FALCON

1969
FAIRLAN 1E

MUSTANG
CAR
SHOP
FORD

MANUAL
THUNDERBIRD

MONTEGO

COUGAR
VOLUME ONE
CHASSIS
METEOR
EELS and TIRES, SUSPENSION, STEERING, BRAKES
CLUTCH and TRANSMISSION, REAR AXLE

MERCURY

LINCOLN
CONTINENTAL
CONTINENTAL
MARK Ill_
 GROUP INDEX

1969
VEHICLE IDENTIFICATION

BRAKES 2
SUSPENSION, STEERING WHEELS AND TIRES

REAR AXLE 4

CAR DRIVE SHAFT AND CLUTCH

MANUAL SHIFT TRANSMISSION 6

SHOP AUTOMATIC TRANSMISSION

MANUAL
VOLUME ONE
CHASSIS
WHEELS and TIRES, SUSPENSION, STEERING, BRAKES,
CLUTCH and TRANSMISSION, REAR AXLE

M FIVE
SERVICE PUBLICATIONS
SPECIFICATIONS AND SPECIAL SERVICE TOOLS
FIRST PRINTING-NOVEMBER, 1968
AT END OF EACH GROUP
© 1968 FORD MOTOR COMPANY, DEARBORN, MICHIGAN
 Copyright © 2006, Forel Publishing Company, LLC, Woodbridge, Virginia

All Rights Reserved. No part of this book may be used or reproduced in any manner
whatsoever without written permission of Forel Publishing Company, LLC. For
information write to Forel Publishing Company, LLC, 3999 Peregrine Ridge Ct.,
Woodbridge, VA 22192

1969 Ford Car Shop Manual

ISBN: 0-9673211-6-6
EAN: 978-0-9673211-6-5

Forel Publishing Company, LLC

3999 Peregrine Ridge Ct.
Woodbridge, VA 22192
Email address: [email protected]
Website: http://www.ForelPublishing.com

Disclaimer
Although every effort was made to ensure the accuracy of this book, no representations or warranties of
any kind are made concerning the accuracy, completeness or suitability of the information, either expressed
or implied. As a result, the information contained within this book should be used as general information
only. The author and Forel Publishing Company, LLC shall have neither liability nor responsibility to any
person or entity with respect to any loss or damage caused, or alleged to be caused, directly or indirectly by
the information contained in this book. Further, the publisher and author are not engaged in rendering legal
or other professional services. If legal, mechanical, electrical, or other expert assistance is required, the
services of a competent professional should be sought.
 FOREWORD
Thefive volumes of this shop manual provide theservice-~echnician
with completP information for the proper servicing of all the1969 line
of Ford Passenger Cars.

The information is grouped accoriing to the type of work being per-

formed, such as frequently performed adjustments and repairs, in-
vehicle adjustments, major repair, etc. Specifications, maintenance
information and recommendedspecial tools are included.

The descriptions and specifications in this manual-were in effect at the

time {his manual was approved for printing. Ford Motor Company
reserves the right to discontinue models at any time, or changespecifi-
cations or design, without noticeand without incurring obligation.

SERVICE P U B L I C A T I O N S

5006

August 1997
 GENER,AL INFORMATION
Individual carline shop manuals have been combined in one Car
Shop Manual divided into five volumes for 1969.

The 1969 Car Shop Manual has been organized into general
Groups as in previous shop manuals. All Groups are listed in the Group
index on the first page of each Volume. Groups not contained in a
given Volume are listed with a solid gray background. n

To locate the beginning page of any particular Group, first select

the Volume containing that Group. Bend the manual until the black
mark on the first page of the Group can be seen in line with the Group
title on the first page of the Volume.

The first page of each Group lists the material contained in the
Group under Part headings and also lists the beginning page of each
Part.
I
On the beginning page of each .Part, there is a Part index which
lists in detail all information appearing in the Part, the page where
the information is given, and the .vehicles to which the information
applies.

All pages carry a six-digit number which indicates the Group,

Part and Page number.

For Example: Page 03-02-01 indicates

Group 3, Part 2, Page 1

Part Indexes will use only the Part and Page referencinumbers.
For Examljle: Page 03-02-01 will appear in the Part Index as 02-01.

Each Part will start with Page 01

@ MODEL YEAR CODE @ COLOR CODE
1

@ ASSEMBLY PLANT CODE @ TRIM CODE I

@ BODY SERIALCODE @ DATE CODE

I
@ ENGINE CODE @ DISTRICT-SPEC. EQUIP. CODE I
I
@ ' CONSECUTIVE UNIT NO. @ REAR AXLE CODE

@ @
BODY TYPE CODE TRANSMISSION CODE
8 ' I W 1001-A

Fig. I-Warranty Plates-Passenger Cars

!

Fig. 2-Typical Vehicle Identification Number (VIN) Tab

: 01-01-02 Vehicle Identification 0 1-01-02
I
, VEHICLE W A R R A N T Y NUMBER COUGAR
The vehiclewarranty number is the .first line of numbers and
~ o d y Body
; letters appearing on the Warranty Plates (Fig. 1). The Warranty Serial Style
i Plate i s riveted to the left front door lock face panel. The first Code Code Body Type Model
I number indicates the model year. The letter following the model
year number indicates the manufacturing assembly plant. 'The next 91 ' 65A 2-Door Hardtop@ Standard
two numbers designate the Body Serial Code followed by a letter 92 76A Convert~ble~
expressing the Engine Code. The group of six digits remaining o n
the first line indicate the Consecutive Unit Number. 93 65B 2-Door Hardtop@ XR-7 Luxury ..
94 768 Convertible@

VEHICLE D A T A 91 65C 2.Door Hardtop@ Standard

The vehicle data appears on the second or lower line o n the @Bench Seat @Split Bench @Bucket Seats
Warranty Plate. The first two numbers and a letter identify the
Body Style. A letter or a number appears next indicating the MERCURY
Exterior Paint Color followed by a number-letter combination
designating the Interior Trim. To the right of this code appears the Body Body
Date Code indicating the date the car was manufactured. A two- Serial Style
digit number next designates the ,district i n which the car was Code Code Body Type Model
ordered and may appear i n conjunction with a Domestic Special 44 54A &Door Sedan@ Monterey
Order or Foreign Special Order'number when applicable. The final 46 65A 2-Door Hardtop-Formal@
two spaces indicate the Rear Axle Ratio (numbers for regular axles, 48 57A 4.Door Hardtop@
letters for locking-types) and the Transmission type (numbers.for 45 76A Convertible@
manual, letters for automatic). CANADA ONLY.
40 53M 4-Door Hardtop Sedan@ Marquis
OFFICIAL VEHICLE I D E N T I F I C A T I O N NUMBER 41 .65M 2-Door Hardtop-FormalO
42 57M 4-Door Hardtop@
The official Vehicle Identification .Number (VIN) for title and -
registration purposes i s stamped on an aluminum tab that is riveted 54 54C 4-Door Sedan@ Monterey-Custom
to the instrument panel close to the windshield on the driver's side 56 658 2-Door Hardtop-Formal@
of the car and is visible from outside (Fig. 2). 58 578 4.Door Hardtop@
63 53F 4.Door ~ a r d t osedan@@
~ Marquis
M O D E L YEAR C O D E 66 65F 2.Door Hardtop-Formal@@
68 57F 4-Door Hardtop@@
The number 9 designates 1969. 65 76F Convertible@@
63 53C 4-Door Hardtop Sedan@ Brougham (Option)
ASSEMBLY P L A N T CODES 66 65C 2-Door Hardtop-FormalO
68 57C 4-Door Hardtop@
Code Code
Letter Letter 60 63G 2-Door Hardtop (Tunnel Roof)@@ Marauder
61 63H 2-Door Hardtop (Tunnel Roof)@@@
A,. . . . . . . . . . . . . . . . . . . . . ..Atlanta L.. . . . . . . . . . . . . . ..Michigan Truck
B . . . . . . . . . . . . . .Oakville (Canada) N.. . . . . . . . . . . . . . . . . . . . . .Norfolk 72 718 4-Door 2 Seat@ ,Monterey Wagon
C.. ..... :. . . . . . . . ..Ontario Truck P.. . . . . : . . . . . . . . . . . ..Twin Cities 72 71C &Door 3 Seat (Side Facing@
D.. . . . . . . . . . . . . . . . . . . . . . ..Dallas R . . . . . . . . . . . . . . . . . . . . . San
. Jose
E. . . . . . . . . . . . . . . . . . . . . . . .Mahwah
. S . . . . . . . . . . (Pilot).. . Allen Park 74 71F 4-Door2 Seat@ Monterey-Custom Wagon
F... . . . . . . . . . . . . . . . . . .Dearborn
. T . . . . . . . . . . . . . . . . . . . . . .Metuchen 74 71G 4-Door 3 Seat (Side Facingb
G . . . . . . . . . . . . . . . . . . . . . . . .Chicago U.. . . . . . . . . . . . . . . . . . . . .Louisville
H. . . . . . . . . . . . . . . . . . . . . . . . Lorain W.. . . . . . . . . . . . . . . . . . . . . ..Wayne 76 71E 4-Door L.Seat@@ Marquis Colony Park
J.. . . . . . . . . . . . . . . . . . Los . Angeles X . . . . . . . . . . . . . . . . . . ..St. Thomas 76 71A 4-Door 3 Seat (Side Facing)@@
.K.. . . . . . . . . . . . . . . . . ..Kansas City Y . . . . . . . . . . . . . . . . . . . . . . ..Wixom
Z . . . . . . . . . . . . . . . . . . . . . S t . Louis @Bench Seat @Split Bench @Bucket Seats
METEOR (CANADA)
B O D Y SERIAL A N D STYLE CODES Bodv Bodv
, The two-digit numeral which follows the assembly plant code
identifies the body series. This two-digit number i s used i n con-
Serial
Code
Styk
Code Body Type Model
junction with the Body Style Code, i n the Vehicle Data, which 20 54A 4-Door Sedan@ Rideau
consists of a two-digit number with a letter suffix. The following -
c h a r t lists tti'e Body Serial Codes, Body Style Codes and the model. 21 548 Sedan@ .Rideau 500
23 658 2-Door Hardtop-FormalO
1 LINCOLN CONTINENTAL
30 54C &Do01 Sedan@ Montcalm
Body Body 35 65C 2-Door Hardtop-Formal13
' Serial Style 35 65E 2-Door Hardtop-Formal(5-33)W
Code Code Body Type 33 57C 4-Door Hardtop@
34 76C Convertible@
82 53A 4.DoorSedan 34 76E Convertible (S-33)@@
80 65A 2-Door Hardtop
24 65F 2.Door Hardtop-Formal@@ LeMoyne
27 57F 4-Door Hardtop@@
I CONTINENTAL MARK Ill '

28 718 Rideau 5 0 0 6 passenger6 Station Wagons

Body Body 29 71C Rideau 500-Dual Face Rear@
Serial Style 38 71E Montcalmd Passenger@
Code Code Body Type 39 71A Montcalm4ual Face Rear@
@Bench Seat OSplite Bench @Bucket Seats
0 1-01-03 Vehicle Identification
I
I

0 1-01 - 0 3
I

B O D Y SERIAL A N D STYLE CODES-(continued)

. . I

MONTEGO MUSTANG
. .
I
Body Body Body Body . I
Serial Style ' Serial Style
Code Code Body Type Model Code Code Body Type Model '
01 65A 2-Door Hardtop4ormal 01 65A 2-Door Hardtop@@ Standard
(Sports Coupe)@ Comet 02 63A FDoor Fastback@@
02 54A &Door Sedan(Sports)@ 03 76A Convertible@@
06 548 4-Door Sedan@ Montego. 01 658 2-Door Hardtop@@ Luxury
07 658 2-Door Hardtop4ormalO 02 638 24001 Fastback@@
03 768 Convertible@@
10 54D 4-DoorSedan~ Montego MX
11 65D 2-Door Hardtop-Formal@ 01 65C 2-Door Hardtop@ Standard
12 76D Convert~ble@
01 65D 2-Door Hardtop@ luxury '
11 65E 2-Door Hardtop-Formal@ Montego MX
12 768 Convertible@ 01 65E 2-Door Hardtop@ Grand
10 54C &Door Sedan@ Montego MX Brougham 02 63C 2-Door Fastback@ Mach 1
11 65C 2-Door Hardtop4ormalO
@Bench Seat @Split Bench OBucket Seats @Hi-Back Bucket
15 63A 2-Door Hardtop Fastback@'
(GT Ap earance Opt.@) Cyclone
15 63C 2-Door lardtop Fastback@
16 63H ?.Door Hardtop Fastback@
(Sports Appearance Opt.@) - Cyclone CJ
03 718 Montego@ Station Wagons4 Door
08 71C MontegoMXO FORD
08 71A Montego MX (Woodgrain)@
@Bench Seat @Split Bench . . @Bucket Seats
Body Body
Serial Style I
Code Code Body Type Model
50 62E 2-Door Sedan@ Custom
51 54E 4-Door Sedan@
52 628 2-~oo;~edan@ Custom 500 ,
53 548 Sedan@
-

54 54A 4-Door Sedan@ Galaxie 500 1

Body Body 55 638 2.Door Hardtop4astbackO I

Serial Style 58 65C 2-Door Hardtop-Formal@ 1

Code Code Body Type Model 56 578 4.Door Hardtop@ I
57. 76A Convertible@
83 65A 2-Door Hardtop@
83
84
65C
658
2-Door Hardtop@
2-Door Landau @@
60
61
63C
766
2-Door Hardtop4astbackOO
Convertible@@
Ford XL ' I
84 65D 2-Door Landau @@
87 578 Landau @ 64 54C 4-Door Sedan@@ Ford LTD
87 57C 4-D001 Landau @ 62 65A 2-Door Hardtop-Formal@@
66 57F &Door Hardtop@@
@Bench Seat @Split Bench @Bucket Seats @Blind Quarter Roof
RanchwagondPassenger@ Station w a g o n s 4 Door
Custom 500 Ranchwagon- !
6 Passenger@ I

Custom 500 Ranchwagon-

Dual Face Rear@
Country Sedan4 Passenger@
Country Sedan-Dual Face Rear@
Country S q u i r e d Passenger@
FALCON ' Country Squire-Dual Face Rear@
Body Body @Bench Seat @Split Bench OBucket Seats
Serial Style
Code Code Body Type Model
10 . 62A 2-Door Sedan@ Standard
11 . 54A 4-Door Sedan@
20 628 2-Door Sedan@ Futura
22 62C 2-Door Sports Coupe6
21 548 4-Door Sedan@
12 71A Standard@ ' Station Wagons
23 718 Futuraa 4 Door
@Bench Seat @Split Bench @Bucket Seat
01-01-04 Vehicle Identification 01'-01-04

B O D Y SERIAL A N D STYLE CODES-(conttnued) E~GINE

CODES
FAIRLANE Code Type
Body Body U ....................6 Cyl. 170 Cu. In. (1V)
Serial Style T ....................6 Cyl. 200 Cu. In. (1V)
Code Code Body Type Model 2 ....................6 Cyl.0 200 Cu. In. (1V)
30 65A 2-Door Hardtopdormal@ Fairlane
L .................... 6 Cyl. 250 CU.~ ni .l Y j
3 ...................:6 Cyl.0 250 Cu. In. (1V)
31 54A 4-D001 Sedan@ V .................... 6 Cyl. 240 Cu. In. (1V)
5 .................... 6 Cyl.0 240 Cu. In. (1V)
34 548 4-Door Sedan@ Fairlane 500 B....................:6 Cyl. 240 Cu: In. (1V) Police
35 638 2-Door Hardtop-Fastback@ E ....................6 Cyl. 240 Cu. In. (lV) Taxi
33 658 2.Door HardtopdormalO F ....................8 Cyl. 302 Cu. In. (2V)
36 768 Convertible@ 6 ....................8 Cyl.0 302 Cu. In. (2V)
D ....................8Cyl. 302 Cu. In. (2V) Police & Taxi
35 63E 2-Door Hardtopdastback@ Fairlane 500 H .................... 8 Cyl. 351 Cu. In. (2V)
33 65E 2-Door Hardtop-Formal@ M ...................8 Cyl. 351 Cu. In. (4V)
36 76E Convertible@ Y ....................8Cyl. 390 Cu. In. (2V)
X .................... 8 Cyl.0 390 Cu. In. (2V)
40 65C 24001 Hardtop-Formal@ Torino S .................... 8 Cyl.@ 390 Cu. In. (4V)
41 54C 44-001 Sedan@ P .................... 8 Cyl.0
Q .................... 8 Cyl.
42 63F 2-Door HardtopdastbackO Torino GT R ....................8 Cyl.@
44 . 65F 2-Door HardtopdormalO K .................... 8 Cyl.
43 76F Convertible@ N ....................8 Cyl.
A ....................8 Cyl.
42 63D 2-Door HardtopqastbackQ Torino GT
44 65D 2.Door Hardtop-Formal@ @Low Compression @Premium Fuel @Improved Performance
43 76D Convertible@ @High Performance @Ram Air Induction
46 638 2:~oo~ardtopdastback@ Cobra
46 63E 2-Door HardtopdastbackO
-45. 65A 2.Door HardtopdormalO -.
45 65E 2.Door HardtopdormalO
32 71D Fairlane@ Station Wagons4 Door CONSECUTIVE U N I T NUMBER
37 718 Fairlane 5 0 0 0 Starting Serial ~umbers-1969 Passenger Cars
38 71E Fairlane'Torino SqliireO 100,00ldord, Fairlane. Falcon, Mustang, Thunderbird
500,001-Mercury, Montego, Cougar, Meteor-
47 66A Ranchero@ Ranchero 848,0004incoln Continental &Continental Mark Ill
48 66B Ranchero 5 0 0 0
48 66B Ranchero 500.a Ranchero
(Opt.)
49 66C Ranchero@ Ranchero GT EXTERIOR P A I N T C O L O R CODES
49 66D Ranchero@
@Bench Seat @Split Bench @Bucket Seats Reference
Code Number Color
-

REAR AXLE RATIO CODES 2 ............................1724-A ................................. Black

B ............................ 3059-A ....................................Maroon
Conventional Limited-Slip Ratio C ............................3197.A .................................... Dk. Ivy Green Met.
D ............................3303-A ....................................Pastel Gray
E ............................3191-A ....................................Lt. Aqua
F ..................:.........3065-A ....................................Dk. Aqua Met. (Brt.)
G .......................... .:3203-A ................................... Med. Orchid Met.
H ............................ 2067-A .................................... Lt. Green
I ............................. 20414 ....................................Med. Lime Met.
J ............................3080-A ....................................Dk. Aqua Met.
K ............................3204.A .................................... Dk. Orchid Met.
L ............................3060-A ................................... Lt. Gray Met.
M ...........................1619-A .....................................White
N ............................ 921.A ....................................Platinum
P ............................ 3064.A ................................... Med. Blue Met.
Q ...........................J624.A ....................................Med. Blue Met.
R-............................3198-A ....................................Lt. Gold
S ............................3199-A ....................................Med. Gold Met.
T ............................2008.A ....................................Red
T R A N S M I S S I O N CODES U ............................1070-A ....................................Med. Aqua Met.
V ............................3201-A .................................... Lt. Aurora Copper Met.
Code Type W ...........................3120.A ...................................:Yellow
X ............................3061-A ....................................Dk. Blue Met.
1 .........................................S p e d Manual Y ............................3202.A ...................................Burnt Orange Met.
5 .................................... 4 S p e e d Manual-wide ratio (2.78 1st Gear) Z ............................2044-A .....................:..............Dk. Grey Met.
6 ...................................... S p e d Manual-close ratlo (2.32 1st Gear) 2 ............................3071-A ....................................Lt. Ivy Yellow
W ......................................... A t o m a t c (C4) (XP.3) 3 ............................1730-A ....................................Calypso Coral
U .................................... Automatic (C6) (XPL) 4 ............................3230-A ................................... Med. Emerald Met.
Y ..........................................Automatic (MX) 6 ............................3077-A ...................:....T....:.....Med. Blue Met. (Brt.)
X ...................................... Automatic (FMX) 7 ............................3193-A ................................... Lt. Emerald Green Met.
Z ..........................................Automatic (C6 Special) (XPL, Special)@ 8 ............................ 3190-A ....................................Lt. Blue
9 ............................M6J.49B ................................. Red Primer
@For Police &trailer to,wing -Not available with bucket seats 9 ..............................M6J.50B ,,,............................Grey Primer
 I
I

01-01-05 Vehicle Identification 01-01-05 1

. INTERIOR T R I M CODES INTERIOR T R I M CODES-(cont~nued)

Code Trim Schemes Code Trim Schemes
1A ........................................Back Vinyl (Cougar, Falcon)
- 5 0 ...................................... 0 . Red Knit and/or Vinyl 1
1A .................:......................Back Cloth &Vinyl 5 0 ....................................... 0 . Red Leather & Vinyl (Lincoln)
1 0 ........................................M e . Blue ClothILt. Blue Vinyl 5F ........................................ M e . Saddle Leather & Vinyl (Lincoln)
1 0 ........................................ M e . or Lt:Blue Vinyl 56 ........................................ 0 . Ivy Gold Knit andlor Vinyl
1 0 ........................................ 0 . Blue Cloth &Vinyl 5G ........................................ 0 . Ivy Gold Cloth & Vin I
(Lincoln, T-Bird, Mark Ill, Mercury) 5G ........................................ 0 . Ivy Gold Leather & d n y l (Lincoln)
10 ........................................ Lt. Bluecloth & Vinyl 5K ........................................ A q u a Cloth & Vinyl (Montego)
(Ford, Montego, Meteor) 5K ........................................ Lt. Aqua Vinyl
1 0 ........................................ 0 . Red Cloth and Vinyl 5K ........................................L t Aqua Leather & Vin I (Lincoln)
1F ........................................ M e . Saddle Vinyl (Cougar)
1G ........................................0 . Ivy Gold Cloth &Vinyl
5W ...................................... d
W h e wBlack K n ~an t /or Vinyl
5W .......................................Whde w1BIack Leather & Vinyl (Lincoln)
1G ........................................ Lt. Ivy Gold Vinyl (Cougar) 5Y ....................................... Lt. Nugget Gold Cloth & Vinyl
1K ........................................Lt. Aqua Cloth andlor Vinyl 5Y ........................................ Lt. Nugget Gold Knit andlor Vinyl (Mustang,
1P ........................................ G r e y Cloth &Vinyl (Mark Ill) Fairlane)
1Y ........................................ Lt. Nugget Gold Vinyl (Cougar-Falcon) 5Y ........................................ N u et Gold Leather & Vinyl (Lincoln)
1Y ........................................ Lt. Nugget Gold Cloth & Vinyl 6 1 ........................................Black t i ! andlor Vinyl
2A ........................................ Back Vinyl 6A ........................................ B l a c k l o t h & Vin I(Lincoln)
2A ........................................ Back Leather & Vinyl (Lincoln) 6 1 ........................................ Black Leathy & d n Y l (Cougar)
2A ........................................Back Leather (Mark Ill) 6 0 ........................................ 0 . or Lt. Blue Vinyl
. 28 ................................... ....0 . or Lt: Blue Vinyl 6 0 ........................................ 0 . Blue Leather & Vinyl (Cougar)
28 .................................... . . Blue Leather & Vinyl (Lincoln) 6 0 ........................................ 0 . Red Knit andlor Vinyl . .
28 ......................................0 . Blue Leather (Mark Ill) 6 0 ........................................ 0 . Red Leather & Vinyl (Cougar)
2 0 ........................................ Dk. Red Vinyl 6F ........................................ M e . Saddle Leather & Vinyl
2 0 ........................................ 0 . Red Leather & Vinyl (Lincoln) 6G ........................................ 0 . Ivy Gold Vinyl
2 0 ...:....................................0 , Red Leather (Mark Ill) 6G ........................................ 0 . Ivy Gold Leather & Vinyl (Cougar)
2F ........................................ M e . Saddle Vinyl'(Cougar) 6K ........................................ L . Aqua Vinyl
2F ........................................ S a d d l e Leather & Vinyl (Lincoln) 6K ......................................... A q u a Leathy & Vinyl (Cougar)
2F ........................................M e . Saddle Leather (Mark Ill) 6W ....................................... White wBlack Vinyl
2G ........................................L o r Dk. Ivy Gold Vinyl 6Y ................................... :...Lt. Nugget Gold Vinyl
26 ........................................0 . Ivy Gold Leather & Vinyl (Lincoln) 6Y ......................................... L t Nu get Gold Leather & Vinyl (Cougar)
2G ........................................ 0 . Ivy Gold Leather (Mark Ill) 7A ........................................ Back k n y l
2K ........................................ A q u a Vinyl 7A .................. :.....................Back Cloth &Vinyl (Fairlane)
2K ........................................ Lt. Aqua Leather & Vinyl \Lincoln) 7A ........................................ Back Leather & V~nyl(L~ncoln)
2K ........................................ Lt. AqualLeather (Mark II ) 70 ........................................ Lt. Blue Vinyl (Cougar, Montego, Ford)
2P ........................................ G r e y Leather (Mark Ill) 78 ........................................ 0 . Blue Cloth & Vin I
2U ............:........................... Pastel Parchment wBlack Leather (Mark Ill) 7 8 ................................ X.."...0 . Blue Leather & i n y \ (Lincoln)
2W ...........!...........................White w1Black Vinyl 70 ........................................ 0 . Red Vinyl (Mustang)
2W .......................................White w/Black Leather & Vinyl (Lincoln) 7 0 ........................................ 0 . Red Cloth & Vinyl
2W ..............................:........WhitewIBlack Leather (Mark Ill) 7G ....................................... .. Ivy Gold Cloth andlor Vinyl 1
2Y ........................................Lt. Nugget Gold Vinyl 7G ........................................ 0 . Ivy Gold Leather & Vinyl (Lincoln)
2Y ..:..................................... L t Nugget Gold Leather & Vinyl (Lincoln) 7K ........................................ L . Aqua Cloth &Vinyl
2Y ........................................ Lt. Nugget Gold,Leather (Mark Ill) 7W ....................................... White w1Black Vinyl
3A ........................................Back w/Red K n ~and/ort Vinyl . (Mustang,
.
7W .......................................
7Y ........................................ L t ~ u g g eGold t Cloth*k Vinyl
:
White Leather & V~nyl Lincoln)
Montego)
3A ........................................Back K n ~andlor
t Vinyl 7Y ........................................Lt. Nugget Gold Vinyl
3A ........................................Back Cloth &Vlnyl (Ford, Meteor, Mustang)
3A ..................................... Back Leather & Vinyl (Lincoln) 8A ........................................ Back Knit andlor Vinyl
38 ........................................ Lt. Blue Knit andlor Vinyl 8'A ........................................ Back Leather & Vinyl (T-Bird)
38 ........................................L t or Dk. Blue Cloth & Lt. Blue Vinyl 8 8 ........................................ 0 . or Lt. Blue Knit andlor Vinyl
3 8 ........................................Lt. Blue Cloth &Vinyl 8 0 ....................................... 0 . Red Knit andlor V~nyl 1

