Ford - Cougar - Workshop Manual - 1969 - 1969

GROUP INDEX 1969 CAR SHOP MANUAL VEHICLE IDENTIFICATION BRAKES SUSPENSION, STEERING WHEELS AND TIRES REAR AXLE MANUAL SHIFT TRANSMISSION AUTOMATIC TRANSMISSION WHEELS and TIRES, SUSPENSION, STEERING, BRAKES, CLUTCH and TRANSMISSION, REAR AXLE M FIVE FIRST PRINTING-NOVEMBER, 1968 © 1968 FORD MOTOR COMPANY, DEARBORN, MICHIGAN 4 DRIVE SHAFT AND CLUTCH VOLUME ONE CHASSIS SERVICE PUBLICATIONS 2 SPECIFICATIONS AND SPECIAL SERVICE TOOLS AT END OF EACH GROUP 6 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 The five volumes of this shop manual provide the Service Technician with complete information for the proper servicing of all the 1969 line of Ford Passenger Cars. The information is grouped according to the type of work being performed, such as frequently performed adjustments and repairs, invehicle adjustments, major repair, etc. Specifications, maintenance information and recommended special tools are included. The descriptions and specifications in this manual were in effect at the time this manual was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design, without notice and without incurring obligation. SERVICE PUBLICATIONS GENERAL 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. 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. 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 reference numbers. For Example: Page 03-02-01 will appear in the Part Index as 02-01. Each Part will start with Page 01. 01-01-02 01-01-02 Vehicle Identification VEHICLE WARRANTY NUMBER COUGAR The vehicle warranty number is the first line of numbers and letters appearing on the Warranty Plates (Fig. 1). The Warranty Plate is riveted to the left front door lock face panel. The first number indicates the model year. The letter following the model year number indicates the manufacturing assembly plant. The next two numbers designate the Body Serial Code followed by a letter expressing the Engine Code. The group of six digits remaining on the first line indicate the Consecutive Unit Number. Body Body Serial Style Code Code Model Body Type 91 92 65A 76A 2-Door Hardtop© Convertible© Standard 93 94 65B 76B 2-Door Hardtop© Convertible® XR-7 Luxury VEHICLE DATA 91 65C 2-Door Hardtop® Standard The vehicle data appears on the second or lower line on the Warranty Plate. The first two numbers and a letter identify the Body Style. A letter or a number appears next indicating the Exterior Paint Color followed by a number-letter combination designating the Interior Trim. To the right of this code appears the Date Code indicating the date the car was manufactured. A twodigit number next designates the district in which the car was ordered and may appear in conjunction with a Domestic Special Order or Foreign Special Order number when applicable. The final two spaces indicate the Rear Axle Ratio (numbers for regular axles, letters for locking-types) and the Transmission type (numbers for manual, letters for automatic). ® Bench Seat OFFICIAL VEHICLE IDENTIFICATION NUMBER The official Vehicle Identification Number (VIN) for title and registration purposes is stamped on an aluminum tab that is riveted to the instrument panel close to the windshield on the driver's side of the car and is visible from outside (Fig. 2). MODEL YEAR CODE The number 9 designates 1969. ASSEMBLY PLANT CODES Code Letter A B C D E F G H J K Code Letter ., Atlanta Oakville (Canada) Ontario Truck Dallas Mahwah Dearborn Chicago Lorain Los Angeles Kansas City L N P R S T U W X Y Z Michigan Truck Norfolk Twin Cities San Jose . (Pilot). ...Allen Park Metuchen Louisville Wayne St. Thomas Wixom St. Louis ©Split Bench ©Bucket Seats MERCURY Body Body Serial Style Code Code Model Body Type Monterey 44 46 48 45 54A 65A 57A 76A 4-Door Sedan© 2-Door Hardtop-Formal® 4-Door Hardtop® Convertible® 40 41 42 53M 65M 57M CANADA ONLY 4-Door Hardtop Sedan® 2-Door Hardtop-Formal® 4-Door Hardtop® 54 56 58 54C 65B 57B 4-Door Sedan® 2-Door Hardtop-Formal® 4-Door Hardtop® Monterey-Custom 63 66 68 65 53F 65F 57 F 76F 4-Door Hardtop Sedan®© 2-Door Hardtop-Formal®© 4-Door Hardtop®® Convertible®® Marquis 63 66 68 53C 65C 57C 4-Door Hardtop Sedan© 2-Door Hardtop-Formal© 4-Door Hardtop© Brougham (Option) 60 61 63G 63H 2-Door Hardtop (Tunnel Roof)®© Marauder 2-Door Hardtop (Tunnel Roof)®®© 72 72 71B 71C 4-Door 2 Seat® 4-Door 3 Seat (Side Facing)® Monterey Wagoi 74 74 71F 71G 4-Door 2 Seat® 4-Door 3 Seat (Side Facing)® Monterey-Custom Wagon 76 76 71E 71A 4-Door 2 Seat®© 4-Door 3 Seat (Side Facing)®© Marquis Colony Park ©Bench Seat ©Split Bench Marquis ©Bucket Seats METEOR (CANADA) BODY SERIAL AND STYLE CODES The two-digit numeral which follows the assembly plant code identifies the body series. This two-digit number is used in conjunction with the Body Style Code, in the Vehicle Data, which consists of a two-digit number with a letter suffix. The following chart lists the Body Serial Codes, Body Style Codes and the model. LINCOLN CONTINENTAL Body Body Serial Style Code Code 82 80 53A 65A Body Type 4-Door Sedan 2-Door Hardtop CONTINENTAL MARK III Body Body Serial Style Code Code 89 65A Body Type 2-Door Hardtop Body Body Serial Style Code Code Body Type Model 20 54A 4-Door Sedan® Rideau 21 23 54B 65B 4-Door Sedan® 2-Door Hardtop-Formal® Rideau 500 30 35 35 33 34 34 54C 65C 65E 57C 76C 76E 4-Door Sedan® Montcalm 2-Door Hardtop-Formal® 2-Door Hardtop-Formal{5-33)®® 4-Door Hardtop® Convertible® Convertible (S-33)®® 24 27 65F 57F 2-Door Hardtop-Formal®© 4-Door Hardtop®® LeMoyne 28 29 38 39 71B 71C 71E 71A Rideau 500-6 Passenger® Rideau 500-Dual Face Rear® Mo ntcalm-6 Passenger® Montcalm-Dual Face Rear® Station Wagons. ©Bench Seat ©Splite Bench ©Bucket Seats 01-01-03 Vehicle Identification 01-01-03 BODY SERIAL AND STYLE CODES-(continued) MONTEGO MUSTANG Body Body Serial Style Code Code Model Body Type 02 54A 2-Door Hardtop-formal (Sports Coupe)® 4-Door Sedan (Sports)® 06 07 54B 65B 4-Door Sedan® 2-Door Hardtop-Formal® Montego 10 11 12 54D 65D 76D 4-Door Sedan® 2-Door Hardtop-Formal® Convertible® Montego MX 11 12 65 E 76B 2-Door Hardtop-Formal© Convertible® Montego MX 10 11 54C 65C 4-Door Sedan® 2-Door Hardtop-Formal® Montego MX Brougham 15 63A 01 15 16 65A Comet 2-Door Hardtop Fastback® (GT Appearance Opt.®) 63C 2-Door Hardtop Fastback® 63H 2-Door Hardtop Fastback® (Sports Appearance Opt.©) 03 08 08 71B 71C 71A ©Bench Seat Montego® Montego MX® Montego MX (Woodgrain)® ©Split Bench Body Body Serial Style Code Code Body Type Model 01 02 03 65A 63A 76A 2-Door Hardtop©© 2-Door Fastback©® Convertible®® Standard 01 02 03 65B 63B 76B 2-Door Hardtop®® 2-Door Fastback®© Convertible©® Luxury 01 65C 2-Door Hardtop® Standard 01 65D 2-Door Hardtop® Luxury 01 65E 2-Door Hardtop© Grand 02 63C 2-Door Fastback® Machl ©Bench Seat ©Split Bench ©Bucket Seats ©Hi-Back Bucket Cyclone Cyclone CJ Station Wagons-4 Door FORD Body Body Serial Style Code Code ©Bucket Seats Model Body Type 50 51 62E 54 E 2-Door Sedan® 4-Door Sedan® Custom 52 53 62B 54B 2-Door Sedan® 4-Door Sedan® Custom 500 54 55 58 56 57 54A 4-Door Sedan® 63B 2-Door Hardtop-Fastback® 65C 2-Door Hardtop-Formal® 57B 4-Door Hardtop® 76A Convertible® 60 61 63C 76B 2-Door Hardtop-Fastback®® Convertible®© Ford XL 64 62 66 54C 65A 57F 4-Door Sedan®® 2-Door Hardtop-Formal®® 4-Door Hardtop®© Ford LTD 70 71 Station Wagons-4 Door 71D Ranchwagon-6 Passenger© 71H Custom 500 Ranchwagon6 Passenger© 71J Custom 500 RanchwagonDual Face Rear© 71B Country Sedan-6 Passenger® 71C Country Sedan-Dual Face Rear® 71E Country Squire—6 Passenger® 71A Country Squire-Dual Face Rear® THUNDERBIRD Body Body Serial Style Code Code 83 83 84 84 87 87 65A 65C 65B 65D 57B 57C ©Bench Seat Body Type 2-Door 2-Door 2-Door 2-Door 4-Door 4-Door Model Hardtop® Hardtop® Landau ® Landau ® Landau © Landau ® ©Split Bench ©Bucket Seats ©Blind Quarter Roof 72 73 74 75 76 FALCON Body Body Serial Style Code Code ©Bench Seat Body Type Model 10 11 62A 54A 2-Door Sedan® 4-Door Sedan® Standard 20 22 21 62B 62C 54B 2-Door Sedan® 2-Door Sports Coupe® 4-Door Sedan© Futura 12 23 71A 71B Standard© Futura© Station Wagons - 4 Door ©Bench Seat ©Split Bench ©Bucket Seat ©Split Bench Galaxie 500 ©Bucket Seats 01-01-04 01-01-04 Vehicle Identification BODY SERIAL AND STYLE CODES-(continued) ENGINE CODES FAIRLANE Type Code Body Body Serial Style Code Code Body Type Model 30 31 65A 54A 2-Door Hardtop-formal® 4-Door Sedan® Fairlane 34 35 33 36 54B 63B 65B 76B 4-Door Sedan® 2-Door Hardtop—Fastback® 2-Door Hardtop-formal® Convertible® Fairlane 500 35 33 36 63E 65E 76E 2-Door Hardtop—Fastback© 2-Door Hardtop-Formal© Convertible® Fairlane 500 40 41 65C 54C 2-Door Hardtop-Formal® 4-Door Sedan® Torino r t U T 6Cyl. 6Cyl. 2 6 Cyl.