Copyright © 2007, 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
1971 Ford Car Shop Manual ISBN: 0-9673211-8-2 EAN: 978-0-9673211-8-9
Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192 Email address: [email protected] Website: http://www.ForelPublishing.com
This publication contains material that is reproduced and distributed under a license from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company.
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.
WHEELS and TIRES
. , BRAKES \
€&ARCING SYSTEM...... 31 STEERING I. LI6HTING SYSTEM...... 32' SUSPENSION
VEMTICATING, HEATING ad AIR COND1TIONIIG ...... 38 SPEED CONTROL ag ANTI- DRIVING AXLES SKID CONTROL...... $?*: and DRIVESHAFT tDENTIFICATION C~DES...... 40 SEAIS...... 4t WIRDOW GLASS clnd CLUTCH and MANUAL TRANSMISSION INTERIOR TRIM ...... 45 TOP5 and EXTERIOR FINISHES ... 46 BODY SHELL, EXTERIORTRIM, .. FRAME AND UNDERBODY ... 47 AUTOMATIC TRANSMISSION
FIRST PRINTING-SEPTEMBER, 1970 SE RV lC E PUBLICAT IONS (i31970 FORD MARKETING CORPORATION, DEARBORN.MICHIGAN FOREWORD
This manual is divided into five volumes: I - Chassis, 2 - Eltgine, 3 - Electrical, 4 - Body, 5 - Maintenance and Lubrication. These volumes should provide.Service Technicians with complete information covering normal service repairs on all 19 71 model passenger cars (except Pinto) built by the Ford Companies in the U.IS. and Canada. Service procedures for the Pinto are covered in the Pinto Car Shop Manual. As changes in the product occur, this information will be updated by Technical Service Bulletins. When issued TSB information always supersedes that published herein.
Within each volume, information is grouped by system or component plus 'General Service"' parts which contain information which is common to several similar components.
The table of contents on the first page of each volume indicates the general content of the book and provides a handy tab locater to make it easy to find the first page of each "Group ': nut page will contain an index to 'Parts " and the first page of each 'Yurt" contains a detailed index which gives page location for each service operation covered. Page numbers are consecutive in each '!Part".
To make reference easier,. information has been broken down into smaller units so that essentially there is now one '%rt" for each component or system. Group numbers indicate the volume in which the group .may be found.
Indicates: 42 - 04 - 23 A \\ Volume 4 - Group 42 - Part 4 - Page 23
The descriptions and specifications in this manual were in effect at the time this manual was approved for printing. Ford Marketing Corporation reserves the right to discontinue models at any time, or change specifications.or design, without notice and without incurring oblication.
SERVICE PUBLICATIONS
5006 . May ,I996 10-00-0 1 Identification Codes 10-00-0 1
OFFICIAL VEHICLE VEHICLE CERf IFlCAf ION LABEL ASSEMBLY PLANT CODES IDENTlFlCAfION NUMBER The Vehicle Certification Label Code Letter The official Vehicle Identification (V.C. Label) is attached to the rear I . A ...... Atlanta Number (VIN) (Fig. 1) for title and face of the driver's door. The upper B ...... Oakville (Canada) registration purposes is stamped on a half of the label wntains the name of E ...... Mahwah metal tab that is fastened to the the manufacturer, the month and year F ...... Dearborn instrument panel close to the windsh- of manufacture and the certification G ...... Chicago statement. The V.C. label also contains H ...... Lorain ield on the driver's side of the car and I ...... Lot Angeles is visible from outside. the Vehicle Identification Number. K ...... Kansas City N ...... Norfolk P ...... Twin Cities R ...... San Jose S ...... Allen Park T ...... Metuchen U ...... Louisville W ...... Wayne X ...... St. Thomas 1 Y ...... Wixom Z...... St. Louis
Assy Plant Codes
This number is also used for Warranty r identification of the vehicle. The first MANUFACTURED BY 100001 number indicates the model year. The FORD MOTOR COMPANY letter following the model year number indicates the manufacturing 08/70 THIS VEHICLE c,ON;$C)RMS ' NOTE:WORDING .::. ::.:,>.;. assembly plant. The next two numbers J 1 WILL VARY T 0 A L L A P P L I G~A F'@D E WITH .:;:. :;/:: @&~,...; :.... y $&:, designate the Body Serial Code VEHICLE followed by a letter expressing the 0 T 0 R.;y E @$@$$ $LFE,@+. fA - LINE .... .:;.;;. .;.:.:.:;;;; :;:, ,:::. D&"s gH,,Efip&.~.:ON ,,ATE OF Engine Code. The last six digits of the ..... ;.. .. 4: .c.. Vehicle Identification Number indicate MA&FkC?URE SHOWN ABOVE. the Consecutive Unit Number. 1 The remaining information on the V.C. Label wnsists of pertinent vehicle identification codes. The BODY code is two numerals and a letter identifying the body style. The
T FOR TITLE OR REGISTRATIO COL (wlor) code is a number or letter (or both) indicating the exterior paint MADE IN U.S.A. wlor code. The TRIM code consists of a number-letter combination des- ignating the interior trim. The Axle @ CONSECUTIVE UNIT NO. @ REAR AXLE CODE 0/ code is a number or letter indicating @ BODY SERIAL CODE @ COLOR CODE the rear axle ratio and standard or locking type axles. The TRNS. code is @ MODEL YEAR CODE @ BODY TYPE CODE a number or letter indicating the type of transmission, numerals for manual @ ASSEMBLY PLANT CODE 10 DISTRICT -SPECIAL EQUIPMENT CCOE and letters for automatic. The DSO 0 code consisting of two numbers @ ENGINE CODE @ TRANSMISSION CODE designates the district in which the car was ordered and may appear in @ TRIM CODE conjunction with a Domestic Special Order or Foreign Special Order number when applicable. Ford of Canada DSO codes consist of a letter FIG. 1 Vehicle ldentification Labels and a number. 10-00-02 lden tification Codes 10-00-02
DATE CODES DISTRICT CODES (DSO) A number signifying the date precedes Units built on a Domestic Special Or- this space is the two-digit code number of the month code letter. A second-year code der, Foreign Special Order, or other Spe- the District which ordered th'e unit. If the letter will be used if the model exceeds I2 cia1 orders will have the completc order unit is a regular production unit. only the months. number in this space. Also to appear in District code number will appear.
Month Code Code LINCOLN.MERCURY FORD First Year Second . Year Code District Code District January ...... A ...... N 11...... Boston 11 ...... Boston February ...... B ...... P 15 ...... New York 13 ...... New York March ...... C ...... Q 16 ...... Philadelphia 15 ...... Newark April ...... D ...... R 17 ...... Washington 16 ...... Philadelphia May ...: ...... E ...... S 21 ...... Altanta 17 ...... Washington June...... F ...... T 22 ...... Dallas 21 ...... Atlanta July ...... G ...... U 23 ...... Jacksonville 22 ...... Charlotte August ...... H ...... V 26 ...... Memphis 24 ...... Jacksonville September ...... J ...... W 31 ...... Buffalo 25 ...... Richmond October ...... K ...... X ,32 ...... Cincinnati 28 ...... Louisville November ...... L ...... Y 33 ...... Cleveland 32 ...... Cleveland December ...... M ...... Z 34 ...... Detro~t 33 ...... Detroit - -- 41 ...... Chicago 35 ...... Lansing 42 ...... St. Louis 37 ...... Buffalo 46 ...... : ...... Twin Cities 38 ...... Pittsburgh ENGINE CODES 51 ...... Denver 41 ...... Chicago 52 ...... Los Angeles 43 ...... Milwaukee No. of 44 Twin Cities Code Cyls. Displacement 53 ...... Oakland ...... 54 ...... Seattle 46 ...... Indianapolis U 6 -170 CID 84 ...... Home Office Reserve 47 ...... Cincinnati T 6 200 CID-1V 90 ...... Export 51 ...... Denver 20 6 200 CID-1V 53 ...... Kansas City .. L 6 250 CID.lV 54 ...... Omaha 30 6 250 CID-1V 55 ...... St. Louis V 6 240 CID-1V 56 ...... Davenport B 6 240 CID-1V (Police) 61 ...... : ...... Dallas E 6 240 CID-1V (Taxi) 62 ...... Houston 63 ...... Memphis F 8 302 CID-2V FORD OF CANADA * 60 8 302 CID-2V 64 ...... New Orleans D 8 302 CI D-2V (Taxi) 65 ...... Oklahoma City Mercury Region Ford 71 ...... Los Angeles G 8 302 CID4V (Boss) Code Code H 8 351 CID-2V 72 ...... San Jose 73 ...... Salt Lake City 8 351 CID4V A1 ...... Central ...... B1 74 Seattle 8 351 CID.4V GT ...... 6' A2 ...... Eastern ...... 82 75 ...... Phoenix Y 8 390 CID-2V A3 ...... Atlantic ...... B3 S 8 400 CID-2V 83 ...... Government i A4 ...... Midwestern ...... 84 84 ...... Home Office Reserve K .. 8 429 CID-2V A6 ...... Western ...... B6 N 8 429 CID4V 85 ...... American Red Cross A7 ...... Pacific ...... B7 87 ...... Body Company C 8 429 CID4V CJ 12 ...... Export ...... : ...... 12 1 8 429 CID4V CJ Ram-Air 89 ...... Transportation Services P 8 429 CID-4V Police 90.99 ...... Export A 8 460 CID-4V @Low Compression Export-