(Fairlane, Ford, Montego, Meteor) 8F ........................................ M e . Saddle Knit andlor Vinyl :

3 8 ........................................ M e . Blue Cloth & Lt. Blue V~nyl 8G ...................................... . .. Ivy Gold Knit andlor Vinyl
38 ........................................ 0 . Blue'Cloth & Vin I (T Bird, Mercury) 8K ........................................ L Aqua Knit andlor Vinyl .
3 8 ........................................ 0 . Blue Leather & i n y l i ~ i n c o l n ) 8W ....................................... White w/Black andlor Vin I,
3 0 ........................................0 . Red Cloth & Vinyl 8W ....................................... White w1Black Leather & b~ny!(T-Bird)
3 0 ........................................ 0 . Red Knit andlor Vinyl 8Y ..................................... ; . . Nugget Gold Knit andlorv~nyl
36 ........................................ 0 . Ivy Gold Cloth &Vinyl 9A ........................................ Back Knit andlor Vin I
3G ........................................ 0 . Ivy Gold Leather & Vinyl (Lincoln) 9 1 ........................................ Black Cloth &Vinyl (told, ~ete;r)
3K ........................................ L t Aqua Cloth & Vinyl 9 0 ..................................:.....L t Blue Knit and/or Vin I
3W .......................................White w/Black Knit and/or Vinyl 9 8 ....................................... Ok. Blue I t & Vinyl ( o r Meleor)
3W .......................................White w/Black Leather & Vinyl (Lincoln) 9 0 ........................................ 0 . Red K n ~andlor
t .Vin I 1
3Y ........................................ Lt. Nugget Gold Cloth &Vinyl 9 0 ................... :.................... 0 . Red Cloth &Vinyl ( { o l d - ~ e t ~ r )
3Y .......................................L . Nu et Gold K n ~andlor t Vinyl (T-Bird) 9G ........................................ 0 . Ivy Gold Cloth & Vinyl
4A ........................................ Black foth.& Vinyl 9K ........................................ Lt. Aqua Cloth & Vin I i
4A ........................................ Back Knit andlor Vinyl 9Y ....................................... .Lt . Nugget Gold clot%andlor ~ i "I '
48 ........................................ 0 . Blue Vinyl 9Y ........................................ Lt. N u s e t Gold Knit andlor vinyl
48 ........................................ 0 . or Lt. Blue Vinyl AA(1W) ................................ Wh~teVlnylWith Black (Cougar)
40 ........................................0 . Red Vin I AA ........................................ Back Cloth & Vin I (Lincoln)
4G ........................................k . Ivy Gol(rCloth & Vinyl AB(1W) ................................White Vin I With glue (Cygar)
46 ........................................ 0 . Ivy Gold Vinyl AB .....,.................................. Lt. Blue Both & Vinyl (Lmcoln)
4K .......................................L t Aqua Vinyl AD(1W) ................................ Whitevinyl With Red (Cou ar) i
4W ....................................... White wlllack Vinyl AG(1W) ...........:.................... W h e n I With Iv Gold (iougar)
4Y .......................... :.............
Lt. Nu et Gold Knit andlor Vinyl AG ........................................ L t Ivy ~ o r Cloth
d %vinyl (Lincoln)
5A ...................................... Back & k t h &Vinyl AK (1W) ............................... White Vin IWith Aqua (Cougar) I
5A ........................................ Back Knit andlor Vinyl AK ........................... L..........Lt. Aqua 4 0 t h & Vinyl (Lincoln)
5A ........................................ Back Leather & V~nyl(Lincoln) AL ...................... :.................L t Silver Cloth &Vinyl (Lincoln)
5 8 ........................................
50 ........................................
r
Lt. Blue Cloth andlor Vin I
5 0 ....................................... . . B l u e Knit andlor Vin
0 . Blue Leather & viny/(Lincoln)
AY ........................................
AY(1W) ................................
BA(2W) ..........................
L t Nugget Gold Cloth &Vinyl (Lincoln)
Whi eVinyl With Nu et Gold (Cougar)
Whi~eVinyWith 01% (Cougar)
5 0 ........................................0 . Blue Cloth & Vinyl (Mercury) BA ........................................ Back Vlnyl (Fairlane)
5 0 ........................................ 0 . Red Cloth & Vinvl (Monteno)
- BB(2W) ................................ Wh~teV~nyl With Blue (Cougar)

I
 Vehicle Identification

INTERIOR T R l M CODES-(continued) INTERIOR T R l M CODESi-(continued)

Code Trim Schemes Code Trim Schemes
BB ........................................ Lt. Blue Vinyl (Fairlane) H Y ( ~ W................................
) White Vinyl With Nugget Gold (Cougar)
BB ........................................ Lt. Blue Leather & Vinyl (Lincoln) HY........................................Lt. Nugget Gold Knlt andlor Vinyl
BD(2W) .............................;.Whitevinyl With Red (Cou ar) JA ........................................ a Knit and/or Vinyl
BG(2W) ................................ White Vinyl With Ivy Gold (tougar) JB ....................................... L Blue Cloth & Vinyl (Lincoln)
BG ........................................ Lt. Ivy Gold Leather & Vinyl (Lincoln) JG ........................................ L . IVY Gold Cloth& Vinyl
BK(2W) ................................ White Vlnyl With Aqua (Cougar) JW ........................................ White w/Black Knit and/or Vinyl
BY(2W) ................................Whitevinyl With Lt. Nu et Gold (Cougar) JY ........................................ Lt. Nugget Gold Knit andlor Vinyl
BY ..................................... L t Nu get Gold Vinyl (&lane) JY ........................................ t Nugget Gold Cloth & Vinyl (Lincoln)
CA ........................................ Back !loth & Vinyl KA, .......................................Back K n ~and/or t Vln I
CA ........................................ Back Vin I (Montego) KA ........................................ Black Cloth & Vin I (?ord-~ercury-~eteor)
CB ................................:.......Dk. Blue b o t h &Vinyl
CB ........................................L t Blue Vlnyl (Montego)
KA ........................................ J.
Back Leather & ~ n y(Lincoln)
l
KB ........................................ k . Blue Cloth & Vinyl
CD ...................................... k . Red Cloth & Vinyl KB ........................................M e Blue Cloth & Lt. Blue Vinyl (Ford-Montego)
CD ........................................ k . Red Vinyl KB ........................................ k . Blue Leather & Vinyl (Lincoln)
CG .......................................k Ivy Gold Cloth & Vinyl KD........................................ k Red Cloth &Vinyl
CG ........................................Lt. Ivy Gold Leather & Vlnyl (Lincoln) KG ........................................ Dk. Ivy Gold Leather & Vinyl (Lincoln)
CK ........................................Lt. Aqua Cloth &Vinyl KG ....................................... k Ivy Gold Cloth & Vinyl
CY ........................................Lt. Nugget Gold Cloth &Vinyl KL ........................................ Lt. Silver Leather & Vinyl (Lincoln)
CY ........................................Lt. Nu get Gold Vinyl (Montego) KW ....................................... White W/Black Leather & Vinyl (Lincoln)
DA ..................................... Back [loth &Vinyl KY ............................. ;.......... Lt. Nugget Gold Knit and/or Vinyl
DA(4W) ...............................Whitevinyl With Black (Cougar) KY ........................................ L t Nugget Gold Cloth & Vinyl
DA ........................................ Black Knit and/or Vinyl LA ........................................ Back Knit and/or Vinyl
DB .......................................Dk. Blue Cloth & Vinyl LA ........................................ Back Leather & Vinyl (Lincoln)
DB.......................................k Blue Vlnyl (Mercury) LB ........................................ L t Blue Knit and/or Vinyl
DB(4W) ............................... White Vinyl With Blue (Cougar) LB ........................................ k Blue Leather & Vinyl (Lincoln)
DD(4W) ............................... White Vin I With Red (Cougar) LD ....................................... D k Red Knit and/or Vinyl
DD .....................................,Slk Red Jnit and/or Vinyl LE .......................................Lt. & Med. Beige Vinyl
DD .......................................Dk. Red Cloth & Vinyl LG ......:................................. k Ivy Gold Leather & Vinyl (Lincoln)
DG .......................................Dk. Ivy Gold Vinyl LW ..................................... White w/Black Knit and/or Vinyl
DG .......................................Dk. Ivy Gold Cloth &Vinyl . LW ....................................... White w/Black Leather & Vinyl (Lincoln)
DK .......................................L t Aqua Cloth &Vinyl LY ........................................ Lt. Nugget Gold Knit and/or Vinyl
DW .......................................White w/Black Knit and/or Vinyl . MA ....................................... Black Vlnyl
DY .........r .............................L . Nugget Gold Cloth & Vinyl MB .......................................Lt. Blue Vinyl
DY ........................................ L t Nugget Gold Vlnyl (Mercury) MD ....................................... Dk. Red Vlnyl
EA ........................................Back Knit and/or Viqyl MW ...................................... White wWlack Vin I
EA ........................................Back Cloth &Vinyl NA ........................................ Black Knit and/or &inyl
EB ...................................... k Blue Cloth &Vinyl NB ....................................... Lt. Blue Vin I
ED ........................................ k . Red Cloth &Vinyl NY ..................................... L t N u q e t (told Knit andlor Vinyl
EG ........................................k Ivy Gold Cloth & Vinyl PA ........................................Black V~nyl
EK ........................................L t Aqua Cloth & Vinyl PB ........................................ L t Blue Vin I
EW ......................................White w/Black Knit and/or Vinyl PY ........................................Lt. Nugget Jold Vinyl
EY ........................................Lt. Nugget Gold Cloth & Vinyl QA........................................ Back Knit and/or Vinyl
FA .......................................Back Knit and/or Vin I Lt. Blue Vinyl
FA(6W) ................................ Whitevinyl With Mac[ (Cougar) ...................................... White Knit and/or Vinyl
FB ........................................ Lt. or Dk. Blue Vinyl QY........................................ Lt. Nugget Gold Vinyl
FB(6W) ................................White Vlnyl W ~ t hBlue (Cougar) RA ........................................ Back Knit and/or Vinyl
FD ........................................ k Red Knit andlor Vinyl RA ....................................... Back Leather & Vinyl
FD(6W) ................................ Whitevinyl With Red (Cougar) RB..: ....................................L t Blue Knit and/or Vinyl
FG ...................................... k Ivy Gold Vinyl RD ....................................... D k Red Knit and/or Vinyl
FG(6W) ................................Whitevinyl With Ivy Gold (Cougar) RD ....................................... Dk. Red Leather & Vinyl
FK(6W) ............................... White Vin I With Lt Aqua (Cougar) RW ....................................... White w/Black Leather & Vinyl
FW ....................................... White wdlack ~nit'and/orVinyl RW ....................................... White W/Black Knit and/or Vinyl
FY ..............................:.........L t Nugget Gold Vinyl RY ........................................ Lt. Nugget Gold Knit andlor Vlnyl
FY(6W) ................................Whitevinyl With Nugget Gold (Cougar) SB ........................................ Lt. Blue Leather & Vinyl(Linco!n)
GA ........................................ Back Vinyl SG ........................................ Lt. IvyGold Leather & V~nyl(L~ncoln)
GB ........................................ L t Blue Vinyl TG ........................................ Lt. Ivy Gold Leather & Vinyl (Lincoln)
GD ........................................ k Red Vin I VA ........................................ Back K n ~and/ort Vinyl
dY
GG ........................................ k Ivy Gol Vinyl
GY ........................................Lt. Nugget Gold Vinyl
VB ........................................ Dk. Blue Vinyl
VG ........................................ k . Ivy Gold Vinyl
HA ........................................ Black Knit and/or Vinyl VW ..................................... White w/Black Knit and or Vinyl
HA(8W) ................................White Vinyl With Black (Cougar) VY ..................................... . . .. Nugget Gold Vinyl
HA ...................................... Black Leather & Vinyl (Mercury) WA ....................................... Black Knit and/or Vinyl
HB....................................... L t Blue Vinyl WW ...................................... White w/Black Knit,and/or Vinyl
HB (8W) .............................. Whitevinyl With Blue (Cougar) WY ....................................... Lt. Nu get Gold K n ~and/or
t Vinyl
HD .......................................D k Red Vinyl YA ................................. .......Back !loth &Vinyl
HD ....................................... Dk. Red Leather & Vinyl (Mercury) YB ........................................k . Blue Cloth &Vinyl
HD(8W) ...............................White Vinyl With Dk. Red (Cougar) YD ........................................ k . Red Cloth & Vinyl
HG......................................k Ivy Gold Vinyl YG ............;........................... k . Ivy Gold Cloth & Vinyl
HG(8W) ............................... Whitevinyl With Ivy Gold (Cougar) YK ........................................ Lt. Aqua Cloth &Vinyl
HK ....................................... L t Aqua Vinyl YY ........................................ Lt. Nu get Gold Cloth & Vinyl
HK(8W) ...............................White Vin IWith Lt. Aqua (Cougar) ZA ..................................... Black !loth & Vinyl
HW ............................. :........ White w d a c k Leather & Vinyl (Mercury) ZB ........................................ k Blue Cloth & Vinyl
HW ....................................... White w/Black Vinyl (Fairlane) ZG ...........!............................ k . Ivy Gold Cloth & Vinyl
 Vehicle Identification

DATE CODES
A n u m b e r signifying t h e date precedes t h e m o n t h code letter. A
second-year code letter w i l l b e used i f t h e m o d e l exceeds 12 months.
LINCOLN-MERCURY
Code Code Code District Code District
Month First Year Second Year
11.. . . . . . . . .Boston 34. . . . . . . . . .Detroit
January.. . . . . . . . . . . . . . . . . . A , . . . . . . . . . . . . . . . . . . . . .N 15.. . . . . . . . .New York 41. . . . . . . . . .Chicago
February.. . . . . . . . . . . . . . . . . .B.. . . . . . . . . . . . . . . . . . . . . .P 16. . . . . . . . . .Philadelphia 42.. . . . . . . . .St. Louis
March.. . . . . . . . . . . . . . . . . . . . .C.. . . . . . . . . . . . . . . . . . . . . Q. 17.. . . . . . . . .Washington 46. . . . . . . . . .Twin Cities
April.. . . . . . . . . . . . . . . . . . . . . .D. . . . . . . . . . . . . . . . . . .R 21.. . . . . . . . .Altanta 51.. . . . . . . . .Denver ,
May.. . . . . . . . . . . . . . . . . . . . . . .E.. . . . . . . . . . . . . . . . . . . . . S. 22.. . . . . . . . .Dallas 52.. . . . . . . . .Los Angeles
June.. . . . . . . . . . . . . . . . . . . . . F..
. . . . . . . . . . . . . . . . . . . ..T 23. . . . . . . . ..Jacksonville 53. . . . . . . . ..Oakland
July. . . . . . . . . . . . . . . . . . . . .:r:G.. . . . . . . . . . . . . . . . . . . . . . U 26.. . . . . . . . .Memphis 54. . . . . . . . ..Seattle .
August.. . . . . . . . . . . . . . . . . . . H . . . . . . . . . . . . . . . . . . . . . . .. V 31.. . . . . . . ..Buffalo 84. . . . . . . . ..Home Office Reserve
September.. . . . . . . . . . . . . . . . .J . . . . . . . . . . . . . . . . . . . . . . . .W 32. . . . . . . . . .Cincinnati
October.-. . . . . . . . . . . . . . . . . . .K . . . . . . . . . . . . . . . . . . . . . . .X 33. . . . . . . . ..Cleveland
November.. . . . . . . . . . . . . . . . .L.. . . . . . . . . . . . . . . . . . . . . .Y
December.. . . . . . . . . . . . . . . . . M . . . . . . . . . . . . . . . . . . . . . . .Z
FORD O F CANADA
DISTRICT CODES (DSO) Code District Code District
U n i t s b u i l t o n a Domestic Special Order, Foreign Special Order,
o r other special orders w i l l have t h e complete order n u m b e r i n B l . . . . . . . . . . . . . . . . .Central 84.. . . . . . . . . . . . . . . .Midwestern
82.. . . . . . . . . . . . . . . .Eastern 66.. . . . . . . . . . . . . . .Western
.
t h i s space. Also t o appear i n t h i s space i s t h e t w o - d i g i t code n u m b e r 63.. . . . . . . . . . . . . . . .Atlantic 67.. . . . . . . . . . . . . . . .Pacific
of t h e District which ordered t h e unit. I f t h e u n i t i s a regular I 1 thru 17.. . . . : . . . . .Export
production unit, o n l y t h e District code n u m b e r w i l l appear.
Note: Canadian Lincoln-Mercury units use prefix "A" in place of "6".
FORD
Code District Code District
11.. . . . . . .Bodon 51.. . . . . . .Denver .
1 3 . . . . . . . .New York 53.. . . . . . .Kansas City
15. . . . . . . .Newark 54. . . . . . . .Omaha
16. . . :. . . .Philadelphia 55.. . . . . . .St. Louis
17. . . . . . . .Washington 56.. . . . . . .Davenoort
21. . . . . . . .Atlanta 61. . . . . . . .Dallas'
22. . . . . . . .Charlotte 62. . . . . . . .Houston
24.. . . . . . .Jacksonville 63.. . . . . . .Memphis
25. . . . . . . .Richmond 64. . . . . . . .New Orleans
28. . . . . . . .Louisville 65. . . . . . ..Oklahoma City
32. . . . . . . .Cleveland 71. . . . . . . . Los Angeles
33.. . . . . . .Detroit 72.. . . . . . .San Jose
73.. . . . . . .Salt Lake City
74. . . . . . . .Seattle
75. . . . . . . .Phoenix
41. . . . . . . .Chicago- 83 . . . . . . .Government
43.. . . . . . . Milwaukee 84. . . . . . . . Home Off ice Reserve
44.. . . . . . .Twin Cities 85. . . . . . . .American Red Cross
89.. . . . . . .Transportation Services
90's . . . . . .Export
 PART 2-1 PAGE PART 2-3 PAGE
General Brake Service ................ 02-01 - 0 1 Specifications .............................02-03-0 1.
PART 2-2
Brake System .............................. 02-02-0 1

Part 2-1 General Brake Service

. .

. . COMPONENT INDEX

Adjlistment (Centralize)
I

I A page number indicates that the item is for the vehicle listed at the head of the column.
NIP; indicates that the item is not applicable to the vehicle listed.

.Always check the fluid level in the BRAKE PEDAL FREE pedal linkage for missing, worn, or
master cylinder before performing the HEIGHT A N D TRAVEL damaged bushings, or loose attaching
test procedures. If the fluid level is not MEASUREMENTS bolts and replace them, if required.
within 114 inch of the top of the mas- 3. If the pedal free height is still
ter cylinder reservoirs,, add Ford With .the ,engine running for full out of spec~fication,check! the brake
Brake Fluid - Extra Heavy Duty - power brake operation, measure the pedal booster or master cylinder to be
Part Number C~AZ-19542-A (ESA- brake pedal free height, and check the sure the correct parts are installed.
M6C25-A) or equivalent for all brake brake pedal.travel with the use o f ' t h e Replace the worn or damaged parts as
applications. The -extra heavy duty Brake Pe'dal Pressure Gauge, Tool necessary. .
brake fluid is colored blue for identifi- WREL500-50 as follows:
cation purposes.' D o not mix low tem- BRAKE PEDAL TRAVEL
.perature brake fluids with the speci- BRAKE PEDAL FREE HEIGHT MEASUREMENT '
fied brake fluid. MEASUREMENT
Should one of the wheel ,brakes be 1. Insert a slender, sharp pointed 1. Install a Brake Pedal Effort
locked ,and the vehicle must be moved, prod through the carpet and sound Gauge on the brake pedal pad (Fig. 2).
open the bleeder screw long enough to deadener to the dash panel metal and 2. Hook a steel measuring tape to
let out a few drops of brake fluid. measure the distance to the brake the brake pedal as shown in Fig. I .
This bleeding operation will release pedal (Fig. I). Measure and record the distance from
the brakes but will not correct the 2. If the position of the pedal is not the brake pedal free height position to
cause of trouble. within specification, check the brake the reference point, which is at the six
02 -0 1 -02 Brakes 02-0 1 -02

o'clock position on the steering wheel

STEERING WHEEL RIM
rim.
3. W i t h the steel tape still hooked
to the brake pedal depress the brake
pedal by pressing downward on the
brake pedal effort gauge. ply a 50
pound load to the center of the pedal
by observing the pressure gauge, and
measure the distance from the brake
pedal to the fixed reference point on
the steering wheel r i m parallel to the
centerline of the steering column.
4. The difference between the brake
pedal free height and the depressed
pedal measurement under a 50 pound
load should be within the specified
maximum pedal travel service specifi-
cation B i n Fig. I.
5. I f the pedal travel is more than
the specified maximum shown i n Fig.
I, dimension C, make several sharp
reverse stops (equivalent to 50 pounds
pedal pressure) with a forward stop
before ea'ch. Move the vehicle i n rev-
erse and forward for a distance 0 f . a ~ -
proximately ten feet; then, apply the
brakes sharply and hold the brake
pedal down until the vehicle is com-
pletely stopped. This will actuate the
brake self-adjusters. I f these .stops do
not bring the brake pedal travel within
specification, make several additional
forward and reverse stops as outlined
above.
6. I f the second series of stops do
not bring the brake pedal travel within
N 0 T E : A B B DIMENSION TO BE MEASURED T O SHEET M E T A L specification, remove the brake drums
and check the brake adjusters to make
C DIMENSION T O BE MEASURED PARALLEL T O THE V E R T I C A L CENTERLINE OF THE sure they are functioning. Check the
STEERING COLUMN WlTH A 50 POUND LOAD APPLIED T O T H E CENTERLINE OF THE brake linings for wear or damage. Re-
J R A K E PEDAL PAD. (CHECKS ON POWER BRAKE VEHICLES MADE WlTH ENGINE RUNNING
b pair or replace all worn or damaged
parts and non-functioning adjusters.
Adjust the brake lining outside diame-
ter to the approximate inside diameter
of the brake drum with Rotunda Tool
FIG. 1 - Brake Pedal H e i g h t a n d Travel Measurements
HRE-8650 (Fig. 12, Part 2-2).
7. I f all the brake adjusters, brake
drums and linings are functional and
the brake travel is not within specifi-
cations, check the pedal linkage for
missing or worn bushings, or loose at-
tachments. Bleed the brakes and cen-
tralize the differential valve.
POWER BRAKE
FUNCTIONAL TEST
I.Check the hydraulic brake sys-
tem for leaks or insufficient fluid.
2. W i t h the transmission i n neutral,
stop the engine and appIy the, parking
brake. Depress the brake pedal several
times to exhaust all vacuum i n the
system.
3. W i t h the engine shut off .and all
vacuum i n the system exhausted. deD-
ress the pedal, and hold i t i n the ab-
FIG. 2-Brake P e d a l E f f o r t G a u g e Installed .plied position. Start the engine. I f the
 I
i !
02-0 1-03 Brakes 02-01-03 ,

vacuum system is operating, the pedal be adapted to any other vacuum hose Pump Tester 345. This can be nccom-
will tend to fall away under foot pres- or rubber connector in the vacuum plished by removing the hose from
sure and less pressure will be required systems. each component and attaching it to
to hold the pedal in the applied posi- Failure to maintain 10 inches of the vacuum gauge. Connect two dis-
tion. I f no action is felt, the vacuum vacuum (Hg.) during vacuum system tributor tester vacuum hose adapters
.booster system is not functioning. tests could be caused by a loose hose together with a coupling as a connec- ,
I f the brake pedal movement feels connection, resulting in a vacuum tor to attach the gauge. A nlinimum ,

spongy, bleed the hydraulic system to leak., When checking for'vacuum be- of ten inches of vacuum is required to
remove air from the system. Refer to tween two points, trace the hose along actuate the parking brake vacuum I