® L 3 V 5 . 6 Cyl. 6 Cyl CD 6 Cyl." 6 Cyl CD B .6 Cyl. E F 6 D H M Y X S P 6 Cyl. 8 Cyl. 8 Cyl.® 8 Cyl. 8 Cyl. 8 Cyl. 8 Cyl. 8 Cyl.© 8 Cyl.© 8 Cyl.® 8 Cyl. 8 Cyl.® 8 Cyl. 8 Cyl. 8 Cyl. 170 Cu. In. (IV) 200 Cu. In. (IV) 200 Cu. In. (IV) 250 Cu. In. (IV) 250 Cu. In. (IV) 240 Cu. In. (IV) 240 Cu. In. (IV) 240 Cu. In. (IV) Police 240 Cu. In. (IV) Taxi 302 Cu. In. (2V) 302 Cu. In. (2V) 302 Cu. In. (2V) Police & Taxi 351 Cu. In. (2V) 351 Cu. In. (4V) 390 Cu. In. (2V) 390Cu.ln.(2V) 390 Cu. In. (4V) 428 Cu. In. (4V) Police Interceptor 428 Cu. In. (4V) CJ 428 Cu. In. (4V) CJ 429 Cu. In. (2V) 429 Cu. In. (4V) 460 Cu. In. (4V) 42 44 43 63F 65F 76F 2-Door Hardtop—FastbackCD 2-Door Hardtop-Formal® Convertible® Torino GT 42 44 43 63D 65D 76D 2-Door Hardtop—Fastback® 2-Door Hardtop-Formal® Convertible® Torino GT 46 46 45 45 63B 63E 65A 65E 2-Door 2-Door 2-Door 2-Door Cobra 32 37 38 71D 71B 71E Fairlane® Fairlane 500® Fairlane Torino Squire® Station Wagons-4 Door CONSECUTIVE UNIT NUMBER 47 48 66A 66B Ranchero® Ranchero 500® Ranchero Starting Serial Numbers—1969 Passenger Cars 100,001—Ford, Fairlane, Falcon, Mustang, Thunderbird 500,001 -Mercury, Montego, Cougar, Meteor 848,000—Lincoln Continental & Continental Mark III 48 66B Ranchero 500® (Opt.) Ranchero 49 49 66C 66D Ranchero GT ©Bench Seat Hardtop-Fastback® Hardtop-Fastback® Hardtop-Formal® Hardtop-formal® Ranchero® Ranchero® ©Split Bench K N A ©Low Compression ©High Performance ©Bucket Seats Reference Number Code Limited-Slip Ratio 1 2 3 4 J K L M 2.50:1 2.75:1 2.79:1 2.801 5 6 7 8 N 0 P Q 2.83:1 3.00:1 3.10:1 3.20:1 9 A R S 3.25:1 3.50:1 B T 3.07:1 C U 3.08:1 D V 3.91:1 E W 4.30:1 TRANSMISSION CODES Code Type 1 5 6 W U Y X Z 3-Speed Manual 4-Speed Manual-wide ratio (2.78 1st Gear) 4-Speed Manual-close ratio (2.32 1st Gear) Automatic (C4) (XP-3) Automatic (C6) (XPL) Automatic (MX) Automatic (FMX) Automatic (C6 Special) (XPL, Special)® ©For Police & trailer towing - Not available with bucket seats ©Improved Performance EXTERIOR PAINT COLOR CODES REAR AXLE RATIO CODES Conventional ©Premium Fuel ©Ram Air Induction A B c D E F G H | J K L M N p . . Q R S. T .. . u v W X Y z2 . .. 3 4 6. . 7 8 . .. 1724-A 3059-A 3197-A 3303-A 3191-A 3065-A 3203-A .. ,.2067-A 2041-A 3080-A 3204-A 3060-A 1619-A .. 921-A 3064-A 1624-A 3198-A 3199-A 2008-A 1070-A 3201-A 3120-A 3061-A . 3202-A 2044-A 3071-A . 1730-A 3230-A . 3077-A 3193-A 3190-A ..M6J-49B.. ....M6J-50B. Color . . . . . 1Black Maroon Dk. Ivy Green Met. Pastel Gray Lt. Aqua . . Dk. Aqua Met. (Brt.) Med. Orchid Met. Lt. Green Med. Lime Met. Dk. Aqua Met. Dk. Orchid Met. Lt. Gray Met. White Platinum Med. Blue Met. Med. Blue Met. Lt. Gold Med. Gold Met. Red Med. Aqua Met. Lt. Aurora Copper IVIet. Yellow Dk. Blue Met. Burnt Orange Met. Dk. Grey Met. Lt. Ivy Yellow Calypso Coral Med. Emerald Met. Med. Blue Met. (Brt) Lt. Emerald Green Met. Lt. Blue Red Primer Grey Primer 01-01-05 Vehicle Identification INTERIOR TRIM CODES 01-01-05 INTERIOR TRIM CODES-(continued) Code Trim Schemes Code Trim Schemes 1A 1A IB IB IB Black Vinyl (Cougar, Falcon) Black Cloth & Vinyl Med. Blue Cloth/Lt. Blue Vinyl Med. or Lt. Blue Vinyl Dk. Blue Cloth & Vinyl (Lincoln, T-Bird, Mark III, Mercury) Lt. Blue Cloth & Vinyl (Ford, Montego, Meteor) Dk. Red Cloth and Vinyl Med. Saddle Vinyl (Cougar) Dk. Ivy Gold Cloth & Vinyl Lt. Ivy Gold Vinyl (Cougar) Lt. Aqua Cloth and/or Vinyl Med. Grey Cloth & Vinyl (Mark III) Lt. Nugget Gold Vinyl (Cougar-Falcon) Lt. Nugget Gold Cloth & Vinyl Black Vinyl Black Leather & Vinyl (Lincoln) Black Leather (Mark III) Dk. or Lt. Blue Vinyl Dk. Blue Leather & Vinyl (Lincoln) Dk. Blue Leather (Mark III) Dk. Red Vinyl Dk. Red Leather & Vinyl (Lincoln) Dk. Red Leather (Mark III) Med. Saddle Vinyl (Cougar) Med. Saddle Leather & Vinyl (Lincoln) Med. Saddle Leather (Mark III) Lt. or Dk. Ivy Gold Vinyl Dk. Ivy Gold Leather & Vinyl (Lincoln) Dk. Ivy Gold Leather (Mark III) Lt. Aqua Vinyl Lt. Aqua Leather & Vinyl (Lincoln) Lt. Aqua Leather (Mark III) Med. Grey Leather (Mark III) Pastel Parchment w/Black Leather (Mark III) Whitew/Black Vinyl White w/Black Leather & Vinyl (Lincoln) Whitew/Black Leather (Mark III) Lt. Nugget Gold Vinyl Lt. Nugget Gold Leather & Vinyl (Lincoln) Lt. Nugget Gold Leather (Mark III) Black w/Red Knit and/or Vinyl (Mustang, Montego) Black Knit and/or Vinyl Black Cloth & Vinyl Black Leather & Vinyl (Lincoln) 5D 5D 5F 5G 5G 5G 5K 5K 5K 5W 5W 5Y 5Y Dk. Red Knit and/or Vinyl Dk. Red Leather & Vinyl (Lincoln) Med. Saddle Leather & Vinyl (Lincoln) Dk. Ivy Gold Knit and/or Vinyl Dk. Ivy Gold Cloth & Vinyl Dk. Ivy Gold Leather & Vinyl (Lincoln) Lt. Aqua Cloth & Vinyl (Montego) Lt. Aqua Vinyl Lt. Aqua Leather & Vinyl (Lincoln) White w/Black Knit and/or Vinyl White w/Black Leather & Vinyl (Lincoln) Lt. Nugget Gold Cloth & Vinyl Lt. Nugget Gold Knit and/or Vinyl (Mustang, Fairlane) Lt. Nugget Gold Leather & Vinyl (Lincoln) Black Knit and/or Vinyl Black Cloth & Vinyl (Lincoln) Black Leathe; & Vinyl (Cougar) Dk. or Lt. Blue Vinyl Dk. Blue Leather & Vinyl (Cougar) Dk. Red Knit and/or Vinyl Dk.Red Leather & Vinyl (Cougar) Med. Saddle Leather I Vinyl Dk. Ivy Gold Vinyl Dk. Ivy Gold Leather & Vinyl (Cougar) Lt. Aqua Vinyl Lt. Aqua Leather & Vinyl (Cougar) White w/Black Vinyl Lt. Nugget Gold Vinyl Lt. Nugget Gold Leather & Vinyl (Cougar) Black Vinyl Black Cloth & Vinyl (Fairlane) Black Leather & Vinyl (Lincoln) Lt. Blue Vinyl (Cougar, Montego, Ford) Dk. Blue Cloth & Vinyl Dk. Blue Leathe; & Vinyl (Lincoln) Dk. Red Vinyl (Mustang) Dk. Red Cloth & Vinyl Dk. Ivy Gold Cloth and/or Vinyl Dk. Ivy Gold Leather & Vinyl (Lincoln) Lt. Aqua Cloth & Vinyl White w/Black Vinyl White Leather & Vinyl (Lincoln) Lt. Nugget Gold Cloth & Vinyl Lt. Nugget Gold Vinyl (Ford, Meteor, Mustang) Black Knit and/or Vinyl Black Leather & Vinyl (T-Bird) Dk. or Lt. Blue Knit and/or Vinyl Dk. Red Knit and/or Vinyl Med. Saddle Knit and/or Vinyl Dk. Ivy Gold Knit and/or Vinyl Lt. Aqua Knit and/or Vinyl White w/Black and/or Vinyl White w/Black Leather & Vinyl (T-Bird) Lt. Nugget Gold Knit and/or Vinyl Black Knit and/or Vinyl Black Cloth & Vinyl (Ford, Meteor) Lt. Blue Knit and/or Vinyl Dk. Blue Cloth & Vinyl (Ford, Meteor) Dk. Red Knit and/or Vinyl Dk. Red Cloth & Vinyl (Ford-Meteor) Dk. Ivy Gold Cloth & Vinyl Lt. Aqua Cloth & Vinyl Lt. Nugget Gold Cloth and/or Vinyl Lt. Nugget Gold Knit and/or Vinyl White Vinyl With Black (Cougar) Black Cloth & Vinyl (Lincoln) White Vinyl With Blue (Cougar) Lt. Blue Cloth & Vinyl (Lincoln) White Vinyl With Red (Cougar) White Vinyl With Ivy Gold (Cougar) Lt. Ivy Gold Cloth & Vinyl (Lincoln) White Vinyl With Aqua (Cougar) Lt. Aqua Cloth & Vinyl (Lincoln) Lt. Silver Cloth & Vinyl (Lincoln) Lt. Nugget Gold Cloth & Vinyl (Lincoln) White Vinyl With Nugget Gold (Cougar) White Vinyl With Black (Cougar) Black Vinyl (Fairlane) White Vinyl With Blue (Cougar) IB ID IF 1G 1G IK IP 1Y 1Y 2A 2A 2A 2B 2B 2B 2D 2D 2D 2F 2F 2F 2G 2G 2G 2K 2K 2K 2P 2U 2W 2W 2W 2Y 2Y 2Y 3A 3A 3A 3A 3B 3B 3B 3B 3B 3B 3D 3D 3G 3G 3K 3W 3W 3Y 3Y 4A 4A 4B 4B 4D 4G 4G 4K 4W 4Y 5A 5A 5A 5B 5B 5B 5B 5D Lt. Blue Knit and/or Vinyl Lt. or Dk. Blue Cloth & Lt. Blue Vinyl Lt. Blue Cloth & Vinyl (Fairlane, Ford, Montego, Meteor) Med. Blue Cloth & Lt. Blue Vinyl Dk. Blue Cloth & Vinyl (T-Bird, Mercury) Dk. Blue Leather & Vinyl (Lincoln) Dk.Red Cloth & Vinyl Dk. Red Knit and/or Vinyl Dk. Ivy Gold Cloth & Vinyl Dk. Ivy Gold Leather & Vinyl (Lincoln) Lt. Aqua Cloth & Vinyl White w/Black Knit and/or Vinyl Whitew/Black Leather & Vinyl (Lincoln) Lt. Nugget Gold Cloth & Vinyl Lt. Nugget Gold Knit and/or Vinyl (T-Bird) Black Cloth & Vinyl Black Knit and/or Vinyl Dk. Blue Vinyl Dk. or Lt. Blue Vinyl Dk.Red Vinyl Dk. Ivy Gold Cloth & Vinyl Dk. Ivy Gold Vinyl Lt. Aqua Vinyl White w/Black Vinyl Lt. Nugget Gold Knit and/or Vinyl Black Cloth & Vinyl Black Knit and/or Vinyl Black Leather & Vinyl (Lincoln) Lt. Blue Cloth and/or Vinyl Lt. Blue Knit and/or Vinyl Dk. Blue Leather & Vinyl (Lincoln) Dk. Blue Cloth & Vinyl (Mercury) Dk.Red Cloth & Vinyl (Montego) 5Y 6A 6A 6A 6B 6B 6D 6D 6F 6G 6G 6K 6K 6W 6Y 6Y 7A 7A 7A 7B 7B 7B 7D 7D 7G 7G 7K 7W 7W 7Y 7Y 8A 8A 8B 8D 8F 8G 8K 8W 8W 8Y 9A 9A 9B 9B 9D 9D 9G 9K 9Y 9Y AA(1W) AA AB(1W) AB AD(1W) AG(1W) AG AK (1W) AK AL AY AY(1W) BA(2W) BA BB(2W) 01-01-06 INTERIOR TRIM CODES-(continued) Code BB BB BD(2W) BG(2W) BG BK(2W) BY(2W) BY CA CA CB CB CD CD CG CG CK CY CY DA DA(4W) DA DB DB DB(4W) DD(4W) DD DD DG DG DK DW DY DY EA EA EB ED EG EK EW EY FA FA(6W) FB FB(6W) FD FD(6W) FG FG(6W) FK(6W) FW FY FY(6W) GA GB GD GG GY HA HA(8W) HA HB HB (8W) HD HD HD(8W) HG HG(8W) HK HK(8W) HW HW 01-01-06 Vehicle Identification Trim Schemes Lt. Blue Vinyl (Fairlane) Lt. Blue Leather & Vinyl (Lincoln) ..White Vinyl With Red (Cougar) White Vinyl With Ivy Gold (Cougar) Lt. Ivy Gold Leather & Vinyl (Lincoln) White Vinyl With Aqua (Cougar) White Vinyl With Lt. Nugget Gold (Cougar) Lt. Nugget Gold Vinyl (Fairlane) Black Cloth & Vinyl Black Vinyl (Montego) Dk. Blue Cloth & Vinyl Lt. Blue Vinyl (Montego) Dk. Red Cloth & Vinyl Dk. Red Vinyl Dk. Ivy Gold Cloth & Vinyl Lt. Ivy Gold Leather & Vinyl (Lincoln) Lt. Aqua Cloth & Vinyl Lt. Nugget Gold Cloth & Vinyl Lt. Nugget Gold Vinyl (Montego) Black Cloth & Vinyl White Vinyl With Black (Cougar) Black Knit and/or Vinyl Dk. Blue Cloth & Vinyl Dk. Blue Vinyl (Mercury) White Vinyl With Blue (Cougar) White Vinyl With Red (Cougar) Dk. Red Knit and/or Vinyl Dk. Red Cloth & Vinyl Dk. Ivy Gold Vinyl Dk. Ivy Gold Cloth & Vinyl Lt. Aqua Cloth & Vinyl White w/Black Knit and/or Vinyl Lt. Nugget Gold Cloth & Vinyl Lt. Nugget Gold Vinyl (Mercury) Black Knit and/or Vinyl Black Cloth & Vinyl Dk. Blue Cloth & Vinyl Dk. Red Cloth & Vinyl Dk. Ivy Gold Cloth & Vinyl Lt. Aqua Cloth & Vinyl White w/Black Knit and/or Vinyl Lt. Nugget Gold Cloth & Vinyl Black Knit and/or Vinyl White Vinyl With Black (Cougar) Lt. or Dk. Blue Vinyl White Vinyl With Blue (Cougar) Dk. Red Knit and/or Vinyl White Vinyl With Red (Cougar) Dk. Ivy Gold Vinyl White Vinyl With Ivy Gold (Cougar) White Vinyl With Lt. Aqua (Cougar) White w/Black Knit and/or Vinyl Lt. Nugget Gold Vinyl White Vinyl With Nugget Gold (Cougar) Black Vinyl Lt. Blue Vinyl Dk. Red Vinyl Dk. Ivy Gold Vinyl Lt. Nugget Gold Vinyl Black Knit and/or Vinyl White Vinyl With Black (Cougar) Black Leather & Vinyl (Mercury) Lt. Blue Vinyl White Vinyl With Blue (Cougar) Dk. Red Vinyl Dk. Red Leathe; & Vinyl (Mercury) White Vinyl With Dk. Red (Cougar) Dk. Ivy Gold Vinyl White Vinyl With Ivy Gold (Cougar) Lt. Aqua Vinyl White Vinyl With Lt. Aqua (Cougar) White w/Black Leather & Vinyl (Mercury) White w/Black Vinyl (Fairlane) INTERIOR TRIM CODES-(contlnuad) Code Trim Schemes HY(8W) HY JA JB JG JW JY JY KA KA KA KB KB KB KD KG KG KL KW KY KY LA LA LB LB LD LE LG LW LW LY MA MB MD MW NA White Vinyl With Nugget Gold (Cougar) Lt. Nugget Gold Knit and/or Vinyl Black Knit and/or Vinyl Lt. Blue Cloth & Vinyl (Lincoln) Lt. Ivy Gold Cloth & Vinyl .....White w/Black Knit and/or Vinyl Lt. Nugget Gold Knit and/or Vinyl Lt. Nugget Gold Cloth & Vinyl (Lincoln) Black Knit and/or Vinyl Black Cloth & Vinyl (Ford-Mercury-Meteor) Black Leather & Vinyl (Lincoln) Dk. Blue Cloth & Vinyl .....Med. Blue Cloth & Lt. Blue Vinyl (Ford-Montego) Dk. Blue Leather & Vinyl (Lincoln) Dk. Red Cloth & Vinyl Dk. Ivy Gold Leather & Vinyl (Lincoln) Dk. Ivy Gold Cloth & Vinyl Lt. Silver Leather & Vinyl (Lincoln) White W/Black Leather & Vinyl (Lincoln) Lt. Nugget Gold Knit and/or Vinyl Lt. Nugget Gold Cloth & Vinyl Black Knit and/or Vinyl Black Leather & Vinyl (Lincoln) Lt. Blue Knit and/or Vinyl Dk. Blue Leather & Vinyl (Lincoln) Dk. Red Knit and/or Vinyl Lt. & Med. Beige Vinyl Dk. Ivy Gold Leather & Vinyl (Lincoln) White w/Black Knit and/or Vinyl White w/Black Leather & Vinyl (Lincoln) Lt. Nugget Gold Knit and/or Vinyl Black Vinyl Lt. Blue Vinyl Dk Red Vinyl White w/Black Vinyl Black Knit and/or Vinyl NB NY PA PB PY QA )B JW RA RB RD RD RW RW RY SB SG TG VA VB VG VW VY WA WW WY YA YB YD YG YK YY ZA ZB ZG Lt. Blue Vinyl . Lt. Nugget Gold Knit and/or Vinyl Black Vinyl Lt. Blue Vinyl Lt. Nugget Gold Vinyl Black Knit and/or Vinyl Lt Blue Vinyl White Knit and/or Vinyl Lt. Nugget Gold Vinyl Black Knit and/or Vinyl Black Leather & Vinyl Lt. Blue Knit and/or Vinyl Dk. Red Knit and/or Vinyl Dk. Red Leather & Vinyl White w/Black Leather & Vinyl White W/Black Knit and/or Vinyl Lt. Nugget Gold Knit and/or Vinyl Lt. Blue Leather & Vinyl (Lincoln) Lt. Ivy Gold Leather & Vinyl (Lincoln) Lt. Ivy Gold Leather & Vinyl (Lincoln) Black Knit and/or Vinyl Dk Blue Vinyl Dk. Ivy Gold Vinyl White w/Black Knit and or Vinyl Lt. Nugget Gold Vinyl Black Knit and/or Vinyl White w/Black Knit and/or Vinyl Lt. Nugget Gold Knit and/or Vinyl Black Cloth & Vinyl Dk. Blue Cloth & Vinyl Dk. Red Cloth & Vinyl Dk. Ivy Gold Cloth & Vinyl Lt. Aqua Cloth & Vinyl Lt. Nugget Gold Cloth & Vinyl Black Cloth & Vinyl Dk. Blue Cloth & Vinyl Dk. Ivy Gold Cloth & Vinyl 01-01-07 01-01-07 Vehicle Identification DATE CODES A number signifying the date precedes the month code letter. A second-year code letter will be used if the model exceeds 12 months. Code First Year Month January February March April May June July August September October November December Code Second Year ....A.. ...B.. ...C. ...D.. ...E.. . . . F.. . . . G. ...H. ...J.. .. K. . ...L. ...M. LINCOLN-MERCURY Code District Code 11 15 16 17 21 22 23 26 31 32 33 Boston New York Philadelphia Washington Altanta Dallas Jacksonville Memphis Buffalo Cincinnati Cleveland 34 41 42 46 51 52 53 54 84 90's... District ... .. .. ... Detroit Chicago St. Louis Twin Cities Denver Los Angeles Oakland Seattle Home Office Reserve Export FORD OF CANADA DISTRICT CODES (DSO) Units built on a Domestic Special Order, Foreign Special Order, or other special orders will have the complete order number in this space. Also to appear in this space is the two-digit code number of the District which ordered the unit. If the unit is a regular production unit, only the District code number will appear. Code District Code Bl B2 B3 Central Eastern Atlantic Export B4. B6. B7. I I thru 17.. District Midwestern Western . Pacific Note: Canadian Lincoln-Mercury units use prefix " A " in place of«"B". FORD Code District Boston 11... 13 . . . . . . N e w York Newark 15... 1 6 . . . ...Philadelphia 17... Washington 21... Atlanta Charlotte 22 . . . 2 4 . . . ...Jacksonville Richmond 25... 2 8 . . . . ...Louisville 3 2 . . . . . ...Cleveland 3 3 . . . . . . . Detroit Lansing 35... 3 7 . . . ...Buffalo 3 8 . . . . . . . .Pittsburgh Chicago 41... Milwaukee 43... Twin Cities 44... 