ome vehicles have more than their fair share of brake noise problems. And fixing one problem may result in another unwanted symptom. For example: Changing a friction formulation to minimize a squeal complaint may result in a creeping, moaning, or droning noise just as the vehicle comes to a full stop, or it may drastically shorten the pad life. Our job would be simple if a formula change could satisfy all concerns. In the real world, the many components that make up the system must all function together to insure proper operation. Just throwing another set of pads on the vehicle wont resolve the issue. Consider the Ford Escort and Mercury Tracer vehicles. We have encountered many noise-related challenges with these applications dating back to 1991.

AUTO PARTS

BRAKES 101

FORD ESCORT BRAKES

Getting the Noises Out Can Be a Challenge!
especially with light pedal pressure applied. The symptoms fit the description of loose or worn parts. When diagnosing a knocking complaint, some basic concerns should be examined:
Rotor Runout: Excessive runout promotes pad movement as the rotor wipes the pad, vibrating it in its mounting. Runout should always be checked on the vehicle with the lug nuts torqued to spec and not on the brake lathe. Parallelism: The rotor thickness should be checked in at least four positions. A variation in rotor thickness of as little as.0005 inches can result in disc pad movement and unwanted noises. Material Transfer: If an uneven transfer of friction material to the rotor occurs, a slip/stick condition can be encountered. The non-uniform transfer of the material affects the parallelism of the rotor, resulting in pulsation and noises. This condition has resulted in many vehicle manufacturers specifying the use of oncar lathes to machine rotors. Non-Directional Finish: Directional lines etched in the rotor from the machining process promote pad movement and frustrating, hard-to-pinpoint noises. Following the machining process, make certain a nondirectional finish is applied. Loose Parts: Check all suspension components, bearings, bushings, etc. for wear or missing parts.
If these considerations fail to identify the cause of the noise, the problem may be due to wear spots or ridges on the upper caliper sleeve. This condition will not affect the braking performance; instead, it will only produce knocking noises. The noise will occur in proportion to wheel rotation and may be present during light braking. If pedal pressure is maintained, the noise will continue until the vehicle stops.
DISC PAD VIBRATION Ford addressed brake noise complaints of persistent squeal on 199196 Ford Escorts and 199196 Mercury Tracers, especially while braking at speeds below 35 mph. They acknowledge the noise condition and advise that it may be due to a vibration between the semi-metallic pads and the rotor. Ford modified their formula and they recommend the application of Silicone Brake Caliper Grease to the shims, prior to replacing the pads. The lubricant serves as a damper, thus reducing the potential for noise. The lubricant takes the place of any noise abatement compounds previously used. Volvo has been recommending the use of the silicone grease for years.
KNOCKING NOISES Ford acknowledges that a knocking noise may occur on their 199196 Ford Escorts and 199196 Mercury Tracer vehicles under light braking conditions. The noise is proportional to wheel rotation and may continue until the vehicle comes to a complete stop,
Fords solution: The fix is to install Fords revised caliper sleeves (#F4CZ-2B393-B) as illustrated in fig. 1. The wear on the upper sleeve is the reason for the noise; however, we recommend replacing both sleeves.
UPPER MAIN CALIPER SLEEVE

GUIDE PLATES

into the guide plate that still incorporates the tabs (see fig. 5). When this procedure is completed, the guide plates are doubled or piggybacked.

FIG. 3

FIG. 1
CLICKING NOISES Customer complaints of clicking noises while braking, especially after changing direction, while driving a 199799 Ford Escort or 199799 Mercury Tracer, may be due to excessive clearance between the caliper support bracket and the inner disc pad plate. To determine, drive the vehicle in a forward direction and apply the brakes; then drive the vehicle in reverse and brake. The noise is usually more pronounced as the brakes are initially applied. Ford now offers a revised guide plate to reduce the clearance, thus eliminating the clicking noise.
Install the revised and modified guide plate assembly and check the clearance. If clearance is still a problem, it is acceptable to modify the opposite guide plate as previously mentioned, and install it on the opposite side of the steering knuckle, as long as the measurement (illustrated in fig. 2) does not fall below.016 inches.