Hydraulic System Bleeding, Part I, ' the entire routing to be sure it is not motor. D o not remove any of the vac-
Section 2. crossed with another hose and con- uum hoses from the junction block
nected t o the wrong connection. unless the junction block is being re-
V A C U U M . TESTS-VACUUM All of the vacuum parking brake placed, as the plastic nipples are thin
RELEASE P A R K I N G BRAKES control checks are to be performed and very brittle and damage may re-
with the engine running a t idle speed. sult. I f a minimum reading is not .
Leaks in the parking brake hoses or present when checking each of the
Visually check the 'peration of the a disconnected o r i m p r o p e r l y con- a f o r e m e n tioned compo'nents, they
brake' linka'ge as lhe brake pedal is nected hose can usually be found by must be replaced.
depressed. Then, check the operation listening for a hissing sound the
of the brake linkage when the manual hose routings, Under no circumstances R O A D TEST
r e l e a s e l e v e r is a c t i v i a t e d . T h e s e should air pressure be applied to the
checks should indicate whether the system as the actuator dia- A road test should be conducted
manual parking brake control linkage phragm in the parking brake vacuum only when the operator is sure the
is operating properly or requires re- motor may be damaged. brakes will stop the vehicle.
pair or adjustment due to inability of I. Start the engine and run it a t I f the road test reveals h e or more
Ihe parking brake lo idle speed. With the transmission shift p r o b ~ mconditions, correct all ,
moderate vehicle movement. Perform control i n neutral, depress the parking functions of the vacuum system, brake '
tests of the parking brake system and brake pedal to a p p l y the parking
controls after making certain the link- - brake, M~~~ the transmission shift
booster and hydraulic system prior to
removing brake drums, brake calipers,
age and manual controls control to D range and observe the brake shoes and liningsl or backing ,
properly. parking brake pedal to see that the plates.
When testing a parking brake vacu- pedal moves upward and the parking
um release system, 'a minimum of 10 brake releases. I f the parking brake ANTI-SKID C O N T R O L
inches of vacuum (Hg.) should be releases, the parking brake vacuum
control is working properly. SYSTEM TESTS
available at all points where vacuum is
applied. This can be checked with a 2. I f the parking brake does not re- No adjustments or repairs are to be
Rotunda Fuel Pump Tester Gauge lease, test for vacuum a t the steering performed on the skid co?trol system. ,
(ARE345) and two Distributor Tester column neutral switch port in the Damaged or worn parts are to be re-
hose adapters (Marked Q) connected junction block, vacuum lines and the placed.
together with a coupling. This allows parking brake release vacuum motor. Refer to Ford C a r and Truck Diag-
the Fuel Pump Tester Gauge hose to Use the Rotunda Vacuum and Fuel nosis Manual for Testinglprocedures. ,
I

2 C O M M O N ADJUSTMENTS AND REPAIRS

P A R K I N G BRAKE L I N K A G E
ADJUSTMENT
L.H. R E A R )
WHEEL CABLE-2A809 2 A P l (2 R,EQUlREDI
FORD, M E R C U R Y , M E T E O R ,
FAIRLANE, MONTEGO,
FALCON, M U S T A N G
AND COUGAR
Check the parking brake cables
when the brakes are fully released. I f '
the cables are loose, adjust them as
follows:
I. Fully release the parking brake
pedal by pulling the release lever.
2. Depress the parking brake pedal R.H.
until it is engaged in the first notch of
the control. On a vacuum release , ADJUSTING NUT-2A
brake, the first notch will be approxi- , ' H 1537-c
mately two inches of pedal travel.
3 . R a i s e t h e v e h i c l e . W i t h the FIG. 3-Parking Brake Adjirstrnent-Ford, Mercury, Meteor, ,
transmission in neutral, t u r n , the ad- Thunderbirdand Continental M a r k
justing nut forward against the equal-
izer (Figs. 3 and 4) until there is 100
 02-0 1-04 Brakes

I ft-lb breakaway torque. The breaka- THUNDERBIRD, POWER BRAKE MASTER

way torque is the torque required to C O N T I N E N T A L M A R K Ill, CYLINDER PUSH ROD
' turn the rear wheels the direction of AND LINCOLN i
I ADJUSTMENT
forward rotation with a torque wrench CONTINENTAL
and tool shown in Fig. 5. The torque
measurement must be made relative t o Check the parking brake cables The push r o d is provided with an'
the center line of the wheel. when the brakes are fully released. I f adjustment screw to maintain the cor-
4. Release the parklng brake, and the cables are loose, adjust them as rect relationship between the booster
I check to make sure that the brake follows: control valve plunger and the master
: shoes return t o the fully released posi- I. Fully release the parking ' brake cylinder. I f the plunger is too long i t
tion. pedal by pushing down the manual re- w i l l prevent the master cylinder piston
I
5. Depress the parking brake pedal lease lever. from completely releasing hydraulic
to the third notch. Under normal con- 2. Depress the parking brake pedal pressure and can cause the brakes to
ditions, this will hold the vehicle satis- 1 114 inch from its normal released drag. I f the plunger is too short i t will
, factorily. position. result i n excess pedal travel and an
6. Release the parking brake again, 3. Raise the vehicle with the trans- undesirable clunk i n the booster area.
and check as i n step 4. mission i n neutral. The adjustment screw is set to the
7. I f the rear brakes do not fully 4. Loosen the lock nut and turn the correct height at the time of original
1 release, check the cables for kinks or adjusting nut forward against the assembly of the power unit. Under
I binds. Free the cables as required. equalizer (Figs. 3 and 6) until there is normal service the adjustment screw
8. Lower the vehicle. Remove the 100 ft-lbs breakaway torque. The does not require any further attention
torque wrench and tool. Install the breakaway torque is the torque re- providing the original push rod assem-
wheel attaching nuts and torque them quired to turn the rear wheels the di- bly remains i n the original unit.
I to specification. Install the wheel rection of forward rotation with a tor- I f a check of the push rod adjust-
cover. que wrench and tool shown i n Fig. 5. ment is necessary, the push rod length
The torque measurement must be may be verified with a push rod length
RETAINER R E A R WHEEL made relative to the centerline of the gauge and measured with the engine
wheel. Tighten'the lock nut. running to apply vacuum,to the boost-
5. Release the parking brake, and er (Fig. 7).
check to make sure that the brake The push rod length verification and
shoes return to the fully released posi- adjustment o f Midland-Ross power
tion. brake booster assemblies must be
6. Depress the parking brake pedal done according to the following proce-
PA~KING I until i t is fully engaged. dure:
: BRAKE CABLE SPRING SEAT-2A616
I AND CONDUIT 7. Release the parking brake again,
and check as i n step 5.
REAR WHEEL ADJUSTING NUT LOCK
8. Depress the pedal 112 inch. The
brakes should not drag.

, FIG. 4-Parking Brake Linkode

9. I f the rear brakes do not fully
release, check the cables for kinks or
EQUALIZER \ \
( Adjustment-Fairlane, Montego, binds. Free the cables as required.
! Falcon, M u s t a n g a n d C o u g a r 10. Lower the vehicle. Remove the
torque wrench and tool. Install the
wheel attaching nuts and torque them
to specification. Install the wheel
cover.

/L CABLE ASSEMBLY H1611-A

FIG. 6-Parking Brake Linkage

Adjustment-Lincoln Continental

'
#16 U.S.S. GAUGE SHEET STEEL
1 - 2 . 7 / 8 " - 1 4I-

H1087-E
FIG. 7-Push Rod G a u g e
: FIG. 5-Checking Parking Brake Breakaway Torque Dimensions
I
02-0 1 -05 Brakes

1. Disconnect the master cylinder sion against the push rod is required and rear) hydraulic brake systems are
from the booster assembly and secure to assure that the push rod is firmly individual systems and are bled separ-
away 'from the booster without discon- seated in the booster assembly.) See ately. Bleed the longest line first on
necting the brake tubes. Figure 8. the individual system being serviced.
2 . 1Reinstall the air filter assembly 3. Install the master cylinder on the During the complete bleeding opera-
on the booster if it was removed with brake booster and tighten the retain- tion, D O N O T allow the reservoir to
the master cylinder (Fig. 8). ing nuts to the specified torque. run dry. Keep the master cylinder res-
3. Install and tighten the master D o not set up side forces on the ervoirs filled with Ford Fluid-Extra
cylinder retaining nuts to retain the .push rod as it may break the valve Heavy Duty - P q t Number C6AZ-
air filter assembly securely against the plunger. 19542-A (ESA-M6C 25-A). the extra
booster body and to seal the booster This is an approximate adjustment heavy duty brake fluid is colored blue
bellows against air leaks. only. T o verify the adjustment, look for identification purposes. D o not
4. Place the gauge against the through the make-up (rear) port of the mix low temperature brake fluids with
master cylinder mounting surface of master cylinder when installing the the specified fluid during the bleeding
the air filter assembly. master cylinder to the booster. The operations. Never re-use brake fluid
5. Adjust the push rod screw to master cylinder piston should not which has been drained fro'm the hy-
provide a slight tension against the move more than 0.015 inch as it con- draulic systems.
inner edge of the adjustment gauge tacts the push rod. No movement 1. I f t h e m a s t e r c y 4 i n d e r i s
slot. (Approximately 5 pounds of ten- (exact contact) is ideal. equ~pped with a bleed screw, loosen
'sion against the push rod is required the bleed screw. Push the brake pedal
to assure that the push rod is firmly down slowly through its full travel.
HYDRAULIC SYSTEM BLEEDING Close the bleeder fitting and return
seated in the booster assembly.)
6 . Remove the retaining nuts from A N D CENTRALIZING O F THE the pedal to the fully released posl-
the booster master cylinder mounting DIFFERENTIAL V A L V E tion. Repeat this operation ,until fluid
studs. is free of air bubbles, then tighten the
7. ,Install the master cylinder on the When any part of the hydraulic sys- bleeder screw. D o not use the second-
brake booster and tighten the retain- tem has been disconnected for repair ary piston stop screw, located on the
ing nuts to the specified torque. or replacement, air may enter the sys- bottom of the master cylinder to bleed
The push rod length verification of tem and cause spongy pedal action. the brake system. Looseni,ng or re-
t h e B e n d i x p o w e r b r a k e booster Bleed the hydraulic system after it has moving this screw could result in dam-
assemblies is accomplished as follows: been properly connected, to be sure age to the secondary piston or stop
1. Disconnect the master cylinder that all air is expelled. screw.
from the booster assembly and secure 2. T o bleed the secondary (rear)
away from the booster without discon- M A N U A L BLEEDING brake system, position a suitable 318
necting the brake tubes. inch box wrench (Fig. 9) on the bleed-
2. Adjust the push rod screw to The Lincoln Continental hydraulic er fitting on the brake wheel cylinder.
provide a slight tension against the brake system is to be bled only with Attach a rubber drain tube to the
I
inner edge of the adjustment gauge pressure bleeding equipment. bleeder fitting. The end of the tube I
slot. (Approximately 5 pounds of ten- The primary and secondary (front should fit snugly around the bleeder

MANIFOLD CHECK VALVE-2365 19.25 IN. LB.

-
fittine.
APPROXIMATELY 25' \

ADJUST PUSH ROO SCREW T O

FIG. 9-Wrench f o r Bleeding
Brake Hydraulic System
I
I I
3. Submerge the free end of the
tube in a container partially filled with
clean brake fluid, and loosen the
bleeder fitting approximately 314 turn.
ADJUSTMENT 4. Push the brake pedal down slow-
ly through its full travel. 'Close the
bleeder fitting, then return1 the pedal I

to the full-released position. Repeat

this operation until air bubbles cease
to appear at the submerged end of the
bleeder tube.
5. When the fluid is completely free
PUSH ROD ADJUSTMEHT-MIDLMD-ROSS
of air bubbles, close the bleyder fitting
and remove the bleeder tube.
6. Repeat t h ~ s procedure a t the
FIG. 8-Brake Booster Push Rod M e a s u r e m e n t brake wheel cylinder on the opposite
 Brakes 02-0 1 -06

side. Refill the master cylinder reser- the bleed screw and bleed the master be removed to gain access to the
, voir after each wheel cylinder is bled cylinder until the fluid is free of air bleeder fittings on the calipers. Also
and install the master cylinder cover bubbles; then, tighten the bleed screw. on Lincoln Continental models the
and gasket. Be sure the diaphragm D o not use the secondary piston stop metering valve release rod must be
; type gasket is properly positioned i n screw, located on the bottom of the pulled outward and held a minimum
; the master cylinder cover. When the master cylinder, t o bleed the master of 1/16 inch (Fig. 10) while bleeding
I bleeding operation is completed, the cylinder. the primary brake system.
: fluid level should be filled t o within 4. I f the rear wheel cylinders, the 10. I f the vehicle contains drum- '

114 inch of the top of the reservoirs. secondary brake system, are to be type front brakes and the primary
/ 7. I f the primary (front brake) sys- bled, position a 318 inch box wrench (front) brake system is to be bled, re-
tem is to be bled. Repeat steps 2 (Fig. 9) on the bleeder fitting on the peat steps 4 through 7, starting at the
/ through 6 at the right front brake cal- right rear brake wheel cylinder. A t - right front wheel cylinder ending at
1 iper or cylinder and ending at the left tach a bleeder tube to the bleeder fil- the left front wheel cylinder.
front brake caliper or cylinder. ting. The end of the tube should fit
11. When the bleeding operation i s
8. O n disc brake equipped models snugly around the bleeder fitting.
completed, close the bleeder tank
; be sure that the front brake pistons 5. Open the valve on the bleeder
valve and remove the tank hose from
I
are returned to their normal positions tank to admit pressurized brake fluid
the adapter fitting.
I and that the shoe and liqing assem- to the master cylinder reservoir.
blies are properly seated by depressing 6. Submerge the free end of the 12. O n disc b r a k e equipped ve-
: the brake pedal several times until tube i n a container partially filled with hicles, be sure that the front brake
; normal pedal travel is established. clean brake fluid, and loosen the pistons are returned to their. normal
I 9. Centralize the pressure differen- bleeder fitting. positions and that the shoe and lining
tial valve. Refer to the Centralizing 7. When air bubbles cease to ap- assemblies are properly seated by dep-
the Pressure Differential Valve proce- pear i n the fluid at the submerged end ressing the brake pedal several times
I dures which follow. of the bleeder tube, close the bleeder until normal pedal travel is esta-
I fitting and remove the tube. blished.
PRESSURE BLEEDING 8. Repeat steps 3 through 7 at the 13. Remove the Pressure Bleeder
left rear wheel cylinder. Adapter Tool. F i l l the master cylinder
The Lincoln Continental hydraulic 9. I f the vehicle, is equipped with ,reservoirs t o within 114 inch of the
brake system is to be bled only with disc brakes, repeat,steps 4 through 7, top. Install. the master cylinder cover
pressure bleeding equipment. starting at the right front disc caliper adi gasket. Be sure the Diaphragm
Bleed the longest lines first. The and ending at the left front disc cali- type gasket is properly positioned i n
bleeder tank should contain enough per. the master cylinder cover.
new Ford Brake Fluid to complete the O n Lincoln Continental models the 14. Centralize the pressure differen-
bleeding operation. Use Ford Brake front wheel and tire assemblies must tial valve as follows.
Fluid - Extra Heavy Duty - Part
Number , G 6 A Z - 19542-A (ESA-
M6C25-A) or equivalent for all brake
applications. The brake fluid is col-
ored blue for identification purposes.
D o not mix low temperature brake
fluid with the specified brake fluid
during the bleeding operations. Never
re-use brake fluid that has been
drained from the hydraulic system.
The tank should be charged with ap-
proximately 10 to 30 pounds of air
pressure. Never exceed 50 pounds
pressure.
1. Clean all dirt from the master
cylinder reservoir cover.
2. Remove the master cylinder res-
/ Tool J-21741

t ervoir cover and rubber gasket, and

' COMPRESS
fill the master cylinder reservoir with TOOL AND
I the specified brake fluid. Install the POSITION
ONTO V A L V E .
pressure bleeder adapter tool to the RELEASE TO
i master cylinder, and attach the bleed- ALLOW
: er tank hose to the fittng on the SPRING
ACTION TO
I adapter. FORCE
1 Master cylinder pressure bleeder ROD OUT
/ adapter tools can be obtained from
1 the various manufacturers of pressure
bleeding equipment. Follow the in-
structions of the manufacturer when
installing the adapter.
RELEASE ROD
3. I f t h e m a s t e r c y l i n d e r i s
equipped with a bleed screw, loosen FIG. 70-Gisc Brake M e t e r i n g Valve-Lincoln Continental
02-01-07 Brakes

CENTRALIZING THE light after a repair operation, a pres- differential valve is moved to a cen-
PRESSURE DIFFERENTIAL sure differential or unbalance condi- tralized position and the brake warn-
VALVE tion must be created in the opposite ing light goes out; then, immediately
brake system from the one that was tighten the outlet port tube nut.
After a failure of the primary (front repaired or bled last. 2. Check the fluid level in the mas-
brake) or secondary (rear brake) sys- 1. Turn the ignition switch to the ter cylinder reservoirs and f i l l them to
tem has been repaired and bled, the ACC or O N position. Loosen the dif- within 1/4 inch of the top with the
dual-brake warning light will usually ferential valve assembly brake tube specified brake fluid, if necessary.
continue to be illuminated due to the nut at the outlet port on the opposite 3. Turn the ignition switch tb the
pressure differential valve remaining in side of the brake system that was O F F position.
the off-center position. wheel balanced, repaired and/or bled 4. Before driving the vehicle, check
T o centralize the pressure differen- last. Depress the brake pedal slowly to the operation of the brakes and be
tial valve and turn off the warning build line pressure until the pressure sure that a firm pedal is obtained.

3 CLEANING AND INSPECTION

DlSC BRAKES Rotunda Disc Brake Attachment inboard rotor face (dimension B )
FRE-2249-2 is the only approved tool and the outb.oard rotor surface and
I. Remove the wheel and tire and to be used to refinish the disc brake the inboard bearing c u p (dimension
the shoe and lining assemblies as out- rotors. The step-by-step resurfacing A), must be observed when remov-
lined in Part 2-2, Section 2. procedure provided with the tool must ing material from the rotor braking
2. On all models except Lincoln be adhered to. surfaces.
Continental, make thickness measure- The finished braking surface of the When the runout check, is finished
ments with a micrometer across the rotor must be flat and parallel within be sure to adjust the bearings as out-
thinnest section of the shoe and lining. 0.0007 inch; lateral runout must not lined i n Group 3, in order to prevent
I f the assembly has worn to a thick- exceed 0.003 inch total indicator bearing failure.
ness of 0.230-inch (shoe and lining to- reading, braking surface are to be 801 15 6. Check the rotor for scoring. Mi-
gether) or 0.030-inch (lining material micro inches. nor scores can be removed with a
only) at any one of three measuring On all models except Lincoln Con- fine emery cloth. If the rotor is ex-
locations or i f there is more than tinental the minimum limiting dimen- cessively scored, refinish it as out-
0.125 taper from end to end or if lin- sion from the inboard bearing cup to lined in step 5 or replace the rotor,
ing shows evidence of brake fluid con- the inboard rotor face and the mini- i f required.
tamination, replace all (4) shoe and mum rotor thickness dimension, must 7. Visually check the caliper. I f the
lining assemblies on both front wheels. be observed when removing material caliper housing is leaking it should be
O n L i n c o l n Continental brakes from the rotor braking surfaces. A replaced. I f a seal .is leaking the cali-
make three thickness measurements ball and gage bar (Rotunda Kit FRE per must be disassembled and new
with a micrometer across the middle 70160) is to be used when checking .seals installed. I f a pisto,n is seazed
section of the shoe and lining. Take minimum dimensions (Fig. I I). in the b.ore a new caliper housing is
one reading at each side and one in required.
the center. I f the assembly has worn On Lincoln Continental models the
two halves of the caliper assembly
to a thickness of 0.231 inch (shoe and
lining together) or 0.066 inch (lining
FALCON-FAIRLANE
MUSTANG-COUGAR
MONTEGO
4 k 'IN should never be separated.1 Damage or
material only) at any one of the three failure of one requires replacement of
measuring locations, replace all (4) both as a unit.
shoe and lining assemblies on both Check the brake hoses for signs of
front wheels. cracking, leaks or abrasion. Replace
3. Check the caliper to spindle at- them if necessary.
taching bolts torque. Torque them to
DlSC BRAKE SERVICE
specification, if required.
PRECAUTIONS
4. T o check rotor runout, first
eliminate the wheel bearing end play 1. Grease or any other 'foreign ma-
by tightening the adjusting nut. After terial must be kept off the caliper as-
tightening the nut, check to see that sembly, surfaces of the rotor and ex-
the rotor can still be rotated. ternal surfaces of the hub during serv-
5. Clamp a dial indicator to the ice operations. Handling ?f the rotor
caliper housing so that the stylus con- and caliper assemblies should be done
tact the rotor at a point approximate- -
METEOR THUNDERBIRD I I in a way to avoid deformhion of the
ly I inch from the outer edge. Rotate 1.12 M I N . ~ 1- H1633-A
brake rotor and nicking o,r scratching
the rotor and take an indicator read- FIG. 1 1-Disc Brake Rotor of brake linings.,
ing. I f the reading exceeds 0.003 inch Service Limits-All Models Except 2. If a caliper piston is removed for
total lateral runout on the indicator, Lincoln Continental any reason, the plston seal must be re-
replace or resurface the disc brake placed.
rotor. The following requirement must O n Lincoln Continental models the 3. During removal and installation
be met when resurfacing disc brake minimum limiting dimension (Fig. 12) of a wheel assembly, exercise care not
rotors: from the inboard bearing cup to the to ~nterferewith and damage the cali-
 Brakes

wheel, tire and drum are removed as a fluid. Replace lining in axle sets. Prior
unit. to replacement of lining, the drum di-
9. On floating caliper type disc ameter should be checked to deter-
brakes whenever the caliper is re- mine if oversize linings must be in-
moved the caliper locating pins should . stalled.
be inspected for wear or damage. 4. Check the condition of brake
10. On floating caliper type disc shoes, retracting springs, hold-down
BEARING CUP
brakes, the caliper assembly must be springs, and drum for signs of over-
removed from the spindle prior to re- heating. If the shoes have a slight blue
DIMENSION "0"
moval of the shoe and lining assem- coloring, indicating overheating, re-
0.755 MINIMUM blies. placement of the retracting and hold-
11. On floating caliper type disc down springs is strongly recommended.
brakes the calipers must not be inter- ~ v e r h e a t e d ~ s ~ r lose
i n ~ stheir pull and
DIMENSION "A" changed from one side to the other.
0.395 MINIMUM could cause the new lining to wear
When the caliper is installed on its prematurely, if they are not replaced.
proper anchor plate and spindle, the 5. I f ,the vehicle has 30,000 or more
bleeder screw will point to the rear of miles of operation on the brake linings
Hl532-B the vehicle (Fig. 22). If a caliper is in- or signs of overheating are present
\ stalled on the wrong side of the vehi- when relining brakes, the wheel cylin-
FIG. 12-Disc Brake Rotor S e r v k e cle, it is not possible to bleed the sys- ders should be disassembled and in-
Limits-Lincoln Continental tem properly. spected for wear and entrance of dirt
12. Do not attempt to clean or re- into the cylinder. The cylinder cups
per splash shield or the bleeder screw store oil or grease soaked brake lin- should be replaced, thus avoiding fu-
fitting. ings. When contaminated linings are ture problems.
4. Front wheel bearing end play is found, brake linings must be replaced 6. Inspect all other brake parts and
critical and must be within specifica- in complete axle sets. replace any that are worn or dam-
tions. DRUM BRAKES aged.
5. Be sure the vehicle is centered on 7. Inspect the brake drum and, if
the hoist before. servicing any front 1. Remove the wheel from the necessary, refinish. Refer to Part 2-2,
end components, to avoid bending or drum, and remove the drum as out- Section 4 for refinishing.
damaging the rotor splash shield on lined in Part 2-2, Section 2.
full right or left wheel turns. 2. Brush all dust from the backing
6. The proportioning valve should plates and interior of the brake BRAKE BOOSTER
not be disassembled or adjustments drums.
attempted on it. 3. Inspect the brake shoes for ex- Check the booster operation as
7. Riding of the brake pedal (com- cessive lining wear or shoe damage. If noted in Part 2-1, Section I, Power
mon on left foot applications) should the lining is worn within 1/32 inch of Brake Functional Test. If the brake
be avoided during vehicle operation. the rivet heads or if the shoes are booster is damaged or defective, re-
8. The wheel and tire must be re- damaged, they must be replaced. Re- place it with a new booster. The brake
moved separately from the brake place any lining that had been con- booster is serviced only as an assem-
rotor, unlike drum brakes where the taminated with oil, grease or brake bly;
 Brake System

Part 2-2 Brake System

MODEL APPLICATION
= T =
-"l
' r ?
6
COMPONENT INDEX
iI ,
t. z 6 c
m
o m
c ;=
i . E , = . . -t
g m
3 , .,L
O -28 z" c , $ ; , ,
51"
=* gu ; i 6 2, 56 lc

ANTl SKID CONTROL SYSTEM

ANTl SKIDCONTROL MODULE

.- See Part 2- 1
A page number indicates that the item is for the vehicle listed at the head of the column. I
N/A indicates that the item is not applicable to the vehicle listed.
02-02-02 Brake System 02-02-02

COMPONENT INDEX

Removal and Installation - Non-Power 02-19 02-19 02-19 02-20 02-20 02-20 02-20 02-20 N / A N/A N/A
Removal and Installation - Power 02-2 1
PARKING BRAKE
Description 02-06
PARKING BRAKE ACTUATOR T O
CONTROL CABLE
Removal and installation 02-34 02-34 02-34 N/A N/A N/A N/A N/A N/A 02-34 02-34
PARKING BRAKE ACTUATOR T O
E Q U A L I Z E R CABLE
Removal and Installation 02-35 02-35 02-35 N / A N/A NIA N / A NIA N/A 02-35 02-35
PARKING BRAKE CONTROL
Removal and Installation 02-27 02-27 02-27 02-30 02-27 02-27 02-27 02-30 02-30 02-30 02-30
PARKING BRAKE EQUALIZER T O
CONTROL CABLE
Removal-und Installation N/A N/A N/A 02-34 02-34 02-34 02-34 02-34 02-35 N / A N/A
P A R K I N G BRAKE E Q U A L I Z E R T O
REAR WHEELCABLE
Removal and Installation 02-35 02-35 02-35 02-36 02-36 02-36 02-36 02-36 02-36 02-35 02-35
P R E S S U R E D I F F E R E N T I A L VALVE
Removal and Installation 02-22
P R E S S U R E M E T E R I N G VALVE
Removal and Installation N/A N/A N/A N/A N / A N/A N/A N/A 02-24 N/A N/A
P R O P O R T I O N I N G VALVE
Removal and Installation 02-23 02-23 02-23 02-23 02-23 02-23 02-23 02-23 02-24 02-24 02-24
WHEEL: C Y L I N D E R
Cleaning and Inspection 02-08
Disassembly and Overhaul 02-07
Removal and Installation 02-10

A page number indicates that the item is for the vehicle listed a t the head of the column.
NJA indicates that the item is not applicable to the vehicle listed.
02-02-03 Brake System 02-02-03
1

1 DESCRIPTION

Disc brakes are available as option- DlSC BRAKE FLOATING CALIPER-

al equipment for the front wheels on ALL MODELS EXCEPT
Ford, Mercury, Meteor, Fairlane, LINCOLN CONTINENTAL
Montego, Falcon, Mustang and Cou- . The disc brake consists of a venti-
gar models and are standard on Thun- lated rotor and caliper assembly. The The caliper assem1.y is made up of
derbird, Continental Mark Ill, and caliper used on all models except Lin- a floating caliper housing assembly
L i n c o l n C o n t i n e n t a l models. T h e coln Continental is a single piston and an anchor plate. The anchor plate
dual-master cylinder equipped hydrau- floating caliper (Fig. 3). The caliper is bolted to .the wheel spindle arm by
lic brake system employs single an- used on Lincoln Continental models is two bolts. The floating caliper is at-
c h o r , i n t e r n a l expanding and self- a four piston fixed caliper (Fig. 4). tached to the anchor plate by steel
adjusting drum brake assemblies on A proportioning valve in the rear stabilizers on Ford, Mercury, Meteor,
the rear wheels of vehicles with disc hydraulic circuit provides balanced Thunderbird and Continental Mark
brakes, and on the front and rear braking action between front and rear 111 models and by one stabilizer on
wheels of all others. brakes. Fairlane, Montego, Falcon, Mustang
A vacuum booster is used with the On all models except Lincoln a and Cougar models. The floating cali-
power disc brake system. pressure imp!lse valve located at the per slides on two locating pins which
primary inlet of the pressure differen- also attach to the stabi!izers. The
DUAL MASTER CYLINDER . tial valve prevents brake fluid surge floating caliper contains the single cyl-
back to the master cylinder reservoir. inder and piston assembly. The cylin-
BRAKE SYSTEM On Lincoln Continental models a der bore contains a pisdon with a
metering valve, in the hydraulic line molded rubber dust boot to seal the
The dual-master cylinder brake sys- between the differential valve and the cylinder bore from contamination
tem has been incorporated in all mod- front wheel disc brakes, prevents the (Fig. 5). A square section rubber pis-
els to provide increased safety. The front brakes from applying until ap- ton seal is positioned in a groove in
system consists of a dual-master cylin- proximately 125 psi is obtained in the the cylinder bore and is used to pro-
der (Fig. I), pressure differential valve system (Fig. 21). This delaying action vide sealing between the cylinder and
assembly and a switch (Fig. 2). The is required to prevent the front brakes piston (Fig. 7).
switch on the differential valve acti- from performing all the braking ac- The outer brake shoe and lining as-
vates a dual-brake warning light, lo- tion on low speed stops and thereby sembly is longer than the inner assem-
cated on the instrument panel. increasing the rate of lining wear. bly, and the shot: and lining abem-

DlSC B R A K E S

- PRIMARY SYSTEM B R A K E
FLUID RESERVOIR
I

R E T U R N SPRING (PRIMARY) !