4 6 . . . . ...Indianapolis 47... Cincinnati Code District . . . Denver 51 .. .Kansas City 53 54 .. Omaha 55 ...St. Louis .. Davenport 56 .. Dallas 61 . . . Houston 62 .. Memphis 63 .. New Orleans 64 65 .. .Oklahoma City 71 . . . Los Angeles 72 ...San Jose ...Salt Lake City 73 ...Seattle 74 .. .Phoenix 75 .. Government 83 84 . . . Home Office Reserve 85 .. American Red Cross 89 ...Transportation Services 90's .. ...Export Brakes 02-01-02 02*01-02 STEERING WHEEL RIW CHECKING POINTS STEERING COLUMNSTEEL MEASURING TAPE TOEBOARD OR DASH METAL VEHICLE TYPE PEDAL FREE HEIGHT-A PEDAL FREE HEIGHT-B" PEDAL TRAVEL-C FORD, MERCURY AND METEOR NON-POWER DRUM 8.09-7.17 3.10 3.27 FORD, MERCURY AND METEOR POWER DRUM & DISC 6.18-5.99 FORD, MERCURY AND METEOR NON-POWER DISC 8.65-7.82 2.18 FORD, MERCURY AND METEOR POLICE POWER DISC 7.58-6.72 3.27 FAIRLANE, MONTEGO AND FALCON NON-POWER DRUM 8.13-6.91 2.90 FAIRLANE, MONTEGO AND FALCON POWER DISC 7.25-5.71 2.35 MUSTANG AND COUGAR NON-POWER DRUM 7.49-6.43 2.58 MUSTANG AND COUGAR POWER DISC 6.25-5.56 THUNDERBIRD POWER DISC 5.96-5.04 3.00 MARK III POWER DISC 5.96-5.04 3.00 LINCOLN CONTINENTAL POWER DISC 6.50-5.50 2.25 CONTINENTAL 1.75 NOTE:AgB DIMENSION TO BE MEASURED TO SHEET METAL C DIMENSION TO BE MEASURED PARALLEL TO THE VERTICAL CENTERLINE OF THE STEERING COLUMN WITH A 50 POUND LOAD APPLIED TO THE CENTERLINE OF THE BRAKE PEDAL PAD. (CHECKS ON POWER BRAKE VEHICLES MADE WITH ENGINE RUNNING H1630-A FIG. 1 — Brake Pedal Height and Travel Measurements Tool-WRE-l o'clock position on the steering wheel rim. 3. With the steel tape still hooked to the brake pedal depress the brake pedal by pressing downward on the brake pedal effort gauge. Apply 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 rim 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 specification B in Fig. I. 5. If the pedal travel is more than the specified maximum shown in Fig. 1, dimension C, make several sharp reverse stops (equivalent to 50 pounds pedal pressure) with a forward stop before each. Move the vehicle in reverse and forward for a distance of approximately ten feet; then, apply the brakes sharply and hold the brake pedal down until the vehicle is completely stopped. This will actuate the brake self-adjusters. If these stops do not bring the brake pedal travel within specification, make several additional forward and reverse stops as outlined above. 6. If the second series of stops do not bring the brake pedal travel within specification, remove the brake drums and check the brake adjusters to make sure they are functioning. Check the brake linings for wear or damage. Repair or replace all worn or damaged parts and non-functioning adjusters. Adjust the brake lining outside diameter to the approximate inside diameter of the brake drum with Rotunda Tool HRE-8650 (Fig. 12, Part 2-2). 7. If all the brake adjusters, brake drums and linings are functional and the brake travel is not within specifications, check the pedal linkage for missing or worn bushings, or loose attachments. Bleed the brakes and centralize the differential valve. POWER BRAKE FUNCTIONAL TEST HI525-A FIG. 2—Brake Pedal Effort Gauge Installed 1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in neutral, stop the engine and apply the parking brake. Depress the brake pedal several times to exhaust all vacuum in the system. 3. With the engine shut off and all vacuum in the system exhausted, depress the pedal, and hold it in the applied position. Start the engine If the 02-01-03 vacuum system is operating, the pedal will tend to fall away under foot pressure and less pressure will be required to hold the pedal in the applied position. If no action is felt, the vacuum booster system is not functioning. If the brake pedal movement feels spongy, bleed the hydraulic system to remove air from the system. Refer to Hydraulic System Bleeding, Part 1, Section 2. VACUUM TESTS—VACUUM RELEASE PARKING BRAKES Visually check the operation of the brake linkage as the brake pedal is depressed. Then, check the operation of the brake linkage when the manual r e l e a s e lever is activiated. These checks should indicate whether the manual parking brake control linkage is operating properly or requires repair or adjustment due to inability of the parking brake to hold against moderate vehicle movement. Perform tests of the parking brake system and controls after making certain the linkage and manual controls operate properly. When testing a parking brake vacuum release system, a minimum of 10 inches of vacuum (Hg.) should be available at all points where vacuum is applied. This can be checked with a Rotunda Fuel Pump Tester Gauge (ARE345) and two Distributor Tester hose adapters (Marked Q) connected together with a coupling. This allows the Fuel Pump Tester Gauge hose to Brakes 02-01-03 be adapted to any other vacuum hose or rubber connector in the vacuum systems. Failure to maintain 10 inches of vacuum (Hg.) during vacuum system tests could be caused by a loose hose connection, resulting in a vacuum leak. When checking for vacuum between two points, trace the hose along the entire routing to be sure it is not crossed with another hose and connected to the wrong connection. All of the vacuum parking brake control checks are to be performed with the engine running at idle speed. Leaks in the parking brake hoses or a disconnected or improperly connected hose can usually be found by listening for a hissing sound along the hose routings. Under no circumstances should air pressure be applied to the vacuum system as the actuator diaphragm in the parking brake vacuum motor may be damaged. 1. Start the engine and run it at idle speed. With the transmission shift control in neutral, depress the parking brake pedal to apply the parking brake. Move the transmission shift control to D range and observe the parking brake pedal to see that the pedal moves upward and the parking brake releases. If the parking brake releases, the parking brake vacuum control is working properly. 2. If the parking brake does not release, test for vacuum at the steering column neutral switch port in the junction block, vacuum lines and the parking brake release vacuum motor. Use the Rotunda Vacuum and Fuel Pump Tester 345. This can be accomplished by removing the hose from each component and attaching it to the vacuum gauge. Connect two distributor tester vacuum hose adapters together with a coupling as a connector to attach the gauge. A minimum of ten inches of vacuum is required to actuate the parking brake vacuum motor. Do not remove any of the vacuum hoses from the junction block unless the junction block is being replaced, as the plastic nipples are thin and very brittle and damage may result. If a minimum reading is not present when checking each of the aforementioned components, they must be replaced. ROAD TEST A road test should be conducted only when the operator is sure the brakes will stop the vehicle. If the road test reveals one or more problem conditions, correct all malfunctions of the vacuum system, brake booster and hydraulic system prior to removing brake drums, brake calipers, brake shoes and linings or backing plates. ANTI-SKID CONTROL SYSTEM TESTS No adjustments or repairs are to be performed on the skid control system. Damaged or worn parts are to be replaced. Refer to Ford Car and Truck Diagnosis Manual for Testing procedures. COMMON ADJUSTMENTS AND REPAIRS PARKING BRAKE LINKAGE ADJUSTMENT L.H. REAR WHEEL CABLE - 2 A 8 0 9 > 2A791 (2 REQUIRED) FORD, MERCURY, METEOR, FAIRLANE, MONTEGO, FALCON, MUSTANG AND COUGAR Check the parking brake cables when the brakes are fully released. If1 the cables are loose, adjust them as follows: 1. Fully release the parking brake pedal by pulling the release lever. 2. Depress the parking brake pedal until it is engaged in the first notch of the control. On a vacuum release brake, the first notch will be approximately two inches of pedal travel. 3 . R a i s e the vehicle. With the transmission in neutral, turn the adjusting nut forward against the equalizer (Figs. 3 and 4) until there is 100 EQUALIZER-TO-ACTUATOR CABLE-2A815 R.H. REAR WHEEL CABLE-2A635 ADJUSTING NUT-2A812 H 1537-C FIG. 3—Parking Brake Adjustment—Ford, Mercury, Meteor, Thunderbird and Continental Mark III 02-01-04 ft-lb breakaway torque. The breakaway torque is the torque required to turn the rear wheels the direction of forward rotation with a torque wrench and tool shown in Fig. 5. The torque measurement must be made relative to the center line of the wheel. 4. Release the parking brake, and check to make sure that the brake shoes return to the fully released position. 5. Depress the parking brake pedal to the third notch. Under normal conditions, this will hold the vehicle satisfactorily. 6. Release the parking brake again, and check as in step 4. 7. If the rear brakes do not fully release, check the cables for kinks or binds. Free the cables as required. 