Ford Orion. Manual - part 47

4

Front brake disc - inspection,
removal and refitting

2

Note: To prevent uneven braking, BOTH front
brake discs should be renewed or reground at
the same time.

Inspection

1 Apply the handbrake, loosen off the front
roadwheel nuts on the side concerned, then
jack up the front of the vehicle and support it
on axle stands. Remove the appropriate front
roadwheel.
2 Temporarily refit two of the wheel nuts to
diagonally-opposite studs, with the flat sides
of the nuts against the disc. Tighten the nuts
progressively, to hold the disc firmly.
3 Scrape any corrosion from the disc. Rotate
the disc, and examine it for deep scoring,
grooving or cracks. Using a micrometer,
measure the thickness of the disc in several
places  (see illustration). Light wear and
scoring is normal, but if excessive, the disc
should be removed, and either reground by a
specialist, or renewed. If regrinding is
undertaken, at least the minimum thickness
must be maintained. Obviously, if the disc is
cracked, it must be renewed.
4 Using a dial gauge or a flat metal block and
feeler gauges, check that the disc run-out 10
mm from the outer edge does not exceed the
limit given in the Specifications. To do this, fix
the measuring equipment, and rotate the disc,
noting the variation in measurement as the disc

is rotated (see illustration). The difference
between the minimum and maximum
measurements recorded is the disc run-out.
5 If the run-out is greater than the specified
amount, check for variations of the disc
thickness as follows. Mark the disc at eight
positions 45

∞

apart, then using a micrometer,

measure the disc thickness at the eight
positions, 15 mm in from the outer edge. If the
variation between the minimum and maximum
readings is greater than the specified amount,
the disc should be renewed.

Removal

6 Remove the caliper and its anchor bracket
with reference to Section 3, but do not
disconnect the hydraulic brake hose.
Suspend the caliper assembly from the front
suspension coil spring, taking care to avoid
straining the brake hose.
7 Remove the wheel nuts which were
temporarily refitted in paragraph 2.
8 Using a Torx-type socket bit or driver,
unscrew the screw securing the disc to the
hub, and withdraw the disc. If it is tight, lightly
tap its rear face with a hide or plastic mallet.

Refitting

9 Refit the disc in a reversal of the removal
sequence. If new discs are being fitted, first
remove their protective coating. Ensure
complete cleanliness of the hub and disc
mating faces and tighten the screw securely.
10 Refit the caliper/anchor bracket with
reference to Section 3.
11 Refit the roadwheel, lower the vehicle to
the ground, and tighten the wheel nuts to the
specified torque wrench setting.

5

Rear brake drum - removal,
inspection and refitting

2

Note: To prevent uneven braking, BOTH rear
brake drums should be renewed at the same
time.

Removal

1 Chock the front wheels, loosen off the rear
roadwheel nuts on the side concerned, then
jack up the rear of the vehicle and support it
on axle stands. Remove the appropriate rear
roadwheel, and release the handbrake.
2 On all except Van models, undo the four
bolts securing the drum/hub to the rear axle
flange, then withdraw the drum/hub from the
axle (see illustrations). If the brake drum is
stuck on the shoes, remove the rubber access
plug from the inside face of the brake
backplate, and release the automatic brake
adjuster by levering the release catch on the
adjuster pawl through the backplate.
3 On Van models, prise free the drum
retaining clip from the wheel nut stud, then
withdraw the drum over the studs and remove
it. Note that the retaining clip must be
renewed during reassembly.
4 With the brake drum removed, brush or
wipe the dust from the drum, brake shoes,
wheel cylinder and backplate. Take great care
not to inhale the dust, as it may contain
asbestos.
5 If required, remove the hub from the drum
(where applicable) as described in Chap-
ter 10.

Inspection

6 Clean the inside surfaces of the brake drum
and hub, then examine the internal surface of
the brake drum for signs of scoring or cracks
(see illustration). If any deterioration of the
friction surface is evident, renewal of the drum
is necessary. To detach the hub from the
drum (where applicable), refer to Chapter 10.

