENTRAL

B2 EASTERN

B3 ATLANTICB4 MIDWESTERN

B6 WESTERN

B7 PACIFIC

12 EXPORT

NOTE: EXPORT ALPHABETICAL 1

CW1171-A


TRANSMISSION CODES

Code

Bronco

C

Econoline—Club Wagon

C

G

Light, Medium and Heavy Truck,

A

B

B

C

C

D

D

E

E

F

F

G

G

J

K

L

M

N

0

Description

3 Speed Manual

3 Speed Manual

Automatic

Parcel Delivery and School Bus

New Process 435 4 Speed

Warner T-85 Overdrive 3 Speed

Spicer P8516 Overdrive

Ford-Manual 3 Speed

Fuller RT-610 10 Speed

Warner T-89F 3 Speed

Clark 387 V 5 Speed

Warner T-87G 3 Speed

Fuller 5 H74 5 Speed

Fuller 5HA74 5 Speed

Warner T-18 4 Speed

C-4 Automatic

Clark 380 Overdrive 5 Speed

Fuller RTO 9513

Spicer 6453A 5 Speed

Allison AT540

Clark 285V 5 Speed

Spicer 6352 5 Speed

New Process 542FL 5 Speed

Code

Light,

0 .

P .

Q .

R .

S .

T .

T

U .

V .

w .X .

Y .

Z .

1

1 .

2

3 .

4

5

6 .

7

9

9

Description

Medium and Heavy Truck, Parcel Delivery and School Bus (Cont'd.)

Fuller T-905B 5 Speed

Warner T-19 4 Speed

Spicer 5652 5 Speed

Spicer 8716

Spicer 5756-B 5 Speed

New Process 542 FO 5 Speed

Fuller RTO-9509 B 9 Speed

Spicer 6852G 5 Speed

Fuller RT-910

Spicer 6352B 5 Speed

Fuller T-905A 5 Speed

Transmatic MT-41 6 Speed


Spicer 8552A 5 Speed


Clark 282V 5 Speed

Fuller RT-906

Clark 280 VO 5 Speed

Fuller RTO-910

Fuller RTO-915

Clark 385V 5 Speed

Fuller RT-915

New Process 542 FD 5 Speed

BRONCO-ECONOLINE AXLE COOES

Bronco

Code03A30418B8

Ford2780 Lb.

4.114.11 Lock

4.573.50

3.50 Lock

Code

A5

B9

Ford3300 Lb.

4.11 Lock

3.50 Lock

Econoline

Code

111210

Ford3050 Lb.

3.503.70

3.25

Code

0805

1709

Ford3300 Lb.

3.504.11

3.253.70

Code

717273

Dana5050 Lb.

3.543.734.10

Code

G1

G3

LimitedSlip

Dana5050 Lb.

3.54

4.10

F-100 THRU 350 LIGHT TRUCK AXLE CODES

Code37382425

Dana5250 Lb.

3.543.734.104.56

CodeC7

C8B4

Limited SlipDana

5250 Lb.3.54

3.734.10

3330 Lb.Ford

17-3.2508-3.5009-3.7005-4.1102-3.00

3300 Lb.Ford

Limited Slip

A2-3.70

3600 Lb.Ford

Limited Slip

H2-3.50H3-4.09

7400 Lb.Dana 7027-4.1028-4.56

36-3.7322-4.88

7400 Lb.Dana 70

Limited SlipD 7-4.10

P- AND M- SERIES AXLE CODES

5200 Lb.Dana 60

24-4.1025-4.56

7400 Lb.Dana 70

22-4.8828-4.56

13000 Lb.Rockwell 0-100

42-6.2044-6.80

F & B 500 THRU 6000 AXLE CODES

13000 Lb.Rockwell D-100

41-5.8342-6.20

15000 Lb.Rockwell F 106

62-6.2064-6.8066-7.20

15000 Lb. 2 SPDEaton 15201

F1-5.14/7.17F2-5.83/8.12F3-6.33/8.81

17500 Lb.Rockwell H-170

52-5.8653-6.1454-6.8355-7.17

17500 Lb. 2 SPDEaton 16244

E1-5.57/7.75E2-6.17/8.58E3-6.50/9.04

CW1172-A


REAR AXLE CODE (2780-lb. to 7400-lb. Capacity)

Code

A2

A3

A5

B4

B8

B9

C7

C8

D7

H2

H3

03

Description

Ford 3300©

Ford 2780©

Ford 3300©

Dana 6 0 © (5200)

Ford 2780©

Ford 3300©

Dana 6 0 © (5200)

Dana 6 0 © (5200)

Dana 7 0 ©

Ford 3600©

Ford 3600 ©

Ford 2780

Ratio

3.70

4.11

4.11

4.10

3.50

3.50

3.54

3.73

4.10

3.50

4.09

4.11

Code

04

05

08

09

10

11

12

02

17

18

22

23

Description

Ford 2780

Ford 3300

Ford 3300

Ford 3300

Ford 3050

Ford 3050

Ford 3050

Ford 3300

Ford 3300

Ford 2780

Dana 70

Dana 70

Ratio

4.57

4.11

3.50

3.70

3.25

3.50

3.70

3.00

3.25

3.50

4.88

5.13

Code

24

25

27

28

71

72

73

36

37

38

Description

Dana 60 (5200)

Dana 60 (5200)

Dana 70

Dana 70

Dana 60 (5050)

Dana 60 (5050)

Dana 60 (5050)

Dana 70

Dana 60 (5200)

Dana 60 (5200)

Ratio

4.10

4.:6

4.10

4.:6

3.:4

3./3

4.10

3.13

3.:4

3./3

Limited-Slip or Traction-Lok

REAR AXLE CODE (11,000-lb to 18,500-lb.

Code

El

E2

E3

F1

F2

F3

EH

FH

GH

HH

Description

Eaton 16244

Eaton 16244

Eaton 16244

Eaton 15201

Eaton 15201

Eaton 15201

Eaton 17221

Eaton 17221

Eaton 17221

Eaton 17221

Capacity)

Ratio

5.57/7.75

6.17/8.58

6.50/9.04

5.14/7.17

5.83/8.12

6.33/8.81

5.57/7.60

6.14/8.38

6.50/8.87

7.17/9.77

Code

FQ

GQ

HQ

JQ

32

34

31

40

41

Description

Eaton 17121

Eaton 17121

Eaton 17121

Eaton 17121

Rockwell C-100

Rockwell C-100

Rockwell C-100

Rockwell D-100

Rockwell D-100

Ratio

6.14

6.50

7.17

7.60

6.20

6.80

5.83

5.29

5.83

Code

42

44

52

53

54

55

62

64

66

Description

Rockwell D-100

Rockwell D-100

Rockwell H-170

Rockwell H-170

Rockwell H-170

Rockwell H-170

Rockwell F-106

Rockwell F-106

Rockwell F-106

Ratio

6.20

6.80

5.86

6 / 4

6.83

7 / 7

6.20

6.80

7.20

REAR AXLE CODE (22,000-lb and 23,000-lb.

Code

DB

EB

FB

GB

AG

BG

CG

DG

EG

FG

Description

Eaton 18221

Eaton 18221

Eaton 18221

Eaton 18221

Eaton 19121

Eaton 19121

Eaton 19121

Eaton 19121

Eaton 19121

Eaton 19121

Single-Axle)

Ratio

5.57/7.60

6.14/8.38

6.50/8.87

7.17/9.77

4.11

4.33

4.88

5.43

6.17

6.67

Code

HG

DK

EK

GK

AP

CP

DP

EP

GP

H1

Description

Eaton 19121

Eaton 18121

Eaton 18121

Eaton 18121

Eaton 19221

Eaton 19221

Eaton 19221

Eaton 19221

Eaton 19221

Rockwell R-171

Ratio

4.56

6.50

7.17

7.60

4.33/5.90

5.43/7.39

6.17/8.40

6.67/9.08

4.11/5.60

4.11

Code

H2H3

H4

H5

H6

H7

H9

Y4

Y5

P5

Description

Rockwell R-171Rockwell R-171

Rockwell R-171

Rockwell R-171

Rockwell R-171

Rockwell R-171

Rockwell R-171

Rockwell R-302

Rockwell R-302

Rockwell RT-241

Ratio

4.334.63

4.EI8

5.29

5.EI6

6.14

3.70

6.42/8.38

7.09/9.07

7.51

TANDEM REAR AXLE CODES

Code Description Ratio Code Description Ratio Code Description Ratio

EC

FC

GC

JF

BF

CF

DF

FF

Eaton 30DSC

Eaton 30DSC

Eaton 30DSC

Eaton 34DSC

Eaton 34DSC

Eaton 34DSC

Eaton 34DSC

Eaton 34DSC

6.50

7.17

7.60

4.11

4.33

4.56

4.88

5.57

GF

HF

MF

KF

LF

FWGW

Eaton 34DSE

Eaton 34DSE

Eaton 34DSE

Eaton 34DSE

Eaton 34DSC

Eaton 34DTEEaton 34DTE

6.14

6.50

7.17

7.60

3.70

6.1468.386.50/8.87

HW Eaton 34DET 7.17/9.77

C/1173-B


T A N D E M REAR A X L E CODES

Code

AJBJCJDJEJFJGJHJJJKJ

DN

FN

GN

AR

DR

ER

PR

Description

Eaton 38DSCEaton 38DSCEaton 38DSCEaton 38DSEEaton 38DSEEaton 38DSCEaton 38DSCEaton 38DSCEaton 38DSEEaton 38DSE

Eaton 34DPC

Eaton 34DPC

Eaton 34DPE

Eaton 38DPC

Eaton 38DPC

Eaton 38DPC

Eaton 38DPC

Ratio

4.564.885.576.146.504.114.335.297.177.60

6.21

7.60

8.38

5.05

6.22

6.65

7.60

Code

AV

CV

DV

BA

B1

B2

B3

B4

B6

B7

B8

B9

BO

Description

Eaton 42DPB

Eaton 42DPB

Eaton 42DPB

Rockwel l SLHD

Rockwel l SLHD

Rockwel l SLHD

Rockwel l SLHD

Rockwel l SLHD

Rockwel l SLHD

Rockwel l SLHD

Rockwel l SLHD

Rockwel l SLHD

Rockwel l SLHD

Ratio

7.60

5.05

5.91

3.55

4.11

4.44

4.63

4.88

5.83

6.17

6.83

7.80

8.60

Code

DA

01

D2

D3

D4

D5

D6

D7

D8

AX

Description

Rockwel l SQHD

Rockwel l SQHD

Rockwel l SQHD

Rockwel l SQHD

Rockwel l SQHD

Rockwel l SQHD

Rockwel l SQHD

Rockwel l SQHD

Rockwel l SQHD

Eaton 50DP

Ratio

6.17

4.11

4.44

4.63

5.29

5.83

6.83

7.80

4.88

5.61

FORD T R U C K SERIES D I S I G N A T I O N S

Prefix

U

R

F

F

L

L

LT

LT

LTS

LTS

LN

LN

LN

LN

Series Numbers

100

100 thru 300

100 thru 750

6000 and 7000

800 and 900

8000 and 9000

800 and 900

8000 and 9000

800 and 900

8000 and 9000

500 thru 750

800 and 900

6000 and 7000

8000 and 9000

*Special Order

Series

Bronco

Econoline Van

Conventional-Gas

Conventional-Diesel

Conventional-Gas

Conventional-Diesel

Conventional Tandem-Gas

Conventional Tandem-Diesel

46" BA Conventional Tandem-Gas

46" BA Conventional Tandem-Diesel

95.3" BBC Conventional-Gas

93.3" BBC Conventional-Gas

95.3" BBC Conventional-Diesel

93.3" BBC Conventional-Diesel

Prefix

LNT

LNT

C

C

CT

*CT

W

WT

B

B

P

*P

P

M

Series Numbers

800 and 900

8000 and 9000

500 thru 900

6000 thru 8000

800 and 900

8000

9000

9000

500 thru 750

6000 and 7000

350 thru 500

600

3500 thru 500

350 thru 500

Series

9 3 . 3 " BBC Convent ional Tandem-Gas

9 3 . 3 " BBC Convent ional Tandem-Diesel

T i l t Cab-Gas

Ti l t Cab-Diesel

T i l t Cab Tandem-Gas

Ti l t Cab Tandem-Diesel

Hi -T i l t Tractor-Diesel

Hi-Ti l t Tractor-Diesel

School Bus Chassis-Gas

School Bus Chassis-Diesel

Parcel Delivery-Gas

Parcel Delivery-Gas

Parcel Delivery-Diesel

Motor Home Chassis-Gas

CLUB & CHATEAU WAGON

CLUB

Series Code

E-100 E-110

E-200 E-210

E-213

E-211

E-212

E-214

E-215

E-300 E-310

E-311

E-314

E-315

E-313

E-312

E-316

CUSTOM CLUB

Series Code

E-200 E-223

E-224

E-225

E-300 E-321

E-324

E-325

E-323

E-322

E-326

CHATEAU

Series Code

E-200 E-233

E-234

E-235

E-300 E-331

E-334

E-335

E-333

E-332

E-336

M O D E L CODES A N D GROSS V E H I C L E W E I G H T

BRONCO

Code

U-140 Pickup

U-141 Pickup

U-142 Pickup

U-150 Wagon

U-151 Wagon

U-152 Wagon

GVW

4300

4500

4900

4300

4500

4900

CW1174-B


CLUB WAGON BUS MODELS, MODEL CODES AND GROSS VEHICLE WEIGHT

CLUBSeries

E-200

E-300

Model Code

E-272E-275

E-371E-376E-372E-373E-374E-375

GVW5,4006,000

6,8006,8007,5007,6007,8007,800

CUSTOM CLUB

Series

E-200

E-300

Model Code

E-285

E-381E-386E-382E-383E-384E-385

GVW

6,000

6,8006,8007,5007,6007,800

• 7.800

CHATEAUSeries

E-200

E-300

Model Code

E-295

E-391E-396E-392E-393E-394E-395

GVW

6,000

6,8006,8007,5007,6007,8007,800

CUTAWAY CAMPER

Series

E-300

Model Code

E-300E-301

GVW

8,3007,600

ECONOLINE

Series

E-100

E-200

Model Code

E-140E l 41E-142E-150E-151E-152E-160E-161E-162

E-240E-241E-242E-243E-244E-245E-250E-251E-252

GVW4,3004,6004,8004,3004,6004,8004,3004,6004,800

5,2505,4506,0005,2505,4506,0005,2505,4506,000

Series

E-200

E-300

Model Code

E-253

E-254

E-255

E-260

E-261

E-262

E-263

E-264

E-265

E-340E-341E-342E-343E-344E-345E-346E-347E-348

GVW5,2505,4506,0005,2505,4506,0005,2505,4506,000

6,0506,2006,8007,0007,5007,7008,3007,5007,700

Series

E-300

Model Code

E-350

E-351

E-352

E-353

E-354

E-355

E-356

E-357F ?RR

E-360

E-361r QCO

E-363E-364

E-365

E-366

E-367E-368

GVW6,050

6,200

6,800

7,000

7,500

7,700

8,300

7,5007 7nn/, / uu

6,0506,200c onnb,oUU

7,0007,500

7,7008,300

7,5007,700

LIGHT & MEDIUM TRUCK MODEL CODES AND GROSS VEHICLE WEIGHT

Series

F - 1 0 0 - 4 x 2

F - 1 0 0 - 4 x 4

F - 2 5 0 - 4 x 2

Pickups

F-100F-101F-102F-103F-104F-105

F-110F-111F-112F-113

F-250F-251F-252F-253

Chassis Cab

F-170F-171F-172F-173F-174F-175

F-180F-181F-182F-183

F-270F-271F-272F-273

GVW

4,4504,5504,8005,0005,5005,500

5,2005,6005,2005,600

6,2006,9007,5008,100

Series

F 2 5 0 - 4 x 2

F250-4 x4

F-350 - 4 x 2

Pickups

F254F-255

F-260F-261F-262F-263F-264

F-350F-351

NANANANANA

Chassis Cab

F-274F-275

F280F-281F-282F-283F-284

F-370F-371F-372F-373F-374F-375F-376

GVW

7,5008,100

6,5007,1007,7007,1007,700

6,6008,0008,3009,000

10,00010,0009,000

Series Model Code GVW Series Model Code GVW Series Model Code GVW

F-500 F-500F-501F-502F-503F-504F-505

15,00010,10016,00017,00018,00020,000

F-6000-Diesel

F-600 F-600F-601F-602F-603F-610F-611F-612F-613F-614F-615F-616F-617F-618

19,50015,00020,00017,00021,00022,00023,00023,00023,00024,00019,70020,00017,990

K-602K-603K-610K-611K-612K-613K-614K-615K-616

19,50017,00021,00022,00023,00023,00023,00024,00019,700

P-400 - Parcel P-403 7,000P-500 - Parcel P-500

P-501P-503

15,00010,10012,000

DSO P-600 - Parcel P-600P-601P-602P-603

17,00015,00015,00017,000

B-500 - Bus B-500B-501B-502B-503B-504B-505

15,00010,10016,00017,00018,00020,000

DSO P-5000 - Parcel

Diesel

G-500G-501G-502G-503G-504

15,00010,10015,00012,00012,000

B-600 - Bus

F - B 0 0 4 x 4 F-650

F-651

F-652

F-653F-660F-661F-662F-663

16,00015,00017,00018,00020,00020,00024,00024,000

B-600B-601B-602B-603B-610B-611B-612B-613B-614

19,50015,00020,00017,00021,00022,00023,00024,00019,700

DSO Motor Home

M-400

M-500

M-400M-401M-402

M-501M-502M-503M-504

10,00010,0008,000

13,50013,50012,00012,000

P-350 - Parcel P-350P-351P-352P-353

F-6000- Diesel K-600K-601

20,00015,000

8,0006,1006,5008,000

N / A - Not Applicable

P-400 - Parcel P-400P-402

10,0008,000 CW1175-B

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11-01-1 General Wheel and Tire Service 11-01-1

GROUP

11PART 11-01 Page

General Wheel and Tire Service 11-01-01

PART 11-02

Wheels and Tires-

Drop Center Rim 11-02-01

PART 11-03

Wheels and Tires-

Two Piece Rims 11-03-01

PART 11-04

Wheels and Tires-

Three Piece Rims 11-04-01

PART 11-10 Page

Wheel Hubs and

Bearings-Front 11-10-01

PART 11-11

Wheel Hubs and

Bearings-Rear 11-11-01

PART 11-12

Wheel Hubs and Bearings-

Front Wheel Drive 11-12-01

PART 11-14

Wheel Hubs and Bearings-

Rear (Full Floating Axle) 11-14-01

PART 11-01 General Wheel and Tire ServiceApplies to All Models

COMPONENT INDEX

FRONT WHEEL BEARING

Maintenance

Page

01-1

COMPONENT INDEX

TIRE INSPECTION

WHEEL INSPECTION

Page

01-2

01-2

ADJUSTMENTS

WHEEL BALANCING

See the instructions provided with theRotunda Wheel Balancer.

Make certain that the brakes are notdragging before attempting to spin thewheels. On vehicles equipped with discbrakes, push the brake shoes into the cali-per to free the rotor.

FRONT WHEEL BEARINGMAINTENANCE

Wheel bearings are adjustable to cor-rect for bearing and spindle shoulderwear. Satisfactory operation and long lifeof bearings depend on proper adjustmentand correct lubrication. If bearings areadjusted too tightly, they will overheat

and wear rapidly. An adjustment that isexcessively loose will cause pounding andcontribute to uneven tire wear, steeringdifficulties and inefficient brakes. Thebearing adjustment should be checked atregular inspection intervals.

11-01-2 General Wheel and Tire Service 11-01-2

CLEANING AND INSPECTION

WHEELS

Wheel stud nuts should be inspectedand tightened in the first 500 miles, toavoid accidental loosening of the wheels.Loose wheel stud nuts may cause shimmyand vibration. Elongated stud holes in thewheels may also result from the loosestud nuts.

Keep the wheels and hubs clean.Stones or lumps of mud wedged betweenthe wheel and drum will unbalance awheel and tire.

Check for damage that would affectthe runout of the wheels. Wobble orshimmy caused by a damaged wheel willeventually damage the wheel bearings.Inspect the wheel rims for dents thatcould permit air to leak from the tires.

TIRES

The tires should be checked fre-quently to be sure that the air pressuresagree with those specified for the tiresand vehicle model. Inspect the tire

threads, and remove all stones, nails,glass or other objects that may be wedgedin the thread. Check for holes or cuts thatmay permit air leakage from the tire, andmake the necessary repairs.

Inspect the tire side walls for cuts,bruises, and other damage. If internaldamage is suspected, demount the tirefrom the wheel for further inspection andrepair or replacement.

Check the tire valve for air leaks, andreplace the valve if necessary. Replaceany missing valve caps.

On F-100, 250, 350 and Econolinemodels, it is important that except fordeep dish (dual type) all be balanced.

Fig. 1 describes common tire wearconditions.

FRONT WHEEL BEARINGS

Wheel bearings are adjustable to cor-rect for bearing and spindle shoulderwear. Satisfactory operation and long lifeof bearings depend on proper adjustmentand correct lubrication If bearings are

adjusted too tightly, they will overheatand wear rapidly. An adjustment that isexcessively loose will cause pounding andcontribute to uneven tire wear, steeringdifficulties and inefficient brakes. Thebearing adjustment should be cracked atregular inspection intervals.

Front hubs and bearings should becleaned, inspected and lubricated when-ever the hubs are removed or al themileage/time periods indicated in themaintenance schedule.

New hub grease seals should be in-stalled when the hub is removed. An im-perfect seal may permit bearing lubricant

to reach the brake linings resulting infaulty brake operation and necessitatingpremature cleaning or replacement of lin-ings.

Bearing adjustment is described inPart 11-10 for front wheels. Part 11-12covers front drive bearing adjustment.Part 11-11, and 11-14 cover rear wheelbearing adjustments.

11-02-1 Wheels and Tires Drop Center Rim 11-02-1

PART 11-02 Wheels and Tires Drop Center Rim

Applies to F-100-350, Bronco and Econoline

COMPONENT INDEX

FRONT WHEEL ASSEMBLY

Description


4-WHEEL DRIVE

Description

Page

02-1

02-1

COMPONENT INDEX

REAR WHEEL ASSEMBLY

Description

WHEEL REPLACEMENT •'.

TIRE REPLACEMENT

Page

02-1

02-3

02-3

DESCRIPTION


Each front wheel and tire assembly isbolted to its respective front hub andbrake drum or rotor assembly. Two op-posed tapered roller bearings are in-stalled in each hub (Figs. 1, 2 and 3). Agrease retainer is installed at the innerend of the hub to prevent lubricant fromleaking into the drum. The entire assem-

bly is retained to its spindle by the locknut and/or adjusting nut and cotter pin.

FRONT WHEELASSEMBLY—FOUR-WHEEL DRIVE

The front axles used on 4-wheel drivemodels are covered in Group 15, Parts15-30, 15-32 and 15-33 of this manual.

REAR WHEEL ASSEMBLY

The rear wheel, hub, and drum assem-blies are connected to the rear axle shaftflanges and ride on two opposed taperedroller bearings. The inner end of eachaxle shaft is splined to the engine pow-ered differential.

HUB AND BRAKEDRUM ASSEMBLY

ADJUSTINGNUT BEARING

OUTER CUPBEARING

CONE ANDROLLER

INNER BEARINGCONE AND

ROLLER

WHEELASSEMBLY

F1422-A

FIG. 1 Front Hub, Bearings and Grease Retainer—Drum Brakes F-100 ThroughF-350, Econoline


HUB AND BRAKEDRUM ASSEMBLY

WHEEL HUB

GREASE CAP

SNAP RINGOUTER BEARING

SPACER COREAND ROLLER

WHEEL BEARINGADJUSTING NUT

INNER BEARING CUP\

GREASE RETAINER

NUT

HUB BOLT

SPLINED DRIVING HUB OUTER BEARING CUP

FIG. 2 Front Wheel and Hub Installation—Four-Wheel Drive

INNER BEARINGCONE

AND ROLLER

WHEEL ASSEMBLY

F 1300-B

HUB AND ROTORASSEMBLY

ADJUSTINGNUT

INNER GREASEBEARING RETAINER

CUP

OUTERBEARING

OUTER CUPBEARING

CONE ANDROLLER

INNER BEARINGCONE AND

ROLLER

WHEELASSEMBLY

F1416-A

FIG. 3 Front Hub, Bearings and Grease Retainer—Disc Brakes—Typical


REMOVAL AND INSTALLATION

WHEEL REPLACEMENT

Light Vehicles

Removal1 Pry off the hub cap (if the vehicle is

so equipped), and loosen but do notremove the wheel stud nuts.

2. Raise the truck until the wheel andtire clear the floor.

3. Remove the wheel stud nuts and thewheel and tire from the hub anddrum.

Installation

1. Clean all dirt from the hub and drum.The replacement wheel and tire mustbe clean.

2. Position the wheel and tire on the huband drum, and install the wheel studnuts. Tighten the stud nuts enough tohold the wheel firmly in place. Al-ways tighten alternate nuts to drawthe wheel evenly against the hub anddrum.On dual wheels, be sure to back off

the outer nut before tightening the innernut. Then tighten the outer nut. Somedual wheels have mounting bolt holeswhich are alternately flared inward andoutward. These surfaces must be matedwhen the wheels are mounted. Fig. 4 il-lustrates the dual wheel radial alignmentlocating pin used on certain applications.3. Lower the vehicle to the floor, and

tighten the wheel stud nuts to thespecified torque. On a new vehicle,•and each time a wheel and tire is in-stalled, the wheel nuts should bechecked for tightness. When install-ing the hub cap, notice the wheelnubs. The hub cap should be posi-tioned on the wheel over one of theretaining nubs and the two locatingnubs. Be sure that the lip of the hubcap is firmly seated in the groove ofthe retaining nub, and then force thecap over the second retaining nub.Any other procedure necessitatesheavy pounding with possible damageto the hub cap. —

Medium Vehicles

ALIGN DUAL WHEELSON LOCATING PIN F 1829-A

FIG. 4 Dual Wheel Radial Alignmentto Hub (F-350)

Removal1. Loosen but do not remove the wheel

stud nuts.2. Raise the vehicle until the wheel and

tire clear the floor.3. Remove the wheel stud nuts and the

wheel and tire from the hub anddrum.

Installation1. Clean all dirt from the hub and drum.

The replacement wheel and tire mustbe clean.

2. Position the wheel and tire on the huband drum, and install the wheel studnuts. Tighten the stud nuts enough tohold the wheel firmly in place. Al-ways tighten alternate nuts to drawthe wheel evenly against the hub anddrum.On dual wheels, be sure to back off

the outer nut before tightening the innernut. Then tighten the outer nut.3. Lower the truck to the floor, and

tighten the wheel stud nuts to thespecified torque. On new vehicles, andeach time a wheel and tire is installed,the wheel nuts should be checked fortightness.

TIRE REPLACEMENTPRECAUTIONS

The tire must be completely deflatedbefore removal, and the bead must not bedamaged by a tire iron.

After installation, a tube tire shouldbe inflated to recommended pressure, de-flated, and then inflated again to insurethat the tube is not folded inside the tire.Be sure the tube flap is properly posi-tioned before inflating the tire. On F-100and 250 series, it is important that eachfront and rear tire and wheel be balanced.On E-100 and E-300 all wheels should bebalanced. On U-100, and vehicles withdual rear wheels, only front wheelsshould be balanced.

When installing tires on vehiclesequipped with Safety Ledge rims, thor-oughly lubricate the tire beads. Inflatethe tire until the bead seats against therim of the wheel, then deflate to the speci-fied pressure.

Removing Conventional TubelessTire From Wheel

The tire can be demounted on amounting machine. Be sure that theouter side of the wheel is positioneddownward. If tire irons are used, followthe procedure given here.1. Remove the valve cap and core, and

deflate the tire completely.2. With a bead loosening tool, break

loose the tire side walls from thewheel (Fig. 5).

3. Position the outer side of the wheel

F1424-A

FIG. 5 Loosening Tire Bead

downward, and insert two tire ironsabout eight inches apart between thetire inner bead and the back side ofthe wheel rim. Use only tire ironswith rounded edges or irons designedfor removing tubeless tires.

4. Leave one tire iron in position, andpry the rest of the bead over the rimwith the other iron. Take small b:teswith the iron around the tire in orderto avoid damaging the sealing surfaceof the tire bead.

5. Stand the wheel and tire upright withthe tire outer bead in the drop centerwell at the bottom of the wheel. Insertthe tire iron between the bead and theedge of the wheel rim and pry thewheel out of the tire.

Mounting Conventional TubelessTire To Wheel

1. If a used tire is being installed removeall dirt from the tire.If a tire is being mounted to the origi-

nal wheel, clean the rim with emery clothor fine steel wool. Check the rim fordents.

If a new wheel is being installed, coata new valve with rubber lubricant andposition the valve to the new wheel. Usea rubber hammer or a valve replacingtool to seat the valve firmly against theinside of the rim.2. Apply RUGLYDE or a similar rub-

ber lubricant to the sealing surface onboth tire beads. With the outer sideof the wheel down, pry the beads overthe wheel rim with two tire irons. Donot use a hammer or mallet to forcethe beads over the rim.

3. Hold the beads against the rim flangesby positioning a tire mounting bandover the tire (Fig. 6). If a mountingband is not available, tie a tourniquetof heavy cord around the circumfer-ence and in the center of the tire.Tighten the cord with a tire iron. Cen-ter the tire on the wheel with a rubbermallet.

4. Give the tire a few quick bursts of air


to seat the beads properly, then inflatethe tire to 40 psi pressure. Check tosee that the bead positioning rings(outer rings near the side walls) areevenly visible just above the rimflanges all the way around the tire. Ifthe rings are not even, deflate the tirecompletely and inflate it again.

5. When the rings are properly posi-tioned, deflate the tire to the recom-mended pressure.

Removing Tube Type Tire FromWheel

The drop center rim (Fig. 7) is usedfor either tube or tubeless tires.1. After completely deflating the tire by

removing the valve core, loosen thebeads, and force them into the dropcenter of the rim.

2. Using a pair of tire irons, pry thewheel out of the tire.

Mounting Tube Type Tire to Wheel

1. After inspection and cleaning of thetire and wheel, install the valve corein the inner tube and inflate the tubeuntil it is barely rounded out.

2. Position the tube in the tire, soap thetire beads, and force the bottom beadinto the drop center.

3. At a point on the wheel opposite thevalve, insert a tire iron between thetop bead and the rim, prying the beadover the rim.

4. Hold this iron in position, and withanother iron, pry the bead into posi-tion all the way around the rim. Donot use a hammer or mallet to forcethe beads over the rim.

F1425-A

FIG. 6 Tubeless Tire Mounting Band

R I M F1457-A

FIG. 7 Drop Center Rim

WHEEL TORQUE LIMITS - F 100 THRU F-350, ECONOLINE, BRONCO, P-350 THRU 500

Model

E-100, E-200F-100 (4 x 4), U-100 (Std. Wheel) P-100F-250-250 (4 x 4)P-350 (W-5200 Ib. Axle)E-300 (8-Stud Wheel)F-350, P-350P-400, (W/8-StudWheel and 74001b. Axle)

NutSize

1/2-20

9/16-18

Ft-Lbs

90

135

Model

F-350, P-350, P-450,(W/Dual Wheelsand 7400 Ib Axle)P-350, P-400(W/17" Wheels)P-500

Nut Size

9/16-18

5/8-18

3/4-16 or1-1/8-16

Ft-Lbs

210

210

450

CF 1804B

11-03-1 Wheels and Tires—Two Piece Rims 11-03-1

PART 11-03 Wheels and Tires-Two Piece Rims

Applies to All 500-9000 Series Vehicles

COMPONENT INDEX

TIRE REMOVALAND MOUNTING-

Two-Piece Rims

Page

03-1

COMPONENT INDEX

TIRE REMOVAL ANDMOUNTING-

Two-Piece Semi-DropCenter Rims

Page

03-2

DESCRIPTION

Two piece rims, for disc wheels areused with tube-type tires only. These rimshave a 5 degree tapered seat and are avail-able in 5.0, 5.50 and 6.5 rim sizes.



After installation, a tube tire shouldbe inflated to recommended pressure, de-flated, and then inflated again to insurethat the tube is not folded inside the tire.Be sure the tube flap is properly posi-tioned before inflating the tire.

TIRE REMOVAL ANDMOUNTING—TWO PIECE RIMRemoving Tire From Wheel

To remove the rim ring (Fig. 1) froma rim without a tire, stand the wheel upso that the tool slot of the ring is at thetop, and the lower portion of the ring isin the rim well. Insert the rim tool be-tween the rim slot and the gutter of therim, lift the ring over the gutter, and prythe ring off the rim (Fig. 2).

WHEEL ASSEMBLY FLANGE

2-PIECE RIM

F1805-A

FIG. 1 Two-Piece Rim Installation

1. Place the wheel (ring side up) on thefloor. Insert the hook end of the rimtool between the ring flange and thetire bead, and continuing around thering, pry the tire off the tapered seatof the ring (Fig. 2).

2. Press the side of the ring opposite thedouble embossing down into the ringwell. Insert the straight end of the rimtool into the notch between and belowthe double embossing (Fig. 4).

3. Force the tool downward to disengagethe ring from the rim gutter. Workthe tool around the rim, freeing thering from the rim, and remove thering.

4. Turn the wheel over and loosen theopposite tire bead from the rim byhammering the hook end of the rimtool between the rim flange and thetire bead. Pry the tire bead away fromthe taper, and remove the tire fromthe rim (Fig. 3).

Mounting Tire to Wheel

1. After positioning the tube in the tire,place the wheel gutter (Fig. 4). Hookthe section soap both beads of the tireand position the tire on the rim.

2. After positioning the tube in the tire,place the wheel gutter (Fig. 4). Hookthe section opposite the notch underthe gutter so that the cutaway por-tions of the ring retaining bead spanthe rim gutter (Fig. 4).

3. Insert the straight end of the rim toolin the notch, and pull the ring onto

F1459-A

FIG. 2 Removing Ring and LooseningTire Bead—Two-Piece Rim

the rim, at the same time forcing thering over the gutter with a soft ham-mer (Fig. 5). Remove the tool, andcontinue to drive the ring down untilit is entirely engaged in the gutter.Press down on the ring (as shown inFig. 5) to make certain that it willrock. If there is no movement, thering is not completely seated and willbe forced off violently, either duringinflation or when the truck is ope-rated. When inflating the tire, do notstand in front of the ring.

