Mercury - Montego - Workshop Manual - (1969)

FALCON 1969 CAR SHOP MANUAL VOLUME ONE CHASSIS FAIRLAN Click Here1E MUSTANG www.FordManuals.com FORD THUNDERBIRD MONTEGO COUGAR METEOR EELS and TIRES, SUSPENSION, STEERING, BRAKES CLUTCH and TRANSMISSION, REAR AXLE MERCURY LINCOLN CONTINENTAL CONTINENTAL MARK Ill_ 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 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 performed, such as frequently performed adjustments and repairs, invehicle 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 changespecifications 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. 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 I @ @ ASSEMBLY PLANT CODE @ BODY SERIALCODE @ @ @ ENGINE CODE MODEL YEAR CODE ' CONSECUTIVE UNIT NO. BODY TYPE CODE @ @ @ @ @ @ COLOR CODE 1 TRIM CODE I DATE CODE I DISTRICT-SPEC. EQUIP. CODE I I REAR AXLE CODE TRANSMISSION CODE 8 Fig. I-Warranty Plates-Passenger ' I Cars ! Fig. 2-Typical Vehicle Identification Number (VIN) Tab W 1001-A : 01-01-02 Vehicle Identification 0 1-01-02 I , ; i I VEHICLE W A R R A N T Y NUMBER The vehiclewarranty number is the .first line of numbers and letters appearing on the Warranty Plates (Fig. 1). The Warranty Plate i s 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 o n the first line indicate the Consecutive Unit Number. VEHICLE D A T A The vehicle data appears on the second or lower line o n 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 i n which the car was ordered and may appear i n 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). OFFICIAL VEHICLE I D E N T I F I C A T I O N NUMBER The official Vehicle Identification .Number (VIN) for title and registration purposes i s 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). M O D E L YEAR C O D E The number 9 designates 1969. ASSEMBLY P L A N T CODES Code Letter Code Letter A,. . . . . . . . . . . . . . . . . . . . . ..Atlanta B . . . . . . . . . . . . . .Oakville (Canada) C.. ..... :. . . . . . . . ..Ontario Truck D.. . . . . . . . . . . . . . . . . . . . . . ..Dallas E. . . . . . . . . . . . . . . . . . . . . . . .Mahwah . F... . . . . . . . . . . . . . . . . . .Dearborn . G . . . . . . . . . . . . . . . . . . . . . . . .Chicago H. . . . . . . . . . . . . . . . . . . . . . . . Lorain J.. . . . . . . . . . . . . . . . . . Los . Angeles .K.. . . . . . . . . . . . . . . . . ..Kansas City L.. . . . . . . . . . . . . . ..Michigan Truck N.. . . . . . . . . . . . . . . . . . . . . .Norfolk P.. . . . . : . . . . . . . . . . . ..Twin Cities R . . . . . . . . . . . . . . . . . . . . . San . Jose S . . . . . . . . . . (Pilot).. . Allen Park T . . . . . . . . . . . . . . . . . . . . . .Metuchen U.. . . . . . . . . . . . . . . . . . . . .Louisville W.. . . . . . . . . . . . . . . . . . . . . ..Wayne X . . . . . . . . . . . . . . . . . . ..St. Thomas Y . . . . . . . . . . . . . . . . . . . . . . ..Wixom Z . . . . . . . . . . . . . . . . . . . . . S t . Louis COUGAR ~ o d y Body Serial Style Code Code 91 92 Body Type Model 65A 76A 2-Door Hardtop@ Convert~ble~ Standard 93 94 65B 768 2-Door Hardtop@ Convertible@ XR-7 Luxury 91 65C 2.Door Hardtop@ Standard ' @Bench Seat @Split Bench @Bucket Seats MERCURY Body Body Serial Style Code Code 44 46 48 45 Body Type Model 54A 65A 57A 76A Monterey 40 41 42 &Door Sedan@ 2-Door Hardtop-Formal@ 4.Door Hardtop@ Convertible@ CANADA ONLY. 53M 4-Door Hardtop Sedan@ .65M 2-Door Hardtop-FormalO 57M 4-Door Hardtop@ 54 56 58 54C 658 578 4-Door Sedan@ 2-Door Hardtop-Formal@ 4.Door Hardtop@ Monterey-Custom 63 66 68 65 63 66 68 53F 65F 57F 76F 53C 65C 57C 4.Door ~ a r d t osedan@@ ~ 2.Door Hardtop-Formal@@ 4-Door Hardtop@@ Convertible@@ 4-Door Hardtop Sedan@ 2-Door Hardtop-FormalO 4-Door Hardtop@ Marquis 60 61 63G 63H 2-Door Hardtop (Tunnel Roof)@@ Marauder 2-Door Hardtop (Tunnel Roof)@@@ 72 72 718 71C 4-Door 2 Seat@ &Door 3 Seat (Side Facing@ ,Monterey Wagon 74 74 71F 71G 4-Door2 Seat@ 4-Door 3 Seat (Side Facingb Monterey-Custom Wagon 76 76 71E 71A 4-Door L.Seat@@ Marquis Colony Park 4-Door 3 Seat (Side Facing)@@ @Bench Seat @Split Bench Marquis - Brougham (Option) @Bucket Seats METEOR (CANADA) , B O D Y SERIAL A N D STYLE CODES The two-digit numeral which follows the assembly plant code identifies the body series. This two-digit number i s used i n conjunction with the Body Style Code, i n the Vehicle Data, which 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. 1 LINCOLN CONTINENTAL ' Body Body Serial Style Code Code 82 80 I 53A 65A Body Type 4.DoorSedan 2-Door Hardtop CONTINENTAL MARK Ill Body Body Serial Style Code Code Bodv Serial Code 20 - Bodv Styk Code Body Type 54A 4-Door Sedan@ Model Rideau 21 23 548 658 Sedan@ 2-Door Hardtop-FormalO .Rideau 500 30 35 35 33 34 34 54C 65C 65E 57C 76C 76E &Do01 Sedan@ Montcalm 2-Door Hardtop-Formal13 2-Door Hardtop-Formal(5-33)W 4-Door Hardtop@ Convertible@ Convertible (S-33)@@ 24 27 65F 57F 2.Door Hardtop-Formal@@ 4-Door Hardtop@@ LeMoyne 28 29 38 39 718 71C 71E 71A Rideau 5 0 0 6 passenger6 Rideau 500-Dual Face Rear@ Montcalmd Passenger@ Montcalm4ual Face Rear@ Station Wagons ' Body Type .. @Bench Seat OSplite Bench @Bucket Seats I I 0 1-01-03 0 1-01 - 0 3 Vehicle Identification I B O D Y SERIAL A N D STYLE CODES-(continued) . . I MONTEGO MUSTANG . Body Body Serial Style Code Code . Body Type Model 02 54A 2-Door Hardtop4ormal (Sports Coupe)@ &Door Sedan(Sports)@ 06 07 548 658 4-Door Sedan@ 2-Door Hardtop4ormalO Montego. 10 11 12 54D 65D 76D 4-DoorSedan~ 2-Door Hardtop-Formal@ Convert~ble@ Montego MX 11 12 65E 768 2-Door Hardtop-Formal@ Convertible@ Montego MX 10 11 54C 65C &Door Sedan@ 2-Door Hardtop4ormalO Montego MX Brougham 15 63A 15 16 63C 63H 2-Door Hardtop Fastback@' (GT Ap earance Opt.@) 2-Door lardtop Fastback@ ?.Door Hardtop Fastback@ (Sports Appearance Opt.@) 01 03 08 08 65A 718 71C 71A Montego@ MontegoMXO Montego MX (Woodgrain)@ @Bench Seat @Split Bench . Comet Body Body ' Serial Style Code Code I . I Body Type Model 01 02 03 65A 63A 76A 2-Door Hardtop@@ FDoor Fastback@@ Convertible@@ Standard 01 02 03 658 638 768 2-Door Hardtop@@ 24001 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@ Mach 1 @Bench Seat @Split Bench OBucket Seats ' @Hi-Back Bucket Cyclone - Cyclone CJ Station Wagons4 Door FORD Body Body Serial Style Code Code . @Bucket Seats I Body Type Model 50 51 62E 54E 2-Door Sedan@ 4-Door Sedan@ Custom 52 53 628 548 2-~oo;~edan@ Sedan@ Custom 500 , 54 55 58 56 57. 54A 638 65C 578 76A 4-Door Sedan@ 2.Door Hardtop4astbackO 2-Door Hardtop-Formal@ 4.Door Hardtop@ Convertible@ Galaxie 500 60 61 63C 766 2-Door Hardtop4astbackOO Convertible@@ Ford XL 64 62 66 54C 65A 57F 4-Door Sedan@@ 2-Door Hardtop-Formal@@ &Door Hardtop@@ Ford LTD - Body Body Serial Style Code Code 83 83 84 84 87 87 Body Type Model 2-Door Hardtop@ 2-Door Hardtop@ 2-Door Landau @@ 2-Door Landau @@ Landau @ 4-D001 Landau @ 65A 65C 658 65D 578 57C @Bench Seat @Split Bench @Bucket Seats @Blind Quarter Roof Body Body Serial Style Code Code @Bench Seat Body Type Model 10 . 62A 11 . 54A 2-Door Sedan@ 4-Door Sedan@ Standard 20 22 21 628 62C 548 2-Door Sedan@ 2-Door Sports Coupe6 4-Door Sedan@ Futura 12 23 71A 718 Standard@ Futuraa Station Wagons 4 Door @Bench Seat ' @Split Bench @Bucket Seat 1 I 1 I ' I RanchwagondPassenger@ Station w a g o n s 4 Door ! Custom 500 Ranchwagon6 Passenger@ I Custom 500 RanchwagonDual Face Rear@ Country Sedan4 Passenger@ Country Sedan-Dual Face Rear@ Country S q u i r e d Passenger@ Country Squire-Dual Face Rear@ ' FALCON ' @Split Bench OBucket Seats 01-01-04 Vehicle Identification B O D Y SERIAL A N D STYLE CODES-(conttnued) 01'-01-04 E~GINE CODES FAIRLANE Code Body Body Serial Style Code Code U ....................6 Cyl. T ....................6 Cyl. 2 ....................6 Cyl.0 L .................... 6 Cyl. 3 ...................:6 Cyl.0 V .................... 6 Cyl. 5 .................... 6 Cyl.0 B....................:6 Cyl. E ....................6 Cyl. F ....................8 Cyl. 6 ....................8 Cyl.0 D ....................8Cyl. H .................... 8 Cyl. M ...................8 Cyl. Y ....................8Cyl. X .................... 8 Cyl.0 S .................... 8 Cyl.@ P .................... 8 Cyl.0 Q .................... 8 Cyl. R ....................8 Cyl.@ K .................... 8 Cyl. N ....................8 Cyl. A ....................8 Cyl. Body Type Model 30 31 65A 54A 2-Door Hardtopdormal@ 4-D001 Sedan@ Fairlane 34 35 33 36 548 638 658 768 4-Door Sedan@ 2-Door Hardtop-Fastback@ 2.Door HardtopdormalO Convertible@ Fairlane 500 35 33 36 63E 65E 76E 2-Door Hardtopdastback@ 2-Door Hardtop-Formal@ Convertible@ Fairlane 500 40 41 65C 54C 24001 Hardtop-Formal@ 44-001 Sedan@ Torino 42 63F 44 . 65F 43 76F 2-Door HardtopdastbackO 2-Door HardtopdormalO Convertible@ Torino GT 42 44 43 63D 65D 76D 2-Door HardtopqastbackQ 2.Door Hardtop-Formal@ Convertible@ Torino GT 46 638 63E 65A 65E 2:~oo~ardtopdastback@ 2-Door HardtopdastbackO 2.Door HardtopdormalO 2.Door HardtopdormalO Cobra 46 -45. 45 32 37 38 71D 718 71E Fairlane@ Fairlane 5 0 0 0 Fairlane'Torino SqliireO Station Wagons4 Door 47 48 66A 66B Ranchero@ Ranchero 5 0 0 0 Ranchero 48 66B Ranchero 500.a (Opt.) Ranchero 49 49 66C 66D Ranchero GT @Bench Seat Ranchero@ Ranchero@ @Split Bench Type @Low Compression @High Performance 170 Cu. In. (1V) 200 Cu. In. (1V) 200 Cu. In. (1V) 250 CU.~ ni .l Y j 250 Cu. In. (1V) 240 Cu. In. (1V) 240 Cu. In. (1V) 240 Cu: In. (1V) Police 240 Cu. In. (lV) 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) 390 Cu. In. (2V) 390 Cu. In. (4V) @Premium Fuel @Ram Air Induction @Improved Performance -. CONSECUTIVE U N I T NUMBER Starting Serial ~umbers-1969 Passenger Cars 100,00ldord, Fairlane. Falcon, Mustang, Thunderbird 500,001-Mercury, Montego, Cougar, Meteor848,0004incoln Continental &Continental Mark Ill EXTERIOR P A I N T C O L O R CODES @Bucket Seats Reference Number Code Color - 2 ............................1724-A ................................. REAR AXLE RATIO CODES Conventional Limited-Slip Ratio T R A N S M I S S I O N CODES Code Type 1 .........................................S p e d Manual 5 .................................... 4 S p e e d Manual-wide ratio (2.78 1st Gear) 6 ...................................... S p e d Manual-close ratlo (2.32 1st Gear) W ......................................... A t o m a t c (C4) (XP.3) U .................................... Automatic (C6) (XPL) Y .......................................... Automatic (MX) X ...................................... Automatic (FMX) Z ..........................................Automatic (C6 Special) (XPL, Special)@ @For Police &trailer to,wing -Not available with bucket seats Black B ............................ 3059-A ....................................Maroon 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 U ............................1070-A ....................................Med. Aqua Met. V ............................3201-A .................................... Lt. Aurora Copper Met. W ...........................3120.A ...................................:Yellow X ............................3061-A ....................................Dk. Blue Met. Y ............................3202.A ...................................Burnt Orange Met. Z ............................2044-A .....................:..............Dk. Grey Met. 2 ............................3071-A ....................................Lt. Ivy Yellow 3 ............................1730-A ....................................Calypso Coral 4 ............................3230-A ................................... Med. Emerald Met. 6 ............................3077-A ...................:....T....:.....Med. Blue Met. (Brt.) 7 ............................3193-A ................................... Lt. Emerald Green Met. 8 ............................ 3190-A ....................................Lt. Blue 9 ............................M6J.49B ................................. Red Primer 9 ..............................M6J.50B ,,,............................Grey Primer I 01-01-05 . Vehicle Identification INTERIOR T R I M CODES Code 01-01-05 INTERIOR T R I M CODES-(cont~nued) Trim Schemes 1A ........................................Back Vinyl (Cougar, Falcon) 1A .................:......................Back Cloth &Vinyl 1 0 ........................................M e . Blue ClothILt. Blue Vinyl 1 0 ........................................ M e . or Lt:Blue Vinyl 1 0 ........................................ 0 . Blue Cloth &Vinyl (Lincoln, T-Bird, Mark Ill, Mercury) 10 ........................................ Lt. Bluecloth & Vinyl (Ford, Montego, Meteor) 1 0 ........................................ 0 . Red Cloth and Vinyl 1F ........................................ M e . Saddle Vinyl (Cougar) 1G ........................................0 . Ivy Gold Cloth &Vinyl 1G ........................................ Lt. Ivy Gold Vinyl (Cougar) 1K ........................................Lt. Aqua Cloth andlor Vinyl 1P ........................................ G r e y Cloth &Vinyl (Mark Ill) 1Y ........................................ Lt. Nugget Gold Vinyl (Cougar-Falcon) 1Y ........................................ Lt. Nugget Gold Cloth & Vinyl 2A ........................................ Back Vinyl 2A ........................................ Back Leather & Vinyl (Lincoln) 2A ........................................Back Leather (Mark Ill) ................................... ....0 . or Lt: Blue Vinyl . 28 28 .................................... . . Blue Leather & Vinyl (Lincoln) 28 ......................................0 . Blue Leather (Mark Ill) 2 0 ........................................ Dk. Red Vinyl 2 0 ........................................ 0 . Red Leather & Vinyl (Lincoln) 2 0 ...:....................................0 , Red Leather (Mark Ill) 2F ........................................ M e . Saddle Vinyl'(Cougar) 2F ........................................ S a d d l e Leather & Vinyl (Lincoln) 2F ........................................M e . Saddle Leather (Mark Ill) 2G ........................................L o r Dk. Ivy Gold Vinyl 26 ........................................0 . Ivy Gold Leather & Vinyl (Lincoln) 2G ........................................ 0 . Ivy Gold Leather (Mark Ill) 2K ........................................ A q u a Vinyl 2K ........................................ Lt. Aqua Leather & Vinyl \Lincoln) 2K ........................................ Lt. AqualLeather (Mark II ) 2P ........................................ G r e y Leather (Mark Ill) 2U ............:........................... Pastel Parchment wBlack Leather (Mark Ill) 2W ...........!...........................White w1Black Vinyl 2W .......................................White w/Black Leather & Vinyl (Lincoln) 2W ..............................:........WhitewIBlack Leather (Mark Ill) 2Y ........................................Lt. Nugget Gold Vinyl 2Y ..:..................................... L t Nugget Gold Leather & Vinyl (Lincoln) 2Y ........................................ Lt. Nugget Gold,Leather (Mark Ill) 3A ........................................Back w/Red K n ~and/or t Vinyl . (Mustang, . Montego) 3A ........................................Back K n ~andlor t Vinyl 3A ........................................Back Cloth &Vlnyl 3A ..................................... Back Leather & Vinyl (Lincoln) 38 ........................................ Lt. Blue Knit andlor Vinyl 38 ........................................L t or Dk. Blue Cloth & Lt. Blue Vinyl 3 8 ........................................Lt. Blue Cloth &Vinyl (Fairlane, Ford, Montego, Meteor) 3 8 ........................................ M e . Blue Cloth & Lt. Blue V~nyl 0 . Blue'Cloth & Vin I (T Bird, Mercury) 38 ........................................ 3 8 ........................................ 0 . Blue Leather & i n y l i ~ i n c o l n ) 3 0 ........................................0 . Red Cloth & Vinyl 3 0 ........................................ 0 . Red Knit andlor Vinyl 36 ........................................ 0 . Ivy Gold Cloth &Vinyl 3G ........................................ 0 . Ivy Gold Leather & Vinyl (Lincoln) 3K ........................................ L t Aqua Cloth & Vinyl 3W .......................................White w/Black Knit and/or Vinyl 3W .......................................White w/Black Leather & Vinyl (Lincoln) 3Y ........................................ Lt. Nugget Gold Cloth &Vinyl t Vinyl (T-Bird) 3Y .......................................L . Nu et Gold K n ~andlor Black foth.& Vinyl 4A ........................................ 4A ........................................ Back Knit andlor Vinyl 48 ........................................ 0 . Blue Vinyl 48 ........................................ 0 . or Lt. Blue Vinyl 40 ........................................0 . Red Vin I 4G ........................................k . Ivy Gol(rCloth & Vinyl 46 ........................................ 0 . Ivy Gold Vinyl 4K .......................................L t Aqua Vinyl 4W ....................................... White wlllack Vinyl 4Y .......................... :............. Lt. Nu et Gold Knit andlor Vinyl 5A ...................................... Back & k t h &Vinyl 5A ........................................ Back Knit andlor Vinyl 5A ........................................ Back Leather & V~nyl(Lincoln) 5 8 ........................................ Lt. Blue Cloth andlor Vin I 5 0 ....................................... . . B l u e Knit andlor Vin 50 ........................................ 0 . Blue Leather & viny/(Lincoln) 5 0 ........................................0 . Blue Cloth & Vinyl (Mercury) 5 0 ........................................ 0 . Red Cloth & Vinvl (Monteno) - Code Trim Schemes 5 0 ...................................... 0 . Red Knit and/or Vinyl 1 5 0 ....................................... 0 . Red Leather & Vinyl (Lincoln) M e . Saddle Leather & Vinyl (Lincoln) 5F ........................................ 56 ........................................ 0 . Ivy Gold Knit andlor Vinyl 5G ........................................ 0 . Ivy Gold Cloth & Vin I 5G ........................................ 0 . Ivy Gold Leather & d n y l (Lincoln) 5K ........................................ A q u a Cloth & Vinyl (Montego) 5K ........................................ Lt. Aqua Vinyl 5K ........................................L t Aqua Leather & Vin I (Lincoln) 5W ...................................... W h e wBlack K n ~an t /or Vinyl 5W .......................................Whde w1BIack Leather & Vinyl (Lincoln) 5Y ....................................... Lt. Nugget Gold Cloth & Vinyl 5Y ........................................ Lt. Nugget Gold Knit andlor Vinyl (Mustang, Fairlane) 5Y ........................................ N u et Gold Leather & Vinyl (Lincoln) 6 1 ........................................Black t i ! andlor Vinyl 6A ........................................ B l a c k l o t h & Vin I(Lincoln) 6 1 ........................................ Black Leathy & d n Y l (Cougar) 6 0 ........................................ 0 . or Lt. Blue Vinyl 6 0 ........................................ 0 . Blue Leather & Vinyl (Cougar) 6 0 ........................................ 0 . Red Knit andlor Vinyl . . 6 0 ........................................ 0 . Red Leather & Vinyl (Cougar) 6F ........................................ M e . Saddle Leather & Vinyl 0 . Ivy Gold Vinyl 6G ........................................ 0 . Ivy Gold Leather & Vinyl (Cougar) 6G ........................................ 6K ........................................ L . Aqua Vinyl 6K ......................................... A q u a Leathy & Vinyl (Cougar) 6W ....................................... White wBlack Vinyl 6Y ................................... :...Lt. Nugget Gold Vinyl 6Y ......................................... L t Nu get Gold Leather & Vinyl (Cougar) Back k n y l 7A ........................................ 7A .................. :.....................Back Cloth &Vinyl (Fairlane) 7A ........................................ Back Leather & V~nyl(L~ncoln) 70 ........................................ Lt. Blue Vinyl (Cougar, Montego, Ford) 78 ........................................ 0 . Blue Cloth & Vin I 7 8 ................................ X.."...0 . Blue Leather & i n y \ (Lincoln) 70 ........................................ 0 . Red Vinyl (Mustang) 7 0 ........................................ 0 . Red Cloth & Vinyl 7G ....................................... .. Ivy Gold Cloth andlor Vinyl 1 7G ........................................ 0 . Ivy Gold Leather & Vinyl (Lincoln) L . Aqua Cloth &Vinyl 7K ........................................ White w1Black Vinyl 7W ....................................... 7W ....................................... White Leather & V~nyl Lincoln) 7Y ........................................ L t ~ u g g eGold t Cloth*k Vinyl 7Y ........................................Lt. Nugget Gold Vinyl (Ford, Meteor, Mustang) 8A ........................................ Back Knit andlor Vinyl 8'A ........................................ Back Leather & Vinyl (T-Bird) 8 8 ........................................ 0 . or Lt. Blue Knit andlor Vinyl 8 0 ....................................... 0 . Red Knit andlor V~nyl 8F ........................................ M e . Saddle Knit andlor Vinyl : 8G ...................................... . .. Ivy Gold Knit andlor Vinyl 8K ........................................ L Aqua Knit andlor Vinyl . 8W ....................................... White w/Black andlor Vin I, 8W ....................................... White w1Black Leather & b~ny!(T-Bird) 8Y ..................................... ; . . Nugget Gold Knit andlorv~nyl 9A ........................................ Back Knit andlor Vin I 9 1 ........................................ Black Cloth &Vinyl (told, ~ete;r) 9 0 ..................................:.....L t Blue Knit and/or Vin I 9 8 ....................................... Ok. Blue I t & Vinyl ( o r Meleor) 9 0 ........................................ 0 . Red K n ~andlor t Vin I 1 9 0 ................... :.................... 0 . Red Cloth &Vinyl ( { o l d - ~ e t ~ r ) 9G ........................................ 0 . Ivy Gold Cloth & Vinyl i 9K ........................................ Lt. Aqua Cloth & Vin I 9Y ....................................... .Lt . Nugget Gold clot%andlor ~ i "I ' 9Y ........................................ Lt. N u s e t Gold Knit andlor vinyl AA(1W) ................................ Wh~teVlnylWith Black (Cougar) Back Cloth & Vin I (Lincoln) AA ........................................ AB(1W) ................................White Vin I With glue (Cygar) AB .....,.................................. Lt. Blue Both & Vinyl (Lmcoln) AD(1W) ................................ Whitevinyl With Red (Cou ar) i AG(1W) ...........:.................... W h e n I With Iv Gold (iougar) AG ........................................ L t Ivy ~ o r Cloth d %vinyl (Lincoln) White Vin IWith Aqua (Cougar) I AK (1W) ............................... AK ........................... L..........Lt. Aqua 4 0 t h & Vinyl (Lincoln) AL ...................... :.................L t Silver Cloth &Vinyl (Lincoln) L t Nugget Gold Cloth &Vinyl (Lincoln) AY ........................................ AY(1W) ................................ Whi eVinyl With Nu et Gold (Cougar) BA(2W) .......................... Whi~eVinyWith 01% (Cougar) Back Vlnyl (Fairlane) BA ........................................ BB(2W) ................................ Wh~teV~nyl With Blue (Cougar) d : 1 . r - I I 1 Vehicle Identification INTERIOR T R l M CODES-(continued) Code INTERIOR T R l M CODESi-(continued) Trim Schemes BB ........................................ Lt. Blue Vinyl (Fairlane) Lt. Blue Leather & Vinyl (Lincoln) BB ........................................ BD(2W) .............................;.Whitevinyl With Red (Cou ar) BG(2W) ................................ White Vinyl With Ivy Gold (tougar) BG ........................................ Lt. Ivy Gold Leather & Vinyl (Lincoln) BK(2W) ................................ White Vlnyl With Aqua (Cougar) BY(2W) ................................Whitevinyl With Lt. Nu et Gold (Cougar) L t Nu get Gold Vinyl (&lane) BY ..................................... CA ........................................ Back !loth & Vinyl CA ........................................ Back Vin I (Montego) CB ................................:.......Dk. Blue b o t h &Vinyl CB ........................................L t Blue Vlnyl (Montego) CD ...................................... k . Red Cloth & Vinyl CD ........................................ k . Red Vinyl CG .......................................k Ivy Gold Cloth & Vinyl CG ........................................Lt. Ivy Gold Leather & Vlnyl (Lincoln) CK ........................................Lt. Aqua Cloth &Vinyl CY ........................................Lt. Nugget Gold Cloth &Vinyl CY ........................................Lt. Nu get Gold Vinyl (Montego) Back [loth &Vinyl DA ..................................... DA(4W) ...............................Whitevinyl With Black (Cougar) DA ........................................ Black Knit and/or Vinyl DB .......................................Dk. Blue Cloth & Vinyl DB.......................................k Blue Vlnyl (Mercury) White Vinyl With Blue (Cougar) DB(4W) ............................... DD(4W) ............................... White Vin I With Red (Cougar) DD .....................................,Slk Red Jnit and/or Vinyl DD .......................................Dk. Red Cloth & Vinyl DG .......................................Dk. Ivy Gold Vinyl DG .......................................Dk. Ivy Gold Cloth &Vinyl DK .......................................L t Aqua Cloth &Vinyl DW .......................................White w/Black Knit and/or Vinyl DY .........r .............................L . Nugget Gold Cloth & Vinyl DY ........................................ L t Nugget Gold Vlnyl (Mercury) EA ........................................Back Knit and/or Viqyl EA ........................................Back Cloth &Vinyl EB ...................................... k Blue Cloth &Vinyl ED ........................................ k . Red Cloth &Vinyl EG ........................................k Ivy Gold Cloth & Vinyl EK ........................................L t Aqua Cloth & Vinyl EW ......................................White w/Black Knit and/or Vinyl EY ........................................Lt. Nugget Gold Cloth & Vinyl FA .......................................Back Knit and/or Vin I FA(6W) ................................ Whitevinyl With Mac[ (Cougar) FB ........................................ Lt. or Dk. Blue Vinyl FB(6W) ................................White Vlnyl W ~ t hBlue (Cougar) FD ........................................ k Red Knit andlor Vinyl FD(6W) ................................ Whitevinyl With Red (Cougar) FG ...................................... k Ivy Gold Vinyl FG(6W) ................................Whitevinyl With Ivy Gold (Cougar) FK(6W) ............................... White Vin I With Lt Aqua (Cougar) FW ....................................... White wdlack ~nit'and/orVinyl FY ..............................:.........L t Nugget Gold Vinyl FY(6W) ................................Whitevinyl With Nugget Gold (Cougar) GA ........................................ Back Vinyl GB ........................................ L t Blue Vinyl GD ........................................ k Red Vin I GG ........................................ k Ivy Gol Vinyl GY ........................................Lt. Nugget Gold Vinyl HA ........................................ Black Knit and/or Vinyl HA(8W) ................................White Vinyl With Black (Cougar) HA ...................................... Black Leather & Vinyl (Mercury) HB....................................... L t Blue Vinyl HB (8W) .............................. Whitevinyl With Blue (Cougar) HD .......................................D k Red Vinyl HD ....................................... Dk. Red Leather & Vinyl (Mercury) HD(8W) ...............................White Vinyl With Dk. Red (Cougar) HG......................................k Ivy Gold Vinyl HG(8W) ............................... Whitevinyl With Ivy Gold (Cougar) HK ....................................... L t Aqua Vinyl HK(8W) ...............................White Vin IWith Lt. Aqua (Cougar) HW ............................. :........ White w d a c k Leather & Vinyl (Mercury) HW ....................................... White w/Black Vinyl (Fairlane) dY Code Trim Schemes H Y ( ~ W................................ ) White Vinyl With Nugget Gold (Cougar) HY........................................Lt. Nugget Gold Knlt andlor Vinyl JA ........................................ a Knit and/or Vinyl JB ....................................... L Blue Cloth & Vinyl (Lincoln) JG ........................................ L . IVY Gold Cloth& Vinyl White w/Black Knit and/or Vinyl JW ........................................ Lt. Nugget Gold Knit andlor Vinyl JY ........................................ JY ........................................ t Nugget Gold Cloth & Vinyl (Lincoln) KA, .......................................Back K n ~and/or t Vln I KA ........................................ Black Cloth & Vin I (?ord-~ercury-~eteor) KA ........................................ Back Leather & ~ n y(Lincoln) l KB ........................................ k . Blue Cloth & Vinyl KB ........................................M e Blue Cloth & Lt. Blue Vinyl (Ford-Montego) k . Blue Leather & Vinyl (Lincoln) KB ........................................ KD........................................ k Red Cloth &Vinyl KG ........................................ Dk. Ivy Gold Leather & Vinyl (Lincoln) k Ivy Gold Cloth & Vinyl KG ....................................... KL ........................................ Lt. Silver Leather & Vinyl (Lincoln) KW ....................................... White W/Black Leather & Vinyl (Lincoln) ;.......... Lt. Nugget Gold Knit and/or Vinyl KY ............................. KY ........................................ L t Nugget Gold Cloth & Vinyl Back Knit and/or Vinyl LA ........................................ LA ........................................ Back Leather & Vinyl (Lincoln) L t Blue Knit and/or Vinyl LB ........................................ k Blue Leather & Vinyl (Lincoln) LB ........................................ LD ....................................... D k Red Knit and/or Vinyl LE .......................................Lt. & Med. Beige Vinyl LG ......:................................. k Ivy Gold Leather & Vinyl (Lincoln) White w/Black Knit and/or Vinyl LW ..................................... LW ....................................... White w/Black Leather & Vinyl (Lincoln) Lt. Nugget Gold Knit and/or Vinyl LY ........................................ MA ....................................... Black Vlnyl MB .......................................Lt. Blue Vinyl Dk. Red Vlnyl MD ....................................... MW ...................................... White wWlack Vin I NA ........................................ Black Knit and/or &inyl NB ....................................... Lt. Blue Vin I NY ..................................... L t N u q e t (told Knit andlor Vinyl PA ........................................Black V~nyl PB ........................................ L t Blue Vin I PY ........................................Lt. Nugget Jold Vinyl QA........................................ Back Knit and/or Vinyl Lt. Blue Vinyl ...................................... White Knit and/or Vinyl Lt. Nugget Gold Vinyl QY........................................ RA ........................................ Back Knit and/or Vinyl RA ....................................... Back Leather & Vinyl RB..: ....................................L t Blue Knit and/or Vinyl D k Red Knit and/or Vinyl RD ....................................... Dk. Red Leather & Vinyl RD ....................................... White w/Black Leather & Vinyl RW ....................................... White W/Black Knit and/or Vinyl RW ....................................... Lt. Nugget Gold Knit andlor Vlnyl RY ........................................ Lt. Blue Leather & Vinyl(Linco!n) SB ........................................ SG ........................................ Lt. IvyGold Leather & V~nyl(L~ncoln) TG ........................................ Lt. Ivy Gold Leather & Vinyl (Lincoln) Back K n ~and/or t Vinyl VA ........................................ Dk. Blue Vinyl VB ........................................ k . Ivy Gold Vinyl VG ........................................ VW ..................................... White w/Black Knit and or Vinyl VY ..................................... . . .. Nugget Gold Vinyl Black Knit and/or Vinyl WA ....................................... White w/Black Knit,and/or Vinyl WW ...................................... WY ....................................... Lt. Nu get Gold K n ~and/or t Vinyl .......Back !loth &Vinyl YA ................................. YB ........................................k . Blue Cloth &Vinyl YD ........................................ k . Red Cloth & Vinyl YG ............;........................... k . Ivy Gold Cloth & Vinyl Lt. Aqua Cloth &Vinyl YK ........................................ Lt. Nu get Gold Cloth & Vinyl YY ........................................ ZA ..................................... Black !loth & Vinyl ZB ........................................ k Blue Cloth & Vinyl ZG ...........!............................ k . Ivy Gold Cloth & Vinyl J. . . 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. Code First Year Month Code Second Year January.. . . . . . . . . . . . . . . . . . A , . . . . . . . . . . . . . . . . . . . . .N February.. . . . . . . . . . . . . . . . . .B.. . . . . . . . . . . . . . . . . . . . . .P March.. . . . . . . . . . . . . . . . . . . . .C.. . . . . . . . . . . . . . . . . . . . . Q. April.. . . . . . . . . . . . . . . . . . . . . .D. . . . . . . . . . . . . . . . . . .R May.. . . . . . . . . . . . . . . . . . . . . . .E.. . . . . . . . . . . . . . . . . . . . . S. . . . . . . . . . . . . . . . . . . . ..T June.. . . . . . . . . . . . . . . . . . . . . F.. July. . . . . . . . . . . . . . . . . . . . .:r:G.. . . . . . . . . . . . . . . . . . . . . . U August.. . . . . . . . . . . . . . . . . . . H . . . . . . . . . . . . . . . . . . . . . . .. V September.. . . . . . . . . . . . . . . . .J . . . . . . . . . . . . . . . . . . . . . . . .W October.-. . . . . . . . . . . . . . . . . . .K . . . . . . . . . . . . . . . . . . . . . . .X November.. . . . . . . . . . . . . . . . .L.. . . . . . . . . . . . . . . . . . . . . .Y December.. . . . . . . . . . . . . . . . . M . . . . . . . . . . . . . . . . . . . . . . .Z LINCOLN-MERCURY Code District Code 11.. . . . . . . . .Boston 15.. . . . . . . . .New York 16. . . . . . . . . .Philadelphia 17.. . . . . . . . .Washington 21.. . . . . . . . .Altanta 22.. . . . . . . . .Dallas 23. . . . . . . . ..Jacksonville 26.. . . . . . . . .Memphis 31.. . . . . . . ..Buffalo 32. . . . . . . . . .Cincinnati 33. . . . . . . . ..Cleveland District 34. . . . . . . . . .Detroit 41. . . . . . . . . .Chicago 42.. . . . . . . . .St. Louis 46. . . . . . . . . .Twin Cities 51.. . . . . . . . .Denver , 52.. . . . . . . . .Los Angeles 53. . . . . . . . ..Oakland 54. . . . . . . . ..Seattle . 84. . . . . . . . ..Home Office Reserve FORD O F CANADA DISTRICT CODES (DSO) Code 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 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 of t h e District which ordered t h e unit. I f t h e u n i t i s a regular production unit, o n l y t h e District code n u m b e r w i l l appear. B l . . . . . . . . . . . . . . . . .Central 82.. . . . . . . . . . . . . . . .Eastern 63.. . . . . . . . . . . . . . . .Atlantic I 1 thru 17.. . . . : . . . . .Export FORD Code District 11.. . . . . . .Bodon 1 3 . . . . . . . .New York 15. . . . . . . .Newark 16. . . :. . . .Philadelphia 17. . . . . . . .Washington 21. . . . . . . .Atlanta 22. . . . . . . .Charlotte 24.. . . . . . .Jacksonville 25. . . . . . . .Richmond 28. . . . . . . .Louisville 32. . . . . . . .Cleveland 33.. . . . . . .Detroit 41. . . . . . . .Chicago43.. . . . . . . Milwaukee 44.. . . . . . .Twin Cities Code District . 51.. . . . . . .Denver 53.. . . . . . .Kansas City 54. . . . . . . .Omaha 55.. . . . . . .St. Louis 56.. . . . . . .Davenoort 61. . . . . . . .Dallas' 62. . . . . . . .Houston 63.. . . . . . .Memphis 64. . . . . . . .New Orleans 65. . . . . . ..Oklahoma City 71. . . . . . . . Los Angeles 72.. . . . . . .San Jose 73.. . . . . . .Salt Lake City 74. . . . . . . .Seattle 75. . . . . . . .Phoenix 83 . . . . . . .Government 84. . . . . . . . Home Off ice Reserve 85. . . . . . . .American Red Cross 89.. . . . . . .Transportation Services 90's . . . . . .Export District Code District 84.. . . . . . . . . . . . . . . .Midwestern 66.. . . . . . . . . . . . . . .Western . 67.. . . . . . . . . . . . . . . .Pacific Note: Canadian Lincoln-Mercury units use prefix "A" in place of "6". PART 2-1 PAGE General Brake Service ................ 02-01 - 0 1 PART 2-3 PAGE Specifications .............................02-03-0 1. PART 2-2 Brake System .............................. 02-02-0 1 Part 2-1 General Brake Service . . . . COMPONENT INDEX I 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 master cylinder before performing the test procedures. If the fluid level is not within 114 inch of the top of the master cylinder reservoirs,, add Ford Brake Fluid - Extra Heavy Duty Part Number C~AZ-19542-A (ESAM6C25-A) or equivalent for all brake applications. The -extra heavy duty brake fluid is colored blue for identification purposes.' D o not mix low tem.perature brake fluids with the specified brake fluid. Should one of the wheel ,brakes be locked ,and the vehicle must be moved, open the bleeder screw long enough to let out a few drops of brake fluid. This bleeding operation will release the brakes but will not correct the cause of trouble. BRAKE PEDAL FREE HEIGHT A N D TRAVEL MEASUREMENTS With .the ,engine running for full power brake operation, measure the brake pedal free height, and check the brake pedal.travel with the use o f ' t h e Brake Pe'dal Pressure Gauge, Tool WREL500-50 as follows: BRAKE PEDAL FREE HEIGHT MEASUREMENT 1. Insert a slender, sharp pointed prod through the carpet and sound deadener to the dash panel metal and measure the distance to the brake pedal (Fig. I). 2. If the position of the pedal is not within specification, check the brake pedal linkage for missing, worn, or damaged bushings, or loose attaching bolts and replace them, if required. 3. If the pedal free height is still out of spec~fication,check! the brake pedal booster or master cylinder to be sure the correct parts are installed. Replace the worn or damaged parts as necessary. . BRAKE PEDAL TRAVEL MEASUREMENT ' 1. Install a Brake Pedal Effort Gauge on the brake pedal pad (Fig. 2). 2. Hook a steel measuring tape to the brake pedal as shown in Fig. I . Measure and record the distance from the brake pedal free height position to the reference point, which is at the six 02 -0 1 -02 02-0 1 -02 Brakes STEERING WHEEL RIM N 0 T E : A B B DIMENSION TO BE MEASURED T O SHEET M E T A L C DIMENSION T O BE MEASURED PARALLEL T O THE V E R T I C A L CENTERLINE OF THE STEERING COLUMN WlTH A 50 POUND LOAD APPLIED T O T H E CENTERLINE OF THE J R A K E PEDAL PAD. (CHECKS ON POWER BRAKE VEHICLES MADE WlTH ENGINE RUNNING b FIG. 1 - Brake Pedal H e i g h t a n d Travel Measurements o'clock position on the steering wheel 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 specification 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 reverse 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 completely 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 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. I f 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 FIG. 2-Brake P e d a l E f f o r t G a u g e Installed I.Check the hydraulic brake system 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. deDress the pedal, and hold i t i n the ab.plied position. Start the engine. I f the I i 02-0 1-03 02-01-03 Brakes 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. I f no action is felt, the vacuum .booster system is not functioning. I f the brake pedal movement feels spongy, bleed the hydraulic system to remove air from the system. Refer to Hydraulic System Bleeding, Part I, Section 2. ' V A C U U M . TESTS-VACUUM RELEASE P A R K I N G BRAKES Visually check the 'peration of the brake' linka'ge as lhe brake pedal is depressed. Then, check the operation of the brake linkage when the manual 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 checks should indicate whether the manual parking brake control linkage is operating properly or requires repair or adjustment due to inability of Ihe parking brake lo moderate vehicle movement. Perform tests of the parking brake system and controls after making certain the linkage and manual controls 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 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 t o the wrong connection. All of the vacuum parking brake control checks are to be performed with the engine running a t idle speed. Leaks in the parking brake hoses or a disconnected o r i m p r o p e r l y connected hose can usually be found by the listening for a hissing sound hose routings, Under no circumstances should air pressure be applied to the system as the actuator diaphragm in the parking brake vacuum motor may be damaged. I. Start the engine and run it a t - ! idle speed. With the transmission shift control i n neutral, depress the parking brake pedal to a p p l y the parking brake, M~~~ 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. I f the parking brake releases, the parking brake vacuum control is working properly. 