Attachment III - Technical Information
Brake Actuation SystemAffected Vehicles:
Certain 1995 Model Year 2-Door Explorers
Technical Instructions
Reference: 1995 Model Year Explorer Body, Chassis Service Manual
^ Master Cylinder Removal/Installation: Section 06-06-7
NOTE:
The torque specifications in Step 1 for the master cylinder installation have been revised. The new torque specifications are 16.5 +/- 3.5 ft-lbs. (22.3 +/- 4.7 N-m).
^ Brake Master Cylinder Reservoir Removal/Installation: Section 06-06-8
^ Hydraulic System Bleeding: Section 06-06 pages 13-16
NOTE:
Figure 1 indicates the correct routing of the brake tubes. The shop manual figure in Section 06-09B (Hydraulic Control Unit) is incorrect.
NOTE:
Affected vehicles with less than 50 miles (80 Km) do not require the master cylinder to be replaced. Install only the new brake tubes. For affected vehicles with 50 miles or more, replace cylinder and brake tubes.
Step 1
^ Check odometer reading. If vehicle has fifty miles or more, proceed to step # 2. If vehicle has less than fifty miles, proceed to step # 3.
Step 2
^ If vehicle has fifty miles or more, remove the original master cylinder, scrap and replace with new service master cylinder F5TZ-2140-A (without cruise control) or F5TZ-2140-B (with cruise control).
^ The torque specification for attachment of the master cylinder to the two studs on the brake booster has been revised. The new torque specification is 16.5 +/- 3.5 ft-lbs. (22.3 +/- 4.7 N-m).
^ Proceed to Step # 3 for brake tube removal and installation instructions.
Step 3
^ Remove and scrap both original master cylinder outlet tubes. Replace with tubes from service kit F57Z-2234-AA.
^ Install the hard tube (tagged PM-F57A-2234-MD) first. Hand start both ends before setting final torque. Torque specification for brake tube ends is 17.5 +/- 2.5 N-m (12.5 +/- 1.5 ft-lb).
^ Install the flex tube (tagged PM-F57A-2234-NE) next. Hand start both ends of each tube.
NOTE:
The flex tube will tend to rotate during installation and tightening. This flex tube must not contact the prop valve when tightening. Keep a finger's thickness (approximately 10-15 mm) between the flex tube and the prop valve while tightening. There must be no contact between the flex tube and the prop valve after final installation. Both tube ends leading into the hydraulic control unit (HCU) must be parallel to each other after installation. If they are not, the flex line is likely twisted and must be repositioned so lines are parallel.
^ Torque the master cylinder end if the flex tube first. Next, torque the HCU end of the flex tube, taking special care not to allow the tube to rotate into the prop valve or twist.
Step 4
^ See Service Manual Section 06-06 page 13-16 for instructions on hydraulic brake system bleeding.
NOTE:
Bleed at both HCU brake tube connections instead of bleeding at the master cylinder brake tube connections as described in Service Manual Section 06-06-15.