Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake9•2 Braking systemTorque wrench settings Nm lbf ftMaster cylinder to servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 15 to 18Servo to mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 to 45 26 to 33Pedal-to-servo cross-link brackets to bulkhead . . . . . . . . . . . . . . . . . . 20 to 25 15 to 18Rear drum/hub to axle flange bolts* . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 to 76 41 to 56Caliper-to-spindle carrier (anchor bracket) bolts . . . . . . . . . . . . . . . . . . 50 to 66 37 to 49Caliper piston housing retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 15 to 18Load-apportioning valves to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 25 15 to 18Load-apportioning valve bracket to vehicle . . . . . . . . . . . . . . . . . . . . . . 21 to 28 15 to 21Load-apportioning valve adjustment screw . . . . . . . . . . . . . . . . . . . . . . 12 to 16 9 to 12Load-apportioning valve-to-axle beam link rod nut . . . . . . . . . . . . . . . . 21 to 28 15 to 21Modulator pivot and adjusting clamp bolts . . . . . . . . . . . . . . . . . . . . . . 22 to 28 16 to 21Modulator drivebelt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 12 6 to 9Roadwheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 to 110 52 to 74*Applies to all models except Courier. No figures are quoted by the manufacturers for Courier models.1 General informationThe braking system is of the diagonallysplit, dual-circuit hydraulic type, with servoassistance to the front disc brakes and reardrum brakes. The dual-circuit hydraulicsystem is a safety feature - in the event of amalfunction somewhere in one of thehydraulic circuits, the other circuit continuesto operate, providing at least some brakingeffort. Under normal circumstances, bothbrake circuits operate in unison, to provideefficient braking.The master cylinder (and the vacuum servounit to which it is bolted) is located on the lefthandside of the bulkhead in the enginecompartment. On all right-hand drive variants,they are jointly operated via a transversecross-link from the brake pedal.Brake pressure control valves are fitted inlineto each rear brake circuit, their functionbeing to regulate the braking force available ateach rear wheel, reducing the possibility ofthe rear wheels locking up under heavybraking. Courier models also have a “lightladen”valve incorporated into the rear brakingcircuits for the same reason.The front brake discs are of the ventilatedtype on XR2i and ABS-equipped models, withsolid discs fitted on all other models. The frontbrake calipers are of single sliding piston typemounted on the front spindle carriers eachside.Each rear brake shoe assembly is operatedby a twin-piston wheel cylinder. The leadingbrake shoe in each brake unit has a thickerlining than the trailing shoe, so that they wearproportionally. To take up the brakeadjustment as the linings wear, each rearbrake assembly incorporates an automaticadjuster mechanism.The cable-operated handbrake acts onboth rear brakes, to provide an independentmeans of brake operation.An anti-lock braking system (ABS) isavailable on some models, and has many ofthe components in common with theconventional braking system. Further detailson ABS can be found later in this Chapter.Note: When servicing any part of the system,work carefully and methodically; also observescrupulous cleanliness when overhauling anypart of the hydraulic system. Always renewcomponents (in axle sets, where applicable) ifin doubt about their condition, and use onlygenuine Ford replacement parts, or at leastthose of known good quality. Note thewarnings given in “Safety first” and at relevantpoints in this Chapter concerning the dangersof asbestos dust and hydraulic fluid.2 Front brake pads - renewal2Warning: Disc brake pads MUSTbe renewed on both frontwheels at the same time -NEVER renew the pads on onlyone wheel, as uneven braking may result.The front brake calipers will be of Bendixor Teves manufacture, and if they or theircomponent parts require renewal, ensurethat the correct type is fitted. Dust createdby wear of the pads may contain asbestos,which is a health hazard. Never blow it outwith compressed air, and do not inhale anyof it. DO NOT use petroleum-basedsolvents to clean brake parts - use brakecleaner or methylated spirit only. DO NOT2.3a Remove the rubber blanking plugs foraccess to the caliper mounting bolts . . .allow any brake fluid, oil or grease tocontact the brake pads or disc. Also referto the warning in Section 13 concerningthe dangers of hydraulic fluid.1 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and Vehicle Support”). Removethe front roadwheels.2 Hold the caliper support spring with a pairof pliers, and prise it out of its location in thecaliper housing using a screwdriver (seeillustration).3 Prise free the blanking plugs from thecaliper upper and lower mounting bolts.Unscrew the bolts, then withdraw the caliperfrom the anchor bracket (see illustrations).Suitably support the caliper to avoid strainingthe brake hose.2.2 Prise out the caliper support springwith a screwdriver2.3b . . . unscrew the bolts then withdrawthe caliper from the anchor bracket