Chapter 1 Routine maintenance and servicing

Braking system 9•78.3 Compress the retaining lugs (arrowed),and release the handbrake cable from thebackplate8 Rear brake backplate -removal and refitting3Removal1 Remove the brake drum/hub assembly asdescribed in Section 5.2 Remove the rear brake shoes as describedin Section 6.3 Compress the three retaining lugs, andrelease the handbrake cable from thebackplate by pushing it back through theplate (see illustration).4 Using a suitable hose clamp, isolate therelevant rear brake unit by clamping itsflexible brake hose.5 Disconnect the brake pipe at the wheelcylinder union, and fit blanking plugs toprevent dirt ingress.6 Drill out the pop-rivets securing thebackplate to the rear axle, and remove thebackplate (see illustration).7 Remove the single bolt securing the wheelcylinder to the brake carrier plate, andwithdraw the wheel cylinder.8 If required, remove the handbrakeadjustment plunger from the backplate bygently prising the spring off, over the plungerabutment, then withdraw the plunger from thebrake shoe side (see illustration). Remove theplunger collar from the rear of the backplate.Refitting9 Locate the wheel cylinder in positionandsecurely tighten the retaining bolt.8.6 Drilling out a pop-rivet securing thebrake backplate to the axle flange10 If removed, refit the handbrakeadjustment plunger to the backplate.11 Place the backplate in position andtemporarily insert the hub/drum retainingbolts to ensure correct alignment. Now securethe brake backplate using new pop rivets12 Refit the handbrake cable, and ensurethat the retaining lugs are secure.13 Connect the brake pipe to the wheelcylinder and remove the brake hose clamp.14 Refit the rear brake shoes as described inSection 6.15 Refit the brake drum/hub as described inSection 5.16 On completion, bleed the brake hydraulicsystem as described in Section 13 or 14 (asapplicable).9 Master cylinder - removal,overhaul and refitting3Note: Before starting work, refer to thewarning at the beginning of Section 13concerning the dangers of hydraulic fluid.Removal1 Disconnect the wiring multi-plug from thefluid level warning indicator in the reservoirfiller cap, then remove the filler cap from thereservoir. Note that the filler cap must not beinverted. The brake fluid should now beremoved from the reservoir.2 Identify each brake pipe and its connectionto the master cylinder. Unscrew the fluid pipe8.8 Handbrake adjustment plungerA Plunger B Spring C CollarAn ideal way to remove fluidfrom the master cylinderreservoir is to use a cleansyringe or an old poultrybaster.to master cylinder union nuts and disconnectthe pipes. On models equipped with anti-lockbrakes, disconnect the modulator returnhoses from the brake fluid reservoir, collectingfluid spillage from the hoses in a suitable tray(see illustration). The modulator return hoseunions should be disconnected by firstpushing the hose into the reservoir, thenretaining the collar against the reservoir bodywhilst withdrawing the hose. Note that themodulator return hoses are colour coded - theleft-hand modulator has a black return hoseand connector, and should be fitted to theforward section of the reservoir, whilst theright-hand modulator has a grey return hoseand connector, and should be fitted to therear section of the reservoir.3 Unscrew the mounting nuts and withdrawthe master cylinder from the servo unit.Overhaul4 With the master cylinder removed, emptyany remaining fluid from it, and clean itexternally.5 Withdraw the brake fluid reservoir from thetop of the master cylinder by pulling androcking it free from its retaining seals (seeillustration).6 Extract the reservoir seals from the top faceof the master cylinder (see illustration).99.2 Modulator return hose connections atthe brake fluid reservoirA Return hoses B Collars9.5 Removing the brake fluid reservoirfrom its seals in the master cylinder9.6 Brake fluid reservoir seal1595Ford Fiesta Remake