Common Problems in Ford Fitting

 

COMMON PROBLEMS FOUND IN FITTING NEW DISC ROTORS OR BRAKE PADS TO FORD

FALCONS, FAIRLANES AND LTD’S WITH ABS BRAKING SYSTEMS.

When fitting to Ford Falcons, Fairlanes and LTD’s with an ABS braking system, at all times a measurement should be made of the abs sensor ring positioning, as it can move during shipping and transport. Whilst extreme care is taken in the manufacturing process, the sensor ring is subject to movement through jarring and transport and if the sensor ring has moved from its correct positioning, the abs light will remain on and brake sensation will be reduced.

The correct depths for confirming measurement are as follows;-

  • Ford EA-ED model FALCON/DA-DC LTD’S/NC FAIRLANE with ABS (RDA 130 PART NUMBER), the top of the abs sensor ring (outer part of the sensor ring where the slots are is the correct measuring face) should be located at a depth of 5.80mm EXACTLY from the top of the inner bearing cup.
  • Ford EF-EL model FALCON/NF-NL FAIRLANE/DF-DL LTD’S with ABS (RDA 132 PART NUMBER), the depth of the sensor ring should be 9.64mm EXACTLY from the top of the inner bearing cup..

 

  • IMPORTANT WARNING!
  • Due to the minimal tolerance & precise measurement required for fitting it is company policy that we do not provide any guarantee or warranty unless these particular part number applications are fitted by qualified mechanics or engineers and all fitting instructions have been dutifully followed at all times.

Preventing Disc Thickness Variation (DTV) on FORD EB to EL Falcons

One of the most common problems encountered today is brake pedal pulsation and/or brake shudder in EB to EL model Ford Falcons. This is due to Disc Thickness Variation (DTV). As little as 15 microns of DTV will cause this problem, which may not be apparent until the vehicle has travelled between 6000 and 8000 kilometres, after new pads have been fitted. During this time, while the brakes are in the off position, the pads continue to rub along the face of the rotor scalloping out high spots. The more aggressive the pad material the worse the problem becomes.

Consider that there are 27 microns to one thousandth of an inch and you can realise that this becomes very difficult to measure. Running a dial indicator over the face of the disc will not read DTV but by measuring with a micrometer over eight different places along the face of the disc this will indicate if DTV is present.

To rectify the problem you may machine the rotor, if it remains within the scrap tolerance, or replace the rotor, but to prevent DTV returning, there are several important service procedures that must be adhered to:

FRONT HUB SEAL POSITION PLEASE TAKE IN LINE DRAWING

For long term performance of disc rotors to suit Ford models:

EA - EL, DA - DL,  NA - NL it is recommended to follow these fitment procedures.

  • BEARING SEAL ASSEMBLY
  • Ensure the bearing seal is pressed completely into the recess.
  • This allows for true torque adjustment.

The seal must be inserted all the way to the bottom of the bore (refer to diagram). (DTV Pic 1) If it does not go all the way in, when attempting to adjust the bearings, the seal presses against the end of the stub axle and therefore you cannot adjust the bearing correctly. Because of the design of the rotor, it tends to lean over towards the hub and if the bearings are not adjusted correctly   and built-in run-out will occur.

  • WHEEL BEARING ADJUSTMENT PROCEDURE
  • PLEASE TAKE IN LINE DRAWING

It is important to follow the correct bearing adjustment procedure as specified in the Ford Repair Manual.

  • 1. Remove the wheel where necessary.
  • 2. Pry off the hub dust cap.
  • 3. Remove the split pin and nut retainer.
  • 4. Loosen the bearing-adjusting nut three turns. Then, rock the wheel/hub and disc in and out several times to push the brake pads away from the disc.
  • 5. While rotating the wheel/hub torque the adjusting nut to 30 Nm to seat the bearings (step 1. in diagram).
  • 6. Loosen the adjusting nut on-half turn then re-tighten the nut to 1.5 Nm (steps 2 & 3. in diagram).
  • 7. Selectively position the nut retainer on the adjusting nut so that a set of slots lines up with the hole in the spindle (step 4 in diagram).
  • 8. Lock the adjusting nut and nut retainer with a new split pin (step 4. In diagram).
  • 9. Check the wheel/hub rotation. If the bearings rotate properly, install the hub dust cap. Install the wheel if necessary. If the bearings are rough or noisy in operation, clean or replace the bearing assemblies as required.
  • 10. Lower the vehicle.
  • 11. Before driving the vehicle, pump the brake pedal several times to obtain normal brake lining to disc clearance to restore normal brake pedal travel.

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