(SECONDARY) \ (PRIMARY) I
B R A K E OUTLET SECONDARY PISTON BRAKE OUTLET PRIMARY PISTON
PORT ASSEMBLY PORT ASSEMBLY

FIG. ]-Dual Master Cylinder-Typical

 BRAKE WARNlFlC CAMP SWITCH BRAKE WARNING LAMP SWITCH
BRAKE WARNING LAMP SWITCH

WARNING LAMP

LOW PRESSURE SIDE

BRAKE WARNING LAMP

FRONT BRAKE FRONT 3RAKE

OUTLET VALVE PISTON IS CENTRALIZED. VALVE PISTON HAS MOVED TO LOW

PROPORT'ONING
VALVE
PRIMARY AND SECONDARY SYSTEM PRESSURE AREA. WARNING LAMP SWITCH PLUNGER IS
PRESSURES ARE EQUALIZED DISC BRAKES DEPRESSED, LIGHTING THE BRAKE WARNING LAMP. H1634-A

FIG. 2-Pressure Differential Valve and Brake Warning -Light' Switch

blies are riot interchangable ( ~ i g 23).
.
The outboard shoe and lining is fixed
to the floating caliper and is retained
by two pins and spring clips. The shoe
and lining assembly consists of fric-
tion material bonded to a metal plate
called the shoe. It is replaced as a
unit.

FIXED CALIPER
LINCOLN CONTINENTAL

The caliper assembly is bolted di-

rectly to the wheel spindle arm by two
bolts. The caliper assembly consists of
two caliper housings bolted together
with each half containing two cylinder
bores of 1.938 inch diameter. Each
saci
H1
cylinder bore contains a piston with
FIG. 3-Disc Brake Assembly- FIG. 4-Disc Broke Assembly- an attached molded rubber dust boot
Floating Caliper-All Models Fixed Caliper-Lincoln to seal the cylinder bore from contam-
Except Lincoln Continental Continental ination (Fig. 6). Square-section rubber
 Brake System

piston seals are positioned in grooves

in the cylinder bores and are used to
provide hydraulic sealing between the
cylinders and pistons (Fig. 7).
The cylinders are connected hydrau-
lically by means of internal passages
in the caliper housings and an external
transfer tube between the two halves
of the caliper assembly. One bleeder
screw and fluid inlet fitting is provided
on each caliper assembly.
The shoe and lining assemblies are
located in between parallel machined
abutments within the caliper, and are
supported radially by tabs on the
duter ends of the shoe assemblies (Fig.
46). The shoes slide axially in the cali- P~STON'~EAL h\ ANCHOR PLATE

per abutments by means of the tabs

which ride on machined ledges (bridg-
es) when hydraulic pressure is applied
to the piston (Fig. 6). A shoe and lin- FIG. 5-Floating Caliper Assembly-Sectional View
ing assembly consists of friction mate-
rial riveted to a metal plate called the
shoe. It is replaced as a unit. Clips are
attached to the top of the caliper to R
retain the shoe and lining assemblies.
The caliper assembly is mounted on
the front wheel spindle to the rear of
the wheel vertical centerline.

The cast iron disc is of the ventilat-

ed rotor-type incorporating forty fins
and is attached to, and rotates with
the wheel hub. A splash shield bolted
to the spindle is used primarily to pre-
vent road contaminants from contact-
ing the inboard rotor and lining sur-
faces. The wheel provides protection
for the outboard surface of the rotor.

DRUM BRAKE FIG. 6-Fixed Caliper Assembly-Sectional View

The drum brake system employs

single anchor, internal expanding and
self adjusting brake assemblies.
PISTON SEAL PISTON SEAL R E L A X E D ,
The self-adjusting brake mechanism DISTORTED PISTON
consists of a cable, cable guide, ad-
justing lever, adjusting screw assem-
bly, and adjuster spring (Fig. 8). The
cable is hooked over the anchor pin at
the top and is connected to the lever
at the bottom. The cable is routed
along the webb of the secondary brake
shoe by means of the cable guide. The
adjuster spring is hooked to the pri-
mary brake shoe and to the lever. The
automatic adjuster operates only when
the brakes are applied while the vehi-
I
cle is moving rea-rward and only when CALIPER HOUSING I
the secondary shoe is free to move B R A K E S APPLIED BRAKES RELEASED H1569-B
toward the drum beyond a predeter-
mined point. FIG. 7-Function of Piston S e a l
02-02-06 Brake system 02-02-06

SHOE WlDE (ANCHOR PIN) PLATE SHOE WIDE (WCHOP PIN) PLATE PRIMARY SHOE .TO.ANCHOR
WASHER I \ SPRING

FIG. 8-Self-Adjusting Brake Assemblies-Typical

nects the actuator to the equalizer. lease type (Fig. 9) is used on the Mer-
BRAKE BOOSTER SYSTEM
The rear brake cables connect the cury, Ford LTD, Meteor LeMoyne,
equalizer assembly to the parking Thunderbird, Continental Mark 111
This diaphragm-type brake booster brake lever at each rear secondary and Lincoln Continental models. All
is a ' self-contained vacuum-hydraulic shoe (Fig. 8). other models use the manual release-
braking unit mounted on the engine Two types of brake pedal control type (Fig. 10).
side of the dash panel. are used. The automatic (vacuum) re- On the automatic-type, the vacuum
The brake booster is of the vacuum
suspended-type which utilizes engine
intake manifold vacuum and atmos-
pheric pressure for its power.
Adjustment of the push rod and re-
placement of the check valve and
grommet are the only services permit-
ted on the brake boostqr. The booster
unit is to be exchanged when it is in-
spected, checked and found to be de-
fective.

P A R K I N G BRAKE

An independent foot-operated park-

ing brake control actuates the rear
wheel brake shoes through a cable
linkage. On all models except Ford,
Mercury, Meteor, Thunderbird and
Continental Mark Ill, the operating
cable is routed from the parking brake
control assembly to the equalizer. On
Ford, Mercury, Meteor, Thunderbird,
and Continental Mark Ill, the operat-
ing cable is routed from the parking
brake control asse,mbly to the actuator FIG.. 9-Parking Brake Control Assembly
assembly. An intermediate cable con- With Automatic Release-Typical
 02-02-07 Brake System

ANTI-SKID CONTROL SYSTEM

'6
RELEASE PAWL CAM PIN

The .anti-skid control system con-

sists of three major components (Fig.
39). Mechanically driven electromag-
netic sensors at each rear wheel; an
electronic control module mounted
under the glove box; a vacuum pow-
ered actuator attached to a bracket on
the inside of the right front frame rail
under the toe board.
The sensors consist of steel rings
having teeth on their outer diameters,
pressed on each axle shaft just out-
board of the wheel bearing. The teeth
rotate past corresponding teeth on the
inside diameter of stationary steel
rings mounted in the bearing retain-
ers. Also mounted in the retainers, are
ring-shaped permanent magnets and
coils of wire. Two wires: from each
sensor connect the sensors to the con-
trol module.
ti 1636-A The control module consists of solid
FIG. 10--Parking Brake Control Assembly state electronic components sealed in
With M a n u a l ~ l e a s e - ~ ~ ~ i c a l a container. I t is connected to the sen-
sors and to a solenoid on the actuator.
power unit with mounting bracket is in the event of vacuum power failure The actuator is similar to a vacuum
riveted to the control assembly. The or for optional manual release at any brake booster and consists ol three
vacuum actuated piston within the time. parts. A chamber divided by a vacuum
unit is connected by a rod to the Hoses connect the power unit and suspended diaphragm; a hydraulic cyl-
upper end of the release lever (Fig. 9). the engine manifold to a vacuum re- inder connected to the diaphragm; and
The lower end of the release lever ex- lease valve in the transmission neutral a solenoid connected electrically to the
tends out for alternate manual release safety switch. control module.

2 I N-VEHICLE ADJUSTMENTS AND REPAIRS

After any brake service work, ob- T o adjust the brake shoes: and tighten the nuts to specification. ,
tain a firm brake pedal before moving 1. Use Rotunda Tool H R E 8650, 7. Complete the adjustment by
the vehicle. Riding the brake pedal (Fig. I I) to determine the inside diam- applying the brakes several times with ;
(common on left foot application) eter of the drum braking surface. a minimum of 50 Ibs pressure on the
should be avoided when driving the 2. Reverse the tool as shown in Fig. pedal while backing the vehicle. After
vehicle. I I and adjust the brake shoe diameter each stop the vehicle must be moved
to fit the gauge. Hold the automatic forward.
BRAKE SHOE ADJUSTMENTS-
adjusting lever out of engagement 8. After the brake sho4s have been 1
while rotating the adjusting screw, to properly adjusted, check the operation I
DRUM BRAKES, prevent burring the screw slots. Make of the brakes by making several stops '
sure the adjusting screw rotates freely. while operating in a forward direction.
1 I
, The hydraulic drum brakes are If necessary, lubricate the adjusting
self-adjusting and require a manual
adjustment only after the brake shoes
screw threads with a thin, uniform
coating of MIC- 100-A.
WHEEL CYLINDER REPAIR-
have been relined, replaced, or when 3. Rotate Tool H R E 8650 around DRUM BRAKE
the length of the adjusting screw has the brake shoes to be sure of the set-
been changed while performing some ting. Wheel cylinders shouldl not be di- ,
other service operation. The manual
adjustment is performed with the
4. Apply a small quantity of high
t e m p e r a t u r e g r e a s e t o the points
sassembled unless they are leaklng or
unless new cups and boots are to be
,
drums removed, using the tool and the where the shoes contact the backing installed. It is not necessary to remove
procedure detailed below. plate, being careful not to get the lu- the brake cylinder from the backing
When adjusting the rear brake bricant on the linings. plate to disassemble, inspect, or hone
shoes, check the parking brakd cables 5. Install the drums. Install Tinner- and overhaul the cylinder. Removal is a

for proper adjustment. Make sure that man nuts and tighten securely. necessary orlly when the 1 cylinder is ,
the equalizer operates freely. 6. Install the wheels on the drums damaged or scored beyond repair.
02-02-08 Brake System 02-02-08

A i Tw/-HR~-8650 Place a boot over each end of the cyl-

inder. Bleed the brake system.

H Y D R A U L I C LINE LREPAIR
, .
Steel tubing IS used throughout the
brake system with the exception of the
flexible hoses at the front wheels and
at the' rear axle housing brake tube
connection (Figs. 17 thru 21).
Always bleed the applicable pri-
mary or secondary brake system after
primary or secondary brake system
hose or? line replacement. Centralize
the pressure differential valve after
bleeding the system.
4 -.-
I
" -r

.BRAKE TUBE
REPLACEMENT
I *

If slction of the brake tubing be-

comes , dam'aged, the entire section
should be replaced w i d tubing of the
same type, size, shape and length.
Copper tubing should not be used in a
h y d r a u l i c s y s t e m . When bending
brake tubing to fit underbody or rear
axle contours; be careful not to kink
.or crack,the tube.
'
All brake tubing should be double
,FIG. 7 7 -Adjusting Brake Shoes Using Tool HRE-8650 flared properly to provide good leak-
proof connections. Clean t h e brake
tubing by flushing with clean brake
fluid before installation.
When connecting a tube to a hose,
tube connector, or brake cylinder,
'

tighten the.tube fitting nut to specified

torque with Milbar tool 1 1 12-144 or
equivalent. ,

BRAKE HOSE
REPLACEMENT

A flexlble brake hose should be ;e-

H'"5-0 placed- i f +it shows signs of softening,
FIG. 72-Brake Wheel Cylinder-Typical cracking, or ,other damage.
When installing a new front brake
hose, position the hose to avoid con-
DISASSEMBLY 3. Inspect the cylinder bore for tact with other,,chassis, parts. Place a
score marks or rust. If either condi- new copper 'gasket,over they'hb'se fit-
I. Remove the links and the rubber tion is present the cylinder bore must ting and thread the'hoie assembly into
boots from the ends of the brake cyl- b e h o n e d . H o w e v e r , the cylinder , therfront wheel cylinder. "Engage the
inder. Remove the pistons, cups, and should not be honed more than ,0.003 opposite end .of the hosk: to the brack-.
return spring from the cylinder bore inch beyond its original diameter. et on the frame..Install the horsesho-
(Fig. 12). 4. Check the bleeder hole to be sure e-type retaining clip,. and connect the '
2. Remove the bleeder screw from that it is open. tube to the hose -with ,the' tube,'fitting
the cylinder. a , nut (Figs. 17 thru' 21). .:s

ASSEMBLY A rear brake ,hose should be in-

stalled so ,that it does not touch the
INSPECTION 1. Apply a light coating of heavy- muffler outlet pipe or shock absorber.
duty brake fluid to all internal parts. Thread the .hose into the rear, brake
1. Wash all parts in clean brake 2. Thread the bleeder screw into the tube connector. Engage the front end
fluid. Dry with compressed air. cylinder and tighten securely. of t h ~hose to the bracket on the
2. Replace scored pistons. Always 3. Insert the return spring, cups, frame. Install the horseshoe-type re-
replace the rubber cups and dust and pistons into their respective posi- taining. clip, and connect the tube to
boots. tions in the cylinder bore (Fig. 12). the hose with the tube fitting nut.
02 -02-09 Brake System

3 REMOVAL A N D INSTALLATION

FRONT BRAKE D R U M in the inner cup, and ~nstallthe new 2. Adjust the brakes as outlined
grease seal see Part 3-5, Section 4. under Brake Shoe ~djustm'entsin this
If the original drum is being in- section. Place the drum over the brake
REMOVAL stalled, make sure that the grease in assembly and into pos~tion. '
the hub is clean and adequate. 3. Install the three Tinnerman nuts
1. Raise the vehicle until the wheel 2. Adjust the brakes and install the and t~ghtensecurely. Install !the wheel
and tire clear the floor. Remove the drum assembly as out'ined under on the axle shaft flange studs against
wheel cover or hub cap, and remove Brake Shoe Adjustments in this sec- the drum, and t~ghten the attaching
the wheel and tire from the drum. aon. nuts to spec~flcat~ons.
I
2. Remove the grease cap from the 3. Install the outer wheel bearing,
hub. Remove the cotter pin, nut lock, washer and adjusting nut, #

4. Adjust the wheel bearing as out- BRAKE SHOES A N D

adjusting nut, and flat washer from
lined in Part 3-7, Section 2, then in- ADJUSTING SCREW-
'the spindle. Remove the outer bearing
cone and roller assembly. stall the grease cap. Install the wheel D R U M BRAKES
3. Pull the drum off the wheel .and hub cap.
spindle: . '
4. If the drum will not come off, REAR BRAKE :DRUM REMOVAL
pry the rubber cover from the brake
backing plate. Insert a narrow screw- 1. With the wheel and drum re-
driver through the slot and disengage REMOVAL moved install a clamp over the ends of
the adjusting lever from, the adjusting the brake cylinder as shown in Fig.
screw. While holding the adjusting 1. Raise the vehicle so that the tire 14.
lever away from the screw, back off is clear of the floor. 2. Remove the secondary shoe to
the adjusting screw with the brake ad- 2. Remove the hub cap and wheel. anchor spring with the tool shown in
.justing tool (Fig. 13). Be very careful Remove the three Tinnerman nuts and Fig. 14. With the same tbol remove
not to burr, chip, or damage the remove the brake drum:' If the drum the primary shoe to anchor spring and
'
notches in the adjusting screw; other- will not ,come off, pry the rubber unhook the cable eye from the anchor
wise the self-adjusting mechanism will cover from the backing plate. Insert a pin.
not function properly. narrow screwdriver through the hole 3. O n F o r d , Mercury, Meteor,
in the backing plate, and disengage Thunderbird, Continental Mark 11 I
INSTALLATION the adjusting lever from the adjusting and Lincoln Continental models, re-
screw. While holding the adjusting move the shoe guide (anchor pin)
1. If the drum is being replaced, re- lever away from, the adjusting screw, plate (Fig. 8).
move the protective coating from the back off the adjusting screw with the 4. Remove the shoe hold-down
new drum with carburetor degreaser. brake adjusting tool (Fig. 13). Be very springs, shoes, adjusting screw, pivot
Then, use sandpaper to insure that no careful not to burr, chip, or damage nut, socket and automatic adjustment
residue remains. Wipe the drum with the notches in .the adjusting screw; parts.
a cloth soaked with denatured alcohol. otherwise, the self-adjusting mecha- 5. On rear brakes, remove the
Install new bearings and grease seal. nism will not function properly. parking biake 'link and spring. Dis-
Pack the wheel bearings, install the connect the parking brake cable from
inner bearing cone and roller assembly INSTALLATION the parking brake lever.
s. After removing the rear brake
1. Remove the protective coating secondary shoe, disassemble the park-
from a new drum with carburetor de- ing brake lever from the shoe by re-
greaser; then sand lightly and wipe moving the retaining clip, and spring
with a cloth soaked with denatured al- w,asher (Fig.- 8).
cohol.
INSTALLATION . .
.
. - 1. Before installing the rear brake
shoes, assemble the park.ing, brake
lever to the secondary shoe and secure
with the .spring washer ,and retaining
clip. . . . ,#
2. Apply a light coating, of high-
t e m p e r a t u r e g r e a s e a t ' t h e points
where ,.the brake shoes .contact the
backing plate.
3. Position the brake shoes on the
backingplate and secure the assembly
with the hold down springs. On the
FIG. 13-Backing Off Brake FIG. 14-Retracting Spring rear brake, install the parking brake
Adjustment Removal link and spring, back off .the parking
 Brake System

\
brake ?djustment then connect the 10. Place the adjusting socket on as the lever is actuated by the cable.
parking ,.brake cable to the parking the screw and install this assembly be- T o determine the cause of this con-
brake lever (Fig. 8). tween the shoe ends with the adjusting dition:
4. Install the 'shoe guide' (anchor screw toothed wheel nearest the sec- a. Check the cable end fittings. The
.pin) plate on the.anchor pin when so ondary shoe. cable should completely,~fill or extend
equipped. 11. Hook the cable hook into the slightly beyond the crimped section of
5. Place the ,cable eye over the an- hole in the adjustihg lever. The adjust- the fittings. I f , i t does not meet this
chor pin with the crimped side'toward ing levers are stamped with an R or L specification, possible damage is indi-
the backing plate. to indicate their installation on- right cated and the cable assembly should
6. Install the primary shoe. to
.
an- or left brake assembly (Fig. 16). be replaced.
chor spring' (Fig. 15). 12. Position the hooked end of the b. Check the cable length. On
Ford, Mercury, Meteor, Thunderbird,
L M R
ADJUS~~NG Continental Mark 111, and Lincoln
Continental. models, the cable should
measure l l 118 inches (plus or minus
1/64 inch) from the end of the cable
anchor to the end of the cable hook.
O n Fairlane, Montego, Falcon,
Mustang, and Cougar models the
cable should measure 8 13/32 inches
on 9 inch brakes or 9 314 inches on
10 inch brakes from the end of the
ADJUSTING SCREW
cable anchor to the end of the cable
IDENTIFICATION LINES hook.
c. Check the cable g u ~ d efor dam-
age. The cable groove should be paral-
I. FIG. 15-Retracting Spring FIG. 16-Adjusting Screw a n d lel to the shoe web, and the body of
Installation Lever Identification the guide should lie flat against the
web. Replace the guide if it shows
7. Install the cable guide on th.e adjuster spring completely into, the damage.
secondary shoe web with the ,flanged large hole in the primary shoe web. d. Check the pivot hook on the
hole fitted into the hole in the second- The last coil of.the spring should be at lever. The hook s'urfaces should be
arv shoe web. Thread the cable the edge of the hole. Connect the loop square with the'body of the lever for
arbund the cable guide groove (Fig. end of the spring to the adjuster lever proper pivoting. Replace the lever if
8). ' hole. the hook shows damage.
It. is imperative that the cable be 13. Pull the adjuster lever, cable e. See that the adjusting screw
positioned i n this groove and not be- and automatic adjuster spring down socket is properly seated in the notch
tween the guide and the shoe web. and toward the rear to engage the in the shoe web.
8.. Install the secondary shoe to an- pivot hook in the large hole insthe sec-
chor spring with the tool shown in ondary shoe web (Fig. 8). WHEEL CYLINDER
Fig. 15. 14. After installation, check the ac-
Be certain that the cable eye is not tion of the adjuster by pulling the'sec- DRUM BRAKE
cocked or binding on the anchor pin tion of the cable between the cable
when inst'alled. All parts should be flat g u ~ d eand the anchor pin toward the
on the anchor p i n . ~ ~ e m o vthe
e brake secondary shoe web far enough'to lift
cylinder clamp. the lever past a tooth on the adjusting
9. Apply high-temperature grease screw wheel. The lever should snap 1. Remove the wheel and the drum.
(MIC-100-A) to the threads' and the into position behind the next tooth, 2. Remove the brake shoe assem-
socket end of the adjusting screw. and release of the cable should cause blies, Following procedures outlined in
Turn the adjusting screw,into the ad- the adjuster spring to return the lever this section. .
justing pivot nut to the limit of the to its original position. This return ac- % 3 .Disconnect the brake line from
threads and then back off 112 turn. tion of the lever will turn the adjusting the brake cylinder Figs. 17 thru 21.
Interchanging the brake shoe ad- screw one tooth. O n a vehicle with a vacuum brake
justing screw assemblies from one side If pulling the cable does not pro- booster, be sure the engine is stopped
of the vehicle to the other would cause duce the action described, or if the and there is no' vacuum in the booster
the brake shoes to retract,rather than lever action is sluggish instead of posi- system before disconnecting the hy-
expand each time the automatic ad- tive and sharp, check the position of draulic lines.
justing mechanism operated. T o pre- the lever on the adjusting screw T o disconnect the hose a t a front
vent installation on the wrong side of toothed wheel. With the brake in a cylinder, loosen the tube fitting that
the vehicle, the socket end of the'ad- vertical position (anchor at the top), connects the opposite end of the hose
justing screw is stamped with an R or the lever should contact the adjusting to the brake tube a t a bracket on the
L (Fig. 16). The adjusting pivot. nuts wheel 3/16 inch (plus or minus 1/32 frame. Remove the horseshoe-type re-
can be distinguished by .the number of inch) above the centerline of the taining clip from the hose and brack-
grooves machined around the body of screw. If the contact point is below et, disengage the hose from the brack-
the nut: Two grooves on the nut indi- this centerline, the lever will not lock et, then unscrew the e n t ~ r ehose as-
cate a . right thread; one groove indi- on the teeth in the adjusting screw sembly from the front wheel cylinder.
cates a left tliread. wheel, and the screw will not be turned At a rear cylinder, unscrew the tube
 EXISTING B O L T
T U d E 2267.2268
AND WASHER
+ \. HOSE 2A448
\

VlEW T

T U d E 2263
PRESSURE IMPULSE

OPORTlONlNG VALVE DASH PANEL

/ VIEW I N CIRCLE J
I
PRESSURE DIFFERENTIAL
VALVE 26257.D ASSEMBLY
TUBE 2265 @ VIEW I N CIRCLE N
VIEW Z T Y P l CAL - --.
_ 2 PLACES
DISC BRAKE VlEW I N CIRCLE W
TUOE 2253 2264
TUBE 28253 ASSEMBLY
TUBE 2 2 M /-TUBE
2A040 ASSEMBLY T U 8 E 27.65

VlEW I N CIRCLE X VlEW I N CIRCLE V /

T Y P I C A L 3 PLACES TYPICAL 5 PLACES
PRESSURE DIFFERENTIAL . h
a
2263-2264 ASSY.
C9AA-2149 m / &
C7AA-2082-A R.H.
i
C7AA-2A056-L.H.