F1410-A

FIG. 3 Removing Ring and RemovingTire—Two-Piece Rim

11-03-2 Wheels and Tires—Two Piece Rims 11-03-2

" C " RING

F102 7-A

FIG. 4 Positioning and StartingRing—Two-Piece Rim

TIRE REMOVAL ANDMOUNTING—TWO-PIECESEMI-DROP CENTER RIM WITHC-STYLE RING

This two-piece wheel uses a split C-type ring (Fig. 6).

Removal of Side Ring from RimWithout Tire1. Stand the wheel up so that the tool

slot of the ring is at the top and thelower portion of the ring is in the rimwell.

2. Insert the rim tool between the rimslot and the gutter of the rim. Lift thering over the gutter, and pry the ringoff the rim.

Removal of Side Ring from RimWith Tire1. Deflate tire completely and place the

wheel (ring side up) on the floor.2. Break the tire bead free from the rim,

being careful not to damage the bead(Fig. 7).

3. Insert the straight end of the rim toolinto and under the notch in the ring(Fig. 8).

4. Force the tool downward to disengagethe ring from the rim gutter. Workthe tool around the rim, freeing thering from the rim, and remove thering.

5. Turn the wheel over and loosen theopposite tire bead from the rim byhammering the hook end of the rimtool between the rim flange and thetire bead. Pry the tire bead away fromthe taper, and remove the tire fromthe rim (Fig. 9).

Mounting Tire to Wheel1. Position the tube in the tire and place

the wheel (gutter side up) on the floor.Soap both beads of the tire and posi-tion the tire on the rim. It is importantthat the tire be soaped well as it must

1028-A

SAFETY BEAD HUMP

FIG. 6 Two-Piece Split Ring

be forced over the safety bead humpand the rim edge (Fig. 10).

2. Position the ring with the notch about3 inches from the valve stem.

3. Insert the rim tool under the ring ata position approximately 180 degreesfrom the notch and pry onto rim.Work the remaining section of rimover the gutter with a second tool.

4. Make certain that the ring is entirelyseated in the gutter. If the ring is notseated correctly as described, it maybe forced off violently, either duringinflation or when the truck is ope-rated.

5. After installation, the tire should beover-inflated to 75 psi to snap the tirebeads over the bead humps and fullyseat the tire against the rim and sidering. Then the tire should be deflated,and then inflated again to recom-mended pressure to insure that thetube is not folded inside the tire. Besure the tube flap is properly posi-tioned before inflating the tire. Al-ways use a cage or safety chain duringinitial inflation.It is important that the new C shaped

side ring be used only with the new wheelwith a bead hump. (See Fig. 6) The oldstyle ring must be used only with the oldtapered seat rim.

Rim Tools

FIG. 5 Installing and CheckingRing—Two-Piece Rim

F1473-B

Rim Tool WORK INDIRECTIONOF ARROW

F1338-B

FIG. 8 Removing Split Ring

Rim Tools

F1340-A

FIG. 9 Removing Tire From Rim

F1341-A

F1337-B

FIG. 7 Loosening Tire BeadFIG. 10 Installing Tire First Bead on

Wheel

11-04-1 Wheels and Tires—Three Piece Rims 11-04-1

PART 11-04 Wheels and Tires-Three Piece Rims

Applies To All 500-9000 Series Vehicles

COMPONENT INDEX

TIRE REMOVAL

A N D M O U N T I N G -

Three Piece Rims

Page

04-1

COMPONENT INDEX

TIRE REMOVAL

AND MOUNTING-

Cast Spoke Wheels

Page

04-2

DESCRIPTION

Three piece rims are non-demounta-ble for disc wheels or demountable forcast spoke wheels, Fig. 1, shows a dualwheel sectional view.

Demountable rims for cast-spokewheels are secured by a lane at the backedge of each spoke, and a lug retained bya stud and nut at the edge of each spoke.

WHEEL ASSEMBLY WHEEL RIM LOCK RING FLANGE

3-PIECE RIM, DUAL WHEELS

FIG. 1 Three Piece Rim—Dual Wheel Sectional View

F1806-A



After installation, a tube tire shouldbe inflated to recommended pressure, de-flated, and then inflated again to insurethat the tube is not folded inside the tire.Be sure the tube flap is properly posi-tioned before inflating the tire.

TIRE REMOVAL ANDMOUNTING—THREE-PIECE RIM

Tire mounting procedures are the

F1461-A

FIG. 2 Loosening Tire Bead andLocking Ring—Three-Ring Rim

same for disc wheels and for cast wheelsequipped with the three-piece rims, ex-cept that cast spoke wheels require spe-cial final centering and runoutadjustment.

Removing Tire From Wheel

1. Place the wheel and deflated tire onthe floor, with the ring up. Insert thestraight end of the rim tool in thedepression in the locking ring andloosen the tire bead by pressing downon the side ring (Fig. 2).

2. Insert the straight end of the rim toolin the notch provided in the lockingring, and pry the locking ring out ofthe gutter (Fig. 2). Lift out the lockingring, and remove the slide ring (Fig.3).

3. Turn the wheel over and loosen thetie bead from the rim by hammeringthe hooked end of the rim tool be-tween the rim flange and the tire bead.Pry the tire bead away from the taperall the way around the rim until thetire is free. Remove the tire.

F1462-A

FIG. 3 Removing Locking Ring andPositioning LockingRing—Three-Piece Rim

Mounting Tire To Wheel

1. Position the wheel (gutter side up) onthe floor. Soap both beads of the tireand position the tire on the rim.

2. Position the solid side ring on the tire,and insert the tapered toe of the splitlocking ring between the rim and theside ring (Fig. 3).

3. Using a soft hammer, drive the lock-ing ring into place (Fig. 4). Start atone end of the split ring and progres-sively drive the ring into the gutteruntil the entire ring is seated (Fig. 4).

11-04-2 Wheels and Tires—Three Piece Rims 11-04-2

The ring must be entirely seatedaround the entire circumference ofthe rim. The split ends must be en-gaged in the gutter, or the ring will beforced off violently during inflationor when the truck is driven. Wheninflating the tire do not stand in frontof the ring.

F1463-A

FIG. 4 Starting Locking Ring andLocking RingInstalled—Three-Piece Rim

TIRE REMOVAL ANDMOUNTING—CAST SPOKEWHEELSRemoval1. To remove the rim and tire from a

cast wheel, apply the parking brake,and block at least one wheel. Raisethe vehicle and rim clamps.

2. With dual rear wheels, lift off theouter rim and tire, remove the spacerrim, and the inside rim and tire as-sembly.

Installation

1. To install the tire and rim on a dualwheel, place the inner tire and rim onthe wheel hub. The rim must ride highenough up on the tapered retainerflange of the inner section of thewheel to prevent the assembly fromsliding down on the tapered surface.

2. Position the spacer between the innerand outer rim.

3. Place the outer rim and tire assemblyon the wheel, and install the 6 clamps(Fig. 5). First, draw up the top clamptightly so that the spacer will push theinner rim up on the tapered surfaceof the inner section of the wheel, andthen tighten the bottom clamp. This

procedure tends to center the rim onthe wheel.

4. Tighten the remaining clamps alter-nately and evenly, and torque allwheel nuts to specification. Lateral orside run-out should not exceed 1/8inch for front rims and 1/4-inch fordual rear rims, checked at the outerbead surface of the wheel.

HUB ASSEMBLY

OUTERWHEEL RIM

CLAMPF1456-A

FIG. 5 Three-Piece Rim Installed onCast Wheel

11-10-1 Wheel Hubs and Bearings—Front 11-10-1

PART 11-10 Wheels, Hubs and BearingsFront (Except Front Drive)

Applies To All Vehicles

COMPONENT INDEX

FRONTWHEELASSEMBLYDescription

FRONT WHEELBEARINGAdjustment

Page

10-1

10-1

COMPONENT INDEX

FRONT WHEEL GREASESEAL AND BEARINGRemoval and InstallationRepacking

Page

10-2

10-2

DESCRIPTION

FRONT WHEEL ASSEMBLYEach front wheel and tire assembly is

bolted to its respective front hub andbrake drum or rotor assembly. Two op-posed tapered roller bearings are installedin each hub (Fig. 1, Part 11-02 and Figs.3 and 4 of this Part). A grease retaineris installed at the inner end of the hub toprevent lubricant from leaking into thedrum. The entire assembly is retained toits spindle by the locknut and/or adjust-ing nut and cotter pin, or an adjustingnut, lock nut combination (Figs. 3 and 4).

ADJUSTMENTS

FRONT WHEEL BEARINGADJUSTMENT

To check the wheel bearing adjust-ment, raise the front of the vehicle, graspthe tire at the sides, and alternately pushinward and pull outward on the tire. Ifany looseness is felt, adjust the frontwheel bearings.

F-100, 250, 350, Econoline

1. Remove the hub cap and remove thegrease cap from the hub.

2. Wipe any excess grease from the endof the spindle and remove the cotterpin and nut lock.

3. While rotating the wheel, torque theadjusting nut (Fig. 1, Part 11-02) to17-25 ft-lb to seat the bearings.

4. Install the nut lock so that the cotterpin hole in the spindle is aligned with

a slot in the nut lock.5. Back off the adjusting nut and nut

lock two slots of the nut lock and in-stall the cotter pin.

6. Check the front wheel rotation. If thewheel rotates freely with no noticea-ble end play, install the grease cap. Ifthe wheel is still loose, or it rotatesroughly or noisily, the bearing conesand rollers and the cups are dirty orworn and should be cleaned or re-placed.

7. Install the hub cap.

P-350 thru 500

1. Remove the hub cap, if so equipped,and remove the grease cap from thehub.

2. Remove any excess grease from theend of the spindle and remove the ad-justing nut cotter pin.

While rotating the wheel, torq ae theadjusting nut (See Fig. 4, underDisassembly and Assembly) to 40-55ft-lbs to seat the bearings.Back off the adjusting nut to the nextcastellation if necessary to align thenut with the cotter pin hole. Then,back off the adjusting nut two castel-lations and install the cotter pin.Check the front wheel rotation. If thewheel rotates freely with no noticea-ble end play, install the grease cap. Ifthe wheel is still loose, or it rotatesroughly or noisily, the bearing conesand rollers and the cups are dirty orworn and should be cleaned or re-placed.Install the hub cap, if used.


All Medium, Heavy and ExtraHeavy TrucksSingle Nut with Cotter Pin (5000-7000Pound Front Axles)1. While rotating the wheel, torque the

adjusting nut to 70-100 ft-lb to seatthe bearings.

2. Back off the adjusting nut 180 degrees(one half turn).

3. Hand tighten the adjusting nut fingertight (13-17 in-lb) while moving thetop part of the tire in and out.

4. If the cotter pin hole lines up with acastellation in the nut, insert and se-cure a new cotter pin. If they do notline up, back off the adjusting nut toalign a castellation with the first avail-able cotter pin hole. Final bearing ad-justment must provide .001-.010 endplay.

5. Install the gasket and grease cap andadjust the brakes. The final adjust-ment must not result in a preloadedbearing.

Double Nut with Lock Ring (15000Pound Front Axle)

1. While rotating the wheel in both di-rections, torque the adjusting nut to100-125 ft-lbs to seat the bearings.

2. Back off the adjusting nut one com-plete turn (See Fig. 4, under Removaland Installation).

3. Again while rotating the wheel inboth directions, retorque the adjust-ing nut to 40-55 ft-lb.

4. Back off the adjusting nut to obtainan initial .004 and .010 inch end playbetween the wheel hub and spindle.

5. Install the lock ring.6. Install the washer with the dimple in-

dexed in one of the holes in the lock-ing ring.

7. Install the lock nut and torque to 100-125 ft-lb.

8. Recheck the end play (Final limit .001to .010 inch). Re-adjust if necessary.

9. Bend the washer outward to lock thenut in position.

10. Install the gasket and grease cap andadjust the brakes. The final adjust-ment must not result in a preloadedbearing.

Double Nut with Double Washer(12000 Pound Center Point Axle)

1. While rotating the wheel in both di-rections, torque the adjusting nut to100-125 ft-lb to seat the bearings.

2. Back off the adjusting nut one com-plete turn (See Fig. 4, under Disas-sembly and Assembly).


4. Back off the adjusting nut to obtainan initial .004 to .010 inch end playbetween the hub and spindle.

5. Install the outer washer and lock nutand torque to 100-125 ft-lb.

6. Recheck the end play (final limit .001to .010 inch). Re-adjust if necessary.

7. Install the gasket and grease cap andadjust the brakes. The final adjust-ment must not result in a pre-loadedbearing.

Single Nut with Cotter Pin (16000,18000 and 20000 Pound FrontAxle)1. While rotating the wheel in both di-

rections, torque the adjusting nut to100-125 ft-lb to seat the bearings.

2. Back off the adjusting nut one com-plete turn (See Fig. 4, under Disas-sembly and Assembly).

3. Again while rotating the wheel in

both directions, retorque the adjust-ing nut to 40-55 ft-lb.

4. Back off the adjusting nut if necessaryto align the nut castellations with thefirst available cotter pin hole.

5. Using the same cotter pin hole as areference point, back off the adjustingnut one additional castellation to al-low the wheel to rotate freely withinthe limits of .001 to .010 inch endplay.

6. Insert and secure the cotter pin.7. Install the gasket and grease cap and

adjust the brakes. The final adjust-ment must not result in a pre-loadedbearing.

Double Nut with Lock Ring (9000and 12000 Pound Front Axle)1. While rotating the wheel in both di-

rections, torque the adjusting nut to100-125 ft-lb to seat the bearing.

2. Back off the adjusting nut one com-plete turn.


4. Back off the adjusting nut to obtainan initial .004 to .010 inch end playbetween the wheel hub and spindle.

5. Install the lock ring making sure theadjusting nut dowel is inserted intothe lock ring.

6. Install the outer washer and lock nut.Torque to 100-150 ft-lb.

7. Recheck the end play (final limit .001to .010 inch). Re-adjust if necessary.

8. Bend the washer outward to lock theouter nut in position.

9. Install the gasket and grease cap andadjust the brakes. The final adjust-ment must not result in a pre-loadedbearing.

DISASSEMBLY AND ASSEMBLY

FRONT WHEEL GREASE SEALAND BEARING REMOVAL ANDINSTALLATION AND/ORREPACKING

Wheel bearing lubricant has beenchanged from sodium base grease to lith-ium base grease.

Sodium base grease is not compatiblewith lithium base grease and should notbe intermixed. Therefore, do not lubri-cate front and/or rear wheel bearingswithout first ascertaining the type oforiginal wheel bearing lubricant. Usageof incompatible bearing lubricants couldresult in premature lubricant breakdown.

If bearing adjustment will not elimi-nate looseness or rough and noisy opera-tion, the hub and bearings should be

cleaned, inspected, and repacked withspecified wheel grease. If the bearing cupsor the cone and roller assemblies areworn or damaged, they should be re-placed.

Light Vehicle

1. Raise the vehicle until the wheel andtire clear the floor and remove thewheel and tire from the hub. If thedrums will not remove easily, back offthe brake shoe adjusting screw so thatthe shoes do not contact the brakedrum. Remove the grease cap fromthe hub.

2. Remove the cotter pin, nut lock, ad-justing nut and washer from the spin-dle (Fig. 1, Part 11-02).

3. Remove the outer bearing cone and

roller. Pull the hub and drum assem-bly off the wheel spindle. Then,remove the discard, the grease re-tainer and the inner bearing cone androller from the hub. Remove all tracesof old lubricant from bearings, hubs,and axle spindle.

4. Inspect the cups for scratches, pits orcracks. If the cups are worn or da-maged, remove them with a drift.Clean the inner and outer bearingcones and rollers with solvent and drythem thoroughly. Do not spin thebearings dry with compressed air.

5. Inspect the cones and rollers forcracks, nicks, brinelling, or seizedrollers. Inspect the grease retainerand replace it if it is cracked, nicked,or dented. If the new grease retainer


is leather, soak it in light engine oil forabout 30 minutes before installation.

6. Cover the spindle with a clean clothand brush all loose dust and dirt fromthe brake assembly. Remove the clothfrom the spindle carefully to preventdirt from falling on the spindle.

7. Install the inner and outer bearingcups in the hub with the appropriateinstalling Tool (Fig. 1). Be sure to seatthe cups properly in the hub. Thecups will be properly seated whenthey are fully bottomed. Pack the in-side of the hub with C1AZ-19590-Bwheel bearing grease. Fill the hub un-til the grease is flush with the insidediameters of both bearing cups. Packthe bearing cones and rollers withwheel bearing grease. Use a bearingpacker for this operation. If a packeris not available, work as much lubri-cant as possible between the rollersand cages. Lubricate the cone surfaceswith grease.

8. Place the inner bearing cone androller in the inner cup and install thegrease retainer (Fig. 2) with the ap-propriate driving tool. Be sure thatthe retainer is fully bottomed. Installthe hub and drum on the wheel spin-dle. Keep the hub centered on thespindle to prevent damage to thegrease retainer or the spindle threads.

9. Install the outer bearing cone androller and the flat washer on the spin-dle, then install the adjusting nut.

10. Adjust the wheel bearing as outlinedunder Adjustments.

Medium, Heavy and Extra HeavyVehicles

There are two basic types of hub, discand cast, shown in Fig. 3. The basic de-sign of the hub bearings is the same in allhubs, but minor differences in size existbetween the various models. The outerbearing attaching parts differ accordingto front axle weight capacity as indicatedin Fig. 3. For further detailed views ofhubs, bearings and grease retainers SeeFig. 4.1. Raise the vehicle until the tires clear

the floor and install safety stands to

Toot-T56P-1217-A

support the front axle. Remove thegrease cap and gasket from the hub.To check the wheel bearing adjust-ment, alternately push inward andoutward on the tire. If any excessivelooseness is felt or there is no endplay, adjustment of the front wheelbearings is necessary.With 5000, 5500, 6000, 7000, 16000,18000 or 20000 pound capacity frontaxles, remove the cotter pin, adjustingnut and flat washer from the spindle.With 9000, 12000 or 15000 poundcapacity front axles, remove the locknut, washer, locking ring and the ad-justing nut and pin. With a 12000pound capacity center point frontaxle, remove the lock nut, innerwasher, adjusting nut and outerwasher.Inspect the condition of the spindleand nut threads to insure a free run-ning nut when reassembling.

F1465-*

FIG. 2 Installing Grease Retainer

5. Remove the outer bearing cone androller. Pull the hub and drum assem-bly off the spindle. Remove the innerbearing and seal using a brass drift.Be careful not to damage the bearingcage.

6. Remove all traces of old lubricant

HUB BOLT

INNER CUPINSTALLATION

OUTER CUPINSTALLATION

GREASE RETAINER SPACER*

INNER BEARING

INNER BEARING SPACER*

GREASE RETAINER

WHEEL BEARING CUP - © - # — ''

'USED WITH 15000 LB. CAPACITY FRONT AXLE ONLY

F1464-A F1466-B

FIG. 1 Installing Bearing Cups FIG. 3 Typical Front Hubs and Bearings


INNER BEARING1201

ADJUSTING NUT374504-S

INNER BEARING1201

ADJUSTING NUT351163-S

P - SERIES 5000 - 5500 - 6000 - 7000 LB. AXLES

BEARINGPA PF1201 BEARING

1 RACE1216

GREASERETAINER

1190

n, l V r n BEARINGOUTER RACF

BEARING L E

12161216

9000- 12000 LB. AXLES

WASHER1A043

12000 LB. AXLE(CENTER POINT)

INNER BEARING1201 ADJUSTING NUT

3294

LOCK RING3293

WASHER1195

INNERBEARING

1

COTTER PIN

15000 LB. AXLE 16000, 18000, 20000 LB. AXLES

F1474-C

FIG. 4 Front Hubs, Bearings and Grease Retainers


from the bearings, hubs and axle spin-dle. Inspect the cups for pitting, gall-ing or unusual wear. If either cup isworn or damaged, remove it with abrass drift. Clean the inner and outerbearing cones and rollers with solventand dry them throughly. Do not spinthe bearings dry with compressed air.

7. Inspect the cones and rollers for pit-ting, galling or unusual wear. Particu-larly inspect the rollers for end wearand flat or rough spots. Replace allworn or damaged assemblies. It isrecommended that the cone and rollerassemblies and cups be replaced insets.

8. Replace the grease retainer.9. Cover the spindle with a clean cloth

and brush all loose dust and dirt fromthe brake assembly. Remove the clothfrom the spindle carefully to preventdirt falling on the spindle.

10. Install the inner and outer bearing

cups in the hub with the appropriatetool (Fig. 1). Check for proper seatingof the new bearing cups by trying toinsert a 0.0015 inch feeler gauge be-tween the cup and wheel hub. Thefeeler gauge should not enter.

11. Pack the inside of the hub with Lith-ium base wheel bearing grease(C1AZ-19590-B). Fill the hub untilthe grease is flush with the inside dia-meters of both bearing cups. Pack thebearing cones and rollers with wheelbearing grease. Use a bearing packerfor this operation. If a packer is notavailable, work as much lubricant aspossible between the rollers andcages. Lubricate the cone surfaceswith grease.

12. Place the inner bearing cone androller in the inner cup and install thegrease retainer with the appropriatetool. Be sure the retainer is fully bot-tomed. On all synthetic type seals,

SEAL LIP

VENT

VIEW FOR 15000 LB.FRONT AXLE ONLY

E 2124-A

FIG. 5 Front Seal Installation (Stemco)

coat the seal lips with wheel bearinggrease (C1AZ-19590-B) before in-stalling the hub and drum. On sealswhich are not coated on the OD withsealer by the supplier, coat the greaseseal bore in the hub with a thin coatof non-hardening sealer prior to in-stalling the grease seal.

13. Install the hub and drum on the wheelspindle. Keep the hub centered on thespindle to prevent damage to thegrease retainer or the spindle threads.

14. With 5000, 5500, 6000, 7000, 16000,18000 or 20000 pound capacity frontaxles, install the outer bearing coneand roller and the flat washer on thespindle. Then, install the adjustingnut. With 9000, 12000 and 15000pound capacity front axles, instal' theouter bearing cone and roller and thebearing adjusting nut. With a 12000pound capacity center point frontaxle, install the washer and adjustingnut. Make the final bearing adjust-ment, under Adjustments.

Medium, Heavy and Extra HeavyVehicles (Oil Lubrication)

Stemco Seals and National Sealsavailable as regular production otpions,provide sealing where oil is used for bear-ing lubrication. The tools required forStemco Seal Installation are only availa-ble from the Stemco warehouse. Refer toSpecifications for the tooling required.Fig. 5 illustrates a front wheel StomcoSeal Installation. —

Front Hub Seal Installation

Clean all parts before starting the in-stallation of Stemco Seals.1. Oil the spindle and push the axle ring

flush against the axle face where ap-plicable.

2. Remove all burrs from the wheel hubbore seal area and clean thoroughly.

3. Position the seal in the hub bore (PartNumber Up).Drive the seal into position using the

correct tool. It must be perfectly squarewith the bore, and bottom evenly. Installthe wheel and adjust the bearings. 1 nstallthe Stemco hub cap. Remove the fillerplug and add oil (ESW-M2C105-E SAE90). Double check the oil level beforereleasing the vehicle for service. Oil levelmust be between the oil level line on thehub cap and 1/4-inch above the line.

National Seals (Fig. 6) are installed asfollows:1. Clean all parts, remove rough spots

and install axle ring flush against facewhere applicable.

2. Position the seal into the hub (noticeoil side marking) with drive tool andhammer in to a press fit.

3. Install the wheel and adjust the bear-ings the same as for any seal ir.stalla-tion. Install the see through hubcap


and the retaining screws.4. Remove the filler plug and add oil to

level on see through hubcap.

WEAR SLEEVE

SEAL

SEE-THROUGH OIL CHECK

FIG. 6 National Seal Installation

F1831-A

SPECIFICATIONS

WHEEL TORQUE LIMITS-F-100 THRU F-350, ECONOLINE,BRONCO, P-SERIES

ModelE-100, E-200

F-100 (4 x 4), U-100 {Std. Wheel)F-250-250(4x4)P-350-3500 (W-5200 Ib. Axle)

E-300 (Std. Wheel)F-350, P-350F-350, P-350, P-450

P-3500, P-4000 (W/Dual Wheels

and 74001b. Axle)P-350, P-400, P-3500,P-4000 (W/17" Wheels)

Nut Size

1/2-20

9/16-18

9/16-18

5/8-18

Ft-Lbs90

90

135

210

210

WHEEL TORQUE LIMITS-500 THRU 9000 SERIES

SPECIAL SERVICE TOOLS

Tool No.T-59T-1197-B

Tool 1175-ABT50T-100-AT56P-1217-A

DescriptionFront Wheel BearingAdjustment Spanner Wrench

Grease Seal Remover HeadImpact Slide HammerFront Hub Bearing Cup Replacer

SPECIAL SERVICE TOOLS-STEMCO

DescriptionFront Wheel Nut

Cast Wheel Rim Nut

Nut SizeAll

5/8-11

3/4-10

Ft-Lbs

450170-200

170-220

Ford Seal Kit Part No.DOHZ-1190-A

DOHZ-1190-B

DOHZ-1190-C

DOHC-1190-D

DOHZ-1190-E

Stemco Tool No.5064-53515061-50625066-53535067-5398None-53865007-5358

Ford Seal Kit Part Name

Kit - Front Hub

Grease Retainer

and Wiper

Kits on this page consist of one axle ring and one seal for just one wheel

CF 1810-B

11-11-1 Wheel Hubs and Bearings—Rear 11-11-1

PART 11-11 Wheel Hubs and Bearings-RearApplies To Bronco, Econoline

COMPONENT INDEX

AXLE SHAFTRemoval and Installation

DESCRIPTION

Page

11-1

11-1

E100, E200 and F-100 Only

COMPONENT INDEX

REAR WHEEL BEARINGAND SEAL

Removal and Installation

Page

11-1

DESCRIPTION

REAR WHEEL ASSEMBLY

The rear wheel hub and brake drumassembly is attached to studs on the rearaxle shaft flange by three speed nuts. The

wheel and tire mounts on the same rearaxle shaft flange studs and is held againstthe hub and drum by the wheel nuts. Therear wheel bearing is pressed onto the

axle shaft just inside the shaft flange, andthe entire assembly is retained to the rearaxle housing by the bearing retainer p .atewhich is bolted to the housing flange.


REMOVAL OF AXLE SHAFT

The rear axle shafts, wheel bearings,and oil seal can be replaced withoutremoving the differential assembly fromthe axle housing.

Synthetic wheel bearing seals areused. Removal and insertion of rear axleshafts must be performed with caution.The entire length of the shaft (includingspline) up the seal journal must passthrough the seal without cutting of theseal element during axle removal or in-stallation will result in early seal failure.1. Remove the wheel cover, wheel and

tire from the brake drum.2. Remove the nuts that secure the brake

drum to the axle shaft flange, thenremove the drum from flange.

3. Working through the hole provided ineach axle shaft flange, remove thenuts that secure the wheel bearing re-tainer plate. Then pull the axle shaftassembly out of the axle housing (Fig.1). The brake backing plate must notbe dislodged. Install one nut to holdthe plate in place after the axle shaftis removed.

1662-A

FIG. 1 Removing Axle Shaft

REMOVAL OF REAR WHEELBEARING AND SEAL

Synthetic seals must not be cleaned,soaked or washed in cleaning solvents.

Removal of the wheel bearings fromthe axle shaft makes them unfit for fur-ther use.1. Loosen the inner retainer ring by

nicking it deeply with a cold chisel inseveral places (Fig. 2). It will thenslide off easily.

2. Remove the bearing from the axleshaft with Tool T6OK-1225-A.

3. Whenever a rear axle shaft is re-placed, the oil seal must be replaced.Remove the seal with Tool 1175-ABand a slide hammer.

INSTALLATION OF REAR WHEELBEARING AND SEAL

1. Inspect the machined surface of theaxle shaft and the axle housing forrough or other irregularities whichwould affect the sealing action of theoil seal. Check the axle shaft splinesfor burrs, wear or twist. Carefullyremove any burrs or rough spots. Re-place worn or damaged parts.

2. Lightly coat wheel bearing bores withaxle lubricant.

3. Place the bearing retainer plate on theaxle shaft, and press the new wheelbearing on the shaft with the tool

FIG. 2 Removing Rear WheelBearing Retainer Ring

shown in Fig. 3. Do not attempt topress on both the bearing and the in-ner retainer ring at the same time.

4. Using the bearing installation tool(Tool 4621-A), press the bearing in-ner retainer ring on the shaft until theretainer seats firmly against the bear-ing.

5. Install the new oil seal with the toolsshown in Fig. 4. Wipe a small amountof oil resistant sealer on the oute:~ edgeof the seal before it is installed. Do notput sealer on the sealing lip.

INSTALLATION OF AXLE SHAFT

1. Carefully slide the axle shaft into thehousing so that the rough forging ofthe shaft will not damage the oil seal.Start the axle splines into the side

11-11-2 Wheel Hubs and Bearings—Rear 11-11-2

gear, and push the shaft in until thebearing bottoms in he housing.

2. Install the bearing retainer plate andthe nuts that secure it. Torque thenuts to specification.

3. Install the brake drum and the drumattaching (Tinnerman) nuts.

4. Install the wheel and tire on thedrum. Install the wheel cover.

AXLE SHAFT FLANGEARBOR PRESS RAM

Tool-4621-A/

F1668-A

FIG. 3 Installing Rear Wheel Bearing

Tool-1177T66N-1177-A

ORT60K-1177-B

F1669-A

FIG. 4 Installing Rear Wheel BearingOil Seal

11-12-1 Wheels, Hubs and Bearings Front Wheel Drive 11-12-1

PART 11-12 Wheel Hubs and Bearings-Front Wheel Drive

COMPONENT

ADJUSTMENTS

DESCRIPTION

Applies To

INDEX

Bronco, F-100,

Page

12-1

12-1

F-250 and F-600 Only

COMPONENT INDEX

DISASSEMBLY ANDASSEMBLY

REMOVAL AND INSTALLATION .

Page

12-6

12-2

DESCRIPTION

Front drive assemblies are availablefor Bronco, F-100, F-250 and F-600 vehi-cles.

ADJUSTMENTS

FRONT WHEEL BEARINGADJUSTMENT

Bronco and F-100

1. Raise the vehicle and install safetystands.

2. Back off the brake adjusting screw ifnecessary.

3. Remove the front hub grease cap andthe driving hub snap ring (Fig. 1).

4. Remove the splined driving hub andthe pressure spring. This may requirea slight prying assist (Fig. 2).

5. Remove the wheel bearing lock nutand lock ring.

6. Using Tool T59T-1197-B and atorque wrench, tighten the bearingadjusting nut to 50 ft-lbs while rotat-

F 1812-A

FIG. 1 Removing Snap Ring

ing the wheel back and forth to seatthe bearing.

7. Continue rotating the wheel, loosenthe adjusting nut and then retorqueit to 30-40 ft-lbs.

8. Back off the adjusting nut approxi-mately 1/4 turn (90 degrees).

9. Assemble the lock ring by turning thenut to the nearest notch where thedowel pin will enter.

10. Install the outer lock nut and torqueto 50 ft-lbs. Final end play of thewheel on the spindle should be 0.001to 0.010 inches.

11. Install the pressure spring and drivinghub, the driving hub snap ring andafter applying non-hardening sealerto the seating edge of the grease cap,install the grease cap. If equippedwith free-running lock-out hubs, referto Front Wheel Drive Lock-Out HubInstallation in Group 15.

12. Adjust the brake if it was backed off.13. Remove the safety stands and lower

the vehicle.

F-250


2. Back off the brake adjusting screw, ifnecessary. Remove the wheel cover,if installed.

3. Remove the front hub grease cap.Remove the driving hub retainingsnap ring and slide the splined drivinghub from between the axle shaft andthe wheel hub (Fig. 2, Part 11-02).Remove the driving hub spacer. (Ifequipped with free running lock-out

F 1813-A

FIG. 2 Removing Splined DrivingHub

hubs, refer to Front Wheel DriveLock-Out Hub Removal in Group15).

4. With Tool T59T-1197-B, remove thelock nut and lock ring from th;: spin-dle.

5. Using Tool T59T-1197-B and atorque wrench, tighten the bearingadjusting nut (Fig. 2, Part 11-02) to50 ft-lb, while rotating the wheel backand forth to seat the bearings.

6. Continue rotating the wheel and then,loosen and re-torque the adjustingnut to 30-40 ft-lb.

7. Back the adjusting nut off approxi-mately 1/4 turn (90 degrees). Assem-ble the lock ring by turning the nut


to the nearest notch where the dowelpin will enter.

8. Install the outer lock nut and torqueto 50 ft-lb. Final end play of the wheelon the spindle should be 0.001 to 0.-010 inch.

9. Install the driving hub, spacer, snapring and hub grease cap. Apply a thincoat of non-hardening sealer to thesetting edge of the grease cap, beforeinstallation. (If equipped with free-running lock-out hubs, refer to FrontWheel Drive Lock-Out Hub Installa-tion in Group 15).

10. Adjust the brake, if backed off to per-mit drum removal.

11. Remove the safety stands and lowerthe vehicle.

F-600

1. Remove the outer hub cap retainingscrews, and remove the cap.

2. Remove the retaining lock ring (Fig.3).

3. Remove the retaining screws andremove the splined drive plate.

4. Bend the tab of the lock washer awayfrom the lock nut and remove the locknut (Fig. 4).

5. Remove the lock washer and discardit.

6. While rotating the wheel back andforth to correctly seat the bearings,torque the adjusting nut to 50 ft-lbs.

7. Back off the adjusting nut from 1/4to 1/3 turn.

8. Position a new lock washer againstthe adjusting nut and apply a film ofoil to the outer face of the lockwasher.

9. Run the lock nut up against the lockwasher and torque it to 100-150 ft-lbs.

10. Bend one tab of the lock washer overthe adjusting nut.

11. Bend one tab of the lock washer (inthe opposite direction) over the locknut. Use a blunt tool when bendingthe tabs to avoid making any chips

LOCK RING

which could cause serious bearingdamage.

12. Apply Silastic Sealer to the front andrear mounting faces of the splineddrive plate.

13. Position the drive plate, install the re-taining screws and torque them tospecifications.

14. Install the retaining lock ring.15. Position the outer hub cap and install

the retaining screws and torque themto specifications.

