Home

06-02 Brakes, Rear Drum

1. Installation 1 Ifa new brake drum is to be installed remove the protective coating from the new brake drum with carburetor degreaser or equivalent 2 Adjust the rear brake shoe and lining 2200 as described in this section using Brake Adjustment Gauge D81L 1103A or equivalent Brake drum turning may be performed as long as the maximum inside diameter is not exceeded The maximum inside diameter is cast into the drum face 3 Install the brake drum 4 Install the wheel on the wheel hub bolts against the brake drum and tighten the lug nuts 1012 to 135 Nm 100 Ib ft file CNTSOMsocachevVDTOM 5368NSVK us en file SVK62008 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 4 of 4 file CNTSOMsocachevVDTOM 5368NSVK us en file SVK62008 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 16 Section 06 02 Brakes Rear Drum 1997 Aerostar Ranger Workshop Manual REMOVAL AND INSTALLATION Brake Shoes and Lining SPECIAL SERVICE TOOL S REQUIRED Hold Down Spring Tool T73T 2300 A AN CAUTION To ensure correct assembly note the position of each part removed Removal 1 Remove the wheel 1007 and brake drum 11296 2 NOTE If the boots are not removed brake fluid leakage past the cups may go undetected because the boots may seal the fluid in the rear wheel cylinder If leaks are found the rear wheel cylinder must be repaired or replaced Inspect rear wheel cylinder for signs of leaks or presence of r
2. Brake Backing Plate 1 Inspect the brake backing plate for correct mounting and securely tightened mounting nuts 2 Inspect the brake shoe and lining contact pads where the rear brake shoe and lining rest e Deep grooves in the brake shoe and lining contact pads could restrict brake shoe and lining movement e If grooves exist hand sand the brake shoe and lining contact pads e If the grooves are still present after hand sanding the rear brake backing plate must be replaced Any attempt to remove the grooves by grinding may result in improper brake shoe and lining to brake drum contact 3 Inspect all other brake parts and replace any that are worn or damaged file C TSO tsocache VDTOM_5368 S VK us en file S VK62015 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 3 of 3 file C TSO tsocache VDTOM_5368 S VK us en file S VK62015 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 2 Section 06 02 Brakes Rear Drum 1997 Aerostar Ranger Workshop Manual ADJUSTMENTS Brake Drum Refinishing Minor scores on brake drums 1126 can be removed with sandpaper Do not refinish brake drums to remove score marks A drum surface which is highly polished can cause brake lockup or noise This polished condition should be removed with sandpaper A brake drum that is out of round sufficient to cause vehicle vibration or roughness when braking should be refinished Remove only enough stock to true up the brake drum When brake d
3. C TSO tsocache VDTOM_5368 S VK us en file S VK62011 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 3 of 6 10 INCH REAR BRAKE amm 3 hem Par Number 2 Anchor Pin Part of 2211 3 4 Rear Brake Shoe and Lining Secondary Adjusting Lever Pin Part of 2200 10 2 176 Brake Shoe Adjusting Lever 11 2A180 Adjusting Lever Return Spring 12 12047 Brake Shoe Adjusting Screw Nut file C TSO tsocache VDTOM_5368 S VK us en file S VK62011 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 4 of 6 13 2041 Brake Adjuster Screw Rear Brake Shoe and Lining Primary 2A601 Parking Brake Link Spring 2A642 Primary Brake Shoe Parking Brake Lever Link 2296 Brake Shoe Retracting Spring Short 4 Remove the axle shaft 4234 Refer to Section 05 02A or Section 05 02B Use care not to damage the oil seal 5 Remove the nuts retaining the brake backing plate to the rear axle housing and remove the brake backing plate and the rear wheel gasket from the rear axle housing Installation 1 Apply Silicone Rubber D6AZ 19562 AA or BA or equivalent meeting Ford specification ESB M4G92 A or ESE M4G195 A to braking plate mounting hole to seal axle shaft flange mounting area 2 Position the brake backing plate and rear wheel gasket on the rear axle housing 3 Install the backing plate retaining nuts Alternately and evenly tighten the nuts to 34 47 Nm 25 35 Ib ft 4 Apply a light coating of Disc Brake Caliper
4. 1997 Aerostar Ranger Page 3 of 16 RETAINER CLIP AND SPRING WASHER PART OF 2A637 PARKING BRAKE LEVER 2A637 Rear Brake Ranger Brake Shoe Hold Down Spring Pin 221 2026 Brake Shoe Anchor Pin Gude Pae 5 2 Brake Shoe Revracing Spang Sho s freke Shoe Revacing Spring Long s peas wem CCS s mos Paring Brake Lever PinRetaner Part Number Description 2 2028 Item 3 file C TSO tsocache VDTOM_5368 SVK us en file SVK62009 HTM gen ref 2011 04 28 1997 Aerostar Ranger Page 4 of 16 15 2048 Brake Shoe Adjusting Screw Stud 16 372583 S Thrust Washer 7 18 19 20 Rear Brake Shoe and Lining Primary 21 Brake Shoe Adjusting Lever Cable 22 Brake Backing Plate Rear Brake Aerostar file C NTSOMtsocache lVDTOM 5368NSVK us en file SVK62009 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 5 of 16 14 2A787 Parking Brake Spring Retainer 15 2 176 Brake Shoe Adjusting Lever 16 2048 Brake Shoe Adjusting Screw Socket 17 18 19 20 21 Rear Brake Shoe and Lining Primary 22 23 Installation 1 Clean the ledge pads on the brake backing plate 2 Apply a light coating of Disc Brake Caliper Slide Grease D7AZ 19590 A or equivalent meeting Ford specification ESA M1C172 A at the points where the brake shoes touch the brake backing plate 3 Before installing the rear brake shoes and linings assemble