2. I f the parking brake does not release, test for vacuum a t 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 nccomplished 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 nlinimum of ten inches of vacuum is required to actuate the parking brake vacuum motor. D o 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. I f a minimum reading is not , , , I . present when checking each of the a f o r e m e n tioned compo'nents, they must be replaced. R O A D TEST A road test should be conducted only when the operator is sure the brakes will stop the vehicle. I f the road test reveals h e or more p r o b ~ mconditions, correct all functions of the vacuum system, brake booster and hydraulic system prior to removing brake drums, brake calipers, brake shoes and liningsl or backing plates. , ' , ANTI-SKID C O N T R O L SYSTEM TESTS No adjustments or repairs are to be performed on the skid co?trol system. Damaged or worn parts are to be replaced. Refer to Ford C a r and Truck Diagnosis 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 until it is engaged in the first notch of the control. On a vacuum release brake, the first notch will be approxi- , ' 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 transmission in neutral, t u r n , the adjusting nut forward against the equalizer (Figs. 3 and 4) until there is 100 , R.H. ADJUSTING NUT-2A H 1537-c FIG. 3-Parking Brake Adjirstrnent-Ford, Thunderbirdand Continental M a r k Mercury, Meteor, , 02-0 1-04 I ' I I : I , 1 I I 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 t o the center line of the wheel. 4. Release the parklng brake, and check to make sure that the brake shoes return t o 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 i n step 4. 7. I f 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 : PA~KING BRAKE CABLE I AND CONDUIT , ( ! Brakes R E A R WHEEL I SPRING SEAT-2A616 FIG. 4-Parking Brake Linkode Adjustment-Fairlane, Montego, Falcon, M u s t a n g a n d C o u g a r THUNDERBIRD, C O N T I N E N T A L M A R K Ill, AND LINCOLN CONTINENTAL i 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 pushing down the manual release lever. 2. Depress the parking brake pedal 1 114 inch from its normal released position. 3. Raise the vehicle with the transmission i n 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 i n 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 i t is fully engaged. 7. Release the parking brake again, and check as i n step 5. 8. Depress the pedal 112 inch. The brakes should not drag. 9. I f 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 r o d is provided with an' adjustment screw to maintain the correct relationship between the booster control valve plunger and the master cylinder. I f the plunger is too long i t w i l l prevent the master cylinder piston from completely releasing hydraulic pressure and can cause the brakes to drag. I f the plunger is too short i t will result i n excess pedal travel and an undesirable clunk i n 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 i n the original unit. I f 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 o f Midland-Ross power brake booster assemblies must be done according to the following procedure: REAR WHEEL ADJUSTING NUT EQUALIZER \ /L LOCK \ CABLE ASSEMBLY H1611-A FIG. 6-Parking Brake Linkage Adjustment-Lincoln Continental #16 1 - 2 . 7 / 8 " - 1 U.S.S. GAUGE SHEET STEEL 4I- H1087-E : I FIG. 5-Checking Parking Brake Breakaway Torque FIG. 7-Push Dimensions Rod G a u g e ' 02-0 1 -05 Brakes 1. Disconnect the master cylinder from the booster assembly and secure away 'from the booster without disconnecting the brake tubes. 2 . 1Reinstall 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 ten'sion 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 t h e B e n d i x p o w e r 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- 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. D o not set up side forces on the .push rod as it may break the valve plunger. This is an approximate adjustment only. T o 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 A N D CENTRALIZING O F THE DIFFERENTIAL V A L V E 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. M A N U A L 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, D O N O T allow the reservoir to run dry. Keep the master cylinder res- ervoirs filled with Ford Fluid-Extra Heavy Duty - P q t Number C6AZ19542-A (ESA-M6C 25-A). the extra heavy duty brake fluid is colored blue for identification purposes. D o not mix low temperature brake fluids with the specified fluid during the bleeding operations. Never re-use brake fluid which has been drained fro'm the hydraulic systems. 1. I f t h e m a s t e r c y 4 i n d e r i s equ~pped 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 posltion. Repeat this operation ,until fluid is free of air bubbles, then tighten the bleeder screw. D o not use the secondary piston stop screw, located on the bottom of the master cylinder to bleed the brake system. Looseni,ng or removing this screw could result in damage to the secondary piston or stop screw. 2. T o bleed the secondary (rear) brake system, position a suitable 318 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 fittine. - APPROXIMATELY 25' I I \ ADJUST PUSH ROO SCREW T O FIG. 9-Wrench f o r Bleeding Brake Hydraulic System I ADJUSTMENT PUSH ROD ADJUSTMEHT-MIDLMD-ROSS FIG. 8-Brake Booster Push Rod M e a s u r e m e n t 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. 4. Push the brake pedal down slowly through its full travel. 'Close the bleeder fitting, then return1 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 bleyder fitting and remove the bleeder tube. 6. Repeat t h ~ s procedure a t the brake wheel cylinder on the opposite I I I 02-0 1 -06 Brakes , ; ; I : / / 1 ; I I : ; I I 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 i n the master cylinder cover. When the bleeding operation is completed, the fluid level should be filled t o within 114 inch of the top of the reservoirs. 7. I f 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. O n disc brake equipped models be sure that the front brake pistons are returned to their normal positions and that the shoe and liqing 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. I PRESSURE BLEEDING t ' I i : I 1 / 1 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 (ESANumber , G 6 A Z - 19542-A M6C25-A) or equivalent for all brake applications. The brake fluid is colored 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 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. 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 the bleed screw and bleed the master cylinder until the fluid is free of air bubbles; then, tighten the bleed screw. D o not use the secondary piston stop screw, located on the bottom of the master cylinder, t o bleed the master cylinder. 4. I f the rear wheel cylinders, the secondary brake system, are to be bled, position a 318 inch box wrench (Fig. 9) on the bleeder fitting on the right rear brake wheel cylinder. A t tach a bleeder tube to the bleeder filting. 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 i n a container partially filled with clean brake fluid, and loosen the bleeder fitting. 7. When air bubbles cease to appear i n 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. I f 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. O n 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. I f 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 i s completed, close the bleeder tank valve and remove the tank hose from the adapter fitting. 12. O n disc b r a k e 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. F i l l the master cylinder ,reservoirs t o within 114 inch of the top. Install. the master cylinder cover adi gasket. Be sure the Diaphragm type gasket is properly positioned i n the master cylinder cover. 14. Centralize the pressure differential valve as follows. Tool J-21741 COMPRESS TOOL AND POSITION ONTO V A L V E . RELEASE TO ALLOW SPRING ACTION TO FORCE ROD OUT RELEASE ROD FIG. 70-Gisc Brake M e t e r i n g Valve-Lincoln Continental ' 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. T o centralize the pressure differential valve and turn off the warning 3 Brakes 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 O N 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 f i l l them to within 1/4 inch of the top with the specified brake fluid, if necessary. 3. Turn the ignition switch tb the O F F position. 4. Before driving the vehicle, check the operation of the brakes and be sure that a firm pedal is obtained. CLEANING AND INSPECTION DlSC BRAKES I. 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. I f 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 i f 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. O n L i n c o l n 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. I f 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. T o 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 I inch from the outer edge. Rotate the rotor and take an indicator reading. I f 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 801 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. I I). FALCON-FAIRLANE MUSTANG-COUGAR MONTEGO 4 k 'IN inboard rotor face (dimension B ) and the outb.oard rotor surface and the inboard bearing c u p (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 i n Group 3, in order to prevent bearing failure. 6. Check the rotor for scoring. Mi- nor 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, i f required. 7. Visually check the caliper. I f the caliper housing is leaking it should be replaced. I f a seal .is leaking the caliper must be disassembled and new .seals installed. I f a pisto,n is seazed in the b.ore a new caliper housing is required. On Lincoln Continental models the two halves of the caliper assembly should never be separated.1 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. DlSC BRAKE SERVICE PRECAUTIONS - METEOR THUNDERBIRD I 1.12 M I N . ~ I 1- H1633-A FIG. 1 1-Disc Brake Rotor Models Except Service Limits-All Lincoln Continental O n 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 ?f the rotor and caliper assemblies should be done in a way to avoid deformhion of the brake rotor and nicking o,r scratching of brake linings., 2. If a caliper piston is removed for any reason, the plston seal must be replaced. 3. During removal and installation of a wheel assembly, exercise care not to ~nterferewith and damage the cali- Brakes BEARING CUP DIMENSION "0" 0.755 MINIMUM DIMENSION "A" 0.395 MINIMUM Hl532-B \ FIG. 12-Disc Limits-Lincoln Brake Rotor S e r v k e 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 . 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 holddown springs is strongly recommended. ~ v e r h e a t e d ~ s ~ r lose i n ~ stheir pull and could cause the new lining to wear prematurely, if they are not replaced. 5. I f ,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 I, 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; Brake System Part 2-2 Brake System MODEL APPLICATION COMPONENT INDEX iI = * gu " l t. , z g o 6 c 3 , .,L m O ; i 6 2, m -28 z" = T ' r ? c c , $ ; , , 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. N/A indicates that the item is not applicable to the vehicle listed. = 6 ;= i . E , = . . -t m I 51" 02-02-02 02-02-02 Brake System COMPONENT INDEX Removal and Installation - Non-Power Removal and Installation - Power PARKING BRAKE Description PARKING BRAKE ACTUATOR T O CONTROL CABLE Removal and installation PARKING BRAKE ACTUATOR T O E Q U A L I Z E R CABLE Removal and Installation PARKING BRAKE CONTROL Removal and Installation PARKING BRAKE EQUALIZER T O CONTROL CABLE Removal-und Installation P A R K I N G BRAKE E Q U A L I Z E R T O REAR WHEELCABLE Removal and Installation P R E S S U R E D I F F E R E N T I A L VALVE Removal and Installation P R E S S U R E M E T E R I N G VALVE Removal and Installation P R O P O R T I O N I N G VALVE Removal and Installation WHEEL: C Y L I N D E R Cleaning and Inspection Disassembly and Overhaul Removal and Installation 02-19 02-19 02-19 02-20 02-20 02-20 02-20 02-20 N / A N/A N/A 02-2 1 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 NIA N / A NIA 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 a t the head of the column. NJA indicates that the item is not applicable to the vehicle listed. 02-02-03 02-02-03 Brake System 1 1 DESCRIPTION DUAL MASTER CYLINDER BRAKE SYSTEM FLOATING CALIPERALL MODELS EXCEPT LINCOLN CONTINENTAL DlSC BRAKE 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 Ill, and L i n c o l n C o n t i n e n t a l models. T h e 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. . 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 valve located at the pressure imp!lse 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 dual-master cylinder brake system has been incorporated in all models to provide increased safety. The system consists of a dual-master cylinder (Fig. I), 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. The caliper assem1.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 111 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 stabi!izers. The floating caliper contains the single cylinder and piston assembly. The cylinder bore contains a pisdon 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 shot: and lining abem- DlSC B R A K E S ! - PRIMARY SYSTEM B R A K E FLUID RESERVOIR R E T U R N SPRING (PRIMARY) (SECONDARY) B R A K E OUTLET PORT FIG. ]-Dual \ SECONDARY PISTON ASSEMBLY (PRIMARY) BRAKE OUTLET PORT Master Cylinder-Typical I PRIMARY PISTON ASSEMBLY I ! BRAKE WARNING LAMP SWITCH BRAKE WARNlFlC CAMP SWITCH BRAKE WARNING LAMP SWITCH WARNING LAMP LOW PRESSURE SIDE BRAKE WARNING LAMP I FRONT BRAKE OUTLET FIG. 2-Pressure FRONT 3RAKE VALVE PISTON IS CENTRALIZED. PRIMARY AND SECONDARY SYSTEM PRESSURES ARE EQUALIZED PROPORT'ONING VALVE DISC BRAKES VALVE PISTON HAS MOVED TO LOW PRESSURE AREA. WARNING LAMP SWITCH PLUNGER IS DEPRESSED, LIGHTING THE BRAKE WARNING LAMP. H1634-A 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 friction material bonded to a metal plate called the shoe. It is replaced as a unit. FIXED CALIPER LINCOLN CONTINENTAL saci H1 FIG. 3-Disc Brake AssemblyFloating Caliper-All Models Except Lincoln Continental FIG. 4-Disc Broke AssemblyFixed 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 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 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 duter 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. P~STON'~EAL FIG. 5-Floating h \ ANCHOR PLATE Caliper Assembly-Sectional View R 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 and 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 rea-rward and only when the secondary shoe is free to move toward the drum beyond a predetermined point. FIG. 6-Fixed Caliper Assembly-Sectional PISTON SEAL DISTORTED PISTON View PISTON SEAL R E L A X E D , I CALIPER HOUSING B R A K E S APPLIED FIG. 7-Function of Piston S e a l I BRAKES RELEASED H1569-B 02-02-06 02-02-06 Brake system SHOE WIDE (WCHOP PIN) PLATE SHOE WlDE (ANCHOR PIN) PLATE I WASHER FIG. 8-Self-Adjusting \ PRIMARY SHOE .TO.ANCHOR SPRING Brake Assemblies-Typical BRAKE BOOSTER SYSTEM This diaphragm-type brake booster is a ' self-contained vacuum-hydraulic braking unit mounted on the engine side of the dash panel. The brake booster is of the vacuum suspended-type which utilizes engine intake manifold vacuum and atmospheric pressure for its power. nects the actuator to the equalizer. The rear brake cables connect the equalizer assembly to the parking brake lever at each rear secondary shoe (Fig. 8). Two types of brake pedal control are used. The automatic (vacuum) re- lease type (Fig. 9) is used on the Mercury, Ford LTD, Meteor LeMoyne, Thunderbird, Continental Mark 111 and Lincoln Continental models. All other models use the manual releasetype (Fig. 10). On the automatic-type, the vacuum Adjustment of the push rod and replacement of the check valve and grommet are the only services permitted on the brake boostqr. The booster unit is to be exchanged when it is inspected, checked and found to be defective. P A R K I N G BRAKE An independent foot-operated parking 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 operating cable is routed from the parking brake control asse,mbly to the actuator assembly. An intermediate cable con- FIG.. 9-Parking Brake Control Assembly With Automatic Release-Typical 02-02-07 Brake System ANTI-SKID CONTROL SYSTEM '6 RELEASE PAWL CAM PIN ti 1636-A FIG. 10--Parking Brake Control Assembly With M a n u a l ~ l e a s e - ~ ~ ~ i c a l power unit with mounting bracket is riveted to the control assembly. The vacuum actuated piston within the unit is connected by a rod to the upper end of the release lever (Fig. 9). The lower end of the release lever extends out for alternate manual release 2 I N-VEHICLE ADJUSTMENTS AND REPAIRS After any brake service work, obtain a firm brake pedal before moving the vehicle. Riding the brake pedal (common on left foot application) should be avoided when driving the vehicle. BRAKE SHOE ADJUSTMENTSDRUM BRAKES, , in the event of vacuum power failure or for optional manual release at any time. Hoses connect the power unit and the engine manifold to a vacuum release valve in the transmission neutral safety switch. The .anti-skid control system consists of three major components (Fig. 39). Mechanically driven electromagnetic sensors at each rear wheel; an electronic control module mounted under the glove box; a vacuum powered 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 outboard of the wheel bearing. The teeth rotate past corresponding teeth on the inside diameter of stationary steel rings mounted in the bearing retainers. Also mounted in the retainers, are ring-shaped permanent magnets and coils of wire. Two wires: from each sensor connect the sensors to the control module. The control module consists of solid state electronic components sealed in a container. I t is connected to the sensors and to a solenoid on the actuator. The actuator is similar to a vacuum brake booster and consists ol three parts. A chamber divided by a vacuum suspended diaphragm; a hydraulic cylinder connected to the diaphragm; and a solenoid connected electrically to the control module. The hydraulic drum brakes are self-adjusting and require a manual adjustment only after the brake shoes have been relined, replaced, or when the length of the adjusting screw has been changed while performing some other service operation. The manual adjustment is performed with the drums removed, using the tool and the procedure detailed below. When adjusting the rear brake shoes, check the parking brakd cables for proper adjustment. Make sure that the equalizer operates freely. T o adjust the brake shoes: 1. Use Rotunda Tool H R E 8650, (Fig. I I) to determine the inside diameter of the drum braking surface. 2. Reverse the tool as shown in Fig. I I and adjust the brake shoe diameter to fit the gauge. Hold the automatic adjusting lever out of engagement while rotating the adjusting screw, to prevent burring the screw slots. Make sure the adjusting screw rotates freely. If necessary, lubricate the adjusting screw threads with a thin, uniform coating of MIC- 100-A. 3. Rotate Tool H R E 8650 around the brake shoes to be sure of the setting. 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 where the shoes contact the backing plate, being careful not to get the lubricant on the linings. 5. Install the drums. Install Tinnerman nuts and tighten securely. 6. Install the wheels on the drums and tighten the nuts to specification. 7. Complete the adjustment by applying the brakes several times with a minimum of 50 Ibs pressure on the pedal while backing the vehicle. After each stop the vehicle must be moved forward. 8. After the brake sho4s have been properly adjusted, check the operation of the brakes by making several stops while operating in a forward direction. 1 WHEEL CYLINDER , ; 1 I ' I REPAIR- DRUM BRAKE Wheel cylinders shouldl not be disassembled unless they are leaklng or unless new cups and boots are to be installed. It is not necessary to remove the brake cylinder from the backing plate to disassemble, inspect, or hone and overhaul the cylinder. Removal is necessary orlly when the 1 cylinder is damaged or scored beyond repair. , , a , 02-02-08 A 02-02-08 Brake System Tw/-HR~-8650 i Place a boot over each end of the cylinder. 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 primary or secondary brake system after primary or secondary brake system hose or? line replacement. Centralize the pressure differential valve after bleeding the system. -.- " -r I 4 .BRAKE TUBE REPLACEMENT I * If slction of the brake tubing becomes , 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 ,FIG. 7 7 -Adjusting brake tubing to fit underbody or rear axle contours; be careful not to kink .or crack,the tube. ' All brake tubing should be double flared properly to provide good leakproof 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 Shoes Using Tool HRE-8650 ' BRAKE HOSE REPLACEMENT H'"5-0 FIG. 72-Brake Wheel Cylinder-Typical DISASSEMBLY I. Remove the links and the rubber boots from the ends of the brake cylinder. Remove the pistons, cups, and return spring from the cylinder bore (Fig. 12). 2. Remove the bleeder screw from the cylinder. 3. Inspect the cylinder bore for score marks or rust. If either condition is present the cylinder bore must b e h o n e d . H o w e v e r , the cylinder should not be honed more than ,0.003 inch beyond its original diameter. 4. Check the bleeder hole to be sure that it is open. a , ASSEMBLY INSPECTION 1. Wash all parts in clean brake fluid. Dry with compressed air. 2. Replace scored pistons. Always replace the rubber cups and dust boots. 1. Apply a light coating of heavyduty brake fluid to all internal parts. 2. Thread the bleeder screw into the cylinder and tighten securely. 