LOCKWASHEF

E2131-A

FIG. 3 Access To Lock RingFIG. 4 Lock Nut and Washer

Assembled


LOCK-OUT HUB (INTERNAL TYPE)

Bronco, F-100, F-250 (3300 LbAxle)

Removal

1. Remove the lock-out hub screws andwashers (refer to Fig. 5).

2. Remove the hub ring and the knob,wipe the parts clean.

3. Remove the internal snap ring fromthe groove in the hub.

4. Remove the cam body ring and clutchretainer (as an assembly) from thehub. Disassemble the parts.

5. Remove the axle shaft snap ring. Itmay be necessary to push inward onthe gear and pull out on the axle witha bolt to make the snap ring removaleasier.

6. Remove the drive gear and clutchgear. A slight rocking of the hub maymake them slide out easier.

7. Remove the coil spring.8. Remove the spring retainer ring.

Installation

1. Grease the inner hub with high speedgrease (Fig. 6).

2. Install the spring retainer ring, posi-tioned as shown with recessed under-cut area going in first. Be sure it seatsagainst the bearing (Fig. 7).

3. Install the coil spring with large endentering first (Fig. 8).

4. Install the axle shaft sleeve and ringand the inner clutch ring. Notice thatthe teeth are meshed together in alocked position for easy assembly. Itmay be necessary to rock the hubback and forth for spline alignment.Keep the two gears in locked position(Fig. 9).

5. Install the axle shaft snap ring. Pushinward on gear, and if necessary, pullout axle shaft with bolt to allow clear-ance in groove for snap ring on theaxle shaft. Be sure snap ring is fullyseated in the snap ring groove of theshaft (Fig. 10).

6. Install the actuating cam body ringinto the outer clutch retaining ring.Assemble into hub (Fig. 11).

7. Install the internal snap ring. Be suresnap ring is fully seated in the snap

ring groove of the hub (Fig. 12).8. Apply a small amount of Lubriplate

Grease on the ears of the cam (Fig.13).

9. Apply a small amount of Parker O-ring lube in groove of actuating knobbefore assembling outer O-ring (Fig.13).

10. Assemble knob in hub ring and as-semble to axle with knob in lockedposition. Assemble screws and wash-ers alternately and evenly, makingsure the retainer ring is not cocked inthe hub.

11. Torque the six lock-out hub screws to35 to 40 inch pounds. Be sure thewashers are under each retainingscrew. At first the lock-out hubs willprobably seem hard to engage anddisengage, but after mileage theyshould loosen up for easier operation.Either lock-out hub will fit eitherwheel.

Do not drive vehicle until you are surethat both lock-out hubs are engaged ordisengaged. When vehicle is driven in wa-ter deep enough to cover the hubs, it is


recommended that the internal parts bedisassembled and inspected for possiblewater or dirt. After inspection, relubri-cate all parts before assembly to preventrusting or corrosion.

LOCK-OUT HUB (EXTERNALTYPE)

F-250 (3500 Lb Axle)

Removal

1. Remove the lock-out hub screws andwashers (refer to Fig. 14), and discardthem.

2. Loosen the gear hub housing and slideaway from the hub and drum assem-bly.

3. Remove the inner metal gasket (anddiscard it), the gear hub housing, andremove and discard the outer gasket.Wipe clean the exposed parts.

4. Remove the snap ring while holdingpressure on the clutch gear.

5. Ease the clutch gear and pressurespring out of the assembly. The actua-tor knob should be in the lock posi-tion for this step.

6. Turn the actuator knob to the freeposition. With a drift, drive the lockpin out of the assembly.

7. Remove the actuating cam from theknob.

8. Remove the knob retainer snap ringand remove the knob from the knobretainer.

9. Using a capscrew pull out slightly onthe axle shaft and remove the snap

ring which retains the bushing andinner clutch gear assembly.

10. Remove these parts and disassemble.If wear or damage are evident on ei-ther the inner or outer clutch gearthey should both be replaced as a set.

Installation

Before assembling lock-out hubs in-spect the splines of the axle shaft makingsure they are free of any possible nicksor burrs.

Threaded screw holes in the wheelhub should be cleaned before assemblingnew retainer screws. These holes can becleaned by directing compressed air intothe threaded holes.1. Apply a small amount of MOLY XL

hi-speed grease to the back face andthe thrust face of the bushing, also tothe splines of the inner clutch gear.Assemble inner clutch gear into bush-ing. Install the bushing and innerclutch gear onto axle shaft, makingsure the splines of the inner clutchgear are aligned with the splines of theaxle shaft, as shown (Fig. 15).

2. Install a new snap ring. If necessary,pull out axle shaft with capscrew toallow clearance in groove for snapring on axle shaft. Be sure snap ringis fully seated (Fig. 16).

3. Apply a small amount of Parker CD-ring lubricant on the actuator knob,making sure knob is completely lu-bricated in the area shown. AssembleO-ring onto actuating knob.

4. Install the actuating knob into theknob retainer with arrow pointing to

2299-A

FIG. 6 Grease Application

free position. Install the knob retainersnap ring. Spread snap ring with snapring pliers. Use a small screwdriver toposition the snap ring in the grooveof the knob (Fig. 17).

5. Install the actuating cam onto theknob, aligning ears of the cam withthe slots of the retainer. Position partson a small piece of wood as shown.Assemble the lock pin through thegroove of the cam and holes in theactuating knob. Be sure ends of thepin are flush with the outside dia-meter of the cam (Fig. 18).

6. Turn actuator knob to lock position.Apply a small amount of MOLY XLhi-speed grease to both grooves of thecam as shown (Fig. 19).

ACTUATING CAM BODY

INTERNAL SNAP RING

PRESSURE SPRING

RETAININGPLATE BOLTS AXLE SHAFT SLEEVE AND RING

AXLE SHAFT SNAP RING

OUTER CLUTCH RETAINING RING

RETAINER KNOB-HUB RING " O " RING

ACTUATOR KNOB "O" RING

RETAINER KNOB-HUB RINGE2298-A

FIG. 5 Lock-Out Hub Internal Type


E2304-A

FIG. 7 Spring Retainer RingInstallation

FIG. 8 Coil Spring Installation FIG. 11 Installing Cam Body Ringinto the Clutch RetainingRing

7. Install the pressure spring and outerclutch gear, compress the pressurespring by forcing down on clutch gearand assemble snap ring. Make suresnap ring is secure in the groove of thecam. Turn actuator knob to free posi-tion. Assemble six dished washers tothe six retainer screws exactly asshown (Figs. 20 and 21).

8. Install 2 screws with correctly posi-tioned washers into the knob retainer.This will properly line up the parts insteps 9 and 10. Apply a small amountof hi-speed grease to the outer splineand teeth of the outer clutch gear.Remove any excess lubricant from thegasket surface of the retainer.

9. Install a new outer retainer gasket.Assemble gear hub housing by align-ing the splines of the housing withthose of the outer clutch gear asshown. Assemble a new inner (metal)gasket on hub housing (Fig. 22).

10. Position the lock-out hub subassem-bly to axle assembly using the twonew retainer screws as pilots to assurethat the holes of the gasket are inalignment with the holes of the wheelhub. Tighten retainer screws to se-cure the lock-out hub. Turn actuatorknob to lock position.

11. Install the remaining four new re-tainer screws with washers. Tightenscrews evenly. Torque to 30-35 ft-lbs.The lock-out may be hard to engageand disengage, however after use,they should loosen up for easier oper-ation. Either lock-out will fit eitherwheel.

12. Do not drive vehicle until both lock-out hubs are either engaged or disen-gaged.

FIG. 9 Axle Shaft Sleeve and ring,and Inner Clutch RingInstallation

FIG. 12 Installing Internal Snap Ring

E2303-A

E2307-A

FIG. 10 Installing Axle Shaft SnapRing FIG. 13 Lubrication Areas


AXLE SHAFT SNAP RING

GEAR HUB HOUSING

ACTUATING KNOB

RETAINER SNAP RING

DISHED WASHER INNER CLUTCH GEAR

INNER (METAL) GASKET

LOCK-OUT HUB

RETAINER SCREWS OUTER RETAINER GASKET

OUTER CLUTCH GEAR

PRESSURE SPRING

ACTUATING CAM

ACTUATING KNOB RETAINER

ACTUATING KNOB "O" RING

ACTUATING KNOB E2I5O6-A

FIG. 14 Lock-Out Hub—External Type

E2308-A

FIG. 15 Bushing and Inner ClutchGear Installation

E2309-A E2310-A

FIG. 16 Snap Ring Installation FIG. 17 Knob Retainer Snap RingInstallation


E2311-A

f i t

E2313-A E2315-A

FIG. 18 Lock Pin Installation FIG. 20 Pressure Spring and OuterClutch Gear Installation

FIG. 22 Assembly Positions of GearHub Housing and Gaskets

2312-A E2314-A

FIG. 19 Grease Application FIG. 21 Dished Washer AssemblyDetail

DISASSEMBLY AND ASSEMBLYFRONT WHEEL GREASE SEALAND BEARING REMOVAL ANDINSTALLATION AND/ORREPACKING

Wheel bearing lubricant has beenchanged from sodium base grease to lith-ium base grease.

Sodium base grease is not compatiblewith lithium base grease and should notbe intermixed. Therefore, do not lubri-cate front and/or rear wheel bearingwithout first ascertaining the type oforiginal wheel bearing lubricant. Usageof incompatible bearing lubricants couldresult in premature lubricant breakdown.

If bearing adjustment will not elimi-nate looseness or rough and noisy opera-tion, the hub and bearings should becleaned, inspected, and repacked withspecified wheel grease. If the bearing cups

or the cone and roller assemblies areworn or damaged, they should be re-placed.

Bronco and F-100

1. safetyRaise the vehicle and installstands.

2. Back off the brake adjusting screw ifnecessary.

3. Remove the front hub grease cap anddriving hub snap ring (Fig. 1).

4. Remove the splined driving hub andthe pressure spring. This may requirea slight prying assist (Fig. 2).

5. Remove the wheel bearing lock nut,lock ring, and adjusting nut (Fig. 23),using tool T59T-1197-B.

6. Remove the hub and drum assembly.The outer wheel bearing and springretainer will slide out as the hub isremoved (Fig. 24).

7. Carefully drive the inner bearing coneand grease seal out of the hub (Fig.25) usingT69L-1102-A.

8. Inspect the bearing cups for pits orcracks. If necessary, remove themwith a drift (Fig. 26). If new cups areinstalled, install new bearings. Thebearings should be lubricated withC1AZ-19590-B wheel bearing grease.Clean all old grease from the hub.Pack the cones and rollers. If a bear-ing packer is not available, work asmuch lubricant as possible betweenthe rollers and the cages.

9. Position the inner bearing cone androller in the inner cup and install thegrease retainer.

10. Carefully position the hub and drumassembly on the spindle.

11. Install the outer bearing cone androller and the adjusting nut.


F 1814-A

FIG. 23 Lock nut, Lock Ring andAdjusting Nut Removal

12. Using Tool T59T-1197-B and atorque wrench, tighten the bearingadjusting nut to 50 ft-lbs while rotat-ing the wheel back and forth to seatthe bearings.

13. Continue rotating the wheel, loosenthe adjusting nut and then retorqueit to 30-40 ft-lbs.

14. Back off the adjusting nut approxi-mately 1/4 turn (90 degrees).

15. Assemble the lock ring by turning thenut to the nearest notch where thedowel pin will enter.

16. Install the outer lock nut and torqueto 50 ft-lbs. Final end play of thewheel on the spindle should be 0.001to 0.010 inches.

17. Install the pressure spring and drivinghub snap ring and after applying non-hardening sealer to the seating edgeof the grease cap, and install thegrease cap. If equipped with free-run-ning lock-out hubs, refer to Removaland Installation for the type of hubinvolved.

18. Adjust the brake if it was backed off.19. Remove the safety stands and lower

the vehicle.

F-250


2. Back off the brake adjusting screw, ifnecessary. Remove the wheel cover,if installed.

3. Remove the front hub grease cap.Remove the driving hub retainingsnap ring (Fig. 2, Part 11-02) andslide the splined driving hub from be-tween the axle shaft and the wheelhub. Remove the driving hub spacer.If equipped with free-running lock-out hubs, refer to Removal and Instal-lation for the type of hub involved.

4. With Tool T59T-1197-B, remove thelock nut, washer, and wheel bearing

F 1815-A

FIG. 24 Hub, Drum and OuterBearing Removal

F 1816-A

FIG. 25 Inner Bearing Cone andGrease Seal Removal

adjusting nut (Fig. 2, Part 11-02)from he spindle. Remove the wheel,hub and drum as an assembly, thewheel outer bearing will be forced offthe spindle at the same time. Protectthe spindle and inner bearing conefrom dirt.

5. Remove the grease retainer and theinner bearing cone and roller assem-bly from the hub with Tool 1175AB,and T50T-100-A. Discard the greaseretainer.

6. Clean the lubricant off the inner andouter bearing cups with solvent andinspect the cups for scratches, pits,excessive wear, and other damage. Ifthe cups are worn or damaged,remove them with a drift.

7. Thoroughly clean the inner and outerbearing cones and rollers with sol-vent, and dry them thoroughly. Donot spin the bearings with compressedair.Inspect the cone and roller assemblies

for wear or damage, and replace them if

necessary. The cone and roller assem-blies and the bearing cups should be re-placed as a unit if damage to either isencountered.8. Thoroughly clean the spindle and the

inside of the hub with solvent toremove all old lubricant.Cover the spindle with a clean cloth,

and brush all loose dust and dirt from thebrake assembly. To prevent getting dirton the spindle, carefully remove the clothfrom the spindle.9. If the inner bearing cup was removed,

install the cup or a new cup in thehub. Be sure to seat the cup properlyin the hub.

10. Install the outer bearing cup h thehub with a suitable tool. Be sure thecup is properly seated in the hub.

i 1. Pack the inside of the hub with speci-fied wheel bearing grease. Add lubri-cant to the hub only until the greaseis flush with the inside diameter ofboth bearing cups.

12. All old grease should be completelycleaned from the bearings before re-packing them with new grease. Packthe bearing cone and roller assemblieswith wheel bearing grease. A bearingpacker is desirable for this operation.If a packer is not available, work asmuch lubricant as possible betweenthe rollers and cages. Lubricate thecone surfaces with grease.

13. Place the inner bearing cone androller assembly in the inner cup, andinstall the new grease retainer. Besure that the retainer is properlyseated. Coat the grease retainer seal-ing lip with a liberal amount ofgrease.

14. Install the wheel, hub, and drum as-sembly on the wheel spindle. Keepthe hub centered on the spindle toprevent damage to the grease retaineror the spindle threads.

F 1817-A

FIG. 26 Bearing Cup Removal


15. Install the wheel outer bearing coneand adjusting nut. Adjust the frontwheel bearings as detailed in Adjust-ments under Front Wheel BearingAdjustment.

F-600

1. Remove the wheel and tire from thehub and drum. Remove the outer hubcap retaining screws, and remove thecap.

2. Remove the retaining lock ring (Fig.3).

3. Remove the retaining screws andremove the splined drive plate.

4. Bend the tab of the lock washer awayfrom the lock nut and remove the locknut (Fig. 4).

5. Remove the lock washer and discardit.

6. Remove the adjusting nut.7. Remove the hub and drum carefully

from the spindle. Cover the spindle toprotect it from dirt and foreignmaterial. If the drum is difficult toremove, back off the brake adjust-ment to provide clearance.

8. Carefully remove the inner bearingand seal.

9. Clean the bearing recess and using asuitable solvent, clean the bearings.Do not spin dry with compressed air.Repack the bearings with grease afterdrying thoroughly. Inspect the bear-ing cups. If cracked, pitted, or other-wise damaged, they should bereplaced. If they are replaced, thebearings should also be replaced.

10. The cups can be removed using ahammer and a drift.

11. Install the new cups using Tool T68T-1174-AB for the inner bearing cupand Tool T68T-1173-AB for theouter bearing cup.

12. Install the inner bearing, lubricateand install the grease seal using toolT68T-1173-AC.

13. Position the hub and drum on thespindle.

14. Install the outer bearing and the ad-justing nut. Install the wheel and tireon the hub and drum.

15. While rotating the wheel back andforth to correctly seat the bearings,torque the adjusting nut to 50 ft-lbs.

16. Back off the adjusting nut from 1/4to 1/3 turn.

17. Position a new lock washer againstthe adjusting nut and apply a film ofoil to the outer face of the lockwasher.

18. Run the lock nut up against the lockwasher and torque it to 100-150 ft-lbs.

19. Bend one tab of the lock washer overthe adjusting nut.

20. Bend one tab of the lock washer (inthe opposite direction) over the locknut. Use a blunt tool when bendingthe tabs to avoid making any chipswhich could cause serious bearingdamage.

21. Apply Silastic Sealer to the front andrear mounting faces of the splineddrive plate.

22. Position the drive plate, install the re-taining screws and torque them tospecifications.

23. Install the retaining lock ring.24. Position the outer hub cap and install

the retaining screws.

11-14-1 Wheels, Hubs and Bearings—Rear (Full Floating Axle) 11-14-1

PART 11-14 Wheel Hubs and Bearings(Full Floating Axle)

— Rear

COMPONENT

DESCRIPTION

INDEX

Applies To All 250 and

Page

14-1

Higher Series Vehicles

COMPONENT INDEX


Page

14-2

DESCRIPTION

On all the full-floating axle wheelhubs with tapered roller bearings, a sealis installed behind the inner bearing tokeep the wheel bearing lubricant fromthe brake lining and brake drum (Figs.1 and 2).

The wheel bearings are packed withwheel bearing lubricant (C1AZ-19590-B)to provide initial lubrication until axlelubricant flows into the wheel hubs andbearings during vehicle operation. Onthese axles the wheel hub is ventedthrough the axle housing vent. The sealassembly (500-9000 Series) mounts onthe wheel hub and seals on a wear sleeve(wiper) which is installed on the axlehousing tube (Fig. 2).

The wear sleeves (500-9000 Series)must be installed squarely on the axlehousing using the appropriate tools (Fig.3). Do not use heat on the wear sleevesto facilitate installation. Use the propertool as shown in fig. 3. The sleeves aredesigned with flanges to eliminate thepossibility of installing the sleeves back-wards. Although preservative has beenapplied to the wear sleeve prior to pack-aging, a light oil (SAE-10 or its equiva-lent) should be applied to the wear sleeveto facilitate assembly of the sleeve to theaxle housing. After installation of thewear sleeve, the clearance between he endof the wear sleeve and inner wheel bear-ing shoulder should be 0.010 to 0.025 in-ches (Fig. 2).

The seal assembly is to be installed inthe wheel hub. The garter spring shouldbe checked to assure the spring is in thespring groove behind the primary seal lipafter the seal is in position. Before in-stalling the wheel, apply grease (C1.AZ-19590-B) between the lips of the seal.

The wheel bearing must be thoroughlycleaned and repacked with lithium basegrease (C1AZ-19590-B) before installingthe wheel assembly.

To prevent damage to the primary andsecondary lips of the seal assembly, alocator sleeve or tool should be used toguide the hub and drum onto the ax le. Anew seal assembly must be installedwhenever a wheel is removed.

MUST BE FLUSH WITHEND OF HUB W/LIPSPRING SIDE INTO HUB

WIPE SEAL LIPSURFACES WITH GREASEPRIOR TO ASSEMBLY BOLT

GASKET LOCKNUT1144

BRAKE ASSY.2210

WIPE SEAL DIAMETERGREASE PRIOR TOASSEMBLY

BEARING

LOCKWASHER 1 2 4 0

1124

LOCKWASHER

BOLT

E1972-A

FIG. 1 Rear Wheel Hub—Dana Full-Floating Axle—Models 60, 603E, and 70


NUT ASSY.LOCK WASHER 4255

1124

VIEW IN CIRCLE E1771-C

FIG. 2 Typical Rear Wheel Hub—Full-Floating Axle—500-9000 Series

WEAR SLEEVEREPLACER TOOL

WEAR SLEEVE

TOOL IDENTIFICATION

DRIVE WITH SOFT

FACED HAMMER E1928-A

FIG. 3 Tool Application of WearSleeve (Wiper) Installation


BEARINGS, CUPS AND SEALS

F-250, F-350, E-300 andP-3500-4000 Series

1. Set the parking brake and loosen theaxle shaft retaining bolts (Fig. 1).

2. Raise the rear wheels off the floor andplace work stands under the rear axlehousing so that the axle is parallelwith the floor. Back off the rear brakeadjustment, if necessary.

3. Remove the axle shaft retaining boltsand discard them.

4. Remove the axle shafts.5. Remove the wheel lock nut, lock

washer and wheel bearing adjustmentnut using tool T70T-4252-D, orT70T-4252-E. Under no conditionshould the lock nut be removed witha chisel. Discard the lock washer.

6. With the type of wheel jack shown infig. 4, raise the wheel to the point thatall weight is removed from the wheelbearings. Remove the outer bearingcone. Now, pull the wheel assemblystraight out and away from the axle.

7. Thoroughly clean the spindle of theaxle housing.

8. With a brass drift, and care to preventdamaging the bearing cage, drive theinner bearing cone and inner seal outof the wheel hub.

9. Clean all old grease and axle lubricantout of the wheel hub.

10. Inspect the bearing races and rollersfor pitting, galling or erratic wear pat-terns. Inspect the rollers for end wear.Replace the bearings if worn or da-maged.


E 1770-A

FIG. 4 Typical Wheel Jack

11. If the bearing cups are to be replaced,drive them out with a brass drift. In-stall the new cups with a tool such asOTC 27797.

12. Check for proper seating of the newbearing cups by trying to insert a 0.-0015 inch feeler gauge between thecups and the wheel hub.

13. Pack each bearing cone and roller as-sembly with a bearing packing tool,using M1C75B long life lubricant.

14. Place the inner bearing cone androller assembly in the wheel hub. In-stall a new hub inner seal.

15. Position the wheel assembly at theaxle housing. Wrap the threads of thespindle with electricians tape. Care-fully slide the wheel assembly straight(to avoid seal damage) onto the axlehousing spindle. Remove the electri-cians tape.

16. Install he outer wheel bearing andstart the bearing adjuster nut.Remove the wheel jack.

17. Torque the adjusting nut to 50-80 ft-lbs while rotating the wheel. Back off(loosen) the adjusting nut 3/8 of aturn.

18. Install a new lock washer coated withaxle lube and smooth side out. Install

1767-A

FIG. 5 Axle Shaft Removal—TaperedDowels

the lock nut (Tool T70T-4252-D orT70T-4252-E). Torque the lock nutto 90-110 ft-lbs. With the lock nut atproper torque, the wheel assemblymust rotate freely and with an endplay of 0.001-0.010 inch, be sure ofthis specification. Check it closelywith a suitable dial indicator set up.

19. With a satisfactory end play andfreely turning wheel bend two lockwasher tabs inward over flats of theadjusting nut and two tabs outwardover flats of the lock nut.

20. Install the axle shaft, new metalflange, gasket, lock washers and newaxle shaft retaining bolts, torque thelock bolts to 40-50 ft-lbs.

21. Adjust the brakes. Then, remove thework stands and lower the vehicle.

500-9000 Series

1. Release the parking brake and loosenthe axle shaft stud nuts.

2. Raise the rear wheels off the floor andplace the work stands under the rearaxle housing so that the axle is paral-lel with the floor, back off the rearbrake adjustment.

3. Remove the axle shaft stud nuts.4. If tapered dowels are installed in the

axle shaft flange, place a drift in thecenter of the flange and strike itsharply to loosen the dowels (Fig. 5).Remove the axle shaft.

On axles where tapered dowels are notused, two puller threads (5/8-11) are pro-vided in the axle shaft flange. These axleshafts may be pulled with a slide hammerinstalled in the puller threads or with thetype of tool shown in Fig. 6. This tool canbe made from a piece of flat steel bar withan 11/16 inch hole in it, and a 2 1/4 inchlong 5/8-11 bolt. As the bolt is turnedclockwise, the axle shaft flange is pulledaway from the wheel hub. If the threadload becomes excessive when pulling anaxle shaft, install a second puller on theopposite side of the flange, if so equipped.

5. Bend the lock washer tab away fromthe lock nut, and then remove thelock nut, lock washer, and the adjust-ing nut.

6. With the type of wheel jack shown inFig. 4, raise the wheel to the pointthat all wheel weight is removed fromthe wheel bearings, remove the outerbearing cone. Now, pull the wheelstraight out and away from the axle.

7. Inspect the inner seal wear sleeve onthe axle housing spindle for signs ofwear or pitting. If necessary to replacethe wear sleeve, use a hammer and acold chisel. Being careful not to dam-age the seal journal of the axle hous-ing, make two evenly spacedindentations in the wear sleeve sur-

AXLE SHAFT FLANGE HAS

TWO 5/8-H THREADS

Puller Tool ISMADE FROM

A HAT STEEiLBAR WITH% INCH

HOLE AND A5/8-H X 2 14

INCH BOLT

E 176K-A

FIG. 6 Axle Shaft Puller

face and slip the wear sleeve off theaxle housing. Thoroughly clean thespindle of the axle housing. Then, po-sition a new proper size wear sleevesquarely to the axle housing spindleand, with the use of proper drivingtool (Fig. 3), and a soft faced hammer,drive the wear sleeve on the axle hous-ing spindle until it seats evenly againstthe shoulder of the seal journal of thespindle. A light coating of S.A.I:,. 10oil should be applied to the inner sur-face of the wear sleeve to facilitateassembly of the wear sleeve to axlehousing.

8. With a piece of hard wood which willjust clear the outer bearing cup, or abrass drift, carefully drive the innerbearing cone and inner seal out of thewheel hub.

9. Clean all the old grease or axle lubri-cant out of the wheel hub.

10. Inspect the bearing races and rollersfor pitting, galling, and erratic wearpatterns. Inspect the rollers for endwear (Fig. 7).

11. If the bearing cups are to be replaced,drive them out with a drift. Install thenew cups with the tool shown in Fig.8 or press them in.

NEW ROLLER

FIG. 7 Roller Bearing End


/ ~ 753T-7239-ATool -T53T-1239-A,

Deiail

FIG. 8 Installing Bearing Cup

12. Check for proper seating of the newbearing cups by trying to insert a 0.-0015 inch feeler gauge between thecup and the wheel hub.

13. Pack each bearing cone and roller as-sembly with a bearing packer tool.

14. Place the inner bearing cone androller assembly in the wheel hub, andthen install a new hub inner seal.

15. Apply a light film of M1C75 lubri-cant to the axle spindle; then positiona seal protector tool over the axlespindle threads.

16. Position the wheel assembly at theaxle housing. Carefully slide thewheel assembly straight (to avoid sealdamage) onto the axle housing spin-dle. Then, remove the seal protectorfrom the axle spindle.

17. Install the outer wheel bearing andstart the bearing adjuster nut.Remove the wheel jack.

18.11000-17500 lb. Single Rear Axlesand 30000 lb. Tandem Rear Axles:Torque the adjusting nut to 140 ft-lbswhile rotating the wheel to seat thebearings. Back off (loosen) the adjust-ing nut 1/2 turn; then, torque the ad-justing nut again to 50 ft-lbs whilerotating the wheel. Back off (loosen)the adjusting nut 1/3 turn. Install thelock washer. Back off the adjustingnut, if necessary to align the lock

f-OTC-410 E 1769-A

FIG. 9 Installing Lock Nut

washer hole with the dowel pin. In-stall the lock nut and tighten to 125ft-lbs. The wheel assembly must ro-tate freely and with an end play of0.001 to 0.010 inch. Do not preloadthe bearings.All Other Single and tandem Rear

Axles: Torque the adjusting nut to 185ft-lbs while rotating the wheel to seat thebearings. Back off (loosen) the adjustingnut 1/2 turn; then, torque the adjustingnut again to 50 ft-lbs while rotating thewheel. Back off (loosen) the adjusting nut1/6 turn.19. Install a new lock washer and select

a tab which is centered on one of theadjusting nut flats.Remove the lock washer and bend

this tab approximately 45 degrees suchthat the final bend will fit flush on thenut. Reinstall the lock washer. Install thelock nut and torque it to 125 ft-lbs (Fig.9). With the lock nut at proper torque,the wheel assembly must rotate freely andwith an end play of 0.001-0.010 inch. Donot preload the bearings. Bend the pre-bent lock washer tab flush against the flatof the adjusting nut. Bend another tabflush on the lock nut. Do not use a chiselor other sharp tool to bend the tabs asmetal chips could work into the bearings.20. Install the axle shaft, a new gasket,

lock washers and axle shaft retaining

nuts. Torque the nuts to specifica-tions.

21. Adjust the brakes. Then, remove thework stands and lower the vehicle.

Medium, Heavy and Extra HeavyVehicles (Oil Lubrication)

Stemco Seals available as regular pro-duction options, provide sealing where oilis used for bearing lubrication. The toolsrequired for Stemco Seal Installation areonly available from the Stemco ware-house. Refer to specifications for the tool-ing required. Fig. 10 illustrates a rearwheel Stemco Seal installation.Rear Hub Seal Installation

1. Thoroughly clean the axle spindle.2. If the spindle shoulder is scored or

pitted apply a thin coat of PermatexNo. 2.

3. Position the axle ring and drive it intoposition flush with the inner bearingshoulder using the correct tool.Procedures vary with different ap-plications. Refer to the instructionspacked with each seal set.

4. Remove all burrs and protrusionsfrom the oil seal area of the wheelhub.

5. Pack the inner bearing cone withM1C75-B and position it in the bear-ing cup.

6. Position the oil seal at the mouth ofthe bore and drive it squarely into po-sition using the correct tool. The sealmust be evenly bottomed.

7. Take special care not to damage theoil seal while installing the wheel.

8. Fill the wheel cavity with oil beforeinstalling the outer bearing.

9. Pack the outer bearing with M1C75-B and install it and then adjust thebearings as outlined in Part 11-11,Adjustments.

10. Inspect axle shaft gasket mating sur-faces for nicks, burrs, and dirt; theninstall the axle shaft.

11. Check the rear axle lube level and addoil if required.


SEAL LIP

VIEW FOR 11000, 13000, & 15000 LB.REAR AXLES ONLY

E2125-A

FIG. 10 Rear Seal Installation (Stemco)

SPECIFICATIONS

SPECIAL SERVICE TOOLS STEMCO®

Ford Seal Kit Part No.

D0HZ-1175-A

D0HZ-1175-B

D0HZ-1175-C

D0HZ-1175-D

D0HZ-1175-E

D0HZ-1175-F

Stemco Tool No.

5008-5308

5002-5011

5074-5383

5072-5397

5071-5391

5076-5399

Ford Seal Kit Part Name

Kit - Oil Seal

Inner Rear Wheel

0 K i t s on th i s page cons is t o f one ax le r i ng a n d one seal for just one w h e e l .

CE2330-A

12-01-1 General Hydraulic Brake Service 12-01-1

PagePART 12-01

General Hydraulic Brake Service 12-01-1PART 12-02

Drum Brakes - Single Cylinder,Dual Piston 12-02-1

PART 12-05Drum Brakes - Single Cylinder,Single Piston 12-05-1

PART 12-08Drum Brakes - Dual Cylinders,

Dual Pistons 12-08-1PART 12-09

Drum Brakes - Dual Cylinders,Single Piston (Wagner) 12-09-1

PART 12-24Disc Brakes- Dual Piston

Floating Caliper 12-24-1PART 12-40

General Air Brake Service 12-40-1PART 12-43

Air Brakes - Single Wedge(Rockwell) 12-43-1

PART 12-44Air Brakes-Single Wedge

(Bendix) 12-44-1PART 12-46

Air Brakes- Double Wedge(Bendix) 12-46-1

PART 1248Air Brakes - Cam Type 12-48-1

PART 12-50Vacuum Brake Booster - Single

Diaphragm, Dash-Mounted(Bendix) 12-50-1

PART 12-52Vacuum Brake Booster -Tandem

Diaphragm, Dash-Mounted(Bendix) 12-52-1


Diaphragm, Frame-Mounted(Bendix) 12-53-1

PART 12-54Vacuum Brake Booster — Tandem

Diaphragm, Frame-Mounted(Bendix)


Diaphragm, Dash-Mounted(Midland)


Diaphragm, Frame-Mounted(Midland)

PART 12-70Parking Brake - Cable Actuated,

Rear WheelsPART 12-77

Parking Brake - External Band,Transmission Mounted

PART 12-79Parking Brake - Internal Shoe,Transmission Mounted

PART 12-81Parking Brake - Internal Shoe,Transfer Case Mounted

PART 12-83Parking Brake - Maxibrake, RearWheels, Air

.12-54-1

12-58-1

12-60-1

12-70-1

12-77-1

12-79-1

12-81-1

12-83-1

PART 12-84Parking Brake - MGM Stopgard-

Rear Wheels, Air

PART 12-85Parking Brake - MGM Shortstop, RearWheels, Air

PART 12-86Parking Brake - MGM Low Profile,

Rear Wheels, AirPART 12-87

Parking Brake - Anchor Lok, RearWheels, Air

.12-84-1

12-85-1

12-86-1

12-87-1


PART 12-01 General Hydraulic Brake Service

COMPONENT INDEX

Applies to Models as Indicated

BRAKE BOOSTER

Cleaning and Inspection

Push Rod Adjustment

Testing

BRAKE CYLINDER


BRAKE DRUMCleaning and Inspection

Refinishing


BRAKE PEDAL

Adjustment

BRAKESHOEAND LINING

OverhaulBRAKE SYSTEM

Description

Hydraulic Line Repair

Manual Bleeding

Power Brake Function Test

Preliminary Checks

Pressure Bleeding

Warning Light Test

DISC BRAKES


MASTER CYLINDERCleaning and Inspection

PRESSURE DIFFERENTIAL VALVE

Centralizing

All

Mod

els

01-13

01-13

01-12

01-12

01-9

01-12

01-1

Econ

oiin

e &

Bron

co

N/A

N/A

01-8

01-13

01-11

01-901-8

01-8

01-10

01-8

N/A

01-13

01-11

P-35

0-40

0

01-14

01-9

01-8

01-13

01-11

01-9

01-8

01-8

01-10

01-8

N/A

01-13

01-11

oo1X9

01-14

01-9

01-8

01-13

01-11

01-901-8

01-8

01-10

N/A

N/A

01-13

01-11

B-50

0-75

0,60

00-7

000

01-14

01-9

01-8

01-13

01-11

01-901-8

01-8

01-10

01-8

N/A

01-13

01-11

F-10

0-35

0

01-14

01-9

01-8

01-13

01-11

01-901-8

01-8

01-10

01-8

01-13

01-13

01-11

F-50

0-75

0,L-

800-

900

01-14

01-9

01-8

01-13

01-1101-9

01-8

01-8

01-10

01-8

N/A

01-13

01-11

L-80

00-9

000

N/A

N/A

N/A

N/A

N/AN/AN/A

N/AN/AN/A

N/A

N/A

N/A

LT-8

00-9

00,

8000

,900

0

01-14

01-9

01-8

01-13

01-11

01-9

01-8

01-8

01-10

01-8

N/A

01-13

01-11

C-55

0-90

0,60

00-7

000

01-14

01-9

01-8

01-13

01-1101-9

01-8

01-8

01-10

01-8

N/A

01-13

01-11

C-90

0,C-

8000

CT80

0-90

0

N/A

N/A

N/A

N/A

N/AN/AN/AN/AN/AN/A

N/A

N/A

N/A

LN-5

00-9

00,

8000

-900

0

01-14

01-9

01-8

01-13

01-11

01-901-8

01-8

01-10

01-8

N/A

01-13

01-11

LN-8

00-9

00,8

000-

9000

LNT

Ser

iesW

& W

T Se

ries

N/A

N/A

N/A

N/A

N/AN/AN/AN/AN/AN/A

N/A

N/A

N/A

A page number indicates that the item is for the vehicle(s) listed at the head of the column.N/A indicates that the item is not applicable to the vehicle(s) listed.


