Advanced Brake Service and Brake Lathe Training Course Code 38S09T0 FCS-13983-REF FCS13983ref Student Guide November, 2003 IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle • • Always wear safety glasses for eye protection • • • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure • • Do not smoke while working on the vehicle Set the parking brake when working on the vehicle If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation If you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation • Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood Use safety stands whenever a procedure requires you to be under the vehicle • Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide • Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice WARNING: Many brake linings contain asbestos fibers When working on brake components, avoid breathing the dust Breathing the asbestos dust can cause asbestosis and cancer Breathing asbestos dust is harmful to your health Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag If a vacuum bag suitable for asbestos is not available, cleaning should be done wet If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs Only technicians concerned with performing brake or clutch service should be present in the area Copyright © 2003 Ford Motor Company SERVICE STANDARDS Mission Statement: All dealership personnel will treat every customer as a potential lifetime purchaser, communicating a professional image which embraces honesty and concern for customer wants and needs Dealer-to-Customer Service Standards: Appointment available within one day of the customer’s requested service day Vehicles serviced right on the first visit Write-up begins within four minutes of arrival Service status provided within one minute of inquiry Service needs courteously identified, accurately recorded on Repair Order, and verified with customer Vehicle ready at agreed upon time Thorough explanation of work done, coverages andchanges These seven service standards provide a process and product value that are compelling reasons for owners to purchase and repurchase Ford or Lincoln-Mercury products These standards also help to attract new owners through favorable testimonials and improved owner satisfaction Standard “Fix It Right the First Time, on Time.” The technician is the most important player when it comes to Standard #4 Why Customers tell us “Fixing It Right the First Time, on Time” is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to “Fix it Right the First Time, on Time.” We refer to this as “competency.” Technician’s Role Acquire the skills and knowledge for competency in your specialty via STST NewModel — Web-Based Training — FORDSTAR — Ford Multimedia Training (FMT) — Instructor-Led — Instructor-Led The Benefits The successful implementation of standards means — Satisfied customers — Repeat vehicle sales — Repeat service sales — Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business” Contents LESSON 1: INTRODUCTION Objectives 1- What is the Value of Safety? 1- Introduction .1- The Dealership Difference .1- Ford Service Technician Brake Training 1- Ford Dealership Special Tools and Equipment 1- The Best Technicians Deserve the Best Parts 1- LESSON 2: CUSTOMER RELATIONS Objectives - Reasons to Improve Brake Sales - Why Do We Want This Brake Work? - Who is Doing This Work Now? - Using the Around The Wheel Report Card - “To Get Ahead, Plan Ahead” - Offer the Customer A Choice - Which Service Would you Buy? .2 - Earn a Customer’s Trust and They Are “Your” Customer for Life .2 - 10 LESSON 3: REPLACEMENT BRAKE COMPONENTS Objectives - Introduction to Ford and Motorcraft Parts - Ford Original Equipment Parts “When Only the Best Will Do” .3 - Why Are Motorcraft Pads and Shoes Better than Aftermarket Brands? - Motorcraft Super Duty “Hard-Working Parts for Hard-Working Vehicles” - Straight Talk About Brake Rotors - Ford OE and Motorcraft Rotors verses Aftermarket Rotors - Technically Speaking - Class Summary Summary-1 Brake Diagnostics Job Aid Technician Brake Training Job Aid Brake Information Website List Rotunda Order Sheet ProCut PFM 9.0 On-Vehicle Brake Lathe Operators Guide INTRODUCTION INTRODUCTION OBJECTIVES Upon completion of this lesson the student will be able to: – CONTENTS What is the Value of Safety Introduction Identify the course objectives − Describe the what advantages customers gain by having brake service performed at Ford or Lincoln-Mercury Dealerships when compared to aftermarket repair facilities − Explain that Ford Brake Training is the most The Dealership Difference Ford Service Technician Brake Training Ford Dealership Special Tools and Equipment The Best Technicians Deserve the Best Parts advanced and comprehensive in the automotive industry − Understand that Ford or Lincoln-Mercury Dealerships are best equipped to perform service on Ford/LM vehicles − Describe the basic advantages of Ford OE and Motorcraft parts Advanced Brake Service and Brake Lathe Training November, 2003 1-1 INTRODUCTION WHAT IS THE VALUE OF SAFETY? How much is the safety of your loved ones and yourself worth? In fact, the safety of those you love is priceless isn’t it? Most of us would never dream of cutting corners on any item that helps to ensure our safety Yet, how many of us trust the care and maintenance of one of the most important safety systems that we depend on every day to personnel that often don’t have the training or expertise to ensure that system is operating at its peak? By now you might be wondering what system is being referred to It’s none other than the brake system on your car! The brake system on any car is the most important safety system! Getting