/ TUBE 2565 i
TUBE 2265 3
1 2 REQUIREP
1

FIG. 17---Service Brake System-Ford, Mercury and Meteor

 02 -02- 1 2 Brake System 02-02-1 2
I

. '7
TUBE-2263 R.H. 2264 L.H.

VlEW I N CIRCLE Y
TYPICAL 2 PLACES

. .

GASKET-2149 2 REQUIRED,
VlEW I N CIRCLE W
TYPICAL 2 PLACES
D R W BRAKES VlEW I N CIRCLE M
POWER DISC BRAKES

"
BRAKE HOSE MUST BE ASSEMBLED
WITH WHEELS STRAIGHT AHEAD.,

-
STRIPE ON HOLE HOSE ASSEMBLY
MUST SHOW NO EVIDENCE OFTWLST.

FIG. 18-Service Brake System-Fairlane, Montego and Falcon

 \
L.H. FENDER APRON REF. nEw w

VIE* R
FOR DRUM BRAKES VIEW IN URCLE U

VIEW IN a R a E T

..
VIEW IN c l R a E s --
TYPICAL 4 PLACES

FIG. 19-Service Brake System-Mustang and Cougar

FIG. 20-Service Brake System-Thunderbird, Continental M a r k Ill
FIG. 2 1 -Service Brake System-Lincoln Continental
 Brake System

fitting that connects the tube to the BRAKE BACKING PLATE- BLEEDER SCREW FACING THIS DIRECTION
cylinder. Do not pull the metal tube DRUM BRAKE
away from the cylinder. Pulling the
tube out of the cylinder connection
will bend the metal tube and make in-
REMOVAL
stallation difficult. The tube will sepa-
rate from the cylinder when the cylin-
1. Remove the wheel and brake
der is removed from the backing
drum. Disconnect the brake line from
plate.
4. On all except the front wheels on the brake cylinder.
Ford, Mercury, and Meteor models, 2. Remove the brake shoe and ad-
remove the wheel cylinder attaching juster assemblies and the wheel cylin-
bolts and lock washers and remove the der as outlined in this section. On the
cylinder. On the front wheel of Ford, rear wheels, disconnect the parking
Mercury and Meteor models, remove brake lever from the cable.
3. I f the rear backing plate is being
the nut and washer that attaches the
replaced, remove the axle shaft from
cylinder to the anchor pin. Remove
the applicable rear axle as outlined in
the cylinder from the anchor pin.
Group 4, Part 4-2- Rear Axle, Sec-
l NSTALLATION tion 2, disengage parking brake cable FIG. 22.-Floating Caliper.
retainer from backing plate. Remove Installed
Wipe the end(s) of the hydraulic the backing plate and gasket.
line to remove any foreign matter be- I f the front backing plate is being 1. Remove the front wheel cover.
fore making connections. replaced, remove the bolts and nuts Remove the wheel and tire assembly
1. On all models except Ford, Mer- that secure the backing plate to the from the hub and rotor assembly. Be
cury and Meteor, to install a front front wheel spindle and remove the careful to avoid damage or interfer-
wheel cylinder, position the cylinder to plate and gasket. ence with the caliper splash shield or
the backing plate. lnstall the two lock bleeder screw fitting.
washers and attaching bolts. Torque INSTALLATION 2. Disconnect the brake line from
them to specifications. the caliper. C a p the hose to prevent
On Ford, Mercury and Meteor I f a rear backing plate is to be re-
placed, position a new rear backing '.he brake fluid from leaking from the
models, to install a front wheel cylin- master cylinder.
der, position the cylinder on the an- plate and gasket on the attaching
bolts in the axle housing flange. Insert 3. Remove the safety wire and the
chor pin against the backing plate. In- two bolts that attach thc caliper as-
stall the washer and cylinder attaching parking brake cable into backing plate
and secure retaining fingers. Install sembly to the spindle.
nut on the anchor pin, and torque it 4. Lift the caliper assembly off the
to specification. Lock the washer re- the rear axle shaft for applicable rear
axle. Refer to Group 4, Part 4-2- rotor and place it on the bench.
tainer securely.
2. Install a new copper gasket over Rear Axle, Section 2 for the proper
the hose fitting. Thread the hose into installation procedure. Installation
the cylinder 'and tighten it to specified 1. I f the front brake backing plate
torque. is to be replaced, position a new front I. Position the caliper assembly on
3. Engage the opposite end of the backing plats and gasket to the wheel the rotor, and mate the mounting bolt
hose to the bracket on the frame. I n - spindle and install the attaching bolts holes in the caliper with those in the
stall the horseshoe-type retaining clip, and nuts. spindle. It may be necessary to push
and connect the brake tube to the 2. Install the wheel cylinder and the caliper piston into the cylinder
hose with the tube fitting nut. Tighten connect the brake line as outlined in bore to obtain clearance between the
the nut to specification with tool this section. shoe and lining assembly and the
I 1 12- 144. 3. Install the brake shoe and ad- rotor.
4. To install a rear wheel cylinder, juster assemblies as outlined in, this 2. Install the caliper to spindle at-
place the rear wheel cylinder into po- section. On a rear brake, connect the taching bolts and torque them to spe-
sition. Enter the tubing into the cylin- parking brake cable to the lever. cification. The upper bolt must be
der, and start the tube fitting nut into 4. Adjust the brake shoes (Section tightened first. Install the safety wire
the threads of the cylinder. 2), and install the brake drums and on the bolts and twist the wire ends at
5. Secure the cylinder to the back- wheels. Bleed the brake system and least five turns. Push the wire ends
ing plate by installing the .attaching centralize the differential valve as out- against the spindle to avoid interfer-
bolts and lock washers. lined in Part 2-1. Section 2. ence with the brake hose and the
6. Tighten the tube fitting nut' to steering stop. Check to insure that the
specification with tool 1 1 12-144. DISC BRAKE CALIPER rotor runs squarely and centrally be-
7. Install the links in the ends of ASSEMBLY tween the two brake shoes.
the wheel cylinder, install the shoes 3. Position the brake hose fitting
and adjuster assemblies, and adjust with a new copper washer on each
the shoes as outlined in this section. ALL MODELS EXCEPT side of the fitting on the caliper as-
8. Adjust the brakes (Part 2-2, Sec- LINCOLN CONTINENTAL sembly. Install the bolts and torque to
tion 2). Install the brake drum and specification.
wheel. Bleed the brakes and centralize Removal 4. Bleed the brake system and cen-
the differential valve as outlined in tralize the differential valve as out-
Part 2-1. Section 2. . Refer to Figs. 22 and 23. lined in Part 2-1. Check the master
02-02- 1 7 Brake System

CONE AND ROLLER

3106-L.H.

ROTOR S P W H SHlEL

2KOO5-L.H.

FIG. 23--~isc Brake-Disassembled-All Models Except Lincoln

cylinder fluid level and add the speci- L I N C O L N CONTINENTAL Remove the wheel and tire assembly
fied fluid, as required. Pump the from the hub and rotor assembly. Be
brake pedal several times to actuate careful to avoid damage ;or intcrfcr-
the piston seals and to position the Removal ence with the caliper splash shield,
1
shoe and lining assemblies. bleeder screw fitting or transfer tube.
5. Install the wheel and tire assem- Refer to Fig. 24. 2. Disconnect the steel, brake line
bly and the wheel cover. transfer tube from the caliper (Fig.
6. Road test the vehicle. I. Remove the front wheel cover. 21). Leave the steel tube donnected to
,

CALl PER PARTS -2B120-R.H. -20121-L.H.

{INBOARD HOUSING
CLIP
/P ISTI34 SEALS 1 4 \ -181 1 5

CALIPER ASSEMBLY
'20118-R.H.

SPINDLE

ASSEMBLIES -2018 2196

CONE AND ROLLER

3106-L.H.

ROTOR SPLASH SHIELD

2K004-R.H.
2KOO5-L.H. GREASE SEAL

I
' H 1650

FIG. 24 - D i s c Brake Disassembled-Lincoln Continental

 Brake System

the brake hose connector and bracket the hub and rotor assembly. a t least five turns. Push the wire ends
assenibly. 2. Remove the caliper froni the ve- against the spindle to avoid interfer-
3. Remove the two bolts retaining hicle following the procedures outlined ence with the brake hose and the
the broke hose bracket and calliper as- under Disc Brake Caliper Assembly. steering stop.
senibly to the spindle. Take care to 3. T o facilitate removal of the cali- 8. With moderate pressure applied
avoid loosening the bridge I)olts that per asseniblies, the piston may have to to the brake pedal, Lorque the stahiliz-
hold the two halves of the caliper to- be pushed into its bore. Apply a er attaching screws and caliper locat-
gether. steady inward pressure against the ing pins to specification.
4. Lift the caliper assembly off the inner shoe and lining assembly. Main-
rotor and place it on the bench. tain the pressure for a t least a minute. LINCOLN CONTI NENI'AL
4. Slide the two outer shoe retain-
Installation ing clips off the retaining pins (Fig.
1. I f the caliper assenibly is to be
23). Removal
5. Remove the two retaining pins
replaced, transfer the steel tubing and
from the outer shoe, then remove the
the bleeder screw to the new caliper. 1. Remove the wheel and tire as-
shoe from the stationary caliper.
2. Position the caliper assenibly on sembly from the hub and rotor assem-
6. Slide the inner brake shoe out-
the rotor, and mate the niounting bolt bly. Be careful to avoid damage or in-
ward until it is free of the hold-down
holes in the caliper with those in the terference with the caliper splash
springs, then remove the brake shoe.
spindle. It niap bc necessary to push shield, bleeder screw fitting or transfer
7. Remove the caliper locating pins
the caliper pistons into the cylinder tube.
and stabilizer attaching bolts, then re-
bores to obtain clcarance bctween the 2. Remove the two bolts that retain
move and discard the stabilizer or sta-
shoe and lining assembly and the the caliper splash shield, and remove
bilizers.
rotor. The shoe and lining assemblies the shield (Fig. 4).
8. Remove the locating pin insula-
should be seated properly on the 3. T o facilitate removal and instal-
tors from the anchor plate.
bridges. lation of the shoe and lining asseni-
3. Install the caliper to spindle re- Installation blies, the pistons must be pushed into
taining bolts and torque them to spec- their bores. Apply a steady inward .
ification. Check to insure that the pressure against each shoe and lining
rotor runs squarely and centr;~llybe- When installing new shoes and lin-
assembly toward its respective caliper
tween the two halves of the caliper. ings it will be necessary to force the
housing on each side of the rotor (Fig.
These should be approximately 0.090- piston to the bottom of its bore. 6). Maintain the pressure for a t least
0.120 inch clearance between the cali- Apply sufficient pressure to overcome
a minute. I f the pistons will not go in
per and the rotor outside diameter the grip of the piston seal on the pis-
easily, force them in with water pump
(Fig. 6). ton. pliers.
4. Position the steel transfer tube I. Install new caliper locating pin 4. Grasp the metal flange on the
brake hose bracket and caliper asseni- insulators in the anchor plate. outer end of the shoe with two pairs
bly to the spindle. Install the retaining 2. Position the caliper assembly in
of pliers and pull the shoe out of the
bolts then torque them to specifica- the anchor plate.
caliper (Fig. 25).
tion. 3. Position the new stabilizer or
5. Connect the front wheel steel stabilizers and install the caliper locat-
'

ing pins to engage approxiniately four Installation

transfer tube froni the caliper to the
front brake hose connector. Check the threads. I. Position a new shoe and lining
hose for proper installation (Fig. 21). If the caliper locating pins are rust- assembly on each side of the rotor so
6. Bleed the brake systcni and cen- ed or corroded they should be re- that the lining faces the rotor. Be sure
tralize the dil'fercntial valve a s out- placed.
lined in Part 2-1. Check the master Apply water or isopropyl alcohol to
cylindcr fluid level and add the speci- the caliper locating pins before instal-
fied fluid, a s required. P u m p the lation. Oil or grease must not be used
hrake pedal several times to actuate on the locating pins.
the piston seals and to position the 4. Position the outer brake shoe on
shoe and lininl: assemblies. the caliper and install the two retain-
7. Install the wheel and tire assem- ing pins and clips.
bly and the wheel cover. 5. Install the inner brake shoe so
8. Road test the vehicle. that the ears of shoe are on top of the
anchor plate bosses and under the
shoe hold-down springs.
DISC BRAKE SHOE AND 6. Position the shoe and lining
LINING assemblies so that the caliper assem-
bly can be placed over the rotor. Ro-
'Al-I, MODEI,S EXCEPT tate a hammer handle between the lin-
1.INCOLN C O N T I N E N T A L ings to reset the stabilizers.
i 7. lnstall the caliper assembly over
the rotor and on the spindle. Install
the two caliper attaching bolts, and
Removal torque them to specifications. The FIG. 25--Removing Disc B r a k e
I upper bolt must be tightened first. In- S h o e a n d Lining Assembly-
1. Reniove the wheel and tire from stall the safety wire and twist the ends Lincoln C o n t i n e n t a l
 Brake System 02-02- 19

that the tabs on the shoe flanges seat fied grease (M-IC75B), and install the Reinoval in the roregoing procedure
fully against the caliper bridges (Fig. inner bearing cone and roller assembly (it is not necessary to discbnnect hy-
25). in the inner cup: Pack grease lightly draulic connections).
2. Install the caliper splash shield between the lips of a .new grease seal 2. Remove the three bo!ts that at-
and secure the shield to the caliper and install the seal (Figs. 23 and 24). tach the splash shield to the spindle,
with two retaining bolts (Fig. 4). If the original rotor is being in- and remove the shield (Figs. 23 and
3. Pump the brake pedal several stalled, make sure that the grease in 24).
times until a firm pedal is obtained the hub is clean and adequate, that 3. Remove and discard 'the splash
and the shoe and lining assemblies are the inner bearing and grease seal are shield to spindlc gasket.
properly seated.. lubricated and in good condition, and
4. Install the wheel and tire assem- that the rotor braking surfaces are \
INSTALLATION
bly on the hub and rotor assembly. clean.
5. Check and refill the master cyl- 2. Install the hub and rotor assem- 1. Install a new splash shield to
inder reservoir with specified brake bly on the spindle. spindle gasket.
fluid as required. 3. Lubricate and install the outer 2. If the shield is bent, straighten it
6. Road test the car. wheel bearing, washer and adjusting out before installation. Position the
I t should not be necessary to bleed nut. shield to the mounting bracket, install
the system after a shoe and lining re- 4. Adjust the wheel bearings to the attaching bolts, nuts and torque
placement. specification, and then install the nut them to specification.
lock, cotter pin, and grease cap. The 3. Install the hub and rotor assern-
F R O N T WHEEL H U B A N D wheel bearing adjustment is especially bly and the callper as outlined under
important with disc brakes.
R O T O R ASSEMBLY - 5. Mount the caliper assembly on
Installation in the foregoing proce-
dure.
DlSC BRAKES the spindle following the Disc Brake
Caliper Assembly Installation proce- D U A L M A S T E R CYLINDER-
dure in this section.
REMOVAL
NON P O W E R BRAKES
DlSC BRAKE R O T O R
1. Remove the wheel and tire from FORD, M E R C U R Y
SPLASH SHIELD
the hub (Figs. 23 and 24). Be careful AND METEOR
to avoid damage or interference with
the bleeder screw fitting. O n Lincoln REMOVAL
Removal
Continental models be careful to avoid
damage to the caliper splash shield or 1. Remove the caliper and the hub
transfer tube. and rotor assembly as outlined under Refer to Fig. 26.
2. Remove the caliper assembly
from the spindle and the rotor. If the
caliper does not require servicing, it is
not necessary to disconnect the brake BUSYING
hose or remove the caliper from the /
vehicle. Position the caliper out of the
way, and support it with a wire to
avoid damaging the caliper or stretch-
ing' the hose. Insert a clean cardboard
spacer between the linings to prevent
the piston from coming out of the cyl-
inder bore while the caliper is re-
m oved .
Handle the rotor and caliper assem-
blies in such a way as to avoid defor-
mation of the rotor and nicking,
scratching or contamination of the
brake linings.
3. Remove the grease cap from the
hub. Remove the cotter pin, nut lock,
0.
adjusting nut, and flat washer from
the spindle. Remove the outer bearing
cone and roller assembly.
4. Remove the hub and rotor as-
sembly from the spindle.

INSTALLATION BUSHING /
STOPLIGHT SWITCH
13480
1. If the rotor is being replaced, re-
move the protective coating from the
new rotor with carburetor degreaser. FIG. 26-Dual M a s t e r Cylinder Installation- N o n Power Brakes
Pack a new set of bearings with speci- Ford, Mercury, a n d M e t e o r
 Brake System

I. Disconnect the stoplight switch FAIRLANE, MONTEGO, Installation

wires a t the connector. Remove the FALCON, M U S T A N G A N D
spring retainer. Slide the stop light COUGAR
switch off the brake pedal pin just far Refer to Figs. 27 and 28.
1. Position the boot on the push
enough to clear the end of the pin,
then lift the switch straight upward Removal rod and secure the boot t o the master
from the pin. Use care to avoid switch cylinder. Carefully insert the master
damage during removal.
cylinder push rod and boot through
Refer to Figs. 27 and 28.
the dash panel opening.
2. Slide the master cylinder push
I. Working from inside the vehicle 2. On Fairlane, Falcon or Montego
rod and the nylon washers and bush-
below the instrument panel, disconnect models, position the gasket and mas-
ings off the brake pedal pin.
the master cylinder push rod from the ter cylinder on the mounting studs on
3. Remove the brake tube from the
brake pedal assembly. T h e push rod the dash panel. Install the lock nuts
primary and secondary outlet ports of
cannot be remobed from the master on the studs a t the dash panel and
the master cylinder.
cylinder. torque them t o specification.
4. Remove the c a p screws and lock-
2. Disconnect the stoplight switch 3. On Mustang o r Cougar models,
washers that secure the master cylin-
wires a t the connector. Remove the position the gasket and master cylin-
der to the dash panel and lift the cyl-
hairpin retainer. Slide the stop light der on the dash panel. Install the re-
inder forward and upward from the
switch off the brake pedal pin just far taining screws and torque them to
vehicle.
enough t o clear the end of the pin, specification. C o a t the nylon bushings
then lift the switch straight upward with S A E IOW oil. Install the nylon
from the pin. Use care to avoid switch washer and bushing on the brake
Installation damage during removal. pedal pin.
3. Slide the master cylinder push 4. Position the stop light switch on
rod and the nylon washers and bush- the brakc pedal pin, install the nylon
I. Position the boot on the push ings off the brake pedal pin. bushing and washer and secure them
rod and secure the boot t o the master 4. Remove the brake tubes from in position with the spring retainer.
cylinder. Carefully insert the master the primary and secondary outlet 5. Connect the wires a t the stop
cylinder push rod and boot through ports of the master cylinder. light switch connector.
the dash panel opening and position 5. Remove the lock nllts o r cap 6. Connect the brake lines t o the
the master cylinder on the panel. screw and lockwashers that secure the master cylinder and tighten to speci-
2. Install the cap screws a t the dash master cylinder to the dash panel and fied torque.
panel and torque them t o specifica- lift thc cylinder forward and upward 7. Fill the master cylinder with the
tion. from the car. specified brake fluid to within 114
3. Coat. the nylon bushings with
S A E IOW oil. Install the nylon wash-
e r and bushing on the brake pedal pin.
4. Position the stop light switch on
the brake pedal pin, install the nylon
bushing and washer and secure them
in position with the spring retainer.
5. Connect the wires a t the stop -UPPER STUD
light switch connector.
6. Connect the brake lines t o the
master cylinder leaving the brake line
fittings loose.
7. Fill the master cylinder with the
specified brake fluid to within 114
inch of the top of the dual reservoirs.
Use Ford Brake Fluid-Extra Heavy
Duty-Part Number C6AZ-19542-A
(ESA-MGC25-A) or equivalent for all
drum brake applications. T h e extra
heavy duty brake system fluid is col-
ored blue for identification. D o not
mix low temperature brake fluids with
the specified fluid for the power disc
brake system.
8. Bleed the dual-master cylinder
and the primary and secondary brake
systems. Centralize the pressure dif- MASTER CYLINDER
PUSH ROD
ferential valve. Refer to Hydraulic
System Bleeding and Centralizing of
the Differential Valve, Part .2-I, Sec-
tion 2 for proper procedure.
9. Operate the brakes several times, n 15sc
then check for external hydraulic FIG. 27-Dual M a s t e r Cylinder Installation- Non Power Brake
leaks. Fair l a n e , M o n t e g o , a n d Falcon
02-02-2 1 Brake System 02-02-2 1

INSTALLATION I

I. Before installing t h e ma.dtcr cyl-

inder, check the distance f r t ~ r n the
outer end of the booster ;issc;nbly
push rod to the n1;lster cylinder
mounting surface. Turn the push rod
adjustins screw in or out a s required
to obtain the spccified length. Refer to
CLUTCH ASSIS1 Part 2-1. Section 2, Power Brakc:
SPRING
Master Cylinder Push Rod Adjust-
BUSHING
1 ment for the proper procedure.
2. Position the master .cylinder as-
sembly over the booster push rod and
onto the two studs on the boostcr as-
sembly (Figs. 29 thru 33).
3. Install the attaching nuts and
lock washers and torque them to spec-
ifications.
4. Install the front and rear brake'
tubes to the rnnstcr cylinder outlet fit-
tings.
5. ill the master cylinder with the
specified b r ~ ~ k fluid
e to : within I/4
inch of the top of the dual reservoirs.
. -.. - . -,,,--,,
2140 SPACER
STOP LIGHT
SWITCH 13480
' \
-.--&,.,c"
SHAFT
AUTOWTIC
TRANSMISSION
C L ~ T C HP E D A L
BUMPERSTOP H163e-A
Use Ford Brake Fluid-Extra Heavy
Duty---Part Number C6AZ-19542-A
(ESA-M6C25-A) for a11 brake appli-
cations. The extra heavy duty brake
fluid is colored blue for identification.
D o not mix low temperature brake
FIG. 28-Dual M a s t e r Cylinder Installation- fluids with the spccified fluids for the
N o n P o w e r Brake-Mustang a n d Cougar disc brake system.
.inch of the top of the dual reservoirs.
Use Ford Brake Fluid-Extra Heavy
Duty-Part Number C6AZ-19542-A !
for all brake applications. The brake
fluid is colored blue for identification.
D o not mix low temperature brake CLIP
fluids with the specified fluid for the
brake system.
8. Bleed the dual-master cylinder
and the primary and secondary brake
VACUUM BOOSTER
systems. Centralize the pressure dif-
ferential valve. Refer to Hydraulic
System. Bleeding and Centralizing of
the Differential Valve, Part 2-1, Sec-
tion 2 for the proper procedure.
9. Operate the brakes several times,
then check for external hydraulic
leaks.

DUAL MASTER CYLINDER-

POWER BRAKES

REMOVAL

1. Remove the brake tubes from

the primary and secondary outlet SWITCH 13480 SPACER
ports of the master cylinder (Figs. 29
thru 33).
2. Remove the two nuts and two
lock washers attachine the master cvl- H 1642.~
inder to the brake b:oster assernbl;.
3. Slide the master cylinder forward FIG. 29--Master Cylinder Installation-Power Brake-
and upward from the vehicle. Ford, M e r c u r y a n d M e t e o r
I 02-02-22 Brake System

6. Bleed the dual-master cylinder

B R A K E VACUUM BOOSTER -2005 and the primary and secondary brake
systems. Cen~ralize the pressure dif-
ferential valve. Refer to Hydraulic
System Bleeding and Centralizing of
the Differential Valve, Part 2-1, Sec-
tion 2 for the proper procedure.
7. Operate the brakes several times,
then check for external hydraulic
BOOT-2A021 leaks.

PRESSURE DIFFERENTIAL
VALVE A N D PROPORTIONING
V A L V E ASSEMBLY

REMOVAL

1. Disconnect the brake warning

light wire from the pressure differen-
tial valve assembly switch (Figs. 17
thru 21). To prevent damage t o the
brake warning switch wire connector,
expand the plastic lugs to allow re-
moval of the shellwire connector from
STANDARD PUSH ROD the switch body.
TRANSMlSSlON
2. Loosen the tube nuts connecting
the primary and secondary inlet and
outlet tubes at the pressure differential
valve assembly and remove the tubes.
1 FIG. 30 -Master Cylinder Installation-Power Brake- 3. Remove the screw or screws re-
Fairlane, M o n t e g o a n d ,Falcon taining the pressure differential valve
assembly to the chassis and remove
the valve assembly.
4. On disc brake equipped vehicles,
place the pressure differential valve
assembly and mounting bracket in a
vise. Loosen the proportioning valve
tube nuts a t the differential valve and
a t the proportioning valve. Remove
the proportioning valve from the
mounting bracket.
5. I f the differential valve is to be
replaced, remove the brake warning
lamp switch and install the switch in
the new differential valve. T h e pres-
sure differential valve assembly. the
brake warning l a m p , switch, and the
proportioning valve are separate units
and each is serviced as a separate as-
sembly only.