DESCRIPTION

Hydraulically operated service brakesare standard equipment on all 100through 800 Series and on some 900 Se-ries trucks.

Automatic brake shoe adjusters areused on all 100 thru 900 Series truckswith hydraulic brakes.

A dual-master cylinder brake system(Figs. 1 through 4) is used as standardequipment on F-100 through F-350, E-100 through E-300, Bronco, and P-35O-400 vehicles. The dual master cylinder isalso used on F-500, L-900, LN-6OO-75O,F-6000-7000, LN-6OOO-7OOO, C-6000-7000 and B-5OO-75O Series vehiclesequipped with split hydraulic brakes.

Front Disc Brakes are available on F-250 and F-350 trucks.

The standard hydraulic brake systemon some vehicles may be assisted by avacuum booster installed as either stand-ard or optional equipment. Service infor-mation on the vacuum booster units isgiven in Parts 12-50, 12-52, 12-53, 12-54,and 12-60.

The dual, master cylinder contains adouble hydraulic cylinder with two fluidreservoirs, two hydraulic pistons (a pri-mary and secondary) and two residualcheck valves, located in the outlet ports(Fig. 5). The master cylinder secondarysystems outlet port is connected to thesecondary hydraulic circuit and the pri-mary system brake outlet port is con-nected to the primary hydraulic circuit.

The master cylinder primary and se-condary pistons function together when

the primary and secondary systems arefully operative.

Brake lines (tubes) are connectedfrom the brake master cylinder primaryand secondary system outlet ports to thepressure differential valve assembly(Figs. 5 and 6). The electrical brakewarning switch, and the brake lines(tubes) leading from the differential valveassembly to the front and rear wheelbrake cylinders are also shown in Figs. 6and 7.

On all 100-400 Series trucks the dualmaster cylinder primary and secondarycircuits actuate either the front or rearwheel brakes.

On 500-900 Series trucks with a splithydraulic system, each of the two linesfromthe dual-master cylinder actuatesone brake cylinder at each wheel (frontand rear) for vehicles with 15 by 3-inchfront brakes. On vehicles with 14 by 21/2-inch front duo-servo brakes, the sin-gle brake cylinders in both front wheelsare actuated by one line that also operatesone cylinder at each rear wheel. The linefrom the other master cylinder outletport actuates the remaining brake wheelcylinder at each rear wheel. Power boost-ers are frame-mounted on LN-5OO-6OOSeries models. Other 500-900 Series mod-els have dash-mounted boosters.

SINGLE MASTER CYLINDERBRAKE SYSTEM—500-900 SERIES

The standard hydraulic brake system

VACUUM CHECK VALVE

ENGINE MANIFOLD BOOSTER

MECHANICAL STOPLIGHT SWITCH

-WARNING LIGHT

BRAKE PEDAL

IGNITION SWITCH

&

C-Series models is equipped with a singlemaster cylinder and internal drum brakesat all wheels. On all models except P-500,the drum brakes are self adjusting.

The standard hydraulic brake systemon some trucks is assisted by a vacuumbooster which may be installed as eitherstandard or optional equipment.

DRUM BRAKES

All Ford truck models have internalexpanding shoes, except the F-250 andF-350 which may have front disc brakes.The different types of brake assembliesvary in the way that the shoes are an-chored, in the number of wheel cylindersused at each wheel, and in the number ofpistons in the wheel cylinder.

In the single anchor type, both brakeshoes are mounted to the same anchorand are actuated by one wheel cylinder.In the duo-servo, single anchor brake, thewheel cylinder has two pistons. One pis-ton exerts force against the upper end ofthe primary shoe; the other piston exertsforce against the upper end of the second-ary shoe (Figs. 7 and 8).

In the double anchor type, each shoeis mounted to a separate anchor. Theshoes are actuated by one duo-servo (twopiston) cylinder at the upper end.

The front wheels of some trucks areequipped with two cylinders, each havingone piston. The piston in one cylinderexerts force against one end of one shoe;the piston in the other cylinder exertsforce against the opposite end of the othershoe.

The rear wheels of some vehicles areequipped with two cylinders, each havingtwo pistons (four pistons total). Each ofthe four pistons exert force against oneend of one shoe (Fig. 9).

FRONT BRAKESAUTOMATIC ADJUSTERS

REAR BRAKESAUTOMATIC ADJUSTERS

HI 706-A

FIG. 1 Split Hydraulic—Vacuum Brake System with Dash-Mounted Booster


ENGINE MANIFOLD

cfFRONT BRAKES

AUTOMATICADJUSTERS

• • HYDRAULIC PRESSURE - M/CYL. TO BOOSTERS

& BOOSTERS TO WHEELS

"V"V ATMOSPHERE - AIR CLEANER TO BOOSTERS

2 2 ^ . SUPPLY VACUUM - ENGINE MANIFOLD TO BOOSTERS

• I 15x3 FRONT BRAKES ONLY

REAR BRAKESAUTOMATICADJUSTERS

HV32-E

FIG. 2 Split Hydraulic—Vacuum Brake System with Frame-Mounted Boosters—600-900 Series

FRONT BRAKESSELF

ADJUSTING

WARNING LIGHT

BRAKEIGNITION ^ PEDALSWITCH

REAR BRAKESSELF ADJUSTING

WARNINGVALVE & SWITCH

H1985-A

FIG. 3 Typical Hydraulic Brake System—Light Truck


RETAINERGASKET (DIAPHRAGM)

SECONDARY PISTONASSEMBLY

PUSH ROD

O-RING PISTON STOP

FIG. 4 Dual Master Cylinder—Typical (Light Truck)

H1503-C

BRAKE WARNING LAMP SWITCH BRAKE WARNING LAMP SWITCH

PISTON BRAKE WARNING LAMP SWITCHPLUNGER IN OFF POSITION

WASHER

BRAKE WARNING LAMP SWITCHPLUNGER IN THE ON POSITION

. JCONNECTOR

LOW PRESSURE SIDE

VALVE PISTON HAS MOVED TO LOW PRESSURE AREA.WARNING LAMP SWITCH PLUNGER IS DEPRESSED,

LIGHTING THE BRAKE WARNING LAMPBRAKE FLUID

VALVE PISTON IS CENTRALIZED.PRIMARY AND SECONDARY SYSTEM

PRESSURES ARE EQUALIZED H1471-B

FIG. 5 Differential Valve System—100-400 Series


BRAKE WARNING LAMP SWITCHBRAKE WARNING LAMP SWITCH

BRAKE WARNING LAMP SWITCHIN OFF POSITION

VALVE PISTON IS CENTEREDSPLIT BRAKE SYSTEM

PRESSURES ARE EQUALIZED

BRAKE FLUID

BRAKE WARNING LAMP SWITCHIS IN ON POSITION

HIGH PRESSURti

VALVE PISTON HAS MOVED TO LOW PRESSURE AREA.WARNING LAMP SWITCH PLUNGER IS EXTENDED

INTO VALVE PISTON VALLEY LIGHTINGTHE BRAKE WARNING LAMP

H 16/1-A

FIG. 6 Differential Valve System—500-900 Series with Split Hydraulic Brakes

ANCHOR PIN ANCHOR PIN PLATE ANCHOR PIN PLATE

RETRACTINGSPRING

PRIMARY SHOEAND LINING

BRAKE CYLINDER

PARKING BRAKE LEVER

RETAINING C L P

CABLEGUIDE

RETRACTING

SECONDARY SHOE SPRING

AND LINING

PARKING BRAKELINK SPRING

RETRACTINGSPRING

BRAKE SHOEHOLD-DOWN

SPRINGS


PARKINGBRAKELINK

CABLE HOOK

PIVOT HOOK

SOCKETAUTOMATICADJUSTER PIVOTSPRING NUT

r^ CABLE

PARKINGBRAKELEVER

PIVOT HOOK

PARKING BRAKE CABLE

ADJUSTINGSCREW

PARKING BRAKE CABLE ADJUSTINGHOUSING RETAINER SCREW

FRONT BRAKE

FIG. 7 Self Adjusting Brake Assemblies—F-100-250, E-100-200, and Bronco

ADJUSTING LEVER

REAR BRAKE HI340-D

12-01-7General Hydraulic Brake Service

FORWARD

SPRING CLIP RETAINER

BRAKE CYLINDER

ADJUSTING CABLE ANCHOR FITTING

SECONDARY SHOEAND LINING

FORWARDANCHOR PIN PLATE

PARKING BRAKE LEVERASSEMBLY BOLT


RETRACTING _ _ ^ .SPRING I u

ADJUSTING SCREW

RETRACTINGCABLE GUIDE SPRING

BRAKE ADJUSTINGTOOL CONTACT

POINT

BRAKE CYLINDER


ADJUSTING SCREWSOCKET

BRAKE SHOEHOLD-DOWN

SPRINGS


CABLE HOOK

OVER TRAVEL SPRING

PARKING BRAKE CABLE

PARKINGBRAKE LEVER

FRONT BRAKE LEFT SIDE OF VEHICLE

OVER TRAVEL SPRING\

ADJUSTING SCREW SLOTS ADJUSTING LEVER

REAR BRAKE

FIG. 8 Self Adjusting Brake Assemblies-F-250 (Heavy Duty)-350, E-300, and P-350-400H1581-C

L.H. BRAKE ASSEMBLY

BACKINGPLATE

ADJUSTER SPRINGBROWN

GREENLINK

FIG. 9 Two-Cylinder Brake Assembly—Rear (Wagner)

H1731-A


TESTING

BRAKE SYSTEM PRELIMINARYCHECKS

1. Always check the fluid level in thebrake master cylinder reservoir(s)before performing the test proce-dures. If the fluid level is not within1/4 inch of the top of the master cyl-inder reservoirs, add Ford BrakeFluid-Extra Heavy Duty-Part Num-ber C6AZ-19542-A (ESA-M6C25-A)or equivalent for all brake applica-tions. The extra heavy duty brakefluid is colored blue for identificationpurposes. Do not mix low tempera-ture brake fluids with the specifiedbrake fluid.Push the brake pedal down as far as

it will go. If the pedal travels more thanhalfway between the released positionand the floor, adjust the brakes. If thevehicle is equipped with automatic brakeadjusters, several sharp brake applica-tions while backing up may be necessaryto adjust the brakes.

Road test the vehicle and apply thebrakes at a speed of about 20 mph to seeif the vehicle stops evenly. If not, thebrakes should be adjusted. Perform theroad test only when the brakes will applyand the vehicle can be safely stopped.

DUAL BRAKE WARNING LIGHTSYSTEM TESTS

1. Turn the ignition switch to the ACCor ON position. If the light on thebrake warning lamp remains on, thecondition may be caused by a shortedor broken switch, grounded switchwires or the differential pressure valveis not centered. Centralize the differ-ential pressure valve as outlined un-der Hydraulic System Bleeding andCentralizing of the Differential Valvein this Section of the manual. If thewarning light remains on, check theswitch connector and wire for agrounded condition and repair or re-place the wire assembly. If the condi-tion of the wire is good, replace thebrake warning lamp switch.

2. Turn the ignition switch to the startposition. If the brake warning lampdoes not light, check the light andwiring and replace or repair wiring asnecessary.When both brake systems are func-

tioning normally, the equal pressure atthe pressure differential valve duringbrake pedal application keeps the valvecentered. The brake warning light will beon only when the ignition key is in theSTART position.3. If the brake warning lamp does not

light when a pressure differential con-

dition exists in the brake system, thewarning lamp may be burned out, thewarning lamp switch is inoperative orthe switch to lamp wiring has an opencircuit. Check the bulb and replace it,if required. Check the switch to lampwires for an open circuit and repairor replace them, if required. If thewarning lamp still does not light, re-place the switch.

POWER BRAKE FUNCTION TEST

With the engine stopped, eliminate allvacuum from the system by pumping thebrake pedal several times. Then push thepedal down as far as it will go, and notethe effort required to hold it in this posi-tion. If the pedal gradually moves down-ward under this pressure, the hydraulicsystem is leaking and should be checkedby a hydraulic pressure test.

With the brake pedal still pusheddown, start the engine. If the vacuum sys-tem is operating properly, the pedal willmove downward. If the pedal positiondoes not change, the vacuum system isnot operating properly and should bechecked by a vacuum test.

FRAME-MOUNTED VACUUMBOOSTER CHECK VALVE TEST

Disconnect the line from the bottomof the vacuum check valve, and connecta vacuum gauge to the valve. Start theengine, run it at idle speed, and check thereading on the vacuum gauge.

The gauge should register 17-19 in-ches with standard transmission and 14-15 inches in Drive range if equipped withan automatic transmission. Stop the en-gine and note the rate of vacuum drop.If the vacuum drops more than one inchin 15 seconds, the check valve is leaking.If the vacuum reading does not reach 18,or is unsteady, an engine tune-up is neces-sary.

Remove the gauge and reconnect thevacuum line to the check valve.

VACUUM BOOSTERTEST—DIAPHRAGM TYPE

This procedure can be used to test alldiaphragm boosters which are equippedwith a pipe thread outlet on the atmos-phere portion of the diaphragm chamber.

Remove the pipe plug from the rearhalf of the booster chamber, and installa vacuum gauge. Start the engine and runit at idle speed. The gauge should register18-21 inches of vacuum.1. With the engine running, depress the

brake pedal with enough pressure toshow a zero reading on the vacuum

gauge. Hold the pedal in the appliedposition for one minute. Any down-ward movement of the pedal duringthis time indicates a brake fluid leak.Any kickback (upward movement) ofthe pedal indicates brake fluid is leak-ing past the hydraulic piston checkvalve.

2. With the engine running, push downon the brake pedal with sufficientpressure to show a zero reading on thevacuum gauge. Hold the pedal down,and shut the engine off. Maintainpedal position for one minute. A kick-back of the pedal indicates a vacuumleak in the vacuum check valve, in thevacuum line connections, or in thebooster.


ADJUSTMENTS

AIR CHECK BOOSTER PUSH RODADJUSTMENT—MIDLAND ROSSBOOSTER (DASH-MOUNTED)

Whenever the master cylinder orbooster has been repaired or replaced, thebrake system must be checked for properreturn flow of hydraulic brake fluid fromthe wheel cylinders to the reservoir of themaster cylinder. This check will assurethat the brake booster to master cylinderpush rod is properly adjusted to allow themaster cylinder compensating valve toopen when the brake pedal is in the fullyreleased position.

The air check is made after the brakebooster and master cylinder has been in-stalled and before the master cylinder hy-draulic line connection is made and thereservoir is filled with brake fluid.1. Connect the brake vacuum line to the

vacuum booster, if required. Start theengine.

2. Carefully position the nozzle of an airhose to the master cylinder dischargeport. Place a hand over the mastercylinder reservoir and apply air pres-sure through the air hose nozzle.Be careful not to allow dirt to enter

into the system.If free passage air pressure is felt on

the hand located over the master cylinderreservoir, the brake booster push rod isproperly adjusted.

If no air pressure is felt on the handlocated over the reservoir, the master cyl-inder must be removed and the push rodlength shortened. To shorten the push rodlength, turn the acorn-type screw on thebrake booster push rod inward, one turnat a time, until the air check shows thebrake master cylinder compensatingvalve is open.

BRAKE PEDAL ADJUSTMENT

FIG. 10 Pedal Free Travel Check

On dual-brake master cylinder orbrake mounted vacuum booster equippedvehicles, the brake systems are designedto permit full stroke of the master cylin-der when the brake pedal is fully de-pressed. A brake pedal clearanceadjustment is not required.

In order to release the brakes, fluidin a hydraulic brake system must flowback to the master cylinder when pedalpressure is released. A port is providedin the master cylinder to allow this flow,but the piston must move back far enoughto expose the return port. To be sure thatthis will always happen, free-travel isbuilt into the pedal linkage on standardand on frame-mounted booster systems.This free-travel prevents the piston frombecoming trapped in a partially releasedposition. Pedal free travel is not alwaysperceptible in dash-mounted booster sys-tems, however, because the operatingclearance for the piston is adjusted at thebooster push-rod, rather than the pedallinkage. (Refer to Parts 12-50,12-52 and12-58 for instructions on dash-mountedbooster push rod adjustments).

Pedal free travel is not adjustable on500-900 series trucks with a dash-mounted booster and a single or dual sys-tem or units with a dual system and aframe-mounted booster.

If the pedal free travel in a standardhydraulic brake system or frame-mounted hydraulic booster system is lessthan 3/16 inch or more than 3/8 inch(Fig. 10), the pedal should be adjusted.

To adjust free-travel:1. Push the brake pedal down by hand

pressure, and check the free travel.2. Loosen the lock nut on the eccentric

bolt, and rotate the eccentric bolt un-til the free travel is within 3/16-3/8inch.On a P-Series truck, turn the hex head

of the push rod to obtain the requiredfree-travel.3. Hold the bolt securely, and torque the

lock nut to 30-35 ft-lbs.4. Recheck the pedal free-travel to make

sure that the adjustment did notchange when the lock nut was tight-ened.

FRONT DISC BRAKES F-250 ANDF-350

The front disc brake assembly is de-signed so that it is inherently self-adjust-ing. Refer to Part 12-24.

HYDRAULIC SYSTEM BLEEDING

When any part of the hydraulic sys-tem has been disconnected for repair orreplacement, air may get into the lines

and cause spongy pedal action. This re-quires the bleeding of the hydraulic sys-tem after it has been properly connectedto be sure all air is expelled from thebrake cylinders and lines. The hydraulicsystem can be bled manually or withpressure bleeding equipment.

When bleeding the brake system,bleed one brake cylinder at a time, begin-ning at the cylinder with the longest hy-draulic line first. If the brake assemblyis equipped with two cylinders, alwaysbleed the upper cylinder first. Keep themaster cylinder reservoir filled with thespecified C6AZ-19542-A extra heavyduty brake fluid during the bleeding op-eration. Never use brake fluid which hasbeen drained from the hydraulic system.

The procedure for bleeding the singlemaster cylinder on a C-Series truck ispresented separately from the standardhydraulic system bleeding procedures.

If the hydraulic system is equippedwith a vacuum booster, bleed the hydrau-lic section of the booster before bleedingthe rest of the system. On vehiclesequipped with a frame-mounted boosterand split hydraulic brake system, bleedthe two booster slave cylinders first thenagain after bleeding all the wheel cylin-ders. The bleeding operation must bedone with the engine off and with novacuum in the system. If the brake pedalis still spongy after the first bleeding, re-peat the bleeding procedure.

To bleed the hydraulic section of avacuum booster, follow steps 1 through4 of the manual bleeding procedure, at-taching the drain tube to the bleederscrew at the end plate of the booster (orthe bleeder screw nearest the powerchamber). Repeat this procedure at theother bleeder screw if the booster is soequipped.

On dual-brake system hydraulic mas-ter cylinder equipped vehicles, it will benecessary to centralize the pressure dif-ferential valve after a brake hydraulicsystem malfunction has been correctedand the hydraulic system has been bled.Before any attempt is made to bleed thesplit hydraulic brake system on 500-950Series trucks, remove the brake lightwarning switch from the pressure differ-ential valve. Failure to remove the switchfrom the valve could result in possibledamage to the switch assembly.

MANUALBLEEDING—CONVENTIONAL,SINGLE-BRAKE SYSTEMHYDRAULIC MASTER CYLINDER

1. Attach a rubber drain tube to thebleeder screw of the brake wheel cyl-inder. The end of the tube should fit


snugly around the bleeder screw.2. Submerge the free end of the tube in

a container partially filled with cleanbrake fluid. Loosen the bleeder screw.

3. Push the brake pedal down slowly byhand, allowing it to return slowly tothe fullyreleased position. Repeatthis operation until air bubbles ceaseto appear at the submerged end of thetube.

4. When the fluid is completely free ofair bubbles, close the bleeder screwand remove the drain tube.

5. Repeat this procedure at each brakecylinder. Refill the master cylinderreservoir after each brake cylinder isbled with C6AZ-19542-A extra heavyduty brake fluid and when the bleed-ing operation is completed.

MANUALBLEEDING—DUAL-BRAKE SYSTEMHYDRAULIC MASTER CYLINDER

The primary and secondary hydraulicbrake systems are individual systems andare bled separately. Bleed the longest linefirst on the individual system being ser-viced. During the complete bleeding op-eration, DO NOT allow the reservoir torun dry. Keep the master cylinder reser-voirs filled with the specified brake fluid.Never use brake fluid that has beendrained from the hydraulic system.1. Remove the brake light warning light

switch from the pressure differentialvalve (Fig. 7) on 500-900 Seriestrucks.

2. Bleed the master cylinder at the outletport side of the system being serviced.On a master cylinder without bleed

screws, loosen the master cylinder to hy-draulic line nut. Operate the brake pedalslowly until the brake fluid at the outletconnection is free of bubbles, then tightenthe tube nut to the specified torque. Donot use the secondary piston stop screwlocated on the bottom of the master cylin-der to bleed the brake system. Looseningor removing this screw could result indamage to the secondary piston or stopscrew. Operate the brake pedal slowlyuntil the brake fluid at the outlet connec-tion is free of air bubbles, then tighten thebleed screw.3. Position a suitable 3/8 inch box

wrench (Fig. 11) on the bleeder fittingon the brake wheel cylinder. Attach

APPROXIMATELY 45

H 1300-C

FIG. 11 Wrench for Bleeding BrakeHydraulic System

a rubber drain tube to the bleeder fit-ting. The end of the tube should fitsnugly around the bleeder fitting.

4. Submerge the free end of the tube ina container partially filled with cleanbrake fluid, and loosen the bleeder fit-ting approximately 3/4 turn.

5. Push the brake pedal down slowlythru its full travel. Close the bleederfitting, then return the pedal to thefully-released position. Repeat thisoperation until air bubbles cease toappear at the submerged end of thebleeder tube.

6. When the fluid is completely free ofair bubbles, close the bleeder fittingand remove the bleeder tube.

7. Repeat this procedure at the brakewheel cylinder on the opposite side.Refill the master cylinder reservoir af-ter each wheel cylinder is bled.When the bleeding operation is com-

plete, the master cylinder fluid levelshould be filled to within 1/4 inch fromthe top of the reservoirs.8. Centralize the pressure differential

valve. Refer to the Centralizing of thePressure Differential Valve proce-dures in this Section.

9. Install the brake warning light switchon the pressure differential valve on500-900 Series trucks.

PRESSUREBLEEDING—CONVENTIONALSINGLE-BRAKE SYSTEMHYDRAULIC MASTER CYLINDER

Be sure that the tank is clean andthere is enough of the specified brakefluid (C6AZ-19542-A extra heavy duty)in the bleeder tank to complete the bleed-ing operation and that the tank is chargedwith 10-30 pounds of air pressure. Neverexceed 50 pounds pressure.

On a C-Series truck with a single mas-ter cylinder, the master cylinder can onlybe bled manually. Therefore, bleed theentire hydraulic system first before bleed-ing the master cylinder.1. On a L-, LN-, or LT-Series truck,

clean all dirt from around the fillerhole on the top of the master cylinderreservoir, and attach the bleeder tankhose to the filler hole.On a C-Series truck with a single mas-

ter cylinder, disconnect the line from thebottom of the master cylinder and con-nect the line to the pressure bleeder tankhose. Install a 5/16 inch Weatherheadplug into the bottom of the master cylin-der.2. Attach a rubber drain tube to the

bleeder screw of the brake cylinder.The end of the tube should fit snuglyaround the bleed screw.

3. Submerge the free end of the tube ina container partially filled with cleanbrake fluid and then loosen the

bleeder screw.4. Open the valve on the bleeder tank to

admit pressurized brake fluid tc themaster cylinder reservoir (or line).

5. When air bubbles cease to appear inthe fluid at the submerged end of thedrain tube, close the bleeder screwand remove the tube.

6. Repeat this procedure at each brakecylinder.

7. When the bleeding operation is comp-leted, close the bleeder tank valvt: andremove the tank hose from the fillerhole.On a C-Series truck with a single mas-

ter cylinder, remove the line from thetank hose and connect it to the mastercylinder.8. On all vehicles, refill the master cylin-

der reservoir to within 1/4 inch fromthe top of the filler neck.

C-SERIES TRUCK SINGLE MASTERCYLINDER BLEEDING

1. Loosen the fittings at the bottom ofthe master cylinder, approximatelyone turn.

2. Wrap a shop cloth, or a piece of cleanwaste material, around the tubing be-low the fitting to absorb expendedbrake fluid.

3. Push the brake pedal down slowly byhand to the floor of the cab. This willforce air which may be trapped in themaster cylinder to escape at the fit-ting.

4. Hold the pedal down and tighten thefitting. Release the, brake pedal. Donot release the brake pedal until thefitting is tightened as additional airwill be introduced into the master cyl-inder.

5. Repeat this procedure until air ceasesto escape at the fitting and a firmpedal is obtained.

PRESSURE BLEEDING—DUALBRAKE SYSTEM HYDRAULICMASTER CYLINDER

Bleed the longest lines first. Thebleeder tank should contain enough ofthe specified brake fluid (C6AZ-19542-Aextra heavy duty) to complete the bleed-ing operation. The tank should becharged with approximately 10 to 30pounds of air pressure. Never exceed 50pounds pressure. Never use brake fluidthat has been drained from the hydraulicsystem.1. Remove the brake warning light

switch from the pressure differentialvalve on 500-900 Series trucks (Fig.7).

2. Clean all dirt from the master cylin-der reservoir cover.

3. Remove the master cylinder reservoircover and rubber gasket, and fill the


master cylinder reservoir with thespecified brake fluid. Install the pres-sure bleeder adapter tool to the mas-ter cylinder, and attach the bleedertank hose to the fitting on the adapter.Master cylinder pressure bleeder

adapter tools can be obtained from thevarious manufacturers of pressure bleed-ing equipment. Follow the instructions ofthe manufacturer when installing theadapter.4. Position a 3/8 inch box wrench (Fig.

11) on the bleeder fitting on the rightrear brake wheel cylinder. Attach ableeder tube to the bleeder fitting. Theend of the tube should fit snuglyaround the bleeder fitting.

5. Open the valve on the bleeder tank toadmit pressurized brake fluid to themaster cylinder reservoir.

6. Submerge the free end of the tube ina container partially filled with cleanbrake fluid, and loosen the bleeder fit-ting.

7. When air bubbles cease to appear inthe fluid at the submerged end of thebleeder tube, close the bleeder fittingand remove the tube.

8. Repeat steps 3 through 6 at the oppo-site wheel cylinder of the system beingbled.

9. When the bleeding operation is comp-leted, close the bleeder tank valve andremove the tank hose from theadapter fitting.

10. Remove the Pressure BleederAdapter Tool. Fill the master cylin-der reservoirs to within 1/4 inch fromthe top. Install the master cylindercover and gasket.

11. Centralize the pressure differentialvalve.

12. Install the brake warning light switchon the pressure differential valve on500-900 Series trucks.

CENTRALIZING THE PRESSUREDIFFERENTIAL VALVE

F-100-350, E-100-300, P-350-400and Bronco1. Turn the ignition switch to the ACC

LEFT FRAME SIDE RAIL BRAKE TUBES

CONNECTOR

FIG. 12 Front Brake TubeConnector—Typical

H1017-C

or ON position. Loosen the pressuredifferential valve inlet tube nut on thesystem that remained operative, orthe side opposite the system that wasbled last. Operate the brake pedalcarefully and gradually until the pres-sure differential valve is returned toa centralized position and the brakewarning light goes out. Tighten thetube nut.

2. Check the fluid level in the mastercylinder reservoirs and fill them towithin 1/4 inch of the top with thespecified C6AZ-19542-A extra heavyduty brake fluid.

3. Turn the ignition switch to the OFFposition.

500-900 Series Trucks with SplitHydraulic Brakes

The pressure differential valve usedwith the split hydraulic brake system hasa self centering spring. Use the followingprocedure to reset the valve:1. Remove the switch connector wire.2. Remove the threaded hex-shaped

electrical switch body from the centerof the valve. This allows the valve cen-tering springs to re-position the valve.

3. Install the electrical switch and con-nect the wire.

4. Apply the brakes a few times andcheck the operation of the warninglight. The light should go on with theignition switch in the START posi-tion only.

HYDRAULIC LINE REPAIR

Steel tubing is used in the hydrauliclines between the master cylinder and thefront brake tube connector (Fig. 12), andbetween the rear brake tube connector(Fig. 13) and the rear brake cylinders.Flexible hoses connect the brake tube tothe front brake cylinders and to the rearbrake tube connector.

When replacing hydraulic brake tub-ing, hoses, or connectors, tighten all con-nections securely. After replacement,bleed the brake system at the wheel cylin-ders and at the booster, if so equipped.

BRAKE TUBE

If a section of the brake tube becomesdamaged, the entire section should be re-placed with tubing of the same type, size,shape, and length. Copper tubing shouldnot be used in the hydraulic system.When bending brake tubing to fit theframe or rear-axle contours, be carefulnot to kink or crack the tube.

All brake tubing should be doubleflared to provide good leak-proof connec-tions. Always clean the inside of a newbrake tube with clean isopropyl alcohol.

REAR AXLE HOUSING ! 5 A K E H O S E VENi

CONNECTOR BRAKE TUBES H1018-C

FIG. 13 Rear Brake Tube Connector

BRAKE HOSE

A flexible brake hose should be re-placed if it shows signs of softening,cracking, or other damage.

When installing a new brake hose, po-sition the hose to avoid contact withother truck parts.



BRAKE DRUM REMOVAL ANDINSTALLATION THROUGH 1000SERIES

The service procedures covered hereapply to both hydraulic and air brakes.Since the F-100 through 350, E-100through 300, Bronco or the P-350, 400(front and rear) and the 4-wheel drivefront brake drum procedures apply to hy-draulic brakes only, they are covered inthe Removal and Installation Section ofPart 12-02.

FRONT BRAKE DRUM

1. Raise the truck until the wheel andtire clear the floor and remove thewheel and tire from the hub. Back offthe brake shoe adjusting screw so thatthe shoes do not contact the brakedrum. Remove the grease cap and thegasket (if so equipped) from the hub.

2. With 4,000 through 7,000 lb. and 18,-000 lb. front axles, remove the cotterpin, adjusting nut and flat washerfrom the spindle.On trucks with a 9,000 lb. or 11,000

or 15,000 lb. axle, remove the lock nut,the dimpled washer, the locking ring andthe adjusting nut and pin assembly.3. Remove the outer bearing cone and

roller. Pull the hub and drum assem-bly off the wheel spindle.

4. Remove the front wheel to hub retain-ing nuts or rim and tire attachingnuts. Remove the wheel or rim andtire from the hub and drum.

5. Remove the brake drum retainers andattaching bolts, screws, or bolts andnuts.

6. Remove the brake drum from thehub.

7. Check the drum for damage or wear,

and repair or replace as necessary. Ifa new drum is to be installed, be sureto remove the protective coating witha suitable degreaser.New grease retainer seals should be

installed whenever a wheel and hub isremoved.8. Place the brake drum to the hub and

install the retainers and retainingbolts, screws, or bolts and nuts.

9. Install the hub and drum on the wheelspindle. Keep the hub centered on thespindle to prevent damage to thegrease retainer or the spindle threads.

10. With 4,000 through 7,000 lb. and 18,-000 lb. front axles, install the outerbearing cone and roller and the flatwasher on the spindle, then install theadjusting nut. With front axles of 9,-000 lbs., 11,000 or 15,000 lbs.capacity, install the outer bearingcone and roller and the bearing ad-justing nut and pin assembly.

11. Install the wheel and tire on the hub,then install the clamps (if applicable)and the wheel stud nuts.

12. Torque the adjusting nut to specifica-tions while rotating the wheel. Referto Group 11 for the wheel bearingadjustment procedure.Install the dimpled washer with the

dimple indexed in one of the holes in theadjusting nut. Install the lock nut andtorque to specifications. Bend the dim-pled washer over a flat of the lock nut.13. Install the gasket (if so equipped) and

the grease cap, and torque the wheelstud nuts to specifications. Install thehub cap if so equipped, and adjust thebrakes.

REAR BRAKE DRUM

1. Raise the truck and install safety

stands.2. Remove the wheel and tire as an as-

sembly. Then back off the rear brakeshoe adjustment.

3. Remove the rear axle shaft retainingnuts, adapters, axle shaft, and greaseseal.

4. Remove the wheel bearing locknut,lock washer, and adjusting nut.

5. Remove the hub and drum from theaxle.

6. Remove the brake drum to hub re-taining screws, bolts, or bolts andnuts. Then remove the brake drumfrom the hub.

7. Check the drum for damage or wear,and repair or replace as necessary.Brake drums must not be machinedto a braking surface diameter gi eaterthan the maximum diameter shownon the drum. If a new drum is to beinstalled, be sure to remove the pro-tective coating with a suitable de-greaser.New grease retainer seals should be

installed whenever a wheel and hub isremoved.8. Position the brake drum to the hub

and install the attaching screws, bolts,or bolts and nuts.

9. Position the hub and drum as an as-sembly on the axle and start the ad-justing nut.

10. Adjust the wheel bearing nut andthen install the wheel bearing lockwasher and lock nut.

11. Install a new rear axle oil seal, axleshaft and gasket, stud adapters, andattaching nuts.

12. Install the wheel and tire as an assem-bly.

13. Adjust the brake shoes and thenremove the safety stands and lowerthe truck.

OVERHAUL

BRAKE DRUM REFINISHING

Minor scores on a brake drum can beremoved with fine emery cloth, providedthe emery is thoroughly cleaned off thedrum after the operation.