a car to move is important, but getting it to stop is critical Additionally, modern brake systems not only stop your car, but also is the primary part of your vehicle stability assist and traction control systems too! Yet how many drivers have their brakes serviced at muffler shops! Did the muffler shop technicians take more than 100 hours of intensive hands-on and electronic training on both conventional and advanced brake systems? Ford Brake Technicians do, and that is in addition to several web-based training courses on basic and advanced brake systems! Additionally, Ford Brake Technicians use the best parts available for your Ford car or truck! Both Ford and Motorcraft parts are specifically designed and engineered for use on Ford vehicles They must meet standards that are set well above those of aftermarket brake parts You don’t have a plumber work on the electrical system of your house, why would you have a muffler mechanic work on the brake system of your car? 1-2 November, 2003 Advanced Brake Service and Brake Lathe Training INTRODUCTION INTRODUCTION The statement on the previous page was quite dramatic, yet it’s true? • You are a Ford Brake Technician, how much training did you attend to become certified in specialty 38? • Do you think that Midas or Sears provides their brake technicians with the same level of training on Ford vehicles? Not likely • Modern vehicles no longer have just brake systems, they have complete Vehicle Motion Control Systems Vehicle Motion Control Systems include anti-lock braking, stability assist, traction control, panic assist braking, and electronic brake distribution functions Ford Motor Company invests millions of dollars each year training our technicians to be the best in the industry • You invest your valuable time by attending that training • Ford technical training requires that you put forth your best efforts to become certified, so why wouldn’t you your best to reap the rewards of your efforts? • Brake service is one of the most common regular maintenance procedures performed on all vehicles The objectives of this training is to: Reduce the time required and improve the quality of your brake repairs Identify more vehicles that need brakes Explain the differences between Ford Original Equipment (OE), Motorcraft and aftermarket brake parts Demonstrate the use and operation of the Pro-Cut on-vehicle brake lathe Develop a consistent source of quick and profitable repairs Advanced Brake Service and Brake Lathe Training November, 2003 1-3 INTRODUCTION THE DEALERSHIP DIFFERENCE So why drivers take their vehicles to muffler shops for brake service rather than to the dealership? As you know, many drivers perceive (often correctly or incorrectly) that dealership prices are much higher than those of aftermarket facilities Yet, what is the true value of the service the driver is receiving? • Ford and Lincoln-Mercury Dealership Technicians have the best training in the industry • Ford and Lincoln-Mercury Dealerships are equipped with the special tools and equipment that is specifically designed for Ford Vehicles • Ford and Lincoln Mercury Dealerships offer genuine original equipment parts that are specifically designed for Ford Vehicles and meet the most rigorous standards in the industry • Motorcraft brake parts programs allow Ford and Lincoln-Mercury Dealerships to price their brake service competitively with aftermarket facilities These seem like bold statements, let’s look at the merit of each statement individually 1-4 November, 2003 Advanced Brake Service and Brake Lathe Training REPLACEMENT BRAKE COMPONENTS TECHNICALLY SPEAKING Let’s compare the professions of two neighbors We’ll call them John Smith and Jim Jones • John Smith works in a field where he performs maintenance and repairs on systems that are well established These systems have operated the same way using the same components for as long as anyone can remember Once John get’s his licence to work on these systems, he never has to renew it, and any supplemental training he takes is strictly voluntary • On the other hand, Jim Jones works on systems that are constantly being changed and improved More pages of technical information are printed about these systems than all the pages used to print the phone books of New York, Chicago, and Los Angles combined Additionally, every few years Jim must undergo extensive testing to ensure he understands and can work with all the new technology in his field! Here’s the catch; John Smith is a medical doctor, while Jim Jones is an automotive service technician! As a Ford Brake Service Technician you are always learning just to stay current with the vehicles you service Think about it, the methods your father used to service the cars of his day are certainly not the way you work on the vehicles of today! One system that has changed dramatically from your father’s time is the brake system Brakes don’t just stop the vehicle anymore, they are advanced vehicle motion control systems • Anti-lock brakes (which are found on almost all cars produced today) are computer controlled hydro-electronic systems designed to stop a vehicle while providing maximum steering control • Vehicle stability systems (such as the Ford Advance Trac system) use advanced electronics in combination with the brake system to help prevent drivers from losing control • Traction control systems combine brake system components and electronic engine management systems to help prevent loss of vehicle control due to wheel spin during acceleration and while driving on slippery roads! • Panic Assist Braking features sense when a driver has applied full brakes in a panic situation and