Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake9•4 Braking system4.4 Checking brake disc run-out using adial gauge15 Unplug the hydraulic hose, and check thatthe unions are clean. Reconnect the caliper tothe hose so that the hose is not twisted orstrained. The hose union connection can befully tightened when the caliper is refitted.16 Refit the brake pads as described inSection 2.17 The brake hydraulic hose can now be fullytightened. When secured, turn the steeringfrom lock-to-lock to ensure that the hosedoes not foul on the wheel housing orsuspension components.18 Bleed the brake hydraulic system asdescribed in Section 13 or 14 according totype. Providing suitable precautions weretaken to minimise loss of fluid, it should onlybe necessary to bleed the relevant frontbrake.19 Refit the roadwheel, lower the vehicle tothe ground, then tighten the wheel nuts to thespecified torque.4 Front brake disc - inspection,removal and refitting2Note: Before starting work, refer to thewarning at the beginning of Section 2concerning the dangers of asbestos dust.InspectionNote: If a disc requires renewal, BOTH frontdiscs should be renewed or reground at thesame time to ensure even and consistentbraking. New brake pads should also be fitted.1 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and Vehicle Support”). Removethe appropriate front roadwheel.2 Temporarily refit two of the wheel nuts todiagonally-opposite studs, with the flat sidesof the nuts against the disc. Tighten the nutsprogressively, to hold the disc firmly.3 Scrape any corrosion from the disc. Rotatethe disc, and examine it for deep scoring,grooving or cracks. Using a micrometer,measure the thickness of the disc in severalplaces. Light wear and scoring is normal, butif excessive, the disc should be removed, andeither reground by a specialist, or renewed. If4.8a Extract the brake disc securingscrew . . .regrinding is undertaken, at least the minimumthickness must be maintained. Obviously, ifthe disc is cracked, it must be renewed.4 Using a dial gauge, check that the disc runout,measured at a point 10.0 mm from theouter edge of the disc, does not exceed thelimit given in the Specifications. To do this, fixthe measuring equipment, and rotate the disc,noting the variation in measurement as thedisc is rotated (see illustration). Thedifference between the minimum andmaximum measurements recorded is the discrun-out.If a dial gauge is notavailable, check the run-outby positioning a fixedpointer near the outer edge,in contact with the disc face. Rotatethe disc and measure the maximumdisplacement of the pointer with feelerblades.5 If the run-out is greater than the specifiedamount, check for variations of the discthickness as follows. Mark the disc at eightpositions 45° apart, then using a micrometer,measure the disc thickness at the eightpositions, 15.0 mm in from the outer edge. Ifthe variation between the minimum andmaximum readings is greater than thespecified amount, the disc should berenewed.Removal6 Remove the caliper and its anchor bracketwith reference to Section 3, but do notdisconnect the hydraulic brake hose.Suspend the caliper assembly from the frontsuspension coil spring, taking care to avoidstraining the brake hose.7 Remove the wheel nuts which weretemporarily refitted in paragraph 2.8 Unscrew the screw securing the disc to thehub, and withdraw the disc (seeillustrations). If it is tight, lightly tap its rearface with a hide or plastic mallet.Refitting9 Refit the disc in a reversal of the removalsequence. If new discs are being fitted, first4.8b . . . and remove the disc from the hubremove their protective coating. Ensurecomplete cleanliness of the hub and discmating faces and tighten the screw securely.10 Refit the caliper/anchor bracket withreference to Section 3.11 Refit the roadwheel, lower the vehicle tothe ground, and tighten the wheel nuts to thespecified torque.5 Rear brake drum - removal,inspection and refitting 2Note: Before starting work, refer to thewarning at the beginning of Section 6concerning the dangers of asbestos dust.Removal1 Chock the front wheels then jack up therear of the car and support it on axle stands(see “Jacking and Vehicle Support”). Removethe appropriate rear roadwheel, and releasethe handbrake.2 Undo the four bolts securing the drum/huband stub axle assembly to the rear axleflange, then withdraw the drum/hub from theaxle. If the brake drum is stuck on the shoes,remove the rubber access plug from the rearof the brake backplate, and release theautomatic brake adjuster by levering therelease catch on the adjuster pawl through thebackplate (see illustration).3 With the brake drum removed, brush orwipe the dust from the drum, brake shoes,5.2 Removing the rubber access plug fromthe rear of the brake backplate