5. BRAKE SHOE REMOVAL RETRACTING INSTALLATION SPRING 2296 BRAKE CYLINDER CLAMP D81L 1103 B NOTE Make sure the brake shoe adjusting lever cable is positioned in the groove and not between the cable guide and the shoe web Install the cable guide on the secondary shoe web with the flanged holes fitted into the hole in the secondary shoe web Thread the brake shoe adjusting lever cable around the cable guide groove NOTE Make sure the cable end is not cocked or binding on the anchor pin when installed All parts should be flat on the anchor pin Install the secondary shoe to anchor long spring Remove the wheel cylinder clamp AN CAUTION Install the brake adjuster screw in the same location from which it was removed Interchanging the brake adjuster screws from one side of the vehicle to the other will cause the rear brake shoe and lining to retract rather than expand each time the automatic adjusting mechanism is operated NOTE For Aerostar to prevent incorrect installation the socket end of each brake shoe adjusting screw is stamped with R or L to indicate their installation on the right or left side of the vehicle The brake shoe adjusting screw nuts can be distinguished by the number of lines machined around the body of the nut Two lines indicate a right hand nut one line indicates a left hand nut Another way to identify adjusters is to check thread pitch The right side adjuster has right hand threads while the left side
6. CAREFULLY USED TO REMOVE ANY DUST ADHERENT DUST SHOULD BE REMOVED WITH A DAMP RAG ANY DUST SHOULD BE CONTAINED IN A SEALED AND LABELED BAG FOR DISPOSAL WEAR AN APPROVED HIGH EFFICIENCY CARTRIDGE OR AIR LINE RESPIRATOR AND USE EXTRA CAUTION TO AVOID BREATHING THIS DUST ALWAYS USE NON ASBESTOS REPLACEMENT PARTS The rear brakes are automatically adjusted while driving the vehicle in reverse and sharply applying the brakes and then driving forward It may be necessary to do this several times to obtain the proper rear brake adjustment Manual brake adjustment is required only after the brake shoes have been replaced or if brake shoe adjusting lever has malfunctioned and has been repaired or replaced Perform the manual adjustment with the brake drums 1126 removed using Brake Adjustment Gauge D81L 1103 A or equivalent and the procedure described below When adjusting the rear brake shoes check the parking brake rear cable and conduit 2A635 for proper operation Make sure the equalizer operates freely For parking brake service refer to Section 06 05 1 Raise vehicle on hoist Position suitable safety stands under vehicle Remove wheel 1007 Remove brake drum as described in this section 2 Use Rotunda Brake Clutch Service Vacuum 091 R0001 or equivalent to remove any dust present on the brake assembly 3 Carefully remove the brake shoe hold down spring Using sandpaper clean the shoe to backing plate contact points while holding th
7. HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 5 of 7 BRAKE BACKING PLATE 2211 MOVED UPWARD TO EXPAND BRAKES AND DOWN TO CONTRACT ADJUSTER H9975 A Aerostar file C TSO tsocache VDTOM_5368 S VK us en file S VK62017 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 6 of 7 PLUG REMOVED C BRAKE SHOE ADJUSTING LEVER KIT 2A176 G HANDLE MOVED UPWARD TO RETRACT BRAKE SHOES HANDLE MOVED DOWNWARD TO EXPAND BRAKE SHOES H1582 F 3 When the rear brake shoes and linings are against the brake drum loosen the brake shoe adjusting screw nut 10 to 12 notches so that the brake drum rotates freely without drag 4 Ifthe brake drum does not rotate freely remove the wheel and brake drum and vacuum out any dust and dirt from the linings using Rotunda Brake Clutch Service Vacuum 091 R0001 or equivalent 5 Using sandpaper remove any rust from the points where the shoes touch the brake backing plate 6 Check brake backing plate for damage If none is found apply a light coating of Disc Brake Caliper Slide Grease D7AZ 19590 A or equivalent meeting Ford specification ESA M1C172 A Do not get the lubricant on the rear brake shoe and lining 7 Install the wheel and brake drum and adjust the rear brake shoe and lining 8 Install the adjusting hole cover in the brake backing plate 9 Check and adjust the other rear brake assembly 10 Apply the brakes If the pedal travels more than halfway t