Refitting

7 Check that the automatic brake adjuster is
fully retracted, then according to type, refit the
drum/hub to the axle. Tighten the retaining

9•6 Braking system

5.6  Examine the inside surfaces of the

brake drum for signs of excessive wear

and/or cracks

5.2B  Removing the rear brake 

drum/hub

5.2A  Rear brake drum/hub securing

methods

A

Brake drum/hub retaining bolts

B Brake drum retaining clip on Van models

4.4  Checking the brake disc run-out using

a dial gauge

4.3  Checking the brake disc thickness

using a micrometer

bolts to the specified torque, or fit the drum
over the wheel studs, and press a new
retaining clip over one of the studs.
8 With the brake drum refitted, refit the
roadwheel. Fully depress the brake pedal
several times, to actuate the rear brake
adjuster and take up the adjustment. Check
that the rear wheels spin freely when the
brakes are released, then apply the
handbrake, lower the vehicle and tighten the
wheel nuts to the specified torque wrench
setting. Remove the wheel chocks from the
front wheels.

6

Rear brake shoes - renewal

2

Warning: Drum brake shoes
MUST be renewed on both rear
wheels at the same time - NEVER
renew the shoes on only one

wheel, as uneven braking may result. Also,
the dust created by wear of the shoes may
contain asbestos, which is a health hazard.
Never blow it out with compressed air, and
don’t inhale any of it. An approved filtering
mask should be worn when working 
on the brakes. DO NOT use petroleum-
based solvents to clean brake parts - 
use brake cleaner or methylated spirit
only.

1 Remove the rear brake drum with reference
to Section 5.
2 Note the fitted positions of the springs and
the adjuster strut (see illustration).
3 Remove the shoe steady springs by
depressing and turning them through 90

∞

(see illustration). Remove the springs and
pins.
4 Pull the leading brake shoe from the bottom
anchor, and disconnect the lower return
spring (see illustration).
5 Move the bottom ends of the brake shoes
towards each other, then disconnect the tops
of the shoes from the wheel cylinder. Be
careful not to damage the wheel cylinder
rubber boots. To prevent the wheel cylinder
pistons from being accidentally ejected, fit a

suitable elastic band (or wire) lengthwise over
the cylinder/pistons (see illustrations).
6 Disconnect the upper return (pull-off) spring
from the brake shoes.
7 Unhook the handbrake cable from the
handbrake operating lever on the trailing
shoe. Disconnect the support spring from the
strut, twist the trailing shoe through 90

∞

, and

detach it from the strut (see illustrations).
8 Disconnect the strut from the leading shoe.
As the strut is pulled from the shoe, the
automatic adjuster will operate and release
the pawl from the shoe (see illustration).
9 Clean the adjuster strut and its associated
components.
10 Clean the backplate, then apply a little
high-melting-point grease to the shoe contact

Braking system   9•7

6.4  Disengage the leading brake shoe

from the bottom anchor . . .