EXTERIOR PAINT COLOR CODES TRANSMISSION CODES M.32.J M.32.1 Code Type 1 Code Number Color I I Code Number Color I 1 ...... 3-Speed Manual A ...... 1724-A ...... Black 1736-A...... Med. Gray Gold Met. 5 ...... 4.Speed Manual-wide ratio M ...... 1619.A ...... White 3341-A ...... Yellow 6 ...... 4-Speed Manual4lose ratio 1 ...... 1730-A ...... Calypso Coral 3470-A ...... Bright Yellow W ...... Automat~c(C4) T ...... 2008.A ...... Red 3565-A ...... Lt. Goldenrod Yellow U ...... Automat~c(C6) 3 ...... 3560-A ...... Bright Red 3492.A ...... Med. Goldenrod Yellow X ...... Automatic (FMX) B ...... 3562-A ...... Maroon Met. 3659.A ...... Grabber Orange Z ...... Automatic (C6 Special) L ...... 3318-A ...... Lt. Gray Met. 5003.A ...... Med. Tan K...... 3346-A: ...... Dk. Slat Gray Met. 3314.A ...... Lt. Pewter Met. REAR AXLE RATIO CODES N ...... 921-A ...... Platinum 3342-A ...... Dk: Brown Me!. Q ...... 3064-A ...... Med. Blue Met. 3564.A ...... Med. Ginger Met. X ...... 1903-A ...... Dk. Blue Met. Conventional Lock Ratio 6 ...... 3077-A ...... Bright Blue Met. 1 ...... 3657-A ...... Grabber Blue GLAMOUR PAINTS 2 ...... K...... 2.75:l Y ...... 3320-A ...... Br~ghtAstra Blue Met. 3 ...... - ...... 2.79:l F ...... 3321-A ...... Med. Bright Aqua Met. . 49 ...... 5072.A ...... Med. Ivy Bronze Met. 4 ...... M ...... 2.80:l H ...... 3472-A ...... Lt. Green 79 ...... 5071-A ...... Med. Ginger Bronze 6 ...... 0 ...... 3.00:l P...... 3462-A ...... Med. Green Met. Met. 9 ...... R...... 3.25: 1 C ...... 3542.A ...... Dk. Gieen Met. E9 ...... 5069-A ...... Med. Ivy Bronze Met. A ...... S ...... 3.50:l Z ...... 5002-A ...... Grabber Green Met. 39 ...... 5008-A ...... Med. Ginger Bronze Met. -B ...... 3.07:l G...... !... 3345.A ...... Dk. Vintage Green ...... v ...... 3.91:l 1...... 5001-A ...... Bright Lime Green D9 ...... 5007-A ...... Med. Blue Met. - ...... Y ...... 4.11:l 8 ...... 3198-A ...... Lt. Gold C9 ...... 5070-A ...... Med. Red Met. " 'f~ote', Codes 10-00-03 Identification Codes 10-00-03
BODY SERIAL AND STYLE CODES body series. This two-digit number is of a two-digit number with a letter suffix. The two-digit numeral which follows used in conjunction with the Body Style The following chart lists the Body Serial the assembly plant code identifies the Code, in thevehicle Data,which consists Codes, Body Style Codes and the model. Body Body Body Body Vehicle Serial Style Body Type Model Vehicle Serial Style Body Type Model Code Code Code Code Torino MERCURY 48 578 4.01. hard to^ TORINO 27 54A 4.Dr.Sedan I I 25 65A 2-Dr. Hardtop 1 54 1 53F 1 4-Dr. Sedan I~onterey- I Custom- 34 63C 2-Dr. Hardto~Sportsroof Torino 500 56 65F 2-Dr. Hardtop 58 57F 4-Dr. Hardtop I I Marquis 131~ - 54C. - 4-Dr.- . Sedan.. ~ 63 53H 4.Dr. hard to^ Sedan 1 I I I
32 57C 4-Dr. Hardtop 1 66~ ~ I 65H 1 2-Dr. Hardtoo 1 36 57E 2.Dr. Hardtop-Formal Torino 68 1 57H 4-Dr. Hardtop Brougham. 33 65E 4-Dr. Hardtop 62 / 53K 4-Dr. Hardtop Sedan Brougham 35 63F 2-Dr. HardtopSportsroof Torino GT 64 65K 2-Dr. Hardtop 37 76F Convertible 67 57K 4-Dr. Hardtop 38 63H 2-Dr. HardtooSoartsraof Cobra 72 718 4-Dr. 6 Pass.@ Manterey
C
OAlsoavailable w/Dual Face Rear Seats @Also "BOSS" @I Merchandised as options (Bucket seats) @Also "GT" Body Serial and Style Codes CY1302-A . 10-00-04 Identification Codes
INTERIOR TRIM CODES 1 Code Trim Scheme I Code Trim Scheme I 1 Code Trim Scheme I 1A ...... Black Vinyl 4Y .: ...... Lt. Gray Gold Vinyl 9R ...... Med.Green Cloth and Vinyl 1A ...... Black Cloth and Vinyl 4Y ...... Lt. Gray Gold Leather and Vinyl 9Y ...... Lt. Gray Gold Cloth and Vinyl 1B...... Med. Blue Vinyl 42 ...... Dk. Tobacco Leather and Vinyl 9Y ...... Lt. Gray Gold Vinyl 1B...... Dk. Blue Cloth and Vinyl 5A ...... Black Knit Vinyl 9Z ...... Dk. Tobacco Vinyl 1B...... Med. Blue Cloth and Vinyl 5A ...... Black Cloth and Vinyl AA ...... Black Cloth and Vinyl 1D ...... Dk. Red Vinyl 5A ...... Black Vinyl AB ...... Dk. Blue Cloth and Vinyl 1D ...... Dk. Red Cloth and Vinyl 5B...... Med. Blue Knit Vinyl AD ...... Dk. Red Cloth and Vinyl 1E ...... Med. Vermilion Vinyl 5B...... Med. Blue Cloth and Vinyl AE ...... Med. Vermilion Cloth and Viny 1F ...... Med. Ginger Vinyl 58...... : ...... Med. Blue Vinyl AF ...... Med. Ginger Cloth and Vinyl 1R ...... Med. Green Vinyl 5D ...... Dk. Red Knit Vinyl AK ...... Lt. Aqua Cloth and Vinyl 1R ...... Med.Green Cloth and Vinyl 5D ...... Dk. Red Cloth and Vinyl . AP ...... Med. Gray Cloth and Vinyl 1R ...... Dk.Green Cloth and Vinyl 5E ...... Med.Vermilion Knit Vinyl AR ...... Dk. Green Cloth and Vinyl 1W ...... White Vinyl SF ...... Med. Ginger Knit Vinyl AY ...... Lt.Gray Gold Cloth and Vir,yl 1Y ...... Lt. Gray Gold Vinyl SF ...... ,Med. Ginger Cloth and Vinyl BA ...... Black Cloth and Vinyl 1Y ...... Lt. Gray Gold Cloth and Vin) 5R ...... Med. Green Knit Vinyl BA ...... Black Knit Vinyl 1Z ...... Dk. Tobacco Cloth and Vin! 5R ...... Med.Green Cloth and Vinyl BA ...... Black Vinyl 2A ...... Black Cloth and Vinyl 5W ...... White Knit Vinyl BB ...... Med. Blue Cloth and Vinyl 2A ...... Black Vinyl . 5Y ...... Lt. Gray Gold Knit Vinyl BB ...... Med.Blue Vinyl 2A ...... Black Knit Vinyl 5Y ...... Lt. Gray Gold Cloth and Vinyl BE ...... Med. Vermilion Cloth and Viny 28...... Med. Blue Cloth and Vinyl 5Y ...... Lt.Gray Gold Vinyl BF ...... Med.Ginger Cloth and Vinyl 28...... Med, Blue Vinyl 5Z ...... Dk. Tobacco Cloth and Vinyi BF ...... Med. Ginger Knit Vinyl 28...... Dk. Blue Knit Vinyl 6A ...... Black Vinyl BR ...... Med.Green Cloth and Vinyl 2D ...... Dk. Red Vinyl 6A ...... Black Cloth and Vinyl BR Med. Green Knit Vinyl 2E ...... Med. Vermilion Cloth and Vin! 6A ...... Black Leather and Vinyl BR ...... Med. Green Vinyl 2E ...... Med. Vermilion Vinyl 6B ...... Med. Blue Leather and Vinyl BY ...... Lt. Gray Gold Vinyl 2F ...... Med. Ginger C!oth and Viny! 6B...... Med.Blue Vinyl CA ...... Black Knit Vinyl 2F ...... Med. Ginger Vlnyl 6D ...... Dk. Red Leather and Vinyl . CA ...... Black Vinyl 2R ...... Med.Green Cloth and Vinyl 6D ...... Dk. Red Vinyl CA ...... Black Cloth and Vin I 2R ...... Med. Green Vinyl 6E ...... Med. Vermilion Vinyl CB ...... Med. Blue Knit ~ind 2R ...... Dk. Green Knit Vinyl 6F ...... ; ...... Med. Ginger Leather and Vinyl CB ...... Med. Blue Vinyl 2W ...... White Vinyl 6F ...... Med. Ginger Vinyl CB ...... Dk. Blue Cloth and Vinyl 2W ...... White Knit Vinyl 6R ...... Med. Green Leather and Vinyl CD ...... Dk. Red Vinyl 2Y ... :...... Lt. Gray Gold Cloth and Vinyl 6R ...... Med. Green Vinyl CD ...... Dk. Red Cloth and Vinyl 2Y ...... Lt. Gray Gold Vinyl 6W ...... White Leather and Vinyl CE ...... Med.Vermilion Knit Vinyl 3A ...... Black Knit Vinyl 6W ...... White Vinyl CF ...... : ...... Med. Ginger Knit Vinyl 3A ...... Black Cloth and Vinyl 6Y ...... Lt.Gray Gold Vinyl CF ...... Med.Ginger Cloth and Vinyl 38...... Med. Slue Cloth and .Vinyl 7A ...... Black Cloth and Vinyl CF ...... Med. Ginger Vinyl 38 ...... Med. Blue Knit Vinyl 7A ...... Black Vinyl CR ...... Med.Green Knit Vinyl 38...... Dk. Blue Cloth and Vinyl 7A ...... Black Leather and Vinyl CR ...... Med. Green Vinyl 3D ...... Dk. Red Cloth and Vinyl 78...... Med. Blue Cloth and Vinyl CR ...... 0k.Green Cloth and Vinyl 3E ...... Med. Vermilion Cloth and Vin! 78...... Med. Blue Vinyl CW ...... White Knit Vinyl 3F ...... Med. Ginger Cloth and Vinyl 78...... Dk. Blue Leather and Vinyl CY ...... Lt. Gray Gold Cloth and Viny 3F ...... Med. Ginger Knit Vinyl 7D ...... Dk. Red Cloth and Vinyl .DA ...... Black Cloth and Vinyl 3P ...... Med.Gray Cloth and Vinyl 7D ...... Dk. Red Leather and Vinyl DB ...... Med. Blue Cloth and Vinyl 3R ...... Dk. Green Cloth and Vinyl 7F ...... Med. Ginger Cloth and Vinyl DD ...... Dk. Red Cloth and Vinjl 3R ...... Med. Green Knit Vinyl 7F ...... Med. Ginger Vinyl DE ...... Med. Vermilion Cloth and Viny, 3R ...... Med. Green Cloth and Vinyl 7R ...... Med.Green Cloth and Vinyl DF ...... Med.Ginger Cloth and Vinyl 3W ...... White Knit'Vinyl 7 R...... Med. Green Vinyl DR ...... Med.Green Cloth and Vinyl 3Y ...... Lt. Gra Gold Cloth and Vinyl 7R ...... Dk. Green Leather and Vinyl DY ...... Lt. Gra Gold Cloth and Vinyl 4A ...... Black Jgth ?nd Vinyl 7W ...... White Leather and Vinyl EA ...... Black 40th and Vinyl 4A ...... Black Kn~tV~nyl 7Y ...... Lt. Gray Gold Cloth and Vinyl EB ...... Med. Blue Cloth and Vinyl 4A ...... Black Vinyl 8A ...... Black Cloth and Vinyl EB ...... Dk. Blue Cloth and Vinyl 4A ...... Black Leather and Vinyl 8A ...... Black Knit Vinyl ED ...... Dk. Red Cloth and Vinyl . 