Falcon 1991 EA – 1997 EL

CAUSES RELATING TO BRAKE SHUDDER PULSATING PEDAL & STEERING WHEEL VIBRATION

1. Seal protruding above casting fowling on the stub axle (see illustration)
2. Incorrect bearing adjustment (follow the Ford manual instructions)
3. Run out /Disc Thickness Variation
4. These can in some cases cause severe vibration thru the steering wheel

5. When fitting the rotor and attempting to adjust the bearing (see illustration)
b. Check bearing cone and hub seal are both seated all the way into their respective recesses.
c. The hub seal must not protrude above the casting

WARNING if the seal is not correctly seated it will interfere with the stub axle making it impossible to get the correct bearing adjustment. Then as the rotor rotations intensify the rotor will lean further away from the hub and constantly hit (at the furthest oscillating point) the pad causing a pulsating pedal effect then as brakes are applied a shuddering. Under severe conditions pulsating can occur EVEN WHEN THE BRAKES ARE NOT APPLIED.

6. Bearing torque adjustment
a. Rotate the rotor while tightening the castle nut to 30Nm to seat the bearing, (SEE DIAGRAM)
Loosen castle nut ½ turn and re-tighten to 1.5Nm. (SEE DIAGRAM)
Install split pin and grease cap.
Check that the bearing play does not exceed the manufacturers tolerances

WARNING: Incorrect bearing torque adjustment
b. If the castle nut is too tight, this will cause rotor drag and excessive wear on the bearings.
c. If castle nut is too loose, rotor run will result causing DTV.
d. If the hub seal fouls on the stub axle correct bearing adjustment is impossible, rotor run out will occur causing DTV.

7. Tightening wheel nuts – Fitting wheels Torque as per the vehicle manufacturer’s instructions.
AVOID WARPED ROTOR CLAIMS:
ADB rotors are all machined for perfect parallelism BEFORE LEAVING THE FACTORY

WARNING: Excessive torque with POWER tools will result in rotor distortion/DTV rotor run out.
a. DO NOT OVER TIGHTEN WHEEL NUTS WITH EXCESSIVE TORQUE &
b. DO NOT TIGHTEN WHEEL NUTS COMPLETELY ON ONE SIDE FIRST

CORRECT PROCEDURE:
c. TIGHTEN WHEEL NUTS TO THE MANUFACTURERS RECOMMENDED TORQUE
d. USE THE CORRECT TIGHTENING PATTERN

WARNING: WE RECOMMEND YOU ADVISE THE VEHICLE TO AVOID ANY CONTACT WITH WATER WHEN ROTORS ARE EXTREMELY HOT. CAR WASHES ARE A COMMON PROBLEM.

8. DTV, is when rotor run out causes abnormal wear to only the part off the rotor constantly hitting and
rubbing against the pads. When the brakes are then applied this can result in a bad pedal feel, pulsating or shuddering pedal, knocking noise and a vibration through the steering.

9. ABS SENSOR RING.
a. Check the new rotor sensor ring has the same number of teeth as the old sensor ring.
b. If the rotor supplied is without the sensor ring the old one must be removed and re fitted to the new rotor
c. Fit the pole ring and Ensure the sensor ring run out is within the manufacturer’s specification.

10. Caution when removing and refitting sensor ring.
a. Do not fit a sensor ring with a different number of teeth
b. Take care not to strike the sensor ring on the tip of the speed wheel sensor
c. As both can effect stopping distances and record a fault in the ABS computer system.

11. Bedding-in: Avoid high speed or aggressive braking during first 100 km to allow the rotors and pads to bed-in to avoid heat spots and the subsequent reduction in braking efficiency.


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