INSTALLATION

1. On disc brake equipped vehicles.

connect the proportioning valve inlet
I
I
MASTER C Y L I N D E R
2005 and outlet tubes to the proportioning
I 2140 valve and differential valve bodies.
Tighten the tube nuts to specification.
2. Mount the pressure differential
valve assembly on the chassis and in-
stall the attaching screw or screws.
3. Connect the primary and second-
i ary inlet and outlet tubes to the pres-
I FIG. 31 .--Master Cylinder Installation- sure differential valve assembly and
) P o w e r Brake-Mustang and Cougar tighten the tube nuts to specifications.
 .I
i
02 -02-23 Brake System 02-02-23

4. Connect the shell-wire connector

to the brake warning lamp switch.
Make sure the plastic lugslon the con-
BOOSTER ASSEMBLY- 2005 nector hold the connector securely to
NUT-34444 .S7
the switch.
5. Bleed the brakes and centralize
the pressure differential valve.

PROPORTIONING VALVE

FORD, MERCURY
AND METEOR

On Ford, Mercury and Meteor

models, the proportioning valve must
be removed with the pressure differen-
tial valve. Use the procedure shown
above for replacement of the propor-
tioning valve.
MASTER CYLINDER FA1 RLANE, MONTEGO
AND FALCON

BRAKE TUBE -2264

Removal
I \
PRESSURE DIFFERENTIAL BRAKE T U B E - ~ B ~ ~ ~ Refer to Fig. 18.
VALVE ASSEMBLY-20257
I. Disconnect the two brake lines at
FIG. 32-Master Cylinder- Installation- the proportioning valve.
2. Remove the bolt retaining the
Thunderbird a n d Continental M a r k I l l pressure differential valve' bracket to
the fender apron.
3. L i f t t h e proportioning valve
bracket from behind the yessure dif-
CYLINDER MUST a E F U L L BUSHING\ SLEEVE ferential valve bracket and4rem'ove the
proportioning' valve from the vehicle.

Installation
NUT (4 REQUIRED) -55
W A S H E R ' ~ ~ . R E Q U I R-44
~D)
I. Position the proportioning valve
and bracket to the fender1 apron with
the proportioning valve bracket be-
tween the pressure differential valve
bracket and the fender apron.
2. Connect the two brake lines at
the proportioning valve. Do not tight-
en.
3. Install the bolt retainting the two
valve brackets to the fender apron.
4. Tighten the two brake line tube
nuts at the proportioning valve to
specifications. I
5. Bleed the brakes and centralize
PRESSURE DIFFERENTIAL the pressure differential valve.
VALVE ASSEMBLY-25328
I

MUSTANG AND COUGAR

PROPORTIONING VALVE
Removal
I
Refer to Fig. 19.
H 1530-C
I. Disconnect the two brake lines at
the proportioning valve. ,
NG. 33-Master Cylinder Installation-Lincoln Continental 2. Remove the bolt retaining the
 Brake System

proportioning valve to the fender LINCOLN CONTINENTAL switch off from the brake pedal pin
, apron and remove the proportioning just far enough for the switch outer
valve. 'hole to clear the pin, and then remove
Removal
the switch from the pin .and booster
lnstallation push rod. Be careful not to damage
the switch during removal. Slide the
Refer to Fig. 21. booster push 'rod and the nylon wash-
I. Position the proportioning valve 1. Disconnect the two brake lines at ers and bushing off the brake pedal
to the fender apron. the proportioning valve. pin (Figs. 29 thru 33).
2. Connect the two brake li.nes a t 2. Loosen the bolt and nut on the 2. Open the hood and remove the
the proportioning valve. Do not tight- bracket retaining the proportioning master cylinder from the booster. Se-
en. valve to the chassis. cure, it to one side without disturbing
3. Install the bolt retaining the pro- 3. .Remove the proportioning valve the hydraulic lines. I t is not necessary
portioning valve to the fender apron. from the bracket. to disconnect the brake lines, but care
4. Tighten the brake line tube nuts should be taken that the brake lines
at the proportioning valve to specifica- are not deformed. Permanent defor-
tions. mation of brake lines can lead t o tube
5. Bleed the brakes and centralize failure.
pressure differential valve. @ 1. Position the proportioning valve
in the bracket and connect the two 3. Disconnect the manifold vacuum
brake lines. Do not tighten. hose or hoses from the booster unit.
2. Tighten the bolt and nut on the I. R e m o v e t h e booster-to-dash
THUNDERBIRD A N D bracket. panel attaching nuts or bolts (Figs. 29
C O N T I N E N T A L M A R K Ill 3. Tighten the tube nuts on the thru 33). Remove the booster and
brake lines at the proportioning valve bracket assembly from the dash panel,
to specifications. sliding the push rod link out from the
4. Bleed the brakes and centralize engine side of the dash panel.
Removal 5. O n , Fairlane, Montego, and Fal-
the pressure differential valve. w
con models, remove the push rod link
Refer to Fig. 20. boot from the dash panel.
PRESSURE M E T E R I N G VALVE-
'
I 1. Disconnect the two hydraulic
brake lines a t the master cylinder. llNCOLN CONTINENTAL
INSTALLATION
2. Remove the two nuts retaining
the master cylinder to the booster and I. On Fairlane, Montego and Fal-
remove the master cylinder for clear- REMOVAL con models, install the push rod link
ance. boot in the hole in the dash panel as
3. Disconnect the two brake lines at Refer to Fig. 21. shown in Fig. 23. lnstall the four
the proportioning valve. 1. Loosen the tube nuts connecting spacers on the mounting studs.
4. Remove the bolt and nut retain- the inlet and outlet tubes a t the me- 2. Mount the booster and bracket
ing the proportioning valve to the tering valve, and remove the tubes. assembly to the dash panel by insert-
pressure differential valve bracket and 2. Remove the two screws retaining ing the push rod or push.rod link in
remove the proportioning valve assem- the metering valve to the frame through the hole and boot in the dash
bly. crossmember, and remove the me- p a n e l . I n s t a l l the bracket-to-dash
tering valve. The metering valve is ser- panel attaching lock nuts or bolts
Installation viced as an assembly only. (Figs. 29 thru 33).
3. Connect the manifold vacuum
1. Transfer the bracket to the new hose or hoses to the booster.
proportioning valve. 4. Before installing the master cyl-
2. Position the proportioning valve 1. Position the metering valve to inder, check the distance from the
assembly to the pressure differential the frame crossmember, and install outer end of the booster assembly
valve bracket. the retaining screws. push. rod to master cylinder surface.
3. Connect the two brake lines to 2. Connect the inlet and outlet Turn the screw in or out to obtain the
the proportioning valve. Do not tight- tubes to the metering valve, and tight- specified length. Refer to Part 2-1,
en. en the tube nuts to specification. Section 2, Power Brake Master Cylin-
4. Install the bolt and nut retaining der Push Rod Adjustment. Install the
the proportioning valve to the pressure BRAKE BOOSTER master cylinder and torque the attach-
differential valve bracket. ing nuts to specifications.
5. Tighten the two brake line tube 5. Working from inside the vehicle
nuts at the proportioning valve to
'
below the instrument panel, connect
specifications. the booster push rod link to the brake
6.' Position the master cylinder to 1. Working from inside the, vehicle pedal assembly. To d o this, proceed as
the booster and install the nuts retain- below the instrument panel, disconnect follows:
ing the master cylinder to the booster. the booster push rod from the brake Install the inner nylon washer, the
7. Connect the two brake lines at pedal assembly. T o do this, proceed as booster push rod, and the bushing on
the master cylinder and tighten the follows: the brake pedal pin. Position the
tube nuts to specifications. Disconnect the stop light switch switch so that it straddles the push
8 . ,Bleed the brakes and centralize wires a t the connector. Remove the rod with the switch slot on the pedal
the pressure differential valve. hairpin retainer. Slide the stop light pin and the switch outer hole just
 Brake System

clearing the pin. Slide the switch com- 5. Check the Brake Pedal Free 6. Connect the stop light switch
pletely onto the pin, and install the Height. and Travel Measurements, wires to the connector, and install the
nylon washer as shown in Figs. 29 Part 2-1, Section 1. wires to the retaining clip:
thru 33. Be careful not to bend or de- 7. Adjust the clutch pedal free play
form the switch. Secure these parts to FAIRLANE, MONTEGO A N D (Group 5) to specification, if required.
the pin with the hairpin retainer. Con- FALCON-MANUAL-SHIFT 8. Check the Brake Pedal Free
nect the stop light switch wires to the TRANSMISSION Height and Travel ~ e a s u r e m e n t s
connector, and install the wires in the (Part 2-1, Section I).
retaining clip.
Removal
M U S T A N G A N D COUGAR-
BRAKE PEDAL MANUAL-SHIFT
1. Remove the clutch pedal assist TRANSMISSION
spring.
2. D i s c o n n e c t the clutch pedal-
FORD, M E R C U R Y to-equalizer rod at the clutch pedal by Removal
A N D MET'EOR removing the retainer and bushing.
3. Disconnect the stop light switch
wires at the connector. 1. Disconnect the battery ground
Removal 4. Remove the switch retainer,,and cable from the battery.
slide the stop light switch off the 2. Remove the steering column.
1. Disconnect the stop light switch brake pedal pin just far enough for Refer to Part 3-4, Section 2 for pro-
wires at the connector. the switch outer hole to clear the pin. cedure. I

Then lower the switch away from the 3. On non-power brakes, remove
2. Remove the hairpin retainer.
Slide the stop light switch off the pin. the two cap screws retaining the mas-
brake pedal pin just far enough for 5. Slide the master cylinder or ter cylinder to the dash panel and re-
the switch outer hole to clear the pin, booster push rod and the nylon wash- move the two cap screws retaining the
and then lift the switch straight up- , ers and bushing off from the brake brake pedal support bracket to the
ward from the pin. Be careful not to pedal pin (Figs. 27 and 30). dash panel. On power brakes remove
damage the switch during removal. 6. Remove the self-locking pin and the two cap screws- retaining the,
Slide the master cylinder or booster washer from the clutch and brake booster to the dash panel!
push rod and the nylon washers and pedal shaft, then remove the clutch 4. Working inside the vehicle, se-
bushing off the brake pedal pin (Figs. pedal and shaft assembly, the brake cure the clutch pedal against the
26 and 29). pedal assembly, and t h bushings
~ from bumper stop with a small IC-clamp as
3. Remove the hairpin type retainer the pedal support bracket (Figs. 27 shown in Figs. 28 and 3 1.
and washer from the brake pedal and 30). 5. D i s c o n n e c t the clutch pedal-
shaft, then remove the shaft, the brake to-equalizer rod at the clutch pedal by
pedal and the bushings frnm the pedal removing the retainer and, bushing. I
Installation 6. Disconnect the stop light switch
support bracket.
wires at the connector.
1. Apply a coating of SAE 10 en- 7. Remove the switch fetainer and
Installation gine oil to the bushings and locate all slide the stop light switch off the '!
bushings in their proper places on the brake pedal pin just far enough for ,

1. Apply a coating of SAE 10 En- clutch and brake pedal assemblies. the switch outer hole to clear the pin.
gine oil to the bushings and locate 2. Position the brake pedal to the Then lower the switch away from the
bushings in their proper places on the support bracket, then install the clutch pin. Remove the master !cylinder or !
pedal assembly and pedal support pedal and shaft assembly through the booster push rod, bushing and nylon
bracket (Figs. 26 and 29). support bracket and brake pedal as- washer from the brake pedal pin.
2. Position. the brake pedal assem- sembly. Install the spring clip (Figs. 8. Remove the screw retaining the
bly to the support bracket, then install 27 and 30). pedal support bracket to the top inner
the pedal.shaft through the support' 3. Install the clutch pedal assist cowl bracket (Figs. 28 and 31).
bracket and brake pedal assembly. In- spring. 9. Remove the two sheet metal
stall the retainer. 4. C o n n e c t t h e c l u t c h p e d a l - screws retaln~ng the pedal support
3. Install the inner nylon washer, to-equalizer rod to the clutch pedal bracket to the dash panel. On power
the master cylinder or booster push assembly with the bushing and the brakes remove the nuts from the
rod, and the bushing on the brake spring clip retainer. Apply S A E 10 brake booster studs.
pedal pin. Position the switch so that engine oil to the bushing. 10. Remove the two screws retaln- ,
it straddles the push rod with the 5. Install the inner nylon washer, ing the pedal support brqcket to the ,
switch slot on the pedal pin and the the master cylinder or booster push upper cowl brace and lower the pedal
switch outer hole just clearing the pin. rod, and the bushing on the brake support bracket away from the steer-
Slide the switch completely onto the pedal pin. Position the switch so that ing column studs. I
pin, and install the nylon washer as it straddles the push rod with the 11. R e m o v e t h e pedal support
shown in Figs. 26 and 29. Be careful switch slot on the pedal pin and the bracket assembly from the vehicle.
not to bend or deform the switch. Se-
cure these parts to the pin with the
switch outer hole just clearing the pin.
Slide the switch completely onto the
12. Position the pedal and support
bracket assembly in a vise.
,
hairpin retainer. pin, and install the outer nylon washer 13. Remove the C-clamp to release
4. Connect the stop light switch as shown in Figs. 27 and 30. Secure the clutch pedal from its bumper stop
wires to the connector, and install the these parts to the pin with the self- and p~vot the pedal away from the
wires in the retaining clip. locking pin. bumper.
 . .
Brake System .: . 02-02-26

14. ~ e h o v ethe clutch pedal assist engine oil to the bushing. Remove the 3. lnstall the inner nylon washer,
spring. C-clamp from the clutch pedal. the master cylinder or booster. push
15. On non-power brakes, remove 11. Working from the engine side rod, and the bushing on the brake
the retainer clip from ,the clutch and of the dash panel, on non-power pedal pin. Position the switch so that
brake pedal shaft, then remove the brakes, install the two cap screws at- it straddles the push rod with the
clutch pedal 'and shaft assembly, the taching the pedal support bracketato switch slot on the pedal pin,' and the
brake pedal assembly, and the bush- the dash panel. Then install the two switch out'er hole just clearing the pin.
ings from the pedal support bracket. screws attaching the master cylinder Slide the switch completely onto the
On power bra.kes, remove the retainer to the dash panel. On power brakes pin, and install the outer nylon washer
nut -from the brake pedal shaft .then install the cap screws retaining the as shown in Figs. 27, 28, 30 and 31.
remove the pedal shaft, the brake brake booster to the dash panel. Secure these parts .to the pin :with the
pedal assembly and the bushings from 12. lnstall the steering column. self-locking pin.
the pedal support bracket. Refer to Part 3-4, Section 2 for pro- 4. Connect the stop light switch
cedure. wires to the connector, and install the
Installation 13. Adjust the clutch pedal free wires in the retaining clip.
play (Group 5) to specification, if re- Check the Brake Pedal ~ r e kHeight
quired. and Travel Measurements, Part 2,
1. Apply a coating of S A E 10 en- 14. Check the Brake Pedal Free Section I .
gine oil to the bushings and locate all Height and Travel Measurements
bushings in their proper places on the (Part 2-1, Section I). T H U N D E R B I R D AND
clutch and brake pedal assemblies. 15. Connect the ground cable to the CONTINENTAL MARK 111
2. On non-power brakes, position battery.
the brake pedal to the pedal support . .
bracket, then install the clutch pedal Removal
. .
FA1 RLANE, MONTEGO,
and shaft assembly through the sup- FALCON, MUSTANG
port bracket and brake pedal assem- AND COUGAR- . 1. Loosen the booster mounting
bly. On power brakes position the AUTOMATlC TRANSMISSION . nuts.
brake pedal to the pedal support 2. Disconnect the stop light switch
bracket, then install the pedal shaft wires at the connector.
and nut. Removal 3. Remove the hairpin ,retainer.
3. lnstall the clutch pedal assist Slide the stop light switch off from
spring and pivot the clutch pedal I. Disconnect the stop light sw~tch the brake pedal pin just far enough
against its bumper stop. Secure the wires at the connector. for the switch outer hole to clear the
pedal to the stop with a small C- 2. Remove the self-locking pin and pin, and then l ~ f tthe switch straight
clamp as shown in Figs. 28 and 31. slide the stop light switch off the upward from the pin. Slide the master
4. P o s i t i o n t h e p e d a l s u p p o r t brake pedal pin just far enough for cylinder push rod and the nylon wash-
bracket assembly to the dash panel, the switch outer hole to clear the pin. ers and bushing off from the brake
and to the steering column retainer Then lower the switch away from the pedal pln (Fig. 32).
studs. pin. Slide the master cylinder or 4. Remove the pivot bolt and nut
5. Align the pedal support bracket booster push rod and the nylon wash- that holds the pedal to the pedal sup-
holes with the holes in the dash panel ers and bushing off from the brake port bracket. Remove the brake pedal
and install the two attaching sheet pedal pin (Figs. 27, 28, 30 and 31). assembly from the pedal support
metal screws. On power brakes install 3. On all vehicles except Mustang bracket, ,and remove the bushings.
the nuts on the brake booster studs. and Cougar with power brakes, re-
6. Install the two cap screws at- move the self-locking pin and washer Installation
taching the pedal support bracket to from the brake pedal shaft, then re-
the upper cowl bracket. move the shaft, the brake pedal as-
7. lnstall the cap screw attaching 1. Apply a coating of SAE 10 en-
sembly and the bushings from the
the pedal support bracket to the top gine oil to the bushings and locate all
pedal support bracket. On Mustang
inner cowl bracket (Figs. 28 and 31). the bushings in their proper places on
a n d C o u g a r v e h i c l e s with power
8. Install the inner nylon washer, the pedal assembly (Fig. 32).
brakes, remove the locknut and bolt 2. lnstall the brake pedal assembly
the master cylinder push rod, and the from the pedal. Remove the pedal as-
bushing on the brake pedal pin. Posi- and bushings to the support bracket,
sembly from the support bracket (Fig. and then install the pivot bolt through
tlon the stop light switch so that it
straddles the push rod with the switch 3). the support bracket and brake pedal
slot on the pedal pin and the switch assembly. lnstall the pivot bolt nut
outer hole just clearing the pin. Slide Installation and torque to specifications.
the switch completely onto the pin, 3. Install the inner nylon washer,
and install the outer nylon washer as 1. Apply a coating of S A E 10 en- the master cylinder push rod: and the
shown in Figs. 28 and 31. Secure gine oil to the bushings and locate all bush~ngon the brake pedal pin. Posi-
these parts to the pin with the self- the bushings in their proper places on tlon the switch so that it straddles the
locking retainer. the pedal assembly and pedal support push rod with the switch slot on the
9. Connect the stop light switch bracket (Figs. 27, 28, 30 and 3 1). pedal pin and the switch- outer hole
wires to the connector. 2. Position the brake pedal assem- just clearing the pin. Slide the switch
10. C o n n e c t t h e c l u t c h p e d a l - bly to the support bracket, then install completely onto the pin, install the
to-equalizer rod to the clutch pedal the pedal ,shaft or bolt through the outer nylon washer as shown in Fig.
assembly with the bushing and the support bracket and brake pedal as- 32. Secure these parts to the pin with
spring clip retainer. Apply SAE 10 sembly. Install the retainer or locknut. the hairpin retainer. , , '
 Brake System

4. Connect the stop light switch the support bracket and pedal assem- and remove the cable from the rear of
wires to the connector, and install the bly. Install the pivot bolt nut and tor- the instrument panel. I

wires in the retaining clip. que it to specification. 5. Remove the two nuts attaching
5. Torque the booster mounting 4. Install the inner nylon washer-the the control assembly to the dash
nuts to specifications. master cylinder push rod link, and the panel.
bushing on the brake pedal pin. Posi- 6. Remove the cap screw attaching
Ll NCOLN CONTl NENTAL tion the switch so that it straddles the the control assembly to the cowl side
push rod link with the switch slot on bracket.
the pedal and the switch outer hole 7. Disconnect the hose do the park-
just clearing the pin. install the outer ing brake vacuum unit, i f so equipped.
nylon washer as shown in Fig. 33. In- 8 Remove the front cable assembly
stall the hair-pin type retainer on the retamer clip from the cable assembly
I . ' D i s c o n ~ c t the . battery brake pedal pin. and disconnect the cable ball from the
cable from the battery.
2; It is necessary to obtain' clear-
5. Connect the stop light switch control clevis..
wires to the connector, and install the 9. Remove the control assembly
ance to remove vacuum hoses and'the wires in the retaining clip. from the vehicle.
electrical connector to the temperature 6. Position the wire^ harness and
heat control box. Remove , t h e . two clip on the temperature control box Installation
screws retaining the relay to the fend- and install the retaining screw. Posi-
er and push the'.relay aside. Discon- tion the temperature control box to
nect the vacuum hoses and ,connector the dash panel and install the two re- I. Position the control assembly in
at the heat control box. taining bolts. the vehicle.
3. Working under the instrument 7. Connect the vacuum lines and 2. Fit the cable assembly through
panel, disconnect the vacuuin hoses, the electrical connector to the control its mounting hole and install the re-
wires and retaining clip from the tem- box. Position the wire harness to the taining clip,. Connect the cable ball to
perature heat control box. Remove the control box and install the retaining ,the control clevis.
two screws securing the temperature clip.
3. ,Connect the vacuum hose to the
control box to the dash pan$ 8. Position the wire harness shield parking brake unit, if so equipped.
4. Remove the lower control hous- and install two retaining bolts. 4. Install the attaching cap screw to
ing retaining screws (6). Disconnect 9. Connect the wire harnesses to the cowl side bracket. Do not tighten.
the wire harnesses at the lower control the lower control panel and install the
5. Install the two control assemb-
panel and place .the panel aside. Re- ly-to-dash panel nuts. Tighten the nuts
retaining screws.
move the wire harness shield. Remove 10. W o r k i n g within the engine and the cap screw to specifications.
the wire harness clip. Position the compartment, connect the wire con- 6. Insert the release cable into the
wire harness aside. Remove the tem- instrument panel and install the re-
nector to the temperature heat control
perature control box and position it taining nut.
box.
aside. . , .
11. Position the relay to the fender 7. Install the release knob'
on the
5. Remove the hair-pin type reiain- apron and install the retaining bolts. cable with the roll pin.
er. Slide the stop light switch off the 12. Connect the ground cable to the 8. Check the operation of the park-
brake pedal pin just far enough for, battery. ing brake. Adjust the parking brake
the switch outer hole to clear. the pin. 13. Check the brakes and light as required.
Lift- the switch upward from the pin. switch for proper operation. Close the
Slide the master cylinder push rod, hood. F A I R L A N E , MONTECO
nylon washers and bushing off the AND FALCON
brake pedal pin.
6. Remove the pivot bolt and nut PARKING BRAKE CONTROL I

that holds the pedal to the pedal sup- ASSEMBLY Removal

port bracket. Remove the brake pedal
assembly from the support bracket
Refer to Fig. 35. I ,
and remove the bushings. FORD, M E R C U R Y ' . ,

7. If required, remove the brake 1. Make sure the parking brake is

AND METEOR , .
completely released.
pedal pad retaining nuts and remove
the brake pedal pad.
2. Remove all tension from the rear
1
cables by backing off the jam nut and
, Removal adjusting nut from the equalizer.
Installation 3. Working inside the vehicle, re-
Refer to Fig. 34. move the four' bolts and one nut re-
1. If the brake pedal pad was re- taining the, left air vent and cable as-
moved, position the pad on the pedal. 1. Make sure the parking brake is sembly to the dash and instrument
Install the pad retaining nuts and tor- fully released. panels. Remove the vent assembly.
que them to specification. 2. Remove all tension from the rear 4. Remove the parking brake front
2. Apply SAE 10 engine oil to the cables by backing off the adjusting nut cable ball retaining clip from the clev-
bushings and locate all the bushings in from the equalizer. is.
t h e ~ r proper places on the pedal as- 3. Remove the roll pin that secures ' 5. Disconnect the' cable 'ball from

sembly. the release knob to the cable and re- the notch in the brake clevis.
3. Install the brake pedal assembly move the knob. 6. Remove the three screws that at-
and bushings to the support bracket, 4. Remove the nut that secures the tach the control assembly to 'the left
and then install the pivot bolt through release cable to the instrument panel cowl inner side panel.
- - - - - - - -- - - - - --- -- - . - - - - - - - - - - - - - - - - - - - - - - --- -- - -

BRAKE PEDAL BRACKET CABLE WST BE n ~ n ~

ON -4 CROSSYEIIBER
/
INSTRUMENT PANEL

VIEW z
VACUUM RELEPJE

VIEW X
4

CABLE AND HWSING L.H.