48...... Med. Blue Cloth and Vinyl 8A ...... Black Leather and Vinyl EE ...... Med. Vermilion Cloth and Vinyl 48...... Med. Blue Vinyl 88...... Med. Blue Cloth and Vinyl EF ...... Med.Ginger Cloth and Vinyl 48...... Med. Blue Knit Vinyl 88...... Med. Blue Knit Vinyl ER ...... Med. Green Cloth and Vinyl 48...... Dk. Blue Knit Vinyl 8D ...... Dk. Red Knit Vinyl ER ...... Dk.Green Cloth and Vinyl 48 ...... Dk. Blue Leather and Vinyl 8D ...... Dk. Red Leather and Vinyl EY ...... Dk. Gray Gold Cloth and Vinyl 4D ...... Dk. Red Vinyl 8E ...... Med. Vermilion Cloth and Vinyl EZ ....: ...... Dk. Tobacco Cloth and Vinyl 4D...... Dk. Red Leather and Vinyl 8E ...... Med. Vermilion Knit Vinyl FA ...... Black Vinyl 4E ...... Med. Vermilion Cloth and Vin! 8F ...... Med. Ginger Knit Vinyl FA ...... Black Leather and Vinyl 4E ...... Med. Vermilion Knit Vinyl 8F ...... Med. Ginger Leather and Viny FB ...... Med.Blue Vinyl 4F ...... Med.Ginger Cloth and Vinyl 8R ...... Med. Green Knit Vinyl FD ...... Dk. Red Vinyl 4F ...... Med. Ginger Vinyl 8W ...... White Knit Vinyl FD ...... Dk. Red Leather and Vinyl 4F ...... Med. Ginger Leather and Vin) 8Y ...... It. Gray Gold Cloth and Vinyl FF ...... Med. Ginger Vinyl 4K ...... Lt. Aqua Leather and Vinyl 9A ...... Black Vinyl FR ...... Med. Green Vinyl 4P ...... Med. Gray Leather and Vin) 9A ...... Black Cloth and Vinyl FW ...... White Vinyl 4R ...... Med. Green Cloth and Vinyl 9B...... Med. Blue Vinyl ' FY ...... Lt. Gray Gold Vinyl 4R ...... Med. Green Vinyl 9B...... Med. Blue Cloth and Vinyl . FZ ...... Dk. Tobacco Leather and Vinyl 4R ...... Dk. Green Knit Vinyl 9D ...... Dk. Red Cloth and Vinyl GA ...... Black Vinyl 4R ...... Dk. Green Leather and Vinyl 9D ...... Dk. Red Vinyl GA ...... Black Knit Vinyl 4W ...... White Vinyl 9E ...... Med. Vermilion Cloth and Viny, GB ...... Med.Blue Vinyl 4W ...... White Knit Vinyl 9E ...... Med. Vermilion Vinyl GD ...... Dk. Red Knit Vinyl 4W ...... White Leather and Vinyl - 9F ...... Med. Ginger Vinyl GE ...... Med. Vermilion Vinyl 4Y ...... Lt. Gray' Gold Knit and Vin) 9F ...... Med. Ginger Clolh and Vinyl GF ...... I ...... Med. Ginger Vinyl 4Y ...... Lt. Gray Gold Cloth and Vinyl 9R ...... Med. Green Vinyl GR ...... Med. Green Vinyl
f Interior Trim Codes '\ Identification Codes
INTERIOR TRIM CODES Cont'd. Code Trim Scheme Code Trim Scheme Code Trim Scheme
GW ...... White Knit Vinyl MB ...... Med. Blue Knit Vinyl Black Cloth and Vinyl HA ...... Black Cloth and Vinyl NA ...... Black Knit Vinyl Black Vinyl HB ...... Med. Blue Cloth and Vinyl PB ...... Med. Blue Cloth and Vinyl Med. Blue Vinyl HR ...... Med. Green Cloth and Vinyl PE ...... Med. Vermilion Cloth and Vinyl Dk. Red Cloth and Vinyl HY ...... Lt. Gray Gold Cloth and Vinyl PF ...... Med. Ginger Cloth and Vinyl Dk. Red Vinyl JA ...... Black Vinyl QA ...... Black Knit Vinyl Med. Ginger Vinyl JB ...... Med. Blue Vinyl QF ...... Med. Ginger Knit Vinyl Med. Green Vinyl JE ...... Med. Vermilion Vinyl QR ...... Med. Green Knit Vinyl Lt. Gray Gold Vinyl IF...... Med. Ginaer-. Vinvl I QW ...... White Knit Vinyl Dk. Tobacco Vinyl JR ...... Med. Green Viml RA ...... Black Knit Vinyl Black Cloth and Vinyl JW ...... Wh~teVlnyl RA ...... B~CKVinyl Black Knit Vinyl JY ...... Lt. Gray Gold Vinyl RA ...... Black Cloth and Vinyl Black Vinyl KA ...... Black Vlnyl RB ...... Med. Blue Knit Vinyl Med. Blue Cloth and Vinyl KA ...... Black Knlt Vlnyl RB ...... Med. Blue Vinyl Med. Blue Vinyl KA ...... Black Cloth and Vinvl RD ...... Dk. Red Cloth and Vinyl Dk. Red Vinyl KA ...... Black Leather and Vinyl RE ...... Med. Vermilion Knit Vinyl Med. Vermilion Cloth and Vin) KB ...... Med. Blue Cloth and Vinyl RE ...... Med. Vermilion Vinyl Med. Ginger Cloth and Vinyl KB ...... Dk. Blue Leather and Vinyl RF ...... Med. Ginger Knit Vinyl Med. Ginger Vinyl KD ...... Dk. Red Cloth and Vinyl R F ...... Med. Ginger Vinyl Med.Green Cloth and Vinyl KD ...... Dk. Red Leather and Vinyl RR ...... Med. Green Knit Vinyl Med. Green Vinyl KF ...... Med. Ginger Leather and Vinyl RW ...... White Knit Vinyl White Knit Vinyl KK ...... Lt. Aqua Leather and Vinyl TA ...... Black Knit Vinyl Black Knit Vinyl KP ...... Med. Gray Leather and Vinyl TB ...... Med. Blue Knit Vinyl Med. Blue KnltVinyl KR ...... Dk. Green Leather and Vinyl TE ...... Med. Vermilion Knit Vinyl Med. Vermilion Knit Vinyl KR ...... Med.Green Cloth and Vinyl IF...... Med. Ginger Knit Vinyl Med. Ginger Knit Vinyl KW ...... White Knit Vinyl TR ...... Med. Green Knitvinyl Med. Green Knit Vinyl KW ...... White Leather and Vinyl UA ...... Black Knit Vinyl White Knit Vinyl KY ...... Lt. Gray Gold Knit Vinyl UA ...... Black Vinyl Black Cloth and Vinyl KY ...... Lt. Gray Gold Vinyl UB ...... Med. Blue Vinyl Med. Blue Cloth and Vinyl KY ...... Lt. Gray Gold Cloth and Vinyl UF ...... Med. Ginger Knit Vinyl Dk. Red Cloth and Vinyl KY ...... Lt. Gray Gold Leather and Vinyl UR ...... Med. Green Knit Vinyl Med.Ginger Cloth and Vinyl KZ ...... Dk. Tobacco Cloth and Vinyl UW ...... White Knit Vinyl Med.Green Cloth and Vinyl KZ ...... Dk. Tobacco Leather and Vinyl UY ...... Lt. Gray Gold Knit Vinyl Lt. Gray Gold Cloth and Vin) LU ...... Lt. Beige Vinyl UY ...... Lt. Gray Gold Vlnyl Dk. Tobacco Cloth and Vin) MA ...... Black Knit Vinyl VA ...... Black Knit Vinyl
Interior Trim Codes Cont'd.
MODEL YEAR CODE The number 1 designates 1971. CONSECUTIVE UNIT NUM- BERS1971 Passenger cars 100,001-Ford, Torino, Mustang, Thunderbird, Maverick 500,001-Mercury, Meteor, Montego, Cougar, Comet 800,001-Lincoln Continental and Mark 111 1 1-00-0 1 General Wheel and Tire Service 11-01-01
PART 11-01 PAGE PART11-10 PAGE General Wheel Wheel Hubs and and Tire Service ...... 1 1-01-01 Bearings-Front ...... 1 1-1 0-01 PART 1 1-02 PART 11-1 1 I Wheels and Tires-Drop Wheel Hubs and Center Rim ...... 1 1-02-01 Bearings-Rear ...... 1 1-1 1-01
BARB 19 -01 General Wheel and Tire Service
Applies to All Models
COMPONENT INDEX Page COMPONENT INDEX Page
FRONT WHEEL BEARING WHEEL BALANCING ...... 1 1-01-01 MAINTENANCE ...... 11-01-01 WHEEL INSPECTION ...... 11-01-01
3 ADJUSTMENTS
cation. If bearings are adjusted too WHEEL BALANCING FRONT WHEEL BEARING tightly, they will overheat and wear MAINTENANCE rapidly. An adjustment that b See the instructions provided with excessively loose will cause pounding the Rotunda Wheel Balancer. and contribute to uneven tire wear, Make certain that the brakes are Wheel bearings are adjustable to steering difFiculties and inefficient not dragging before attempting to spin correct for bearing and spindle brakes. The bearing adjustment should the wheels. On vehicles equipped with shoulder wear. Satisfactory operation checked at regular inspection disc brakes, push the brake shoes into and long life of bearings depend on intervals. the caliper to free the rotor. proper adjustment and correct lubri-
5 CLEANING AND INSPECTION
affect the runout of the wheels. lubricant to reach the brake linings WHEEL INSPECTION Wobble or shimmy caused by a resulting in faulty brake operation and damaged wheel will eventually damage necessitating premature cleaning or Wheel hub nuts should be in- the wheel bearings. Inspect the wheel replacement of linings. spected and tightened to specification rims for dents that could permit air to at predelivery. Loose wheel hub nuts leak from the tires. may cause shimmy and vibration. Front hubs and bearings should be TIRE INSPECTION Elongated stud holes in the wheels cleaned, inspected and lubricated may also result from loose hub nuts. whenever the hubs are removed or at Incorrect wheel alignment can Keep the wheels and hubs clean. the mileage/time periods indicated in cause tire wear. Abnormal or excessive Stones wedged between the wheel and the maintenance schedule. tire wear can also be caused by drum and lumps of mud or grease can New hub grease seals should be wheelhire unbalance or incorrect tire unbalance a wheel and tire. installed when the hub is removed. An pressure. Typical tire wear patterns Check for damage that would imperfect seal may permit bearing are shown in Fig. 1. 11-01-02 General Wheel and Tire Service 11-01-02
CUPPING-UNOERINFLATION AND/OR MECHANICAL IRREGULARITIES .
