Attachment III

RIGHT FRONT BRAKE TUBE REPAIR

AFFECTED VEHICLES:
CERTAIN 1999 MODEL YEAR EXPLORER AND MOUNTAINEER VEHICLES

INTRODUCTION

This repair involves the replacement of the right front brake tube nut and threadsaver located at the Hydraulic Control Unit. The right front brake tube will be removed from the HCU, the tube flare will be removed and the nut will be discarded. A new RF brake tube nut, containing a green identifying mark, will be installed and the brake tube will be double-flared. The threadsaver will be replaced, the brake tube will be connected and the front brake system will be bled to complete the repair.

SERVICE PROCEDURE

1. Install memory saver, then disconnect the battery ground cable.





2. Remove the brake tube retainer from the brake tubes at the Hydraulic Control Unit (HCU). See Figure 1.

3. Identify the right front wheel brake tube. The tube is located nearest the battery and will have a red tag with base part No. 2263. See Figure 1.

4. Disconnect the right front wheel brake tube from the HCU. See Figure 1.

5. Position the brake tube nut as far back on the brake tube as possible.

6. Using a mini tubing cutter, cut the brake tube as close to the flared end of the tube as possible.

7. Remove and discard the brake tube nut.

8. Using a suitable deburring tool, deburr the cut end of the brake tube.

9. WARNING:
EXPOSED DRILL BIT END SHOULD BE WRAPPED WITH TAPE OR HELD WITH A SHOP TOWEL TO PREVENT THE POSSIBILITY OF PERSONAL INJURY.

NOTE:
Drill bit should not be inserted more than 25 mm (1 inch) into the brake tube.





Using a 7/64 inch drill bit, insert the shank end of the drill bit into the brake tube and carefully bend the brake tube as necessary to allow the new brake tube nut to slide past the radius. See Figure 2.

10. Install the new brake tube nut (new nut contains a green identifying mark) on the brake tube, and position it back on the tube to allow clearance for installation of the flaring tool.

11. NOTE:
Be sure the new nut is installed on the tube before flaring.





Using a 3/16 inch tube flaring tool, double-flare the end of the brake tube. See Figure 3.

12. Using 320 grit emery cloth, clean the flare seating areas so they are free of the black nylon coating. See Figure 3.

13. Remove the threadsaver from HCU and discard. See Figure 1.

14. Install the new threadsaver. Tighten the threadsaver to 45 Nm (33 lb-ft).

15. Position the brake tube nut all the way to the flared end of the brake tube.

16. WARNING:
EXPOSED DRILL BIT END SHOULD BE WRAPPED WITH TAPE OR HELD WITH A SHOP TOWEL TO PREVENT THE POSSIBILITY OF PERSONAL INJURY.

17. Connect the brake tube to the HCU. Tighten the nut to 23 Nm (17 lb-ft).

18. Install the brake tube retainer.

19. Adjust RF brake tube height as necessary. Brake tube height should not exceed the height of the other tubes.

20. Adjust the clearance between the tubes as necessary. Clearance should be a minimum of 10 mm (3/8 inch) between brake tubes.

21. Connect the battery ground cable and remove the memory saver.

22. Manually bleed air from the front brake system. Have an assistant pump-up and hold the brake pedal. Then, loosen the right front caliper bleeder screw while the assistant maintains pressure on the brake pedal. Repeat this step until clear, bubble-free fluid comes out of the bleeder.

23. Repeat Step 22 for the left front wheel.


24. Fill the brake fluid reservoir with brake fluid as necessary.

25. Check brake pedal feel and check for leaks.