8. Make sure the adjuster rotates freely 9 If necessary remove the adjuster for disassembly and cleaning then lubricate the adjusting screw threads and pilot end with a thin uniform coating of Disc Brake Caliper Slide Grease D7AZ 19590 A or equivalent meeting Ford specification ESA M1C172 A Checking Adjustment Typical file C TSO tsocache VDTOM_5368 S VK us en file S VK62017 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 4 of 7 10 11 12 13 D81L 1103 A Install the brake drums Install the wheel on the brake drum and tighten the lug nuts 1012 to 135 Nm 100 Ib ft Remove the safety stands and lower the vehicle After adjusting the brake shoes check brake operation before moving the vehicle Complete the adjustment by sharply applying the brakes several times while driving the vehicle alternately in forward and reverse Drums Installed Adjust the single anchor brake by turning the adjusting screw located between the lower ends of the shoes T Place transmission 7003 in neutral Raise the vehicle until the tires clear the floor Install safety stands Remove the cover from the adjusting hole at the bottom of the brake backing plate and turn the brake shoe adjuster assembly using Brake Adjustment Tool D81L 1103 C or equivalent inside the hole to expand the brake shoes until they lock the brake drum Refer to illustration Ranger file C TSO tsocache VDTOM_5368 S VK us en file S VK62017
9. Slide Grease D7AZ 19590 A or equivalent meeting Ford specification ESA M1C172 A to the ledge pads at the points where the rear brake shoe and lining contact the brake backing plate file C TSO tsocache VDTOM_5368 S VK us en file S VK62011 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 5 of 6 10 11 LUBRICATE LEDGES WITH DISC BRAKE CALIPER SLIDE GREASE 07 2 19590 ESA MIC172 A OR EQUIVALENT Feed the parking brake rear cable and conduit through its hole in the brake backing plate and engage locking fingers Install the axle shaft Refer to Section 05 02A or Section 05 02B as required in the Powertrain Drivetrain Service Manual Use care not to damage the oil seal Install the rear wheel cylinder and rear brake shoe and lining and adjust using Brake Adjustment Tool D81L 1103 C or equivalent Connect the parking brake rear cable and conduit to the parking brake lever Install the rear brake shoe and lining Refer to the procedure in this section Connect the brake line to the rear wheel cylinder Tighten the brake line fitting to 15 20 Nm 11 14 Ib ft Install the brake drum 1126 and wheel and tire assembly Tighten the lugnuts to 135 Nm 100 Ib ft Bleed air from the system as described in Section 06 06 file C TSO tsocache VDTOM_5368 S VK us en file S VK62011 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 6 of 6 file C TSO tsocache VDTOM_5368 S VK us en file S VK62011 HTM gen ref HTM 2
10. adjuster has left hand threads The adjuster will also increase in length when the adjusting lever is operated if properly installed Apply Premium Long Life Grease XG 1 C or K or equivalent meeting Ford specification ESA M1C75 B to the threads of the brake adjuster screw the thrust washer and the brake shoe adjusting screw stud or socket Turn the adjusting screw into the brake shoe adjusting screw nut to the end of the threads and then loosen it one half turn Refer to illustrations file C TSO tsocache V DTOM_5368 S VK us en file S VK62009 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 9 of 16 Aerostar em Partnumber Description EN _ Part of 2041 Identification Lines RH Part of 2047 2047 Brake Adjuster Screw Nut Ranger file C TSO tsocache VDTOM_5368 S VK us en file S VK62009 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 10 of 16 H9978 A hem PatNumbe Desorption 2047 6 on fbrekeShoeAdustngSeew A terhandidentfer ing p 11 Assemble the adjuster and install the assembly between the shoe ends Refer to illustrations Aerostar file CNTSOMsocachevVDTOM 5368NSVK us en file SVK62009 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 11 of 16 H4718 1A 12 Onthe Aerostar hook the cable hook into the hole in the brake shoe adjusting lever from the outboard plate side The brake shoe adjustin
11. and linings 2200 for excessive lining wear or shoe damage If lining is damaged or worn within 0 79mm 1 32 inch of the rivet heads on riveted linings it must be replaced Replace any rear brake shoe and lining that has been contaminated with oil grease or brake fluid Replace rear brake shoe and lining in axle sets only Never replace just one rear brake shoe and lining of a brake assembly Replace both primary and secondary shoes Prior to replacement of lining brake drum diameter should be checked to determine that brake drum diameter is within specification If braking surface diameter exceeds specification the brake drum must be replaced Check condition of rear brake shoes and linings retracting spring hold down springs and brake drum for signs of overheating If rear brake shoe and lining metal parts have a slight blue coloring indicating overheating retracting and hold down springs should be replaced Overheated springs lose their tension and could allow new rear brake shoe and lining to drag and wear prematurely if not replaced Springs Check springs for file C TSO tsocache VDTOM_5368 S VK us en file S VK62015 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 3 e Spread or collapsed coils e Twisted bent or damaged shanks e Discoloration This is a sign of brake overheating Overheated springs lose some of their tension and should be replaced SPREAD OR COLLAPSED COILS DISCOLORATION H9179 A