7. -_.- .'.dm-".-."&*- STONE BRUISE OR SEVERE CORNERING
I STONE BRUISE UIDERINFLATIOI ROCK CUT
BRUISE HEAT BRUISE DOUBLE BRUISE-SHARP OB,IECT AND RESULTING FATIGUE F1467-C
FIG. 1 Tire Wear Conditions \-I 1 1-02-0 1 Wheel and Tires-Drop Center Rim 1 1-02-0 1 PART 11-02 Wheels and Tires-Drop Center Rim
COMPONENT INDEX Page COMPONENT INDEX Page
FRONT WHEEL ASSEMBLY REAR WHEEL ASSEMBLY Description ...... 1 1-02-01 Description ...... 1 1-02-01 FRONT WHEEL BEARING SPACE SAVER SPARE TlRE Adjustment ...... 11-02-02 Description ...... 1 1-02-01 HOISTING INSTRUCTIONS ...... 1 1-02-02 WHEELS AND TIRES Removal and Installation ...... 11-02-03
1 DESCRIPTION
SPACE SAVER SPARE TlRE A space saver spare tire is available as a regular production option on Mustang vehicles. The Space Saver Spare is designed primarily to provide more room in the luggage compartment. The tire is installed on the wheel in a deflated condition and protrudes barely beyond the periphery of the wheel; thereby, leaving extra storage space. Although more storage space is available, the vehicle full rated load specification must not be exceeded. This tire is not designed for extended mileage; there- fore, it should not be used as a FIG. 2 Front Hub and Rotor Bearing and Grease Retainer Disc permanent substitute for conventional Brakes-Typical tires. The Space Saver Spare will enable the driver to drive at normal 19F514-A or Equivalent. Tire war- discharge. Read the instructions on speed and load to the nearest service ranty for the Space Saver Spare is the the bottle label. Always dispose of the facility for repairs to a flat tire. same as original equipment tires. This empty bottle. Do not puncture or To inflate, carefully follow the warranty is void if inflators with incinerate. instructions shown on the tire inflator sealants are used. The inflator, when completely can which is stowed under the tire and While inflating, keep hands off of used, will Mate the tire within wheel assembly in the trunk metal parts of the inflator since the specifications. Use FoMoCo Inflator C9WA- bottle becomes extremely cold during The Space Saver Spare can, in case of a puncture, be repaired the same as an original equi~menttire. HUB AND BRAKE DRUM ASSEMBLY FRONT WHEEL ASSEMBLY Each front wheel and tire is bolted ADJUSTING NUT to its respective front hub and brake drum or rotor assembly. Two opposed tapered roller bearings are installed in each hub. A grease retainer is installed at the inner end of the hub to prevent lubricant from leaking into the drum or on the rotor. The entire assembly is retained to its spindle by the adjusting nut, nut lock and cotter pin (Figs. 1 and 2).
REAR WHEEL ASSEMBLY F1422-A The rear wheel hub and brake drum assembly is attached to studs on FIG. 1 Front Hub, Bearing and Grease Retainer Drum Brakes the rear axle shaft flange by three 11-02-02 . Wheel and Tires-Drop Center Rim 1 1-02-02
speed nuts. The wheel and tire mounts drum by the wheel, nuts. The rear the entire assembly is retained to the on the same rear axle shaft flange wheel bearing is pressed onto the axle rear axle housing by the bearing studs and is held against the hub and shaft just inside the shaft flange, and retainer plate which is bolted to the housing flange.
3 ADJUSTMENTS
HOIS'TING INSTRUCTIONS Damage to steering linkage com- ponents and front suspension struts may occur if care is not exercised when positioning the hoist adapters of '2 post hoistsLprior to lifting the vehicle.
If a 2 post hoist is used to lift the WITH WHEEL ROTATING BACK ADJUSTING ' TIGHTEN ADJUSTING INSTALLGELKK TORQUE ADJUSTING NU^, NUT OFF 1/2 TURN NUT TO 10.15 IN.-LBS. AND A NEW COTTER PIN vehicle, place the adapters under the TO 17-25 FT. L85. lower arms or the No. 1 crossmember. Do not allow the adapters to contact steering linkage. If the adapters are placed under the crossmember, a piece FIG. 3 . Front Wheel Bearing Adjustment of wood (2x4~16inches) should be placed on the hoist channel between 'the adapters. This will prevent the to 10-15 in-lbs with a torque wrench several times to push the shoe and adapters from damaging the fror or finger tight. linings away from the rotor. suspension struts. 6. Position the nut lock .pn the 5. While rotating the wheel, hub, adjusting nut so that the castellations and rotor assembly, torque the FRONT WHEEL BEARING on the lock are aligned with the cotter adjusting nut to 17-25 ft-lbs to seat the' ADJUSTMENT pin hole in the spindle, and install a bearings (Fig. 3). new cotter pin. Bend the ends of the 6. Back the adjusting nut off one The front wheel bearings should be cotter pin around the castellated flange half turn. Retighten the adjust ing nut adjusted if the wheel is loose on the of the nut lock. to 10-15 in-lbs with a torque wrench spindle or if the wheel does not rotate 7. Check the front wheel rota- or finger tight. freely. The following procedures will tion. If the wheel rotates properly, 7. Locate the' nut lock on the bring the bearing adjustment to install the grease cap and the hub cap adjusting nut so that the castellations specification. or wheel cover. If the wheel still on the lock are aligned with the cotter Drum Brakes rotates roughly or noisily, clean, pin hole in the spindle. inspect or replace the bearings and 8. Install a new cotter pin, and 1. Raise the vehicle until the cups as required. bend the ends of the cotter pin around wheel and 'tire clear the floor. the castellated flange of the nut lock. 2. Pry off the hub cap or wheel Disc Brakes 9. Check the front wheel rota- cover and remove the grease cap (Fig. .I, Raise the vehicle until the tion. If the wheel rotates properly; 1) from the hub. wheel and tire clear the floor. install the grease cap and the hub cap 3. Wipe the excess grease from 2. Pry off the wheel cover and or wheel cover. If the wheel still the end of the spindle, and remove the remove the grease cap (Fig. 2) from rotates roughly or noisily, clean or cotter pin and nut lock. the hub. replace the bearings and cups as 4. While rotating the wheel, hub, 3. Wipe the excess grease from required. and drum assembly, torque the the end of the spindle, and remove the 10. Before driving the vehicle, adjusting nut.to 17-25 ft-lbs to seat the adjusting nut cotter pin and nut lock. pump the brake pedal several times to bearings (Fig. 3). 4. Loosen the bearing adjusting obtain normal brake lining to rotor 5. Back off the adjusting nut one nut three turns. Then, rock the wheel, clearance and restore normal brake half turn. Retighten the adjusting nut hub, and rotor assembly In and out pedal travel.
4 REMOVAL AND INSTALLATION
may occur if care is not exercised vehicle, place the adapters under th'e HOISTING INSTRUCTIONS when positioning the hoist adapters of lower arms or the No. 1 crossmember. 2 post hoists prior to lifting the Do not allow the adapters to contact Damage to steering linkage com- vehicle. the steering linkage. If the adapters are \ If a 2 post hoist is used to lift the placed under the crossmember, a piece ponents and front suspension struts \', Wheel and Tires-Dro~ Center Rim 1 1-02-03 of wood (2x4~16inches) should be 3. Lower the vehicle to the floor, If a new wheel is being installed, placed on the hoist channel between and torque the hub nuts to specifica- coat a new valve with RUGLYDE or the adapters. This will prevent the tion. similar rubber lubricant and position adapters from damaging the front the valve to the new wheel. Use a Removing suspension struts. rubber hammer or a valve replacing Conventional Tire From tool to seat the valve firmly against the Wheel WHEELS AND TIRES inside of the rim. The tire can be demounted on a 2. Apply RUGLYDE or a sim- mounting machine. Be sure that the ilar rubber lubricant to the sealing Whool and Tire outer side of the wheel is positioned surface on both tire beads. With the Removal' downward. If tire irons are used, outer side of the wheel down, pry the 1. Pry off the wheel hub cap or follow the procedure given here. beads over the wheel rim with two tire wheel cover. Loosen but do not 1. Remove the valve cap and irons. Do not use a hammer or mallet remove the wheel hub nuts. core, and deflate the tire completely. to force the beads over the rim. 2. Raise the vehicle until the 2. With a bead loosening tool, 3. Align the balance mark on the wheel and tire clear the floor. break loose the tire side walls from the tire with the valve on the wheel. 3. Remove the wheel hub nuts wheel (Fig. 4). 4. Hold the beads against the rim from the bolts, and pull the wheel and 3. Position the outer side of the flanges by positioning a tire mounting tire from hub and drum. wheel downward, and insert two tire band over the tire (Fig. 5). If a irons about eight inches apart between mounting band is not available, tie a Whoel and Tire the tire inner bead and the back side tourniquet of heavy cord around the Installation of the wheel rim. Use only tire irons circumference and in, the center of the 1. Clean all dirt from the hub with rounded edges or irons designed tire. Tighten the cord with a tire iron. and drum. for removing tubeless tires. Center the tire on the wheel with a 2. Position the wheel and tire on 4. Leave one tire iron in position, rubber mallet. the hub and drum. Install the wheel and pry the rest of the bead over the 5. Give the tire a few quick hub nuts and tighten them alternately rim with the other iron. Take small bursts of air to seat the beads properly, to draw the wheel evenly against the bites with the iron around the tire in then inflate the tire to 40 psi pressure. hub and drum. order to avoid damaging the sealing Chezk to see that the bead positioning surface of the tire bead. rings (outer rirfgs near the side walls) 5. Stand the wheel and tire are evenly visible just above the rim upright with the tire outer bead in the flanges all the way around the tire. If drop center well at the bottom of the the rings are not even, deflate the tire wheel. Insert the tire iron between the completely and inflate it again. bead and the edge of the wheel rim 6. When the rings are properly
and .pry . the wheel out of the tire. positioned, deflate the tire to the recommended pressure. Mounting Conventional Tire To Wheel 1. If a used tire is being installed remove all dirt from the tire. If a tire is being mounted to the original wheel, clean the rim with emery cloth or fine steel wool. Check FIG. 4 Loosening Tire Bead the Am for dents. FIG. 5 Tubeless Tire Mounting Band 1 1-1 0-01 Wheel and Tire Removal 11-10-01
PART 11-10 Wheel Hubs and Bearings-Front
Applies to All Models
COMPONENT INDEX Page COMPONENT INDEX Page
FRONT HUB AND DRUM ASSEMBLY FRONT WHEEL GREASE SEAL Itemoval and Installation .'...... 1 1-10-03 Removal and lnstallation ...... 1 1- 10-01 FRONT HUB AND ROTOR ASSEMBLY HOISTING INSTRUCTIONS ...... 11-10-01 11-10-03 Removal and Installation ...... SPECIAL TOOLS ...... 11-10-04 FRONT WHEEL ASSEMBLY Description ...... 1 1 - 10-01
1 DESCRIPTION
drum or rotor assembly. Two opposed or on the rotor. The entire assembly is FRONT WHEEL ASSEMBLY tapera roller bearings are installed in retained to its spindle by the adjusting each hub. A grease retainer is installed nut, nut lock and cotter pin (Figs. 1 Each front wheel and tire is bolted at the inner end of the hub to prevent and 2, Part 11-02, Section I). to its respective front hub and brake lubricant from leaking into the drum
4 REMOVAL AND INSTALLATION