GUIDE PLATE WITH TABS

GUIDE PLATE WITH TABS REMOVED

FIG. 4

CLEARANCE MEASUREMENTS With a feeler gauge, measure the clearance between the disc pad steel plate and the steering knuckle (see fig. 2) while the pad is forced to the extreme side of the knuckle. The clearance should be between.016.037 inches. If the clearance exceeds.037, remove the caliper and inspect for a missing guide plate (see fig. 3). If missing, install a new guide plate, reassemble, and re-check the measurement. If the clearance is greater than.028, obtain a new guide plate (Ford #F5CZ2B164-AA). Modify the new guide plate for installation by breaking the tabs off the guide plate, as illustrated in fig. 4. Now insert the modified guide plate FIG. 2
Now, remove the inner disc pad shims and clean with a brake cleaner. Without contaminating the friction, apply a thin coat of the previously mentioned Silicone Brake Caliper Grease to the back of FIG. 5 the inner brake pad INSERT MODIFIED GUIDE PLATE and reinstall the shim. INTO GUIDE PLATE WITH TABS Reassemble the components and re-check the previously mentioned clearance measurements. Road test the vehicle. If the modification was successful, the clicking noise is history.
LARRY HAMMER TECHNICAL SERVICES
MIGHTY DISTRIBUTING SYSTEM OF AMERICA, INC.

The car whose lines revolutionised the racing world is here
SCX PRESENTS THE FORD ESCORT RS COSWORTH
SCX recreates the legend woven by the Ford Escort RS Cosworth, in which the great Tommi Mkinen made his dbut
SCX launches the Ford Escort RS Cosworth in which the Finnish driver Tommi Mkinen made his dbut, winning the Lakes Rally. The Ford Escort RS Cosworth is the result of an alliance between two giants of the rally world, Ford and Cosworth. This is a car with attractive lines, a 3-door coup which combines aggression with style. Just like the real car, the decoration of the SCX Ford Escort RS Cosworth adds to its competitive feel with its diagonal blue lines. Its sport wheels bear the logo of their manufacturer, Michelin, and the chassis also features a wealth of detail.
An eye-catching feature at the front of the SCX car is the bank of high-powered headlights, extremely large for increased visibility during night stages. The ordinary lights are also unusual, with their small round shape. Underneath them the first air intakes can be seen. The second are on the bonnet, decorated with the number 7 and a large Mobil 1 logo. The Ford Escort RS Cosworth from SCX shows the lock fitted to the real car to stop the bonnet coming open when the car passes over punishing terrain. A final noteworthy feature is the detail of the wipers on the windscreen essential in any rally.
The top of the car is entirely white, featuring two aerials which can be removed if desired. At the back of the model the most striking features are the exhaust pipe and the two spoilers, one of them very large to generate sufficient down force and the other smaller to back it up. The interior of this SCX model includes a spare wheel in the back and the roll bars, as well as the usual detail on the driver and co-driver, the latter with a route map and both of them with helmet, gloves and safety belts.

Track Trials

The other Ford great missing from the SCX paddock was a 90's Escort. The authentic rival of Lancia, Subaru and Toyota, this is a car which meets the specifications for all 4x4 rally cars. The Ford Escort RS Cosworth features a double pinion system on a stable chassis with consistent behaviour. It includes a new-generation motor. The RX-81 B, with a different internal design, makes the car nippier than ever before. After minimal running in of the double gearing of the motor against the crown gears, it moves off and adapts quickly, making the car a smoother drive. This is when we see just how easy it is to drive this SCX model in sport style, without any surprises and with a drive which helps to gain yards reliably.
The effectiveness of the SCX Ford Escort RS Cosworth's 4x4 traction is noticeable on the bends. Highly linear in its behaviour, it helps you get out of half skids simply by giving it a little gas. The model has excellent tyres fitted both front and back, a factor which helps both to hold the rear end in place and to accelerate without losing traction. The car's system of lights deserves a special mention. It is simply spectacular to see a legendary model getting ahead comfortably on the track while showing off all the aggression of the headlights.
* Tests conducted without supplementary magnet.