supplements their efforts by applying maximum brake pressure to the wheels • Electronic brake distribution systems automatically sense which wheels need more stopping power for the vehicle loading, and distribute the stopping power as needed Staying current in the latest technology will allow you to more quickly and effectively diagnose and service brake system concerns Remember, the best tool you have for servicing brakes is under your hat! 3-8 November, 2003 Advanced Brake Service and Brake Lathe Training REPLACEMENT BRAKE COMPONENTS TECHNICALLY SPEAKING (CONTINUED) Here are a few technical tips that will also help improve your customer satisfaction when working on brakes: • Educate your customers about brake dust - The law now requires that brake pads contain no asbestos Unfortunately, current technology has found no replacement compound for asbestos that will provide the same quiet performance without creating dust Explain this to your customers and they will be more tolerant of the dust producing nature of their brakes • Soap and water is the best cleaning agent for the rotors - After performing brake service and before the brakes are applied for the first time, always clean the rotors with soap and water Failure to so will result in metal contamination being forced into the new pads when the brakes are applied and cause a decrease in brake stopping ability • Test the rotor - place a clean rag on the surface and spin the rotor several rotations inspecting the rag to ensure you removed all metal particles before installing pads • Use only silicone brake grease when servicing brakes - Conventional grease will slowly convert to acid when subjected to water, static electricity and high temperatures This will result in pitting and scoring of brake system components Always use only silicone grease when servicing brake systems Advanced Brake Service and Brake Lathe Training November, 2003 3-9 REPLACEMENT BRAKE COMPONENTS NOTES - 10 November, 2003 Advanced Brake Service and Brake Lathe Training CLASS SUMMARY Class Summary Advanced Brake Service and Brake Lathe Training November, 2003 Summary - CLASS SUMMARY PRO-CUT BRAKE LATHE DEMONSTRATION SUMMARY • Ensure you have correctly setup the Ford supplied Pro-Cut lathe • The new Pro-Cut 9.0 PFM on-vehicle lathe will improve your speed and quality when turning rotors • Lateral runout is caused by hub versus rotor tolerance Always check hub runout • Lateral runout causes pads to touch on each rotation leading to thickness variation resulting in pedal pulsation • Always cleaning and adjust the tool holder before resurfacing • Ensure there are no bent arms Keys to good surface finish: • Fresh/undamaged cutting tips (OEM) • True tool holder plate (bent plate will result in poor surface finish) • Cutting head tight in dovetail • Snug gib on cutting box (loose gib will result in poor surface finish) • Use chip deflector/silencer Important Tips When Resurfacing Rotors • Count and tracking cuts on a bit and rotation • Never use Imitation bits • Clean rotors with soap and water • Clean the hub surface thoroughly • Importance of indexing the rotor • Using Torque Sticks to install the wheels Summary - November, 2003 Advanced Brake Service and Brake Lathe Training CLASS SUMMARY SUMMARY Your dealership sent you to this class today to help you improve your brake service skills In the past, many service technicians believed that they only need be concerned with improving their technical skills to improve their income In today’s competitive automotive service market your skill as a technician is not the only skill you need! Your skill and initiative as part of a complete service and service sales team is essential to your success! During this class you have seen a great deal of information about brakes service, customer relations, and components The importance of all the people in your dealership service department working together as a team to improve brakes service and sales is critical As a member of your dealership service team, it is up to you to spread the ideas you’ve learned here today to the other team members Class Highlights This class covered more than how to repair vehicles, it also incorporated other elements of the brake service business These include: • Ford and Lincoln-Mercury Dealerships only get 18% of the brake repairs on Ford and LincolnMercury vehicles • The strengths of your dealership include: • Brake Service Technicians have over 150 hours of intensive brake service training • Your dealership is equipped with the special tools and equipment required to correctly service Ford and Lincoln-Mercury brake systems • Ford OE and Motorcraft parts are designed specifically for Ford Vehicles • There is a tremendous amount of potential brake repairs in your shop every day - YOUR JOB is to pull the wheels and find the work • Use better/best selling method to improve the closing ratio • Emphasize the superiority of Ford OE and Motorcraft brake parts over aftermarket brands • Properly use the old and new style Pro-Cut on-vehicle brake lathe to deliver high quality brake repairs quickly • Remember the importance of rotor finish on stopping distance and noise Advanced Brake Service and Brake Lathe Training November, 2003 Summary - CLASS SUMMARY Additional Tips Here are a few tips on actions you can take to improve the performance of your team! • Understand that each member of your team are highly-skilled professionals working for a professional organization! Conduct yourself accordingly, and your customers will know it too! • Use the special tools you have available (including the Around the Wheel Report Card) to provide the service to your customers that