3. Insert the return spring, cups, and pistons into their respective positions in the cylinder bore (Fig. 12). A flexlble brake hose should be ;eplaced- i f +it shows signs of softening, cracking, or ,other damage. When installing a new front brake hose, position the hose to avoid contact with other,,chassis, parts. Place a new copper 'gasket,over they'hb'se fitting and thread the'hoie assembly into , therfront wheel cylinder. "Engage the opposite end .of the hosk: to the brack-. et on the frame..Install the horseshoe-type retaining clip,. and connect the ' tube to the hose -with ,the' tube,'fitting nut (Figs. 17 thru' 21). A rear brake ,hose should be installed so ,that it does not touch the muffler outlet pipe or shock absorber. Thread the .hose into the rear, brake tube connector. Engage the front end of t h ~hose to the bracket on the frame. Install the horseshoe-type retaining. clip, and connect the tube to the hose with the tube fitting nut. .:s 02 -02-09 3 Brake System REMOVAL A N D INSTALLATION FRONT BRAKE D R U M REMOVAL 1. Raise the vehicle until the wheel and tire clear the floor. Remove the wheel cover or hub cap, and remove the wheel and tire from the drum. 2. Remove the grease cap from the hub. Remove the cotter pin, nut lock, adjusting nut, and flat washer from 'the spindle. Remove the outer bearing cone and roller assembly. 3. Pull the drum off the wheel spindle: . ' 4. If the drum will not come off, pry the rubber cover from the brake backing plate. Insert a narrow screwdriver through the slot and disengage the adjusting lever from, the adjusting screw. While holding the adjusting lever away from the screw, back off the adjusting screw with the brake ad.justing tool (Fig. 13). Be very careful not to burr, chip, or damage the notches in the adjusting screw; otherwise the self-adjusting mechanism will not function properly. INSTALLATION 1. If the drum is being replaced, remove the protective coating from the new drum with carburetor degreaser. Then, use sandpaper to insure that no residue remains. Wipe the drum with a cloth soaked with denatured alcohol. Install new bearings and grease seal. Pack the wheel bearings, install the inner bearing cone and roller assembly in the inner cup, and ~nstallthe new grease seal see Part 3-5, Section 4. If the original drum is being installed, make sure that the grease in the hub is clean and adequate. 2. Adjust the brakes and install the drum assembly as out'ined under Brake Shoe Adjustments in this secaon. 3. Install the outer wheel bearing, washer and adjusting nut, # 4. Adjust the wheel bearing as outlined in Part 3-7, Section 2, then install the grease cap. Install the wheel .and hub cap. REAR BRAKE :DRUM REMOVAL 1. Raise the vehicle so that the tire is clear of the floor. 2. Remove the hub cap and wheel. Remove the three Tinnerman nuts and remove the brake drum:' If the drum will not ,come off, pry the rubber cover from the backing plate. Insert a narrow screwdriver through the hole in the backing plate, and disengage the adjusting lever from the adjusting screw. While holding the adjusting lever away from, the adjusting screw, back off the adjusting screw with the brake adjusting tool (Fig. 13). Be very careful not to burr, chip, or damage the notches in .the adjusting screw; otherwise, the self-adjusting mechanism will not function properly. INSTALLATION 1. Remove the protective coating from a new drum with carburetor degreaser; then sand lightly and wipe with a cloth soaked with denatured alcohol. FIG. 13-Backing Adjustment Off Brake FIG. 14-Retracting Removal Spring 2. Adjust the brakes as outlined under Brake Shoe ~djustm'entsin this section. Place the drum over the brake assembly and into pos~tion. ' 3. Install the three Tinnerman nuts and t~ghtensecurely. Install !the wheel on the axle shaft flange studs against the drum, and t~ghten the attaching nuts to spec~flcat~ons. I BRAKE SHOES A N D ADJUSTING SCREWD R U M BRAKES REMOVAL 1. With the wheel and drum removed install a clamp over the ends of the brake cylinder as shown in Fig. 14. 2. Remove the secondary shoe to anchor spring with the tool shown in Fig. 14. With the same tbol remove the primary shoe to anchor spring and unhook the cable eye from the anchor pin. 3. O n F o r d , Mercury, Meteor, Thunderbird, Continental Mark 11 I and Lincoln Continental models, remove the shoe guide (anchor pin) plate (Fig. 8). 4. Remove the shoe hold-down springs, shoes, adjusting screw, pivot nut, socket and automatic adjustment parts. 5. On rear brakes, remove the parking biake 'link and spring. Disconnect the parking brake cable from the parking brake lever. s. After removing the rear brake secondary shoe, disassemble the parking brake lever from the shoe by removing the retaining clip, and spring w,asher (Fig.- 8). 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 hight 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 rear brake, install the parking brake link and spring, back off .the parking ' Brake System \ brake ?djustment then connect the parking ,.brake cable to the parking brake lever (Fig. 8). 4. Install the 'shoe guide' (anchor .pin) plate on the.anchor pin when so equipped. 5. Place the ,cable eye over the anchor pin with the crimped side'toward the backing plate. 6. Install the primary shoe. to an. chor spring' (Fig. 15). 10. Place the adjusting socket on the screw and install this assembly between the shoe ends with the adjusting screw toothed wheel nearest the secondary shoe. 11. Hook the cable hook into the hole in the adjustihg lever. The adjusting levers are stamped with an R or L to indicate their installation on- right or left brake assembly (Fig. 16). 12. Position the hooked end of the ADJUS~~NG L M R ADJUSTING SCREW IDENTIFICATION LINES I. FIG. 15-Retracting Spring FIG. 16-Adjusting Screw a n d Installation Lever Identification 7. Install the cable guide on th.e secondary shoe web with the ,flanged hole fitted into the hole in the secondarv shoe web. Thread the cable arbund the cable guide groove (Fig. 8). It. is imperative that the cable be adjuster spring completely into, the large hole in the primary shoe web. The last coil of.the spring should be at the edge of the hole. Connect the loop end of the spring to the adjuster lever hole. 13. Pull the adjuster lever, cable and automatic adjuster spring down and toward the rear to engage the pivot hook in the large hole insthe secondary shoe web (Fig. 8). 14. After installation, check the action of the adjuster by pulling the'section of the cable between the cable g u ~ d eand the anchor pin toward the secondary shoe web far enough'to lift the lever past a tooth on the adjusting screw wheel. The lever should snap into position behind the next tooth, and release of the cable should cause the adjuster spring to return the lever to its original position. This return action of the lever will turn the adjusting screw one tooth. If pulling the cable does not produce the action described, or if the lever action is sluggish instead of positive and sharp, check the position of the lever on the adjusting screw toothed wheel. With the brake in a vertical position (anchor at the top), the lever should contact the adjusting wheel 3/16 inch (plus or minus 1/32 inch) above the centerline of the screw. If the contact point is below this centerline, the lever will not lock on the teeth in the adjusting screw wheel, and the screw will not be turned ' positioned i n this groove and not between the guide and the shoe web. 8.. Install the secondary shoe to anchor spring with the tool shown in Fig. 15. Be certain that the cable eye is not cocked or binding on the anchor pin when inst'alled. All parts should be flat e brake on the anchor p i n . ~ ~ e m o vthe cylinder clamp. 9. Apply high-temperature grease (MIC-100-A) to the threads' and the socket end of the adjusting screw. Turn the adjusting screw,into the adjusting pivot nut to the limit of the threads and then back off 112 turn. Interchanging the brake shoe adjusting screw assemblies from one side of the vehicle to the other would cause the brake shoes to retract,rather than expand each time the automatic adjusting mechanism operated. T o pre- vent installation on the wrong side of the vehicle, the socket end of the'adjusting screw is stamped with an R or L (Fig. 16). The adjusting pivot. nuts can be distinguished by .the number of grooves machined around the body of the nut: Two grooves on the nut indicate a . right thread; one groove indicates a left tliread. as the lever is actuated by the cable. T o determine the cause of this condition: a. Check the cable end fittings. The cable should completely,~fill or extend slightly beyond the crimped section of the fittings. I f , i t does not meet this specification, possible damage is indicated and the cable assembly should be replaced. b. Check the cable length. On Ford, Mercury, Meteor, Thunderbird, 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 cable anchor to the end of the cable hook. c. Check the cable g u ~ d efor damage. The cable groove should be parallel to the shoe web, and the body of the guide should lie flat against the web. Replace the guide if it shows damage. d. Check the pivot hook on the lever. The hook s'urfaces should be square with the'body of the lever for proper pivoting. Replace the lever if the hook shows damage. e. See that the adjusting screw socket is properly seated in the notch in the shoe web. WHEEL CYLINDER DRUM BRAKE 1. Remove the wheel and the drum. 2. Remove the brake shoe assem- blies, Following procedures outlined in this section. . % 3 .Disconnect the brake line from the brake cylinder Figs. 17 thru 21. O n a vehicle with a vacuum brake booster, be sure the engine is stopped and there is no' vacuum in the booster system before disconnecting the hydraulic lines. T o disconnect the hose a t a front cylinder, loosen the tube fitting that connects the opposite end of the hose to the brake tube a t a bracket on the frame. Remove the horseshoe-type retaining clip from the hose and bracket, disengage the hose from the bracket, then unscrew the e n t ~ r ehose assembly from the front wheel cylinder. At a rear cylinder, unscrew the tube / I / TUBE 2265 3 1 PRESSURE DIFFERENTIAL TUBE 28253 ASSEMBLY /-TUBE 2A040 ASSEMBLY TUBE 2265 FIG. 17---Service Brake System-Ford, TUBE 2 2 M VIEW Z DISC BRAKE OPORTlONlNG VALVE PRESSURE IMPULSE PRESSURE DIFFERENTIAL VALVE 26257.D ASSEMBLY T U d E 2263 Mercury and Meteor TUOE 2253 2264 C9AA-2149 TUBE 2565 i . VlEW I N CIRCLE X T Y P I C A L 3 PLACES @ h DASH PANEL 1 i C7AA-2082-A R.H. C7AA-2A056-L.H. m + / 2 REQUIREP 2263-2264 ASSY. & VlEW I N CIRCLE V TYPICAL 5 PLACES VlEW T / a \ HOSE 2A448 VIEW I N CIRCLE J VlEW I N CIRCLE W T U 8 E 27.65 \. T U d E 2267.2268 VIEW I N CIRCLE N T Y P l CAL _ 2 PLACES - --. EXISTING B O L T AND WASHER 02 -02- 1 2 02-02-1 2 Brake System 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 - FIG. .. -- and Cougar VIEW IN c l R a E s TYPICAL 4 PLACES Brake System-Mustang VIE* R FOR DRUM BRAKES 19-Service \ L.H. FENDER APRON REF. VIEW IN URCLE U VIEW IN a R a E T nEw w 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 cylinder. Do not pull the metal tube away from the cylinder. Pulling the tube out of the cylinder connection will bend the metal tube and make installation difficult. The tube will separate from the cylinder when the cylinder is removed from the backing plate. 4. On all except the front wheels on Ford, Mercury, and Meteor models, remove the wheel cylinder attaching bolts and lock washers and remove the cylinder. On the front wheel of Ford, Mercury and Meteor models, remove the nut and washer that attaches the cylinder to the anchor pin. Remove the cylinder from the anchor pin. l NSTALLATION Wipe the end(s) of the hydraulic line to remove any foreign matter before making connections. 1. On all models except Ford, Mercury and Meteor, to install a front wheel cylinder, position the cylinder to the backing plate. lnstall the two lock washers and attaching bolts. Torque them to specifications. On Ford, Mercury and Meteor models, to install a front wheel cylinder, position the cylinder on the anchor pin against the backing plate. Install the washer and cylinder attaching nut on the anchor pin, and torque it to specification. Lock the washer retainer securely. 2. Install a new copper gasket over the hose fitting. Thread the hose into the cylinder 'and tighten it to specified torque. 3. Engage the opposite end of the hose to the bracket on the frame. I n stall the horseshoe-type retaining clip, and connect the brake tube to the hose with the tube fitting nut. Tighten the nut to specification with tool I 1 12- 144. 4. To install a rear wheel cylinder, place the rear wheel cylinder into position. Enter the tubing into the cylinder, and start the tube fitting nut into the threads of the cylinder. 5. Secure the cylinder to the backing plate by installing the .attaching bolts and lock washers. 6. Tighten the tube fitting nut' to specification with tool 1 1 12-144. 7. Install the links in the ends of the wheel cylinder, install the shoes and adjuster assemblies, and adjust the shoes as outlined in this section. 8. Adjust the brakes (Part 2-2, Section 2). Install the brake drum and wheel. Bleed the brakes and centralize the differential valve as outlined in Part 2-1. Section 2. BRAKE BACKING PLATEDRUM BRAKE BLEEDER SCREW FACING THIS DIRECTION REMOVAL 1. Remove the wheel and brake drum. Disconnect the brake line from the brake cylinder. 2. Remove the brake shoe and adjuster assemblies and the wheel cylinder as outlined in this section. On the rear wheels, disconnect the parking brake lever from the cable. 3. I f the rear backing plate is being replaced, remove the axle shaft from the applicable rear axle as outlined in Group 4, Part 4-2- Rear Axle, Section 2, disengage parking brake cable retainer from backing plate. Remove the backing plate and gasket. I f the front backing plate is being replaced, remove the bolts and nuts that secure the backing plate to the front wheel spindle and remove the plate and gasket. INSTALLATION I f a rear backing plate is to be replaced, position a new rear backing plate and gasket on the attaching bolts in the axle housing flange. Insert parking brake cable into backing plate and secure retaining fingers. Install the rear axle shaft for applicable rear axle. Refer to Group 4, Part 4-2Rear Axle, Section 2 for the proper installation procedure. 1. I f the front brake backing plate is to be replaced, position a new front backing plats and gasket to the wheel spindle and install the attaching bolts and nuts. 2. Install the wheel cylinder and connect the brake line as outlined in this section. 3. Install the brake shoe and adjuster assemblies as outlined in, this section. On a rear brake, connect the parking brake cable to the lever. 4. Adjust the brake shoes (Section 2), and install the brake drums and wheels. Bleed the brake system and centralize the differential valve as outlined in Part 2-1. Section 2. DISC BRAKE CALIPER ASSEMBLY ALL MODELS EXCEPT LINCOLN CONTINENTAL Removal . Refer to Figs. 22 and 23. FIG. 22.-Floating Caliper. Installed 1. Remove the front wheel cover. Remove the wheel and tire assembly from the hub and rotor assembly. Be careful to avoid damage or interference with the caliper splash shield or bleeder screw fitting. 2. Disconnect the brake line from the caliper. C a p the hose to prevent '.he brake fluid from leaking from the master cylinder. 3. Remove the safety wire and the two bolts that attach thc caliper assembly to the spindle. 4. Lift the caliper assembly off the rotor and place it on the bench. Installation I. Position the caliper assembly on the rotor, and mate the mounting bolt holes in the caliper with those in the spindle. It may be necessary to push the caliper piston into the cylinder bore to obtain clearance between the shoe and lining assembly and the rotor. 2. Install the caliper to spindle attaching bolts and torque them to specification. The upper bolt must be tightened first. Install the safety wire on the bolts and twist the wire ends at least five turns. Push the wire ends against the spindle to avoid interference with the brake hose and the steering stop. Check to insure that the rotor runs squarely and centrally between the two brake shoes. 3. Position the brake hose fitting with a new copper washer on each side of the fitting on the caliper assembly. Install the bolts and torque to specification. 4. Bleed the brake system and centralize the differential valve as outlined 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 I cylinder fluid level and add the specified fluid, as required. Pump the brake pedal several times to actuate the piston seals and to position the shoe and lining assemblies. 5. Install the wheel and tire assembly and the wheel cover. 6. Road test the vehicle. L I N C O L N CONTINENTAL Remove the wheel and tire assembly from the hub and rotor assembly. Be careful to avoid damage ;or intcrfcrence with the caliper splash shield, bleeder screw fitting or transfer tube. Removal Refer to Fig. 24. I. Remove the front wheel cover. 2. Disconnect the steel, brake line transfer tube from the caliper (Fig. 21). Leave the steel tube donnected to , CALl PER PARTS -2B120-R.H. -20121-L.H. {INBOARD HOUSING /P CLIP 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 ' FIG. 24 - D i s c Brake Disassembled-Lincoln Continental H 1650 1 Brake System the brake hose connector and bracket assenibly. 3. Remove the two bolts retaining the broke hose bracket and calliper assenibly to the spindle. Take care to avoid loosening the bridge I)olts that hold the two halves of the caliper together. 4. Lift the caliper assembly off the rotor and place it on the bench. Installation 1. I f the caliper assenibly is to be replaced, transfer the steel tubing and the bleeder screw to the new caliper. 2. Position the caliper assenibly on the rotor, and mate the niounting bolt holes in the caliper with those in the spindle. It niap bc necessary to push the caliper pistons into the cylinder bores to obtain clcarance bctween the shoe and lining assembly and the rotor. The shoe and lining assemblies should be seated properly on the bridges. 3. Install the caliper to spindle retaining bolts and torque them to specification. Check to insure that the rotor runs squarely and centr;~llybetween the two halves of the caliper. These should be approximately 0.0900.120 inch clearance between the caliper and the rotor outside diameter (Fig. 6). 4. Position the steel transfer tube brake hose bracket and caliper assenibly to the spindle. Install the retaining bolts then torque them to specification. 5. Connect the front wheel steel transfer tube froni the caliper to the front brake hose connector. Check the hose for proper installation (Fig. 21). 6. Bleed the brake systcni and centralize the dil'fercntial valve a s outlined in Part 2-1. Check the master cylindcr fluid level and add the specified fluid, a s required. P u m p the hrake pedal several times to actuate the piston seals and to position the shoe and lininl: assemblies. 7. Install the wheel and tire assembly and the wheel cover. 8. Road test the vehicle. ' DISC BRAKE SHOE AND LINING i I 'Al-I, MODEI,S EXCEPT 1.INCOLN C O N T I N E N T A L Removal 1. Reniove the wheel and tire from the hub and rotor assembly. 2. Remove the caliper froni the vehicle following the procedures outlined under Disc Brake Caliper Assembly. 3. T o facilitate removal of the caliper asseniblies, the piston may have to be pushed into its bore. Apply a steady inward pressure against the inner shoe and lining assembly. Maintain the pressure for a t least a minute. 4. Slide the two outer shoe retaining clips off the retaining pins (Fig. 23). 5. Remove the two retaining pins from the outer shoe, then remove the shoe from the stationary caliper. 6. Slide the inner brake shoe outward until it is free of the hold-down springs, then remove the brake shoe. 7. Remove the caliper locating pins and stabilizer attaching bolts, then remove and discard the stabilizer or stabilizers. 8. Remove the locating pin insulators from the anchor plate. Installation When installing new shoes and linings it will be necessary to force the piston to the bottom of its bore. Apply sufficient pressure to overcome the grip of the piston seal on the piston. I. Install new caliper locating pin insulators in the anchor plate. 2. Position the caliper assembly in the anchor plate. 3. Position the new stabilizer or stabilizers and install the caliper locating pins to engage approxiniately four threads. If the caliper locating pins are rusted or corroded they should be replaced. Apply water or isopropyl alcohol to the caliper locating pins before installation. Oil or grease must not be used on the locating pins. 4. Position the outer brake shoe on the caliper and install the two retaining pins and clips. 5. Install the inner brake shoe so that the ears of shoe are on top of the anchor plate bosses and under the shoe hold-down springs. 6. Position the shoe and lining assemblies so that the caliper assembly can be placed over the rotor. Rotate a hammer handle between the linings to reset the stabilizers. 7. lnstall the caliper assembly over the rotor and on the spindle. Install the two caliper attaching bolts, and torque them to specifications. The upper bolt must be tightened first. Install the safety wire and twist the ends a t least five turns. Push the wire ends against the spindle to avoid interference with the brake hose and the steering stop. 8. With moderate pressure applied to the brake pedal, Lorque the stahilizer attaching screws and caliper locating pins to specification. LINCOLN CONTI NENI'AL Removal 1. Remove the wheel and tire assembly from the hub and rotor assembly. Be careful to avoid damage or interference with the caliper splash shield, bleeder screw fitting or transfer tube. 2. Remove the two bolts that retain the caliper splash shield, and remove the shield (Fig. 4). 