A badly scored, rough, or out-of-round drum should be ground or turnedon a drum lathe. Do not remove anymore material from the drum than isnecessary to provide a smooth surface forthe brake shoe contact. Brake drum max-imum braking surface diameter is shownon each brake drum (Fig. 14). Brakedrums which exceed the maximum brak-ing surface diameter shown on the brakedrum, either through wear or refinishing,

must be replaced. The maximum brakingsurface diameter specification, which isshown on each brake drum, allows for a0.060 inch machining cut over the origi-nal nominal drum diameter plus 0.030inch additional wear before reaching thedrum-discard diameter.

BRAKE SHOE AND BANDREUNING

1. Remove the rivets and remove the oldlining.

2. Clean the shoe or band thoroughlywith cleaning fluid, especially the rimsurface. Wipe the shoe or band dry

and remove all burrs or rough spotsfrom the shoe.

3. On service brake, check the in side dia-meter of the brake drum.

4. Position the new lining on the shoe orband and install new rivets, beginningwith the rivet holes near the center ofthe shoe. On some vehicles, the pri-mary lining is shorter than the se-condary lining. If this conditionexists, position the shorter (primary)lining to line up with the heel end ofthe shoe. Do not let brake fluid, oilor grease touch the brake lining. If abrake lining kit is used to replace theworn linings, install all the parts sup-plied in the kit.


5. Check the clearance between the lin-ing and shoe rim. The lining must seatsnugly against the rim with not morethan 0.005 inch separation midwaybetween any two rivets. If only thelinings are replaced on duo-servo sin-gle anchor brakes with fixed anchorpins, the brake linings must be camground 0.010 inch at the ends afterthe linings are riveted to the brakeshoe.

FRONT DISC BRAKES

1. Remove the wheel and tire, brakeshoe retainers, and the shoe and lin-ings as outlined in Part 12-24.

2. Make three thickness measurementswith a micrometer across the middlesection of the shoe and lining. Takeone reading at each side and one inthe center. If the assembly has wornto a thickness of 0.210 inch (Shoe andlining together) at any one of the threemeasuring locations, or if the liningshows evidence of brake fluid or oilcontamination that is causing a brakepull, replace all (4) shoe and liningassemblies.

3. Check caliper to spindle attachingbolt torque. Torque them to specifica-tion if required.

4. To check rotor runout, first eliminatethe wheel bearing end play by tighten-ing the adjusting nut. After tighteningthe nut, check to see that the rotor canstill be rotated.

5. Clamp a dial indicator to the spindle

H1834-A

FIG. 14 Brake Drum MaximumBraking Surface DiameterMarking Location—TypicalMedium—Heavy TruckShown

so that the stylus contacts the rotorat a point approximately 1 inch fromthe outer edge. Rotate the rotor andtake an indicator reading. If the read-ing exceeds 0.010 inch total lateralrunout within a six inch radius on the

indicator, replace or resurface the discbrake rotor. The following require-ments must be met when resurfacingdisc brake rotors (Fig. 15).Rotunda Disc Brake Refinishing

Lathe, Tool FRE-1466-B should be usedto refinish the disc brake rotors. The step-by-step resurfacing procedure providedwith the tool must be adhered to.

A maximum of 0.020 inch materialmay be machined equally off each surface(A and B) maintaining a 0.940 inch mini-mum thickness.

The finished braking surfaces of therotor must be flat and parallel within 0.-001 inch; lateral runout must not exceed0.010 inch total indicator reading withina six inch radius, and the surface finishof the braking surfaces are to be 15-80micro inches.

When the runout check is finished, besure to adjust the bearings as outlined inPart 11-10, in order to prevent bearingfailure.6. Check the rotor for scoring. Minor

socres can be removed with a fine em-ery cloth. If the rotor is excessivelyscored, refinish it as outlined in Step5 or replace the rotor if required.

7. Visually check the caliper. If it iscracked or if any leakage is evident,it should be replaced. Any leakagearound the dust boot indicates theneed for removal and disassembly.

8. Check brake hoses for signs of crack-ing, leaks, or abrasion. Replace ifnecessary.

BRAKE CYLINDER

1. Clean all brake cylinder parts in cleanisopropyl aocohol. Inspect all partsfor wear or damage. Check the cylin-der bore for rust, scores, or otherdamage. Be sure that the bleederscrew passage is clean and open. Re-place all parts that are worn or da-maged.

2. If dirt is found in any part of the hy-draulic system, flush the entire systemwith clean ispropyl alcohol.

MASTER CYLINDER

1. Clean all master cylinder parts inclean isopropyl alcohol, and inspectthe parts for wear or damage, replac-ing them as required. When a mastercylinder repair kit is used, install allof the parts supplied in the kit.

2. Check the ports and vents in the mas-ter cylinder to make sure that all areopen and free of foreign matter.

3. On a single brake system master cyl-inder, check to see if the spring valve(riveted to the front end of the piston)is loose or has moved so that the pis-ton ports are open, replace the piston.

4. Inspect the cylinder walls for scores

PRODUCTION WIDTHDIMINSION

MINIMUM OVERALLWIDTH-0.940 INCH

H1605-A

FIG. 15 Disc Brake Rotor ServiceLimits

or rust, and recondition them if neces-sary. Hone the cylinder walls no morethan necessary (0.003 inch max-imum), either to remove scores andrust, or to obtain a smooth wall sur-face. Remove any burrs or loose metalthat may have resulted from the hon-ing operation, and clean the cylinderwith clean isopropyl alcohol.

BRAKE DRUMS AND LININGS

1. After removing one front wheel anddrum and one rear wheel and drumfrom the vehicle, inspect the drumsand brake shoe linings for wear ordamage that would affect brake oper-ation. Do not let brake fluid, oil orgrease touch the drum or linings.

2. A brake shoe should be relined whenthe lining face is worn to within 1/32inch of any rivet head, or when thelining has been soaked with brakefluid, oil or grease. If a worn lining isnot replaced, the brake drum maybecome severely damaged. Always re-place the primary and secondarybrake shoe lining assemblies on bothfront or both rear brake assemblies atthe same time.

3. Before relining a brake shoe, inspectthe shoe for distortion, cracks, orlooseness between the rim and web. Ifone of these conditions exists, replacethe shoe. Do not attempt to repair adamaged brake shoe.

4. If the drum and linings are in goodcondition, install the wheel and drum.The condition of the drums and lin-ings of the opposite wheel will usuallybe about the same as that found at thewheel that was removed.

5. Add enough of the specified brakefluid to the master cylinder reservoirto bring the level to within 1/4 inchof the top of the filler neck.

6. Check to be sure that the parkingbrake handle is fully released beforemaking any brake adjustment.

7. Check the front brake anchor pin nutwith a wrench (on brake assemblieswith an adjustable anchor pin). If thebolt is loose, torque it to 80-100 ft-lbs.

12-01-14 Parking Brake—Cable Actuated, Rear Wheels 12-01-14

SPECIAL SERVICE TOOLS

SPECIAL TOOLS

Ford Tool No.

Rotunda ARE 345

Rotunda FRE1431

Description

Fuel Pump Tester Gauge

Brake Drum Micrometer

CH1737-A

12-02-1 Drum Brakes—Single Cylinder, Dual Piston 12-02-1

PART 12-02 Drum Brakes - Single Cylinder,Dual Piston

Applies To Bronco, Econoline and F-100 Thru L-800 Series Trucks

COMPONENT INDEX

BRAKE BACKING PLATE


BRAKE DRUMS


BRAKE MASTER CYLINDER

Disassembly and Overhaul


BRAKE PEDAL

Removal and Installation . . .

Page

02-6

02-2

02-14

02-7

02-11

COMPONENT INDEX

BRAKE SHOES

Adjustment


BRAKEWHEEL CYLINDER

Disassembly and Overhaul


SPECIFICATIONS

Page

02-1

02-3

02-14

02-6

02-20

ADJUSTMENTS

The brake drums should be at normalroom temperature, when the brake shoesare adjusted. If the shoes are adjustedwhen the shoes are hot and expanded, theshoes may drag as the drums cool andcontract.

A brake adjustment re-establishes thebrake lining-to-drum clearance and com-pensates for normal lining wear.

Adjustment procedures for each typeof brake assembly are given under theapplicable heading.

Self Adjusting Brakes—F-100-350,E-100-300, P-350-400 and Bronco

The brake shoes are automatically ad-justed when the vehicle is driven in re-verse and the brakes applied. A manualadjustment is required only after thebrake shoes have been relined or re-placed. The manual adjustment is per-formed while the drums are removed,using the tool and the procedure detailedbelow.

H 1411 - B

FIG. 1 Measuring Drum

When adjusting the rear brake shoes,check the parking brake cables for properadjustment. Make sure that the equalizeroperates freely.

To adjust the brake shoes:1. Use Rotunda Tool HRE865O, (Fig. 1)

and adjust to the inside diameter ofthe drum braking surface.

2. Reverse the tool as shown in Fig. 2.and adjust the brake shoes to touchthe gauge. The gauge contact pointson the shoes (Fig. 2) must be parallelto the vehicle with the center linethrough the center of the axle. Holdthe automatic adjusting lever out ofengagement while rotating the adjust-ing screw, to prevent burring thescrew slots. Make sure the adjustingscrew rotates freely. If necessary, lu-bricate the adjusting screw threadswith a thin, uniform coating ofC1AZ-19590-B grease.

3. Apply a small quantity of C1AZ-19590-B high temperature grease tothe points where the shoes contact thecarrier plate, being careful not to getthe lubricant on the linings.

4. Install the drums. Install the retainingnuts and tighten securely.

5. Install the wheels on the drums andtighten the mounting nuts to specifi-cations.

6. Complete the adjustment by applyingthe brakes several times while backingthe vehicle.

7. After the brake shoes have been prop-erly adjusted, check the operation ofthe brakes by making several stopswhile operating in a forward direc-tion.

H 1412-B

FIG. 2 Measuring Shoes

Front Brake—P-500

Manual AdjustmentThe single anchor brake is adjusted by

turning an adjusting screw located be-tween the lower ends of the shoes.1. Raise the vehicle until the wheels

clear the floor.2. Remove the cover from the adjusting

hole at the bottom of the brake car-rier plate, and turn the adjustingscrew inside the hole to expand thebrakes shoes until they drag againstthe brake drum and lock up the drum.Back off the adjusting screw until aslight drag is noted (Fig. 3).

3. When the shoes are against the drum,back off the adjusting screw 10 to 12notches so that the drum rotatesfreely without drag. If the drum doesnot rotate freely, remove the wheeland drum, and then blow out the dustand dirt from the linings. With sandpaper, remove all rust from the pointswhere the shoes contact the carrier


plate and apply a light coating of hightemperature grease (C1AZ-1959O-B).Be careful not to get the lubricant onthe linings.

4. Install the wheel and drum, and ad-just the shoes. Install the adjustinghole cover on the brake backing plate.

5. Check and adjust the other threebrake assemblies.

6. Apply the brakes. If the pedal travelsmore than halfway down between thereleased position and the floor, toomuch clearance exists between thebrake shoes and the drums. Repeatsteps 2 and 3 above.

7. When all brake shoes have been prop-erly adjusted, lower the vehicle. Roadtest the vehicle and check the opera-tion of the brakes. Perform the roadtest only when the brakes will applyand the vehicle can be safely stopped.

H1006-B

FIG. 3 Single Anchor Brake ShoeAdjustment


BRAKE DRUMS

Front Brake Drum—F-100-350 (4 x2), E-100-300, and P-350-4000 Series

Removal1. Raise the vehicle so that the wheel is

clear of the floor.2. Remove the wheel cover or hub cap,

wheel, bearing dust cap. Remove thecotter pin, nut lock, nut, and washer.

3. Pull he brake drum approximatelytwo inches forward and push backinto position. Remove the wheel bear-ing and withdraw the brake drum.If the brake drum will not come off,

insert a narrow screwdriver through thebrake adjusting hole in the carrier plate,and disengage the adjusting lever fromthe adjusting screw. While thus holdingthe adjusting lever away from the adjust-ing screw, back off the adjusting screwwith the brake adjusting tool (Figs. 4 and5). Back off the adjustment only if thedrum cannot be removed. Be very carefulnot to burr, chip, or damage the notchesin the adjusting screw; otherwise, the selfadjusting mechanism will not functionproperly.

If the adjusting screw was backed off,check to make sure that the adjustinglever is still properly seated in the shoeweb.

Installation in the shoe web.1. If the hub and drum assembly is being

replaced, remove the protective coat-ing from the new drum with carbure-tor degreaser. Install new bearingsand grease retainer. Soak a newleather grease retainer in light engine

oil at least 30 minutes before installa-tion. If the grease retainer is synthetic,it should be dipped in light engine oil.Pack the wheel bearings, install theinner bearing cone and roller assem-bly in the inner cup, and install thenew grease retainer.If the original drum is being installed,

make sure that the grease in the hub isclean and adequate.2. Install the drum assembly, outer

wheel bearing, washer and adjustingnut.

3. Adjust the wheel bearing, install thenut lock and cotter pin, then installthe grease cap.

4. Install the wheel and hub cap. If theadjustment was backed off, adjust thebrake as outlined under Brake ShoeAdjustment.

Rear Brake Drum—F-100,E-100-200 and Bronco

Removal

1. Raise the vehicle so that the wheel isclear of the floor.

2. Remove the hub cap and wheel andtire assembly. Remove the three re-taining nuts and remove the brakedrum.If the brake drum will not come off,

insert a narrow screwdriver through thebrake adjusting hole in the backing plate,and disengage the adjusting lever fromthe adjusting screw. While thus holdingthe adjusting lever away from the adjust-ing screw, back off the adjusting screwwith the brake adjusting tool (Fig. 4).Back off the adjusting screw if the drum

cannot be removed. Be very careful notto burr, chip, or damage the notches inthe adjusting screw; otherwise the selfadjusting mechanism will not functionproperly.

If the adjusting screw was backed off,check to make sure that the adjustinglever is still properly seated in the shoeweb.

Installation1. Remove the protective coating from

a new drum with carburetor de-greaser.

2. Adjust the brakes as outlined underBrake Shoe Adjustments.

3. Install the drum.4. Install the three retaining nuts and

tighten securely. Install the wheel onthe axle shaft flange studs against thedrum, and tighten the retaining nutsto specifications.

Rear Brake Drum—F-250 (HeavyDuty) 350, E-300, P-350

Removal1. Raise the truck and install stands.2. Remove the wheel and tire as an as-

sembly. Then back off the rear brakeshoe adjustment.

3. Remove the rear axle retaining nuts,adapters, axle shaft, and grease seal.

4. Remove the wheel bearing locknut,lock washer, and adjusting nut.

5. Remove the hub and drum from theaxle.

6. Remove the brake drum to hub re-taining screws, bolts, or boks andnuts. Then remove the brake drumfrom the hub.


Installation1. Check the drum for damage or wear,

and repair or replace as necessary. Ifa new drum is to be installed, be sureto remove the protective coating witha suitable degreaser.New grease retainer seals should be

installed whenever a wheel and hub isremoved.2. Position the brake drum to the hub

and install the attaching screws, bolts,or bolts and nuts.

3. Position the hub and drum as an as-sembly on the axle and start the ad-justing nut.

4. Adjust the wheel bearing nut andthen install the wheel bearing lockwasher and locknut.

5. Install a new rear axle oil seal, axleshaft and gasket, stud adapters, andattaching nuts.

6. Install the wheel and tire as an assem-bly.

7. Adjust the brake shoes and thenremove the stand and lower the truck.

Front Brake Drum—F-100-250 (4 x4) and Bronco

Removal1. Raise the vehicle and install stands.2. Back off the brake shoe adjustment.

Remove the hub dust cap.Remove the hub retaining snap ring,

..and slide the splined driving hub frombetween the axle shaft and the wheel hub.Remove the driving hub spacer andspring.3. With Tool T59T-1197-B, remove the

lock nut, the nut lock, and the wheelbearing adjusting nut from the steer-ing spindle. Remove the wheel, huband drum as an assembly. The wheelouter bearing will be forced off thespindle at the same time. Remove the

" wheel inner bearing cone.

RUBBER PLUGREMOVED

•MOVE HANDLE UPWARDTO RETRACT BRAKE SHOES

H1590-A

FIG. 4 Backing Off BrakeAdjustment—F-200-250,E0100-200, and Bronco

If the vehicle is equipped with a lock-ing type hub refer to Part 11-12.4. Remove the front wheel to hub retain-

ing nuts. Remove the wheel and tirefrom the hub and drum.

5. Remove the brake drum retainingbolts and nuts.

6. Remove the brake drum from thehub.

Installation1. Place the brake drum to the hub and

install the retaining bolts and nuts.2. Install the wheel and tire to the hub

and start the retaining nuts.3. Install the wheel hub and drum as-

sembly on the spindle. Install thedriving hub spacer and then the wheelouter bearing cone and the adjustingnut with the dowel outboard.

4. Rotate the wheel in both directionsand at the same time tighten the innerlocknut to 50 ft-lbs with tool T59T-1197-A, to bring the bearing rollersinto proper contact. After the bear-ings are firmly seated, back off theinner locknut and retighten to 30 to40 ft-lbs while hub is rotated.

5. Back off the inner locknut 135 de-grees to 150 degrees. Assemble thelockwasher by turning the nut to thenearest hole in the washer lock. In-stall the outer lock nut and torque to50 ft-lbs minimum.

6. Slide the driving hub on the axle shaftand install the snap ring.If the vehicle is equipped with a lock-

ing type hub, refer to Part 15-08.7. Adjust the brake, and then torque the

wheel nuts.8. Install the dust cap.9. Remove the stands and lower the

truck.

Brake Drums 500 Through 1000Series

Since the brake drum service proce-dures for these models apply to both hy-draulic and air brakes, they are coveredunder Removal and Installation in Part12-01.

BRAKE SHOE AND ADJUSTINGSCREW

F-100-250, E-100-200 and BroncoExcept Heavy DutyRemoval1. With the wheel and drum removed,

install a clamp over the ends of thebrake cylinder as shown in Fig. 6.

2. Contract the shoes as follows:a. Disengage the adjusting lever from

the adjusting screw by pullingbackward on the adjusting lever(Fig. 7).

b. Move the outboard side of the ad-justing screw upward and back offthe pivot nut as far as it will go.

•MOVE HANDLE DOWNWARDTO EXPAND BRAKE SHOES

H1582-A

FIG. 5 Backing Off BrakeAdjustment—F-250-350,E-300, and P-350-400

3. Pull the adjusting lever, cable and au-tomatic adjuster spring down and to-ward the rear to unhook the pivothook from the large hole in the se-condary shoe web. Do not attempt topry the pivot hook out of the hole.

4. Remove the automatic adjusterspring and adjusting lever.

5. Remove the secondary shoe to anchorspring with the tool shown in Fig. 6.With the same tool, remove the pri-mary shoe to anchor spring and un-hook the cable anchor. Remove theanchor pin plate, when so equipped.

6. Remove the cable guide from the se-condary shoe (Fig. 7).

7. Remove the shoe hold-down springs,shoes, adjusting screw, pivot nut, andsocket. Note the color of each hold-down spring for assembly.

8. On rear brakes, remove the parkingbrake link and spring. Disconnect theparking brake cable from the parkingbrake lever.

Removal-2035-N

Installation Tool—2035-N

FIG. 6 Spring Replacement

H1013-A


9. After removing the rear brake second-ary shoe, disassemble the parkingbrake lever from the shoe by remov-ing the retaining clip and springwasher (Fig. 7).

Installation

1. Before installing the rear brake shoes,assemble the parking brake lever tothe secondary shoe and secure withthe spring washer and retaining clip.

2. Apply a light coating of high tempera-ture grease (C1AZ-19590-B) at thepoints where the brake shoes contactthe backing plate.

3. Position the brake shoes on the back-ing plate, and install the hold-downspring pins, springs, and cups. Use thealuminum colored spring on the pri-mary shoe and the purple spring onthe secondary shoe. On the rear brakeinstall the parking brake link, springand washer. Connect the parkingbrake cable to the parking brake lever(Fig. 7).

4. Install the anchor pin plate, when soequipped, and place the cable anchorover the anchor pin with the crimpedside toward the backing plate.

5. Install the primary shoe to anchorspring with the tool shown in Fig. 6.

6. Install the cable guide on the second-ary shoe web with the flanged holesfitted into the hole in the secondarywhoe web. Thread the cable aroundthe cable guide groove (Fig. 7).It is imperative that the cable be posi-

tioned in this groove and not between theguide and the shoe web.7. Install the secondary shoe to anchor

(long) spring (Fig. 6).

Be certain that the cable end is notcocked or binding on the anchor pin wheninstalled. All'parts should be flat on theanchor pin. Remove the brake cylinderclamp.8. Apply high-temperature grease

(C1AZ-19590-B) to the threads andthe socket end of the adjusting screw.Turn the adjusting screw into the ad-justing pivot nut to the limit of thethreads and then back off 1/2 turn.Interchanging the brake shoe adjust-

ing screw assemblies from one side of thetruck to the other would cause the brakeshoes to retract rather than expand eachtime the automatic adjusting mechanismoperated. To prevent installation on thewrong side of the vehicle, the socket endof the adjusting screw is stamped with anR or L (Fig. 8). The adjusting pivot nutscan be distinguished by the number oflines machined around the body of thenut. Two lines indicate right hand nut;one line indicates a left hand nut.9. Place the adjusting socket on the

screw and install this assembly be-tween the shoe ends with the adjust-ing screw nearest the secondary shoe.

10. Hook the cable hook into the hole inthe adjusting lever from the backingplate side. The adjusting levers arestamped with an R or L to indicatetheir installation on the right or lefthand brake assembly (Fig. 8).

11. Position the hooked end of the ad-juster spring in the large hole in theprimary shoe web, and connect theloop end of the spring to the adjusterlever hole.

12. Pull the adjuster lever, cable and au-tomatic adjuster spring down toward

OCKtT

ADJUSTING SCRE*

IDENTIFICATION LINES

H1621-B

FIG. 8 Adjusting Screw and LeverIdentification—F-100-250,E-100-200 and Bronco

the rear to engage the pivot hook inthe large hole in the secondary shoeweb (Fig. 7).

13. After installation, check the action ofthe adjuster by pulling the section ofthe cable between the cable guide andthe adjusting lever toward the se-condary shoe web far enough to liftthe lever past a tooth on the adjustingscrew wheel. The lever should snapinto position behind the next tooth,

ANCHOR PIN ANCHOR PIN PLATE ANCHOR PIN PLATE

FORWARD

BRAKECYLINDER

BRAKE CYLINDER

PARKING BRAKE LEVERRETAINING CLIP

WASHER

RETRACTINGSPRING


BRAKE SHOEHOLD-DOWN

SPRINGS


AUTOMATICADJUSTERSPRING

°ARKINGBRAKELEVER

PIVOT HOOK

PARKING BRAKE CABLE

PIVOTNUT ADJUSTING

SCREW

PARKING BRAKE CABLE ADJUSTINGHOUSING RETAINER SCREW

FRONT BRAKE

FIG. 7 Self Adjusting Brake Assemblies—F-l00-250, E-l00-200, and Bronco

ADJUSTING LEVER

REAR BRAKE H1340-D


and release of the cable should causethe adjuster spring to return the leverto its original position. This returnaction of the lever will turn the ad-justing screw one tooth.If pulling the cable does not produce

the action described, or if the lever actionis sluggish instead of positive and sharp,check the position of the lever on the ad-justing screw toothed wheel. With thebrake in a vertical position (anchor at thetop), the lever should contact the adjust-ing wheel one tooth above the center lineof the adjusting screw. If the contactpoint is below this center line, the leverwill not lock on the teeth in the adjustingscrew wheel, and the screw will not beturned as the lever is actuated by the ca-ble.

To determine the cause of this condi-tion:a. Check the cable end fittings. The cable

should completely fill or extendslightly beyond the crimped section ofthe fittings. If it does not meet thisspecification, possible damage is in-dicated and the cable assembly shouldbe replaced.

b. Check the cable guide for damage. Thecable groove should be parallel to theshoe web, and the body of the guideshould lie flat against the web. Replacethe guide if it shows damage.

c. Check the pivot hook on the lever. Thehook surfaces should be square withthe body on the lever for proper pivot-ing. Repair the hook or replace thelever if the hook shows damage.

d. See that the adjusting screw socket isproperly seated in the notch in theshoe web.

F-250 (Heavy Duty) 350, E-300,P-350-400 Series—Web Ledge

Removal

1. Remove the wheel and drum. If thedrum does not clear the brake shoes,retract the brake shoes as shown inFig. 5.

2. On a front wheel, remove the spring-clip retainer fastening the adjustingcable anchor fitting to the brake an-chor pin (Fig. 9).On a rear wheel, remove the parking

brake lever assembly retaining nut frombehind the backing plate and remove theparking brake lever assembly (Fig. 10).

From this point on the disassembly ofthe front and rear brake assemblies arethe same.3. Remove the adjusting cable from the

anchor pin, cable guide and adjustinglever spring.

4. Remove the brake shoe retractingsprings.

5. Remove the brake shoe hold-downspring from each shoe.

6. Remove the brake shoes and adjust-ing screw assembly.

7. Disassemble the adjusting screw as-sembly.

Installation1. Clean the ledge pads (6) on the back-

ing plate. Sand lightly to bare metal.2. Apply a light coat of (C1AZ-19590-

B) high temperature grease on theledge pads of the backing plate. Alsoapply C1AZ-1959O-B high tempera-ture grease to the retracting and hold-down spring contacts on the brakeshoes and backing plate.

3. Apply C1AZ-1959O-B high tempera-ture grease on the threads and socketend of the adjusting screw.

4. Install the upper retracting spring onthe primary and secondary shoes asshown in Fig. 9 and position the as-sembly on the backing plate with thewheel cylinder push rods positionedin the shoe slots.

5. Install the brake shoe hold-downsprings (Fig. 10).

6. Install the brake shoe adjustmentscrew assembly (the slot in the headof the adjusting screw toward the pri-mary shoe), lower retracting spring,adjusting lever spring, adjusting leverassembly and connect the adjustingcable to the adjusting lever. Positionthe cable in the cable guide and installthe cable anchor fitting on the anchorpin.Interchanging the brake shoe adjust-

ing screw assemblies from one side of thetruck to the other would cause the brakeshoes to retract rather than expand eachtime the automatic adjusting mechanismoperated. To prevent installation on thewrong side of the vehicle, the socket endof the adjusing screw is stamped with anR or L (Fig. 10). The adjusting pivot nutscan be distinguished by the number oflines machined around the body of thenut. Two lines indicate right hand nut;one line indicates a left hand nut.7. On a rear wheel, install the parking

brake assembly in the anchor pin andsecure with the retaining nut behindthe backing plate.

8. Adjust the brakes before installing thedrums, using Rotunda Tool HRE-8650, as outlined in this Part.

ADJUSTING CABLE ANCHOR FITTING


FORWARD

ANCHOR PIN PLATE

PARKING BRAKE LEVERASSEMBLY BOLT

BRAKE CYLINDER


RETRACTINGCABLE GUIDE SPRING

RETRACTINGSPRING

BRAKE ADJUSTINGTOOL CONTACT

POINT

PRIMARY SHOE \AND LINING

RETRACTINGSPRING

ADJUSTING SCREWSOCKET

ADJUSTING SCREW

FRONT BRAKE

BRAKE SHOEHOLD-DOWN

SPRINGS


CABLE HOOK

OVER TRAVEL SPRING

PARKING BRAKE CABLE

PARKINGBRAKE LEVER

LEFT SIDE OF VEHICLE

OVER TRAVEL SPRING

ADJUSTING SCREW SLOTS ADJUSTING LEVER

REAR BRAKE H1581-C

FIG. 9 Self Adjusting Brake Assemblies—F-250 (Heavy Duty)—350, E-300 and P-350-400

12-02-6 Drum Brakes—Single Cylinder, Dual Piston IZ-UZ-0

BRAKE WHEEL CYLINDER

Removal1. Remove the wheel, drum, and brake

shoes. Remove the cylinder-to-shoeconnecting links.

2. Disconnect the brake line from thebrake cylinder.

3. Remove the brake cylinder retainingbolts and lockwashers, and thenremove the cylinder from the backingplate.

Installation1. Position the brake cylinder on the

backing plate and install the retainingbolts and lockwashers.

2. Install a new gasket on the brake linefitting and connect the line to thebrake cylinder.

3. Install the brake shoes and the con-necting links between the shoes andcylinder. Install the drum and thewheel.

4. Adjust the brakes and bleed the sys-tem. Check the pedal operation beforemoving the vehicle.

BRAKE BACKING PLATE

F-100-250, E-100-200 and Bronco(Except 4 x 4 Front)Removal1. Remove the wheel and brake drum.

Disconnect the brake line from thebrake cylinder and submerge the endof the brake line in a can containing

a small amount of brake fluid. Thiswill minimize hydraulic line bleeding.Remove the brake shoes and thebrake cylinder. On the rear wheels,disconnect the parking brake leverfrom the cable.

2. If the rear backing plate is beingremoved, rotate the axle shaft so thatthe hole in the axle shaft flange alignswith the backing plate retaining nuts,then remove the nuts. Pull the axleshaft assembly out of the housingwith tool 4235-C, and a slide hammertool T50T-100-C, (Fig. 11). Lift offthe backing plate.If the front backing plate is being re-

placed, remove the bolts and nuts thatsecure the plate to the front wheel spindleand lift off the plate.

Installation

1. Position the rear backing plate on theretaining bolts in the axle housingflange. Insert the axle shaft assemblyinto the housing so that the splinesengage the differential side gear, withthe bearing retainer sliding onto theretaining bolts and against the carrierplate. Install the retaining nutsthrough the access hole in the axleshaft flange.Position the front backing plate on the

wheel spindle and install the retainingbolts and nuts.2. Install the brake cylinder and brake

shoes. On a rear brake, connect the

Tool-4235-C

FIG. 11 Axle Shaft Removal

parking brake cable to the lever.3. Connect the brake line to the brake

cylinder, then install the wheel andbrake drum. Adjust the brake shoesand bleed the hydraulic system

F-100 4 x 2 Series with Spicer 60—3Axle—Rear

Brake backing plate removal and in-stallation procedure is similar to thatused on the F-100 Ford axle. Hov/ever,certain precautions are necessary if ;a newbacking plate is installed, since the side-to-side end play of the rear axle shafts canbe affected. When replacing a brake back-ing plate with a new or different plate,refer to Group 15—Rear Axle, for assem-bly procedure including end-play adjust-ments, etc.

F-100-250 4 x 4 and BroncoSeries—Front

Removal1. Raise the vehicle on a hoist.2. Remove the hub grease cap. Remove

the hub retaining snap ring, and slide

LOCKNUTBRAKE CYLINDER

2262

2A142

PARKING BRAKELEVER -2A6372A638

PARKING BRAKEASSEMBLY BOLT

SECONDARYSHOE ASSY.

2219

ADJUSTING LEVER2A176

PRIMARY SHOE

RETRACTINGSPRING-2049

ADJUSTING ADJUSTING SCREWSCREW-2041 SOCKET-2047

H1430-C

FIG. 10 Rear Web Ledge Single Anchor Brake—Disassembled


the splined driving hub from betweenthe axle shaft and the wheel hub.Remove the driving hub spacer.If the vehicle is equipped with a lock-ing type hub, refer to Part 15-08.

3. Remove the lock nut, washer, andwheel bearing adjusting nut from thesteering spindle. Remove the wheel,hub and drum as an assembly (Fig.12). The wheel outer bearing will beforced off the spindle at the sametime. Remove the wheel inner bearingcone.

4. Remove the cap screws which retainthe brake backing plate and spindle tothe spindle arm. Remove the brakebacking plate and spindle.

Installation1. Position the spindle and the brake

backing plate on the steering arm, andthen install the retaining cap screws.

2. Install the wheel inner bearing coneon the spindle. Install the wheel huband drum. Install the driving hubspacer and then the wheel outer bear-ing cone and adjusting nut.

3. Rotate the wheel in both directionsand at the same time tighten the innerlocknut to 50 ft-lbs to bring the bear-ing rollers into proper contact. Afterthe bearings are firmly seated, backoff the inner locknut and retighten to30 to 40 ft-lbs while hub is rotated.Back off the inner locknut 135 de-grees to 150 degrees. Assemble thelockwasher by turning the nut to thenearest hole in the washer lock. In-stall the outer lock nut and torque to50 ft-lbs, (Fig. 12).

4. Install the driving hub and snap ring.Install the grease cap.

300 Through 900 Series

Removal1. From front wheel spindles, remove

the hub and drum attaching parts (ax-

AXLE SHAFT LOCK NUT

WHEEL HUB SPINDLEH1625-A

FIG. 12 Front WheelHub—Four-Wheel Drive

les under 9,000 lbs capacity greasecap and gasket if so equipped, cotterpin, bearing adjusting nut and flatwasher). (Axles 9,000 lbs capacity orover-grease cap and gasket, lock nut,dimpled washer, locking ring, andbearing adjusting nut and pin assem-bly). Then, remove the outer wheelbearing and the hub and drum assem-bly from the spindle.

2. On rear wheels, remove the rear axleshaft flange retaining nuts and axleshaft. Remove the rear wheel bearinglock nut, lock washer, and adjustingnut, then remove the hub and drumassembly from the axle housing. Dis-card the grease seal.

3. Remove the brake shoes and adjust-ing screw from the backing plate asoutlined in this Section. Disconnectthe brake line from the brake cylinderand submerge the end of the brakeline in a can containing a smallamount of brake fluid. This will mini-mize hydraulic line bleeding.

4. Remove the backing plate retainingbolts and nuts, then remove the back-ing plate from the front wheel spindleor rear axle housing.

5. Remove the attaching bolts and lockwashers, and the brake cylinder fromthe backing plate.

Installation

1. Assemble the brake cylinder to thebacking plate with the attaching boltsand lock washers.

2. Mount the backing plate to the frontwheel spindle or to the rear axle hous-ing flange, and secure with the attach-ing bolts and nuts.

3. Install the brake shoes and adjustingscrew to the backing plate as outlinedin this section. Connect the brake lineto the brake cylinder.