they need! • Work together with your team to plan a strategy to improve your brake service sales and customer relations methods Doing so will improve your customer satisfaction and increase your customer base! • Emphasize the benefits of Ford OE and Motorcraft Parts over the competition! • Help parts department personnel plan the parts inventory needed to enable you to perform brake service efficiently and quickly Remember, brakes service sales will reduce the “feast or famine” syndrome by providing you with a consistent and ongoing source of service work Improving the service and sales skills of your dealership service department team will help provide you with the consistent income for you and your loved ones to enjoy! Next Steps Perform an Evaluation To Identify Weaknesses • Increased vehicle inspections • Review your prices to ensure you’re competitive • Review parts inventory • Improve Service Advisor sales skills (could include better/best) • Improve other technical knowledge • Update equipment to increase productivity and quality • Develop a team approach Summary - November, 2003 Advanced Brake Service and Brake Lathe Training BRAKE PADS/SHOES Service Caliper guide-pins if there is taper wear on the brake pads Vibration concerns are generally not resolved by replacing pads Lateral runout measurements are not required when machining brake rotors Proper adjustment of the on-vehicle brake lathe will ensure that lateral runout is within specification after machining Noise concerns are generally not resolved by rotor machining or replacement FIGURE 2: PAD MEASUREMENT FIGURE 4: UNEVEN WEAR Note: The descriptions and specifications contained in this document were in effect at the time this document was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring any obligation FIGURE 1: ROTOR MEASUREMENT MEASURING ROTORS AND BRAKE PAD LININGS Replace a rotor in conjunction with a brake pad replacement if rotor is within specifications, is not recommended (see specs page 2) FIGURE 3: CHIPPED Replace pads if measured thickness of lining is less than 3.0 mm for all vehicle lines, see Fig Maintainence and adjustment of on-vehicle Pro-Cut Lathe is essential for proper machining PAD WEAR AND DEFECTS Replace pads if measured thickness of lining is less than 3.0mm for all vehicle lines, see Fig.2 Machine rotors for vibration conditions Brake Pad replacment is generally not required when rotors are machined or replaced unless they are below the specifications Brake pad replacement is not required when rotors are machined or replaced unless the pads have visible defects including the following: (see Fig and Fig 4, for defects) * Cracking * Missing chunks or chipped * Taper wear (Thickness varies by more than 3.0 mm) Measure rotor thickness in places around the rotor at 90 degree increments to determine the thickness of the rotor, see Fig Replace the rotor if the measured thickness is less than machined thickness and turn rotors if the measured thickness is greater than the machined thickness, see spec for machined thickness(page2) All measurements of rotors to be taken on vehicle only The following are guidelines for diagnosis and repair of brake noise and roughness concerns Please refer to shop manuals and SSM's for detailed diagnostics procedures BRAKE DISC BRAKE DIAGNOSTICS JOB AID 00 - 03 00 - 03 00 - 03 01 - 03 F150 F250/F350(Super Duty) F450/F550(Super Duty) Focus, ZTS, ZX3, ZX5 Focus, SVT Grand Marquis Grand Marquis Lincoln LS Maruader MotorHome Chassis Mountaineer Mountaineer Mustang V6/GT Mustang Cobra Mystique Navigator Navigator Ranger Sable Taurus Thunderbird Town Car Town Car Villager Windstar (0.963 ) (1.102 ) (1.102 ) (1.102 ) (0.866 ) (0.787 ) (1.417 ) (1.063 ) (1.091 ) (0.965 ) (0.965 ) (0.965 ) (0.965 ) (1.043 ) (1.091 ) (0.947 ) (0.874 ) (0.874 ) (1.037 ) (1.014 ) 24.50 (0.965 ) HD > 27.70 (1.091) 36.00 (1.417 ) 36.00 (1.417 ) 20.00 (0.787 ) 22.20 (0.874 ) 26.35 (1.037 ) 25.75 (1.014 ) 28.00 (1.102 ) 26.35 (1.037 ) 36.00 (1.417 ) 24.50 (0.965 ) 24.50 (0.965 ) 24.75 (0.974 ) 26.40 (1.039 ) 22.20 (0.874 ) 27.00 (1.063 ) 27.70 (1.091 ) 24.50 (0.965 ) 24.75 (0.974 ) 24.75 (0.974 ) 28.00 (1.102 ) 26.35 (1.037 ) 25.75 (1.014 ) 24.00 (0.945 ) 24.75 (0.974 ) 24.45 28.00 28.00 28.00 22.00 20.00 36.00 27.00 27.70 24.50 24.50 24.50 24.50 26.50 27.70 24.75 22.20 22.20 26.35 25.75 25.10 (0.988 ) HD >28.30 (1.114 ) 36.60 (1.441 ) 36.60 (1.441 ) 20.60 (0.811 ) 22.80 (0.898 ) 26.95 (1.061 ) 26.35 (1.037 ) 28.60 (1.126 ) 26.95 (1.061 ) 36.60 (1.441 ) 25.10 (0.988 ) 25.10 (0.988 ) 25.35 (0.998 ) 27.00 (1.063 ) 22.80 (0.898 ) 27.60 (1.087 ) 28.30 (1.114 ) 25.10 (0.988 ) 25.35 (0.998 ) 25.35 (0.998 ) 28.60 (1.126 ) 26.95 (1.061 ) 26.35 (1.037 ) 24.60 (0.969 ) 25.35 (0.998 ) 25.05 (0.986 ) 28.60 (1.126 ) 28.60 (1.126 ) 28.60 (1.126 ) 22.60 (0.890 ) 20.60 (0.811 ) 36.60 (1.441 ) 27.60 (1.087 ) 28.30 (1.114 ) 25.10 (0.988 ) 25.10 (0.988 ) 25.10 (0.988 ) 25.10 (0.988 ) 27.10 (1.067 ) 28.30 (1.114 ) 25.35 (0.998 ) 22.80 (0.898 ) 22.80 (0.898 ) 26.95 (1.061 ) 26.35 (1.037 ) Minimum Machine Thickness mm (in) (0.413 ) (0.472 ) (0.502 ) (0.709 ) (0.709 ) (0.709 ) (0.512 ) 12.00 (0.472 ) 28.00 (1.102 ) 36.00 (1.417 ) 8.00 (0.315 ) 8.90 (0.350 ) 18.00 (0.709 ) 13.00 (0.512 ) 18.50 (0.728 ) 18.00 (0.709 ) 36.00 (1.417 ) 10.50 (0.413 ) 11.00 (0.433 ) 12.75 (0.502 ) 12.75 (0.502 ) 18.00 (0.709 ) 19.00 (0.748 ) 19.00 (0.748 ) N/A 12.80 (0.504 ) 12.80 (0.504 ) 18.50 (0.728 ) 18.00 (0.709 ) 13.00 (0.512 ) N/A N/A 24.45 (0.963 ) 28.00 (1.102 ) 36.30 (1.429 ) 38.00 (1.496 ) N/A 8.00 (0.315 ) 28.00 (1.102 ) 19.00 (0.748 ) 19.00 (0.748 ) 10.50 (0.413 ) 11.00 (0.433 ) 11.00 (0.433 ) 11.00 (0.433 ) 10.50 12.00 12.75 18.00 