6.3  Removing a shoe steady spring

6.2  General view of the rear brake

assembly with the drum removed

6.8  Disconnecting the strut from the

leading brake shoe

6.7B  Disconnecting the support spring

from the strut

6.5B  Elastic band fitted round the wheel

cylinder to prevent piston ejection

6.5A  . . . then from the wheel cylinder at

the top

6.7A  Disconnecting the handbrake cable

from the trailing brake shoe

9

points on the backplate and the lower anchor
plate (see illustrations).
11 Transfer the strut and the upper return
spring onto the new leading shoe (see
illustration).
12 Locate the other end of the upper return
spring into the new trailing shoe, then twisting
the shoe, engage the strut support spring and
strut. When reconnected, check that the cam
and pawl of the automatic adjuster have
engaged (see illustrations).
13 Remove the elastic band (or wire retainer)
from the wheel cylinder. Reconnect the
handbrake cable to the operating lever on the
trailing shoe, and refit the trailing shoe
assembly into position on the backplate. As
the shoe is engaged over the wheel cylinder,
be careful not to damage the rubber dust
cover.
14 Reconnect the lower return spring to the
trailing shoe and, checking that the handbrake
operating lever is resting on the lever stop
head (not wedged against the side), locate the
shoe in the bottom anchor plate. Refit the
steady pin, spring and cup to secure the shoe
in position.
15 Offer the leading shoe onto the backplate
and insert its steady pin, spring and cup to
hold it in place.
16 Reconnect the lower return spring to the
leading shoe, using a screwdriver to stretch
the spring end into the location hole.
17 Refit the upper return spring, using a

screwdriver to stretch the spring end into the
location hole.
18 Check that the brake shoes and their
associated components are correctly refitted,
then refit the brake drum with reference to
Section 5.
19 Repeat the procedure on the remaining
rear brake.

7

Rear wheel cylinder -
removal, overhaul and refitting

4

Removal

1 Remove the brake drum as described in
Section 5.
2 Pull the brake shoes apart at the top end,
so that they are just clear of the wheel
cylinder. The automatic adjuster will hold the
shoes in this position so that the cylinder can
be withdrawn.
3 Using a brake hose clamp or self-locking
wrench with protected jaws, clamp the flexible
brake hose forward of the shock absorber
(midway between the hose protective sleeve
and the hose rigid connection bracket on the
underside of the body). This will minimise
brake fluid loss during subsequent operations.
4 Wipe away all traces of dirt around the
brake hose union at the rear of the wheel

cylinder, then loosen off the hose-to-wheel
cylinder union nut (see illustration).
5 Unscrew the two bolts securing the wheel
cylinder to the backplate.
6 Withdraw the wheel cylinder from the
backplate so that it is clear of the brake
shoes, then holding the brake hose steady to
prevent it twisting, unscrew and detach the
wheel cylinder from the hose. Plug the hose,
to prevent the possible ingress of dirt and to
minimise further fluid loss whilst the cylinder is
detached from it.

Overhaul

7 Clean the external surfaces of the cylinder,
then pull free the dust cover from each end of
the cylinder.
8 The pistons and seals will probably shake
out; if not, use a foot pump to apply air
pressure through the hydraulic union and
eject them.
9 Clean the pistons and the cylinder by
washing in fresh hydraulic fluid or methylated
spirits (not petrol, paraffin or any other
mineral-based fluid). Examine the surfaces of
the pistons and the cylinder bores. Look for
any signs of rust, scoring or metal-to-metal
rubbing, which if evident, will necessitate
renewal of the wheel cylinder (see
illustration).
10 Begin reassembly by lubricating the first
piston in clean hydraulic fluid. Manipulate its

9•8 Braking system

7.4  Disconnecting the hydraulic hose from

the rear wheel cylinder. Note the hose

clamp (A) and the protective sleeve on the

hose (B)

6.12B  Brake shoes, strut and upper

springs reconnected

6.12A  . . . and trailing shoe

6.11  Reconnect the upper return spring to

the leading . . .

6.10B  Brake shoe contact points

(arrowed) to be lubricated on the

backplate

6.10A  Applying high-melting-point grease

to the brake backplate

new seal into position so that its raised lip
faces away from the brake shoe bearing face
of the piston.
11 Insert the piston into the cylinder from the
opposite end of the cylinder body, and push it
through to its normal location in the bore.
12 Insert the spring into the cylinder, then fit
the second new seal into position on the
second piston (as described for the first) and
fit the second piston into the wheel cylinder.
Take care not to damage the lip of the seal as
the piston is inserted into the cylinder -
additional lubrication and a slight twisting
action may help. Only use fingers (no tools) to
manipulate the piston and seal into position.
13 Fit the new dust covers to each end of the
piston.