3. T o facilitate removal and installation of the shoe and lining asseniblies, the pistons must be pushed into their bores. Apply a steady inward pressure against each shoe and lining assembly toward its respective caliper housing on each side of the rotor (Fig. 6). Maintain the pressure for a t least a minute. I f the pistons will not go in easily, force them in with water pump pliers. 4. Grasp the metal flange on the outer end of the shoe with two pairs of pliers and pull the shoe out of the caliper (Fig. 25). Installation I. Position a new shoe and lining assembly on each side of the rotor so that the lining faces the rotor. Be sure FIG. 25--Removing Disc B r a k e S h o e a n d Lining AssemblyLincoln C o n t i n e n t a l . 02-02- 19 Brake System that the tabs on the shoe flanges seat fully against the caliper bridges (Fig. 25). 2. Install the caliper splash shield and secure the shield to the caliper with two retaining bolts (Fig. 4). 3. Pump the brake pedal several times until a firm pedal is obtained and the shoe and lining assemblies are properly seated.. 4. Install the wheel and tire assembly on the hub and rotor assembly. 5. Check and refill the master cylinder reservoir with specified brake fluid as required. 6. Road test the car. I t should not be necessary to bleed the system after a shoe and lining replacement. F R O N T WHEEL H U B A N D R O T O R ASSEMBLY DlSC BRAKES - fied grease (M-IC75B), and install the inner bearing cone and roller assembly in the inner cup: Pack grease lightly between the lips of a .new grease seal and install the seal (Figs. 23 and 24). If the original rotor is being installed, make sure that the grease in the hub is clean and adequate, that the inner bearing and grease seal are lubricated and in good condition, and that the rotor braking surfaces are clean. 2. Install the hub and rotor assembly on the spindle. 3. Lubricate and install the outer wheel bearing, washer and adjusting nut. 4. Adjust the wheel bearings to specification, and then install the nut lock, cotter pin, and grease cap. The wheel bearing adjustment is especially important with disc brakes. 5. Mount the caliper assembly on the spindle following the Disc Brake Caliper Assembly Installation procedure in this section. REMOVAL 1. Remove the wheel and tire from the hub (Figs. 23 and 24). Be careful to avoid damage or interference with the bleeder screw fitting. O n Lincoln Continental models be careful to avoid damage to the caliper splash shield or transfer tube. 2. Remove the caliper assembly Reinoval in the roregoing procedure (it is not necessary to discbnnect hydraulic connections). 2. Remove the three bo!ts that attach the splash shield to the spindle, and remove the shield (Figs. 23 and 24). 3. Remove and discard 'the splash shield to spindlc gasket. INSTALLATION \ 1. Install a new splash shield to spindle gasket. 2. If the shield is bent, straighten it out before installation. Position the shield to the mounting bracket, install the attaching bolts, nuts and torque them to specification. 3. Install the hub and rotor assernbly and the callper as outlined under Installation in the foregoing procedure. D U A L M A S T E R CYLINDERNON P O W E R BRAKES DlSC BRAKE R O T O R SPLASH SHIELD FORD, M E R C U R Y AND METEOR REMOVAL Removal 1. Remove the caliper and the hub and rotor assembly as outlined under Refer to Fig. 26. from the spindle and the rotor. If the caliper does not require servicing, it is not necessary to disconnect the brake 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 stretching' the hose. Insert a clean cardboard spacer between the linings to prevent the piston from coming out of the cylinder bore while the caliper is rem oved . BUSYING / Handle the rotor and caliper assemblies in such a way as to avoid deformation of the rotor and nicking, scratching or contamination of the brake linings. 3. Remove the grease cap from the 0. hub. Remove the cotter pin, nut lock, adjusting nut, and flat washer from the spindle. Remove the outer bearing cone and roller assembly. 4. Remove the hub and rotor assembly from the spindle. INSTALLATION 1. If the rotor is being replaced, remove the protective coating from the new rotor with carburetor degreaser. Pack a new set of bearings with speci- BUSHING / STOPLIGHT SWITCH 13480 FIG. 26-Dual M a s t e r Cylinder InstallationFord, Mercury, a n d M e t e o r N o n Power Brakes Brake System I. Disconnect the stoplight switch wires a t the connector. Remove the spring retainer. Slide the stop light switch off the brake pedal pin just far enough to clear the end of the pin, then lift the switch straight upward from the pin. Use care to avoid switch FAIRLANE, MONTEGO, FALCON, M U S T A N G A N D COUGAR damage during removal. Refer to Figs. 27 and 28. 2. Slide the master cylinder push rod and the nylon washers and bushings off the brake pedal pin. 3. Remove the brake tube from the primary and secondary outlet ports of the master cylinder. 4. Remove the c a p screws and lockwashers that secure the master cylinder to the dash panel and lift the cylinder forward and upward from the vehicle. Installation I. Position the boot on the push rod and secure the boot t o the master cylinder. Carefully insert the master cylinder push rod and boot through the dash panel opening and position the master cylinder on the panel. 2. Install the cap screws a t the dash panel and torque them t o specification. 3. Coat. the nylon bushings with S A E IOW oil. Install the nylon washe 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 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 Removal I. Working from inside the vehicle below the instrument panel, disconnect the master cylinder push rod from the brake pedal assembly. T h e push rod cannot be remobed from the master cylinder. 2. Disconnect the stoplight switch wires a t the connector. Remove the hairpin retainer. Slide the stop light switch off the brake pedal pin just far enough t o clear the end of the pin, then lift the switch straight upward from the pin. Use care to avoid switch damage during removal. 3. Slide the master cylinder push rod and the nylon washers and bushings off the brake pedal pin. 4. Remove the brake tubes from the primary and secondary outlet ports of the master cylinder. 5. Remove the lock nllts o r cap screw and lockwashers that secure the master cylinder to the dash panel and lift thc cylinder forward and upward from the car. Installation Refer to Figs. 27 and 28. 1. Position the boot on the push rod and secure the boot t o the master cylinder. Carefully insert the master cylinder push rod and boot through the dash panel opening. 2. On Fairlane, Falcon or Montego models, position the gasket and master cylinder on the mounting studs on the dash panel. Install the lock nuts on the studs a t the dash panel and torque them t o specification. 3. On Mustang o r Cougar models, position the gasket and master cylinder on the dash panel. Install the retaining screws and torque them to specification. C o a t the nylon bushings with S A E IOW oil. Install the nylon washer and bushing on the brake pedal pin. 4. Position the stop light switch on the brakc 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 light switch connector. 6. Connect the brake lines t o the master cylinder and tighten to specified torque. 7. Fill the master cylinder with the specified brake fluid to within 114 -UPPER STUD heavy duty brake system fluid is colored 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 differential valve. Refer to Hydraulic System Bleeding and Centralizing of the Differential Valve, Part .2-I, Section 2 for proper procedure. 9. Operate the brakes several times, then check for external hydraulic leaks. MASTER CYLINDER PUSH ROD n 15sc FIG. 27-Dual M a s t e r Cylinder InstallationFair l a n e , M o n t e g o , a n d Falcon Non Power Brake 02-02-2 1 02-02-2 1 Brake System INSTALLATION CLUTCH ASSIS1 SPRING BUSHING 1 . -.. - . -,,,--,, 2140 ' \ -.--&,.,c" SPACER STOP LIGHT SWITCH 13480 SHAFT AUTOWTIC TRANSMISSION C L ~ T C HP E D A L BUMPERSTOP FIG. 28-Dual M a s t e r Cylinder InstallationN o n P o w e r Brake-Mustang a n d Cougar .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 fluids with the specified fluid for the brake system. 8. Bleed the dual-master cylinder and the primary and secondary brake systems. Centralize the pressure differential valve. Refer to Hydraulic System. Bleeding and Centralizing of the Differential Valve, Part 2-1, Section 2 for the proper procedure. 9. Operate the brakes several times, then check for external hydraulic leaks. H163e-A I I. Before installing t h e ma.dtcr cylinder, 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 Part 2-1. Section 2, Power Brakc: Master Cylinder Push Rod Adjustment for the proper procedure. 2. Position the master .cylinder assembly over the booster push rod and onto the two studs on the boostcr assembly (Figs. 29 thru 33). 3. Install the attaching nuts and lock washers and torque them to specifications. 4. Install the front and rear brake' tubes to the rnnstcr cylinder outlet fittings. 5. ill the master cylinder with the e to : within I/4 specified b r ~ ~ k fluid inch of the top of the dual reservoirs. Use Ford Brake Fluid-Extra Heavy Duty---Part Number C6AZ-19542-A (ESA-M6C25-A) for a11 brake applications. The extra heavy duty brake fluid is colored blue for identification. D o not mix low temperature brake fluids with the spccified fluids for the disc brake system. ! CLIP VACUUM BOOSTER DUAL MASTER CYLINDERPOWER BRAKES REMOVAL 1. Remove the brake tubes from the primary and secondary outlet ports of the master cylinder (Figs. 29 thru 33). 2. Remove the two nuts and two lock washers attachine the master cvlinder to the brake b:oster assernbl;. 3. Slide the master cylinder forward and upward from the vehicle. SWITCH 13480 SPACER H 1642.~ FIG. 29--Master Cylinder Installation-Power Ford, M e r c u r y a n d M e t e o r Brake- I 02-02-22 Brake System B R A K E VACUUM BOOSTER -2005 BOOT-2A021 6. Bleed the dual-master cylinder and the primary and secondary brake systems. Cen~ralize the pressure differential valve. Refer to Hydraulic System Bleeding and Centralizing of the Differential Valve, Part 2-1, Section 2 for the proper procedure. 7. Operate the brakes several times, then check for external hydraulic 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 differential valve assembly switch (Figs. 17 thru 21). To prevent damage t o the STANDARD TRANSMlSSlON 1 brake warning switch wire connector, expand the plastic lugs to allow removal of the shellwire connector from the switch body. 2. Loosen the tube nuts connecting PUSH ROD FIG. 30 -Master Cylinder Installation-Power Fairlane, M o n t e g o a n d ,Falcon Brake- the primary and secondary inlet and outlet tubes at the pressure differential valve assembly and remove the tubes. 3. Remove the screw or screws retaining 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 pressure 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 assembly only. INSTALLATION I I I 2005 MASTER C Y L I N D E R 2140 i I ) FIG. 31 .--Master Cylinder InstallationP o w e r Brake-Mustang and Cougar 1. On disc brake equipped vehicles. connect the proportioning valve inlet and outlet tubes to the proportioning valve and differential valve bodies. Tighten the tube nuts to specification. 2. Mount the pressure differential valve assembly on the chassis and install the attaching screw or screws. 3. Connect the primary and secondary inlet and outlet tubes to the pressure differential valve assembly and tighten the tube nuts to specifications. i .I 02 -02-23 02-02-23 Brake System BOOSTER ASSEMBLY- 4. Connect the shell-wire connector to the brake warning lamp switch. Make sure the plastic lugslon the connector hold the connector securely to the switch. 5. Bleed the brakes and centralize the pressure differential valve. 2005 NUT-34444 .S7 PROPORTIONING VALVE FORD, MERCURY AND METEOR On Ford, Mercury and Meteor models, the proportioning valve must be removed with the pressure differential valve. Use the procedure shown above for replacement of the proportioning valve. FA1 RLANE, MONTEGO AND FALCON MASTER CYLINDER BRAKE TUBE -2264 Removal I PRESSURE DIFFERENTIAL VALVE ASSEMBLY-20257 \ BRAKE T U B E - ~ B ~ ~ ~ Refer to Fig. 18. I. Disconnect the two brake lines at the proportioning valve. 2. Remove the bolt retaining the pressure differential valve' bracket to the fender apron. 3. L i f t t h e proportioning valve bracket from behind the yessure differential valve bracket and4rem'ove the proportioning' valve from the vehicle. FIG. 32-Master Cylinder- InstallationThunderbird a n d Continental M a r k I l l CYLINDER MUST a E F U L L BUSHING\ SLEEVE 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 between the pressure differential valve bracket and the fender apron. 2. Connect the two brake lines at the proportioning valve. Do not tighten. 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 I specifications. 5. Bleed the brakes and centralize the pressure differential valve. PRESSURE DIFFERENTIAL VALVE ASSEMBLY-25328 I MUSTANG AND COUGAR PROPORTIONING VALVE Removal I H 1530-C NG. 33-Master Cylinder Installation-Lincoln Continental Refer to Fig. 19. I. Disconnect the two brake lines at the proportioning valve. , 2. Remove the bolt retaining the Brake System , proportioning valve to the fender apron and remove the proportioning valve. LINCOLN CONTINENTAL Removal lnstallation I. Position the proportioning valve to the fender apron. 2. Connect the two brake li.nes a t the proportioning valve. Do not tighten. 3. Install the bolt retaining the proportioning valve to the fender apron. 4. Tighten the brake line tube nuts at the proportioning valve to specifications. 5. Bleed the brakes and centralize pressure differential valve. THUNDERBIRD A N D C O N T I N E N T A L M A R K Ill Removal ' I Refer to Fig. 20. 1. Disconnect the two hydraulic brake lines a t the master cylinder. 2. Remove the two nuts retaining the master cylinder to the booster and remove the master cylinder for clearance. 3. Disconnect the two brake lines at the proportioning valve. 4. Remove the bolt and nut retaining the proportioning valve to the pressure differential valve bracket and remove the proportioning valve assembly. Installation 1. Transfer the bracket to the new proportioning valve. 2. Position the proportioning valve assembly to the pressure differential valve bracket. 3. Connect the two brake lines to the proportioning valve. Do not tighten. 4. Install the bolt and nut retaining the proportioning valve to the pressure differential valve bracket. 5. Tighten the two brake line tube nuts at the proportioning valve to specifications. 6.' Position the master cylinder to the booster and install the nuts retaining the master cylinder to the booster. 7. Connect the two brake lines at the master cylinder and tighten the tube nuts to specifications. 8 . ,Bleed the brakes and centralize the pressure differential valve. switch off from the brake pedal pin just far enough for the switch outer 'hole to clear the pin, and then remove Refer to Fig. 21. 1. Disconnect the two brake lines at the proportioning valve. 2. Loosen the bolt and nut on the bracket retaining the proportioning valve to the chassis. 3. .Remove the proportioning valve from the bracket. 1. Position the proportioning valve in the bracket and connect the two brake lines. Do not tighten. 2. Tighten the bolt and nut on the bracket. 3. Tighten the tube nuts on the brake lines at the proportioning valve to specifications. 4. Bleed the brakes and centralize the pressure differential valve. @ PRESSURE M E T E R I N G VALVEllNCOLN CONTINENTAL REMOVAL Refer to Fig. 21. 1. Loosen the tube nuts connecting the inlet and outlet tubes a t the metering valve, and remove the tubes. 2. Remove the two screws retaining the metering valve to the frame crossmember, and remove the metering valve. The metering valve is serviced as an assembly only. 1. Position the metering valve to the frame crossmember, and install the retaining screws. 2. Connect the inlet and outlet tubes to the metering valve, and tighten the tube nuts to specification. BRAKE BOOSTER ' 1. Working from inside the, vehicle below the instrument panel, disconnect the booster push rod from the brake pedal assembly. T o do this, proceed as follows: Disconnect the stop light switch wires a t the connector. Remove the hairpin retainer. Slide the stop light the switch from the pin .and booster push rod. Be careful not to damage the switch during removal. Slide the booster push 'rod and the nylon washers and bushing off the brake pedal pin (Figs. 29 thru 33). 2. Open the hood and remove the master cylinder from the booster. Secure, it to one side without disturbing the hydraulic lines. I t is not necessary to disconnect the brake lines, but care should be taken that the brake lines are not deformed. Permanent deformation of brake lines can lead t o tube failure. 3. Disconnect the manifold vacuum hose or hoses from the booster unit. I. R e m o v e t h e booster-to-dash panel attaching nuts or bolts (Figs. 29 thru 33). Remove the booster and bracket assembly from the dash panel, sliding the push rod link out from the engine side of the dash panel. 5. O n , Fairlane, Montego, and Falw con models, remove the push rod link boot from the dash panel. INSTALLATION I. On Fairlane, Montego and Falcon models, install the push rod link boot in the hole in the dash panel as shown in Fig. 23. lnstall the four spacers on the mounting studs. 2. Mount the booster and bracket assembly to the dash panel by inserting the push rod or push.rod link in through the hole and boot in the dash p a n e l . I n s t a l l the bracket-to-dash panel attaching lock nuts or bolts (Figs. 29 thru 33). 3. Connect the manifold vacuum hose or hoses to the booster. 4. Before installing the master cylinder, check the distance from the outer end of the booster assembly push. rod to master cylinder surface. Turn the screw in or out to obtain the specified length. Refer to Part 2-1, Section 2, Power Brake Master Cylinder Push Rod Adjustment. Install the master cylinder and torque the attaching nuts to specifications. 5. Working from inside the vehicle below the instrument panel, connect the booster push rod link to the brake pedal assembly. To d o this, proceed as follows: Install the inner nylon washer, the booster push rod, and the bushing on the brake pedal pin. Position the switch so that it straddles the push rod with the switch slot on the pedal pin and the switch outer hole just Brake System clearing the pin. Slide the switch completely onto the pin, and install the nylon washer as shown in Figs. 29 thru 33. Be careful not to bend or deform the switch. Secure these parts to the pin with the hairpin retainer. Connect the stop light switch wires to the connector, and install the wires in the retaining clip. BRAKE PEDAL FORD, M E R C U R Y A N D MET'EOR Removal 1. Disconnect the stop light switch wires at the connector. 2. Remove the hairpin retainer. Slide the stop light switch off the brake pedal pin just far enough for the switch outer hole to clear the pin, and then lift the switch straight upward from the pin. Be careful not to damage the switch during removal. Slide the master cylinder or booster push rod and the nylon washers and bushing off the brake pedal pin (Figs. 26 and 29). 3. Remove the hairpin type retainer and washer from the brake pedal shaft, then remove the shaft, the brake pedal and the bushings frnm the pedal support bracket. Installation 1. Apply a coating of SAE 10 En- gine oil to the bushings and locate bushings in their proper places on the pedal assembly and pedal support bracket (Figs. 26 and 29). 2. Position. the brake pedal assembly to the support bracket, then install the pedal.shaft through the support' bracket and brake pedal assembly. Install the retainer. 3. Install the inner nylon washer, the master cylinder or booster push rod, and the bushing on the brake pedal pin. Position the switch so that it straddles the push rod with the switch slot on the pedal pin and the switch outer hole just clearing the pin. Slide the switch completely onto the pin, and install the nylon washer as shown in Figs. 26 and 29. Be careful not to bend or deform the switch. Secure these parts to the pin with the hairpin retainer. 4. Connect the stop light switch wires to the connector, and install the wires in the retaining clip. 5. Check the Brake Pedal Free Height. and Travel Measurements, Part 2-1, Section 1. FAIRLANE, MONTEGO A N D FALCON-MANUAL-SHIFT TRANSMISSION Removal 1. Remove the clutch pedal assist spring. 2. D i s c o n n e c t the clutch pedalto-equalizer rod at the clutch pedal by removing the retainer and bushing. 3. Disconnect the stop light switch wires at the connector. 4. Remove the switch retainer,,and slide the stop light switch off the brake pedal pin just far enough for the switch outer hole to clear the pin. Then lower the switch away from the pin. 5. Slide the master cylinder or booster push rod and the nylon wash, ers and bushing off from the brake pedal pin (Figs. 27 and 30). 