Chapter 1 Routine maintenance and servicing

1595Ford Fiesta Remake9•6 Braking system6.11 Brake shoe contact points on brakebackplate (arrowed)9 Detach the automatic brake adjustercam in a similar manner to that describedin the previous paragraph, noting itsorientation.10 Clean the adjuster strut and its associatedcomponents.11 Clean the backplate, then apply a littlehigh-melting-point grease to the shoe contactpoints on the backplate and the lower anchorplate (see illustration). On models soequipped, refit the anti-rattle shims to thebrake shoe lower pivot on the backplateensuring that they are securely located.12 Fit the handbrake operating lever to thetrailing shoe, using a new spring clip.13 Fit the automatic brake adjuster cam tothe leading shoe, using a new spring clip.14 Apply a small amount of high-meltingpointgrease to the automatic brake adjustercam and pawl contact faces, and wherethe cam and handbrake operating leversweep across their respective brake shoes.Do not over-apply, as this may result in liningcontamination in use - a thin smear willsuffice. Take care not to allow any grease tocontact the brake linings.15 Fit the adjuster strut to the trailing shoe,securing with its spring, then connect the freeend of the strut to the automatic brakeadjuster cam. Fit the upper pull-off springbetween the tops of the two brake shoes.16 Reconnect the handbrake cable to itsoperating lever.17 Position the brake shoes onto thebackplate so that their upper leading edgesrest against the wheel cylinder pistons, andtheir lower leading edges engage either sideof the lower pivot. Fit the lower pull-off springinto its locating slots at the bottom end ofeach brake shoe.18 Insert the brake shoe locking pins throughthe rear of the backplate, then relocate thesprings and cups. Depress and turn the cupsthrough 90° to secure.19 Check that the brake shoes and theirassociated components are correctly refitted,then refit the brake drum with reference toSection 5.20 Repeat the procedure on the remainingrear brake.7 Rear wheel cylinder -removal, overhaul and refitting 3Note: Before starting work, refer to thewarning at the beginning of Section 13concerning the dangers of hydraulic fluid.Removal1 Remove the brake drum as described inSection 5.2 Using a suitable hose clamp, isolate therelevant rear brake unit by clamping itsflexible brake hose.3 Disconnect the brake pipe at the wheelcylinder union, and fit a blanking plug to thebrake pipe to prevent dirt ingress.4 On all models except Courier, drill out thepop-rivets securing the brake backplate to theaxle flange, and withdraw the backplateassembly with the brake shoes in situ. Notethat it is not possible to remove the backplatecompletely as the handbrake cable will still beattached to the brake shoes.5 Expand the brake shoes by pulling theirtops away from the wheel cylinder. Theautomatic brake adjuster will hold the shoesclear of the wheel cylinder for ease ofremoval.6 Remove the single bolt securing the wheelcylinder to the brake backplate, and withdrawthe wheel cylinder (see illustration).Overhaul7 Clean any heavy dirt or grease depositsfrom the external surfaces of the wheelcylinder, then pull off the dust-excludingcovers (see illustration).8 The pistons and seals will probably shakeout. If they do not, apply air pressure from afoot-operated tyre pump to the brake pipeconnection to eject them.9 Examine the surfaces of the pistons and thecylinder bores for scoring or signs of metal-tometalrubbing. If evident, renew the completecylinder assembly.10 If the cylinder is to be renewed, note that7.6 Rear view of brake backplateA Wheel cylinder-to-brake backplateretaining boltB Wheel cylinder brake pipe connectionC Bleed screwthree sizes are used across the Fiesta range,dependent on specification. Ensure that thenew cylinder obtained is of the correct size tomaintain the rear braking balance.11 Where the pistons and cylinder bores arein good condition, discard the rubberseals and dust excluders and obtain a repairkit.12 Any cleaning of the components shouldbe done using clean hydraulic fluid ormethylated spirit - nothing else.13 Reassemble by dipping the first piston inclean hydraulic fluid, then manipulate its sealinto position using fingers only. Ensure thatthe seal is fitted correctly with its raised lipfacing away from the brake shoe bearing faceof the piston.14 Insert the first piston into the wheelcylinder from the opposite end of the cylinderbody. With it located in position, fit a dustexcludingcover to it.15 Fit the seal to the second piston, asdescribed in paragraph 13, then insert thespring to the wheel cylinder, followed by thesecond piston. Take care not to damage thelip of the seal when fitting to the wheelcylinder - additional lubrication with cleanhydraulic fluid and a slight twisting actionmay help. Once again, only fingers should beused.16 Fit the dust excluding cover to the secondpiston.Refitting17 Refitting is the reverse sequence toremoval. When refitting the backplate, locateit in position and temporarily insert thehub/drum retaining bolts to ensure correctalignment. Now secure the brake backplateusing new pop rivets. Release the automaticbrake adjuster so that the brake shoes arebrought into contact with the wheel cylinder,before refitting the hub/drum assembly asdescribed in Section 5.18 On completion, bleed the brake hydraulicsystem as described in Section 13 or 14 (asapplicable).7 .7 Exploded view of rear wheel cylindercomponentsA Dust cap E PistonB Bleed screw F SealC Wheel cylinder G SpringD Dust-excluding cover