Ford Escort/Tracer 1991-1999 Repair Guide

Brake Booster Pushrod

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ADJUSTMENT



1991-96 Models

Manual Transaxle MODELS without Anti-lock BrakeS (ABS)

See Figures 1 and 2

The use of master cylinder gauge T87C-2500-A or equivalent, is required for this procedure.

  1. Remove the master cylinder.
  2.  
  3. Position master cylinder gauge T87C-2500-A or equivalent on the end of the master cylinder, loosen the setscrew and push the gauge plunger against the bottom of the primary piston.
  4.  
  5. While holding the gauge in position, tighten the setscrew.
  6.  
  7. Use a vacuum pump to apply 19.7 in. Hg (66 kPa) of vacuum to the power brake booster.
  8.  
  9. Invert the gauge and place it over the power brake pushrod.
  10.  
  11. Check that there is no space between the gauge and the pushrod.
  12.  
  13. If there is space between the gauge and pushrod, loosen the pushrod locknut and adjust the pushrod until there is no space. Tighten the pushrod locknut.
  14.  
  15. Install the master cylinder.
  16.  



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Fig. Fig. 1: Push the gauge plunger against the primary piston of the master cylinder, then tighten the setscrew-1991-96 manual transaxle models without ABS



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Fig. Fig. 2: Adjust the brake booster pushrod length to achieve the proper master cylinder piston-to-pushrod clearance-1991-96 manual transaxle models without ABS

Except Manual Transaxle MODELS withOUT Anti-lock BrakeS (ABS)

See Figures 3, 4, 5 and 6

A scan tool is absolutely necessary to bleed the brake hydraulic system on 1997-99 models equipped with an Anti-lock Brake System (ABS). If your vehicle is equipped with ABS, be sure to refer to the ABS bleeding procedures in this section before performing any work on your vehicle's brake hydraulic system.

The use of master cylinder gauge T92C-2500-A or equivalent is required for this procedure.

  1. Remove the master cylinder and mount it in a soft jawed vise.
  2.  
  3. Loosen the brass holding screw on the master cylinder gauge tool T92C-2500-A or equivalent and retract the gauge rod.
  4.  
  5. Attach the gauge to the power brake booster and tighten the gauge nuts to 8-12 ft. lbs. (10-16 Nm).
  6.  



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Fig. Fig. 3: Sectional view of the power brake booster with a gauge installed-1991-96 vehicles except manual transaxle models without ABS

  1. Start the engine and let it idle for about 15 seconds.
  2.  
  3. Push lightly on the end of the gauge rod until the gauge rod just contacts the brake booster pushrod.
  4.  
  5. Tighten the brass holding screw on the gauge securing the gauge rod in place.
  6.  

Use care when removing the gauge from the master cylinder. If the gauge rod setting is changed during removal, a faulty measurement will be taken which could lead to a unnecessary adjustment of the brake booster pushrod.

  1. Use a depth gauge to measure the height of the master cylinder gauge rod as illustrated and record the measurement.
  2.  
  3. Loosen the gauge brass holding screw and set the gauge on the master cylinder as illustrated.
  4.  
  5. Push lightly on the end of the gauge rod, until the end of the gauge rod just bottoms in the master cylinder piston and tighten the brass holding screw.
  6.  
  7. Remove the gauge from the master cylinder.
  8.  
  9. Use a depth gauge to measure the height of the gauge rod as illustrated and record the measurement.
  10.  
  11. Determine the difference between measurements D1 and D2. If D2 is larger than D1, subtract D1 from D2. If D1 is larger than D2, subtract D2 from D1. Adjust the brake booster pushrod nut to lengthen or shorten the pushrod the amount equal to the difference between D1 and D2.
  12.  
  13. Install the master cylinder.
  14.  



Click image to see an enlarged view

Fig. Fig. 4: Use a depth gauge to measure the height of the master cylinder gauge rod (D1)-1991-96 vehicles except manual transaxle models without ABS



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Fig. Fig. 5: Attach the gauge to the master cylinder-1991-96 vehicles except manual transaxle models without ABS



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Fig. Fig. 6: Use a depth gauge to measure the height of the gauge rod (D2)-1991-96 vehicles except manual transaxle models without ABS

 
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