CROSSMEMBER SUSPENSION ARM

INTERMEDIATE CABLE
CONTROL
CQNVERTleLE ONLY
PRONGS MUST BE SECURELY
LOCI(ED IN PLACE WITHIN
BRAKE DRUM
L K W O W R.K TYPICAL
nEw Y
VIEW z
YAHUM RELEASE
HIM-A

FIG. 34 -Parking Brake System-Ford, Mercury and Meteor

 Brake System -

FIG. 35--Parking Brake System-Fairlane, Montego and Falcon

 Brake System

7. Disconnect the wire lead at the 3. Position the parking brake warn-
parking brake warning light switch ing light switch and install the attach-
and remove the control assembly. ing screw. Connect the parking brake
warning light switch wire lead (if vehi-
Installation cle is so equipped). ,
4. Position the cable ball in the
notch in the brake clevis. Refer to Fig. 38.
I. Connect the wire lead to the
parking brake warning light switch.
5. Check the operation of the park- I. Raise the vehicle on a hoist.
ing brake. Adjust the parking brake. 2. Loosen the parking brake cable
2. Position the control assembly to
the cowl inner side panel and install a d j u s t i n g n u t , remove the return
the three attaching screws. spring and remove the cable ball end
3. Connect the ball-end of the park- from the equalizer.
THUNDERBIRD AND
ing brake front cable assembly lo the 3. Lower the vehicle.
CONTINENTAL MARK I11
control assembly, and install the hair- 4. Disconnect the battery.
pin retainer. 5. Disconnect the wire harness con-
4. Position the cable ball in the nector and two vacuum hoses at the
notch in the brake clevis. Removal Automatic Temperature Control box.
5. Position the left air vent assem- 6. Working inside the vehicle, re-
bly to the dash and instrument panels. Refer to Fig. 37. move the windshield wiper control
Install the four bolts and one nut re- knob and ,bezel from the lower control
taining the air vent to the panels. 1. Remove the two nuts retaining panel.
6. Check the operation of the park- the control to the dash panel. 7. Remove the screws retaining the
ing brake. Adjust the parking brake. 2. Remove two screws from the left lower control panel. Lower the control
scuff d a t e . panel and disconnect wire harnesses
MUSTANG AND COUGAR 3. kemove one screw retaining the and vacuum hoses. Position the con-
left cowl trim panel and remove the trol panel aside.
panel. 8. Remove the screw retaining the
Removal 4. Remove the two screws retaining plastic wire cover and place the cover
the left air duct and remove the air aside. 4i
duct. 9. Disconnect three vacuum hoses
Refer to Fig. 36. 5. Remove the two screws retaining and the wiring harness a t the Auto-
the dimmer switch and position the matic Temperature Control box.
1. Make sure the parking brake is switch out of the way. 10. Remove the two screws retain-
completely released. 6. Remove the clip retaining the ing the Automatic Temperature Con-
2. Remove all tension from the rear cable assembly to the control. trol box to the dash panel and remove
cables by backing off the jam nut and 7. Disconnect the cable ball from the box for clearance.
adjusting nut from the equalizer. the control clevis. 11. Disconnect the ball end of the
3. Disconnect the wire lead at the 8. Disconnect the vacuum hose at cable from the control clevis.
parking brake warning light switch (if the brake release. 12. Remove the four bolts retaining
so equipped). 9. Remove the bolt retaining the the control to the dash panel and
4. Remove the parking brake front cpntrol to the cowl side bracket and lower instrument panel flange.
cable ball retaining clip from the clev- remove the control. 13. Disconnect the vacuum release
is. hose from the control and remove the
5. Remove the parking brake warn- control assembly from the vehicle..
Installation
ing light switch and attaching screw (if
so equipped). Installation
6. Disconnect the cable ball from 1. Position the parking brake con-
the notch in the brake clevis. trol in the vehicle.
7. Remove the three screws that at- 2. Install the cable assembly in the 1. Position the control assembly to
tach the control assembly to the left control and connect the cable ball to the dash panel and instrument panel
cowl inner side panel. the control clevis. flange and install the four retaining
8. Pull the control away from the 3. lnstall the clip retaining the screws.
cowl panel. Remove the hair-pin re- cable to the control.' 2. Connect the vacuum release hose
tainer securing the front cable assem- 4. Install the bolt retaining the con- to the control assembly.
bly to the control assembly. Remove trol to the cowl side bracket. 3. Connect the cable ball to the
the control assembly. 5. Connect the vacuum hose to the control clevis.
parking brake release vacuum motor. 4. Position the Automatic Temper-
6. Position the dimmer switch and ature Control box to the dash panel
Installation install the retaining screws. and install the retaining screws.
I
7. Position the air duct and install 5. Connect the wiring harness and
I. Connect the ball-end of the park- the retaining screws. vacuum hoses to the Automatic Tem-
ing brake front cable assembly to the 8. Position the cowl trim panel and perature Control box.
,I control assembly, and install the hair-
pin retainer.
install the retaining screw.
9. Install the two scuff plate screws.
6. Position the plastic wire cove1
and install the retaining screw.
I 2. Position the control assembly to 10.'Install the two nuts retaining 7. Connect the wire harnesses and
the cowl inner side panel and install the control to the dash panel. vacuum lines to the lower control
I the three attaching screws. 11. Adjust the parking brake. panel and position the panel to the in-

I
FIG. 36-Parking Brake System-Mustang a n d Cougar
 PARKING BRAKE
REAR CABLE-2A63S

PARKING BRAKE
REAR CAB/€-ZA635

-IP 2 REQUIRED

FIG. 38 Parking 6 r a k e ' ~ ~ s t ' e r n - ~ i n c o l n Continental

FIG..37-Parking Brake syitem-~hunderbird and 'Continental Mark Ill
 L
02-02-34 , Brake System

strument panel. Install. the ,lower con- THUNDERBIRD A,ND PARKING BRAKE
trol panel retaining screws. CONTINENTAL MARK '111 EQUALIZER TO CONTROL'
8. Install the windshield wipe'r con- CABLE
trol bezel and' knob.
9. Working in the engine compart-
FAIRLANE, MONTEGO
ment connect the' wire harness and Removal . AND
- FALCON : . '
vacuum, hoses. to the.Atitomatic Tem- .' .
~ :
perature Control box. . .
.- Removal
. . .
10. Connect ttie battery cable.
, '

'
Refer to Fig. 37. .
. ,
11. Raise t h e vehicle on a hoist. ,.
1. Partially raise the vehicle. i
12. Connect the cable ball to the 2. Back off the adjusting nut at the
Refer t o Fig. 35.
equalizer and install' the. equalizer equalizer to relieve the tension on the 1. Make'certain the parking brake
lever return spring. : cable. is fully released.
13. Adjust the parking brake cable 3. Remove the spring at the actua- 2. Raise the vehicle on a .hoist. Re-
tension. tor lever and disconnect the control move t h e two nuts that attach, the
14. Lower the vehicle. cable from the clevis o n the, lever. . cable to the equalizer. Remove the
4. Remove the clip retaining. the equalizer, spring seat and spring.
3. Remove the hairpin retainer ' a
control cable assembly to. the frame
bracket. holding the cable assembly to the body
'PARKING BRAKE ACTUATOR- . bracket and remo.ve the cable from
5.. Attach a length of wire to the
TO CONTROL CABLE : . . . the slot in the bracket.
control cable. :
4. Lower the vehicle partially.
6. Working inside ,the vehicle re-
move two screws retaining the left
5. Remove the hairpin retainer
FORD, MERCURY which oretains the cable assembly to
scuff plate. .'..
AND METEOR 7. Remove one screw a n d remove the control.
6. Remove the cable bolt retaining
the left cowl side .trim panel.
. .. . .. 8. Remove the .two screws retaining clip from the control clevis and dis-
the left air duct to the inner panel and connect the cable ball from the clevis.
Removal. ' . '.
. . .
remove the air duct. 7. Pull the cable down through the
9. Remove the two screws retaining opening in the floor pan and frame
1. Raise the vehicle. on a hoist. side rail.
2. Loosen the . actuator, .:lever to
,
the dimmer switch and position the
equalizer cable adjusting nut at the dimmer switch back out of the way.
10. Remove the clip retaining the
Installation
equalizer (Fig. 34). ,: ' . ' . ..- . .
3.' Disconnect the cable. bail from. cable assembly to the control and re-
move the cable ball from the control 1. Route the new cable through
the clevis on the actuator lever. the frame side rail and up through
4. Remove spring clip: that retains clevis.
11. Pull the cable up through the the opening in the floor pan. Pull the
the cable to the frame. cable up into position.
5. From inside of passenger com- opening in the dash panel and remove
the cable from the length of wire. 2. Connect the'cable ball in the con-
partment, remove spring clip that re- trol clevis.
& i n s 'the cable .to the parkink brake . . . ,
3. Insert the cable housing into
control. Disconneot thk cable ball the control and install the hairpin re-
Installation
from the control assembly. - . . tainer.
6. Remove the cabie assembly from 4. Raise the vehicle.
the vehicle. " 1. Attach t h e cable t o t h e lengthof-
. . 'wire and pull the cable down through
5. Position the cable in the body
bracket and install the hairpin re-
the opening in.the dash panel.
.., . ' .
, . . tainer.
.. 2. Position t h e , upper end of the
lnstaliation . , 6. Position the spring,. spring' re-
. .. . . control cable to the, control.. Connect
. tainer and equalizer on the cab.le and
. , . r . the cable ball to the contro!clevis.and "..
i'nstall the two nuts.
1. Po~itibn 'the' cable . through'' the, . install the clip retaining the c a b l e . ;
7. .Adjust the parking brake.'
-0penirigS and in the approxi- , , housing to the control. . .:
mate final installation,,position.. , ; . 3. Remove the length of wire from

,. 2. Install the hairpin retainer'bn the the cable assembly arid position the
'

cable at the frame crossmember. ,.,. . cable in the frame bracket., Install the . .
-3. Connect the ball. en&of the cable . retainer. Removal . ., . .
. .
fo the' barking brake' control. .:Install , ' 4. Connect. the cable. ball to .the ':'
the cable-to-control.,, haifpin retaining . clevis on the actuator lever and install Referto Fig. 36. , .
. .
.clip. . . ' , ,., . .
... ,. . .. ' .., : -the actuator lever spring. . . 1. ,Make certain the parking brake
4. ~ o s i t i d r iih& cable''.'&&,, a t , the . : 5. Adjust the parking brake. , .
. , .
isfully released. . .

dash panel, and slide theretaining clip. . 6 ; ,Reposition the dimmer switch ' 2. Raise the vehicle on a hoist. Re-
upward' 'to seal the, sable' a t the dash , , and install the 'retaining screws. move the. two nuts- that attach. the
,. . . .
o'pening. , . . . 7. Positionthe air.duct to the inner cable to t h e equalizer. Remove ttie
5. Connect the ball end b.f thl cable : panel and install t h e retaining screws. equalizer spring seat and spring., . . , ,

tq'the clevis'on'the actuatdi lever.: - . 8 Position. thecowl side trim panel 3. Remove the, : hairpin . retainer
6. .Adjust the,. .parking . . ,
,brake
.
( P a r t . : . .and: install, the retaining screw. holding' the cable assembly t o ,ihe
2-1, Section 2). . .. .': . . : 9. Install the two screws, in the body bracket and pull the cable o u. t .
. :,.
.. .
7.' Lower vehiile on:$ois.t., . . scuff plate. .. . . of the side rail a c a s s holes. : , ., .. . .
, , . . .
,

. . . .
:
,,
 Brake System

4. Attach a wire to the end of the Installation PARKING BRAKE EQUALIZER

cable to assist in routing new cable. TO REAR WHEEL CABLE
5. Lower the vehicle. I. Route the parking brake control
6. Remove the parking brake front to eq'ualizer cable to the control as-
cable ball retaining clip from the sembly and the equalizer, and install FORD, MERCURY,
clevis. the two bolts that retain the cable METEOR, THUNDERBIRD
7. Disconnect the cable ball from to the dash panel (Fig. 38). AND CONTINENTAL
the notch in the brake clevis. 2. Install the left front fender apron MARK Ill
8: Remove the hairpin retainer and splash shield and the six attaching
' remove the cable assembly from the bolts.
brake control assembly. 3. Lower the vehicle. Removal
9. Pull the cable assembly up through 4. Connect the control cable to the
the opening in the floor and remove clevis on the control assembly. 1. Raise the vehicle and loosen the
the wire from the end of the cable. 5. Raise the car on a hoist. parking brake equalizer rod adjusting
6. Position the supporting clip and nut. Disconnect the equal~zerfrom the
Installation cable on the vehicle and install the rear cables (Figs. 34 and 37).
retaining bolts. Do not tighten the 2. Compress the prongs yn the left
Refer to Fig. 36. bolts. Position the cable armor ap- cable-to-frame side member retainer
1. Connect the wire to the end of proximately 112 inch to the right of so the prong can pass through the
the cable assembly and pull the cable the clip (looking toward the rear of side-member. Remove the clip that at-
down through the opening in the the car) and tighten the retaining taches the left cable to the left lower
floor. Remove the wire. bolts. arm. Pull the cable thru the'frame left
2. Connect the cable assembly to 7. Position the equalizer control .side member.
the brake control assembly and in- cable to the support bracket and in- 3. Compress the prongs on the
stall the hairpin retainer. stall the retaining hairpin clip. right cable-to-frame side member re-
3. Position the ball end of the 8. Connect the ball end of the con- tainer bracket so the prong can pass
cable in the notch of the brake clevis. trol cable to the equalizer lever. through the bracket. Remove the clips
4. Raise the vehicle on a hoist. 9. Adjust the parking brake linkage retaining the right cable to the frame
5. Pull the cable grommet into po- (Part 2- 1, Section 2). , ,a
crossmember.
sitionsand route the cable through 10. Check the operation of the auto- 4. Remove the rear wheel cover and
the access holes in the side rail and matic release mechanism. wheel. Remove the three Tinnerman
under the fuel line. nuts that hold the brake drum in place
6. Insert the cable into the body and remove the drum. I
bracket and install the hairpin re- PARKING BRAKE
5. Working on the wheel 's~deof the
tainer. ACTUATOR-TO-EQUALIZER rear brake, remove the automatic
7. Position the spring, spring seat, CABLE brake adjuster spnng. Compress the
and equalizer on the cable and install prongs on the parking brake cable re-
the two nuts. FORD, MERCURY, tainer so that they can pass through
8. Adjust the parking brake. METEOR, THUNDERBIRD the hole in the brake backing plate.
AND CONTINENTAL Draw the cable retainer through the
M A R K I11 hole.
LINCOLN CONTINENTAL
6. With the spring tension off the
Removal parking brake lever, lift the cable out
Removal of the slot in the lever and r;emove the
II
cable through the backing plate hole.
1. Raise the car on a hoist. dis- Refer to Figs. 34 and 37. I
connect the parking brake cable from 1. Raise the vehicle on a hoist.
the equalizer lever underneath the installation
2. Remove the lock and adjusting
car (Fig. 38). nut which retains the cable to the
2. Remove the retaining clip at the equalizer. 1. Pull enough of the parking brake
cable bracket, and disengage the cable 3. Remove the cable end from the cable through the housing so that the
from the bracket (Fig. 38). equalizer. end of the cable may be inserted over
3. Remove the supporting clip re- 4. Unhook the cable from the act- the slot in the parking brake lever on
I
taining bolts and remove the support uator, and remove from the vehicle. the rear brake shoe.
plate from the underbody. 2. Pull the excess slack from the
4. Lower the car on a hoist. cable, and insert the cable housing
5. With the parking brake in the Installation into the brake backing plate access
fully released position, disconnect the hole so that the retainer prongs ex-
cable at the control assembly. 1. Insert new cable end into act- pand. The prongs must be securely
6. Raise the vehicle on a hoist. Re- uator. locked in place. Install the ,automatic
move* the left front fender apron 2. Insert cable end into equalizer brake adjuster spring.
splash shield retaining bolts and t h e , and tighten the adjusting nut snug. 3. Position the right hand' cable and
splash shield. Install the lock nut. the two retaining clips and screws on
7. Remove the two bolts securing 3. Adjust the parking brake cable the rear crossmember. Compress the
the parking brake control to equaliz- tension and check operation as out- prongs on the right cable and position
er cable bracket to the dash ,panel lined in Part 2- I, Section 2. the cable in the retaining bracket on
and remove the cable from the vehicle. 4. Lower the vehicle. the frame side member. Be sure the
 locating stripe on the cable' is midway brake lever on the brake shoe,and'in- 7. Working on the wheel side of the
between the retaining clips and tighten stall the cable housing retaining grom- backing plate (Fig. 38), compress the
all retaining clip screws. met or steel-pronged Hi-Hat in ,the prongs on the cable retainer so that it
4. Position the left cable, retaining backing plate. can pass through'the hole in the back-
clip and screw on the left lower sus- 4. lnstall the self-adjuster springs. ing plate. Draw the &ble retainer out
pension arm. Compress the prongs on Position the cable housing in the side of the hole. ~

the left cable and position the cable rail bracket and install the hairpin 8. With the spring tension off the
through the frame side-member. The type retainer. parking brake lever, lift the cable out
prongs must be securely locked in 5. Install rear hub and drum as- of .the slot in*the lever and remove it.
place: sembly, wheel and tire assemblies and through the backing plate hole. .
5. lnsert the ball ends of the cables wheel cover as outlined in Section 2.
into the equalizer assembly. 6. Position the cable retainer hooks 'Installation
6. lnstall the rear drum(s) and (station wagon models) in the under-
tighten the three Tinnerman nuts and, body guide (convertible models) and
secure the drum. Install the wheel and install the connector, thus hooking the I. Pull enough of the cable through
tire and the wheel cover. two cables together. the cable housing so that the end of
7. Adjust the .parking brake linkage 7. Insert the cable into the equaliz- the cable may be inseited through the
as outlined in Part 2-1, Section 2. Ad- , er and install the equalizer, spring backing plate hole from the inner side
and engage the cable end with the'slot
just the rear brakes, as' required (Part seat, spring, adjusting nut and lock
2-1. Section 2). nut to the front, parking brake control in the park~ngbrake lever.
cable. 2. Pull the excess slack from the
FA1 RLANE, MONTEGO, 8. Adjust the parking b r a k e q s di- cable and insert the cable housing into
MUSTANG AND COUGAR- rected in Part 2-1, Section 2. the backing plate access hole (Fig.
EXCEPT STATION WAGON 38). The prongs must be securely
F A I R L A N E A N D MONTEGO locked in place.
STATION WAGONS AND 3. Install the brake shoe retracting
FALCON PASSENGER springs.
Removal 4. Position the cable to the u"der-
MODELS
body and install the retaining clamp
I. Remove the equalizer lock nut so that the cable conduit armor ex-
and adjusting nut, equalizer, spring Removal a n d Installation tends forward of the clamp as shown
and spring seat. in Fig. 38. Install the clamp retaining
2. With the cables slack, discon- Refer to Fig. 35. nuts.
nect the ball-ends from the connector G e n e r a l l y follow the procedure 5. Hook the cable housing to the
(Figs. 35 and 36). given above, omitting separation of retainer a t the spring U-bolt.
3. Remove the cable from the re- the cables, since the parking brake 6. Engage the forward end of the
tainer hooks (station wagon models) rear cable assemblies supplied for cable housing with the frame bracket
and the underbody guide (convertible these models is in one piece. Removal and secure it with the hairpin-type
models) if required. and installation of both rear wheels, clip.
4. Remove the hairpin lock retain- tires and drums will also: be .required. 7. Insert the ball end of the cable
ing the cable housing to the side rail into the equalizer.
bracket. LINCOLN CONTINENTAL 8. Make a preliminary brake ad-
5. Remove the wheel cover, wheel justment with the use of Tool HRA-
and tire and the rear brake drum as 8650 (Fig. I I).
outlined in Section 2. Removal 9. lnstall the rear drum. ' ~ i ~ h t d n
6. Remove self-adjuster springs to the three Tinnerman nuts that secure
allow clearance to remove cable re- the drum. lnstall the wheel and wheel
tainer from the backing plate. Discon- I. Raise the car. Remove the rear cover.
nect the rear end of the$cable from the wheel cover. Remove the wheel and 10. Adjust the parkin'g brake link-
parking brake lever on the brake shoe. tire as an assembly. age.
Disengage the .cable housing retaining 2. Remove the three Tinnerman 11. Lower the vehicle.
grommet or steel-pronged Hi-Hat nuts that hold the brake drum in
from the backing plate and withdraw
the cable and housing -from the in-
place, and remove the drum.
3. Remove the brake shoe retract- . . ,~
ANTI-SKID' CONTROL : . "

board side of the backing plate. ing springs. ACTUATOR . , . . : . ... ..

7. Slide the cable and housing out 4. Loosen the equalizer rod adjust-
of the side rail bracket. ing nut and disconnect the cable from
REMOVAL
the equalizer (Fig. 38).
5. Remove the hairpin-type retainer ,
Refer to Fig. 39.
lnrtallation clip that secures the cable housing to
the body bracket, and pull the cable 1. Working in the passenger com-
I. Insert the rear end of the cable and housing out of the bracket (Fig. partment, under the glove box, remote
through the side rail bracket and pull 38). the screw that attaches the forward
the cable and housing into position. 6. Remove the cable to underbody 'end of the control module. retainer to '
2. Insert the rear end of the cable clamp attaching nuts and the clamp. the support assembly. Lower the for-
and housing through the hole in the Disengage the cable housing from the ward end of the control module re-
backing plate from the inboard side. hook-type retainer at the spring U- tainer and remove the. moduleassem- . .
3. Connect the cable to the parking bolt. bly. . . . . . . . . : I
 ...
- . - - - .
. -
VIEW U
. .

FIG. 39-Anti-Skid C o n t r o l System

 2. Disconnect the actuator solenoid through the two holes in the dash 5.. Secure the wiring to the module
and warning switch harness connectors panel from inside the car. Seat the support extension with the retaining
from the control module. wiring harness grommets in the dash strap.
3. Remove the two wiring harness panel.
grommets from the dash panel and 10. Connect the actuator solenoid
push the wiring harness and connec- and brake warning switch wiring har-
tors through the openings in the dash ness connectors to the control mo- ANTI-SKID CONTROL SENSOR
panel. dules.
4. Working in the engine compart- 11. Position the control module in
ment loosen the hose clamp and re- the bracket under the glove box and REMOVAL
move the air hose from the'air filter. install the retaining screw.
5. Remove the engine air cleaner. 12. In the engine compartment con- Refer to Fig. 39.
Loosen the hose clamp and remove nect the air hose to the air filter and 1. Raise the vehicle on a hoist.
the vacuum hose from the vacuum position the hose clamp. 2. Remove the rear wheel and tire
manifold fitting. 13. Connect the vacuum hose to the assembly.
6. Raise the vehicle on a ,hoist. engine vacuum manifold fitting. In- 3. Remove the three Tinnerman
7. Disconnect the exhaust pipes stall the engine air cleaner. nuts (3) and remove the brake drum.
from the exhaust manifold and sup- 14. Bleed the rear brake system and 4. Disconnect the sensor lead from
port with wire to provide access to the centralize the pressure differential the rear wiring harness.
actuator assembly. valve. 5. Unseat the sensor lead grommet
8. Remove the, bolt retaining the 15. Raise the rear wheels. Apply pushing it to the inside of the brake
actuator ground wire to the rear outer the brakes with the rear wheels turn- assembly.
corner of the engine right bank. ing to verify proper operation of the 6. Remove the four nuts that retain
9. Loosen the tube nuts and discon- anti-skid control system. the sensor to the backing plate and
nect the brake system hydraulic tubes pull the axle shaft, sensor assembly
from the hydraulic valve housing. and wheel bearing assembly from the
10. Remove the three nuts retaining ANTI-SKID CONTROL MODULE axle housing.
the actuator assembly to the actuator 7. Press the wheel bearing retainer
support bracket. and wheel bearing off the axle shaft
11. Remove the three bolts that re- REMOVAL (Refer to Part 4-2).
tain the actuator mounting bracket to 8. Remove the sensor assembly and
the side rail and remove the mounting Refer to Fig. 39. press the rotor off the shaft with tool
bracket. 1, Remove the retaining strap hold- T69P-2B384-A Detail 2 and TOOL '

12. Remove the actuator assembly ing the harnesses. 1225-DA.

from the vehicle and place it on a 2. Remove the screw that attaches
bench. the forward end of the control module INSTALLATION
13. Remove the air and vacuum retainei to the support assembly.
hoses from the actuator. 3. Lower the forward end, of the 1. Press a new rotor onto the axle
control module and retainer from the shaft. Install a new sensor assembly
INSTALLATION support assembly; move the module o n t h e s h a f t with tool T69P-
and retainer forward slightly until the 2B384-ADetail I and TOOL 1225-
I. Install the air and vacuum hoses flange clears the slot in the support DA, and press the bearing and bear-
on the new actuator. assembly. ing retainer onto the shaft (Refer to
2. Place the actuator assembly into 4. Disconnect the five wiring har- Part 4-2). *
position under the vehicle, routing the ness plugs from the control module. 2. Insert the axle shaft assembly in
air and vacuum hoses up between the 5. Remove the control module from the rear axle housing onto the four
engine and fender apron and inserting the vehicle. backing plate retaining bolts, feeding ,
the solenoid leads through the holes in the sensor lead through the hole in the
the firewall. INSTALLATION backing plate.
3. Position the ground wire to the 3. Seat the sensor lead grommet in
rear of the engine block and install re- 1. Connect the five wiring harness the backing plate.
taining bolt. plugs to the control module. Only one 4. Install the four nuts on the re-
4. Position the actuator mounting arrangement is possible. taining bolts and tighten to specifica-
bracket to the frame side rail and in- 2. Position the control module in tions.
stall the three retaining bolts., the retainer, orienting the module per 5. Connect the sensor lead to the
5. Position the actuator assembly the markings on it, and insert the re- rear wiring harness and install two re-
to the mounting bracket and install tainer flange into the slot at the rear taining straps.
the three retaining nuts. of the support assembly. 6. Initall the rear brake drum and
6. Connect the hydraulic tubes to 3. Pivot the retainer and control retain with the Tinnerman drum re-
the hydraulic valve assembly and module upward and align the screw taining nuts.
tighten the tube nuts to specifications. hole in the forward end of the retainer 7. Install the rear wheel and tire as-
7. Connect the exhaust pipes to the with the hole in the support bracket sembly and tighten the wheel nuts to
exhaust manifolds. assembly. Install the retaining screw. specifications.
8. Lower the vehicle. 4. Test the vehicle on the hoist to 8. Test the vehicle on the hoist to
9. Pull the actuator solenoid and verify correct operation of the skid verify proper operation of the skid
brake warning switch wiring harness control system. control system.
 I