2. Remove the wheel cover or HOISTING INSTRUCTIONS hub cap. Remove the grease cap from the hub. Remove the cotter pin, nut Damage to steering linkage com- lock, adjusting nut, and flat washer ponents and front suspension struts from the spindle. Remove the outer may occur if care is not exercised bearing cone and roller assembly (Fig. when positioning the hoist adapters of 1, Part 11-02, Section 1). 2 post hoists prior to lifting the 3. Pull the wheel, hub, and drum vehicle. assembly off the wheel spindle. If a 2 post hoist is used to lift the 4. Remove the grease retainer . vehicle, place the adapters under the with Tool 1175AB and discard. lower arms or the No. 1 crossmember. Remove the inner bearing cone and Do not allow the adapters to contact roller assembly from the hub. the steering linkage. If the adapters are 5. Clean the lubricant off the placed under the crossmember, a piece inner- and outer bearing cups with of wood (2x4~16inches) should be solvent and inspect the cups for placed on the hoist channel betw'een scratch&, pits, excessive wear, and the adapters. This will prevent the other damage. If the cups are worn or adapters from damaging the front damaged, remove them with Tool suspension struts. T69L-1102-A (Fig. 1). 6. Thoroughly clean the inner FRONT WHEEL GREASE SEAL and outer bearing cone and roller AND BEARING REMOVAL, assemblies with solvent and dry them INSTALLATION AND/OR ' thoroughly. Do not spin the bearings REPACKING with compressed air. Inspect the cone and roller If bearing adjustment will not assemblies for wear or damage, and eliminate looseness or rough and noisy FIG. 1 Removing Fr~ntWheel replace them if necessary. The cone operation, the hub and bearings should Bearing Cups- Disc (Drum-Type and roller assemblies and the bearing be cleaned, inspected, and repacked Similar) cups should be replaced as a unit .if with specified wheel grease. If the damage to either is encountered. bearing cups or the cone and roller Drum Brakes 7. Thoroughly clean the spindle assemblies are worn or damaged, they 1. Raise the vehicle until the and the inside of the hub with solvent s\hould be replaced. wheel and tire cl& the floor. to remove all old lubricant. Wheel and Tire Removal 11-10-02
Cover the spindle with a clean 4. Remove 2 bolts and washers cloth, and brush all loose dust and dirt that attach the ,caliper to the spindle. from the brake assembly. To prevent Remove the caliper from the rotor and getting dirt on the spindle, carefully wire it to the underbody to prevent remove the cloth from the spindle. damage to the brake hose. 8. If the inner and/o: outer 5. Remove the grease cap from bearing cup(s) were removed, install the hub. Remove the wtter pin, nut the replacement cup(s) in the hub with lock, adjusting nut, and flat washer the tool shown in Fig. 2. Be sure to from the spindle. Remove the outer seat the cups properly in the hub. bearing wne and roller assembly (Fig. 2, Part 11-02, Section 1). 9. Pack the inside of the hub with 6. Pull the hub and rotor specified wheel bearing grease. Add assembly off the wheel spindle. lubricant to the hub only until the 7. Remove and discard the old grease is flush with the inside diameter grease retainer. Remove the inner of both bearing cups (Fig. 3). bearing wne and roller assembly from 10. All old grease should be the hub. completely cleaned from the bearings 8. Clean the lubricant off the and surrounding surfaces before inner and outer bearing cups with repacking them with new grease solvent and inspect the cups for (ClAZ19590-B). The new lithium base scratches, pits, excessive wear, and grease is not compatible with sodium other damage. If the cups are worn or base grease which may have been damaged, remove them with Tool present on the bearing surfaces. Pack T69L-1102-A (Fig. 1). the bearing cone and roller assemblies 9. Thoroughly clean the inner with wheel bearing grease. A bearing and outer bearing cones and rollers packer is desirable for this operation. with cleaning solvent, and dry them If a packer is not available, work as FIG. 3 Front Wheel Hub thoroughly. Do not spin the bearings much lubricant as possible between the Lubrication dry with compressed air. rollers and cages. Lubricate the cone Inspect the cones and rollers for surfaces with grease. 15. Adjust the wheel bearings as wear or damage, and replace them if 11. Place the inner bearing wne outlined in Part 11-02, Section 3 and necessary. The cone and roller and roller assembly in the inner cup. install a new cotter pin. Bend the ends assemblies and the bearing cups should Apply a light film of grease to the of the cotter pin around the castella- be replaced as a set if damage to lip(s) of the grease retainer and install tions of the nut lock. Install the grease either is encountered. the new grease retainer with the cap. reverse end of the tool shown in Fig. 16. Install the hub cap or wheel 10. Thoroughly clean the spindle 2. Be sure that the retainer is properly cover. and the inside of the hub with solvent seated. to remove all old lubricant. 12. Adjust the brake shoes as Disc Brakes Cover the spindle with a clean outlined in Group 12. 1. Raise the vehicle uniil the cloth, and brush all loose dust and dirt 13. Install the wheel, hub, and wheel and tire clear the floor. from the dust shield. To prevent drum assembly on the wheel spindle. 2. Remove the wheel wver or getting dirt on the spindle carefully Keep the hub centered on the spindle hub cap from the wheel. remove the cloth from the spindle. to prevent damage to the grease 3. Remove the wheel and tire . 11. If the inner and/or outer retainer or the spindle threads. from the hub and rotor. bearing cup(s) were removed, install 14. Install the outer bearing wne and roller assembly and the flat washer on the spindle, then install the adjusting nut (Fig. 1, Part 11-02, Section 1).
INNER CUP OUTER CUP INSTALLATION INSTALLATION
FIG. 2 Installing Front Wheel Bearing Cups-Drum FIG. 4 Installing Front Wheel Bearing Cup-Disc Type Wheel and Tire Removal
the replacement cup(s) in the hub with of the cotter pin around the castella- 9. Adjust the brake shoes as the tools shown in Fig. 4. Be sure to tions of the nut lock. outlined in Group 12. seat the cups properly in the hub. 18. Install the caliper to the 10. Install the new hub and drum spindle and torque the attaching bolts assembly on the wheel spindle. Keep 12. Pack the inside of the hub to specifications as detailed in Group the hub centered on the spindle to with the specified wheel bearing 12. prevent damage to the grease retainer. grease. Add lubricant to the hub only 19. Install the wheel and tire on 11. -Install the outer bearing cone until the grease is flush with the inside the hub. and roller assembly and the flat diameter of both bearing cups. 20. Install the hub cap or wheel washer on the spindle; then, install the It is important that all old grease cover. adjusting nut (Fig. 1, Part 11-02, be removed from the wheel bearings 21. Before driving the vehicle, Section 1). and surrounding surfaces because the pump the brake pedal several times to 12. Position the wheel and tire on new Lithium base grease obtain normal brake .lining to rotor the new hub and drum assembly. ClAZ19590-B is not compatible with Sodium clearance and restore normal brake Install the wheel hub nuts and tighten base grease which may pedal travel. them alternately in order to draw the already be present on the bearing wheel evenly against the hub and surfaces. drum. 13. Pack the bearing cone and FRONT HUB AND DRUM ASSEMBLY REMOVAL AND 13. Adjust the wheel bearings as roller assemblies with wheel bearing outlined in Part 11-02, Section 3, and grease. A bearing packer is desirable INST ALLATION .) install a new cotter pin. Bend the ends for this operation. If a packer is not When the hub and drum assembly of the cotter pin around the castella- available, work as much lubricant as is replaced, new bearings and a grease tions of the nut lock. Install the grease possible between the rollers and cages. retainer must be installed in the new cap. Lubricate the cone surfaces with assembly. Coat the new grease retainer 14. Install the hub cap or wheel gr-- with a light film of wheel bearing cover. 14. Place the inner bearing cone and roller assembly in the inner cup. gr-. 1. Raise the vehicle until the FRONT HUB AND ROTOR Apply a light film of grease to the lips wheel and tire clears the floor. Pry off of the grease retainer and install the ASSEMBLY REMOVAL AND the hub cap or wheel cover, and INST ALLATION new grease retainer with the tool remove the wheel and tire from the shown in Fig. 5. Be sure the retainer hub and drum assembly. When the hub and rotor assembly is properly seated. 2. Remove the grease cap from is replaced, new bearings and a grease the hub. Remove the cotter pin, nut , retainer must be installed in the new lock adjusting nut, and flat washer assembly. from the spindle. Remove the outer 1. Raise the vehicle until the bearing cone and roller assembly (Fig. wheel and tire clear the floor. Pry off -a 1, Part 11-02, Section 1). the hub cap or wheel cover, and 3. Pull the hub and drum remove the wheel and tire from the assembly off the wheel spindle. hub and rotor assembly. 4. ,Remove the grease retainer 2. Remove 2 bolts and washers and the inner bearing cone and roller that attach the caliper to the spindle. assembly from the hub with Tool Remove the caliper from the rotor and 1175AB. wire it to the underbody to prevent 5. Remove the protective coating damage to the brake hose. from the new hub and drum with 3. Remove the grease cap from carburetor degreaser. the hub. Remove the cotter pin, nut 6. Pack the inside of the hub with lock, adjusting nut, and flat washer specified wheel bearing grease. Add from the spindle; then, remove the lubricant to the hub only until the outer bearing cone and roller assem- grease is flush with the inside diameter bly, (Fig. 2, Part 11-02, Section 1). of both bearing cups (Fig. 3). 4. Pull the hub and rotor off the 7. All old grease should be spindle. completely cleaned from the bearings 5. Remove the protective coating FIG. 5 Installing Grease before repacking them with new from the new hub and rotor with Retainer-Disc grease. Pack the bearing cone and carburetor degreaser. roller assemblies with wheel bearing 6. Grease and install the inner 15. Install the hub and rotor grease. A bearing packer is desirable bearing cone and roller assembly in assembly on the wheel spindle. Keep for this operation. If a packer is not the inner bearing cup. Apply a light the hub centered on the spindle to available, work as much lubricant as film of grease on the grease retainer prevent damage to the grease retainer possible between the rollers and cages. and install the grease retainer. or the spindle threads. Lubricate the cone surfaces with 7. Install the new hub and rotor 16. Install the outer bearing cone grease. . assembly to the wheel spindle. Keep and roller assembly and the flat 8. Place the inner bearing cone the hub centered on the spindle to washer on the spindle, then install the and roller assembly in the inner cup, prevent damage to the grease retainer. adjusting nut. and install the new grease retainer 8. Install the outer bearing cone 17. Adjust the wheel bearings as with the reverse end of the tool shown and roller assembly and the flat outlined in Part 11-02, Section 3 and in Fig. 2. Be sure that the retainer is washer on the spindle; then, install the \ install a new cotter pin. Bend the ends properly seated. adjusting nut. \ 11-10-04 Wheel and Tire Removal 1 1-1 0-04
9. Install the caliper to the alternately in order to draw the wheel 12. Install the hub cap or wheel spindle and tighten the attaching bolts evenly against the hub and rotor. cover. to specifications as detailed in Group 11. Adjust the wheel bearings as 13. Before driving the vehicle, 12. outlined in Section 2, Part 11-02, pump the brake pedal several times to 10. Position the wheel and tire on Section 3 and install a new cotter pin. obtain normal brake lining to rotor the new hub and rotor. Install the Bend the ends of the cotter pin around clearance and restore normal brake wheel hub nuts and tighten them the castellations of the nut lock. Install pedal travel. the grease cap.