6. Remove the self-locking pin and washer from the clutch and brake pedal shaft, then remove the clutch pedal and shaft assembly, the brake ~ from pedal assembly, and t h bushings the pedal support bracket (Figs. 27 and 30). Installation 1. Apply a coating of SAE 10 engine oil to the bushings and locate all bushings in their proper places on the clutch and brake pedal assemblies. 2. Position the brake pedal to the support bracket, then install the clutch pedal and shaft assembly through the support bracket and brake pedal assembly. Install the spring clip (Figs. 27 and 30). 3. Install the clutch pedal assist spring. 4. C o n n e c t t h e c l u t c h p e d a l to-equalizer rod to the clutch pedal assembly with the bushing and the spring clip retainer. Apply S A E 10 engine oil to the bushing. 5. Install the inner nylon washer, the master cylinder or booster push rod, and the bushing on the brake pedal pin. Position the switch so that it straddles the push rod with the switch slot on the pedal pin and the switch outer hole just clearing the pin. Slide the switch completely onto the pin, and install the outer nylon washer as shown in Figs. 27 and 30. Secure these parts to the pin with the selflocking pin. 6. Connect the stop light switch wires to the connector, and install the wires to the retaining clip: 7. Adjust the clutch pedal free play (Group 5) to specification, if required. 8. Check the Brake Pedal Free Height and Travel ~ e a s u r e m e n t s (Part 2-1, Section I). M U S T A N G A N D COUGARMANUAL-SHIFT TRANSMISSION Removal 1. Disconnect the battery ground cable from the battery. 2. Remove the steering column. Refer to Part 3-4, Section 2 for procedure. I 3. On non-power brakes, remove the two cap screws retaining the master cylinder to the dash panel and remove the two cap screws retaining the brake pedal support bracket to the dash panel. On power brakes remove the two cap screws- retaining the, booster to the dash panel! 4. Working inside the vehicle, secure the clutch pedal against the bumper stop with a small IC-clamp as shown in Figs. 28 and 3 1. 5. D i s c o n n e c t the clutch pedalto-equalizer rod at the clutch pedal by removing the retainer and, bushing. 6. Disconnect the stop light switch wires at the connector. 7. Remove the switch fetainer and slide the stop light switch off the brake pedal pin just far enough for the switch outer hole to clear the pin. Then lower the switch away from the pin. Remove the master !cylinder or booster push rod, bushing and nylon washer from the brake pedal pin. 8. Remove the screw retaining the pedal support bracket to the top inner cowl bracket (Figs. 28 and 31). 9. Remove the two sheet metal screws retaln~ng the pedal support bracket to the dash panel. On power brakes remove the nuts from the brake booster studs. 10. Remove the two screws retalning the pedal support brqcket to the upper cowl brace and lower the pedal support bracket away from the steering column studs. 11. R e m o v e t h e pedal support bracket assembly from the vehicle. 12. Position the pedal and support bracket assembly in a vise. 13. Remove the C-clamp to release the clutch pedal from its bumper stop and p~vot the pedal away from the bumper. I '! , ! , , I , . . Brake System 14. ~ e h o v ethe clutch pedal assist spring. 15. On non-power brakes, remove the retainer clip from ,the clutch and brake pedal shaft, then remove the clutch pedal 'and shaft assembly, the brake pedal assembly, and the bushings from the pedal support bracket. On power bra.kes, remove the retainer nut -from the brake pedal shaft .then remove the pedal shaft, the brake pedal assembly and the bushings from the pedal support bracket. Installation 1. Apply a coating of S A E 10 engine oil to the bushings and locate all bushings in their proper places on the clutch and brake pedal assemblies. 2. On non-power brakes, position the brake pedal to the pedal support bracket, then install the clutch pedal and shaft assembly through the support bracket and brake pedal assembly. On power brakes position the brake pedal to the pedal support bracket, then install the pedal shaft and nut. 3. lnstall the clutch pedal assist spring and pivot the clutch pedal against its bumper stop. Secure the pedal to the stop with a small Cclamp as shown in Figs. 28 and 31. 4. P o s i t i o n t h e p e d a l s u p p o r t bracket assembly to the dash panel, and to the steering column retainer studs. 5. Align the pedal support bracket holes with the holes in the dash panel and install the two attaching sheet metal screws. On power brakes install the nuts on the brake booster studs. 6. Install the two cap screws attaching the pedal support bracket to the upper cowl bracket. 7. lnstall the cap screw attaching the pedal support bracket to the top inner cowl bracket (Figs. 28 and 31). 8. Install the inner nylon washer, the master cylinder push rod, and the bushing on the brake pedal pin. Positlon the stop light switch so that it straddles the push rod with the switch slot on the pedal pin and the switch outer hole just clearing the pin. Slide the switch completely onto the pin, and install the outer nylon washer as shown in Figs. 28 and 31. Secure these parts to the pin with the selflocking retainer. 9. Connect the stop light switch wires to the connector. 10. C o n n e c t t h e c l u t c h p e d a l to-equalizer rod to the clutch pedal assembly with the bushing and the spring clip retainer. Apply SAE 10 engine oil to the bushing. Remove the C-clamp from the clutch pedal. 11. Working from the engine side of the dash panel, on non-power brakes, install the two cap screws attaching the pedal support bracketato the dash panel. Then install the two screws attaching the master cylinder to the dash panel. On power brakes install the cap screws retaining the brake booster to the dash panel. 12. lnstall the steering column. Refer to Part 3-4, Section 2 for procedure. 13. Adjust the clutch pedal free play (Group 5) to specification, if required. 14. Check the Brake Pedal Free Height and Travel Measurements (Part 2-1, Section I). 15. Connect the ground cable to the battery. FA1 RLANE, MONTEGO, FALCON, MUSTANG AND COUGAR- . AUTOMATlC TRANSMISSION . Removal I. Disconnect the stop light sw~tch wires at the connector. 2. Remove the self-locking pin and slide the stop light switch off the brake pedal pin just far enough for the switch outer hole to clear the pin. Then lower the switch away from the pin. Slide the master cylinder or booster push rod and the nylon washers and bushing off from the brake pedal pin (Figs. 27, 28, 30 and 31). 3. On all vehicles except Mustang and Cougar with power brakes, remove the self-locking pin and washer from the brake pedal shaft, then remove the shaft, the brake pedal assembly and the bushings from the pedal support bracket. On Mustang a n d C o u g a r v e h i c l e s with power brakes, remove the locknut and bolt from the pedal. Remove the pedal assembly from the support bracket (Fig. 3). Installation 1. Apply a coating of S A E 10 engine oil to the bushings and locate all the bushings in their proper places on the pedal assembly and pedal support bracket (Figs. 27, 28, 30 and 3 1). 2. Position the brake pedal assembly to the support bracket, then install the pedal ,shaft or bolt through the support bracket and brake pedal assembly. Install the retainer or locknut. . .: 02-02-26 3. lnstall the inner nylon washer, the master cylinder or booster. push rod, and the bushing on the brake pedal pin. Position the switch so that it straddles the push rod with the switch slot on the pedal pin,' and the switch out'er hole just clearing the pin. Slide the switch completely onto the pin, and install the outer nylon washer as shown in Figs. 27, 28, 30 and 31. Secure these parts .to the pin :with the self-locking pin. 4. Connect the stop light switch wires to the connector, and install the wires in the retaining clip. Check the Brake Pedal ~ r e kHeight and Travel Measurements, Part 2, Section I . T H U N D E R B I R D AND CONTINENTAL MARK 111 . . Removal . . 1. Loosen the booster mounting nuts. 2. Disconnect the stop light switch wires at the connector. 3. Remove the hairpin ,retainer. Slide the stop light switch off from the brake pedal pin just far enough for the switch outer hole to clear the pin, and then l ~ f tthe switch straight upward from the pin. Slide the master cylinder push rod and the nylon washers and bushing off from the brake pedal pln (Fig. 32). 4. Remove the pivot bolt and nut that holds the pedal to the pedal support bracket. Remove the brake pedal assembly from the pedal support bracket, ,and remove the bushings. Installation 1. Apply a coating of SAE 10 engine oil to the bushings and locate all the bushings in their proper places on the pedal assembly (Fig. 32). 2. lnstall the brake pedal assembly and bushings to the support bracket, and then install the pivot bolt through the support bracket and brake pedal assembly. lnstall the pivot bolt nut and torque to specifications. 3. Install the inner nylon washer, the master cylinder push rod: and the bush~ngon the brake pedal pin. Positlon the switch so that it straddles the push rod with the switch slot on the pedal pin and the switch- outer hole just clearing the pin. Slide the switch completely onto the pin, install the outer nylon washer as shown in Fig. 32. Secure these parts to the pin with the hairpin retainer. , , ' Brake System the support bracket and pedal assembly. Install the pivot bolt nut and torque it to specification. 4. Install the inner nylon washer-the master cylinder push rod link, and the bushing on the brake pedal pin. Position the switch so that it straddles the push rod link with the switch slot on the pedal and the switch outer hole just clearing the pin. install the outer nylon washer as shown in Fig. 33. Install the hair-pin type retainer on the brake pedal pin. 5. Connect the stop light switch wires to the connector, and install the wires in the retaining clip. 6. Position the wire^ harness and clip on the temperature control box and install the retaining screw. Position the temperature control box to the dash panel and install the two retaining bolts. 7. Connect the vacuum lines and the electrical connector to the control box. Position the wire harness to the control box and install the retaining clip. 8. Position the wire harness shield and install two retaining bolts. 9. Connect the wire harnesses to the lower control panel and install the retaining screws. 10. W o r k i n g within the engine compartment, connect the wire connector to the temperature heat control box. 11. Position the relay to the fender apron and install the retaining bolts. 12. Connect the ground cable to the battery. 13. Check the brakes and light switch for proper operation. Close the hood. 4. Connect the stop light switch wires to the connector, and install the wires in the retaining clip. 5. Torque the booster mounting nuts to specifications. Ll NCOLN CONTl NENTAL I . ' D i s c o n ~ c t the . battery cable from the battery. 2; It is necessary to obtain' clearance to remove vacuum hoses and'the electrical connector to the temperature heat control box. Remove , t h e . two screws retaining the relay to the fender and push the'.relay aside. Disconnect the vacuum hoses and ,connector at the heat control box. 3. Working under the instrument panel, disconnect the vacuuin hoses, wires and retaining clip from the temperature heat control box. Remove the two screws securing the temperature control box to the dash pan$ 4. Remove the lower control housing retaining screws (6). Disconnect the wire harnesses at the lower control panel and place .the panel aside. Remove the wire harness shield. Remove the wire harness clip. Position the wire harness aside. Remove the temperature control box and position it . , . aside. 5. Remove the hair-pin type reiainer. Slide the stop light switch off the brake pedal pin just far enough for, the switch outer hole to clear. the pin. Lift- the switch upward from the pin. Slide the master cylinder push rod, nylon washers and bushing off the brake pedal pin. 6. Remove the pivot bolt and nut that holds the pedal to the pedal support bracket. Remove the brake pedal assembly from the support bracket and remove the bushings. 7. If required, remove the brake pedal pad retaining nuts and remove the brake pedal pad. PARKING BRAKE CONTROL ASSEMBLY FORD, M E R C U R Y ' AND METEOR , , . , . Removal Installation Refer to Fig. 34. 1. If the brake pedal pad was removed, position the pad on the pedal. Install the pad retaining nuts and torque them to specification. 2. Apply SAE 10 engine oil to the bushings and locate all the bushings in t h e ~ r proper places on the pedal assembly. 3. Install the brake pedal assembly and bushings to the support bracket, and then install the pivot bolt through 1. Make sure the parking brake is fully released. 2. Remove all tension from the rear cables by backing off the adjusting nut from the equalizer. 3. Remove the roll pin that secures the release knob to the cable and remove the knob. 4. Remove the nut that secures the release cable to the instrument panel and remove the cable from the rear of the instrument panel. I 5. Remove the two nuts attaching the control assembly to the dash panel. 6. Remove the cap screw attaching the control assembly to the cowl side bracket. 7. Disconnect the hose do the parking brake vacuum unit, i f so equipped. 8 Remove the front cable assembly retamer clip from the cable assembly and disconnect the cable ball from the control clevis. 9. Remove the control assembly from the vehicle. . Installation I. Position the control assembly in the vehicle. 2. Fit the cable assembly through its mounting hole and install the retaining clip,. Connect the cable ball to ,the control clevis. 3. ,Connect the vacuum hose to the parking brake unit, if so equipped. 4. Install the attaching cap screw to the cowl side bracket. Do not tighten. 5. Install the two control assembly-to-dash panel nuts. Tighten the nuts and the cap screw to specifications. 6. Insert the release cable into the instrument panel and install the retaining nut. 7. Install the release knob on the ' cable with the roll pin. 8. Check the operation of the parking brake. Adjust the parking brake as required. F A I R L A N E , MONTECO AND FALCON I Removal Refer to Fig. 35. I 1. Make sure the parking brake is completely released. 2. Remove all tension from the rear cables by backing off the jam nut and adjusting nut from the equalizer. 3. Working inside the vehicle, remove the four' bolts and one nut retaining the, left air vent and cable assembly to the dash and instrument panels. Remove the vent assembly. 4. Remove the parking brake front cable ball retaining clip from the clevis. ' 5. Disconnect the' cable 'ball from the notch in the brake clevis. 6. Remove the three screws that attach the control assembly to 'the left cowl inner side panel. , 1 - - - -- - - / VIEW z VACUUM RELEPJE - - --- Brake System-Ford, VIEW z YAHUM RELEASE BRAKE PEDAL BRACKET - CONTROL - FIG. 34 -Parking - - . - - Mercury and Meteor CQNVERTleLE ONLY INSTRUMENT PANEL -- - - - - - - CROSSMEMBER CABLE AND HWSING L.H. INTERMEDIATE CABLE - 4 nEw Y VIEW X - - - - - - --- -- - n - HIM-A PRONGS MUST BE SECURELY LOCI(ED IN PLACE WITHIN BRAKE DRUM L K W O W R.K TYPICAL SUSPENSION ARM CABLE WST BE n ~ ON -4 CROSSYEIIBER - ~ Brake System FIG. 35--Parking Brake System-Fairlane, Montego and Falcon - Brake System 7. Disconnect the wire lead at the parking brake warning light switch and remove the control assembly. Installation I. Connect the wire lead to the parking brake warning light switch. 2. Position the control assembly to the cowl inner side panel and install the three attaching screws. 3. Connect the ball-end of the parking brake front cable assembly lo the control assembly, and install the hairpin retainer. 4. Position the cable ball in the notch in the brake clevis. 5. Position the left air vent assembly to the dash and instrument panels. Install the four bolts and one nut retaining the air vent to the panels. 6. Check the operation of the parking brake. Adjust the parking brake. MUSTANG AND COUGAR Removal Refer to Fig. 36. 1. Make sure the parking brake is completely released. 2. Remove all tension from the rear cables by backing off the jam nut and adjusting nut from the equalizer. 3. Disconnect the wire lead at the parking brake warning light switch (if so equipped). 4. Remove the parking brake front cable ball retaining clip from the clevis. 5. Remove the parking brake warning light switch and attaching screw (if so equipped). 6. Disconnect the cable ball from the notch in the brake clevis. 7. Remove the three screws that attach the control assembly to the left cowl inner side panel. 8. Pull the control away from the cowl panel. Remove the hair-pin retainer securing the front cable assembly to the control assembly. Remove the control assembly. Installation I ,I I I I I. Connect the ball-end of the parking brake front cable assembly to the control assembly, and install the hairpin retainer. 2. Position the control assembly to the cowl inner side panel and install the three attaching screws. 3. Position the parking brake warning light switch and install the attaching screw. Connect the parking brake warning light switch wire lead (if vehicle is so equipped). , 4. Position the cable ball in the notch in the brake clevis. 5. Check the operation of the parking brake. Adjust the parking brake. THUNDERBIRD AND CONTINENTAL MARK I11 Removal Refer to Fig. 37. 1. Remove the two nuts retaining the control to the dash panel. 2. Remove two screws from the left scuff d a t e . 3. kemove one screw retaining the left cowl trim panel and remove the panel. 4. Remove the two screws retaining the left air duct and remove the air duct. 5. Remove the two screws retaining the dimmer switch and position the switch out of the way. 6. Remove the clip retaining the cable assembly to the control. 7. Disconnect the cable ball from the control clevis. 8. Disconnect the vacuum hose at the brake release. 9. Remove the bolt retaining the cpntrol to the cowl side bracket and remove the control. Installation 1. Position the parking brake control in the vehicle. 2. Install the cable assembly in the control and connect the cable ball to the control clevis. 3. lnstall the clip retaining the cable to the control.' 4. Install the bolt retaining the control to the cowl side bracket. 5. Connect the vacuum hose to the parking brake release vacuum motor. 6. Position the dimmer switch and install the retaining screws. 7. Position the air duct and install the retaining screws. 8. Position the cowl trim panel and install the retaining screw. 9. Install the two scuff plate screws. 10.'Install the two nuts retaining the control to the dash panel. 11. Adjust the parking brake. Refer to Fig. 38. I. Raise the vehicle on a hoist. 2. Loosen the parking brake cable a d j u s t i n g n u t , remove the return spring and remove the cable ball end from the equalizer. 3. Lower the vehicle. 4. Disconnect the battery. 5. Disconnect the wire harness connector and two vacuum hoses at the Automatic Temperature Control box. 6. Working inside the vehicle, remove the windshield wiper control knob and ,bezel from the lower control panel. 7. Remove the screws retaining the lower control panel. Lower the control panel and disconnect wire harnesses and vacuum hoses. Position the control panel aside. 8. Remove the screw retaining the plastic wire cover and place the cover aside. 4i 9. Disconnect three vacuum hoses and the wiring harness a t the Automatic Temperature Control box. 10. Remove the two screws retaining the Automatic Temperature Control box to the dash panel and remove the box for clearance. 11. Disconnect the ball end of the cable from the control clevis. 12. Remove the four bolts retaining the control to the dash panel and lower instrument panel flange. 13. Disconnect the vacuum release hose from the control and remove the control assembly from the vehicle.. Installation 1. Position the control assembly to the dash panel and instrument panel flange and install the four retaining screws. 2. Connect the vacuum release hose to the control assembly. 3. Connect the cable ball to the control clevis. 4. Position the Automatic Temperature Control box to the dash panel and install the retaining screws. 5. Connect the wiring harness and vacuum hoses to the Automatic Temperature Control box. 6. Position the plastic wire cove1 and install the retaining screw. 7. Connect the wire harnesses and vacuum lines to the lower control panel and position the panel to the in- FIG. 36-Parking Brake System-Mustang a n d Cougar FIG. 38 Parking 6 r a k e ' ~ ~ s t ' e r n - ~ i n c o l n Continental -IP 2 REQUIRED PARKING BRAKE REAR CAB/€-ZA635 PARKING BRAKE REAR CABLE-2A63S FIG..37-Parking Brake syitem-~hunderbird and 'Continental Mark Ill L 02-02-34 , strument panel. Install. the ,lower control panel retaining screws. 8. Install the windshield wipe'r control bezel and' knob. 9. Working in the engine compartment connect the' wire harness and vacuum, hoses. to the.Atitomatic Tem- .' perature Control box. 10. Connect ttie battery cable. 11. Raise t h e vehicle on a hoist. 12. Connect the cable ball to the equalizer and install' the. equalizer lever return spring. : 13. Adjust the parking brake cable tension. 14. Lower the vehicle. Removal Refer to Fig. 37. 1. Partially raise the vehicle. 2. Back off the adjusting nut at the equalizer to relieve the tension on the cable. 