12. 011 04 28 1997 Aerostar Ranger Page 1 of 3 Section 06 02 Brakes Rear Drum 1997 Aerostar Ranger Workshop Manual DISASSEMBLY AND ASSEMBLY Wheel Cylinder Rear wheel cylinders should be rebuilt in full axle sets only If one side of the vehicle is done the other side should also be rebuilt Rear wheel cylinders should not be disassembled unless they are leaking Carefully pull lower edges of wheel cylinder boots away from rear wheel cylinder and note whether interior is wet with brake fluid Excessive brake fluid at this point indicates leakage past piston cups and a need for rear wheel cylinder overhaul NOTE A slight amount of brake fluid is nearly always present and acts as a lubricant for the wheel cylinder piston It is not necessary to remove the rear wheel cylinder from the backing plate to disassemble inspect hone and overhaul the rear wheel cylinder Removal is necessary only if the rear wheel cylinder is damaged or scored beyond service Disassembly 1 Remove the rear brake shoe and lining 2200 Refer to the procedure in this section 2 Onten inch brakes remove the wheel cylinder brake shoe links 3 Disengage rear wheel cylinder boots from retaining grooves in rear wheel cylinder casting Remove each wheel cylinder boot and wheel cylinder piston from rear wheel cylinder as an assembly 4 Remove rear wheel cylinder piston cups and wheel cylinder piston cup spring from wheel cylinder bore 5 Discard all rubber part
13. 1997 Aerostar Ranger Page 1 of 1 Section 06 02 Brakes Rear Drum 1997 Aerostar Ranger Workshop Manual REMOVAL AND INSTALLATION Lugnut Torque Requirement NOTE Torque specification is for nut and bolt threads free of dirt and rust Do NOT use oil or grease on threads Use only Ford recommended replacement fasteners Tighten lugnuts to 135 Nm 100 Ib ft file CNTSOMsocachevVDTOM 5368NSVK us en file SVK62007 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 4 Section 06 02 Brakes Rear Drum 1997 Aerostar Ranger Workshop Manual REMOVAL AND INSTALLATION Brake Drum AN WARNING DO NOT INHALE DUST FROM BRAKES OR ASSOCIATED COMPONENTS INHALATION OF DUST CAN BE INJURIOUS TO YOUR HEALTH COMPRESSED AIR OR BRUSHES MUST NOT BE USED TO CLEAN BRAKES BRAKE DRUMS 1126 AND ASSOCIATED COMPONENTS A VACUUM CLEANER SUCH AS ROTUNDA BRAKE CLUTCH SERVICE VACUUM 091 R0001 OR EQUIVALENT EQUIPPED FOR THIS PURPOSE SHOULD BE CAREFULLY USED TO REMOVE ANY DUST ADHERENT DUST SHOULD BE REMOVED WITH A DAMP RAG ANY DUST SHOULD BE CONTAINED IN A SEALED AND LABELED BAG FOR DISPOSAL WEAR AN APPROVED HIGH EFFICIENCY CARTRIDGE OR AIR LINE RESPIRATOR AND USE EXTRA CAUTION TO AVOID BREATHING THIS DUST ALWAYS USE NON ASBESTOS REPLACEMENT PARTS REAR AXLE FLANGE PART OF 4234 EAR R BRAKE SHOE AND LINING 2200 H4513 D Removal 1 Raise and support the vehicle so the wheel 1007 is clear of the floor 2 CAUTION Use of a
14. TS IF A VACUUM SUITABLE FOR ASBESTOS IS NOT AVAILABLE CLEANING SHOULD BE DONE WET IF DUST GENERATION IS STILL POSSIBLE TECHNICIANS SHOULD WEAR GOVERNMENT APPROVED TOXIC DUST PURIFYING RESPIRATORS GRINDING OR SANDING ON BRAKE LININGS PADS ROTORS DRUMS OR CLUTCH FACINGS SHOULD BE DONE ONLY WHILE USING PROPERLY EXHAUST VENTILATED EQUIPMENT OSHA REQUIRES AREAS WHERE ASBESTOS DUST GENERATION IS POSSIBLE TO BE ISOLATED AND POSTED WITH WARNING SIGNS ONLY TECHNICIANS CONCERNED WITH PERFORMING BRAKE OR CLUTCH SERVICE SHOULD BE PRESENT IN THE AREA CAUTION Do not use denatured alcohol for flushing the system or cleaning assemblies where alcohol could be trapped and cause eventual failure of rubber components in the system 1 Denatured alcohol is acceptable for cleaning parts provided the parts are completely air dried and coated with brake fluid before installation 2 Toremove brake fluid contamination clean all parts with denatured alcohol Do not attempt to clean contaminated lining Contaminated brake lining must be replaced file C NTSOMsocache lVDTOM 5368NSVK us en file SVK62014 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 2 file C TSO tsocache VDTOM_5368 S VK us en file S VK62014 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 3 Section 06 02 Brakes Rear Drum 1997 Aerostar Ranger Workshop Manual CLEANING AND INSPECTION Inspection Use Rotunda Brake Clutch Service Vacuum 091 R0001 or