8. Lower the vehicle. Remove the torque wrench and tool. Install the wheel attaching nuts and torque them to specification. Install the wheel cover. RETAINER-*^ REAR WHEEL (CABLE ASSEMBLY NUT EQUALIZER SPRING-2A651 02-01-04 Brakes JAM NUT PARKING SPRING SEAT-2A616 BRAKE CABLE AND CONDUIT ASSEMBLY-2853 H1631-A FIG. 4—Parking Brake Linkage Adjustment—Fairlane, Montego, Falcon, Mustang and Cougar THUNDERBIRD, CONTINENTAL MARK III, AND LINCOLN CONTINENTAL Check the parking brake cables when the brakes are fully released. If the cables are loose, adjust them as follows: 1. Fully release the parking brake pedal by pushing down the manual release lever. 2. Depress the parking brake pedal 1 1/4 inch from its normal released position. 3. Raise the vehicle with the transmission in neutral. 4. Loosen the lock nut and turn the adjusting nut forward against the equalizer (Figs. 3 and 6) until there is 100 ft-lbs breakaway torque. The breakaway torque is the torque required to turn the rear wheels the direction of forward rotation with a torque wrench and tool shown in Fig. 5. The torque measurement must be made relative to the centerline of the wheel. Tighten the lock nut. 5. Release the parking brake, and check to make sure that the brake shoes return to the fully released position. 6. Depress the parking brake pedal until it is fully engaged. 7. Release the parking brake again, and check as in step 5. 8. Depress the pedal 1/2 inch. The brakes should not drag. 9. If the rear brakes do not fully release, check the cables for kinks or binds. Free the cables as required. 10. Lower the vehicle. Remove the torque wrench and tool. Install the wheel attaching nuts and torque them to specification. Install the wheel cover. POWER BRAKE MASTER CYLINDER PUSH ROD ADJUSTMENT The push rod is provided with an adjustment screw to maintain the correct relationship between the booster control valve plunger and the master cylinder. If the plunger is too long it will prevent the master cylinder piston from completely releasing hydraulic pressure and can cause the brakes to drag. If the plunger is too short it will result in excess pedal travel and an undesirable clunk in the booster area. The adjustment screw is set to the correct height at the time of original assembly of the power unit. Under normal service the adjustment screw does not require any further attention providing the original push rod assembly remains in the original unit. If a check of the push rod adjustment is necessary, the push rod length may be verified with a push rod length gauge and measured with the engine running to apply vacuum to the booster (Fig. 7). The push rod length verification and adjustment of Midland-Ross power brake booster assemblies must be done according to the following procedure: REAR WHEEL ADJUSTING NUT CABLES EQUALIZER SPRING CABLE ASSEMBLY Tool-T59L 4204-A, T65K 4204-A, T66L-4204-A, OR Tool-4421UA H1632-A FIG. 6—Parking Brake Linkage Adjustment—Lincoln Continental #16 U.J>.S. \ 0.980" 0.995" GAUGE SHEET STEEL i 1 H1087-E E1897-A FIG. 5—Checking Parking Brake Breakaway Torque FIG. 7—Push Rod Gauge Dimensions 02-01-05 Brakes 1. Disconnect the master cylinder from the booster assembly and secure away from the booster without disconnecting the brake tubes. 2. Reinstall the air filter assembly on the booster if it was removed with the master cylinder (Fig. 8). 3. Install and tighten the master cylinder retaining nuts to retain the air filter assembly securely against the booster body and to seal the booster bellows against air leaks. 4. Place the gauge against the master cylinder mounting surface of the air filter assembly. 5. Adjust the push rod screw to provide a slight tension against the inner edge of the adjustment gauge slot. (Approximately 5 pounds of tension against the push rod is required to assure that the push rod is firmly seated in the booster assembly.) 6. Remove the retaining nuts from the booster master cylinder mounting studs. 7. Install the master cylinder on the brake booster and tighten the retaining nuts to the specified torque. The push rod length verification of the Bendix power b r a k e booster assemblies is accomplished as follows: 1. Disconnect the master cylinder from the booster assembly and secure away from the booster without disconnecting the brake tubes. 2. Adjust the push rod screw to provide a slight tension against the inner edge of the adjustment gauge slot. (Approximately 5 pounds of ten- 02-01-05 sion against the push rod is required to assure that the push rod is firmly seated in the booster assembly.) See Figure 8. 3. Install the master cylinder on the brake booster and tighten the retaining nuts to the specified torque. Do not set up side forces on the push rod as it may break the valve plunger. This is an approximate adjustment only. To verify the adjustment, look through the make-up (rear) port of the master cylinder when installing the master cylinder to the booster. The master cylinder piston should not move more than 0.015 inch as it contacts the push rod. No movement (exact contact) is ideal. HYDRAULIC SYSTEM BLEEDING AND CENTRALIZING OF THE DIFFERENTIAL VALVE When any part of the hydraulic system has been disconnected for repair or replacement, air may enter the system and cause spongy pedal action. Bleed the hydraulic system after it has been properly connected, to be sure that all air is expelled. MANUAL BLEEDING The Lincoln Continental hydraulic brake system is to be bled only with pressure bleeding equipment. The primary and secondary (front MANIFOLD CHECK VALVE-2365 19-25 IN. LB. and rear) hydraulic brake systems are individual systems and are bled separately. Bleed the longest line first on the individual system being serviced. During the complete bleeding operation, DO NOT allow the reservoir to run dry. Keep the master cylinder reservoirs filled with Ford Fluid—Extra Heavy Duty — Part Number C6AZ19542-A (ESA-M6C 25-A). The extra heavy duty brake fluid is colored blue for identification purposes. Do not mix low temperature brake fluids with the specified fluid during the bleeding operations. Never re-use brake fluid which has been drained from the hydraulic systems. 1. If t h e m a s t e r c y l i n d e r is equipped with a bleed screw, loosen the bleed screw. Push the brake pedal down slowly through its full travel. Close the bleeder fitting and return the pedal to the fully released position. Repeat this operation until fluid is free of air bubbles, then tighten the bleeder screw. Do not use the secondary piston stop screw, located on the bottom of the master cylinder to bleed the brake system. Loosening or removing this screw could result in damage to the secondary piston or stop screw. 2. To bleed the secondary (rear) brake system, position a suitable 3/8 inch box wrench (Fig. 9) on the bleeder fitting on the brake wheel cylinder. Attach a rubber drain tube to the bleeder fitting. The end of the tube should fit snugly around the bleeder fitting. APPROXIMATELY 45° TIGHTEN RETAINING NUTS TO SECURE AIR FILTER AGAINST BOOSTER BODY AND BELLOWS H1300-B ADJUST PUSH ROD SCREW TO PROVIDE A SLIGHT TENSION (APPROXIMATELY 5 LBS.) AGAINST THE GAUGE . 9—Wrench for Bleeding Brake Hydraulic System PUSH ROD GAUGE PUSH ROD ADJUSTMENT-MIDLAND-ROSS PUSH ROD ADJUSTMENT-BENDIX H1589-A FIG. 8—Brake Booster Push Rod Measurement 3. Submerge the free end of the tube in a container partially filled with clean brake fluid, and loosen the bleeder fitting approximately 3/4 turn. 4. Push the brake pedal down slowly through its full travel. Close the bleeder fitting, then return the pedal 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 of air bubbles, close the bleeder fitting and remove the bleeder tube. 6. Repeat this procedure at the brake wheel cylinder on the opposite 02-01-06 side. Refill the master cylinder reservoir after each wheel cylinder is bled and install the master cylinder cover and gasket. Be sure the diaphragm type gasket is properly positioned in the master cylinder cover. When the bleeding operation is completed, the fluid level should be filled to within 1/4 inch of the top of the reservoirs. 7. If the primary (front brake) system is to be bled. Repeat steps 2 through 6 at the right front brake caliper or cylinder and ending at the left front brake caliper or cylinder. 