18.00 18.00 13.00 Minimum Discard Thickness mm (in) 12.60 (0.496 ) 28.60 (1.126 ) 36.60 (1.441 ) 8.60 (0.339 ) 9.50 (0.374 ) 18.60 (0.732 ) 13.60 (0.535 ) 19.10 (0.752 ) 18.60 (0.732 ) 36.60 (1.441 ) 11.10 (0.437 ) 11.60 (0.457 ) 13.35 (0.526 ) 13.35 (0.526 ) 18.60 (0.732 ) 19.60 (0.772 ) 19.60 (0.772 ) N/A 13.40 (0.528 ) 13.40 (0.528 ) 19.10 (0.752 ) 18.60 (0.732 ) 13.60 (0.535 ) N/A N/A 25.05 (0.986 ) 28.60 (1.126 ) 36.90 (1.453 ) 38.60 (1.520 ) N/A 8.60 (0.339 ) 28.60 (1.126 ) 19.60 (0.772 ) 19.60 (0.772 ) 11.10 (0.437 ) 11.60 (0.457 ) 11.60 (0.457 ) 11.60 (0.457 ) 11.10 (0.437 ) 12.60 (0.496 ) 13.35 (0.526 ) 18.60 (0.732 ) 18.60 (0.732 ) 18.60 (0.732 ) 13.60 (0.535 ) Minimum Machine Thickness mm (in) REAR DISC BRAKE N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 229.60 (9.04 ) N/A N/A 281.70 (11.09 ) 226.55 (8.92 ) 226.55 (8.92 ) N/A N/A N/A 251.50 ( 9.90 ) 251.55 ( 9.90 ) 310.10 (12.21 ) N/A N/A N/A 230.10 (9.10 ) N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 0.8 (0.03 ) 3.75 ( 15 ) 3.75 ( 15 ) N/A N/A N/A 1.5 (0.06 ) 3.9 (0.15 ) 1.00 (0.04 ) N/A N/A N/A N/A 1.00 (0.04 ) N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Minimum Thickness mm (in) Maximum Inside Diameter mm (in) N/A N/A N/A 229.60 (9.04 ) N/A N/A N/A REAR BRAKE SHOE LINING REAR DRUM (24 ) (23 ) (23 ) (41 ) (26 ) (36 ) (41 ) (41 ) (24 ) (20 ) (24 ) (24 ) (24 ) (20 ) (20 ) (26 ) (21 ) (21 ) (32 ) (24 ) 32 (24 ) 56 nm (41 ) 56 (41 ) 28 (21 ) 29 (21 ) 44 (32 ) 32 (24 ) 35 (26 ) 44 (32 ) 45 (32 ) 32 (24 ) 32 (24 ) 31 (23 ) 31 (23 ) 28 (21 ) 55 (41 ) 33 (24 ) 32 (24 ) 32 (24 ) 32 (24 ) 32 (24 ) 44 (32 ) 32 (24 ) 29 (21 ) 35 (26 ) 33 31 31 55 35 49 56 55 33 27 32 32 32 27 27 35 28 28 44 33 Front Brake Caliper Retaining Bolts Nm (lb-ft) (27 ) (27 ) (27 ) (41 ) (16 ) (38 ) (41 ) (26 ) (26 ) (20 ) (24 ) (20 ) (20 ) (20 ) (20 ) (26 ) (30 ) (21 ) (18 ) (20 ) 27 (20 ) 56 (41 ) 56 (41 ) 35 (26 ) 35 (26 ) 25 (18 ) 27 (20 ) 33 (24 ) 25 (18 ) 55 (41 ) 27 (20 ) 27 (20 ) 33 (24 ) 33 (24 ) 41 (30 ) 35 (26 ) 35 (26 ) N/A, Brake Drum 33 (24 ) 33 (24 ) 33 (24 ) 25 (18 ) 27 (20 ) N/A, Brake Drum N/A, Brake Drum 36 36 36 55 22 52 55 35 35 27 32 27 27 27 27 35 41 28 25 27 Rear Caliper Bolts Torque Nm (lb-ft) Wheel nuts Torque Nm (lb-ft) 12 mm Nuts > 135 (100 ) 14 mm Nuts > 204 (150 ) 210-224 (155-165 ) 210-224 (155-165 ) 128 ( 94 ) 128 ( 94 ) 129 ( 95 ) 129 ( 95 ) 135 (100 ) 129 ( 95 ) 210-214 ( 155-158 ) 135 (100 ) 135 (100 ) 129 ( 95 ) 129 ( 95 ) 128 ( 94 ) 204 (150 ) 135 (100 ) 135 (100 ) 129 ( 95 ) 129 ( 95 ) 135 (100 ) 115 -142 (85-105 ) 115 -142 (85-105 ) 108 ( 80 ) 135 (100 ) 135 (100 ) 200 (147 ) 129 ( 95 ) 128 ( 94 ) 128 ( 94 ) 129 ( 95 ) 115-142 ( 85-105 ) Single 100-180 ( 74 -133 ) 170-230 (125-170 ) 170-230 (125-170 ) 210 (155 ) 133 ( 98 ) 100-135 ( 74-100 ) 210-224 (155-165 ) 204 (150 ) 135 (100 ) 135 (100 ) 135 (100 ) 135 (100 ) 135 (100 ) BOLT / LUG TORQUE Note: The descriptions and specifications contained in this document were in effect at the time this document was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring any obligation This chart is for "blue box" parts only and is not applicable for Motorcraft specifications On REAR rotors for E and F-series trucks with dual rear wheels, rotor replacement is the only acceptable repair for a rotor defect noted 03 00 - 02 00 - 03 03 00 - 03 03 00 - 02 00 - 03 00 - 03 00 03 00 - 02 00 - 03 00 - 03 00 - 03 02 - 03 03 00 - 02 00-02 00 - 03 00 - 03 00 - 03 00 - 03 00 - 03 01 - 03 00 - 03 00 - 03 03 00 - 02 03 00 - 02 01 - 03 01 - 03 Model Year 03 02 - 03 00-02 00 00-02 03 00 - 02 E-Series, E150 E-Series, E250, E350 E-Series, E450 E-Series, E550 Escape Escort & Escort ZX2 Excursion Expedition Expedition Explorer Explorer Explorer Sport Explorer Sport Trac Vehicle Aviator Blackwood Continental Contour Cougar Crown Victoria Crown Victoria Minimum Discard Thickness mm (in) FRONT BRAKE DISC BRAKE DIAGNOSTICS JOB AID Technician Brake Training Job Aid Dealership Name: Date: Current Brake Sales and Opportunity Previous Month # Brake Repairs Retail R.O.s Penetration MC % OE % Top Dlr Penetration Brake R.O.s At Top Dlr Penetration Topics Reviewed in Class: • • • • • • Why customers should have brakes repaired at your dealership versus an aftermarket shop How to increase brake jobs at your dealership: o Increase traffic Advertising o Increase inspections AtW Report Cards o Increase closing ratio Loose fewer repairs o Better/Best selling OE and Motorcraft brakes What's the difference between OE, Motorcraft and aftermarket brake parts The importance of a smooth and clean rotor finish Setting up the old version of the Pro-Cut on vehicle lathe (provided by Ford) Using the new model Pro-Cut lathe to reduce time and improve quality Dealership Evaluation: Technician Involvement All Vehicles Get Inspected Rotor Lathe Condition Tech Knowledge/Skills Service Team Involvement Brake Menu Price is Competitive S.A Sales Skills Pad and Rotor Inventory Dealership Advertising & Merchandising Dealership Has a Team Approach OKAY FUTURE ATTENTION IMMEDIATE ATTENTION Green Yellow Red Dealership Resources: AtW Inspection Process Competitive menu Price: FMCDealer log on as Parts Manager and go to; Parts Product Line Information, Brakes, Pricing Tools This tool starts with a phone mystery shop of your competitors to see how they quote a brake service then compares that to your dealership You can then use the tool to help develop a pad replacement, or pad and rotor turn price using OE or Motorcraft pads Brake Rotor Lathe: Regardless of the lathe your dealership uses, institute a process to track the cuts on a bit In the class you were taught how to use a parts tag attached to the lathe to count