3. Remove the spring at the actuator lever and disconnect the control cable from the clevis o n the, lever. . 4. Remove the clip retaining. the control cable assembly to. the frame bracket. 5.. Attach a length of wire to the . . . control cable. : 6. Working inside ,the vehicle remove two screws retaining the left scuff plate. .'.. 7. Remove one screw a n d remove the left cowl side .trim panel. 8. Remove the .two screws retaining the left air duct to the inner panel and remove the air duct. 9. Remove the two screws retaining the dimmer switch and position the dimmer switch back out of the way. 10. Remove the clip retaining the cable assembly to the control and remove the cable ball from the control clevis. 11. Pull the cable up through the opening in the dash panel and remove the cable from the length of wire. ,. 'PARKING BRAKE ACTUATORTO CONTROL CABLE : FORD, MERCURY AND METEOR .. Removal. ' . . '. . PARKING BRAKE EQUALIZER TO CONTROL' CABLE THUNDERBIRD A,ND CONTINENTAL MARK '111 ' . .. . Brake System . 1. Raise the vehicle. on a hoist. 2. Loosen the . actuator, .:lever to equalizer cable adjusting nut at the equalizer (Fig. 34). ,: ' . ' . ..- . . 3.' Disconnect the cable. bail from. the clevis on the actuator lever. 4. Remove spring clip: that retains the cable to the frame. 5. From inside of passenger compartment, remove spring clip that re& i n s 'the cable .to the parkink brake control. Disconneot thk cable ball from the control assembly. 6. Remove the cabie assembly from the vehicle. " , . . . .- Removal . . ' , . : ~ . . . ' . , Installation Installation . 1. Attach t h e cable t o t h e lengthof'wire and pull the cable down through the opening in.the dash panel. .., . ' . . . 2. Position t h e , upper end of the . .. lnstaliation control cable to the, control.. Connect . . .. . . . , . r . the cable ball to the contro!clevis.and ".. install the clip retaining the c a b l e . 1. Po~itibn 'the' cable . through'' the, . housing to the control. . .: -0penirigS and in the approxi- , . 3. Remove the length of wire from mate final installation,,position.. , ; the cable assembly arid position the ,. 2. Install the hairpin retainer'bn the cable at the frame crossmember. ,.,. . cable in the frame bracket., Install the . -3. Connect the ball. en&of the cable . retainer. , 4. Connect. the cable. ball to .the ':' fo the' barking brake' control. .:Install . clevis on the actuator lever and install the cable-to-control.,, haifpin retaining . . .clip. . . ' ... ,., . . . .. .., : -the actuator lever spring. . . 4. ~ o s i t i d r iih& cable''.'&&,, a t , the . : 5. Adjust the parking brake. , . dash panel, and slide theretaining clip. . 6 ; ,Reposition the dimmer switch , and install the 'retaining screws. upward' 'to seal the, sable' a t the dash . . ,. . o'pening. . . . 7. Positionthe air.duct to the inner 5. Connect the ball end b.f thl cable : panel and install t h e retaining screws. tq'the clevis'on'the actuatdi lever.: - . 8 Position. thecowl side trim panel 6. .Adjust the,. .parking ,brake ( P a r t . : . .and: install, the retaining screw. . . , . . :,. 2-1, Section 2). .. . . .. .': . . : 9. Install the two screws, in the 7.' Lower vehiile on:$ois.t., . . scuff plate. .. . . . . , , . . . . . FAIRLANE, MONTEGO AND . - FALCON : . i Refer t o Fig. 35. 1. Make'certain the parking brake is fully released. 2. Raise the vehicle on a .hoist. Remove t h e two nuts that attach, the cable to the equalizer. Remove the equalizer, spring seat and spring. 3. Remove the hairpin retainer holding the cable assembly to the body . bracket and remo.ve the cable from the slot in the bracket. 4. Lower the vehicle partially. 5. Remove the hairpin retainer which oretains the cable assembly to the control. 6. Remove the cable bolt retaining clip from the control clevis and disconnect the cable ball from the clevis. 7. Pull the cable down through the opening in the floor pan and frame side rail. , . . . , , ; 1. Route the new cable through the frame side rail and up through the opening in the floor pan. Pull the cable up into position. 2. Connect the'cable ball in the control clevis. 3. Insert the cable housing into the control and install the hairpin retainer. 4. Raise the vehicle. 5. Position the cable in the body bracket and install the hairpin retainer. 6. Position the spring,. spring' retainer and equalizer on the cab.le and i'nstall the two nuts. 7. .Adjust the parking brake.' , ' . Removal . . . ., . . ' , ,. ' ' , , , Referto Fig. 36. , . 1. ,Make certain the parking brake . , . isfully released. . . 2. Raise the vehicle on a hoist. Remove the. two nuts- that attach. the cable to t h e equalizer. Remove ttie equalizer spring seat and spring., . . 3. Remove the, : hairpin . retainer holding' the cable assembly t o ,ihe body bracket and pull the cable o u. t . of the side rail a c a s s holes. : , ., .. . . , . : ,, , ' a Brake System 4. Attach a wire to the end of the cable to assist in routing new cable. 5. Lower the vehicle. 6. Remove the parking brake front cable ball retaining clip from the clevis. 7. Disconnect the cable ball from the notch in the brake clevis. 8: Remove the hairpin retainer and ' remove the cable assembly from the brake control assembly. 9. Pull the cable assembly up through the opening in the floor and remove the wire from the end of the cable. Installation Refer to Fig. 36. 1. Connect the wire to the end of the cable assembly and pull the cable down through the opening in the floor. Remove the wire. 2. Connect the cable assembly to the brake control assembly and install the hairpin retainer. 3. Position the ball end of the cable in the notch of the brake clevis. 4. Raise the vehicle on a hoist. 5. Pull the cable grommet into positionsand route the cable through the access holes in the side rail and under the fuel line. 6. Insert the cable into the body bracket and install the hairpin retainer. 7. Position the spring, spring seat, and equalizer on the cable and install the two nuts. 8. Adjust the parking brake. LINCOLN CONTINENTAL Removal Installation I. Route the parking brake control to eq'ualizer cable to the control assembly and the equalizer, and install the two bolts that retain the cable to the dash panel (Fig. 38). 2. Install the left front fender apron splash shield and the six attaching bolts. 3. Lower the vehicle. 4. Connect the control cable to the clevis on the control assembly. 5. Raise the car on a hoist. 6. Position the supporting clip and cable on the vehicle and install the retaining bolts. Do not tighten the bolts. Position the cable armor approximately 112 inch to the right of the clip (looking toward the rear of the car) and tighten the retaining bolts. 7. Position the equalizer control cable to the support bracket and install the retaining hairpin clip. 8. Connect the ball end of the control cable to the equalizer lever. 9. Adjust the parking brake linkage , ,a (Part 2- 1, Section 2). 10. Check the operation of the automatic release mechanism. PARKING BRAKE ACTUATOR-TO-EQUALIZER CABLE FORD, MERCURY, METEOR, THUNDERBIRD AND CONTINENTAL M A R K I11 Removal II 1. Raise the car on a hoist. disconnect the parking brake cable from the equalizer lever underneath the car (Fig. 38). 2. Remove the retaining clip at the cable bracket, and disengage the cable from the bracket (Fig. 38). 3. Remove the supporting clip retaining bolts and remove the support plate from the underbody. 4. Lower the car on a hoist. 5. With the parking brake in the fully released position, disconnect the cable at the control assembly. 6. Raise the vehicle on a hoist. Remove* the left front fender apron splash shield retaining bolts and t h e , splash shield. 7. Remove the two bolts securing the parking brake control to equalizer cable bracket to the dash ,panel and remove the cable from the vehicle. Refer to Figs. 34 and 37. 1. Raise the vehicle on a hoist. 2. Remove the lock and adjusting nut which retains the cable to the equalizer. 3. Remove the cable end from the equalizer. 4. Unhook the cable from the actuator, and remove from the vehicle. Installation 1. Insert new cable end into actuator. 2. Insert cable end into equalizer and tighten the adjusting nut snug. Install the lock nut. 3. Adjust the parking brake cable tension and check operation as outlined in Part 2- I, Section 2. 4. Lower the vehicle. PARKING BRAKE EQUALIZER TO REAR WHEEL CABLE FORD, MERCURY, METEOR, THUNDERBIRD AND CONTINENTAL MARK Ill Removal 1. Raise the vehicle and loosen the parking brake equalizer rod adjusting nut. Disconnect the equal~zerfrom the rear cables (Figs. 34 and 37). 2. Compress the prongs yn the left cable-to-frame side member retainer so the prong can pass through the side-member. Remove the clip that attaches the left cable to the left lower arm. Pull the cable thru the'frame left .side member. 3. Compress the prongs on the right cable-to-frame side member retainer bracket so the prong can pass through the bracket. Remove the clips retaining the right cable to the frame crossmember. 4. Remove the rear wheel cover and wheel. Remove the three Tinnerman nuts that hold the brake drum in place I and remove the drum. 5. Working on the wheel 's~deof the rear brake, remove the automatic brake adjuster spnng. Compress the prongs on the parking brake cable retainer so that they can pass through the hole in the brake backing plate. Draw the cable retainer through the hole. 6. With the spring tension off the parking brake lever, lift the cable out of the slot in the lever and r;emove the cable through the backing plate hole. I installation 1. Pull enough of the parking brake cable through the housing so that the end of the cable may be inserted over the slot in the parking brake lever on I the rear brake shoe. 2. Pull the excess slack from the cable, and insert the cable housing into the brake backing plate access hole so that the retainer prongs expand. The prongs must be securely locked in place. Install the ,automatic brake adjuster spring. 3. Position the right hand' cable and the two retaining clips and screws on the rear crossmember. Compress the prongs on the right cable and position the cable in the retaining bracket on the frame side member. Be sure the locating stripe on the cable' is midway between the retaining clips and tighten all retaining clip screws. 4. Position the left cable, retaining clip and screw on the left lower suspension arm. Compress the prongs on the left cable and position the cable through the frame side-member. The prongs must be securely locked in place: 5. lnsert the ball ends of the cables into the equalizer assembly. 6. lnstall the rear drum(s) and tighten the three Tinnerman nuts and, secure the drum. Install the wheel and tire and the wheel cover. 7. Adjust the .parking brake linkage as outlined in Part 2-1, Section 2. Adjust the rear brakes, as' required (Part 2-1. Section 2). FA1 RLANE, MONTEGO, MUSTANG AND COUGAREXCEPT STATION WAGON Removal I. Remove the equalizer lock nut and adjusting nut, equalizer, spring and spring seat. 2. With the cables slack, disconnect the ball-ends from the connector (Figs. 35 and 36). 3. Remove the cable from the retainer hooks (station wagon models) and the underbody guide (convertible models) if required. 4. Remove the hairpin lock retaining the cable housing to the side rail bracket. 5. Remove the wheel cover, wheel and tire and the rear brake drum as outlined in Section 2. 6. Remove self-adjuster springs to allow clearance to remove cable retainer from the backing plate. Disconnect the rear end of the$cable from the parking brake lever on the brake shoe. Disengage the .cable housing retaining grommet or steel-pronged Hi-Hat from the backing plate and withdraw the cable and housing -from the inboard side of the backing plate. 7. Slide the cable and housing out of the side rail bracket. lnrtallation I. Insert the rear end of the cable through the side rail bracket and pull the cable and housing into position. 2. Insert the rear end of the cable and housing through the hole in the backing plate from the inboard side. 3. Connect the cable to the parking , 7. Working on the wheel side of the backing plate (Fig. 38), compress the prongs on the cable retainer so that it can pass through'the hole in the backing plate. Draw the &ble retainer out of the hole. 8. With the spring tension off the parking brake lever, lift the cable out of .the slot in*the lever and remove it. . through the backing plate hole. brake lever on the brake shoe,and'install the cable housing retaining grommet or steel-pronged Hi-Hat in ,the backing plate. 4. lnstall the self-adjuster springs. Position the cable housing in the side rail bracket and install the hairpin type retainer. 5. Install rear hub and drum assembly, wheel and tire assemblies and wheel cover as outlined in Section 2. 6. Position the cable retainer hooks (station wagon models) in the underbody guide (convertible models) and install the connector, thus hooking the two cables together. 7. Insert the cable into the equalizer and install the equalizer, spring seat, spring, adjusting nut and lock nut to the front, parking brake control cable. 8. Adjust the parking b r a k e q s directed in Part 2-1, Section 2. ~ 'Installation I. Pull enough of the cable through the cable housing so that the end of the cable may be inseited through the backing plate hole from the inner side and engage the cable end with the'slot in the park~ngbrake lever. 2. Pull the excess slack from the cable and insert the cable housing into the backing plate access hole (Fig. 38). The prongs must be securely locked in place. 3. Install the brake shoe retracting springs. 4. Position the cable to the u"derbody and install the retaining clamp so that the cable conduit armor extends forward of the clamp as shown in Fig. 38. Install the clamp retaining nuts. 5. Hook the cable housing to the retainer a t the spring U-bolt. 6. Engage the forward end of the cable housing with the frame bracket and secure it with the hairpin-type clip. 7. Insert the ball end of the cable into the equalizer. 8. Make a preliminary brake adjustment with the use of Tool HRA8650 (Fig. I I). 9. lnstall the rear drum. ' ~ i ~ h t d n the three Tinnerman nuts that secure the drum. lnstall the wheel and wheel cover. 10. Adjust the parkin'g brake linkage. 11. Lower the vehicle. F A I R L A N E A N D MONTEGO STATION WAGONS AND FALCON PASSENGER MODELS Removal a n d Installation Refer to Fig. 35. G e n e r a l l y follow the procedure given above, omitting separation of the cables, since the parking brake rear cable assemblies supplied for these models is in one piece. Removal and installation of both rear wheels, tires and drums will also: be .required. LINCOLN CONTINENTAL Removal I. Raise the car. Remove the rear wheel cover. Remove the wheel and tire as an assembly. 2. Remove the three Tinnerman nuts that hold the brake drum in place, and remove the drum. 3. Remove the brake shoe retracting springs. 4. Loosen the equalizer rod adjusting nut and disconnect the cable from the equalizer (Fig. 38). 5. Remove the hairpin-type retainer clip that secures the cable housing to the body bracket, and pull the cable and housing out of the bracket (Fig. 38). 6. Remove the cable to underbody clamp attaching nuts and the clamp. Disengage the cable housing from the hook-type retainer at the spring Ubolt. . . ,~ ANTI-SKID' CONTROL ACTUATOR . , . . : . : . " ... .. REMOVAL , Refer to Fig. 39. 1. Working in the passenger compartment, under the glove box, remote the screw that attaches the forward 'end of the control module. retainer to ' the support assembly. Lower the forward end of the control module retainer and remove the. moduleassem. . . . . . . . . . bly. : I - FIG. 39-Anti-Skid . C o n t r o l System . . - . - - . VIEW U ... 2. Disconnect the actuator solenoid and warning switch harness connectors from the control module. 3. Remove the two wiring harness grommets from the dash panel and push the wiring harness and connectors through the openings in the dash panel. 4. Working in the engine compartment loosen the hose clamp and remove the air hose from the'air filter. 5. Remove the engine air cleaner. Loosen the hose clamp and remove the vacuum hose from the vacuum manifold fitting. 6. Raise the vehicle on a ,hoist. 7. Disconnect the exhaust pipes from the exhaust manifold and support with wire to provide access to the actuator assembly. 8. Remove the, bolt retaining the actuator ground wire to the rear outer corner of the engine right bank. 9. Loosen the tube nuts and disconnect the brake system hydraulic tubes from the hydraulic valve housing. 10. Remove the three nuts retaining the actuator assembly to the actuator support bracket. 11. Remove the three bolts that retain the actuator mounting bracket to the side rail and remove the mounting bracket. 12. Remove the actuator assembly from the vehicle and place it on a bench. 13. Remove the air and vacuum hoses from the actuator. INSTALLATION I. Install the air and vacuum hoses on the new actuator. 2. Place the actuator assembly into position under the vehicle, routing the air and vacuum hoses up between the engine and fender apron and inserting the solenoid leads through the holes in the firewall. 3. Position the ground wire to the rear of the engine block and install retaining bolt. 4. Position the actuator mounting bracket to the frame side rail and install the three retaining bolts., 5. Position the actuator assembly to the mounting bracket and install the three retaining nuts. 6. Connect the hydraulic tubes to the hydraulic valve assembly and tighten the tube nuts to specifications. 7. Connect the exhaust pipes to the exhaust manifolds. 8. Lower the vehicle. 9. Pull the actuator solenoid and brake warning switch wiring harness through the two holes in the dash panel from inside the car. Seat the wiring harness grommets in the dash panel. 10. Connect the actuator solenoid and brake warning switch wiring harness connectors to the control modules. 11. Position the control module in the bracket under the glove box and install the retaining screw. 12. In the engine compartment connect the air hose to the air filter and position the hose clamp. 13. Connect the vacuum hose to the engine vacuum manifold fitting. Install the engine air cleaner. 14. Bleed the rear brake system and centralize the pressure differential valve. 15. Raise the rear wheels. Apply the brakes with the rear wheels turning to verify proper operation of the anti-skid control system. ANTI-SKID CONTROL MODULE REMOVAL Refer to Fig. 39. 1, Remove the retaining strap holding the harnesses. 2. Remove the screw that attaches the forward end of the control module retainei to the support assembly. 3. Lower the forward end, of the control module and retainer from the support assembly; move the module and retainer forward slightly until the flange clears the slot in the support assembly. 4. Disconnect the five wiring harness plugs from the control module. 5. Remove the control module from the vehicle. INSTALLATION 1. Connect the five wiring harness plugs to the control module. Only one arrangement is possible. 2. Position the control module in the retainer, orienting the module per the markings on it, and insert the retainer flange into the slot at the rear of the support assembly. 3. Pivot the retainer and control module upward and align the screw hole in the forward end of the retainer with the hole in the support bracket assembly. Install the retaining screw. 4. Test the vehicle on the hoist to verify correct operation of the skid control system. 5.. Secure the wiring to the module support extension with the retaining strap. ANTI-SKID CONTROL SENSOR REMOVAL Refer to Fig. 39. 1. Raise the vehicle on a hoist. 2. Remove the rear wheel and tire assembly. 3. Remove the three Tinnerman nuts (3) and remove the brake drum. 4. Disconnect the sensor lead from the rear wiring harness. 5. Unseat the sensor lead grommet pushing it to the inside of the brake assembly. 6. Remove the four nuts that retain the sensor to the backing plate and pull the axle shaft, sensor assembly and wheel bearing assembly from the axle housing. 7. Press the wheel bearing retainer and wheel bearing off the axle shaft (Refer to Part 4-2). 8. Remove the sensor assembly and press the rotor off the shaft with tool T69P-2B384-A Detail 2 and TOOL 1225-DA. ' INSTALLATION 1. Press a new rotor onto the axle shaft. Install a new sensor assembly o n t h e s h a f t with tool T69P2B384-ADetail I and TOOL 1225DA, and press the bearing and bearing retainer onto the shaft (Refer to Part 4-2). * 2. Insert the axle shaft assembly in the rear axle housing onto the four backing plate retaining bolts, feeding the sensor lead through the hole in the backing plate. 3. Seat the sensor lead grommet in the backing plate. 4. Install the four nuts on the retaining bolts and tighten to specifications. 5. Connect the sensor lead to the rear wiring harness and install two retaining straps. 6. Initall the rear brake drum and retain with the Tinnerman drum retaining nuts. 7. Install the rear wheel and tire assembly and tighten the wheel nuts to specifications. 