4. Install a front wheel hub and drumassembly and the outer wheel bearingto the spindle. Install the hub anddrum attaching parts (axle under 9,-000 lbs capacity-flat washer, bearingadjusting nut, cotter pin, grease cap,and gasket if so equipped, axles 9,000lbs capacity or overbearing adjustingnut and pin assembly, locking ring,dimpled washer, lock nut, and greasecap and gasket). Adjust the frontwheel bearings as outlined in Group11.Install a rear wheel hub and drum as-

sembly on the rear axle housing. The rearhub oil seal must be replaced whenevera hub is removed or installed. Install theouter bearing and the adjusting nut, thenadjust the wheel bearings. Install the lockwasher and lock nut, then torque tospecifications. Install the rear axle shaft,gasket and attaching nuts, then torque tospecifications.5. Install the wheel and tire.

H1330-D

FIG. 13 Bendix Booster Push RodGauge Dimensions andAdjustment

6. Bleed the hydraulic system and adjustthe brake shoes.


F-100-600, P-350-400 and L-500-600Series— Power Brake—DashMounted Booster

Removal1. With the engine stopped, depress the

brake pedal to expell vacuum or airpressure from the brake booster sys-tem.

2. Disconnect the hydraulic lines fromthe brake master cylinder.

3. Remove the brake booster to mastercylinder retaining nuts and lockwash-ers. Remove the master cylinder fromthe brake booster.

Installation1. Before installing the master cylinder,

check the distance from the outer endof the booster assembly push rod tofront face of the brake booster as-semby. Turn the push rod adjustingscrew in or out as required to obtainthe specified length (Fig. 13).

2. Position the master cylinder assemblyover the booster push rod and ontothe two studs on the booster assem-bly. Install the attaching nuts andlockwashers and torque them tospecifications.

3. Connect the hydraulic brake systemlines loosely to the master cylinder.

4. Bleed the hydraulic brake system asoutlined in this section of the manual.Centralize the differential valve as ou-


tlined in this Section of the manual.Then, fill the dual master cylinderreservoirs to within 1/4 inch of thetop with the specified C6AZ-19542-Abrake fluid. Install the gasket (dia-phragm) and filler cap.

F-100-350 and P-350-400Series—Non-Power Brake

RemovalRefer to Figure 14.

1. Working from inside the vehicle be-low the instrument panel, disconnectthe wires from the stop light switch.

2. Disconnect the dust boot from therear of the master cylinder at the dashpanel.

3. Remove the retaining nut, shoulderbolt, spacers and bushing securing themaster cylinder push rod and the stoplight switch to the brake pedal assem-bly. Remove the switch.

4. Remove the boot from the master cyl-inder push rod.

5. Disconnect the brake hydraulic sys-tem lines from the master cylinder.

6. Remove the master cylinder to dashpanel retaining screws, and removethe master cylinder.

Installation

1. Position the master cylinder assemblyon the dash panel within the enginecompartment and install the retainingscrews and washers. Tighten the

screws to specification.2. Connect the hydraulic brake system

lines loosely to the master cylinder.3. Working from inside the vehicle be-

low the instrument panel, position theboot over the push rod and secure theboot to the master cylinder.

4. Lubricate the push rod bushing withlubricant (Lubriplate). Position thebushing in the push rod.

5. Position the stop light switch on thepush rod. Install the shoulder boltand spacers. Make sure the bushingsand spacers are installed properly.Secure the push rod and stop lightswitch to the brake pedal assemblywith the self-locking nut.

6. Connect the wires to the stop lightswitch.

7. Bleed the hydraulic brake system asoutlined in this section of the manual.Centralize the differential valve as ou-tlined in this Section of the manual.Then, fill the dual master cylinderreservoirs to within 1/4 inch of thetop with the specified brake fluid. In-stall the gasket (diaphragm) and fillercap.

Econoline and Bronco

Removal1. Disconnect the wires from the stop-

light switch (Fig. 15 and 16).2. Disconnect the brake hydraulic sys-

tem lines at the master cylinder.

BRAKE PEDAL COTTER PINASSEMBLY

RETAINER

WASHER \

BUSHING 2461

INSULATOR BUSHING

SPRING

- SUPPORT ASSEMBLY

WASHERINSULATORASSEMBLY SELF-LOCK NUT BUMPER

THIS LOCATION FOR ALL MODELS EXCEPT (4x2)MODELS WITH 240 C.I.D. ENGINE

SHAFTTHIS LOCATION FOR

(4x2) MODELSWITH 240 C.I.D. ENGINE BUSHING

2461

BRAKEPEDAL ASSEMBLY —BUSHING 2461

AUTOMATIC TRANSMISSION

BRAKE PEDAL ASSEMBLY 2455

SELF-LOCK NUT

SCREW ANDWASHER ASSEMBLY

BOOT

PEDALPAD

LIGHTSWITCH RETAINER

SHOLDERBOLT STOPLIGHT SWITCH H 1504-E

FIG. 14 Dual Master Cylinder and Brake Pedal Installation—Non-PowerBrakes—F-100-350

3. On Bronco models, remove the hairpin retainer and slide the stoplightswitch off the brake pedal pin just farenough for the switch outer hole toclear the pin. Remove the stop lightswitch from the pin.Econoline models, remove the shoul-

der bolt and nut retaining the push rodto the brake pedal. Remove the push rodbushing.4. Slide the master cylinder push rod off

the brake pedal pin. Remove thebushings and washers.

5. Remove the master cylinder retainingbolts and remove the master cylinder.

Installation1. Position the master cylinder assembly

on the dash panel and install the re-taining bolts. Torque the bolts tospecification.

2. Connect the hydraulic brake systemlines to the master cylinder.

3. On Bronco models, lubricate the pushrod bushing with lubricant (SAE1OW-2OW-3O). Insert the bushing inthe push rod. Coat the washers withthe lubricant, and position the pushrod and bushing, washers and stoplight switch on the brake pedal pin.Install the hair pin type retainer.

4. On Econoline models, lubricate thepush rod bushing. Insert the bushingin the push rod and install the shoul-der bolt securing the push rod to thebrake pedal.

5. Connect the stop light switch wires tothe switch.

6. Bleed the hydraulic brake system.

F-500-950, L-500-750 andLT-800-850 Series— Single BrakeSystem

RemovalIf the vehicle is equipped with a

vacuum booster, the engine must bestopped and all vacuum must be expelledfrom the booster system before the hy-draulic lines are disconnected.1. Disconnect the brake line from the

brake fitting.2. Force as much brake fluid as possible

from the master cylinder into a suita-ble container by pushing down thebrake pedal all the way several :imes.

3. On a vehicle with conventionalbrakes, disconnect the rubber bootfrom the rear end of the master cylin-der in the cab. Remove the bolts thathold the master cylinder against thedash panel, and lift the cylinder awayfrom the push rod and out of the en-gine compartment.On vehicles equipped with a dash

mounted booster, remove the nuts andwashers that secure the master cylinderto the power booster unit, and remove themaster cylinder.


BRAKE PEDAL SUPPORT01500

MASTER CYLINDER ASSEMBLY2140

BUSHING2461

SCREW AND WASHER ASSEMBLY

/ \SELF-LOCKING NUT WASHER

34445-SBUMPER

7583BRAKE PEDAL ASSEMBLY

2455

H1475-B

FIG. 15 Brake Master Cylinder and Brake Pedal Installation—Bronco

BRAKE PEDAL SUPPORT


CLUTCH RODBUSHING

7526COTTER PIN

SPRINGRETAINER

MANUAL TRANSMISSION

0BUSHING

BRAKE PEDAL 2461ASSEMBLY

2455

\ BUSHING\ 2A309

AUTOMATIC SHOULDER BOLTTRANSMISSION 2462

CLUTCH PEDAL ASSEMBLY 7519

FIG. 16 Brake Master Cylinder and Brake Pedal Installation—Econoline

H1584-C


Installation

1. On a vehicle with conventionalbrakes, position the rubber boot onthe piston push rod, guide the mastercylinder over the end of the push rodand position the cylinder against themounting surface. Install the mount-ing bolts and torque them to specifica-tions.On vehicles equipped with a dash-

mounted booster, install the master cylin-der over the push rod onto the two studsin the power booster body. Install thelock washers and retaining nuts. Torquethe nuts to specifications.2. Connect the brake line to the master

cylinder fitting, but leave the brakeline fitting loose.

3. Fill the master cylinder reservoir withC6AZ-19542-A extra heavy dutybrake fluid to within 1/4 inch of thetop of the filler neck.

4. Push the brake pedal down slowly byhand several times to let air escape atthe brake line fitting. Hold the pedaldown and tighten the brake line fit-ting. Release the brake pedal. Do notrelease the brake pedal until the fit-ting is tightened as additional air willbe introduced into the master cylin-der.On vehicles equipped with dash-

mounted booster, the cylinder can be bledat the bleed screw on the cylinder.

On a vehicle with a frame-mounted

brake booster assembly, the master cylin-der can be bled at the booster screw(s).5. After seeing that the master cylinder

reservoir is filled with the specifiedfluid to within 1/4 inch to the top ofthe filler neck, install the filler cap.Wipe off any fluid from the outside ofthe cylinder and brake line.

6. Connect the rubber boot to the end ofthe cylinder.

7. Check and, if necessary, adjust thebrake pedal free-travel.

L-, LN-, and B-Series Split BrakeSystem and Frame MountedBooster

RemovalRefer to Figures 17 and 20.


2. On L- and LN-Series, remove theretaining nut, shoulder bolt, spacersand bushing securing the master cyl-inder push rod and the stop lightswitch to the brake pedal assembly.Remove the switch.On B-Series, remove the hair pin clip

from the brake pedal pin. Remove thepush rod, spacers, stop light switch, andbushing from the brake pedal pin.3. Remove the boot from the master cyl-

inder push rod.4. Disconnect the brake hydraulic sys-

tem lines from the master cylinder.5. Remove the master cylinder to dash

panel retaining screws and remove themaster cylinder.


on the dash panel within the enginecompartment and install the retainingscrews and washers. Tighten thescrews to specification.



4. On L- and LN-Series, position thestop light switch on the push rod, in-stall the shoulder bolt and spacers.Make sure the bushings and spacersare installed properly. Secure thepush rod and stop light switch to thebrake pedal assembly with the self-locking nut.On B-Series, install the spacers, push

rod, bushing and stop light switch on thebrake pedal pin. Install the hair pin re-tainer.5. Connect the wires to the stop light

switch.6. Bleed the hydraulic brake sysrem as

outlined in this section of the manual.Centralize the differential valve as ou-tlined in this section of the manual.Then, fill the dual master cylinderreservoirs to within 1/4 inch of thetop with C6AZ-19542-A extra heavyduty brake fluid. Install the gasket(diaphragm) and filler cap.

CLUTCH MASTER CYLINDER2140 BRAKE MASTER CYLINDER

2140

PUSH ROD

PEDAL RETRACTING SPRING

PEDAL SHAFT7506 VIEW A

FIG. 17 L-, LN-, or LT-Series Brake Pedal and Related Parts


C-Series Single Brake System

Removal

If the vehicle is equipped with avacuum or air booster, the engine mustbe stopped and all vacuum or air pressuremust be expelled from the booster systembefore the hydraulic lines are discon-nected.1. Roll back the floor mat, remove the

floor plate, and then disconnect thehydraulic line from the master cylin-der.

2. Force as much brake fluid as possiblefrom the master cylinder into a suita-ble container by pushing down thebrake pedal all the way several times.

3. Disconnect the rubber boot from therear end of the master cylinder in thecab.

4. Remove the two mounting bolts andlower the master cylinder away fromthe push rod and out of the cab.

Installation

1. With the rubber boot on the pistonpush rod, guide the master cylinderover the end of the push rod, and posi-tion the cylinder against the mountingsurface. Install the mounting bolts,and torque them to specifications.

2. Connect the brake line to the mastercylinder fitting, but leave the brakeline fitting loose.

3. Fill the master cylinder reservoir withthe specified brake fluid to within 1/4inch of the top of the filler neck.

4. Push the brake pedal down slowly byhand. Hold the pedal down andtighten the brake line fitting. Releasethe brake pedal. Do not release thebrake pedal until the fitting is tight-ened as additional air will be intro-duced into the master cylinder.Repeat this procedure until air ceasesto escape at the fitting and a firmpedal is obtained.On a vehicle with a brake booster as-

sembly, the master cylinder can be bledat the booster bleed screw(s).5. After seeing that the master cylinder

reservoir is filled with the specifiedC6AZ-19542-A extra heavy duty

BUSHING2461

brake fluid to within 1/4 inch of thetop of the filler neck, install the fillercap. Wipe off any fluid from the out-side of the cylinder and brake line.

6. Connect the rubber boot to the end ofthe cylinder. Install the floor plateand secure with the seven retainingscrews, and place the floor mat in itsproper position.


C-Series—Split Brake System

Refer to Figure 18.All vacuum must be relieved from the

booster before hydraulic lines are discon-nected.1. Disconnect the hydraulic lines from

the master cylinder. Trap the fluiddrip with a shop towel or plug theports.

2. Remove the bolt and nut connectingthe push rod to the brake pedal bellcrank and remove the stop lightswitch, bushing and spacers.

3. Remove the master cylinder mount-ing bolts and remove the master cylin-der from the vehicle.

InstallationRefer to Figure 18.

1. If the master cylinder is being re-placed, transfer the outlet ports to thenew master cylinder.

2. Position the master cylinder to thedash panel and install the mountingbolts.

3. Assemble the stop light switch, bush-ing and spacers on the push rod andinstall the bolt connecting the pushrod to the bell crank.

4. Connect the primary and secondaryoutlet tubes and tighten to specifica-tions.

5. Bleed the brake system.

DUAL BRAKE MASTER CYLINDERPRESSURE DIFFERENTIAL VALVEASSEMBLY

Removal

1. Raise the vehicle on a hoist. Discon-nect the brake warning light wire

LOCKNUT

34445-S2(12-17 FT. LBS.)

MASTERCYLINDER

2140

PEDAL SUPPORT

BRAKEPEDAL

2455

BRACKET2 6 3 5 3 STOP

SWITCH13480

SPACER2474

BOLT(20-29

BUSHING FT.-LBS.)2461

BOLT-2462H1661-B

FIG. 18 Dual Master Cylinder and Brake Pedal Installation—C-Series

from the pressure differential valveassembly switch. To prevent damageto the brake warning switch wire con-nector, expand the plastic lugs to al-low removal of the shell-wireconnector from the switch body.

2. Disconnect the brake hydraulic linesfrom the differential valve assembly.

3. Remove the screw retaining the pres-sure differential valve assembly to theframe side rail and remove the valveassembly.

4. If the differential valve is to be re-placed, remove the brake warninglamp switch and install the switch inthe new differential valve. The pres-sure differential valve assembly andthe brake warning lamp switch areseparate units and each is serviced asa separate assembly only.

Installation1. Mount the pressure differential valve

assembly on the frame side rail andtighten the attaching screw.

2. Connect the brake hydraulic systemlines to the differential valve assemblyand tighten the tube nuts securely.

3. Connect the shell-wire connector tothe brake warning lamp switch. Makesure plastic lugs on the connectorhold the connector securely to theswitch.

4. Bleed the brakes and centralize thepressure differential valve as outlinedin this Section of the manual.

BRAKE PEDAL ASSEMBLY

F-100-350-Series


1. Working inside the vehicle, below theinstrument panel, disconnect thewires from the stop light switch.

2. Disconnect the clutch pedal retract-ing spring and remove the insulators.Remove the retaining nut, shoulderbolt, and bushing securing the pushrod to the brake pedal assembly.

3. On an automatic transmissionequipped vehicle, remove the retainer,washer, bushings and shaft securingthe brake pedal to the support.Remove the brake pedal assembly.

4. On a standard transmission equippedvehicle, remove the cotter pin, nut,washer, bushings and lever securingthe brake pedal assembly to the sup-port. Remove the brake pedal assem-bly.

5. Remove the stop light switch from thebracket on the brake pedal.

6. If required, remove the pedal pad.

Installation1. If required, install the pedal pad on

the brake pedal assembly.2. Install the stop light switch retainer

and the stop light switch in the re-tainer on the brake pedal.

12-02-12 Drum Brakes—Single Cylinder, Dual Piston 12-U2-I2

3. On a standard transmission equippedvehicle, lubricate the bushings withlubricant (Lubriplate).Insert the bushings in the brake pedal

assembly, and install the brake pedal onthe shaft. Install the bushings, lever,washer, nut and cotter pin on the shafts.

Install the bushing in the lever. Con-nect the rod to the lever and install thecotter pin.4. On an automatic transmission

equipped vehicle, lubricate the bush-ings with lubricant (Lubriplate).Insert the bushings in the brake pedal

assembly. Position the bushing on theshaft. Insert the shaft through the sup-port and the pedal assembly.

Insert the outer bushing on the shaftand install the washer and retainer.5. Lubricate the push rod bushing with

lubricant (Lubriplate). Position thebushing on the push rod.

6. Install the shoulder bolt. Secure thepush rod to the brake pedal assemblywith the self-locking nut.

7. Connect the wire to the stop lightswitch.

8. Install the clutch pedal retractingspring insulators and the spring.

Bronco

Removal

Refer to Figure 15.1. Disconnect the wires from the stop

light switch.2. Remove the hair pin retainer (Fig. 15)

and slide the stop light switch off thebrake pedal pin just far enough for theswitch outer hole to clear the pin.Remove the stop light switch from thepin.

3. Slide the master cylinder push rod offthe brake pedal pin. Remove thebushing and washers.

4. Remove the cotter pin from the rightside of the brake and clutch pedalshaft.

5. Slide the shaft toward the left, justenough to allow removal of the brakepedal and two brake pedal bushings.

Installation

1. Coat the brake pedal bushings and theshaft with lubricant (Rotunda EngineOil SEA 1OW-2OW-3O).

2. Position the bushings, pedal and shafton the brake pedal support and installthe retaining cotter pin (Fig. 15).Spread the cotter pin ends.

3. Lubricate the master cylinder pushrod bushing with the lubricant. Insertthe bushing in the push rod. Coat thewashers with the lubricant, and posi-tion the push rod and bushing, wash-ers and stop light switch on the brakepedal pin. Install the hair pin type re-tainer.

4. Connect the wires to the stop lightswitch.

Econoline


1. Remove the shoulder bolt and nut re-taining the master cylinder push rodto the brake pedal.

2. On models with a manual transmis-sion, remove the clutch lever from theclutch pedal shaft.On models with an automatic trans-

mission, remove the spring retainer andwasher from the right end of the clutchpedal shaft.3. Slide the shaft toward the left, just

enough to allow removal of the brakepedal and two brake pedal bushings.

Installation1. Coat the brake pedal bushings and the

shaft with lubricant (Rotunda EngineOil SAE 10W-20W-30).

2. Position the bushings, pedal and shafton the brake pedal support.On Models with a manual transmis-

sion, install the clutch lever on the clutchpedal shaft.

On Models with an automatic trans-mission, install the washer and spring re-tainer on the clutch shaft.3. Lubricate the master cylinder push

rod bushing with the lubricant. Insertthe bushing in the push rod. Installthe shoulder bolt and nut securing themaster cylinder push rod to the brakepedal.

L-500-900, LN-, and LT-Series

Removal1. Remove the brake pedal retracting

spring (Fig. 17).2. Remove the brake master cylinder

push rod eccentric bolt nut, andremove the bolt and two nylon bush-ings.

3. Remove the nut from the pedal shaft.Then slide the shaft to the left andremove the brake pedal and sleeve.

4. Remove the two bushings from thepedal, and remove the bumper fromthe pedal extension bracket if soequipped.

Installation1. Coat all bushings and the pedal shaft

with a small quantity of Lubriplate oran equivalent lubricant.

2. Install the bumper on the pedal exten-sion bracket (if so equipped), and po-sition the nylon bushings in the brakepedal shaft bore.

3. Position the brake pedal assembly andsleeve in the pedal support bracket.Slide the pedal shaft through thesleeve and pedal and secure with thenut. Torque the nut to specifications.

4. Position the nylon bushings in thebore of the push rod. Connect thepush rod to the brake pedal with the

eccentric bolt and nut. Install thepedal retracting spring.

5. Adjust the brake pedal free travel to3/16-3/8 inch (Fig. 11, Part 12-01).Torque the eccentric bolt nut tospecifications.

P-350-4000-Series


1. Remove the brake master cylinderpush rod eccentric bolt nut, andremove the bolt and nylon bushing.

2. Remove the cotter pin and nut fromthe pedal shaft. Then slide the shaftto the right and remove the brakepedal sleeve.

3. Remove the two bushings from thepedal and the two bushings from thepedal support.

Installation1. Coat all bushings and pedal shaft with

a small quantity of Lubriplate or anequivalent lubricant.

2. Position the nylon bushings in thebrake shaft bore and the supportbracket.

3. Position the brake pedal assembly inthe pedal support bracket. Slide thepedal shaft through the pedal and se-cure with the nut. Torque the tiut tospecifications. Install the cotter pin.

4. Position the nylon bushings in thebore of the push rod. Connect thepush rod to the brake pedal wi :h theeccentric bolt and nut.

B-Series


spring (Fig. 20).2. Remove the clevis pin retaining clip

and remove the pin, spacers, mastercylinder push rod bushing and switchassembly.

3. Remove the clip from the pedal shaft.Then slide the shaft to the left andremove the brake pedal.

4. Remove the two bushings from thepedal.



2. Position the nylon bushings in thebrake pedal shaft bore.

3. Position the brake pedal assembly inthe pedal support bracket. Slide thepedal shaft through the pedal and se-cure with the retaining clip.

4. Position the nylon bushing in the boreof the push rod. Connect the pushrod, switch assembly and spacers tothe brake pedal with the clevis pin andsecure with the retaining clip

5. Install the pedal retracting spring.


PEDAL SHAFT BOLT

PUSHROD SHOULDER BOLT2462

STOPLIGHT SWITCH13480

BRAKE PEDAL'2455

H1672-B

FIG. 19 Brake Pedal and Master Cylinder Installation—P-350-400

•MASTER CYLINDER ASSEMBLY2140

RETRACTING SPRING7523

BRAKE PEDAL2455

H1627-C

FIG. 20 F-B-Series Brake Pedal and Related Parts

C-Series


spring (Figs. 18 and 21).2. Remove the brake master cylinder

push rod eccentric bolt nut, bolt andnylon bushings.

3. Remove the brake pedal bumper-to-bracket retaining nut. Then removethe bolt and bumper.

4. On models with a single hydraulicbrake system, remove the master cyl-inder push rod by pulling up on thetab on the push rod boot, and removethe push rod and boot from the cylin-der.

5. Remove the nut from the bolt, slidethe bolt to the right and remove thebrake pedal assembly, sleeve andbushing.

6. Remove the bushings from the pedalassembly.

Installation

1. Coat all bushings and the pedal shaftwith a small quantity of Lubriplate oran equivalent lubricant. Position thenylon bushings in the brake pedalshaft bore.

2. Position the brake pedal assemblysleeve and bushing in the pedal sup-port bracket, slide the bolt to the left


PEDAL RETRACTINGSPRING 9737

BUSHING 2461

PEDAL SHAFT 7506

BUSHING \2461

BOLT 45597-S

PEDAL PAD 2457

BRAKE PEDAL 2455

BRAKE MASTER CYLINDER 2140

H1012-D

FIG. 21 Single Master Cylinder andBrake PedalInstallation—C-Series

and install the nut. Torque the nut tospecifications.

3. On models with a single hydraulicbrake system, install the push rod andboot in the master cylinder.

4. On models with a single hydraulicbrake system, install the pedalbumper bolt, bumper and nut.Tighten the nut securely.

5. Install the two nylon bushings in thepush rod bore, and install the pushrod eccentric bolt and nut.

6. Install the pedal retracting spring.7. On models with a single hydraulic

brake system, adjust the brake pedalfree-travel to 3/16-3/8 inch. Torquethe eccentric bolt nut to specifica-tions.

MAJOR REPAIR OPERATIONS


Disassembly

1. With the wheel cylinder removed,remove the rubber boots from theends of the brake cylinder. Removethe piston(s), cups, and piston returnspring from the cylinder (Fig. 22).

2. Remove the bleeder screw from thecylinder.

Assembly

1. Coat all brake cylinder parts withclean extra heavy duty brake fluidC6AZ-19542-A.

2. Install the bleeder screw (Fig. 22) inthe brake cylinder.

3. Place the piston return spring, cups,and pistons in the cylinder bore, andinstall a boot and link over each endof the cylinder, clamp the brake cylin-der pistons against the ends of the cyl-inder. When a brake cylinder repairkit is used, install all of the parts sup-plied in the kit.

BOOT

PISTON CUP BOOT

H1014-A

FIG. 22 Double Servo Brake Cylinder

MASTER CYLINDER

Single Brake System

Disassembly1. With the master cylinder removed,

clean the outside of the master cylin-der, and remove the filler cap and gas-ket. Pour out any brake fluid that mayremain in the cylinder and reservoir.On a C-Series truck master cylinder

(Fig. 23), remove the 4 bolts that hold thecylinder body on the reservoir, andremove the gasket. Press down on thepiston to compress the return spring, andremove the snap ring. Remove the piston,primary cup, piston filler, return spring,check valve, and check valve seat.

On vehicles equipped with a framemounted vacuum brake booster, thecheck valve is installed in the booster in-stead of in the master cylinder.2. On a L-, LN-, P-, or LT-Series truck

master cylinder with a box-shapedreservoir, remove the brake bolt, fit-ting, and gaskets from the forwardend of the cylinder (Fig. 24). Discardthe gaskets. Remove the snap ringfrom the bore at the rear end of thecylinder, and remove the stop plate,piston cup, spring, check valve, andseat from the cylinder bore. If neces-sary, blow through the forward bolthole to remove the parts.Remove the bolt type fitting from the

forward end of the cylinder. Remove thesnap ring from the bore at the rear endof the cylinder, and remove the piston,

cup, spring, and valve seat. Remove therubber bumper from the pistons (systemswithout booster only).

Assembly1. Dip all parts except the master cylin-

der body in clean hydraulic brakefluid. Use only C6AZ-19542-A heavy-duty brake fluid.

2. On a L-, LN-, P-, LT-Series truckwith a box-shaped master c>linderreservoir, install the brake fitting,bolt, and new gaskets (Fig. 24) on theforward end of the cylinder. Installthe valve seat, valve, spring, cup, pis-ton, and stop plate in the cylinderbore. Install the snap ring in the rearend of the bore.On a L-, LN-, or LT-Series truck with

a cylindrical master cylinder reservoir,install the bolt-type fitting on the forwardend of the master cylinder. In svstemswithout a booster install the rubberbumper in the piston. Insert the valveseat, valve, spring, cup, and piston intothe cylinder bore. Compress the pistonagainst the valve spring and install thesnap ring.3. On a C-Series truck master cylinder,

install the valve seat, valve, spring,piston filler, cup and piston in the cyl-inder bore, push down on the pistonto compress the spring and install thesnap ring in the bore. Position a newgasket over the cylinder body andmount the body to the reservoir. Se-cure with 4 bolts. Tighten bolts se-curely.



2455

MOUNTING BOLTS

MOUNTING BRACKET

RESERVOIR

• SERVICED IN 2004 KIT u

LINK RODECCENTRIC BOLT 2462

• SNAP RING

PISTON 2169

PRIMARY CUP

PISTON FILLER2146

PISTONRETURN SPRING

2145

VALVE SEAT 2178

RESERVOIR GASKET2142

• CYLINDER BODY

LOCK WASHER

BOLT

H1168-D

FIG. 23 C-Series Single Brake Master Cylinder

• CHECK VALVE

BOOT2180PUSH ROD

• SNAP RING 2143LINK ROD

BOLT2462

• RETURN SPRING

• SERVICED IN 2004 KIT

BRAKE PEDAL ASSEMBLY-

HI 167-D

FIG. 24 L-, LN-, or LT-Series Brake Master Cylinder Reservoir

F-100-350. E-100-300, P-350-4000and Bronco

Refer to Figure 25.The master cylinder must be removed

from the vehicle to be overhauled.When a repair is necessary on the

master cylinder, it is required practiceduring the warranty period to replace thecylinder as a unit instead of overhaulingthe cylinder with a service repair kit.

Disassembly1. Clean the outside of the master cylin-

der and remove the filler cap and gas-ket (diaphragm). Pour out any fluidthat remains in the cylinder.

2. Unscrew the piston stop from the bot-tom of the cylinder body. Remove theO-ring seal from the piston stop. Dis-card the seal.

3. Remove the push rod boot, if soequipped, from the groove at the rearof the master cylinder and slide theboot away from the rear of the mastercylinder.

4. Remove the snap ring (Fig. 26) retain-ing the primary and secondary pistonassemblies within the cylinder body.

5. Remove the push rod (if so equipped)and primary piston assembly from themaster cylinder. Discard the pistonassembly, including the boot (if soequipped).

6. Apply an air hose to the rear brakeoutlet port of the cylinder body andcarefully blow the secondary pistonout of the cylinder body.

7. Remove the return spring, spring re-tainer, cup protector, and cups fromthe secondary piston. Discard the cupprotector and cups.

8. Place the master cylinder in a visewith the outlet ports up. Be careful toavoid damage to the master cylinderhousing.

9. Install a spare brake line tube nut inthe rear brake outlet port (Fig. 27).Place a flat washer on a 1 inch No.8 x 32 self-tapping screw and threadthe screw into the tube seat insert inthe port. Hold the screw from turn-ing, and back the tube nut out of theport. This will remove the tube seatinsert from the port.Repeat the same procedure to remove

the tube seat insert from the front brakeoutlet port.10. Remove the master cylinder from the

vise, and then remove the residualpressure check valves and check valvesprings from the outlet ports.


RESERVOIR COVER

PUSH ROD RETAINER

RESERVOIR DIAPHRAGM DUST BOOT

PUSH ROD

MASTER CYLINDER HOUSING

RESIDUAL PRESSURECHECK VALVE SPRINGS

TUBE SEAT INSERTS

CUP

2004 KIT

SECONDARY PISTON RETURN SPRING

• SPRING RETAINER

• PRIMARY CUP

• CUP PROTECTOR

• SECONDARY PISTON

M> SECONDARY CUPH1674-B

FIG. 25 Dual Master Cylinder Disassembled View—100-400 Series

Snap Ring Pliers

SNAP RING

H1477-C H 1673-A

FIG. 26 Removing SnapRing—Typical

FIG. 27 Removing Residual CheckValve and Tube Seat

Inspection and Repair1. Clean all parts in clean isopropyl al-

cohol, and inspect the parts for chip-ping, excessive wear or damage.Replace them as required. When us-ing a master cylinder repair kit, in-stall all the parts supplied.

2. Check all recesses, openings and in-ternal passages to be sure they areopen and free from foreign matter.Use the air hose to blow out dirt andcleaning solvent. Place all parts on aclean pan or paper.

3. Inspect the hydraulic master cylinderbore for signs of etching, pitting orrust. Replacement of the master cyl-inder will be required if any of theseconditions exist.

Assembly1. Place the master cylinder in a vise

with the outlet ports up. Be careful to


avoid damage to the master cylinderhousing.

2. Insert a check valve spring in a newresidual pressure check valve, andplace the assembly in the rear brakeoutlet port. Be sure the spring is prop-erly seated in the bottom of the port.

3. Place a new brass tube seat insert inthe port. Be sure the insert is notcocked. Thread a spare brake linetube nut in the port, and turn downthe nut until the tube seat insert isbottomed in the port (Fig. 28).Remove the tube nut.

4. Repeat the above procedures at thefront brake outlet port.

5. Remove the master cylinder from thevise. Check the outlet ports for brassburrs, and remove the burrs, if pre-sent.

6. Dip all the parts except the cylinderbody in clean C6AZ-19542-A extraheavy duty brake fluid.

7. Assemble the two secondary cups,back-to-back, in the grooves near theend of the secondary piston. Assem-ble the cup protector, primary cup,spring retainer and secondary pistonreturn spring on the other end of thesecondary piston.

8. Install the secondary piston assemblyin the master cylinder.

9. Install a new O-ring on the pistonstop, and start the stop into the cylin-der body.

10. On a vehicle equipped with standardbrakes, position the boot, snap ringand push rod retainer on the pushrod. Make sure the push rod retaineris seated securely on the ball end ofthe rod. Seat the push rod in the pri-mary piston assembly.

11. Install the primary piston assembly inthe master cylinder. Push the pri-mary piston inward and tighten thesecondary piston stop to retain thesecondary piston in the bore.

12. On a vehicle equipped with powerbrakes, position the stop plate andsnap ring on the primary piston. De-press the primary piston and installthe snap ring in the cylinder body.

13. On a vehicle equipped with standardbrakes, press the push rod and pistonsinward and install the snap ring in thecylinder body.

14. Bleed the master cylinder.

Bleeding the Master Cylinder

Before the master cylinder is installedon the vehicle, the unit should be bled.1. Support the master cylinder body in

a vise, and fill both fluid reservoirswith C6AZ-19542-A extra heavyduty brake fluid.

2. Loosely install plugs in the front andrear brake outlet bores. Depress theprimary piston several times until air

bubbles cease to appear in the brakefluid.

3. Tighten the plugs and attempt to de-press the piston. The piston travelshould be restricted after all air is ex-pelled.

4. Remove the plugs. Install the coverand gasket (diaphragm) assembly,and make sure the cover retainer istightened securely.

Wrench TUBE NUTOUTLET PORT

FIG. 28 Installing Residual CheckValve and Tube Seat

500-950 Series—Split HydraulicBrakes and Frame Mounted Booster

DisassemblyRefer to Figure 29.

1. Clean the outside of the master cylin-der. Remove the cylinder cover screw.Lift off the cover and the diaphragmgasket and pour off excess brake fluid.Use the push rod to stroke the cylin-der, forcing fluid from the cylinderthrough the outlet ports.

2. Loosen and remove the piston stopscrew and gasket from the right handside of the cylinder.

3. Pull back the push rod boot andremove the snap ring from the groovein the end of the cylinder bore asshown in Fig. 26.

4. Remove the push rod and stop platefrom the master cylinder.

5. Remove the internal parts from themaster cylinder. If the parts will notslide out loosely assemble the coverplate and seal the primary outlet part,then apply air pressure at the second-ary outlet port.

Inspection and Repair1. Clean all parts in isopropyl alcohol.

Inspect the parts for chipping, exces-sive wear or damage. Replace them asrequired. When using a master cylin-der repair kit, install all the parts sup-plied.

2. Check all recesses, openings and in-ternal passages to be sure they areopen and free of foreign matter. Pas-sages may be probed with soft copperwire, 0.020 inch OD, or smaller.