8. On disc brake equipped models be sure that the front brake pistons are returned to their normal positions and that the shoe and lining assemblies are properly seated by depressing the brake pedal several times until normal pedal travel is established. 9. Centralize the pressure differential valve. Refer to the Centralizing the Pressure Differential Valve procedures which follow. PRESSURE BLEEDING The Lincoln Continental hydraulic brake system is to be bled only with pressure bleeding equipment. Bleed the longest lines first. The bleeder tank should contain enough new Ford Brake Fluid to complete the bleeding operation. Use Ford Brake Fluid — Extra Heavy Duty — Part Number C6AZ-19542-A (ESAM6C25-A) or equivalent for all brake applications. The brake fluid is colored blue for identification purposes. Do 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 approximately 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 reservoir cover and rubber gasket, and fill the master cylinder reservoir with the specified brake fluid. Install the pressure bleeder adapter tool to the master cylinder, and attach the bleeder tank hose to the fittng on the adapter. Master cylinder pressure bleeder adapter tools can be obtained from the various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. 3 . If t h e m a s t e r c y l i n d e r is equipped with a bleed screw, loosen Brakes 02-01-06 the bleed screw and bleed the master cylinder until the fluid is free of air bubbles; then, tighten the bleed screw. Do not use the secondary piston stop screw, located on the bottom of the master cylinder, to bleed the master cylinder. 4. If the rear wheel cylinders, the secondary brake system, are to be bled, position a 3/8 inch box wrench (Fig. 9) on the bleeder fitting on the right rear brake wheel cylinder. Attach a bleeder tube to the bleeder fitting. The end of the tube should fit snugly around the bleeder fitting. 5. Open the valve on the bleeder tank to admit pressurized brake fluid to the master cylinder reservoir. 6. Submerge the free end of the tube in a container partially filled with clean brake fluid, and loosen the bleeder fitting. 7. When air bubbles cease to appear in the fluid at the submerged end of the bleeder tube, close the bleeder fitting and remove the tube. 8. Repeat steps 3 through 7 at the left rear wheel cylinder. 9. If the vehicle is equipped with disc brakes, repeat steps 4 through 7, starting at the right front disc caliper and ending at the left front disc caliper. On Lincoln Continental models the front wheel and tire assemblies must be removed to gain access to the bleeder fittings on the calipers. Also on Lincoln Continental models the metering valve release rod must be pulled outward and held a minimum of 1/16 inch (Fig. 10) while bleeding the primary brake system. 10. If the vehicle contains drumtype front brakes and the primary (front) brake system is to be bled, repeat steps 4 through 7, starting at the right front wheel cylinder ending at the left front wheel cylinder. 11. When the bleeding operation is completed, close the bleeder tank valve and remove the tank hose from the adapter fitting. 12. On disc brake equipped vehicles, be sure that the front brake pistons are returned to their normal positions and that the shoe and lining assemblies are properly seated by depressing the brake pedal several times until normal pedal travel is established. 13. Remove the Pressure Bleeder Adapter Tool. Fill the master cylinder reservoirs to within 1/4 inch of the top. Install the master cylinder cover and gasket. Be sure the Diaphragm type gasket is properly positioned in the master cylinder cover. 14. Centralize the pressure differential valve as follows. METERING VALVE BLEEDER RETAINER SEE VIEW A RELEASE ROD FIG. 10—Disc Brake Metering Valve—Lincoln Continental HI 644-A 02-01-07 CENTRALIZING THE PRESSURE DIFFERENTIAL VALVE After a failure of the primary (front brake) or secondary (rear brake) system has been repaired and bled, the dual-brake warning light will usually continue to be illuminated due to the pressure differential valve remaining in the off-center position. To centralize the pressure differential valve and turn off the warning Brakes 02-01-07 light after a repair operation, a pressure differential or unbalance condition must be created in the opposite brake system from the one that was repaired or bled last. 1. Turn the ignition switch to the ACC or ON position. Loosen the differential valve assembly brake tube nut at the outlet port on the opposite side of the brake system that was wheel balanced, repaired and/or bled last. Depress the brake pedal slowly to build line pressure until the pressure differential valve is moved to a centralized position and the brake warning light goes out; then, immediately tighten the outlet port tube nut. 2. Check the fluid level in the master cylinder reservoirs and fill them to within 1/4 inch of the top with the specified brake fluid, if necessary. 3. Turn the ignition switch to the OFF position. 4. Before driving the vehicle, check the operation of the brakes and be sure that a firm pedal is obtained. CLEANING AND INSPECTION DISC BRAKES 1. Remove the wheel and tire and the shoe and lining assemblies as outlined in Part 2-2, Section 2. 2. On all models except Lincoln Continental, make thickness measurements with a micrometer across the thinnest section of the shoe and lining. If the assembly has worn to a thickness of 0.230-inch (shoe and lining together) or 0.030-inch (lining material only) at any one of three measuring locations or if there is more than 0.125 taper from end to end or if lining shows evidence of brake fluid contamination, replace all (4) shoe and lining assemblies on both front wheels. On Lincoln Continental brakes make three thickness measurements with a micrometer across the middle section of the shoe and lining. Take one reading at each side and one in the center. If the assembly has worn to a thickness of 0.231 inch (shoe and lining together) or 0.066 inch (lining material only) at any one of the three measuring locations, replace all (4) shoe and lining assemblies on both front wheels. 3. Check the caliper to spindle attaching bolts torque. Torque them to specification, if required. 4. To check rotor runout, first eliminate the wheel bearing end play by tightening the adjusting nut. After tightening the nut, check to see that the rotor can still be rotated. 5. Clamp a dial indicator to the caliper housing so that the stylus contact the rotor at a point approximately 1 inch from the outer edge. Rotate the rotor and take an indicator reading. If the reading exceeds 0.003 inch total lateral runout on the indicator, replace or resurface the disc brake rotor. The following requirement must be met when resurfacing disc brake rotors: Rotunda Disc Brake Attachment FRE-2249-2 is the only approved tool to be used to refinish the disc brake rotors. The step-by-step resurfacing procedure provided with the tool must be adhered to. The finished braking surface of the rotor must be flat and parallel within 0.0007 inch; lateral runout must not exceed 0.003 inch total indicator reading, braking surface are to be 80/15 micro inches. On all models except Lincoln Continental the minimum limiting dimension from the inboard bearing cup to the inboard rotor face and the minimum rotor thickness dimension, must be observed when removing material from the rotor braking surfaces. A ball and gage bar (Rotunda Kit FRE 70160) is to be used when checking minimum dimensions (Fig. 11). FALCON-FAIRLANE MUSTANG-COUGAR MONTEGO 875 MIN .046 MAX-** inboard rotor face (dimension B) and the outboard rotor surface and the inboard bearing cup (dimension A), must be observed when removing material from the rotor braking surfaces. When the runout check is finished be sure to adjust the bearings as outlined in Group 3, in order to prevent bearing failure. 6. Check the rotor for scoring. Minor scores can be removed with a fine emery cloth. If the rotor is excessively scored, refinish it as outlined in step 5 or replace the rotor, if required. 