cuts Do you have enough lathes for the number of techs and brake repairs being performed and are they in good condition Purchasing a new Pro-Cut lathe will reduce time and improve quality You can find equipment available through Rotunda on FMCDealer, or contact your local Pro-Cut rep Pad and Rotor Inventory: FMCDealer log on as Parts Manager and go to; Parts Product Line Information, Brakes, Application Charts you can find application coverage, part numbers, and cross references from OE to Motorcraft for both pads/shoes and rotors/drums With pads/shoes generally 20 part numbers cover 80% of your volume If you want to stock Motorcraft pads and today you only sell OE, run a list of your top selling OE pads and use the chart on FMCDealer to cross the OE to the Motorcraft part number Most Motorcraft WDs will be flexible in balancing your inventory 30, 60, or 90 days after putting them on your shelve This same process can be followed for rotors/drums Service Advisor Sales Skills: There are a number of courses S.A.s can take to improve their skills You should use your REACT based sales reports available from your Regional Zone Manager to identify S.A.s with low sales penetrations and make a personalized plan Possible classes include: * * * * Service Advisor Basic Skills web course Maint & Light Repair Selling Value Fordstar Atcon Retail Selling skills (RSS-1) Atcon On-The-Lane training * * * * Selling Ford Brakes web course AtW S.A Training Fordstar Atcon Retail Selling Skills (RSS-2) Regional training events Tech Knowledge/Skills: What is your plan to share what your tech that attended the Brake Course learned with the other brake techs in your shop? Ensure the proper operation of the lathe; rotation and replacement of bits, and the quality of the rotor cleaning are reviewed with all brake techs If there are specific techs that have more brake comebacks than others develop a plan to increase their specific knowledge or limit their brake repairs Dealership Team Approach: This starts with the managers, however everyone must play as a team to be successful If there is a lack of cooperation between S.A.s and techs, or parts and service make a plan to improve • www.procutinternational.com - Provides technical support and parts for Pro-Cut On-Vehicle brake lathes • www.motorcraft.com - Provides brake pad application and technical support for Motorcraft brake parts • http://www.fordtechservice.dealerconnection.com - For quick reference of brake drum and rotor thickness specifications select Service Publications from left menu bar, then select Quick Reference Guides from pull down menu Also provides link to Rotunda Tools The following website adresses can be used by service technicians to get supplemental information on Ford and Motorcraft Brakes BRAKES INFORMATION WEBSITE LIST PREFIX City, State, Zip: Address: COL (if required) COL ADDITIONAL SPECIFICATIONS DESCRIPTION ❏ 36 Mo (Minimum $5,000) September 1999 315-195 Prices subject to change without notice Do not sign this contract before you read it or if it contains any blank spaces You are entitled to an exact copy of the contract you sign Under the law you have the right to pay off in advance the full amount due and under certain circumstances to obtain partial refund of the time charge BUYER ACKNOWLEDGES RECEIPT OF A TRUE AND COMPLETELY FILLED IN COPY OF THIS CONTRACT AT THE TIME OF SIGNING Notice To Buyer: ❏ 90 Days Same as Cash (Minimum $1,000) Installment Plan (Fixed Rate) ❏ 12 Mo (Minimum $1,000) ❏ 24 Mo (Minimum $3,000) ❏ 48 Mo (Minimum $10,000) ❏ 60 Mo (Minimum $15,000) (Reverse side must be completed) ❏ 30 Day Open Account Buyer, having been quoted both an installment Price and a lesser Cash Price, hereby purchases from Seller on installment price basis, upon the terms and conditions set forth on the face hereof, the equipment to be delivered and installed at Buyer’s premises, as described above and agrees to pay Seller the Installment Price therefore as so set forth until paid in full PART II OPTIONAL: CATALOG PAGE NO EXTENDED TOTAL AUTHORIZED DEALERSHIP SIGNATURE (BUYER) PRINT NAME FCSD CREDIT MANAGER APPROVAL (ORDERS OVER $4,000) PART III TOTAL UNIT PRICE FAX NUMBER 1-800-762-6181 FOR TELEPHONE ORDERS USE THE ROTUNDA TOLL-FREE NUMBER 1-800-ROTUNDA (768-8632) DEALER: Be sure you have completed Parts I and II for all orders, Part III for Installment Plan Orders 315-195 (Previous editions may not be used) Ship to arrive by (Date or ASAP): Order Date: Attention: Fax #: Phone #: City, State, Zip: Address: Dealer Name: BAL OF NO ITEM NUMBER Dealer Parts Code #: PART I QTY ORDER FORM Security Interest Buyer hereby grants to Seller a continuing security interest in the Equipment, including all products and proceeds thereof, until all amounts due hereunder are paid Buyer agrees to execute, and pay filing fees for, any financing statement or other documents deemed necessary by Seller to maintain a valid security interest in the Equipment Freight and Taxes Freight costs and applicable taxes will be added to the final invoice and will be borne by Buyer Warranty THE MANUFACTURER’S WARRANTY SHALL BE BUYER’S EXCLUSIVE REMEDY, RECOURSE OR DAMAGE FOR ANY DEFECT IN WORKMANSHIP OR MATERIAL OR ANY FAILURE OF THE EQUIPMENT SELLER MAKES NO WARRANTIES, REPRESENTATIONS, INDEMNITIES OR GUARANTEES WHATSOEVER WITH RESPECT TO EQUIPMENT EITHER EXPRESS OR IMPLIED, ARISING BY LAW OR CUSTOM, INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THE LIABILITY OF THE SELLER SHALL BE LIMITED TO EXPRESS OBLIGATION TO DELIVER THE EQUIPMENT UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE OR RESPONSIBLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES, WHETHER