Attachment III - Technical Information

OVERVIEW
Some 1996 Model Year vehicles do not require service under this Recall Program because they are not equipped with rear-mounted pressure control reducing valves (PCRV).

When performing this Recall procedure, you will:

Affected 1996 Model Year vehicles

^ Determine if the vehicle is equipped with rear-mounted PCRVs. If the vehicle is not equipped with rear-mounted PCRVs, the vehicle does not require service under this Recall Program.

^ If the vehicle is equipped with rear-mounted PCRVs, proceed as follows:

Some 1996 Model Year vehicles and all 1997 and 1998 Model Year vehicles





^ Replace both rear-mounted PCRVs (if equipped) with new, redesigned PCRVs. The new valves have an integral weather boot. (See Figure 1.)

^ Bleed the rear brakes.

INSPECTION

On 1996 Model Year vehicles only, inspect for the presence of a PCRV near either rear wheel. See Figure 2 of the Service Procedure for location. Neither rear tire has to be removed to perform this inspection. If a valve is present, proceed with the service procedure. If a valve is not present, no service is required. Release the vehicle to the owner.

SERVICE PROCEDURE

1. Raise the vehicle on the hoist and remove the rear tires.





2. Apply Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to the brake line and brake hose. See Figure 2.

3. Disconnect the brake line and brake hose from the PCRV. See Figure 2.

4. Remove the PCRV. See Figure 2.

5. Install the new PCRV. Tighten the line fittings to 13 Nm (10 lb-ft).

WARNING
BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY.

CAUTION
Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time.

6. Bleed the rear brakes.

^ DO NOT allow the brake master cylinder reservoir to run dry. Keep the brake master cylinder reservoir filled with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. Connect a clear drain tube to the right-hand rear bleeder screw and the other end in a container partially filled with clean brake fluid.

^ Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.

^ Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw.

^ Repeat until clear, bubble-free fluid comes out of the clear tube.

^ Refill the brake master cylinder reservoir as necessary.

7. Repeat this procedure for the other wheel cylinder or disc brake caliper.

8. Fill the master cylinder reservoir to the MAX line.

9. Check pedal feel. If pedal feels spongy, repeat the bleed procedure.

10. Install the tires. Tighten the lug nuts to 135 Nm (100 lb-ft).

11. Lower the vehicle.