15. adjusting lever should drop below the next tooth on the adjuster screw nut e f the action is not sharp and definite check for binding or lack of lubrication Adjuster Test Ranger file C TSO tsocache V DTOM_5368 S VK us en file S VK62009 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 14 of 16 BRAKE SHOE ADJUSTING LEVER CABLE PULLED TO ACTUATE ADJUSTER H10042 A 19 Using Brake Adjustment Gauge D81L 1103 A or equivalent measure the inside diameter of the brake drum Measuring Brake Drum file C TSO tsocache VDTOM_5368 S VK us en file S VK62009 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 15 of 16 BRAKE ADJUSTMENT GAUGE D81L 1103 A H1411 J 20 Using the brake adjuster screw adjust the rear brake shoe and lining to the brake drum inside diameter Measuring Rear Brake Shoe and Lining D81L 1103 A 21 Install the brake drum file C TSO tsocache VDTOM_5368 S VK us en file S VK62009 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 16 of 16 22 Install the wheel and tire assembly Tighten the lug nuts 1012 to 135 Nm 100 Ib ft file C TSO tsocache VDTOM_5368 S VK us en file S VK62009 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 3 Section 06 02 Brakes Rear Drum 1997 Aerostar Ranger Workshop Manual REMOVAL AND INSTALLATION Wheel Cylinder Removal 1 Raise and support vehicle Remove wheel 1007 Description Brake Shoe Anchor Pin Guide P
16. anger Reg SuperCab Over All Truck Series Under 4580 GVWR 4580 GVWR Aerostar Lining Thickness Primary 189 189 Inches 19 Lining Thickness 28 245 245 Secondary Inches Lining Length Primary 6 10 46 8 46 Inches Lining Length Secondary 8 80 10 88 9 59 Inches file C TSO tsocache VDTOM_5368 S VK us en file S VK62019 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 2 NOTE The following torque specifications are for clean dirt free and paint free dry bolt and nut threads Torque Specifications Description Backing Plateto Rear Housing Nuts 34 47 25 35 Wheel Cylinder to Backing Plate Bolts 12 18 EE 159 Brake Line to Wheel Cylinder Fitting 15 20 11 14 Wheel Cylinder Bleeder Screw 7 9 61 79 file C TSO tsocache VDTOM_5368 S VK us en file S VK62019 HTM gen ref HTM 2011 04 28
17. drum puller or a torch is not recommended Drum distortion may result Remove the hub cap if equipped and wheel 3 Remove the retaining nut and remove the brake drum 4 AN CAUTION Loosen the adjusting screw only if the brake drum cannot be removed Do not burr chip or damage the notches in the adjusting screw assembly or the self adjusting mechanism will not function properly If the brake drum is rusted to the axle shaft pilot use coarse sandpaper or file to remove the rust buildup then work the brake drum off e If the brake drum will not come off insert a narrow screwdriver through the brake adjusting hole in the brake backing plate 2211 and disengage the adjusting lever from the brake adjusting screw assembly While holding the adjusting lever away from the brake adjusting file C TSO tsocache V DTOM_5368 S VK us en file S VK62008 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 4 screw assembly loosen the brake adjusting screw assembly with Brake Adjustment Tool D81L 1103 C or equivalent Ranger BRAKE BACKING PLATE 2211 MOVED UPWARD TO EXPAND BRAKES AND DOWN TO CONTRACT ADJUSTER H9975 A Aerostar file CNTSOMsocachevVDTOM 5368NSVK us en file SVK62008 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 3 of 4 PLUG REMOVED 7 C BRAKE SHOE ADJUSTING LEVER KIT 2A176 HANDLE MOVED UPWARD TO RETRACT BRAKE SHOES HANDLE MOVED DOWNWARD TO EXPAND BRAKE SHOES H1582 F
18. e shoe away from the brake backing plate 4 Check brake backing plate for damage If any damage is found it must be replaced Refer to procedure in this section If no damage is found apply a small amount of Disc Brake Caliper Slide Grease D7AZ 19590 A or equivalent meeting Ford specification ESA M1C172 A to the points where the shoes touch the brake backing plate Be careful not to get the lubricant on the linings e The following illustration is simplified to show contact point location file C TSO tsocache V DTOM_5368 S VK us en file S VK62017 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 7 LUBRICATE LEDGES WITH DISC BRAKE CALIPER SLIDE GREASE 07 2 19590 ESA MIC172 A OR EQUIVALENT 5 Reinstall brake shoe hold down spring 6 Setthe Brake Adjustment Gauge D81L 1103 A or equivalent to the inside diameter of the drum braking surface file C TSO tsocache VDTOM_5368 S VK us en file S VK62017 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 3 of 7 BRAKE ADJUSTMENT GAUGE D81L 1103 A H1411 J 7 Reverse the tool as shown and adjust the rear brake shoe and lining 2200 until they match the gauge setting The gauge contact points on the rear brake shoe and lining must be parallel to the vehicle with the center line through the center of the axle 8 Hold the brake shoe adjusting lever out of engagement while rotating the notched part of the adjuster screw assembly to prevent burring the notches