7. Visually check the caliper. If the caliper housing is leaking it should be replaced. If a seal is leaking the caliper must be disassembled and new .seals installed. If a piston is seazed in the bore a new caliper housing is required. On Lincoln Continental models the two halves of the caliper assembly should never be separated. Damage or failure of one requires replacement of both as a unit. Check the brake hoses for signs of cracking, leaks or abrasion. Replace them if necessary. DISC BRAKE SERVICE PRECAUTIONS .119 MAX. FORD-MERCURY METEOR - THUNDERBIRD 1.12 M I N . - ^ H1633-A ?? — Disc Brake Rotor Service Limits—All Models Except Lincoln Continental On Lincoln Continental models the minimum limiting dimension (Fig. 12) from the inboard bearing cup to the 1. Grease or any other foreign material must be kept off the caliper assembly, surfaces of the rotor and external surfaces of the hub during service operations. Handling of the rotor and caliper assemblies should be done in a way to avoid deformation of the brake rotor and nicking or scratching of brake linings. 2. If a caliper piston is removed for any reason, the piston seal must be replaced. 3. During removal and installation of a wheel assembly, exercise care not to interfere with and damage the cali- 02-01-08 Brakes BEARING CUP DIMENSION " B " 0.755 MINIMUM DIMENSION " A ' 0.395 MINIMUM H1532-B FIG. 12—Disc Brake Rotor Service Limits—Lincoln Continental per splash shield or the bleeder screw fitting. 4. Front wheel bearing end play is critical and must be within specifications. 5. Be sure the vehicle is centered on the hoist before servicing any front end components, to avoid bending or damaging the rotor splash shield on full right or left wheel turns. 6. The proportioning valve should not be disassembled or adjustments attempted on it. 7. Riding of the brake pedal (common on left foot applications) should be avoided during vehicle operation. 8. The wheel and tire must be removed ' separately from the brake rotor, unlike drum brakes where the wheel, tire and drum are removed as a unit. 9. On floating caliper type disc brakes whenever the caliper is removed the caliper locating pins should be inspected for wear or damage. 10. On floating caliper type disc brakes, the caliper assembly must be removed from the spindle prior to removal of the shoe and lining assemblies. 11. On floating caliper type disc brakes the calipers must not be interchanged from one side to the other. When the caliper is installed on its proper anchor plate and spindle, the bleeder screw will point to the rear of the vehicle (Fig. 22). If a caliper is installed on the wrong side of the vehicle, it is not possible to bleed the system properly. 12. Do not attempt to clean or restore oil or grease soaked brake linings. When contaminated linings are found, brake linings must be replaced in complete axle sets. DRUM BRAKES 1. Remove the wheel from the drum, and remove the drum as outlined in Part 2-2, Section 2. 2. Brush all dust from the backing plates and interior of the brake drums. 3. Inspect the brake shoes for excessive lining wear or shoe damage. If the lining is worn within 1/32 inch of the rivet heads or if the shoes are damaged, they must be replaced. Replace any lining that had been contaminated with oil, grease or brake 02-01-08 fluid. Replace lining in axle sets. Prior to replacement of lining, the drum diameter should be checked to determine if oversize linings must be installed. 4. Check the condition of brake shoes, retracting springs, hold-down springs, and drum for signs of overheating. If the shoes have a slight blue coloring, indicating overheating, replacement of the retracting and hold-. down springs is strongly recommended. Overheated springs lose their pull and could cause the new lining i:o wear prematurely, if they are not replaced. 5. If the vehicle has 30,000 or more miles of operation on the brake linings or signs of overheating are present when relining brakes, the wheel cylinders should be disassembled and inspected for wear and entrance of dirt into the cylinder. The cylinder cups should be replaced, thus avoiding future problems. 6. Inspect all other brake parts and replace any that are worn or damaged. 7. Inspect the brake drum and, if necessary, refinish. Refer to Part 2-2, Section 4 for refinishing. BRAKE BOOSTER Check the booster operation as noted in Part 2-1, Section 1, Power Brake Functional Test. If the brake booster is damaged or defective, replace it with a new booster. The brake booster is serviced only as an assembly. 02-02-01 Brake System 02-02-01 Part 2-2 Brake System ContinentalMark III Thunderbird LincolnContinental Fairlane Mustang Cougar Montego Meteor N/A N/A N/A N/A N/A N/A N/A N/A N/A 02-07 02-07 N/A N/A N/A N/A N/A N/A N/A N/A N/A 02-36 02-36 N/A N/A N/A N/A N/A N/A N/A N/A N/A 02-38 02-38 N/A N/A N/A N/A N/A N/A N/A N/A 02-38 02-38 N/A Falcon Mercury ANTI SKID CONTROL SYSTEM Description ANTI SKID CONTROL ACTUATOR Removal and Installation ANTI SKID CONTROL MODULE Removal and Installation ANTI SKID CONTROL SENSOR Removal and Installation BRAKE BACKING PLATE (DRUM) Removal and Installation BRAKE BOOSTER Cleaning and Inspection - See Part 2-1 Description Removal and Installation BRAKE DRUM Cleaning and Inspection - See Part 2-1 Refinishing Removal and Installation (Front) Removal and Installation (Rear) BRAKE PEDAL Removal and Installation BRAKE SHOES (DRUM) Adjustments Relining Removal and Installation DISC BRAKE Description DISC BRAKE CALIPER Cleaning and Inspection Disassembly and Overhaul Removal and Installation DISC BRAKE ROTOR AND HUB Cleaning and Inspection — See Part 2-1 Refinishing Removal and Installation DISC BRAKE ROTOR SPLASH SHIELD Removal and Installation DISC BRAKE SERVICE PRECAUTIONS — See Part 2-1 Ford COMPONENT INDEX All Models MODEL APPLICATION 02-16 02-06 02-24 02-39 02-09 02-09 02-09 02-09 02-09 02-09 02-09 02-09 02-09 N / A 02-09 N/A N/A 02-25 02-25 02-25 02-25 02-25 02-25 02-25 02-25 02-27 02-26 02-26 02-07 02-39 02-09 02-03 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-42 04-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-16 02-16 02-16 02-16 02-16 02-16 02-16 02-16 02-17 02-16 02-16 02-39 02-19 02-19 A page number indicates that the item is for the vehicle listed at the head of the column. N/A indicates that the item is not applicable to the vehicle listed. 02-02-02 02-02-02 Brake System DISC BRAKE SHOE AND LINING Cleaning and Inspection - See Part 2-1 Removal and Installation DRUM BRAKE Description DUAL BRAKE SYSTEM Description HYDRAULIC LINES Removal and Installation (Hose) Removal and Installation (Tube) MASTER CYLINDER Cleaning and Inspection Disassembly and Overhaul Removal and Installation - Non-Power Removal and Installation - Power PARKING BRAKE Description PARKING BRAKE ACTUATOR TO CONTROL CABLE Removal and Installation PARKING BRAKE ACTUATOR TO EQUALIZER CABLE Removal and Installation PARKING BRAKE CONTROL Removal and Installation PARKING BRAKE EQUALIZER TO CONTROL CABLE Removal and Installation PARKING BRAKE EQUALIZER TO REAR WHEEL CABLE Removal and Installation PRESSURE DIFFERENTIAL VALVE Removal and Installation PRESSURE METERING VALVE Removal and Installation PROPORTIONING VALVE Removal and Installation WHEELCYLINDER Cleaning and Inspection Disassembly and Overhaul Removal and Installation ContinentalMark III Thunderbird LincolnContinental Mustang Montego Falcon Fairlane Cougar Meteor Mercury Ford COMPONENT INDEX All Models MODEL APPLICATION 02-18 02-18 02-18 02-18 02-18 02-18 02-18 02-18 02-18 02-18 02-18 02-05 02-03 02-08 02-08 02-40 02-39 02-19 02-19 02-19 02-20 02-20 02-20 02-20 02-20 N/A N/A N/A 02-21 02-06 02-34 02-34 02-34 N/A N/A N/A N/A N/A N/A 02-34 02-34 02-35 02-35 02-35 N/A N/A N/A N/A N/A N/A 02-35 02-35 02-27 02-27 02-27 02-30 02-27 02-27 02-27 02-30 02-30 02-30 02-30 N/A N/A N/A 02-34 02-34 02-34 02-34 02-34 02-35 N/A N/A 02-35 02-35 02-35 02-36 02-36 02-36 02-36 02-36 02-36 02-35 02-35 02-22 N/A N/A N/A N/A N/A N/A N/A N/A 02-24 N/A N/A 02-23 02-23 02-23 02-23 02-23 02-23 02-23 02-23 02-24 02-24 02-24 02-08 02-07 02-10 A page number indicates that the item is for the vehicle listed at the head of the column. N/A indicates that the item is not applicable to the vehicle listed. 