Refitting

14 Wipe clean the backplate, and remove the
plug from the end of the hydraulic hose.
Carefully screw the cylinder onto the hose
connector, and then fit the cylinder onto the
backplate. Tighten the retaining bolts to
securely, then fully tighten the hydraulic hose
union.
15 Retract the automatic brake adjuster
mechanism so that the brake shoes engage
with the pistons of the wheel cylinder.
16 Remove the clamp from the flexible brake
hose. Ensure that the protective sleeve on the

hose is adjacent to the shock absorber (see
illustration 7.4).
17 Refit the brake drum with reference to
Section 5.
18 Bleed the brake hydraulic system as
described in Section 17. Providing suitable
precautions were taken to minimise loss of
fluid, it should only be necessary to bleed the
relevant rear brake.

8

Rear brake backplate -
removal and refitting

3

Drum brake models

Removal

1 On Hatchback/Saloon/Estate models,
remove the brake drum/hub assembly as
described in Section 5. On Van models,
remove the brake drum as described in
Section 5, then remove the rear hub assembly
as described in Chapter 10.
2 Remove the rear brake shoes as described
in Section 6.
3 Remove the wheel cylinder from the
backplate as described in Section 7.
4 Compress the three retaining lugs, and
release the handbrake cable from the
backplate by pushing it back through the
plate.
5 Drill out the pop-rivets securing the
backplate to the rear axle, and remove the
backplate (see illustration).

Refitting

6 Refit in the reverse order of removal. Check
that the plate is correctly located (with the
wheel cylinder aperture at the top) before
riveting it into position.
7 Refit the handbrake cable, and ensure that
the retaining lugs are secure.
8 Refit the wheel cylinder as described in
Section 7.
9 Refit the rear brake shoes as described in
Section 6.
10 Refit the brake drum/hub as described in
Section 5, or the rear hub assembly as
described in Chapter 10, according to model.
11 On completion, bleed the brake hydraulic
system as described in Section 17.

Disc brake models

Removal

12 Remove the rear brake disc as described
in Section 11, then remove the rear hub
assembly as described in Chapter 10.
13 Remove the handbrake shoes as
described in Section 20.
14 Drill out the pop-rivets securing the
backplate to the rear axle, and remove the
backplate.

Refitting

15 Refit in the reverse order of removal,
securing the backplate with new pop-rivets.
16 Refit the handbrake shoes as described in
Section 20.
17 Refit the rear brake disc as described in
Section 11, and the rear hub assembly as
described in Chapter 10.

9

Rear brake pads - renewal

2

Warning: Disc brake pads must
be renewed on BOTH rear wheels
at the same time - NEVER renew
the pads on only one wheel, as

uneven braking may result. Dust created
by wear of the pads may contain asbestos,
which is a health hazard. Never blow it out
with compressed air, and do not inhale any
of it. DO NOT use petroleum-based
solvents to clean brake parts - use brake
cleaner or methylated spirit only. DO NOT
allow any brake fluid, oil or grease to
contact the brake pads or disc. Also refer
to the warnings at the start of Sections 1
and 17 concerning brake fluid.
1 Chock the front wheels, then jack up the
rear of the car and support it on axle stands.
Remove the rear roadwheels.
2 Using a hammer and suitable punch, drift
out the two brake pad retaining pins, and lift
away the anti-rattle plate (see illustration).
3 Withdraw the inner and outer brake pads
from the caliper (see illustration). If the old
pads are to be refitted, ensure that they are
identified so that they can be returned to their
original positions.

Braking system   9•9

8.5  Backplate-to-stub axle rivets

7.9  Rear wheel cylinder components

9.3  Withdraw the inner and outer rear

brake pads from the caliper

9.2  Drift out the two rear brake pad

retaining pins using a punch

9

A

Dust cover

B Piston
C Piston seal
D Wheel cylinder

body

E

Bleed nipple

F

Dust cap

G Spring