19. equivalent to remove all dust from backing plates and interior of brake drums 11296 Wheel Cylinders 1 Rear wheel cylinders should not be disassembled unless they are leaking Pull back each rear wheel cylinder dust boot and inspect for leakage Excessive brake fluid at this point indicates leakage past the piston cups and a need for rear wheel cylinder 2261 overhaul A slight amount of fluid is nearly always present and acts as a lubricant for the pistons If evidence of leakage is noted the rear wheel cylinder should be disassembled inspected and overhauled Inspect the rear wheel cylinder bore for scratches and pitting If the rear wheel cylinder is pitted or has deep scratches the rear wheel cylinder must be replaced Brake Drums A brake drum should be visually inspected and measured with Rotunda Brake Drum Micrometer 104 00046 or equivalent Before making an inspection or measurement remove grease brake fluid or other contaminants from the brake drum using denatured alcohol Best shop practice requires measuring every brake drum with a brake drum micrometer regardless of visual inspection The brake drum micrometer is set to the drum diameter and measures the amount and type of wear Measure the diameter at various points 45 degrees apart around the brake shoe and lining contact area and at the bottom of the deepest groove to determine if the brake drum requires replacement Brake Lining 1 Inspect rear brake shoes
20. g levers are also stamped with an R or L to indicate their installation on the right or left hand brake assembly 13 Onthe Ranger after installation the brake shoe adjusting lever should engage the brake adjuster screw nut just below the centerline Hook the brake shoe adjusting lever cable into the notch in the brake shoe adjusting lever from the inboard side and install the brake shoe adjusting lever and adjusting lever return spring on the pin on the web of the secondary rear brake shoe and lining Ranger file C TSO tsocache VDTOM_5368 S VK us en file S VK62009 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 12 of 16 14 15 16 17 BRAKE SHOE ADJUSTING LEVER CABLE 2 178 BRAKE SHOE ADJUSTING LEVER 2A176 ADJUSTER SCREW ASSEMBLY 2041 ADJUSTING LEVER RETURN SPRING 2A180 H9979 A On the Aerostar install the hooked end of the brake shoe adjusting screw spring in the large hole in the primary shoe web Connect the loop end of the brake shoe adjusting screw spring to the adjuster lever hole On the Ranger install the brake shoe adjusting screw spring in the rear brake shoe and lining On the Aerostar pull the brake shoe adjusting lever brake shoe adjusting lever cable and brake shoe adjusting screw spring down toward the rear to engage the pivot hook in the large hole in the secondary shoe web On the Aerostar check the action of the adjuster by pulling brake shoe adjusting lever cable toward seco
21. he procedure in this section 7 Install brake drum 1126 and wheel 1007 8 Bleed brake system Refer to Section 06 06 Brake Wheel Cylinder Disassembled 353 1 Wheel Cylinder Boot Part of 2261 2196 Wheel Cylinder Piston e 2 Wheel Cynder Piston Cup Sing file C TSO tsocache V DTOM_5368 S VK us en file S VK62013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 3 of 3 file C TSO tsocache VDTOM_5368 S VK us en file S VK62013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 2 Section 06 02 Brakes Rear Drum 1997 Aerostar Ranger Workshop Manual CLEANING AND INSPECTION Cleaning AN WARNING BRAKES CONTAIN ASBESTOS FIBERS AVOID BREATHING DUST BREATHING ASBESTOS DUST MAY CAUSE ASBESTOSIS AND CANCER BREATHING ASBESTOS DUST IS HAZARDOUS TO YOUR HEALTH DUST AND DIRT PRESENT ON WHEEL BRAKE AND CLUTCH ASSEMBLIES MAY CONTAIN ASBESTOS FIBERS THAT ARE HAZARDOUS TO HEALTH WHEN MADE AIRBORNE BY CLEANING WITH COMPRESSED AIR OR BY DRY BRUSHING WHEEL BRAKE ASSEMBLIES AND CLUTCH FACINGS SHOULD BE CLEANED USING A VACUUM CLEANER RECOMMENDED FOR USE WITH ASBESTOS FIBERS SUCH AS ROTUNDA BRAKE CLUTCH SERVICE VACUUM 091 R0001 OR EQUIVALENT DUST AND DIRT FROM VACUUM SHOULD BE DISPOSED OF IN SUCH A MANNER THAT PREVENTS DUST EXPOSURE SUCH AS SEALED BAGS THE BAG MUST BE LABELED AS PER OSHA INSTRUCTIONS AND THE TRASH HAULER NOTIFIED AS TO THE BAG S CONTEN
22. late Wheel Cylinder Brake Shoe Link Rear Wheel Cylinder Brake Backing Plate Bolt Wheel Cylinder to Backing Plate Washer Tighten to 12 18 Nm 106 159 Lb In 2 Remove the brake drum 1126 and rear brake shoes and linings 2201 as described in this section file C TSO tsocache VDTOM_5368 S VK us en file S VK62010 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 3 REAR WHEEL WHEEL CYLINDER BRAKE SHOE CYLINDER 2261 LINK 2042 lt sss XO JAN A BYE o J O TN H4721 C 3 Disconnect the brake line from the rear wheel cylinder Connect a length of hose to the line and submerge end of hose in a can containing a small amount of brake fluid to prevent air from entering the system 4 Remove the rear wheel cylinder retaining bolts and lockwashers and then remove the rear wheel cylinder from the brake backing plate Installation 1 Apply Silicone Rubber D6AZ 19562 AA or BA or equivalent meeting Ford specification ESB M4G92 A or ESE M4G195 A to wheel cylinder mounting area to seal backing plate mounting area 2 Place the rear wheel cylinder on the brake backing plate and install the retaining bolts and lockwashers Tighten the wheel cylinder to backing plate bolts to 12 18 Nm 106 159 Ib in 3 Connect the brake line to the rear wheel cylinder 4 Install the rear brake shoe and lining 2200 as described in this section Install the brake drum and adjust the brakes as described in this sectio
