1991 1999 ford explorer chilton User Manual

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If a leak occurs between the tubing and the tube nut, replace the hose assembly. If a leak occurs between the
tube nut and the pump outlet replace the plastic washer.
Check the fitting to determine whether the leak is between the tube and tube nut or between the tube
nut and pump outlet.
1. 
If the leak is between the tube nut and pump outlet check to be sure the nut is tightened to 30-40 ft.
lbs. Do not overtighten this nut.
2. 
If the leak continues or if the leak is between the tube...

SPECIFICATION CHARTS
Torque SpecificationsClick to enlarge
SPECIFICATION CHARTS 969 

BRAKE OPERATING SYSTEM
Basic Operating Principles
Hydraulic systems are used to actuate the brakes of all modern automobiles. The system transports the power
required to force the frictional surfaces of the braking system together from the pedal to the individual brake
units at each wheel. A hydraulic system is used for two reasons.
First, fluid under pressure can be carried to all parts of an automobile by small pipes and flexible hoses
without taking up a significant amount of room or posing routing...

The secondary piston is actuated by fluid trapped between the two pistons. If a leak develops in front of the
secondary piston, it moves forward until it bottoms against the front of the master cylinder, and the fluid
trapped between the pistons will operate the rear brakes. If the rear brakes develop a leak, the primary piston
will move forward until direct contact with the secondary piston takes place, and it will force the secondary
piston to actuate the front brakes. In either case, the brake pedal...

The sliding and floating designs are quite similar. In fact, these two types are often lumped together. In both
designs, the pad on the inside of the rotor is moved into contact with the rotor by hydraulic force. The caliper,
which is not held in a fixed position, moves slightly, bringing the outside pad into contact with the rotor.
There are various methods of attaching floating calipers. Some pivot at the bottom or top, and some slide on
mounting bolts. In any event, the end result is the same.
DRUM...

Stoplight switch mounting
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Lift the locking tab on the switch connector and disconnect the wiring.
1. 
Remove the hairpin retainer, slide the stoplamp switch, pushrod and nylon washer off of the pedal.
Remove the washer, then the switch by sliding it up or down.
2. 
On some vehicles equipped with speed control, the spacer washer is replaced by the dump valve
adapter washer.
To install: Position it so that the U-shaped side is nearest the pedal and directly over/under the pin.
3. 
Slide...

Cutaway view of the master cylinder assembly
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WARNING
Vehicles with 4-wheel anti-lock brakes require an Anti-lock Brake Adapter (T90P-50-ALA) and Jumper
(T93T-50-ALA) in order to bleed the master cylinder and the Hydraulic Control Unit (HCU). Failure to do
so will trap air in the HCU unit, eventually causing a spongy pedal.
Before performing this procedure, ensure that you have the tools necessary to bleed the master cylinder
and the HCU unit. If the tools are not available, you can still...

To remove the master cylinder, first disconnect the fluid level sensor wire
Next, loosen the fluid line fittings at the master cylinder with a flarenut wrench ... ... then disconnect the lines
HOW TO USE THIS BOOK
976 REMOVAL & INSTALLATION 

If equipped, remove any bracket retaining nuts ...
... and pull the bracket from the mounting stud
Remove the master cylinder-to-power booster attaching bolts ... HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 977 

... then pull the master cylinder off of the mounting studs and remove it from the vehicle.
To install:
Before installing the master cylinder, check the distance from the outer end of the booster assembly
push rod to the front face of the brake booster assembly. Turn the push rod adjusting screw in or out
as required to obtain the length shown. Refer to illustration in this Section.
5. 
Position the master cylinder assembly over the booster push rod and onto the 1 studs on the booster
assembly. Install...