FORESEEABLE OR UNFORESEEABLE, WHICH BUYER MAY INCUR, EXPERIENCE OR CLAIM, INCLUDING, BUT NOT LIMITED TO, CLAIMS FOR LOSS OF PROFITS, INTERRUPTION IN BUSINESS, LOST OPPORTUNITY, WORK STOPPAGE OR OTHER IMPAIRMENT OF ASSETS, ARISING OUT OF MISREPRESENTATION, NEGLIGENCE, STRICT LIABILITY, IN TORT OR OTHERWISE, ON ACCOUNT OF ENTERING INTO OR RELYING ON THIS AGREEMENT, EVEN IF SELLER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES Unconditional Obligation Buyer’s obligation to make payments to Seller or its assignee shall be absolute and unconditional and shall continue unmodified despite any loss, damage or other interruption in the use of Equipment The obligation of Buyer to pay in full any amounts due under this contract shall not be subject to dispute, claim, counterclaim, defense or other right which Buyer may have to assert against Seller or the manufacturer of Equipment Buyer acknowledges that: (a) Buyer has selected Equipment and Manufacturer, and Buyer has determined Equipment’s suitability and fitness for the Buyer’s purpose, (b) Seller is not the manufacturer of Equipment, and (c) Manufacturer issues its own warranty and performs the obligations under such warranty Delays Seller shall not be liable for any failure or delay in delivering Equipment, or for any failure to perform any provision hereof, resulting from fire, flood or other casualty, riot, strike or other labor difficulty, governmental regulation or other restriction, or any other cause beyond Seller’s control Acceptance and Inspection Buyer shall be deemed to have accepted Equipment upon Seller’s delivery Equipment shall be deemed to have been delivered in good condition unless Buyer gives Seller notice to the contrary within 10 days after Seller’s delivery Risk of Loss Seller shall be responsible for risk of loss until Equipment is delivered to the location set forth herein, at which time risk of loss shall be the responsibility of Buyer Title Title to Equipment purchased by Buyer from Seller shall pass to Buyer upon Seller’s receipt of all amounts owing by Buyer to Seller hereunder Payment and Terms of Payment a If Buyer has requested the Dealer Open Account payment plan via the Ford Dealer Statement in Part II of the order form, and Seller agrees to sell pursuant to such plan, then Buyer shall pay the total purchase price shown on the invoice b If Buyer has requested the Installment Plan (Fixed Rate) in Part II of the order form, and Seller agrees to sell pursuant to such Plan, then Buyer shall pay the Down Payment (if any), and the Time Balance in equal monthly installments in accordance with the terms set forth below c If Buyer has requested the Installment Plan (Variable Rate) in Part II of the order form, and Seller agrees to sell pursuant to such Plan, then Buyer shall pay the Total Cash Price and any interest thereon in accordance with the Loan and Security Agreement to be executed by Buyer and Seller 13 Default In the event that Buyer: (a) fails to pay any amount due hereunder within ten (10) days of the due date, (b) fails to comply with any other provision hereof, (c) files, or if there is filed against Buyer, any petition under any bankruptcy or insolvency laws or suffers the appointment of any trustee or receiver for all or any part of Buyer’s business or assets, or (d) has any assignment (voluntarily or involuntarily), lien, attachment or levy issued against the Equipment (unless such petition, assignment or appointment, lien, attachment or levy is withdrawn or nullified within twenty (20) days) then Buyer shall be in default hereunder and all of Buyer’s indebtedness and obligations to Seller shall, at Seller’s option, become immediately due and payable, and Seller may, at its option, terminate this contract and repossess any and all items of Equipment with or without legal process and sell the same at private or public sale without prior notice to Buyer to the extent permitted by law Upon request, Buyer shall deliver the Equipment to Seller at a place designated by Seller Repossession and/or sales of the Equipment upon such default shall not affect the Seller’s right to retain all payments made prior to repossession or to recover the balance due hereunder for any deficiency Buyer shall reimburse Seller all costs of collection, repossession and resale (including reasonable attorneys’ fees, court costs and other expenses incurred by Seller.) Buyer hereby releases Seller from any liability for damages resulting from repossession hereunder The rights and remedies of Seller, in the event of default herein mentioned shall not be deemed exclusive but shall be cumulative and in addition to all other rights and remedies existing under law, and may be enforced successively or concurrently Waiver by Seller of any default shall not be deemed a waiver of any other default 12 Insurance and Indemnification Buyer shall defend, indemnify and hold harmless Seller from and against, and at Buyer’s own expense provide insurance satisfactory to Seller covering any and all losses, damages, claims, expenses and other liabilities (including attorney’s fees,) relating to or arising out of: (I) damage, loss, theft, or destruction of the Equipment, or (ii) death, injury or property damage connected with the use, operation or condition (including without limitation, defects whether or not discoverable by any party) of the Equipment Buyer shall promptly notify Seller of any such claim Seller shall have the right to participate, at its own expense, in any proceeding for which Buyer has undertaken the defense of Seller, and in no event shall Buyer settle any claim against Seller without Seller’s prior written consent, Buyer shall