02-02-39 Brake System 02-02-39

4 M A J O R REPAIR OPERATIONS

is necessary to replace linings, they DUAL MASTER CYLINDER

m w t also be replaced on the wheel on I

Minor scores on a brake drum can the opposite side of the vehicle.
be removed with sandpaper. A drum Inspect brake shoes for distortion, DISASSEMBLY
that is excessively scored or shows a cracks, or looseness. I f this condition
total indicator runout of over 0.007 exists, the shoe must be discarded. D o I. Clean the outside of the master
inch should'be turned down. Remove not attempt to repair a defective brake cylinder and remove the filler cover
only enough stock to eliminate the shoe. and diaphragm. Pour out any brake
scores and true up the drum. The refi- 1. Wash the brake shoes thoroughly fluid that remains in the cylinder. Dis- ,

nished diameter must not exceed 0.060 in a clean solvent. Remove all burrs .card the .old brake fluid.
inch oversize. or rough spots from the shoes. 2. Remove the secondary piston
Check the inside diameter of the 2. Check the inside diameter of the stop bolt from the bottom;of the cyl-
inder (Figs. 40 and 41). '
,
brake drum with a brake drum mi- brake drum with a brake drum mi-
crometer (Tool FRE- 143l). crometer (tool FRE-1431). If the di- 3. Remove the bleed screw, if re-
If the drum diameter is less than ameter is less than 0.030 inches over- quired:
0.030 inch oversize .after refinishing, size, standard lining may be installed. 4. Depress the primary ;piston and I
standard lining may be installed. If If the diameter is 0.030-0.060 inches remove the snap ring from the retain-
the drum diameter is 0.030-0.060 oversize, oversize lining should 'be in- ing groove at the rear of ,the master
inch oversize after refinishing, oversize stalled. cylinder bore. (Fig. 42). Remove the
lining must be installed. 3. Position the new lining on the push rod and the. primary; piston as-
After a drum is turned down, wipe shoe. Starting in the center, insert and sembly from the master cylinder bore.
the refinished surface with a cloth secure the rivets, worklng alternately D o not remove the screw that retains
soaked in clean denatured alcohol. If towards each end. Replacement lin- the primary return spring retainer, re-
one drum is turned down, the opposite ings are ground and no further grind- turn spring, primary cup and protec-
drum on the same axle should also be ing is required. tor on the primary piston. 'This assem,
cut down to the same size. 4. Check the clearance between the bly is factory pre-adjusted and should
shoe and lining. The lining must seat not be disassembled.
tightly against the shoe with not more 5. Remove the secondary piston as-
ROTOR R E F I N I S H I N G
than 0.008 inch clearance between any sembly. D o not remove the ;outlet tube
two rivets. ,seats, outlet check valves ,and outlet
Rotunda Disc Brake Attachment,
FRE-2249-2, is the only recommended
tool to refinish the disc brake rotors.
The step-by-step resurfacing procedure RETAINER - 28245
provided wlth the tool must be ad-
hered to.
The finished braking surfaces of the
rotor must be flat and parallel within COVER - 2166
0.0007 ~ n c h ;lateral runout must not /GASKET-2167 '

exceed 0.003 inch total indicator read- SECONDARY SYSTEM

BRAKE OUTLET
ing, and the surface finish of the brak-

ifd
Ing surfaces are to be 80/15 micro f l / / BOOT
Inches. The minimum limiting dimen-
slons (Figs. 1 1 and 12, Part 2- 1) from
the Inboard bearing cup to the out- 0 PUSH ROD

board rotor face and from the inboard t

RETAINER
bearing cup to the inboard rotor face
must be observed when removing ma-
terial from the rotor braking surfaces.
On all models except Lincoln Con-
tinental, the limiting dimensions are to
be measured with a ball and gage bar
' I I
(Rotunda Kit FRE-70160).
\ / PISTO; STOP
-
BOLT 2A5 1 1
O-RING - 87002.593
SPRING
- .. .
PRO?;~TOR

'
'PRIMARY PI
ASSEMBLY -
S E C O N D ~ R YPISTON,
-
ASSEMBLY 2A502
:
BRAKE S H O E R E L I N I N G
TUBE-SEAT -
t 20220
Brake linings that are worn to wit,,-
with- NOT USED ON POWER B R A K E ECUIPPED VEHICLES
in 1/32 inch of t&,.rivet head or are NOT SERVICED
'REPLACE AS AN ASSEMBLY ONLY
less than 0.030 inch thick (bonded lin-
ing) or have been contaminated "with
brake fluid, grease or oil must be re- H 1499.8
placed. Failure to replace worn linings
will result in a scored drum. When i t FIG. 40-Dual Master Cylinder Disassembled-Except Disc Brakes
02-02-40 Brake System 02-02-40

open and free of foreign matter. Use

an air hose to blow out d i r t and clean-
ing solvent. Place all parts on a clean
pan or paper.
3. Inspect the master cylinder bore
for signs of etching, pitting, scoring or
rust. I f i t is necessary to hone the
master cylinder bore to repair dam-
age, do not exceed allowable hone
specifications.

ASSEMBLY

I. D i p a l l parts except the master

cylinder body i n clean Rotunda Extra
Heavy Duty Brake Fluid.
2. Careflilly insert the complete
secondary piston and return spring as-
sembly i n the master cylinder bore.
3. Install the primary piston assem-
bly i n the master cylinder bore.
4. Depress the primary piston and'
install the snap ring i n the cylinder
bore groove.
5. Install the push rod, boot and re-
tainer on the push rod, i f so equipped.
Install the push rod assembly into the
primary 'piston. M a k e sure the retain-
er is properly seated and holding the
push r o d securely.
6. Position the inner end o f the
FIG. 41-Dual M a s t e r C y l i n d e r Disassembled-Disc rakes push rod boot (if so equipped) i n the
check valve springs f r o m the master master cylinder body retaining groove.
cylinder body. 7. Install th6 secondary piston stop

INSPECTION A N D REPAIR CUTER SHOE

INNER BRAKE RETAINING CLIPS
SHOE AND LINING 2066
ASSEMBLY-2019 L
I.Clean all parts i n clean isopropyl
alcohol, and inspect the parts for
'chipping, excessive wear or damage.
I OUTER BRAKE
SHOE AND LINING
ASSEMBLY-POI8

When using a master cylinder repair

kit, install all the parts supplied.
2. Check all recesses, openings and STABILIZER
internal passages to be sure they are

Snq, Ring P l i e r s

-0CATING PIN

JQ
-.
CLIP
28164
n1m-c
FIG. 42 -Removing Snap FIG. 43--Caliper Assembly-Disassembled-
Ring-Typical A l l M o d e l s Except Lincoln C o n t i n e n t a l
. .
 Brake System

bolt and.0-ring in the bottom of the caliper, tap lightly around the piston 1. Remove the caliper assembly
master cylinder. while applying air pressure. Care from the car as outlined in Section 2.
8. Install the bleed screw (if so should be taken because the piston 2. Remove the two attaching bolts
equipped). Install the gasket (dia: can develop considerable force due to and the caliper splash shield (Fig. 46).
phragm) in the master 'cylinder filler pressure build-up. 3. Remove the two shoe. and lining
cover. Position the gasket as shown in 7. Remove the dust boot from the assemblies.
Figs. 40 and 4 1. Make sure the gasket caliper assembly. 4. Remove the flexible brake hose
is securely seated. 8. Remove the rubber ;iston seal from the caliper.
9. install the cover and gasket on from the cylinder and discard it. 5. Remove the external trans'fer
the master cylinder and secure the tube.
cover into position with the retainer. Cleaning a n d Inspection 6. Remove the four dust boots from
the caliper housings and piston
grooves.
Clean all metal parts with isopropyl 7. Clamp the caliper in la vise and ,
alcohol or a suitable solvent. Use 'secure it by the mounting flanges on
clean, dry, compressed air to clean out the inboard housing (.Fig. 45).
ALL MODELS EXCEPT and dry the grooves and passage ways.
Be sure that the caliper bore and com-
8. Remove the four pistons from ,
LINCOLN CONTINENTAL the cylinder bores with the 'special tool
ponent parts are completely free of shown in Fig. 45. T o prevent cocking

Disassembly
any foreign material.
Check the cylinder bore and piston
with consequent damage to the piston
or bore, rotate the piston with the tool
,
for damage or excessive wear. Replace while pulling it outward at the same
the piston i f it is pitted, scored, or the time. Be careful to avoid scratching or
1. Remove the caliper assembly chrome plating is worn off.
from the vehicle as outlined in Section damaging the outside diamktei surface
or dust boot retaining grooke of the
2.
2. Remove the caliper locating pins Assembly piston. Such damage causes poor seal-
from the caliper assembly and lift the ing.
anchor plate from the caliper. 1. Apply a film of clean brake flu~d If a piston is so completely seized In
3. Slide the two outer shoe retain- to the new caliper piston seal and in- the cylinder bore that it can not be rc-
ing clips off the retaining pins (Fig. stall it in the cylinder bore. Be sure moved with the special tool, the cali-
43). the seal does not become twisted and per housing must be replaced, by posi-
4. Remove the two retaining pins, that it is seated fully in the groove. tioning two screwdrivers in the piston
then remove the outer brake shoe 2. Install a new dust boot by setting dust boot retaining groove jand prying
outward. T o prevent cocking, tap the
,
from the caliper. the flange squarely in the outer groove
5. Slide the inner brake shoe out- of the caliper bore. end of the piston lightly around the
ward until it is free of the hold-down 3. Coat the piston with the speci- circumference with a ham,mer, while
springs, then remove the brake shoe. fied fluid and install the piston in the the prying force is being Gpplied. Be
6. Apply air pressure to the fluid cylinder bore. Spread the dust boot careful to .avoid damaging the dust
port in the caliper with a rubber over the piston as it is installed. Seat boot retainer in the caliper housing ,
tipped nozzle (Tool 7000-DD) as the dust boot in the piston groove. (Fig. 46). I f this method or; removal is I

shown in Fig. 44 to remove the piston. 4. Position the inner brake shoe so used, the pistons must be replaced.
Place a cloth over the piston before that the ears of the shoe rests on the I f the caliper dust boot ,retainer or ,

applying air pressure to prevent dam- top of the anchor plate bosses and .be- r e t a i n i n g g r o o v e is d a m a g e d o r i
'
age to the piston. If the piston is neath the hold-down springs. scratched, pry the retainer out of the
seized and cannot be forced from the 5. Install new caliper locating pin caliper housing with screwdrivers.. I
I
insulators in the anchor plate.
6. Position the caliper on the an-
chor plate.
7. Apply water or isopropyl alcohol
to the caliper locating pins and install
them loosely in the anchor plate. Be
sure the guide pins are free of oil,
grease or dirt.
8. Install the caliper on the spindle
as outlined under Disc Brake Caliper
Assembly.

LINCOLN CONTINENTAL
CALIPER

Disassembly

Do not remove the bridge bolts that

hold the two halves of the caliper to-
FIG. 4 4 -Removing Piston Fiom gether. The two caliper housings are
Coliper-All Models Except, shown separated in Fig. 46 for illus- FIG. 45--Removing o r Instolling
Lincoln Continental tration purposes only. Pistons-Lincoln Continental
I
1 02-02-42 Brake System 02-02-42
I .
CALIPER ABUTMENTS t o new caliper piston seals and install
them i n the grooves o f the cylinder
OUTBOARD CALIPER HOUSING
bore. T h e seal should be positioned at
one area i n the groove and gently
PISTON S E A L ( A )
DUST BOOT RETAINING GROOVE worked around. D o not use the origi-
CXTERNAL nal seals.
TRANSFER TUBE 3. Install the new dust boots by set-
OUST t i n g the flanges squarely i n the outer
grooves of the caliper bores.
4. C o a t the pistons w i t h the speci-
fied fluid and install the pistons i n the
cylinder bores. Spread the dust boots
over the pistons as they are installed.
Seat. the dust boots i n the piston
grooves.
SHOE A N 0 LINING ASSEMBLIES
5. C o a t the outside diameter o f t h e .
pistons w i t h brake fluid and install
them i n the cylinder bores so t h a t the
open end of the piston and the boot
0 retaining groove face out o f the bore.
T o avoid cocking, locate the piston

9BRIDGE BOLTS
INBOARD CALIPER HOUSING
squarely i n the bore and apply a slow
steady pressure. I f a piston w i l l not
easily g o a l l the way i n t o the bore, re-
niove i t and thoroughly inspect the
cylinder bore, the piston seal and the
installation o f the seal. I f the piston
still w i l l not go i n w i t h bore i n good
condition and the piston seal properly
installed, use the tool shown i n F i g .
45. Rotate the piston with the tool
FIG. 46 - C a l i p e r Assembly-Disassembled-Lincoln Continental
while pushing i t inward at the same
time.
9. Remove the rubber piston seals 6. Carefully install four new dust
bore and component parts are com-
f r o m the grooves i n the cylinder bores boots o n the caliper housings and pis-
pletely free o f any foreign material.
by carefully inserting the point o f a tons. Be sure that each boot is fully
Check the cylinder bores and pis-
small knife o r other pointed instru- seated i n the groove o f its respective
tons f o r damage o r excessive wear.
ment under the seal and raising the caliper housing and piston (Fig. 46).
Replace the piston i f i t is pitted.
seal u p far enough t o be pulled out
Do not use the original dust hoots.
scored, or the chrome plating is w o r n
with the fingers. 7. Install the external transfer tube.
off. Check the caliper dust b o o t re-
tainer for wear or damage.
8. Install the flexible brake hose t o
the. caliper.
C l e a n i n g a n d Inspection 9. Install the caliper assembly on
.Asse r n bly the spindle. and install the shoe and
Clean a l l metal parts with isopropyl lining assemblies and the splash shield
alcohol or a suitable solvent (Fig. 46). I. C l a m p the caliper i n a vise and as outlined i n Section 2. Check the
Use clean, dry, compressed air t o secure i t by the m o u n t i n g flange on caliper for f l u i d leaks under m a x i m u m
clean out and d r y the grooves and the inboard housing. pedal pressures. D o not move the car
passage ways. Be sure that the caliper 2. A p p l y a f i l m o f clean brake fluid until a firm brake pedal is ohtained.
02-03-0 1 Specifications
I
02-03-01
!

PART 2-3.Specifications '

LINING DIMENSIONS -DRUM BRAKES -INCHES

Vehicle Position Front ( Rear
FORD, MERCLIRY, METEOR
Ford, Meteor Passenger (RiveteC Primary 2.50 x 9.34 2.25 x 9.34
Lining) Except 390, 429 CID
Galaxie 500XL, Ford LTD, LeMoyne. Secondary 2.50 x 12.12 2.25 x 12.12
Ford, Mercury, Meteor with O i x Primary N/A 2.25 x 9.34
Brakes. Secondary N/A 2.25 x 12.12
Mercury Passenger, Sta. Wag. and *
I
Conv. Ford Meteor Station Wagon Primary 3.00 x 9.34 2.25 x 9.34
and Convertible. 390, 429 CID
Galaxie 500 XL, Ford LTD, LeMoyne. . Secondary 3.00 x 12.12 2.25 x 12.12
Ford, Meteor 240, 302 CID Taxi
Only (Bonded Lining) Max. Wear Pr~mary 3.00 x 9.34 2.50 x 9.34
Resistance. Secondary 3 OOx 12.12 2.50 x 12.12
MONTEGO, FAIRLANE I
Passenger 250, 302 CI D Except Primary 2.25 x 8.43 2.00 x 8.43
Convert~ble Secondary 2.25 x 10.82 2.00 x 10.82
Station Wagon, Ranchero and . I
Convert~ble250, 302 CI D. Pr~mary 2.50 x 8.43 2.00 x 8.43
I
Passenger and Convertible
351, 390, 428 CI D. Secondary 2.50 x 10.82 2.00 x 10.82
Station Wagon and Ranchero 351, Primary 2.50 x 8.43 2.50 x 8.43
390,428 CI D. Secondary 2.50 x 10.82 2.50 x 10.82
FALCON
Sedan 6-Cylinder. Primary 2.25 x 7.62 1.50 x 7.62
Secondary 2.25 x 9.77 1.50 x 9.77
Station Wagon 6-Cylinder. Pr~mary 2.50 x 8.43 2.00 x 8.43
- Secondary 2.50 x 10.82 ' 2.00 x 10.82
Sedan 8-Cylinder. Pr~mary 2.25 x 8.43 2.00 x 8.43
Secondary 2.25 x 10.82 2.00 x 10.82
Station Wagon 8-Cylinder. Primary 2.50 x 8.43 2.00 x 8.43
Secondary 2.50 x 10.82 2.00 x 10.75
MUSTANG, COLIGAR I
200 Cl D Engine. Primary 2.25 x 7.62 1.50 x 7.62
Secondary 2.25 x 9.77 1.50 x 9.77
250, 302 CI D Engines. Primary 2.25 x 8.43 ' 1.175 x 8.43
Secondary 2.25 x 10.82 1.175 x 10.82
351, 390, 428 Cl D Engines. Primary 2.50 x 8.43 2.00 x 8.43
Secondary 2.50 x 10.82 2.00 x 10.82
THUNDERBIRD, CONTINENTAL MARK Ill I
Primary N/A 2.25 x 9.34
Secondary NIA 2.25 x 12.12
1
LINCOLN CONTINENTAL
Primary N/A 3 . 0 0 ~9.39
i
Secondary N/A 3 . 0 0 ~12.21
Wear Limits Riveted: 1/32 inch f rom to^ of rivets. I
Bonded: 0.030 inch total lining thickness.
I BORE DIAMETERS-BRAKE DRUM, WHEELCYUWDER AND MASTER CYLINDER
I Brohe Drum' .
' Whe'el Qli'nder Bore Dia. Master Qlinder.Eore Dia:
0

I Models Inside Boring Limit With Power Less w ~ r

I Diameter (ha) @ ~ r o n t0 1.11 0 B r i b e B~~~:@
: Ford, Taxi and Station Wagon 11.030 11.090 1.094 0.938 1.000 1.000
I Mercury
I and - >

I Meteor Other 11.030 11.090 1.125 ' 0.938 1.000 l.Ob0

' Montego
Pass. except Conv. 250, 302 CID Engines

Pass. and Conv. 351, 390, 428 ClD Eng.

10.000

10.000
10.060

10.060
1.125

1.094
0.875

0.875
0.9375

0.9375 '
1.000
1.000 .
and
Convertible 250, 302 ClD Englnes 10.000 10.060 1.094 0.875 0.9375 1.000
1 Fair lane
Station and Ranchero , 10.000 10.060 1.094 0.938 0.9375 1.000,,
I
I -
9 Inch Brake Passenger Car 9.000 9.060 1.062 9 0.8440 0.9375 , 1.000
I Falcon -
10 Inch Brake Station Wagon 10.000 . 10.060 1.094 0.938 0.9375 1.000
1 10 Inch Brake - Passenger Car 10.000 10.060 1.125 0.875 0.9375 1.000
11 Mustang
200 CID Engine
351, 390J 428 CIO Engine
9.000
10.000
9.060
10.060
1.062 0
1.094
0.8440
0.875
1.000
1.000
1.000
1.000
and Cougar 1.000
I 250, 302, CID Engine 10.000 10.060 1.125 0.875 1.000 '
1 Thunderbird
Continental Mark Ill
11.030
11.030
11.090
11.090
N/A
N/A
0.938
0.938
1.000
1.000
N/A
N/A
1
/
1
Lincoln Continental
@Max. Runout 0.007
11.090 11.130 N/A 0.938 1.000 NIA
@Front Wheel Cylinder cannot be honed on Falcon or Mustang with 9 inch Brakes.
1 @Max. Allowable Hone 0.003
02.755 For Ford, Mercury, Meteor with Disc Brakes.
2.381 For Fairlane, Montego, Falcon, Mustang, Cougar with Disc Brakes.
I SHOE AND LlNlWG DIMENSIONS-

CALIPER CYLINDER BORE DlaWlETER -INCHES TORQUE LIMITS-HUB TO SPINDLE

Ford, Mercury, Meteor, Thunderbird, Continental Mark 111 2.755 Description Ft-Lbs
Mustang, Cougar, Falcon, Fairlane and Montego 2.381 Hub and Drumor Rotor Assembly t o Rotatehubwhile torquing
I Lincoln Continental 1.938 1 Front Wheel Spindle t o 17-25 ft-lbs. Back off
the adjusting nut 112turn
and retighten t o 10.15
inch pounds while rotat-
Ing wheel Selectively posi-
tion nut retainer on ad-
justing nut so that a set
ROTOR DlMEsJSlOWS of slots are i n line with
Wom. Diameter cotter pin hole. Adjusting
nut should not be rotated
Car Line Thickness I
Outside Inside i n this operation. Lockad-
Ford, Mercury, Meteor 1.180 11.72 1 7.785 lusting nut andnut retain-
I Thunderbird, Continental Mark Ill 1.180 . 1
I
11.72 I1 7.785 1 er with cotter pin so that
the cotter pin end does
Fair lane, Falcon, Montego, Mustang not interfere with seatinp
and Cougar ' , 0.935 11.29 7.355 of wheel static collector
1 Llncoln Continental 1 1.240 i n spindle hole.
02-03-03 Specifications 02-03-03

ROTOR REFINISH
I The following requirements must be met when resurfacing disc
brake rotors:
On all models except Lincoln Continental the limiting dimen-
sion from the inner bearing cup to the'inner rotor face must be
'
Rotunda Oisc Brake Attachment FRE-2249-2 is the only approv- measured with a ball and gage bar (Rotunda FRE-70160).
ed tool t o -be used t o refinish the disc brake rotors. The step-by- On Lincoln Continental models the limiting dimension from the
step resurfacing procedure provided with the tool must be adhered inboard hearing cup t o the inboard rotor face of 0.755 inch mini-
to. mum and from the inboard bearing cup t o the outboard rotor face
The finished braking surfaces of the rotor must be flat and of 0.395 inch minimum must be observed.
parallel within 0.0007 inch; lateral runout must not exceed 0.003
Inch total indicator reading, and the surface finish of the braking
surfaces are to be 15.80 micro Inches.

TORQUE LIMITS -GENERAL -FT-LBS '

Fair lane. Thunderbird
Ford-Mercury Montego Mustang- Cont inental Lincoln
Meteor Falcon Cougar Mark Ill Continental
Parking Brake Control Assembly - Cap Screw 12-25 ' 12-25 12-18 Dash Panel
Mounting Nuts and Bolts 12-19 10.20
Inst. Panel
, a Nuts 7-11 7-12
Master Cyl~ndert o Oash Panel Screw 13.20 1520 1520
Master Cylinder to Booster 13-20 13-20 13-20 13-20 13-20
Booster to Dash Panel 13-20 13-20 13.20 13-20 13-20
Upper O Upper O Upper O Upper O
Disc Brake Caliper t o Spindle Bolts 110-140 100- 140 100-140 110-140 100-140
Lower Lower Lower Lower
90-120 55.75 55- 75 90-120
Oisc Brake Rotor Splash Shield
to Spindle 9-14. 9.14 9-14 9-14 9.14
Brake Hose to Callper Connect~onBolt 17.25 17-25 17-25 17-25 -

Callper Locating Pins 25- 35 25-35 25- 35 25- 35

Caliper Stablllzer to Anchor Plate
Bolt 811 8-11 8.11 8-11
Caliper Brake Shoe Cl~ps 6-10 6- 10 6-10 6-10 7.9
Caliper Bleeder Screws 6-15 6-15 6-15 6 15 6-15
10 in. Brake 10 in. Brake
Wheel Cylinder t o Backing Plate Screws 10-20 10-20 10-20 10.20 10-20
9 in. Brake 9 ~ n .Brake
5- 7 5- 7
Wheel Cylinder & Back~ngPlate
Anchor Pin Nut 20-30
Rear Brake Backlng Plate t o Axle
Housing. Removable Carr~er 50-70 50-70 50- 70 50- 70 30-35
Integral Type 20-40 . 20-40 20-40
Front Brake Backing Plate t o Spindle 25-40 2835 2 8 35
32-65 0 32.65 0
Wheel Cylinder Bleeder Screw 6-15 Inch-lb. Inch-lb. 6.15 6-15 I
I
Brake Hose Connection t o Front
Wheel Cylinder 12-20 12-20 12-20
Brake tine Connection to Rear Axle
Housing. Removable Carrier
:
30-40 12-19 12-19 30- 40
Integral Type 25-35 12- 19 12-19
Hydraulic Tube Connections Q
318 x 24 10-15 10-15 10-15 10-15 10.15
7/16 x 24 10-15 10-15 10-15 10-15 10-15
112 x 20 10-17 10-17 10-17 10-17 10-17 I

9/16 1 18 10-17 10-17 10-17 10-17 10-17

4 lug 4 lug
Wheel t o Hub and Drum or Hub and I
55-85 55- 85
Rotor Nuts 70-115 5 lug 5 lug 70-115 70.115
70-115 70-115

@On front disc brake calipers 6-15 ft-lbs.

@All hydraulic lines must be tightened to the specified torque value and be free of f l u ~ dleakage.
 I

i 02-03-04 Specifications 02-03-04

1 SERVl CE TOOLS
Ford Tool No. Former No. Description
I
Rotunda HRE 8650 Brake Adjusting Gage
i LM 119 Brake Cylinder Retaining
Clamp
2018-A , Brake Adjusting Tool
2162 Adapter Cap
2035N Brake Shoe R & R Spring
Tool 7000-00 Rubber Tipped Air Nozzle
Rotunda 70160 Ball and Gage Bar
Tool 33621 33621 Internal Snap Ring Pliers
Milbar
1 I
I
1
I -- 4 -2 -3 5 4
Tool
Rotunda FRE 1431
1,
1112-144
4235-C I
I
I
Inch Pound Torque Wrench
Axle Shaft Remover
Brake Drum Micrometer
II J 22742 (Kent Moore) I Bleeder Valve Clip Spring
I
Rotunda FRE 22492 I I Disc Brake Rotor Attachment
I
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