8. Test the vehicle on the hoist to verify proper operation of the skid control system. , I 02-02-39 4 02-02-39 Brake System M A J O R REPAIR OPERATIONS Minor scores on a brake drum can be removed with sandpaper. A drum that is excessively scored or shows a total indicator runout of over 0.007 inch should'be turned down. Remove only enough stock to eliminate the scores and true up the drum. The refinished diameter must not exceed 0.060 inch oversize. Check the inside diameter of the brake drum with a brake drum micrometer (Tool FRE- 143l). If the drum diameter is less than 0.030 inch oversize .after refinishing, standard lining may be installed. If the drum diameter is 0.030-0.060 inch oversize after refinishing, oversize lining must be installed. After a drum is turned down, wipe the refinished surface with a cloth soaked in clean denatured alcohol. If one drum is turned down, the opposite drum on the same axle should also be cut down to the same size. ROTOR R E F I N I S H I N G Rotunda Disc Brake Attachment, FRE-2249-2, is the only recommended tool to refinish the disc brake rotors. The step-by-step resurfacing procedure provided wlth the tool must be adhered to. The finished braking surfaces of the rotor must be flat and parallel within 0.0007 ~ n c h ;lateral runout must not exceed 0.003 inch total indicator reading, and the surface finish of the brakIng surfaces are to be 80/15 micro Inches. The minimum limiting dimenslons (Figs. 1 1 and 12, Part 2- 1) from the Inboard bearing cup to the outboard rotor face and from the inboard bearing cup to the inboard rotor face must be observed when removing material from the rotor braking surfaces. On all models except Lincoln Continental, the limiting dimensions are to be measured with a ball and gage bar (Rotunda Kit FRE-70160). is necessary to replace linings, they m w t also be replaced on the wheel on the opposite side of the vehicle. I Inspect brake shoes for distortion, cracks, or looseness. I f this condition exists, the shoe must be discarded. D o DISASSEMBLY I. Clean the outside of the master cylinder and remove the filler cover and diaphragm. Pour out any brake fluid that remains in the cylinder. Dis.card the .old brake fluid. 2. Remove the secondary piston stop bolt from the bottom;of the cylinder (Figs. 40 and 41). ' 3. Remove the bleed screw, if required: 4. Depress the primary ;piston and remove the snap ring from the retaining groove at the rear of ,the master cylinder bore. (Fig. 42). Remove the push rod and the. primary; piston assembly from the master cylinder bore. not attempt to repair a defective brake shoe. 1. Wash the brake shoes thoroughly in a clean solvent. Remove all burrs or rough spots from the shoes. 2. Check the inside diameter of the brake drum with a brake drum micrometer (tool FRE-1431). If the diameter is less than 0.030 inches oversize, standard lining may be installed. If the diameter is 0.030-0.060 inches oversize, oversize lining should 'be installed. 3. Position the new lining on the shoe. Starting in the center, insert and secure the rivets, worklng alternately towards each end. Replacement lin- D o not remove the screw that retains the primary return spring retainer, return spring, primary cup and protector on the primary piston. 'This assem, bly is factory pre-adjusted and should not be disassembled. 5. Remove the secondary piston assembly. D o not remove the ;outlet tube ,seats, outlet check valves ,and outlet ings are ground and no further grinding is required. 4. Check the clearance between the shoe and lining. The lining must seat tightly against the shoe with not more than 0.008 inch clearance between any two rivets. RETAINER - 28245 COVER - 2166 /GASKET-2167 ' SECONDARY SYSTEM BRAKE OUTLET ifd / f l / BOOT 0 t RETAINER \ / BRAKE S H O E R E L I N I N G Brake linings that are worn to wit,,within 1/32 inch of t&,.rivet head or are less than 0.030 inch thick (bonded lining) or have been contaminated "with brake fluid, grease or oil must be replaced. Failure to replace worn linings will result in a scored drum. When i t DUAL MASTER CYLINDER t 20220 TUBE-SEAT - PISTO; STOP BOLT 2A5 1 1 - ' O-RING - 87002.593 I I PRO?;~TOR SPRING .. . PUSH ROD 'PRIMARY PI ASSEMBLY S E C O N D ~ R YPISTON, : ASSEMBLY 2A502 ' - NOT USED ON POWER B R A K E ECUIPPED VEHICLES NOT SERVICED 'REPLACE AS AN ASSEMBLY ONLY H 1499.8 FIG. 40-Dual Master Cylinder Disassembled-Except Disc Brakes , , I 02-02-40 02-02-40 Brake System open and free of foreign matter. Use an air hose to blow out d i r t and cleaning 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 damage, do not exceed allowable hone specifications. ASSEMBLY FIG. 41-Dual M a s t e r C y l i n d e r Disassembled-Disc 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 assembly i n the master cylinder bore. 3. Install the primary piston assembly 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 retainer on the push rod, i f so equipped. Install the push rod assembly into the primary 'piston. M a k e sure the retainer is properly seated and holding the push r o d securely. 6. Position the inner end o f the push rod boot (if so equipped) i n the master cylinder body retaining groove. 7. Install th6 secondary piston stop rakes check valve springs f r o m the master cylinder body. INSPECTION A N D REPAIR INNER BRAKE SHOE AND LINING CUTER SHOE RETAINING CLIPS ASSEMBLY-2019 I I.Clean all parts i n clean isopropyl alcohol, and inspect the parts for 'chipping, excessive wear or damage. When using a master cylinder repair kit, install all the parts supplied. 2. Check all recesses, openings and internal passages to be sure they are STABILIZER Snq, Ring P l i e r s -0CATING PIN JQ -. CLIP 28164 n1m-c FIG. 42 -Removing Ring-Typical Snap FIG. 43--Caliper Assembly-DisassembledA l l M o d e l s Except Lincoln C o n t i n e n t a l . . OUTER BRAKE SHOE AND LINING ASSEMBLY-POI8 2066 L Brake System bolt and.0-ring in the bottom of the master cylinder. 8. Install the bleed screw (if so equipped). Install the gasket (dia: phragm) in the master 'cylinder filler cover. Position the gasket as shown in Figs. 40 and 4 1. Make sure the gasket is securely seated. 9. install the cover and gasket on the master cylinder and secure the cover into position with the retainer. ALL MODELS EXCEPT LINCOLN CONTINENTAL Disassembly 1. Remove the caliper assembly from the vehicle as outlined in Section 2. 2. Remove the caliper locating pins from the caliper assembly and lift the anchor plate from the caliper. 3. Slide the two outer shoe retaining clips off the retaining pins (Fig. 43). 4. Remove the two retaining pins, then remove the outer brake shoe from the caliper. 5. Slide the inner brake shoe outward until it is free of the hold-down springs, then remove the brake shoe. 6. Apply air pressure to the fluid port in the caliper with a rubber tipped nozzle (Tool 7000-DD) as shown in Fig. 44 to remove the piston. Place a cloth over the piston before applying air pressure to prevent damage to the piston. If the piston is seized and cannot be forced from the CALIPER caliper, tap lightly around the piston while applying air pressure. Care should be taken because the piston can develop considerable force due to pressure build-up. 7. Remove the dust boot from the caliper assembly. 8. Remove the rubber ;iston seal from the cylinder and discard it. Cleaning a n d Inspection Clean all metal parts with isopropyl alcohol or a suitable solvent. Use clean, dry, compressed air to clean out and dry the grooves and passage ways. Be sure that the caliper bore and component parts are completely free of any foreign material. Check the cylinder bore and piston for damage or excessive wear. Replace the piston i f it is pitted, scored, or the chrome plating is worn off. Assembly 1. Apply a film of clean brake flu~d to the new caliper piston seal and install it in the cylinder bore. Be sure the seal does not become twisted and that it is seated fully in the groove. 2. Install a new dust boot by setting the flange squarely in the outer groove of the caliper bore. 3. Coat the piston with the specified fluid and install the piston in the cylinder bore. Spread the dust boot over the piston as it is installed. Seat the dust boot in the piston groove. 4. Position the inner brake shoe so that the ears of the shoe rests on the top of the anchor plate bosses and .beneath the hold-down springs. 5. Install new caliper locating pin insulators in the anchor plate. 6. Position the caliper on the anchor 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. 1. Remove the caliper assembly from the car as outlined in Section 2. 2. Remove the two attaching bolts and the caliper splash shield (Fig. 46). 3. Remove the two shoe. and lining assemblies. 4. Remove the flexible brake hose from the caliper. 5. Remove the external trans'fer tube. 6. Remove the four dust boots from the caliper housings and piston grooves. 7. Clamp the caliper in la vise and 'secure it by the mounting flanges on the inboard housing (.Fig. 45). 8. Remove the four pistons from the cylinder bores with the 'special tool shown in Fig. 45. T o prevent cocking with consequent damage to the piston or bore, rotate the piston with the tool while pulling it outward at the same time. Be careful to avoid scratching or damaging the outside diamktei surface or dust boot retaining grooke of the piston. Such damage causes poor sealing. If a piston is so completely seized In the cylinder bore that it can not be rcmoved with the special tool, the caliper housing must be replaced, by positioning two screwdrivers in the piston dust boot retaining groove jand prying outward. T o prevent cocking, tap the end of the piston lightly around the circumference with a ham,mer, while the prying force is being Gpplied. Be careful to .avoid damaging the dust boot retainer in the caliper housing (Fig. 46). I f this method or; removal is used, the pistons must be replaced. I f the caliper dust boot ,retainer or 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 scratched, pry the retainer out of the caliper housing with screwdrivers.. I LINCOLN CONTINENTAL Disassembly FIG. 4 4 -Removing Piston Fiom Coliper-All Models Except, Lincoln Continental Do not remove the bridge bolts that hold the two halves of the caliper together. The two caliper housings are shown separated in Fig. 46 for illustration purposes only. FIG. 45--Removing o r Instolling Pistons-Lincoln Continental , , , , , I , i ' I I 1 I . 02-02-42 CALIPER ABUTMENTS OUTBOARD CALIPER HOUSING PISTON S E A L ( A ) DUST BOOT RETAINING GROOVE CXTERNAL TRANSFER TUBE OUST SHOE A N 0 LINING ASSEMBLIES 0 9 INBOARD CALIPER HOUSING BRIDGE BOLTS FIG. 46 - C a l i p e r 02-02-42 Brake System Assembly-Disassembled-Lincoln 9. Remove the rubber piston seals f r o m the grooves i n the cylinder bores by carefully inserting the point o f a small knife o r other pointed instrument under the seal and raising the seal u p far enough t o be pulled out with the fingers. C l e a n i n g a n d Inspection Clean a l l metal parts with isopropyl alcohol or a suitable solvent (Fig. 46). Use clean, dry, compressed air t o clean out and d r y the grooves and passage ways. Be sure that the caliper Continental bore and component parts are completely free o f any foreign material. Check the cylinder bores and pistons f o r damage o r excessive wear. Replace the piston i f i t is pitted. scored, or the chrome plating is w o r n off. Check the caliper dust b o o t retainer for wear or damage. .Asse r n bly I. C l a m p the caliper i n a vise and secure i t by the m o u n t i n g flange on the inboard housing. 2. A p p l y a f i l m o f clean brake fluid t o new caliper piston seals and install them i n the grooves o f the cylinder bore. T h e seal should be positioned at one area i n the groove and gently worked around. D o not use the original seals. 3. Install the new dust boots by sett 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 specified 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. 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 retaining groove face out o f the bore. T o avoid cocking, locate the piston 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, reniove 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 while pushing i t inward at the same time. 6. Carefully install four new dust boots o n the caliper housings and pistons. Be sure that each boot is fully seated i n the groove o f its respective caliper housing and piston (Fig. 46). Do not use the original dust hoots. 7. Install the external transfer tube. Install the flexible brake hose t o the. caliper. 9. Install the caliper assembly on the spindle. and install the shoe and lining assemblies and the splash shield as outlined i n Section 2. Check the caliper for f l u i d leaks under m a x i m u m pedal pressures. D o not move the car 8. until a firm brake pedal is ohtained. 02-03-0 1 I Specifications 02-03-01 ! PART 2-3.Specifications ' LINING DIMENSIONS -DRUM BRAKES -INCHES Vehicle FORD, MERCLIRY, METEOR Ford, Meteor Passenger (RiveteC Lining) Except 390, 429 CID Galaxie 500XL, Ford LTD, LeMoyne. Ford, Mercury, Meteor with O i x Brakes. Mercury Passenger, Sta. Wag. and Conv. Ford Meteor Station Wagon and Convertible. 390, 429 CID Galaxie 500 XL, Ford LTD, LeMoyne. Ford, Meteor 240, 302 CID Taxi Only (Bonded Lining) Max. Wear Resistance. MONTEGO, FAIRLANE Passenger 250, 302 CI D Except Convert~ble ( Rear Front Primary 2.50 x 9.34 2.25 x 9.34 Secondary Primary Secondary 2.50 x 12.12 N/A N/A 2.25 x 12.12 2.25 x 9.34 2.25 x 12.12 Primary 3.00 x 9.34 2.25 x 9.34 Secondary 3.00 x 12.12 2.25 x 12.12 Pr~mary Secondary 3.00 x 9.34 3 OOx 12.12 2.50 x 9.34 2.50 x 12.12 Primary Secondary 2.25 x 8.43 2.25 x 10.82 Pr~mary 2.50 x 8.43 2.00 x 8.43 2.00 x 10.82 I 2.00 x 8.43 Secondary Primary Secondary 2.50 x 10.82 2.50 x 8.43 2.50 x 10.82 2.00 x 10.82 2.50 x 8.43 2.50 x 10.82 Primary Secondary Pr~mary Secondary Pr~mary Secondary Primary Secondary 2.25 x 7.62 2.25 x 9.77 2.50 x 8.43 2.50 x 10.82 2.25 x 8.43 2.25 x 10.82 2.50 x 8.43 2.50 x 10.82 1.50 x 7.62 1.50 x 9.77 2.00 x 8.43 2.00 x 10.82 2.00 x 8.43 2.00 x 10.82 2.00 x 8.43 2.00 x 10.75 Primary Secondary Primary Secondary Primary Secondary 2.25 x 7.62 2.25 x 9.77 2.25 x 8.43 2.25 x 10.82 2.50 x 8.43 2.50 x 10.82 Primary Secondary N/A NIA Primary Secondary N/A N/A I * Station Wagon, Ranchero and . Convert~ble250, 302 CI D. Passenger and Convertible 351, 390, 428 CI D. Station Wagon and Ranchero 351, 390,428 CI D. FALCON Sedan 6-Cylinder. Station Wagon 6-Cylinder. - Position Sedan 8-Cylinder. Station Wagon 8-Cylinder. MUSTANG, COLIGAR 200 Cl D Engine. 250, 302 CI D Engines. 351, 390, 428 Cl D Engines. THUNDERBIRD, CONTINENTAL MARK Ill LINCOLN CONTINENTAL i Wear Limits Riveted: 1/32 inch f rom to^ of rivets. Bonded: 0.030 inch total lining thickness. . I I ' I ' 1.50 x 7.62 1.50 x 9.77 1.175 x 8.43 1.175 x 10.82 2.00 x 8.43 2.00 x 10.82 I 2.25 x 9.34 2.25 x 12.12 1 3 . 0 0 ~9.39 3 . 0 0 ~12.21 I BORE DIAMETERS-BRAKE DRUM, WHEELCYUWDER AND MASTER CYLINDER Master Qlinder.Eore Dia: Brohe Drum' ' Whe'el Qli'nder Bore Dia. With Power Less w ~ r Boring Limit Inside Models ~ r o n t0 1.11 0 B r i b e B~~~:@ (ha) @ Diameter 1.094 0.938 1.000 1.000 11.090 Taxi and Station Wagon 11.030 Ford, Mercury and ' 0.938 l.Ob0 1.000 1.125 11.090 11.030 Other Meteor 0.9375 1.125 1.000 0.875 10.060 Pass. except Conv. 250, 302 CID Engines 10.000 Montego 1.000 . 0.9375 ' 1.094 0.875 10.060 10.000 Pass. and Conv. 351, 390, 428 ClD Eng. and 0.9375 1.000 1.094 0.875 10.060 10.000 Convertible 250, 302 ClD Englnes Fair lane 0.9375 1.000,, 1.094 0.938 10.060 10.000 Station and Ranchero , 0.9375 1.062 9 , 1.000 0.8440 9.060 9.000 9 Inch Brake Passenger Car 0.9375 1.000 1.094 0.938 . 10.060 10.000 10 Inch Brake Station Wagon Falcon 0.9375 1.000 1.125 0.875 10.060 10.000 10 Inch Brake - Passenger Car 1.000 1.000 1.062 0 0.8440 9.060 9.000 200 CID Engine Mustang 1.000 1.000 0.875 1.094 10.060 10.000 351, 390J 428 CIO Engine and Cougar 1.000 1.000 ' 0.875 1.125 10.060 10.000 250, 302, CID Engine 1.000 N/A 0.938 11.090 N/A 11.030 Thunderbird 1.000 N/A 0.938 11.090 N/A 11.030 Continental Mark Ill 1.000 0.938 NIA 11.130 N/A 11.090 Lincoln Continental @Max. Runout 0.007 @Front Wheel Cylinder cannot be honed on Falcon or Mustang with 9 inch Brakes. @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 . I I I : I I > I ' 1 I I I - 1 11 I 1 1 / 1 1 I 0 - SHOE AND LlNlWG DIMENSIONS- I CALIPER CYLINDER BORE DlaWlETER -INCHES Ford, Mercury, Meteor, Thunderbird, Continental Mark 111 Mustang, Cougar, Falcon, Fairlane and Montego Lincoln Continental 2.755 2.381 1.938 1 Diameter Outside Inside 11.72 1 7.785 11.72 I1 7.785 1 ROTOR DlMEsJSlOWS I 1 Car Line Ford, Mercury, Meteor Thunderbird, Continental Mark Ill Fair lane, Falcon, Montego, Mustang and Cougar ' , Llncoln Continental 1 Wom. Thickness 1.180 1.180 . 0.935 1.240 I 1 I 11.29 7.355 TORQUE LIMITS-HUB TO SPINDLE Description Hub and Drumor Rotor Assembly t o Front Wheel Spindle Ft-Lbs Rotatehubwhile torquing t o 17-25 ft-lbs. Back off the adjusting nut 112turn and retighten t o 10.15 inch pounds while rotatIng wheel Selectively position nut retainer on adjusting nut so that a set of slots are i n line with cotter pin hole. Adjusting nut should not be rotated i n this operation. Lockadlusting nut andnut retainer with cotter pin so that the cotter pin end does not interfere with seatinp of wheel static collector i n spindle hole. 02-03-03 I 02-03-03 Specifications ROTOR REFINISH The following requirements must be met when resurfacing disc brake rotors: Rotunda Oisc Brake Attachment FRE-2249-2 is the only approved tool t o -be used t o refinish the disc brake rotors. The step-bystep resurfacing procedure provided with the tool must be adhered to. The finished braking surfaces of the rotor must be flat and 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 Parking Brake Control Assembly Mounting Nuts and Bolts , - a Master Cyl~ndert o Oash Panel Screw Master Cylinder to Booster Booster to Dash Panel Disc Brake Caliper t o Spindle Bolts Oisc Brake Rotor Splash Shield to Spindle Brake Hose to Callper Connect~onBolt Callper Locating Pins Caliper Stablllzer to Anchor Plate Bolt Caliper Brake Shoe Cl~ps Caliper Bleeder Screws Wheel Cylinder t o Backing Plate Screws Wheel Cylinder & Back~ngPlate Anchor Pin Nut Rear Brake Backlng Plate t o Axle Housing. Removable Carr~er Integral Type Front Brake Backing Plate t o Spindle Wheel Cylinder Bleeder Screw Brake Hose Connection t o Front Wheel Cylinder Brake tine Connection to Rear Axle Housing. Removable Carrier Integral Type Hydraulic Tube Connections Q 318 x 24 7/16 x 24 112 x 20 9/16 1 18 Wheel t o Hub and Drum or Hub and Rotor Nuts On all models except Lincoln Continental the limiting dimenbe sion from the inner bearing cup to the'inner rotor face must ' measured with a ball and gage bar (Rotunda FRE-70160). On Lincoln Continental models the limiting dimension from the inboard hearing cup t o the inboard rotor face of 0.755 inch minimum and from the inboard bearing cup t o the outboard rotor face of 0.395 inch minimum must be observed. ' Ford-Mercury Meteor Cap Screw 12-19 Fair lane. Montego Falcon 12-25 ' MustangCougar 12-25 Thunderbird Cont inental Mark Ill 12-18 Lincoln Continental Dash Panel 10.20 Inst. Panel 7-12 Nuts 7-11 13.20 13-20 13-20 Upper O 110-140 Lower 90-120 1520 13-20 13-20 Upper O 100- 140 Lower 55.75 1520 13-20 13.20 Upper O 100-140 Lower 55- 75 13-20 13-20 Upper O 110-140 Lower 90-120 9-14. 17.25 25- 35 9.14 17-25 25-35 9-14 17-25 25- 35 9-14 17-25 25- 35 811 6-10 6-15 8-11 6- 10 6-15 10 in. Brake 10-20 9 in. Brake 5- 7 8.11 6-10 6-15 10 in. Brake 10-20 9 ~ n .Brake 5- 7 8-11 6-10 6 15 7.9 6-15 10.20 10-20 50-70 20-40 2835 32-65 0 Inch-lb. 50- 70 20-40 2 8 35 32.65 0 Inch-lb. 50- 70 30-35 6.15 6-15 10-20 13-20 13-20 100-140 9.14 - 20-30 50-70 20-40 25-40 6-15 . I I 12-20 12-20 12-20 30-40 25-35 12-19 12- 19 12-19 12-19 30- 40 10-15 10-15 10-17 10-17 10-15 10-15 10-17 10-17 4 lug 55-85 5 lug 70-115 10-15 10-15 10-17 10-17 4 lug 55- 85 5 lug 70-115 10-15 10-15 10-17 10-17 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. : 10.15 10-15 10-17 10-17 I I 70-115 70.115 I i 02-03-04 1 Specifications SERVl CE TOOLS Ford Tool No. Rotunda HRE 8650 I i 02-03-04 Former No. LM 119 2018-A 2162 2035N Tool 7000-00 Rotunda 70160 Tool 33621 I 1 I 1 Tool -- 4 -2 -3 5 4 1, Rotunda FRE 1431 II I I 33621 Milbar 1112-144 4235-C Rotunda FRE 22492 I J 22742 (Kent Moore) , I I I I I I Description Brake Adjusting Gage Brake Cylinder Retaining Clamp Brake Adjusting Tool Adapter Cap Brake Shoe R & R Spring Rubber Tipped Air Nozzle Ball and Gage Bar Internal Snap Ring Pliers Inch Pound Torque Wrench Axle Shaft Remover Brake Drum Micrometer Bleeder Valve Clip Spring Disc Brake Rotor Attachment This is only a Demo of the product! Only a few pages are included. Description: The Ford Shop Manual is the original manual used by the Ford dealership mechanics at to guide them through repairs and maintenance. Each section provides information on the operation of major systems, Our manuals are fully diagnostics, troubleshooting, overhaul, as well as the approved and licensed by removal and installation of major components. Written the Ford Motor Company in an easy to understand format, this manual contains step-by-step instructions designed for the novice and the expert. In addition, this manual is filled with illustrations, photographs, and diagrams that help in the identification of parts and proper assembly. We are a licensed distributor of Adobe Reader Adobe Reader: Unlike some CD-ROM versions on the market, this product is produced in Adobe Reader (pdf) format to retain the exact look and feel of the original manual. Simply scroll through the pages and sections like reading a normal printed manual. 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