23. n 5 Install the wheel and tire assembly 6 Bleed the system as described in Section 06 06 Check brake operation before moving the vehicle file C NTSOMsocache lVDTOM 5368NSVK us en file SVK62010 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 3 of 3 file C TSO tsocache VDTOM_5368 S VK us en file S VK62010 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 6 Section 06 02 Brakes Rear Drum 1997 Aerostar Ranger Workshop Manual REMOVAL AND INSTALLATION Brake Backing Plate Removal 1 Raise and support the vehicle 2 Remove the rear brake shoe and lining 2200 and the rear wheel cylinder Refer to the procedures in this section 3 Disconnect parking brake rear cable and conduit 2A635 from brake backing plate by squeezing locking fingers together using a 9 16 inch flare nut wrench and pulling parking brake rear cable and conduit through brake backing plate Aerostar 10 INCH REAR BRAKE LEFT SIDE H8917 A file C TSO tsocache VDTOM_5368 S VK us en file S VK62011 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 6 Part Item Number Description i mes Brake Show Anchor Pin Gude Plate gt pes fwon a peer Rear wheel Cyn suere we 5 2296 or Retracting Spring 2035 2200 Rear Brake Shoe and Lining I Pivot Hook Part of 2A176 15 Parking Brake Cable Housing Retainer Part of 2A809 and 2A635 Cables 7 Ranger file
24. ndary shoe activating brake shoe adjusting lever Brake shoe adjusting lever should snap in above the next tooth of adjuster Release brake shoe adjusting lever cable to return brake shoe adjusting lever to original position and the adjuster should turn one notch Aerostar file CNTSOMsocachevVDTOM 5368NSVK us en file SVK62009 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 13 of 16 PULL CABLE TOWARDS SECONDARY SHOE TO ACTUATE If pulling the brake shoe adjusting lever cable does not produce the action described or if brake shoe adjusting lever kit action is sluggish instead of positive and sharp check the position of the brake shoe adjusting lever on the adjusting screw toothed wheel The brake shoe adjusting lever should contact the adjusting wheel one tooth above the centerline of the brake adjuster screw If the contact point is below this centerline the brake shoe adjusting lever will not lock on the teeth in the adjusting screw wheel and the brake adjuster screw will not be turned as the brake shoe adjusting lever is actuated by the brake shoe adjusting lever cable Refer to Diagnosis and Testing in Section 06 00 for adjuster diagnosis 18 Check the action of the Ranger adjuster mechanism Pull the brake shoe adjusting lever cable toward the secondary rear brake shoe and lining The brake shoe adjusting lever should turn the adjuster screw nut one tooth Release the brake shoe adjusting lever cable and the brake shoe
25. o the floor there is too much clearance between the brake shoes and the brake drums Repeat Steps 2 and 3 of this procedure 11 WARNING PERFORM THE ROAD TEST ONLY WHEN THE BRAKES WILL APPLY AND THE VEHICLE CAN BE SAFELY STOPPED When the rear brake shoes and linings have been properly adjusted lower the vehicle and road test file C TSO tsocache V DTOM_5368 S VK us en file S VK62017 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 7 of 7 to check brake operation file C TSO tsocache VDTOM_5368 S VK us en file S VK62017 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 2 Section 06 02 Brakes Rear Drum 1997 Aerostar Ranger Workshop Manual SPECIFICATIONS SPECIFICATIONS Fluid Specifications D6AZ 19562 AA or BB Silicone Rubber Sealant Brake Specifications Ranger Reg and SuperCab Under Ranger Reg SuperCab Over All Truck Series 4580 GVWR 4580 GVWR Aerostar Axle Usage 2540 2750 2650 Front 2580 2650 2800 Axle Usage 2750 2950 2750 3200 2950 Rear Type DSSA DSSA DSSA Size Inches 9x1 75 10x2 5 gt 10x2 5 Ranger SuperCab with limited slip axles have 10x2 5 inch rear brake regardless of GVWR P 9x1 75 standard with 2 3L engine Bore Diameters Rear Wheel Cylinders Ranger Reg and SuperCab Ranger Reg SuperCab Over All Truck Series Under 4580 GVWR 4580 GVWR Aerostar Rear Wheel Cylinder 0 75 0 75 0 9375 Bore Inches Rear Drum Brake Lining Dimensions Ranger Reg and SuperCab R