9 SPECIAL SERVICE TOOLS
SPECIAL TOOLS Tool No. Description Tool No. Description Tool 1175.AB Grease Seal Remover Tool-1217-K Front Wheel Bearing Cup T69L-1102-A Front Wheel Bearing Remover (Inner) Installer-Disc Tool-1217-J Front Wheel Bearing T56P- 1217-A Front Wheel Bearing Cup Cup (Outer) Installer-Disc (Inner and Outer) Installer-Drum Tool-1175-AH Grease Seal Installer-Disc . 11-1 1-01 Wheels and Tires 11-1 1-01
PART 11-11 Wheel Hubs and Bearings-Rear
Applies To All Models
COMPONENT INDEX Page COMPONENT INDEX Page
BEARING AND SEAL - HOISTING INSTRUCTIONS ...... 1 1-1 1-01 INTEGRAL CARRIER AXLE REAR WHEEL ASSEMBLY Removal and Installation ...... 1 1-1 1-02 Description ...... 1 1 - 1 1-0 1 BEARING AND SEAL - SPECIAL TOOLS REMOVABLE CARRIER AXLE ...... 11-1 1-04 Removal and Installation ...... '1 1-1 1-02 1 DESCRIPTION
integral carrier-Ford Light Duty with 240-1V and 302-2V, and on REAR WHEEL ASSEMBLY (WER) axle equipped vehicles, the Mercury with 35 1-2V engines), the rear wheel bearing is pressed onto the roller-type wheel bearings have no The rear wheel hub and brake axle shaft just inside the shaft flange inner race, and contact the bearing drum assembly is attached to studs on and the entire assembly is retained to journals of the axle shafts. the rear axle shaft flange by three the rear axle housing by the bearing The axle shafts do not use an inner speed nuts. The wheel and tire mounts retainer plate which is bolted to the or outer bearing retainer. They are on the same rear axle shaft flange housing flange. held in the axle by means of C-locks, studs 'and is held against the hub and On integral carrier (WER) axle positioned in a slot on the splined end. drum by the wheel nuts. Except for equipped vehicles (Ford and Meteor
4 REMOVAL AND INSTALLAT16N
adapters from damaging the front HOISTING INSTRUCTIONS suspension struts. Procedures differ for wheel bearing Damage to steering linkage com- and seal removal and installation . ponents and front suspension struts between removable carrier, and inte- may occur if care is not exercised gral carrier (WER) type axles. when positioning the hoist adapters of 2 post hoists prior to lifting the REMOVABLE CARRIER TYPE vehicle. AXLE If a 2 post hoist is used to lift the vehicle, place the adapters under the The rear axle shafts, wheel lower arms or the No. 1 crossmember. bearings, and oil seal can be replaced Do not allow the adapters to contact without removing the differential the steering linkage. If the adapters are assembly from the axle housing. placed under the crossmemyber, a piece Removal of Axle Shaft FIG. 2 Removing Rear Wheel of wood (2 x 4 x 16 inches) should be Bearing Retainer Ring placed on the hoist channel between Synthetic wheel bearing seals are the adapters. This will prevent the used. Removal and insertion of rear axle shafts must be wrformed with caution. The entire length of the shaft the brake drum to the. axle shaft (including spline) up to the seal flange, then remove the drum from journal must. pass through the seal flange. without contact. Any roughening or 3. Working through the hole cutting of the seal element during axle provided in each axle shaft flange, removal or installation will result in remove the nuts that secure the wheel early seal failure. bearing retainer plate. Then pull the 1. Remove the wheel cover, axle shaft assembly out of the axle wheel and tire from the brake drum. housing (Fig. 1). The brake backing \FIG. 1 Removing Axle Shaft 2. Remove the nuts that secure plate must not be dislodged. Instdl 11-1 1-02 Wheels and Tires 11-1 1-02
one nut to bold the plate in place after the retainer seats firmly against the the akle sbaft is removed. bearing. On Ford, Mercury, or Meteor models, before assembling the retainer Removal of Rear Wheel onto the deshaft, tbe shaft journal Bearing and Seal and the inside diameter of the retainer Synthetic seals must not be should be wiped clm with a dry cleaned, soaked or washed in cleaning cloth. Theee parts must not be solvents. degreased or lubricated. Removal of the wheel bearings 5. Install the new oil seal with from the axle shaft makes them unfit the tools shown in Fig. 4. Wipe a for further use. small amount of oil resistant sealer on 1. On all models except Ford, the outer edge of the seal before it is Mercury or Meteor, if the rear wheel installed. Do not put sealer on the bearing is to be replaced, loosen the sealing lip. inner retainer ring by nicking it deeply with a cold chisel in several places FIG. 4 Installing Rear Wheel (Fig. 2). It will then slide off easily. Installation of Axle Bearing Oil Seal On Ford, Mercury and Meteor Shaft models, it is necessary to first drill a 1. Carefully slide the axle shaft shaft lock bolt and the pinion shaft 1/4 inch hole not more than 5/16 inch into the housing so that the rough (Fig. 5). deep in the retainer ring surface before forging of the shaft will not damage using the cold chisel. the oil seal. Start the axle splines into 8. Push the axle shaft(s) inward 2. Remove the bearing from the the side gear, and push the shaft in toward the center of the axle housing. axle shaft with tool T60K-1225-A. until the bearing bottoms in the Remove the C-lock(s) (Fig. 6) from 3. Whenever a rear axle sbaft is housing. the inner end of the axle(s). Remove replaced, the oil seal must be replaced. 2. Install the bearing retainer the axle shaft(s) from the housing. Remove the seal with Tool 1175-AB plate and the nuts that secure it. Extreme care must be used to avoid and a slide hammer. Torque the nuts to specifications. contact of the axle shaft seal lip with Instnllntion of Rear Wheel 3. Install the brake drum and the any portion of the axle shaft except Bearing and Seal drum attaching (Tinnerman) nuts. the seal journal. 1. Inspect the machined surface 4. Install the wheel and tire on 9. Remove the bearing and oil of the axle shaft and the axle housing the drum. Install the wheel cover. -seal from the housing as shown in Fig. for rough spots or other irregularities 7. which would affect the sealing action 10. Inspect the machined surface INTEGRAL CARRIER (WEB) TYPE of the axle shaft and the axle housing of the oil seal. Check the axle shaft AXLE splines for bum, wear or twist. for rough spots or other irregularities Carefully remove any bum or rough Removal which would affect the sealing action spots. Replace worn or damaged parts. Synthetic wheel bearing seals are of the oil seal. Check the axle shaft 2. Lightly coat wheel bearing used for production and as service splines for burrs, wear or damage. bores with axle lubricant. replacements. Removal and insertion Carefully remove any burrs or rough 3. Place the bearing retainer plate of rear axle shafts must be performed spots. Replace worn or damaged parts. on the axle shaft, and press the new with mution. This entire length of the A brownish yellow color on the wheel bearing on the shaft with the shaft (including spline) up to the seal bearing journal of the shaft is normal tool shown in Fig. 3. Do not attempt journal must pass through the seal and the shaft need not be replaced. to press on both the bearing and the without contact. Any roughing or Slight pitting and wear is also normal. Inner retainer rlng at the same time. cutting of the seal element during axle 4. Using the bearing installation removal or installation will result in tool (Tool 4621-A), press the bearing early seal failure. inner retainer ring on the shaft until 1. Raise the vehicle on a hoist. 2. Remove the wheel(s) and tire(s) from the brake drum(s). 3. Position a drain pan and AXLE SHAFT FLANGE loosen the cover to differential housing ARBOR PRESS RAM / retaining bolts. Drain the housing. 4. Remove the attaching (Tin- nerman) nuts that secure the brake drum(s) to the axle shaft flange(s), and then remove the drum(s). 5. Remove the differential hous- ing cover bolts, cover and gasket. Discard the gasket. Remove the drain pan. 6. Position safety stands under the rear frame member. Lower the hoist and allow the axle to lower as far LOCK BOLT ~1663-~ as possible. FIG. 3 Installing Rear Wheel 7. Working through the differ- FIG. 5 Differential Pinion Shaft Bearing ential case opening, remove the pinion and Lock Bolt 11-1 1-03 Wheels and Tires
\ not reguire an oil soak before installation. 4. Install the oil seal with the tool shown in Fig. 9. Installation without the use of the proper tool will distort the seal and cause leakage. 5. Place the O-ring in the C-lock groove on the axle shaft. 6. Slide the axle shafl(s) into place 'iri the axle housing. Exercise care that splines or any portion of the axle shaft(s) do not damage the oil seal(s) and that they engage with the splines of the differential side gends). 7.. Install the axle shaft C-lock(s) FIG. 8 lnstallation of Axle Shaft FIG. 6 Removal and lnstallation on the inner end of the shaft(s) (Fig. Bearing of C-Locks and Axle Shaft 6) and push the shaft(s) outward so that the shaft locks seat in the Installation counterbore(s) of the differential side tighten the attaching (Tinnerman) 1. Lightly coat the wheel bearing gear(s). nuts. rollers with axle lubricant. Install the 8. Position the differential pinion 11. Install the wheel and tire on bearings in the axle housing.with the gears and thrust washers 180 degrees the brake drum. tool shown in Fig. 8. The bearing apart to the differential side gears. 12. Clean the gasket mounting should seat firmly against the shoul- Revolve the gear assembly until the surfaces of the rear axle differential der. holes in the differential case are housing and the cover. Install a new aligned with the pinion gears. cover gasket, ,cover and the attaching 2. Wipe all lubricant from the oil 9. Position the differential pinion bolts. Torque the bolts to specification. seal bore before installing the seal. shaft through the case and pinions, 13. Raise the rear axle. Make 3. Inspect the original seal for , aligning the hole in the shaft with the sure the rear axle is in running nicks, scuffs or abnormal wear, and lock bolt hole. Install the lock bolt and position. Add the amount of specified replace it if necessary. The new seals torque it to specification. lubricant required to reach 1/2 inch are pre-packed with lubricant and do 10. Install the brake drum and below the bottom of the filler plug hole. Install the filler plug and torque it to specification. 14. Remove the safety support stands and lower the vehicle.