3. Minor scratches or blemishes in the

cylinder bore can be removed withcrocus cloth or a clean up hone. Donot oversize the bore more than 0.007inch.

AssemblyRefer to Figure 29.

1. Dip all parts except the master cylin-der in clean extra heavy duty C6AZ-19542-A hydraulic brake fluid.

2. Install the rear rubber cup on the se-condary piston with the cup lip facingthe rear. All other cups face the frontor closed end of the cylinder.

3. Assemble and install the secondarypiston spring, front cup, and the se-condary piston.

4. Install the piston stop screw and gas-ket, making sure the screw enters thecylinder behind the rear of the se-condary piston.

5. Assemble and install the primary pis-ton and push rod parts.

6. Locate the stop plate in the seat in thebore and engage the snap ring into thegroove at the rear of the cylinder.

7. Install the push rod boot onto thepush rod and groove of the cylinderhousing.


Bleeding the Master CylinderBefore the master cylinder is installed

on the vehicle, the unit should be bled.

1. Support the master cylinder body ina vise, and fill both fluid reservoirswith C6AZ-19542-A extra heavyduty brake fluid.

2. Loosely install plugs in the front andrear brake outlet bores. Depress theprimary piston several times until airbubbles cease to appear in the brakefluid.


4. Remove the plugs. Install the coverand diaphragm gasket assembly, andmake sure the cover screw is tight-ened securely.

L- and LN-500-600 Series—SplitBrake System and Dash MountedBoosterDisassembly

Refer to Figure 30.1. Clean the outside of the cylinder and

remove the filler cap and gasket (dia-phragm). Pour out any brake fluidthat may remain in the reservoir.Stroke the push rod three times toremove fluid from the cylinder bore.

2. Remove the reservoir retainers, wash-ers, and reservoir from the master cyl-inder body.

3. Remove the two rubber washers fromthe reservoir and the two O-ringsfrom the reservoir retainers.


HOUSING

SPRING RETAINER

PRIMARYPISTON STOP PRIMARY PISTON SPRING

COVER ASSEMBLY2162

TORQUE-85-115IN-LBS

SECONDARYPISTON

CUP * SECONDARYPISTON SPRING

SECONDARY PISTONPRIMARY PISTON ASSEMBLY*

ASSEMBLY*

BOOT * 2143

TART OF 2004 KIT

C SERIES

H1664-D

FIG. 29 Dual Master Cylinder—Disassembled View -500-900 Series Truck with Split Hydraulic Brakes and Frame-Mounted Booster

SECONDARY PORT PRIMARY PORT

CHECKVALVE

PORTCAP

GASKETO-RING DIAPHRAGM

FILLERCAP

SEALS (2) TO BE MOUNTEDAS SHOWN WITH LARGEDIA. TOWARD PISTON

END RELEAF PORT SNAP STOP SNAP SPLIT SECONDARY PRIMARY SEAL X RETAINER \ PUSH RODCAP SEAL RING ROD RING WASHER PISTON PISTON RETAINER O-RING BUSHING PUSH ROD RETURN SPRIN3

HI 663-A

FIG. 30 Dual Master Cylinder—L-500-600, LN-6000, B-500-700 with Midland-Ross Dash-Mounted Booster


4. Remove the snap ring, spring retainerand push rod spring.

5. Unscrew the retainer bushing coun-terclockwise and remove the pushrod, retainer bushing, seal retainerand primary piston from the mastercylinder.

6. Remove the primary piston from thepush rod and discard it.

7. Remove the seal retainer, and retainerbushing from the push rod. Removethe two lip seals and the two O-ringsfrom the retainer bushing.

8. Unscrew the end cap counterclock-wise and remove the end cap and se-condary piston assembly from themaster cylinder.

9. Remove the snap ring from the se-condary piston and remove the pistonand return spring from the end capand stop rod assembly.

10. Remove the two lip seals from thepiston.

11. Remove the snap ring from the endcap and remove the secondary pistonstop rod, relief port seal spring, thetwo snap rings and the two splitwashers from the end cap.

12. Remove the relief port seal from thesecondary piston stop rod.

13. Remove the O-rings from the endcap.

14. Remove the primary and secondaryport caps and discard.

15. Remove the check valves and springsfrom the ports.


1. Wash all metal parts in alcohol beforeassembly. Dip all parts except themaster cylinder body in clean C6AZ-

19 542-A extra heavy duty hydraulicbrake fluid. When using a master cyl-inder repair kit, install all of the partssupplied.

2. Install a new primary piston into thefront end of the master cylinder bore.Push the piston through the bore untilit is flush with the retainer bushingrecess. Use a non-metallic objectwhich will not scratch the bore.

3. Assemble the O-rings and the two lipseals on the retainer bushing. Be surethe lip seals fit into the undercuts inthe center of the bushing with theirlarge diameters toward the pistonend.

4. Install the retainer bushing onto theclosed end of the push rod and pushit onto the push rod approximatelyhalf way. Be sure the lip seal at thepiston end of the retainer bushing re-mains in the undercut portion of theretainer bushing.

5. Install the seal retainer onto theclosed end of the push rod with theraised lip toward the retainer bushing.

6. Insert the push rod into the mastercylinder bore and hook the push rodonto the primary piston.

7. Slide the seal retainer into the recessin the master cylinder bore.

8. Screw the retainer bushing into themaster cylinder body and tighten to15-20 ft-lbs torque.

9. Install the push rod spring with thelarge end toward the master cylinderand install the spring retainer andsnap ring.

10. Install the O-rings on the end cap.11. Install the relief port seal on the se-

condary piston stop rod.

12. Place the port seal spring, splitwasher (largest of two), and snap ring(largest of two) on the piston stoprod.

13. Slide the assembly into the end capand engage the snap ring into itsgroove.

14. Install the lip seals on the secondarypiston with the large diameters facingoutward.

15. Place the secondary piston returnspring on the end cap assembly.

16. Compress the spring and place the re-maining snap ring and split washer onthe piston stop rod.

17. Slide the piston stop rod into the se-condary piston and engage the snapring in its groove.

18. Slide the end cap and piston assemblyinto the master cylinder bore andscrew the end cap into the master cyl-inder body. Tighten the cap to 15-20ft-lbs torque.

19. Install washers on the reservoir re-tainers and place the retainers in themounting holes of the reservoir.

20. Place the rubber washers and O-ringson the retainers.

21. Place the reservoir and retainer as-sembly on the master cylinder bodyand tighten the retainers to 15-20 ft-lbs torque.

22. Replace the springs and check valvesin the output ports of the cylinder.

23. Replace the primary and secondaryport caps. Tighten to 15-20 ft-lbstorque.

24. Install the mounting seal on theflange of the master cylinder. Installthe filler cap and gasket (diaphragm).

12-02-20 Drum Brakes—Single Cylinder, Dual Piston 12-02 20

SPECIFICATIONS

FRONT HYDRAULIC BRAKES DIMENSIONS

Truck Series

Axle UsageFront

Rear

Type

Sue (Inches)

Cylinder Dia. (Inches)

Lining Thickness (Inches)-Primary

-Secondary

Lining Length (Inches)-Primary

-Secondary

U-100

4 x 4

F-100

4 x 4

3000-U-

100

3000-F-

100

2780

3300-

3600

DSSA

11 x 2

1.125

0.218

0.281

10.80

10.80

E 100

2500

3050

DSSA

10 x

2.50

1.125

0.1875

0.250

9.00

11.07

E 200

2750

3300

DSSA

11-1/32x

3

1.125

0.218

0.281

10.74

12.29

E-300

3300

4800

DSSA

12x3

1.125

0.1875

0.250

11.68

13.05

F-100

2750

3300 T&C

3600

Dana

DSSA

11-1/32x

3

1.125

0.218

0.281

12.29

31.36

F 250

Std.

3000

5200

DSSA

12.125 x

2.0

1.062

0.250

0.250

13.09

13.09

F-250

R.P.O.

3000

5200

(Web

Ledge)

DSSA

12.0 x

2.5

1.062

0.1875

0.250

11.68

13.05

F-250

(4x4)

3000

5200

DSSA

12.125 x

2.0

1.062

0.250

0.250

13.09

13.09

F-250

(4x4)

3500

5200

DSSA

12.125 x

2.0

1.062

0.1875

0.250

13.09

13.09

F-350

3800

7400

(Web

Ledge)

DSSA

12.0 x

3.0

1.062

0.1875

0.250

11.68

13.05

P-350-

P-400-

3800

5200 &

7400

DSSA

12.125 x

2.0

1.125

0.250

0.300

13.09

13.09

P-5CI0-

4703

11030

13000

SS/i

14 >,

2.5:i

0.93:7

0.2:.0

0.2:.0

12.E8

13J5

REAR HYDRAULIC BRAKES DIMENSIONS

Truck Series

Axle Usage Front

Rear

Type

Si/e (inches)

Cylinder Dia. (Inches)

Lining Thickness (Inches)-

Primary

Secondary

Lining Length (Inches)-

Primary

Secondary

U-100

(4x4)

3000

2780

T&C

DSSA

10x2.5

0.8125

0.1875

0.250

9.0

11.07

U-100

(4x4)

3000

3300

T&C

DSSA

11x1.75

0.8125

0.218

0.281

10.80

10.80

E 100

2500

3050

DSSA

10x1.75

0.8125

0.1875

0.250

8.48

10.88

E-200

2750

3300

DSSA

11-1/32x

2.25

0.8125

0.218

0.281

10.74

10.74

E-300

3300

4800

DSSA

12x2.5

0.875

0.1875

0.250

11.68

13.05

F-100

2750

3300

T&C

DSSA

11-1/32x

2.25

0.875

0.218

0.281

10.74

10.74

F-100

2750

3600

T&C

DSSA

11-1/32x

2.25

0.875

0.218

0.281

10.74

10.74

F-100

(4x4)

3000

3300

T&C

DSSA

11-1/32x

2.25

0.875

0.218

0.281

10.74

10.74

F-100

(4x4)

3000

3600

T&C

DSSA

11-1/32x

2.25

0.875

0.218

0.281

10.74

10.74

F-250

(Std.)

3000

5200

DSSA

12.125x

2.0

0.9375

0.250

0.250

13.09

13.09

F-250

(4x2) RPO

P 350

F-250

(4x4)Std

3000 4x2

4x4 3500

4x4 3800

5200

(WebLedge)

DSSA

12 x

2.50

0.9375

0.1875

0.250

11.68

13.05

F-350

3800

7400

(WebLedge)

DSSA

12 x

3.0

1.06

0.1875

0.250

11.81

12.96

P-350

(RPO)

3800

5200

(WebLedge)

DSSA

12 x

2.5

0.9375

0.1875

0.300

11.68

13.05

P 350(RPO) P-500

P400(Std)

3800 4700

7400 11000

(Web 13000Ledge) !B)

DSSA 2 Cyl.

12 x I4.125x

3.0 BX 3.50

1.06 1.50

0.1875 375

0.250 375

11.81 14.42

12.96 14.42

GENERAL TORQUE LIMITS

Unless Otherwise Specified

Bolt or Nut Diameter

1/4"

5/16"

3/8"

7/16"

1/2"

the Following Torque Ranges are to be used for

Torque Range

85-115 IN. LBS.

12-17 FT.LBS.

31-42 FT.LBS.

50-70 FT.LBS.

75-105 FT.LBS.

Fitting or Fastener Diameters as Indicated.

Bolt or Nut Diameter

9/16"

5/8"

3/4"

7/8"

1.0"

Torque Range

110-150 FT.LBS.

150-205 FT.LBS.

220-300 FT.LBS.

360-480 FT.LBS.

540-730 FT.LBS.

CH 1877-A


SPECIFIC TORQUE LIMITS

Front Brake Backing Plate to Spindle (100-400 Series)

Front Brake Backing Plate and Steering Arm to Spindle (100-400 Series)

Rear Backing Plate to Axle (100-400 Series)

Brake Assembly to Front Axle (500-900 Series)

Brake Assembly to Rear Axle (500-900 Series)

Brake Drum to Hub Nuts or Bolts (500-900 Series)

Master Cylinder or Booster Push Rod to Brake Pedal (500-900 Series)

Master Cylinder to Dash Panel (500-900 Series)

Master Cylinder to Booster (Dash Mounted Booster) (500-700 Series)

Booster to Dash Panel (Dash Mounted Booster) (500-700 Series)

Master Cylinder to Pedal Bracket

Eccentric Adjuster Bolt Torque

1/2 x 13,55-70

1/2 x 13,30-40

1/2 x 13,75-105

9/16 x 12, 110-150

9/16 x 12, 110-150

1/2 x 13,68-85

3/8x16, 12-17

5/16 x 18,12-17

14-18

3/8 x 16, 12-17

5/16x24,12-15

80-120 inch lbs.

7/16 x 14,30-50

1/2 x 20, 50-70

1/2x20,50-70

1/2 x 13,75-105

1/2 x 13,75-105

5/8 x 18, 136-170

3/8 x 16,31-42

3/8x24, 13-20

3/8x24,12-17

1/2x20,55-75

7/16 x 14,35-45

1/2x20,75-105

1/2x20,75-105

5/16 x 18, 12-15

TORQUE LIMITS - HYDRAULIC TUBE NUTS (FT-LBS)

Thread Size Ft-Lbs. © Thread Size Ft-Lbs. ©

3/8-24 3-15 1/2-20 12-17

7/16-24 12-17 9/16-18 15-25

© A l l hydraulic line connectfons (nuts) must be torqued to the specified value and free of fluid leakage.

BRAKE DRUM REPAIR LIMITS (BRAKE LATHE)

Brake drums are marked with the maximum allowable braking surface diameter. If this diameter is exceeded by wear or refinishing, the drum must be replaced.

CH 1878-A

12-05-1 Drum Brakes—Single Cylinder, Single Piston^ 12-05-1

PART 12-05 Drum Brakes — Single Cylinder,Single Piston

Applies to P-500 And B-, LN-Series Trucks with 6000-7000 Lb. AxlesCOMPONENT INDEX

BRAKE DRUMSRemoval and Installation

BRAKE BACKING PLATERemoval and Installation

BRAKE SHOESAdjustment

Page

05-2

05-2

05-1

COMPONENT INDEX



Disassembly and Assembly


Page

05-2

05-3

05-2

ADJUSTMENTS

BRAKE SHOE ADJUSTMENT

The brake drums should be at normalroom temperature, when the brake shoesare adjusted. If the shoes are adjustedwhen the shoes are hot and expanded,the shoes may drag as the drums cooland contract.


FRONT BRAKE

Manual AdjustmentThe single anchor brake is adjusted by

turning an adjusting screw located be-tween the lower ends of the shoes.1. Raise the vehicle until the wheels

clear the floor.2. Remove the cover from the adjusting

hole at the bottom of the brake carrierplate, and turn the adjusting screwinside the hole to expand the brakeshoes until they drag against thebrake drum and lock up the drum.Back off the adjusting screw until aslight drag is noted (Fig. 1).

3. When the shoes are against the drum,back off the adjusting screw 10 to 12notches so that the drum rotatesfreely without drag. If the drum doesnot rotate freely, remove the wheeland drum, and then blow out the dustand dirt from the linings. With sand-paper, remove all rust from the pointswhere the shoes contact the carrierplate and apply a light coating of hightemperature grease (C1AZ-19590-B).Be careful not to get the lubricant onthe linings.

4. Install the wheel and drum, and ad-just the shoes. Install the adjustinghole cover on the brake backing plate.

5. Check and adjust the other threebrake assemblies.

6. Apply the brakes. If the pedal travelsmore than halfway down between thereleased position and the floor, toomuch clearance exists between thebrake shoes and the drums. Repeatsteps 2 and 3 above.

7. When all brake shoes have been prop-erly adjusted, lower the vehicle. Roadtest the vehicle and check the opera-tion of the brakes. Perform the roadtest only when the brakes will applyand the vehicle can be safely stopped.

H 006-1

FIG. 1 Single Anchor Brake ShoeAdjustment

12-05-2 Drum Brakes—Single Cylinder, Single Piston 12-05-2

REMOVAL AND INSTALLATIONBRAKE DRUMS Installation

Since the brake drum service proce-dures for these models apply to both hy-draulic and air brakes, they are coveredunder Adjustments in Part 12-01.

BRAKE SHOE AND ADJUSTINGSCREWRemoval

Refer to Figure 2.1. Raise the truck until the wheels clear

the floor. Then remove the wheel anddrum. Do not push down the brakepedal after the brake drum has beenremoved.

2. Clamp the brake cylinder boot againstthe end of the cylinder, and removethe brake shoe retracting springs fromboth shoes.

3. Remove the anchor pin plate (Fig. 2).4. Remove the hold-down spring cups

and springs from the shoes, andremove the shoes and the adjustingscrew parts from the carrier plate. Donot let oil or grease touch the brakelinings.

5. Remove the hold-down spring pinsfrom the carrier plate.

6. Remove the adjusting screw partsfrom the brake shoes.

ANCHOR PIN PLATE

ANCHOR PIN

1. Coat all points of contact between thebrake shoes and the other brake as-sembly parts with Lubriplate or simi-lar lubricant. Lubricate the adjustingscrew threads.

2. Place the adjusting screw, socket, andnut on the brake shoes so that the starwheel on the screw is opposite the ad-justing hole in the carrier plate. Theninstall the adjusting screw spring.

3. Position the brake shoes and the ad-justing screw parts on the carrierplate, and install the hold-downspring pins, springs, and cups.

4. Install the anchor pin plate on the pin.

5. Install the brake shoe retractingsprings on both shoes, being carefulnot to bend the hooks or to stretch thesprings beyond the attaching points.The primary shoe spring must be in-stalled first.

6. Remove the clamp from the brakecylinder boot.

7. Install the wheel and drum.

8. Adjust the brakes, check the brakepedal operation, and lower the truck.

BRAKE CYLINDER(SINGLE PISTON)

PRIMARY BRAKESHOE AND LINING

SECONDARY BRAKE SHOEAND LINING

BRAKE SHOE HOLD-DOWNPIN AND SPRING

ADJUSTING SCREW L I N K ADJUSTING SCREW SPRING

FRONT OF TRUCK H 1684-A

FIG. 2 Single Anchor Brake Shoe—Front—P-500


Removal

1. Remove the wheel, drum, and brakeshoes. Remove the cylinder-to-shoeconnecting links.


3. Remove the brake cylinder retainingbolts and lockwashers, and thenremove the cylinder from the backingplate.


backing plate and install the retainingbolts and lockwashers.




BRAKE BACKING PLATE


the hub and drum attaching parts(grease cap and gasket if so equipped,cotter pin, bearing adjusting nut andflat washer). Then, remove the outerwheel bearing and the hub and drumassembly from the spindle.

2. Remove the brake shoes and adjust-ing screw from the backing plate asoutlined in this Section. Disconnectthe brake line from the brake cylinderand submerge the end of the brakeline in a can containing a smallamount of brake fluid. This will mini-mize hydraulic line bleeding.

3. Remove the backing plate retainingbolts and nuts, then remove the back-ing plate from the front wheel spindle.

4. Remove the attaching bolts and lock-washers, and the brake cylinder fromthe backing plate.

Installation1. Assemble the brake cylinder to the

backing plate with the attaching boltsand lockwashers.

2. Mount the backing plate to the frontwheel spindle and secure with the at-taching bolts and nuts.

3. Install the brake shoes and adjustingscrew to the backing plate as outlinedin this Section. Connect the brake lineto the brake cylinder.

4. Install a front wheel hub and drumassembly and the outer wheel bearingto the spindle. Install the hub anddrum attaching parts (flat washer,

12-05-3 Drum Brakes—Single Cylinder, Single Piston 12-05-3

bearing adjusting nut, cotter pin,grease cap, and gasket if so equipped).Adjust the front wheel bearings as ou-tlined in Group 11.

5. Install the wheel and tire.

6. Bleed the hydraulic system and adjustthe brake shoes.

MAJOR REPAIR OPERATIONS


Disassembly1. With the wheel cylinder removed,

remove the rubber boot from the endof the brake cylinder. Remove the pis-ton, cup, and piston return springfrom the cylinder (Fig. 3).


Assembly1. Coat all brake cylinder parts with

clean extra heavy duty brake fluidC6AZ-19542-A.


3. Place the piston return spring, cup,and piston in the cylinder bore, andinstall a boot and link over each endof the cylinder, clamp the brake cylin-der piston against the end of the cylin-der. When a brake cylinder repair kitis used, install all of the parts suppliedin the kit.

PISTON CYLINDER

BOOTCUP

-0®BLEEDER SCREW'

H1015-A

FIG. 3 Single Servo BrakeCylinder—Disassembled

12-08-1 Drum Brakes — Dual Cylinders, Dual Pistons 12-08-1

PART 12-08 Drum Brakes - Dual Cylinders,Dual Pistons

Applies to 500 thru 900 Series Trucks

COMPONENT INDEX

BRAKE BACKING PLATE


BRAKE MASTER CYLINDERS

Disassembly and Assembly


Page

08-5

08-9

08-5

COMPONENT INDEX

BRAKE PEDALS


BRAKESHOES

Adjustment


SPECIFICATIONS

Page

08-7

08-108-3

08-13

ADJUSTMENTS

BRAKE SHOE ADJUSTMENT

The brake drums should be at normalroom temperature, when the brake shoesare adjusted. If the shoes are adjustedwhen the shoes are hot and expanded,the shoes may drag as the drums cooland contract.


Adjustment procedures for each typeof brake assembly are given under theapplicable heading.

Rear Brake — P-500 Series

The two-cylinder brake assemblybrake shoes are adjusted by turning ad-justing wheels reached through slots inthe backing plate.

The brake adjustment is made withthe vehicle raised. Check the brake dragby rotating the drum in the direction offorward rotation as the adjustment ismade.1. Remove the adjusting slot covers

from the backing plate (Fig. 1).2. Turn the rear (secondary shoe) ad-

justing screw inside the hole to ex-

FIG. 1 Two-Cylinder Brake (Rear)Shoe Adjustment

pand the brake shoe until it dragsagainst the brake drum.

3. Back off the adjusting screw so thatthe drum rotates freely without drag.Depress the brake pedal to center thebrake shoes, and back off the adjust-ing screw an additional notch to pro-vide operating clearance.

4. Repeat the above procedure on thefront (primary) brake shoe.

5. Replace the adjusting hole covers.

Self Adjusting Brakes — Rear —500-900 Series (Except P-500)

The brake shoes are automatically ad-justed when the vehicle is driven in re-verse and the brakes applied. A manualadjustment is required only after thebrake shoes have been relined or re-placed.

The two-cylinder brake assembly(Figs. 2 and 3) brake shoes are adjustedby turning adjusting wheels reachedthrough slots in the backing plate.

Two types of two-cylinder brake as-semblies are used on truck rear wheels.The assemblies differ primarily in the re-tracting spring hookup, and in the designof the adjusting screws and locks.However, the service procedures are thesame for both assemblies.

The brake adjustment is made withthe vehicle raised. Check the brake dragby rotating the drum in the direction offorward rotation as the adjustment ismade.1. Remove the adjusting slot covers

from the backing plate (Fig. 1).2. Turn the rear (secondary shoe) ad-

justing screw inside the hole to ex-pand the brake shoe until a slight dragis felt against the brake drum.

3. Repeat the above procedure on thefront (primary) brake shoe.

4. Replace the adjusting hole covers.

5. Complete the adjustment by applyingthe brakes several times while backingthe vehicle.

6. After the brake shoes have been prop-erly adjusted, check the operation ofthe brakes by making several stopswhile operating in a forward direc-tion.If a brake drum will not come off,

remove the adjusting slot covers andback off the adjuster screws to free thedrum from the shoes.

HYDRAULIC SYSTEM BLEEDING

Refer to Part 12-01 (General Hydrau-lic Brake Service) for hydraulic systembleeding procedures.


L.H. BRAKE ASSEMBLY

BACKINGPLATE

ADJUSTER SPRINGBROWN

HEX ECCENTRIC SCREW(Torque to 17-19 Ft. Lbs.)

ADJUSTERSTAR WHEEL

H1731.B

FIG. 2 Two-Cylinder Brake Shoe (Wagner) — Rear

PRIMARY SHOERETRACTING

SPRING (BLUE)

ADJUSTINGLEVER SPRING

(YELLOW)

SECONDARY SHOERETRACTING

SPRING (GREY)

ADJUSTINGLEVER LINK

BRAKE SHOEADJUSTING LEVER

ADJUSTER BLOCK

ADJUSTING LINK

BRAKE SHOERETRACTING

SPRING (BLACK)

ADJUSTER STARWHEEL AND SCREW

BRAKE SHOEHOLD DOWN

POST

OVER TRAVELSPRING

HOLD DOWNSPRING AND CUPS

ADJUSTINGSCREW SLEEVE

ANCHORBLOCKSPRIN3

TOGG-EPIN

BRAKE SHOERETRACTING

SPRING (GREV/)

IDENTIFICATION GROOVE R.H.

LEFT FRONT

FIG. 3 Hydraulic Brake Assemblies (Kelsey-Hayes)

LEFT REAR HI658-C



BRAKE SHOES AND ADJUSTINGSCREW

P-500 Series — Rear


1. Raise the truck until the wheels clearthe floor. Remove the wheel, and thenremove the drum or the hub anddram assembly. Mark the hub anddrum to aid assembly in the same po-sition.

2. Clamp the brake cylinder bootsagainst the ends of the cylinder andremove the four brake shoe retractingsprings.

3. Remove the brake shoe guide bolt cot-ter pin, nut, washer, and bolt fromboth shoes and remove the shoes fromthe carrier plate.

4. Remove the clamp-type adjustingwheel lock from the anchor pin sup-port, and unthread the adjustingscrew and wheel assembly from theanchor pin support.

Installation

2.

Coat all points of contact between thebrake shoes and other brake assemblyparts with high temperature grease.Thread the adjusting screw and wheelassembly into the anchor pin supportand install the clamp-type adjustingwheel lock. Thread the adjustingwheel into the support so that thebrake shoe will rest against the adjust-ing wheel end.Place the brake shoe against the back-

ing plate, insert the ends in the brakecylinder links, and install the shoeguide bolt, washer and nut (Fig. 4).Finger tighten the nut, then back offone full turn, and install the cotterpin.

4. Install the four retracting springswith the tool shown in Fig. 5.

5. Remove the cylinder clamps, installthe drum or the hub and drum assem-bly, then install the wheel assembly.Align the marks on the hub and drumduring installation.

6. Adjust the brakes, and lower thetruck.

600-900 Series — Rear — Wagner

Removal1. Raise the truck until the wheels clear

the floor. Remove the wheel, and thenremove the drum or the hub anddrum assembly. It may be necessaryto back off the adjusting wheelsslightly to free grooved drums. Takecare not to back off adjustment somuch that adjusting wheel is jammedagainst the friction ring on the ad-juster screw as this may damage thering.Mark the hub and drum to aid assem-

bly in the same position. Be sure the en-gine is stopped and there is no vacuum inthe system before disconnecting the hy-draulic lines.2. Unhook the two automatic adjuster

springs (Fig. 2). Remove each longadjuster link by pivoting back the ad-justing wheel cranks until their slots

Remove/Tool-2035-N

COVERADJUSTING

WHEELLOCK

ADJUSTINGSCREW AND

WHEELASSEMBLY

BRAKESHOE

ANCHOR PIN SUPPORTH 1181-D

FIG. 4 Two Cylinder Brake — Rear — P-500

Installation Tool—2035-N

FIG. 5 Retracting SpringReplacement — Typical

align with the link hooks. Lift out thelinks, then slide the hooks from theanchor pin cranks. Remove the shortlinks by rotating the anchor cranksuntil the link hooks clear the eccen-trics on the shoe webs, then removethe smaller hooks from the cranks.

3. Spread the anchor crank C-washersand remove the cranks (it is usuallyunnecessary to remove the adjustingwheel cranks). If shoes are to be re-lined, remove adjuster eccentricsfrom the shoe webs by unscrewingtheir self-tapping screws.

4. Remove the shoe retraction springsby sliding the looped ends off the pins.Remove the shoe hold-down lockwires, castellated nuts and plainwashers and lift the shoes off thebacking plate.

5. Unthread the adjusting screw and ad-justing wheel from each of the anchorsupports.

Installation

1. Insert the adjusting wheels in the an-chor support slots and thread in theadjuster screws from the shoe side,friction ring end toward the shoe. Fornew linings, back off adjusters, takingcare not to jam the adjusting wheels.Do not lubricate adjuster screws.

2. Position the shoes (Fig. 2) to the back-ing plate. Locate shoe with its toe(cutaway portion of web) positionedin the adjuster slot, heel in the anchorpin slot. Install hold-down bolt, plainwasher and castellated nut fingertight, then back off nut one turn andinstall the lockwire.

3. Install the retracting springs in theshoe web, longest end at the adjuster,and hook the springs over the pins.

4. On each shoe web, install the adjuster


hex eccentric, tightening the self-tap-ping screw finger-tight to permit finaladjustment of the eccentrics.

5. Position the anchor cranks on the an-chor pins with the long end towardthe shoes. Install and crimp the C-washers.

6. At each crank, install the short linkwith the small hook end into the shortarm of the crank. Install the otherlink end around the eccentric on theshoe web.

7. Install the long link S-hook end to thelong arm of the crank. Rotate the ad-justing wheel crank so that slot linesup with link U-hook end and insertthe hook. Rotate the adjusting wheelcrank back to the approximate adjust-ing position.

8. Install the adjuster spring with theshort end on the adjusting wheelcrank finger and the long end on theupper groove of the spring retainerpin. Center the brake shoe assembliesto the backing plate.

9. Lift the adjuster lever up and awayfrom the star wheel. Then loosen thehex eccentric screw and rotate eachhex eccentric until the adjuster leveraligns the adjusting wheel crank pawlwith the center line of the adjustingscrews. A milled slot located on theanchor support is the aligning mark.With the eccentrics adjusted, tightenthe self-tapping screws.

10. Install the drum or the hub and drumassembly, then install the wheel as-sembly. Align the marks on the huband drum during installation.

11. Bleed the brake system and adjust thebrakes. Lower the vehicle.

500-800 Series (Except P-500) Front— Kelsey Hayes


1. Raise the vehicle until the wheelclears the floor. Remove the wheel,drum and hub assembly. Refer to Part12-01.

2. Clamp the wheel cylinder bootsagainst the ends of the cylinder.

3. Remove the brake shoe retractingsprings from both shoes.

4. Remove the adjusting lever link, an-chor plate and the adjusting leverspring.

5. Remove the hold down spring cups,springs and the adjusting lever assem-bly.

6. Remove the brake shoes and adjusterscrew assembly from the backingplate.

7. Remove the hold down pins from thebacking plate and check the pins forstraightness.

Installation

Refer to Figure 3.

1. Clean all brake dust from the brakeassembly parts with a clean dry rag.

2. Coat all points of contact between theshoes and other brake parts with hightemperature grease (C1AZ-19590-Bor E).

3. Coat the adjuster screw with hightemperature grease (C1AZ-19590-Bor E) before assembly. Thread the ad-juster screw into the adjuster screwsleeve.

4. Position the brake shoes on the back-ing plate and install the adjustinglever assembly, hold down pins,springs and cups.

5. Position the adjuster screw assemblyon the brake shoes so that the starwheel is opposite the adjusting slot inthe backing plate. Install the adjust-ing lever spring.

6. Install the anchor plate and adjustinglever link.

7. Install the secondary brake shoe re-tracting spring.

8. Install the primary brake shoe retract-ing spring.

9. Remove the clamp from the wheelcylinder boots.

10. Install the wheel, drum and hub as-sembly.

11. Disengage the adjusting lever, andadjust the brakes. Subsequent adjust-ment will be automatic.

500-800 Series (Except P-500) —Rear — Kelsey Hayes


1. Raise the truck until the wheel clearsthe floor.

2. Remove the wheel, hub and drum as-sembly. Refer to Part 12-01.

3. Clamp the brake cylinder bootsagainst the ends of the cylinder withbrake piston clamps.

4. Note the two different types of brakeshoe retracting springs and removethe springs.

5. Remove the brake shoe hold downpost cotter key, nut, and shoe holddown washer.

6. Loosen and remove the eccentric ad-juster bolt, lock washer, eccentric andadjusting link.

7. Remove the shoe and lining assemblyfrom the backing plate.

8. Remove the anchor block spring andslide the adjuster assembly from theshoe web.

9. Remove the adjuster star wheel andscrew from the adjuster block. Unth-read the star wheel from the adjusterscrew.


1. Wipe all brake dust from the brakeassembly parts with a clean dry rag.Coat all points of contact between

brake shoes and other parts with hightemperature grease (C1AZ-19590-Bor E).

2. Coat the adjuster screw and the insideof the adjuster block with high tem-perature grease (C1AZ-19590-B orE).

3. Thread the adjuster screw onto thestar wheel and insert the adjusterscrew assembly into the adjusterblock. Maintain a 2.12-2.18 inch di-mension from the end of the adjusterblock to the adjuster screw web slot.

4. Install the adjuster assembly onto theshoe web and attach the anchor blockspring.

5. Place the brake shoe over the retract-ing spring toggle pin and insert theends of the shoe in the wheel cylinderlinks.

6. Install the shoe hold down washerand nut. Do not install the cotter pin.

7. Install the four brake shoe retractingsprings. Make sure the retractingsprings are installed as shown in Fig.3. On 15 x 5 inch brakes the innerhook ends face the wheel cylinders.On 15x4 inch brakes the inner hookends face the center of the axle.

8. Install the adjusting link, eccentric,lockwasher and adjuster bolt. Do nottighten.

9. Remove the brake piston clampv.10. Tighten the shoe hold down nut until

there is 0.015-0.025 inch clearancebetween the shoe and hold clownwasher with the shoe held against thebacking plate. Install the cotter pin.

11. Center the shoes on the backing plate.Using a 1/2 inch wrench, rotate theadjuster eccentric until the adjustinglever is at the index mark (Fig. 3).Tighten the eccentric adjuster bolt tospecification.

12. Install the wheel, hub and drum as-sembly.

13. Adjust the brake to obtain a -lightdrag. Subsequent adjustments will beautomatic.


Removal1. Remove the wheel, drum, and brake

shoes. Remove the cylinder-to-shoeconnecting links.


3. Remove the brake cylinder retainingbolts and lockwashers, and thenremove the cylinder from the backingplate. On the two-cylinder brake as-semblies, remove the cover with thebrake cylinder.


backing plate and install the retainingbolts and lockwashers. Torque the re-taining bolts to 150-200 in-lbs. On the


two-cylinder brake assemblies, installthe cover with the brake cylinder.