provide evidence of such insurance to Seller upon demand Seller is under no obligation to examine any insurance certificate or advise Buyer that its insurance does not comply with the requirements set forth herein The losses covered by insurance shall in all cases be payable to Seller and Buyer as their interests may appear If Buyer fails to insure the Equipment as herein provided, Seller may, but is not obligated to, place such insurance upon the Equipment and the Buyer agrees to pay to Seller on demand the premiums for such insurance placed by Seller In no event shall any insurance coverage be deemed to limit or replace Buyer’s obligation to indemnify Seller as provided herein 11 Personal Property Ford proprietary diagnostic equipment (including the software, if applicable) shall be kept at Buyer’s premises as listed on the reverse side and shall remain personal property regardless of how and to what degree it may be affixed or attached to any building or structure or what may be the consequence of its removal from such building or structure Buyer shall not encumber the Equipment (including software, if applicable) until all amounts owing to Seller hereunder are paid In addition, Seller grants to Buyer, and Buyer accepts, a non-exclusive license to use the Equipment (including the software, if applicable) in accordance with the terms and conditions set forth herein The license (and Equipment) shall not be leased, sold, assigned or otherwise transferred, in whole or in part In the event, Buyer proposes to lease, sell assign or otherwise transfer the Equipment (and/or its software, if applicable), in whole or in part, to any person or entity, Ford Motor Company shall have a Right of First Refusal to purchase the Equipment (including all software, if applicable) for Ten and 00/100 Dollars ($10.00) in U.S currency 10 Maintenance Buyer shall use the Equipment carefully and properly Buyer, at Buyer’s own expense, shall maintain and repair all items of the Equipment in order to keep them in good order and condition and, in particular, shall comply fully with the maintenance, operating, usage or other instructions provided by the manufacturer Buyer authorizes Seller, or any third party appointed by Seller, to inspect the Equipment when necessary Buyer shall at all times keep the Equipment free and clear of all liens, charges or encumbrances TERMS & CONDITIONS Unpaid Balance of Cash Price (Difference between and 2) $ $ September 1999 Dealer Signature: 315-195 Prices subject to change without notice MAIL COMPLETED ORDER FORM TO: ROTUNDA EQUIPMENT PROGRAM P.O Box 1450 Kenosha, WI 53141 Date: I agree to pay the time Balance set forth in accordance with the above schedule and the terms and conditions of this order form Installment Payment Price (1 + 4) Number of Installments ❏ 12 ❏ 24 ❏ 36 ❏ 48 ❏ 60 equal monthly installments Taxes and transportation (if any) will be billed separately Time Balance (3 + 4) $ $ $ Down Payment (if any) Finance Charge (Finance charge will reduce each month) Call 1-800-768-8632 for the current finance charge rate $ Cash Price Installment Plan Agreement PART III 15 Finance Charge Monthly portion of Finance Charge (Part III, Item 3) due is calculated each month by multiplying 1/12 of the annual finance charge rate times the remaining portion of the Unpaid Balance of Cash Price, and is added to the portion of the Unpaid Balance of Cash Price due each month 14 General The waiver by either party of, or failure to claim, a breach of any provision of this contract shall not be deemed to be a waiver of any provision of this contract, shall not be deemed to be a waiver of any subsequent breach or to affect in any way the effectiveness of such provision This contract constitutes the entire agreement between the parties and may not be changed except by an instrument in writing signed by the party to be charged This contract may not be assigned by Buyer without the Seller’s prior written consent Seller may assign this contract at any time but shall not thereby be relieved from any liability hereunder In the event that one or more clauses of this contract are found to be unenforceable, illegal or contrary to public policy by court of competent jurisdiction, the remainder of this contract shall remain in full force and effect except for the unenforceable, illegal or other provisions This agreement is a Michigan agreement and shall be interpreted, construed and enforced in accordance with the laws of the State of Michigan, United States of America Each of the parties here to agrees that any legal or equitable action or proceeding with respect to this agreement shall be brought only in any court of the State of Michigan, or in any court of the United States of America sitting in Michigan, and each of the parties hereto submits to and accepts generally and unconditionally the jurisdiction of those courts with respect to such party’s person and property Each party hereby irrevocably waives any objection to the laying of venue of any such action or proceeding in the above described courts ... or standing around drinking coffee? 2-4 November, 2003 Advanced Brake Service and Brake Lathe Training CUSTOMER RELATIONS NOTES Advanced Brake Service and Brake Lathe Training November, 2003. .. Ford Dealer” Advanced Brake Service and Brake Lathe Training November, 2003 - 15 CUSTOMER RELATIONS NOTES - 16 November, 2003 Advanced Brake Service and Brake Lathe Training REPLACEMENT BRAKE COMPONENTS... dealership need brake service! Advanced Brake Service and Brake Lathe Training November, 2003 2-3 CUSTOMER RELATIONS Why Do We Want This Brake Work? Obviously these vehicles brakes were serviced somewhere,