FIG. 9 Rear Axle Shaft Bearing FIG. 7 Removal of Axle Seal or Axle Bearing Seal Installation 11-1 1-04 Wheels and Tires 11-1 1-04
9 SPECIAL SERVICE TOOLS
SPECIAL TOOLS Tool Number I Description Tool 4235-C.Use I Axle Shaft Remover With T50T-100-A With T50T.100.A and Wheel Bearing Remover T60K.1225-A Rear Wheel Bearing Remover Tool 4621-A Rear Wheel Bearing Installer Tool 1175.AB Oil Seal Remover T66N.1177-A or Oil Seal Installer T60K.1177-B CF 1667-A 12-00-0 1 Brakes 12-00-0 1
PART 12-0 1 PAGE PART 12-50 PAGE General Hydraulic Brake Service ...... 12-01-0 1 Vacuum Brake Booster-Single PART 12-02 Diaphragm, Dash Drum Brakes-Single Cylinder, Mounted (Bendix) ...... 12-50-0 1 Dual Piston (Bendix) ...... 12-02-0 1 PART 12-70 PART 12-20 Parking Brakes-Cable Actuated, Disc Brakes-Single Piston, Rear Wheels ...... 12-70-0 1 Floating Caliper ...... 12-20-0 1 12-01-01 General Hydraulic Brake Service 12-01-01
PART 12-01 General Hydraulic Brake Service -2' Ul a a COMPONENT INDEX -a A - u PLL .r? M = ;= Applies to Models As Indicated a 0 a 0 *.L a_;,, U ,, M 6 ;;O'=c'ge i L zg = d I& g j i i isu;ti BRAKE BOOSTER 11111111111111
N/A indicates that the item is not applicable to the vehicle(s) listed. I
2 DIAGNOSIS AND TESTING
Always check the fluid level in the master cylinder before performing the BRAKE PEDAL FREE HEIGHT attaching bolts and replace them, if test procedures. If the fluid level is not MEASUREMENTS required. within 1/4 inch of the top of the 3. If the pedal free height is still master cylinder reservoirs, add Ford With the engine running for full out of specification, check the brake Brake Fluid-Extra Heavy power brake operation and the parking pedal booster or master cylinder to be Duty-Part Number C6AZ-19542-A brake fully released, measure the brake sure the correct parts are installed. (ESAM6C25-A) or equivalent for all pedal free height, and check the brake Replace the worn or daniaged parts as brake applications. The extra heavy pedal travel with the use of the Brake necessary. duty brake fluid is colored blue for Pedal Pressure Gauge, Tool WRE- identification purposes. Do not mix 500-50 as follows: BRAKE PEDAL TRAVEL low temperature brake fluids with the 1. Insert a slender, sharp pointed MEASUREMENT specified brake fluid. prod through the carpet and sound Should one of the wheel brakes be deadener to the dash panel metal and 1. Install a Brake Pedal Effort Iocked and the vehicle must be moved, measure the distance to' the brake Gauge on the brake pedal pad (Fig. 2). open the bleeder screw long enough to pedal (Fig. 1). 2. Hook a steel measuring tape to . let out a few drops of brake fluid. This 2. If the position of the pedal is the brake pedal as shown in Fig. 1: bleeding operation will release the not within specification, check the Measure and record the distance from brakes but will not correct the cause brake pedal linkage for missing, worn, the brake pedal free height position to \ or damaged bushings, or loose the reference point, which is at the six \Of 12-0 1-02 General Hydraulic Brake Service 12-0 1-02
L THUNDERBIRD AND CONTINENTAL MARK Ill MEASURED FROM CENTER LINE OF CURVED PEDAL
LINCOLN CONTINENTAL JY
\ MAVERICK AND COMET STEEL MEASURING TAPE
TOEBOARD
,FORD. MERCURY - METEOR
MONTEGO - TORINO
- NOTE: A R B DIMENSION TO BE MEASURED TO SHEET METAL
B DIMENSION TO BE MEASURED PARALLEL TO THE VERTICAL CENTERLINE OF THE STEERING COLUMN WlTH A 50 POUND LOAD APPLIED TO THE CENTERLINE OF THE BRAKE PEDAL PAD. (CHECKS ON POWER BRAKE VEHICLES MDE WlTH ENGINE RUNNING) MUSTAHG - COUGAR
FIG. 1 Brake Pedal Height and Travel Measurements 12-01-03 General Hydraulic Brake Service
o'clock position on the steering wheel 7. If all the brake adjusters, brake parking brake to hold againsi mod- rim. drums and linings are functional and erate vehicle movement. Perform tests 3. With the steel tape still hooked the brake travel is not within of the parking brakey! system and to the brake pedal depress the brake ' specifications, check the pedal linkage controls after making certain the pedal by pressing downward on the for missing or worn bushings, or loose linkage, and manual controls operate brake pedal effort gauge. Apply a 50 attachments. Bleed the brakes and properly. pound load to the center of the pedal centralize the differential valve. When testing a parking brake by observing the pressure gauge, and vacuum release system, a minimum of measure the distance from, the brake POWER BRAKE FUNCTIONAL 10 inches of vacuum (Hg.) should be pedal to the fixed reference point on TEST available at all points where vacuum is the steering wheel rim parallel to the applied. This can be checked with a centerline of the steering column. 1. Check the hydraulic brake Rotunda Fuel Pump Tester Gauge 4. The difference between the system for leaks or insufficient fluid. (ARE345) and two Distributor Tester brake pedal free height and the 2. With the transmission in hose adapters (Marked Q) connected depressed pedal measurement under a neutral, stop the engine and apply the tzgether with a coupling. This allows 50 pound load should be within the parking brake. Depress the brake the Fuel Pump Tester Gauge hose to specified maximum pedal travel serv- pedal several times to exhaust all be'adapted to any other vacuum hose ice specification B in Fig. 1. vacuum in the system. or rubber connector in the vacuum 3. If the pedal travel is more than 3. With the engine shut off and systems. the specified maximum shown in Fig. , all vacuum in the system exhausted, Failure to maintain 10 inches of 1, dimension .B, make several sharp depress the pedal, and hold it in the vacuum (Hg.) during vacuum system reverse stops (equivalent to 50 pounds applied position. Start the engine. If tests could be caused by a loose hose pedal pressure) with a forward stop the vacuum system is operating, the connection, resulting in ' a vacuum before each. Move the vehicle in pedal will tend to fall away under foot leak. When checking for vacuum reverse and forward for a distance of pressure and less pressure will be between two points, trace the hose approximately ten feet; then, apply the required to hold the pedal in the along the entire routing to be sure it is brakes sharply and hold the brake applied position. If no action is felt, not crossed with another hose and the vacuum booster system is not , pedal down until the vehicle is connected to the wrong connection. . completely stopped. This will actuate functioning. All of the vacuum parking brake the brake self-adjusters. If these stops If the brake pedal movement feels control checks are to be performed do not bring the brake pedal travel spongy, bleed the hydraulic system to with the engine running at idle speed. within specification, make several remove air from the system. Refer to Leaks in the parking brake hoses additional forward and reverse stops Hydraulic System Bleeding, in this or a disconnected or improperly as outlined above. Part. connected hose can usually be found 6. If the second series of stops do by listening for a hissing sound along . not bring the brake pedal travel within * VACUUM TESTS-VACUUM the hose routings. Under no circum- specification, remove the brake drums RELEASE PARKING BRAKES stances should air pressure be applied and check the brake adjusters to make to the vacuum system as the actuator' sure they are functioning. Check the Visually check the operation of the diaphragm in the parking brake brake linings for wear or damage. brake linkage as the brake pedal is vacuum motor may be damaged. Repair or repla& all worn or damaged depressed. Then, check the operation 1. Start the engine and run it at parts and non-functioning adjusters. of the brake linkage when the manual idle speed. With the transmission shift Adjust the brake lining outside release lever is activated. These checks control in neutral, depress the parking diameter to the approximate inside should indicate' whether the manual brake pedal to apply the parking diameter of the brake drum with parking brake control linkage is brake. Move the transmission shift Rotunda To$ HRE-8650 described in o-prating properly or requires repair control to D range and observe the Part 12-02. or adjustment due to inability of ,the parking brake pedal to see that the pedal moves upward and the parking brake releases. If the parking brake releases, the parking brake vacuum control is working properly. 2. If the parking brake does not release, test for vacuum at the vacuum lines to the parking brake release vacuum motor. Use the Rotunda Vacuum and Fuel Pump Tester 345. This can be accomplished by removing the hose from each component and attaching it to the vacuum gauge. Connect two distributor tester vacuum hose adapters together with a coupling as a connector to attach the gauge. A minimum of ten inches of vacuum is required to actuate the parking brake vacuum motor. If a minimum reading is not present when checking each of the aforementioned components, they 'FIG. 2 Brake Pedal Effort Gauge Installed must be replaced.