02-02-03 02-02-03 Brake System DESCRIPTION Disc brakes are available as optional equipment for the front wheels on Ford, Mercury, Meteor, Fairlane, Montego, Falcon, Mustang and Cougar models and are standard on Thunderbird, Continental Mark III, and L i n c o l n C o n t i n e n t a l models. The dual-master cylinder equipped hydraulic brake system employs single anc h o r , i n t e r n a l expanding and selfadjusting drum brake assemblies on the rear wheels of vehicles with disc brakes, and on the front and rear wheels of all others. A vacuum booster is used with the power disc brake system. DUAL MASTER CYLINDER BRAKE SYSTEM The dual-master cylinder brake system has been incorporated in all models to provide increased safety. The system consists of a dual-master cylinder (Fig. 1), pressure differential valve assembly and a switch (Fig. 2). The switch on the differential valve activates a dual-brake warning light, located on the instrument panel. FLOATING CALIPER— ALL MODELS EXCEPT LINCOLN CONTINENTAL DISC BRAKE The disc brake consists of a ventilated rotor and caliper assembly. The caliper used on all models except Lincoln Continental is a single piston floating caliper (Fig. 3). The caliper used on Lincoln Continental models is a four piston fixed caliper (Fig. 4). A proportioning valve in the rear hydraulic circuit provides balanced braking action between front and rear brakes. On all models except Lincoln a pressure impulse valve located at the primary inlet of the pressure differential valve prevents brake fluid surge back to the master cylinder reservoir. On Lincoln Continental models a metering valve, in the hydraulic line between the differential valve and the front wheel disc brakes, prevents the front brakes from applying until approximately 125 psi is obtained in the system (Fig. 21). This delaying action is required to prevent the front brakes from performing all the braking action on low speed stops and thereby increasing the rate of lining wear. The caliper asseml.y is made up of a floating caliper housing assembly and an anchor plate. The anchor plate is bolted to .the wheel spindle arm by two bolts. The floating caliper is attached to the anchor plate by steel stabilizers on Ford, Mercury, Meteor, Thunderbird and Continental Mark III models and by one stabilizer on Fairlane, Montego, Falcon, Mustang and Cougar models. The floating caliper slides on two locating pins which also attach to the stabilizers. The floating caliper contains the single cylinder and piston assembly. The cylinder bore contains a piston with a molded rubber dust boot to seal the cylinder bore from contamination (Fig. 5). A square section rubber piston seal is positioned in a groove in the cylinder bore and is used to provide sealing between the cylinder and piston (Fig. 7). The outer brake shoe and lining assembly is longer than the inner assembly, and the shoe and lining DISC BRAKES RETURN SPRING (SECONDARY) RETAINER PRIMARY SYSTEM BRAKE FLUID RESERVOIR BOOT PUSH ROD RESIDUAL \ ^ CHECK \ TUBE SEAT | VALVE \ (SECONDARY) (PRIMARY) SECONDARY PISTON BRAKE OUTLET BRAKE OUTLET ASSEMBLY PORT PORT FIG. I — Dual Master Cylinder—Typical PRIMARY PISTON ASSEMBLY H 1545-A BRAKE WARNING LAMP SWITCH BRAKE WARNING LAMP SWITCH BRAKE WARNING LAMP SWITCH PLUNGER IN THE ON POSITION BRAKE WARNING LAMP SWITCH PLUNGER IN OFF POSITION PISTON CONNECTOR VALVE PISTON HAS MOVED TO LOW PRESSURE AREA. WARNING LAMP SWITCH PLUNGER IS DEPRESSED, LIGHTING THE BRAKE WARNING LAMP LOW PRESSURE SIDE HIGH PRESSURE SIDE U VALVE PISTON IS CENTRALIZED. PRIMARY AND SECONDARY SYSTEM PRESSURES ARE EQUALIZED DRUM BRAKES CONNEiCTOR TJ BRAKE FLUID BRAKE WARNING LAMP I SWITCH PLUNGER IN ON POSITION REAR BRAKE INLET BRAKE WARNING LAMP SWITCH PLUNGER IN OFF POSITION CONNECTOR FRONT BRAKE INLET FRONT BRAKE OUTLET VALVE PISTON IS CENTRALIZED. PRIMARY AND SECONDARY SYSTEM PRESSURES ARE EQUALIZED REAR BRAKE PROPORTIONING VALVE IS BYPASSED VALVE PISTON HAS MOVED TO LOW PRESSURE AREA. WARNING LAMP SWITCH PLUNGER IS DEPRESSED, LIGHTING THE BRAKE WARNING LAMP H1634-A \ OUTLET TO PROPORTIONING VALVE DISC BRAKES FIG. 2—Pressure Differential Valve and Brake Warning Light Switch CALIPER ASSEMBLY BLEEDER SCREW EXTERNAL TRANSFERTU3E blies are not interchangable (Fig. 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 friction material bonded to a metal plate called the shoe. It is replaced as a unit. FIXED CALIPER LINCOLN CONTINENTAL H1567-B FIG. 3—Disc Brake AssemblyFloating Caliper—All Models Except Lincoln Continental HUB AND ROTOR ASSEMBLY H 1647-A FIG. 4—Disc Brake Assembly— Fixed Caliper—Lincoln Continental The caliper assembly is bolted directly 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 cylinder bore contains a piston with an attached molded rubber dust boot to seal the cylinder bore from contamination (Fig. 6). Square-section rubber 02-02-05 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 hydraulically 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 o'uter ends of the shoe assemblies (Fig. 46). The shoes slide axially in the caliper abutments by means of the tabs which ride on machined ledges (bridges) when hydraulic pressure is applied to the piston (Fig. 6). A shoe and lining assembly consists of friction material riveted to a metal plate called the shoe. It is replaced as a unit. Clips are attached to the top of the caliper to retain the shoe and lining assemblies. The caliper assembly is mounted on the front wheel spindle to the rear of the wheel vertical centerline. Brake System 02-02-05 CALIPER HOUSING PISTON SHOE LINING PISTON SEAL H 1568-B FIG. 5—Floating Caliper Assembly—Sectional View TRANSFER TUBE PISTON DUST BOOT RETAINING GROVE CALIPER TO ROTOR CLEARANCE CALIPER HOUSING PISTON ROTOR The cast iron disc is of the ventilated 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 prevent road contaminants from contacting the inboard rotor and lining surfaces. The wheel provides protection for the outboard surface of the rotor. DRUM BRAKE The drum brake system employs single anchor, internal expanding ancj self adjusting brake assemblies. The self-adjusting brake mechanism consists of a cable, cable guide, adjusting lever, adjusting screw assembly, 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 primary brake shoe and to the lever. The automatic adjuster operates only when the brakes are applied while the vehicle is moving rearward and only when the secondary shoe is free to move toward the drum beyond a predetermined point. SHOE LINING PISTON SEAL CALIPER DUST BOOT RETAINER H 1648-A FIG. 6—Fixed Caliper Assembly—Sectional View PISTON PISTON SEAL RELAXED CALIPER HOUSING BRAKES APPLIED FIG. 7—Function of Piston Seal BRAKES RELEASED H1569-B 19-04-40 Pre-Delivery And Maintenance Procedures 19-04-40 STEERING LINKAGE TORQUE LIMITS (FT-LBS) Description Cylinder Mounting Bracket to Underbody or Frame Cougar, Fairlane, Ford, Falcon, Montego, Mercury, Mark I I I , Lincoln Meteor Thunder bird Continental Mustang (Side Hole) 28-35 - - - (Bottom Hole) 35-43 - - - 18-24 - - - 3-5 - - - Power Cylinder to Bracket Power Cylinder to Bracket Lock Nut Steering Tie Rod End to Spindle Arm 30-40® 35-47® 35-47® 40-55 28-35 28^5 28-35 20-30 Idler Arm Mounting Bracket to Underbody or Frame Pitman Arm to Control Valve (Power Steering) 35-47® Steering Gear to Side Rail or Frame 50-65 Pitman Arm to Sector Shaft 150-225 - - - 50-65 50-65 50-65 150-225 150-225 150-200 Idler Arm to Pitman Arm-to-ldler Arm Rod 60-80® 60-80® 60-50® 40-55 Spindle Connecting Rod Clamp to Adjusting Sleeve 10-14 8-13 8-13 19-26 Pitman Arm to Steering Arm-to-ldler Arm Rod 35-47® 35^7® 35-47® 40-55 Steering Spindle Arm Connecting Rod to Arm-to-ldler Arm Rod 30-40® 35-47® 35-47® 40-55 ©Torque to low limit of specification; then, tighten the nut to the nearest cotter pin slot and insert the cotter pin.