26. rum maximum inside diameter shown on the brake drum is exceeded either through wear or refinishing the brake drum must be replaced Check inside diameter of brake drum with Brake Adjustment Gauge D81L 1103 A or Rotunda Brake Drum Micrometer 104 00046 or equivalent After a brake drum is refinished wipe refinished surface with a cloth soaked in clean denatured alcohol Maximum Diameter Brake drum maximum diameter is cast into the rim of the brake drum The brake drum may be machined enough to correct scoring but only up to the MAX DIA dimension If after machining the brake drum inside braking surface diameter exceeds the specification it must be discarded A Mimun BRAKE DRUM rd TYPICAL 1126 nn y MAXIMUM DIAMETER file C TSO tsocache V DTOM_5368 S VK us en file S VK62016 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 2 file C TSO tsocache VDTOM_5368 S VK us en file S VK62016 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 1 of 7 Section 06 02 Brakes Rear Drum 1997 Aerostar Ranger Workshop Manual ADJUSTMENTS Brake Shoe and Lining Drums Removed WARNING DO NOT INHALE DUST FROM BRAKES OR ASSOCIATED COMPONENTS INHALATION OF DUST CAN BE INJURIOUS TO YOUR HEALTH COMPRESSED AIR OR BRUSHES MUST NOT BE USED TO CLEAN BRAKES BRAKE DRUMS AND ASSOCIATED COMPONENTS A VACUUM CLEANER SUCH AS ROTUNDA BRAKE CLUTCH SERVICE VACUUM 091 R0001 OR EQUIVALENT EQUIPPED FOR THIS PURPOSE SHOULD BE
27. s 6 Remove wheel cylinder bleeder screw from rear wheel cylinder 7 Wash all parts in clean denatured alcohol 8 Inspect pistons for scratches scoring or other visible damage Replace if necessary Always replace rubber parts 9 Inspect the rear wheel cylinder bore for score marks or rust If either condition is present the rear wheel cylinder bore must be honed However the rear wheel cylinder should not be honed more than 0 08mm 0 003 inch beyond its original diameter 10 Wash rear wheel cylinder with clean denatured alcohol after honing dry it with compressed air 11 Inspect the bleeder hole to ensure it is free of obstructions Assembly Use all parts in the wheel cylinder service kit 1 Apply a light coating of High Performance DOT 3 Brake Fluid C6AZ 19542 AA or equivalent DOT 3 fluid meeting Ford specification ESA M6C25 A DOT 3 to all internal parts file C TSO tsocache VDTOM_5368 S VK us en file S VK62013 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 3 2 Thread bleeder screw into rear wheel cylinder Tighten to 7 9 Nm 61 79 Ib in 3 Insert the wheel cylinder piston cup spring wheel cylinder piston cups and wheel cylinder pistons into their respective positions in the wheel cylinder bore Place a wheel cylinder boot over each end of the wheel cylinder 4 Install the bleeder screw 5 Install the wheel cylinder brake shoe links if required 6 Install rear brake shoe and lining Refer to t
28. the parking brake lever on the secondary shoe and on ten inch brakes secure with the spring washer and parking brake lever pin retainer 4 Position the rear brake shoe and lining on the brake backing plate 2211 and install the brake shoe hold down spring pins brake shoe hold down springs and brake shoe hold down spring cups using Hold Down Spring Tool T73T 2300 A Install the primary brake shoe parking brake lever link parking brake link spring and washer Connect the parking brake rear cable and conduit to the parking brake lever file C TSO tsocache VDTOM_5368 S VK us en file S VK62009 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 6 of 16 PARKINGERAKE PARKING BRAKE REAR CABLE pica AND CONDUIT HOLD DOWN SPRING 5 Install the brake shoe anchor pin guide plate Place the brake shoe adjusting lever cable anchor over the anchor pin with the crimped side away from the brake backing plate Aerostar file C TSO tsocache VDTOM_5368 S VK us en file S VK62009 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger ADJUSTER CABLE ANCHOR FITTING PART OF 24178 BRAKE SHOE ANCHOR PIN GUIDE PLATE Page 7 of 16 BRAKE SHOE ADJUSTING LEVER CABLE H9977 A 6 Install the primary shoe to anchor short spring using a brake spring removal installation tool file CNTSOMsocachevVDTOM 5368NSVK us en file SVK62009 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 8 of 16 10
29. ust by removing the boots and inspecting interior surfaces Water leaking into the rear wheel cylinder past the boots will cause rust to form and may cause the rear wheel cylinder to seize 3 If noleaks are found install brake cylinder clamp over the ends of the rear wheel cylinder as shown 4 Remove the brake shoe retracting springs file C NTSOMsocachevVDTOM 5368NSVK us en file SVK62009 HTM gen ref HTM 2011 04 28 1997 Aerostar Ranger Page 2 of 16 5 Remove the brake shoe adjusting lever cable from the anchor pin cable guide and adjusting lever 6 Remove the cable guide from the secondary brake shoe and lining web 7 Remove the adjusting lever and adjusting lever return spring 8 Remove the brake shoe adjusting screw spring 9 Using Hold Down Spring Tool T73T 2300 A remove the brake shoe hold down spring and pin from each rear brake shoe and lining 2200 10 Remove the brake shoe adjuster assembly 11 Remove the primary brake shoe parking brake lever link and parking brake link spring PARKINGERAKE PARKING BRAKE LEVER LINK REAR CABLE AND CONDUIT HOLD DOWN SPRING LOCATION H4716 D 12 Remove the parking brake rear cable and conduit 2A635 from the parking brake lever 13 Remove the rear brake shoe and lining from the vehicle 14 Remove the parking brake lever from the secondary rear brake shoe and lining file C NTSOMsocache lVDTOM 5368NSVK us en file SVK62009 HTM gen ref HTM 2011 04 28

06-02 Brakes, Rear Drum

Contents

Download Pdf Manuals

Related Search

Related Contents