Ford Falcon. Manual - part 77
206-06-28 Hydraulic
Brake
Actuation 206-06-28
DISASSEMBLY AND ASSEMBLY (Continued)
3. Insert proportioning valve (capped end first) into
Item
Description
bore, EXTREME CARE should be taken when
4
master cylinder body
inserting valve to ensure ‘O’ rings are not
1. Carefully install the valve ‘O’ ring in the bottom
damaged. If ‘O’ rings are damaged the master
shoulder of the primary reservoir port.
cylinder will not function correctly and will leak
brake fluid. The proportioning valve assembly
2. Fit the fast-fill valve, ensuring the rubber base
must be bottomed in the bore of the master
with 6 dimples if faced downwards, and secure
cylinder.
with circlip.
4. Assemble a new ‘O’ ring onto the end plug, and
Reservoir
screw end plug into body. Tighten end plug to
25Nm-30 Nm.
Electrical Switch (Pressure Differential)
1. Lightly smear reservoir bores and grommets with
clean brake fluid.
2. Carefully assemble grommets into reservoir bores
1. Before installing the electrical switch, ensure
to locate against the shoulder in each bore.
earthing spring is installed on switch plunger as
3. Assemble reservoir into grommets.
shown in diagram.
4. Push on reservoir to align the retaining screw hole
NOTE: Electrical spring must remain firmly
in the reservoir and cylinder body. Then assemble
attached to the plunger. Small end of spring may
retaining screw, and tighten to 4-5 Nm. Screw
need to be closed down to give required
should just protrude from hole in the master
attachment.
cylinder body.
2. Assemble electrical switch to the master cylinder
NOTE: Both reservoir and master cylinder holes
by hand. Tighten to a torque of 2 Nm. (DO NOT
must be aligned to avoid cross threading.
OVER TIGHTEN.)
Assemble new reservoir seal into reservoir cap.
Fast-Fill Valve
5. Lubricate inside of reservoir lips with clean brake
fluid to accept reservoir cap seal.
6. Push cap and seal assembly onto reservoir and
secure by pressing clip at each end to locate on
reservoir lugs. Caps should be fitted so that
lettering on cap is correct way up when viewed
from side of vehicle.
Item
Description
1
Circlip
2
Fast fill valve
3
’O’ Ring
G22129 en