BRAKE BACKING PLATE

300 Through 900 Series


the hub and drum attaching parts (ax-les under 9,000 lbs capacity-greasecap and gasket if so equipped, cotterpin, bearing adjusting nut and flatwasher) (Axles 9,000 lbs capacity orover-grease cap and gasket, lock nut,dimpled washer, locking ring, andbearing adjusting nut and pin assem-bly.) Then, remove the outer wheelbearing and the hub and drum assem-bly from the spindle.

2. On rear wheels, remove the rear axleshaft flange retaining nuts and axleshaft. Remove the rear wheel bearinglock nut, lock washer, and adjustingnut, then remove the hub and drumassembly from the axle housing. Dis-card the grease seal.

3. Remove the brake shoes and adjust-ing screw from the backing plate asoutlined in this section. Disconnectthe brake line from the brake cylinderand submerge the end of the brakeline in a can containing a smallamount of brake fluid. This will mini-mize hydraulic line bleeding.

4. Remove the backing plate retainingbolts and nuts, then remove the back-ing plate from the front wheel spindleor rear axle housing.

5. Remove the attaching bolts and lockwashers, and the brake cylinder fromthe backing plate.

Installation1. Assemble the brake cylinder to the

backing plate with the attaching boltsand lockwashers.

2. Mount the backing plate to the frontwheel spindle or to the rear axle hous-ing flange, and secure with the attach-ing bolts and nuts.

3. Install the brake shoes and adjustingscrew to the backing plate as outlinedin this section. Connect the brake lineto the brake cylinder.

4. Install a front wheel hub and drumassembly and the outer wheel bearingto the spindle. Install the hub anddrum attaching parts (axles under 9,-000 lbs capacity-flat washer, bearing

adjusting nut, cotter pin, grease cap,and gasket if so equipped, axles 9,000lbs. capacity or over-bearing adjust-ing nut and pin assembly, lockingring, dimpled washer, lock nut, andgrease cap and gasket). Adjust thefront wheel bearings as outlined inGroup 11.Install a rear wheel hub and drum as-

sembly on the rear axle housing. The rearhub oil seal must be replaced whenevera hub is removed or installed. Install theouter bearing and the adjusting nut, thenadjust the wheel bearings. Install the lockwasher and lock nut, then torque tospecifications. Install the rear axle shaft,gasket and attaching nuts, then torque tospecifications.5. Install the wheel and tire.6. Bleed the hydraulic system and adjust

the brake shoes.


500-600 Series — Power Brake —Dash Mounted Booster

Removal1. With the engine stopped, depress the

brake pedal to expell vacuum or airpressure from the brake booster sys-tem.

2. Disconnect the hydraulic lines fromthe brake master cylinder.

3. Remove the brake booster to mastercylinder retaining nuts and lockwash-ers. Remove the master cylinder fromthe brake booster.

Installation1. Before installing the master cylinder,. check the distance from the outer end

of the booster assembly push rod tofront face of the brake booster assem-bly. Turn the push rod adjustingscrew in or out as required to obtainthe specified length (Fig. 6).

2. Position the master cylinder assemblyover the booster push rod and ontothe two studs on the booster assem-bly. Install the attaching nuts andlockwashers and torque them tospecifications.


4. Bleed the hydraulic brake system asoutlined in this section of the manual.Centralize the differential valve as ou-tlined in this Section of the manual.Then, fill the dual master cylinderreservoirs to within 1/4 inch of thetop with the specified C6AZ-19542-Abrake fluid. Install the gasket (dia-phragm) and filler cap.

F-500-750, C-600-900 Series —Single Brake System

RemovalThe engine must be stopped and all

vacuum or air pressure must be expelled

from the booster system before the hy-draulic lines are disconnected.1. Disconnect the stoplight switch wires

from the switch, and disconnect thebrake line from the brake fitting.


3. On a vehicle with a frame-mountedbooster disconnect the rubber bootfrom the rear end of the master cylin-der in the cab. Remove the bolts thathold the master cylinder against thedash panel, and lift the cylinder awayfrom the push rod and out of the en-gine compartment.On vehicles equipped with a dash-

mounted booster, remove the nuts andwashers that secure the master cylinderto the power booster unit, and remove themaster cylinder.

Installation

1. On a vehicle with a frame-mountedbooster, position the rubber boot onthe piston push rod, guide the mastercylinder over the end of the push rodand position the cylinder against themounting surface. Install the mount-ing bolts and torque them to specifica-tions.On vehicles equipped with a dash-

mounted booster, install the master cylin-der over the push rod onto the two studsin the power booster body. Install thelockwashers and retaining nuts. Torquethe nuts to specifications.2. Connect the brake line to the master

cylinder fitting, but leave the brakeline fitting loose.

3. Fill the master cylinder reservoir withC6AZ-19542-A extra heavy dutybrake fluid to within 1/4 inch of thetop of the filler neck.

4. Push the brake pedal down slowly byhand several times to let air escape atthe brake line fitting. Hold the pedaldown and tighten the brake line fit-ting. Release the brake pedal. Do notrelease the brake pedal until the fit-ting is tightened as additional air willbe introduced into the master cylin-der.On vehicles equipped with dash-

mounted booster, the cylinder can be bledat the bleed screw on the cylinder.

On a vehicle with a frame-mountedbrake booster assembly, the master cylin-der can be bled at the booster bleedscrew(s).5. After seeing that the master cylinder

reservoir is filled with the specifiedbrake fluid to within 1/4 inch of thetop of the filler neck, install the fillercap. Wipe off any fluid from the out-side of the cylinder and brake line.

6. Connect the stoplight switch wires tothe switch.


7. Connect the rubber boot to the end ofthe cylinder.


L-, LN-, and B-Series Split BrakeSystem and Frame MountedBooster

RemovalRefer to Figures 7 and 8.


2. On L- and LN-Series, remove the re-taining nut, shoulder bolt, spacersand bushing securing the master cyl-inder push rod and the stop lightswitch to the brake pedal assembly.Remove the switch.On B-Series, remove the hair pin clip

from the brake pedal pin. Remove thepush rod, spacers, stop light switch, andbushing from the brake pedal pin.3. Remove the boot from the master cyl-

inder push rod.4. Disconnect the brake hydraulic sys-

tem lines from the master cylinder.5. Remove the master cylinder to dash

panel retaining screws and remove themaster cylinder.


on the dash panel within the enginecompartment and install the retainingscrews and washers. Tighten thescrews to specification.



4. On L- and LN-Series, position thestop light switch on the push rod, in-stall the shoulder bolt and spacers.Make sure the bushings and spacersare installed properly. Secure thepush rod and stop light switch to thebrake pedal assembly with the self-locking nut.On B-Series, install the spacers, push

rod, bushing and stop light switch on thebrake pedal pin. Install the hair pin re-tainer.5. Connect the wires to the stop light

switch.6. Bleed the hydraulic brake system as

outlined in this section of the manual.Centralize the differential valve as ou-tlined in this Section of the manual.Then, fill the dual master cylinderreservoirs to within 1/4 inch of thetop with C6AZ-19542-A extra heavyduty brake fluid. Install the gasket(diaphragm) and filler cap.

P-500 Series

Removal

1. The engine must be stopped and all

vacuum must be expelled from thebooster system before the hydrauliclines are disconnected.

2. Turn the front wheels all the way tothe left, and remove the fender apronattaching screws so that the apron canbe moved to provide access to themaster cylinder.

3. Disconnect the stoplight switch wiresfrom the switch.

4. Disconnect the brake line from thebrake tube fitting.


6. Disconnect the rubber boot from theend of the master cylinder.

7. Remove the brake pedal returnspring, remove the cotter pin from theclevis pin, and remove the master cyl-inder push rod and boot. Remove thethree mounting bolts and remove themaster cylinder from the mountingbracket and away from the vehicle.

Installation1. Assemble the master cylinder to the

mounting bracket and secure with thethree mounting bolts. Install the pushrod and boot to the front of the mastercylinder. Connect the front end of thepush rod to the upper holes of thebrake pedal extension with the clevispin, and secure with a cotter pin. In-stall the brake pedal retracting spring.

2. Connect the brake line to the mastercylinder fitting, but leave the brakeline fitting loose.

3. Fill the master cylinder with extraheavy-duty brake fluid C6AZ-19542-A to the specified level (1/4 inch fromthe top).

4. Push the brake pedal down slowly byhand several times to let air escape atthe brake line fitting. Hold the pedaldown and tighten the brake line fit-ting. Do not release the brake pedaluntil the fitting is tightened, as addi-tional air will be introduced into themaster cylinder. Repeat this proce-dure until air ceases to escape at thefitting and a firm pedal is obtained.

5. After seeing that the master cylinderreservoir is filled with the specifiedC6AZ-19542-A extra heavy dutybrake fluid to within 1/4 inch of thetop of the reservoir, install the fillercap. Wipe off the fluid from the out-side of the cylinder and brake line.

6. Connect the stoplight switch wires tothe switch.

7. Connect the rubber boot to the end ofthe cylinder. Reposition the fenderapron and secure with the five retain-ing bolts.

8. Check and, if necessary, adjust thebrake pedal free travel.

C-Series Single Brake System

RemovalThe engine must be stopped and all

vacuum must be expelled from thebooster system before the hydraulic linesare disconnected.1. Roll back the floor mat, remove the

floor plate, and then disconnect thehydraulic line from the master cylin-der.


3. Disconnect the rubber boot from therear end of the master cylinder in thecab.

4. Remove the two mounting bolts andlower the master cylinder away fromthe push rod and out of the cab.

Installation1. With the rubber boot on the piston

push rod, guide the master cylinderover the end of the push rod, and posi-tion the cylinder against the mountingsurface. Install the mounting bolts,and torque them to specifications.

2. Connect the brake line to the mastercylinder fitting and tighten the fitting.

3. Fill the master cylinder reservoir withthe specified brake fluid to within 1/4inch of the top of the filler neck.

4. Bleed the brake system.5. After seeing that the master cylinder

reservoir is filled with the specifiedC6AZ-19542-A extra heavy dutybrake fluid to within 1/4 inch of thetop of the filler neck, install the fillercap. Wipe off any fluid from the out-side of the cylinder and brake line.

6. Connect the rubber boot to the end ofthe cylinder. Install the floor plateand secure with the seven retainingscrews, and place the floor mat in itsproper position.


C-Series — Split Brake System

RemovalRefer to Figure 9.All vacuum must be relieved from the

booster before hydraulic lines are discon-nected.1. Disconnect the hydraulic lines from

the master cylinder. Trap the fluiddrip with a shop towel or plug theports.

2. Remove the bolt and nut connectingthe push rod to the brake pedal bellcrank and remove the stop lightswitch, bushing and spacers.

3. Remove the master cylinder mount-ing bolts and remove the master cylin-der from the vehicle.


1. If the master cylinder is being re-placed, transfer the outlet ports, to the


new master cylinder.2. Position the master cylinder to the

dash panel and install the mountingbolts.

3. Assemble the stop light switch, bush-ing and spacers on the push rod andinstall the bolt connecting the pushrod to the bell crank.

4. Connect the primary and secondaryoutlet tubes and tighten to specifica-tions.

5. Bleed the brake system.

DUAL BRAKE MASTER CYLINDERPRESSURE DIFFERENTIAL VALVEASSEMBLY

Removal1. Raise the vehicle on a hoist. Discon-

nect the brake warning light wirefrom the pressure differential valveassembly switch. To prevent damageto the brake warning switch wire con-nector, expand the plastic lugs to al-low removal of the shell-wireconnector from the switch body.

2. Disconnect the brake hydraulic linesfrom the differential valve assembly.

3. Remove the screw retaining the pres-sure differential valve assembly to theframe side rail and remove the valveassembly.

4. If the differential valve is to be re-placed, remove the brake warninglamp switch and install the switch inthe new differential valve. The pres-sure differential valve assembly andthe brake warning lamp switch areseparate units and each is serviced asa separate assembly only.

Installation1. Mount the pressure differential valve

assembly on the frame side rail andtighten the attaching screw.

2. Connect the brake hydraulic systemlines to the differential valve assemblyand tighten the tube nuts securely.

3. Connect the shell-wire connector tothe brake warning lamp switch. Makesure the plastic lugs on the connectorhold the connector securely to theswitch.

4. Bleed the brakes and centralize thepressure differential valve as outlinedin this Section of the manual.


L-, LN-, and LT-Series


spring (Fig. 7).2. Remove the brake master cylinder

push rod eccentric bolt nut, andremove the bolt and two nylon bush-ings.

3. Remove the nut from the pedal shaft.Then slide the shaft to the left and

remove the brake pedal and sleeve.4. Remove the two bushings from the

pedal, and remove the bumper fromthe pedal extension bracket if soequipped.



2. Install the bumper on the pedal exten-sion bracket (if so equipped), and po-sition the nylon bushings in the brakepedal shaft bore.

3. Position the brake pedal assembly andsleeve in the pedal support bracket.Slide the pedal shaft through thesleeve and pedal and secure with thenut. Torque the nut to specifications.

4. Position the nylon bushings in thebore of the push rod. Connect thepush rod to the brake pedal with theeccentric bolt and nut. Install thepedal retracting spring.

5. Adjust the brake pedal free travel to3/16-3/8-inch (Fig. 11, Part 12-01).Torque the eccentric bolt nut tospecifications.

P-500 Series

Removal1. Open the cover and disconnect the

transmission gearshift rods from theshaft levers. Set the rods so that themaximum working space is obtainedat the pedal support bracket.

2. Remove the pedal pads from theclutch and brake pedal (Fig. 10).

3. Remove the eight screws that retainthe two floor covers at the steeringcolumn, and remove the covers. Un-latch the engine cover assembly andopen.

4. Remove the eight floor plate retainingscrews. Pull the accelerator pedalfrom the accelerator linkage andremove the floor plate.

5. Disconnect the clutch and brakepedal retracting springs.

6. Loosen the pedal support bracketclamp bolt. Remove the cotter pinsand clevis pins from the clutch andbrake pedals.

7. Turn the front wheels full left.Through the left front fender apron,remove the locking pin from theclutch pedal and remove the pedal.Push the pedal shaft toward the cen-terline of the vehicle. From inside thecab, slide the pedal shaft and clutchpedal lever to the right and out of thesupport bracket. Remove the brakepedal from the support bracket, thenremove the bushings from the pedaland the pedal support bracket.


with a small quantity of Lubriplate oran equivalent lubricant. Install new

bushings in the pedal support bracketand the brake pedal.

2. Position the brake pedal in the sup-port bracket, and slide the pedal shaftand clutch pedal lever through thebracket and pedal.

3. Through the left front fender apron,install the clutch pedal on the shaftand secure it with a new locking pin.

4. Position the clutch rod on the clutchpedal lever, install the clevis pin andsecure it with a new cotter pin.

5. Position the brake master cylinderpush rod in the brake pedal, install theclevis pin and secure it with a newcotter pin.

6. Install the clutch and brake pedal re-tracting springs.

7. Adjust the brake pedal by removingthe clevis pin from the master cylin-der push rod and turning the hex headof the push rod until the specified freetravel is obtained.

B-Series


spring (Fig. 8).2. Remove the clevis pin retaining clip

and remove the pin, spacers, mastercylinder push rod bushing and switchassembly.

3. Remove the clip from the pedal shaft.Then slide the shaft to the left andremove the brake pedal.

4. Remove the two bushings from thepedal.



2. Position the nylon bushings in thebrake pedal shaft bore.

3. Position the brake pedal assembly inthe pedal support bracket. Slide thepedal shaft through the pedal and se-cure with the retaining clip.

4. Position the nylon bushing in the boreof the push rod. Connect the pushrod, switch assembly and spacers tothe brake pedal with the clevis pin andsecure with the retaining clip.

5. Install the pedal retracting spring.

C-Series


spring (Figs. 9 and 11).2. Remove the brake master cylinder

push rod eccentric bolt nut, bolt andnylon bushings.

3. Remove the brake pedal bumper-to-bracket retaining nut. Then removethe bolt and bumper.

4. On models with a single hydraulicbrake system, remove the master cyl-inder push rod by pulling up on thetab on the push rod boot, and remove


CLUTCH MASTER CYLINDER2140 BRAKE MASTER CYLINDER

2140

PUSH ROD

PEDAL RETRACTING SPRING

PEDAL SHAFT7506

BRAKE PEDAL

H10 34-E

FIG. 7 L-, LN-, or LT-Series Brake Pedal and Related Parts

the push rod and boot from the cylin-der.

5. Remove the nut from the bolt, slidethe bolt to the right and remove thebrake pedal assembly, sleeve andbushing.

6. Remove the bushings from the pedalassembly.

Installation

2. Position the brake pedal assemblysleeve and bushing in the pedal sup-port bracket, slide the bolt to the left

and install the nut. Torque the nut tospecifications.

3. On models with a single hydraulic


Coat all bushings and the pedal shaft,with a small quantity of Lubriplate oran equivalent lubricant. Position thenylon bushings in the brake pedalshaft bore.

15/16'

T2-V8"

t15/16'

1yS

(Ska

0.0890.879

ADJUSTMENTSCREW

wmmmmmmk\

PUSH ROD

H1665-B

FIG. 6 Midland-Ross Booster PushRod Gauge Dimensions andAdjustment

BRAKE PEDAL2455

H1627-C

FIG. 8 B-Series Brake Pedal and Related Parts


brake system, install the push rod andboot in the master cylinder.On models with a single hydraulicbrake system, install the pedalbumper bolt, bumper and nut.Tighten the nut securely.Install the two nylon bushings in thepush rod bore, and install the pushrod eccentric bolt and nut.Install the pedal retracting spring.On models with a single hydraulicbrake system, adjust the brake pedalfree-travel to 3/16-3/8 inch. Torquethe eccentric bolt nut to specifica-tions.

LOCKNUT

34445-S2(12-17 FT. LBS.)

MASTERCYLINDER

2140

PEDAL SUPPORT

SPRING\2472 > ^

BRACKET/BRAKE 2B353 S T O p L | G H T ,PEDAL S W | T C H

2 4 5 5 13480SPACER BOlT.2t62

FIG. 9 Dual Master Cylinder and Brake Pedal Installation — C-Series

PEDAL RETRACTINGSPRING 9737

BUSHING 2461

PEDAL SHAFT 7506

BUSHING \2461

BOLT 45597-S

PEDAL PAD 2457

BRAKE PEDAL 2455

BRAKE MASTER CYLINDER 2140

H1012-D

FIG. 11 Single Master Cylinder andBrake Pedal Installation —C-Series

BRAKE PEDAL2455

PEDAL PAD2454

BRAKE PEDALCLEVIS PIN

2489

CLUTCHMASTER CYLINDER

7A543

COTTER PIN

CLAMP BOLT20426-S

CLUTCHPEDAL LEVER

7524

PEDALRETRACTING

SPRINGS9737

BRAKEMASTER CYLINDER

2140

CLUTCH PEDALCLEVIS PIN 7588

PEDALSUPPORT BRACKET 2467

BRAKE ROD2462

LOCKING PIN 352581-SH1317-B

FIG. 10 Brake Pedal and Related Parts — P-500

OVERHAUL


Disassembly1. With the wheel cylinder removed,

remove the rubber boots from theends of the brake cylinder. Removethe pistons, cups, and piston returnspring from the cylinder (Fig. 12).


Assembly1. Coat all brake cylinder parts with

clean extra heavy duty brake fluidC6AZ-19542-A.


3. Place the piston return spring, cups,and pistons in the cylinder bore, andinstall a boot and link over each end

of the cylinder, clamp the brake cylin-der pistons against the ends of the cyl-inder. When a brake cylinder repairkit is used, install all of the parts sup-plied in the kit.

MASTER CYLINDER

Single Brake System

Disassembly1. With the master cylinder removed,

clean the outside of the master cylin-der, and remove the filler cap and gas-ket. Pour out any brake fluid that mayremain in the cylinder and reservoir.On a C-Series Truck master cylinder

(Fig. 13), remove the 4 bolts that hold thecylinder body on the reservoir, andremove the gasket. Press down on the

piston to compress the return spring, andremove the snap ring. Remove the piston,primary cup, piston filler, return spring,check valve, and check valve seat.

On vehicles equipped with a framemounted vacuum brake booster, thecheck valve is installed in the booster in-stead of in the master cylinder.2. On a L-, LN-, P-, or LT-Series truck

master cylinder with a box-shapedreservoir, remove the stop lightswitch if it is mounted on the mastercylinder, brake bolt, fitting, and gas-kets from the forward end of the cyl-inder (Fig. 14). Discard the gaskets.Remove the snap ring from the boreat the rear end of the cylinder, andremove the stop plate, piston cup,spring, check valve, and seat from the


cylinder bore. If necessary, blowthrough the forward bolt hole toremove the parts.

Assembly1. Dip all parts except the master cylin-

der body in clean hydraulic brakefluid. Use only C6AZ-19542-A heavyduty brake fluid.

2. On a L-, LN-, P-, LT-Series truckwith a box-shaped master cylinderreservoir, install the brake fitting,bolt, and new gaskets (Fig. 14) on theforward end of the cylinder. Installthe valve seat, valve, spring, cup, pis-ton, and stop plate in the cylinderbore. Install the snap ring in the rearend of the bore.

3. On a C-Series truck master cylinder,install the valve seat, valve, spring,piston filler, cup and piston in the cyl-inder bore. Push down on the pistonto compress the spring, and install thesnap ring in the bore. Position a newgasket over the cylinder body andmount the body to the reservoir. Se-cure with 4 bolts. Tighten bolts se-curely.

500-900 Series — Split HydraulicBrakes and Frame Mounted Booster

DisassemblyRefer to Figure 15.

1. Clean the outside of the master cylin-der. Remove the cylinder cover screw.Lift off the cover and the diaphragmgasket and pour off excess brake fluid.Use the push rod to stroke the cylin-der, forcing fluid from the cylinderthrough the outlet ports.

2. Loosen and remove the piston stopscrew and gasket from the right handside of the cylinder.

3. Pull back the push rod boot andremove the snap ring from the groovein the end of the cylinder bore.

4. Remove the push rod and stop platefrom the master cylinder.

5. Remove the internal parts from themaster cylinder. If the parts will notslide out loosely assemble the coverplate and seal the primary outlet port,then apply air pressure at the second-ary outlet port.

Inspection and Repair1. Clean all parts in isopropyl alcohol.

Inspect the parts for chipping, exces-sive wear or damage. Replace them asrequired. When using a master cylin-der repair kit, install all the parts sup-plied.

2. Check all recesses, openings and in-ternal passages to be sure they areopen and free of foreign matter. Pas-sages may be probed with soft copperwire, 0.020 inch OD, or smaller.

3. Minor scratches or blemishes in thecylinder bore can be removed with

crocus cloth or a clean up hone. Donot oversize the bore more than 0.007inch.


1. Dip all parts except the master cylin-der in clean extra heavy duty C6AZ-19542-A hydraulic brake fluid.

2. Install the rear rubber cup on the se-condary piston with the cup lip facingthe rear. All other cups face the frontor closed end of the cylinder.

3. Assemble and install the secondarypiston spring, front cup, and the se-condary piston.

4. Install the piston stop screw and gas-ket, making sure the screw enters thecylinder behind the rear of the se-condary piston.

5. Assemble and install the primary pis-ton and push rod parts.

6. Locate the stop plate in the seat in thebore and engage the snap ring into thegroove at the rear of the cylinder.

7. Install the push rod boot onto thepush rod and the groove of the cylin-der housing.


Bleeding the Master Cylinder

Before the master cylinder is installedon the vehicle, the unit should be bled.1. Support the master cylinder body in

a vise, and fill both fluid reservoirswith C6AZ-19542-A extra heavyduty brake fluid.

2. Loosely install plugs in the front andrear brake outlet bores. Depress theprimary piston several times until airbubbles cease to appear in the brakefluid.


4. Remove the plugs. Install the coverand diaphragm gasket assembly, andmake sure the cover screw is tight-ened securely.

L- and LN-500-600 Series — SplitBrake System and Dash MountedBooster

Disassembly

Refer to Figure 16.1. Clean the outside of the cylinder and

remove the filler cap and gasket (dia-phragm). Pour out any brake fluidthat may remain in the reservoir.Stroke the push rod three times toremove fluid from the cylinder bore.

2. Remove the reservoir retainers, wash-ers, and reservoir from the master cyl-inder body.

3. Remove the two rubber washers fromthe reservoir and the two O-ringsfrom the reservoir retainers.

4. Remove the snap ring, spring retainerand push rod spring.

5. Unscrew the retainer bushing coun-terclockwise and remove the pushrod, retainer bushing, seal retainerand primary piston from the mastercylinder.

6. Remove the primary piston from thepush rod and discard it.

7. Remove the seal retainer, and retainerbushing from the push rod. Removethe two lip seals and the two O-ringsfrom the retainer bushing.

8. Unscrew the end cap counterclock-wise and remove the end cap and se-condary piston assembly from themaster cylinder.

9. Remove the snap ring from the se-condary piston and remove the pistonand return spring from the end capand stop rod assembly.

10. Remove the two lip seals from thepiston.

11. Remove the snap ring from the endcap and remove the secondary pistonstop rod, relief port seal spring, thetwo snap rings and the two splitwashers from the end cap.

12. Remove the relief port seal from thesecondary piston stop rod.

13. Remove the O-rings from the endcap.

14. Remove the primary and secondaryport caps and discard.

15. Remove the check valves and springfrom the ports.

Assembly

Refer to Figure 16.1. Wash all metal parts in alcohol before

assembly. Dip all parts except themaster cylinder body in clean C6AZ-19542-A extra heavy duty hydraulicbrake fluid. When using a master cyl-inder repair kit, install all of the partssupplied.

2. Install a new primary piston into thefront end of the master cylinder bore.Push the piston through the bore untilit is flush with the retainer bushingrecess. Use a non-metallic objectwhich will not scratch the bore.

3. Assemble the O-rings and the two lipseals on the retainer bushing. Be surethe lip seals fit into the undercuts inthe center of the bushing with theirlarge diameters toward the pistonend.

4. Install the retainer bushing onto theclosed end of the push rod and pushit onto the push rod approximatelyhalf way. Be sure the lip seal at thepiston end of the retainer bushing re-mains in the undercut portion of theretainer bushing.

5. Install the seal retainer onto theclosed end of the push rod with theraised lip toward the retainer bushing.


6. Insert the push rod into the mastercylinder bore and hook the push rodonto the primary piston.

7. Slide the seal retainer into the recessin the master cylinder bore.

8. Screw the retainer bushing into themaster cylinder body and tighten to15-20 ft-lbs torque.

9. Install the push rod spring with thelarge end toward the master cylinderand install the spring retainer andsnap ring.

10. Install the O-rings on the end cap.11. Install the relief port seal on the se-

condary piston stop rod.12. Place the port seal spring, split

washer (largest of two), and snap ring(largest of two) on the piston stoprod.

13. Slide the assembly into the end capand engage the snap ring into itsgroove.

14. Install the lip seals on the secondarypiston with the large diameters facingoutward.

15. Place the secondary piston returnspring on the end cap assembly.

16. Compress the spring and place the re-maining snap ring and split washer onthe piston stop rod.

17. Slide the piston stop rod into the se-condary piston and engage the snapring in its groove.

18. Slide the end cap and piston assemblyinto the master cylinder bore andscrew the end cap into the master cyl-inder body. Tighten the cap to 15-20ft-lbs torque.

19. Install washers on the reservoir re-tainers and place the retainers in themounting holes of the reservoir.

20. Place the rubber washers and O-ringson the retainers.

21. Place the reservoir and retainer as-sembly on the master cylinder bodyand tighten the retainers to 15-20 ft-lbs torque.

22. Replace the springs and check valvesin the output ports of the cylinder.

23. Replace the primary and secondaryport caps. Tighten to 15-20 ft-lbstorque.

24. Install the mounting seal on theflange of the master cylinder. Installthe filler cap and gasket (diaphragm).

BOOT CYLINDER


2455

PISTON CUP BOOT

H1014-A

MOUNTING BOLTS

RESERVOIR

• SERVICED IN 2004 KIT

LINK RODECCENTRIC BOLT 2462

• SNAP RING

PISTON 2169

• PRIMARY CUP

PISTON FILLER2146

PISTONRETURN SPRING

2145

VALVE SEAT 2178

RESERVOIR GASKET2142

• CYLINDER BODY

y L O C K WASHER

BOLT

H1168-D

FIG. 13 C-Series Single Brake Master Cylinder — Disassembled

FITTING-2077

VALVE SEAT

PUSH ROD• SNAP RING 2143

LINK RODBOLT2462

FIG. 12 Double Servo Brake Cylinder

• RETURN SPRING

SERVICED IN 2004 KIT

BRAKE PEDAL ASSEMBLY-

HI 167-D

FIG. 14 LN-, P- or LT-Series Brake Master Cylinder — Box Shaped Reservoir


HOUSING

ALL EXCEPT C-SERIES

PRIMARYSTOP PIN

PISTON STOP PRIMARY PISTON SPRING

STOP

SECONDARYPISTON

CUP * SECONDARYPISTON SPRING

SECONDARY PISTONPRIMARY PISTON ASSEMBLY *

ASSEMBLY*

BOOT 2143

COVER ASSEMBLY2162

TORQUE-85-115 IN-LBS

*PART OF 2004 KIT

C SERIES

H1664-E

FIG. 15 Dual Master Cylinder — Disassembled View — 500-850-Series Trucks with Split Hydraulic Brakes andFrame-Mounted Booster

SECONDARY PORT PRIMARY PORT

RESERVOIR GASKETWASHER RETAINER O-RING DIAPHRAGM

\ \ FILLERCAP

SEALS (2) TO BE MOUNTEDAS SHOWN WITH LARGEDIA. TOWARD PISTON

END RELEAF PORT SNAP STOP SNAP SPLIT SECONDARY PRIMARY SEAL X RETAINER \ PUSH RODCAP SEAL RING ROD RING WASHER PISTON PISTON RETAINER O-RING BUSHING PUSH ROD RETURN SPRING

H1463-A

FIG. 16 Dual Master Cylinder — L-500-600, LN-6000, B-500-700 with Midland Ross Dash-Mounted Booster


SPECIFICATIONS

SPECIFIC TORQUE LIMITS

Front Brake Backing Plate to Spindle (100-400 Series)

Front Brake Backing Plate and Steering Arm to Spindle (100-400 Series)

Rear Backing Plate to Axle (100-400 Series)

Brake Assembly to Front Axle (500-900 Series)

Brake Assembly to Rear Axle (500-900 Series)

Brake Drum to Hub Nuts or Bolts (500-900 Series)

Master Cylinder or Booster Push Rod to Brake Pedal (500-900 Series)

Master Cylinder to Dash Panel (500-900 Series)

Master Cylinder to Booster (Dash Mounted Booster) (500-700 Series)

Booster to Dash Panel (Dash Mounted Booster) (500-700 Series)

Master Cylinder to Pedal Bracket

Eccentric Adjuster Bolt Torque

1/2 x 13,55-70

1/2 x 13,30-40

1/2 x 13,75-105

9/16 x 12, 110-150

9/16 x 12, 110-150

1/2 x 13,68-85

3/8 x 16, 12-17

5/16 x 18, 12-17

14-18

3/8 x 16, 12-17

5/16x24, 12-15

80-120 inch lbs.

7/16 x 14,30-50

1/2x20,50-70

1/2x20,50-70

1/2 x 13,75-105

1/2x13,75-105

5/8 x 18, 136-170

3/8 x 16,31-42

3/8x24, 13-20

3/8x24, 12-17

1/2x20,55-75

7/16 x 14,35-45

1/2x20,75-105

1/2x20,75-105

5/16 x 18,12-15

TORQUE LIMITS - HYDRAULIC TUBE NUTS (FT-LBS)

Thread Size

3/8-24

7/16-24

Ft-Lbs. ©

8-15

12-17

© A l l hydraulic line connections (nuts) must be torqued to the specified value and 1

BRAKE DRUM REPAIR LIMITS (BRAKE LATHE)

Brake drums are marked with the maximum allowable braking surface diameter. 1

Thread Size

1/2-20

9/16-18

ree of fluid leakage.

this diameter is exceeded by wear or refinishing, the drum must be replaced.

Ft-Lbs. ©

12-17

15-25

CH 1878-A

50-41-2 Body 50-41-2

LUBRICATION

LUBRICATE HOOD LATCH ANDHINGES

Spray Specified Polyethylene grease(Part 50-03) on all pivot points and on thestriker plate as required to eliminate anybinding condition. Operate the latchmechanism several times to be sure thatthe lubricant has effectively worked in.

LUBRICATE HOOD AUXILIARYCATCH

Spray Specified Polytheylene Grease(Part 50-03) on all pivot points as re-quired to eliminate any binding condi-tions. Operate the catch several times tobe sure that the lubricant has effectivelyworked in.

LUBRICATE LOCK CYLINDERS

Apply Specified Lock Lubricant (Part50-03) sparingly through the key slot. In-

sert the key and operate the lock severaltimes to be sure that the lubricant haseffectively worked in.

LUBRICATE DOOR HINGE, HINGECHECK, ROTOR AND STRIKERPLATE

Spray Ford Polythylene Grease (Part50-03) on the hinge pivot points, rotor,and striker plate as required to eliminateany binding condition. Open and closethe door several times to be sure that thelubricant has effectively worked in.

LUBRICATE TAILGATE HINGE

Spray Specified Polythylene Grease(Part 50-03) on all pivot and frictionpoints to eliminate any binding condi-tions. Operate the tailgate several timesto be sure that the lubricant has effec-tively worked in.

LUBRICATE CAB LATCH(W-SERIES)

Squirt 10W oil into the cab lowerlatch to lubricate the locking cams (Fig.1).

FIG. 1 Cab LatchLubrication—W-Series

MAINTENANCE

CLEAN BODY AND DOOR DRAINHOLES

Drain holes, located along the bottomsurface of the door and side panels,should be inspected periodically for

plugged or obstructed condition. A prac-tical time for inspection is whenever thevehicle is washed. Use a small screw-

driver or similar tool to clean these drainholes.

SPECIFICATIONS

FRONT BUMPER BOLTS TORQUE

3/8 Inch

7/16 Inch

9/16 Inch

1/2 Inch

5/8 Inch

. . 30-40 Ft-Lbs.

. . 50-70 Ft-Lbs.

. . 80-90 Ft-Lbs.

. 75-105 Ft-Lbs.

140-180 Ft-Lbs.

CY 1375-B

Documents

DEMO - 1972 Ford Truck Shop Manual Vol 1-5