\> \ General Hydraulic Brake Service
of the above conditions exist, adjust as more problem conditions, correct all PARKING BRAKE OPERATION required. malfunctions of the vacuum system, brake booster and hydraulic system Check the operation of the parking ROAD TEST prior to removing brake drums, brake brake. With the vehicle on a hoist and calipers, brake shoes and linings or the parking brake fully released, the A road test should be conducted backing plates. cables should not have any slack. only when the operator is sure the Also, the rear brakes should not drag brakes will stop the vehicle. when the wheels are turned. If either If the road test reveals one or
3 ADJUSTMENTS
away from the booster without POWER BRAKE MASTER disconnecting the brake tubes. 2. Adjust the push rod screw to CYLINDER PUSH ROD BOOSTERCHECK VALVE ADJUSTMENT provide a slight tension against the inner edge of the adjustment gauge The push rod is provided with an slot. (Approximately 5 pounds of adjustment screw to maintain the tension against the push rod is ADJUST required to assure that the push rod is PROVID correct relationship between the (APPR booster control valve plunger and the firmly seated in the booster assembly). AGA master cylinder. If the plunger is too See Figure 4. long it will prevent the master cylinder 3. Install the master cylinder on piston from completely releasing the brake booster and tighten the hydraulic pressure and can cause the retaining nuts to the specified torque. brakes to drag. If the plunger is'too Do not set up side forces on the short it will result in excess pedal push rod as it may break the valve travel and an undesirable clunk in the plunger. booster area. This is an approximate adjustment The adjustment screw is set to the only. To verify the adjustment, look correct height at the time of original through the make-up (rear) port of the assembly of the power unit. Under master cylinder when installing the normal service the adjustment screw master cylinder to the booster. The does not require any further attention master cylinder piston should not providing the original push rod move more than 0.015 inch as it assembly remains in the original unit. contacts the push rod. No movement \ If a check of the push rod (exact contact) is ideal. PUSH ROD ADJUSTMENT-BENOIX adjustment is necessary, the push rod H1871-A length may be verified witb a push rod HYDRAULIC SYSTEM BLEEDING length gauge and measured witb the FIG. 4 Brake Booster Push Rod engine running to apply vacuum to the When any part of the hydraulic Measurement booster (Fig. 3). system has been disconnected for extra heavy duty bmke fluid is colored The push rod length verification 'of repair or replacement, air may enter blue for identification purposes. Do the Bendis power bmke booster the system and cause spongy pedal not mix low temperature bmke fluids assemblies is accomplished as follows: action. Bleed the hydraulic system witb the specified fluid during the 1. Disconnect the master cylinder after it has been properly connected, bleeding operations. Never re-use from the booster assembly and secure to be sure that all air is expelled. brake fluid which has been drained Manual Bleeding from the hydraulic systems. 1. If the master cylinder is # 16 U.S.S. GAUGE SHEET STEEL The Ford, Mercury, Meteor, equipped with a bleed screw, loosen Continental Mark 111, Lincoln Con- the bleed screw. Push the brake pedal tinental, Thunderbird models equipped down slowly through its full travel. witb disc brakes must be bled witb Close the bleeder fitting and return the pressure bleeding equipment. The primary and secondary (front APPROXIMATELY 45' and rear) hydraulic brake systems are \ \ individunl systems and are bled separately. Bleed the longest Line tirst on the individunl system being serviced. During the complete bleeding operation. DO NOT allow the reservoir to run dry. Keep the master cylinder reservoirs filled with Ford FIG. 3 Push Rod Gauge Fluid-Extra Heavy Duty-Part Number FIG. 5 Wrench for Bleeding Dimensions C6AZ19542-A (ESA-M6C 25-A). The Brake Hydraulic System 12-0 1-05 General Hydraulic Brake Service r 12-0 1-05
pedal to the fully released position. brake wheel cylinder on the opposite bleeding operation. Use Ford Brake Repeat this operation until fluid is free side. Refill the master cylinder Fluid - Extra Heavy Duty Part of air bubbles, then tighten the bleeder reservoir after each wheel cylinder is Number C6AZ-19542-A screw. Do not use the secondary bled and install the master cylinder (ESAM6C25-A) or equivalent for all piston stop screw, located on the cover and gasket. Be sure the brake applications. The brake fluid is bottom of the master cylinder to bleed diaphragm type gasket is properly colored blue for identification pur- the brake system. Loosening or positioned in the master cylinder poses. Do not mix low temperature removing this screw could result in cover. When the bleeding operation is brake fluid with the specified brake damage to the secondary piston or completed, the fluid level should + fluid during the bleeding operations. stop sciew. filled to within 1/4 inch of the top of Never re-use brake fluid that has been 2. To bleed the secondary (rear) the reservoirs. drained from the hydraulic system. brake system, position a suitable 3/8 7. If the primary (front brake) The tank should be charged with. inch box wrench (Fig. 5) on the system is to be bled. Repeat steps 2 approximately 10 to 30 pounds of air bleeder fitting on the brake wheel through 6 at the right front brake pressure. Never exceed 50 pounds cylinder. Attach a rubber drain tube to caliper or cylinder and ending at the pressure. the bleeder fitting. The end of the tube left front brake ialiper or cylinder. 1. Clean all dirt from the master should fit snugly around the bleeder 8. On disc brake equipped models cylinder reservoir cover. fitting. be sure that the front brake pistons are 2. Remove the master cylinder 3. Submerge the free end of the returned to their normal positions and reservoir cover and rubber gasket, and tube in a container partially filled with that the shoe and lining assemblies are fill the master cylinder reservoir with clean brake fluid, and loosen the properly seated by depressing the the specified brake fluid. Install the bleeder fitting approximately 314 turn. brake pedal several times until normal pressure bleeder adapter tool to the 4. Push the brake pedal down pedal travel is established. ' master cylinder, and attach the bleeder slowly through its full travel. Close the 9. Centralize the pressure dif- tank hose to the fitting on the adapter. bleeder fitting, then return the pedal to ferential valve. Refer to centralizing Master cylinder pressure bleeder the full-released position. Repeat this the Pressure Differential Valve pro- adapter tools can be obtained from the operation until air bubbles cease to cedures. various manufacturers of pressure appear at the submerged end of the bleeding equipment. Follow the in- bleeder tube. Pressure Bleeding All structions of the manufacturer when 5. When the fluid ,is completely Models installing the adapter. 'free of air bubbles, close the bleeder Bleed the longest lines first. The 3. If the master cylinder is fitting and remove the bleeder tube. bleeder tank should contain enough equipped with a bleed screw, loosen 6. Repeat this. procedure at the new Ford Brake Fluid to complete the the bleed screw and bleed the master cylinder until the fluid is free of air bubbles; then, tighten the bleed screw. Do not use the secondary piston stop screw, located on the bottom of the master cylinder, to bleed the master cylinder. 4. If the rear wheel cylinders, the secondary brake system, are to be bled, position a 3/8 inch box wrench (Fig. 5) on the bleeder fitting on the right rear brake wheel cylinder. Attach a bleeder tube to the bleeder fitting. The end of the tube should fit snugly around the bleeder fitting. 5. Open the valve on the bleeder tank to admit pressurized brake fluid to the master cylinder reservoir. 6. Submerge the free end of the COMPRESS tube in a container partially filled with TOOL AND POSITION clean brake fluid, and loosen the ONTO VALVE bleeder fitting. 'RELEASE TO ALLOW 7. When air bubbles cease to SPRING appear in the fluid at the submerged ACTION TO FORCE end of the bleeder tube, close the ROD OUT bleeder fitting and remove the tube. 8. Repeat steps 3 through 7 at the left rear wheel cylinder. 9. If the vehicle is equipped with disc brakes, repeat steps 4 through 7, starting at the right front disc caliper RELEASE ROD and ending at the left front disc - caliper. On Ford, Mercury, Meteor, Con- FIG. 6 Disc Brake Metering Valve--Ford, Mercury, Meteor, Lincoln tinental Mark 111, Lincoln Continental Continental, Continental Mark Ill and Thunderbird and Thunderbird models the metering . - \. 12-01-06 General Hydraulic Brake Service
valve release rod must be pulled 13. Remove the Pressure Bleeder To centralize the pressure differ- outward and held a minimum of 1/16 Adapter Tool. Fill the master cylinder ential valve and turn off the warning inch (Fig. 6) while bleeding the reservoirs to within 1/4 inch of the light after a repair operation: primary brake system. top. Install the master cylinder cover 1. Turn the ignition switch to the 10. If the vehicle contains and gasket. Be sure the Diaphragm ACC or ON position. drumtype front brakes and the type gasket is properly positioned in 2. Check the fluid level in the primary (front) brake system is to be the master cylinder cover. master cylinder reservoirs and fill bled, repeat steps 4 through 7, starting 14. Centralize the pressure dif- them to within 1/4 inch of the top with the specified brake fluid, if at the right front wheel cylinder ferential valve. Refer to Centralizing * ending at the left front wheel cylinder. the Pressure Differential Valve pro- necessary. 11. When -the bleeding operation cedures. 3. Depress the brake pedal and is completed, close the bleeder tank the piston will center itself causing the CENTRALIZING THE PRESSURE brake warning light to go out. valve and%remove the tank hose from DIFFERENTIAL AND/OR the adapter fitting. 4. Turn the ignition switch to the PRESSURE CONTROL VALVE OFF position. 12. On disc brake equipped ' vehicles, be sure that the front brake After any repair or bleeding of the 5. Before driving the vehicle, pistons are returned to their normal primary (front brake) or secondary check operation of the brakes and be positions and that the shoe and lining (rear brake) system, the dual-brake sure that a firm pedal is obtained. assemblies are properly seated by warning light will usually continue to depressing the brake pedal several be illuminated due to the pressure times until normal pedal travel is differential valve remaining in the established. offcenter position.
5 CLEANING AND INSPECTION
reading. If the reading exceeds 0.003 when resurfacing disc brake rotors: DISC BRAKES inch on custom vehicles and 0.002 Rotunda Disc Brake Lathe FRE- inch on light vehicles total lateral 1466-B should be used to refinish the 1. Remove the wheel and tire and runout on the indicator, replace or disc brake rotors. The step-by-step the shoe and lining assemblies as resurface the disc brake rotor. The resurfacing procedure provided with outlined in Part 12-20. following requirement must be met the tool must be adhered to. 2. Inspect the brake shoes and lining for wear. If the lining is worn to within 1/32 inch of the rivet heads or ifthere is more than 0.125 taper from 1.12MIN. CUSTOM end to end or if lining shows evidence FORDMERCURY M of brake fluid contamination, replace THUNDERBIRD-M all (4) shoe and lining assemblies on .LINCOLN both front wheels. 3. Check the caliper to spindle attaching bolt wires. If the wires are damaged, re-torque the bolts and replace the wires. 4. To check rotor runout, first eliminate the wheel bearing end play by tightening the adjusting nut. After tightening the nut, check to see that the rotor can still be rotated. 5. Clamp a dial indicator to the caliper housing so that the pointer contacts the rotor at a point approxi mately 1 inch from the outer edge. Rotate the rotor and take an indicator
ROTOR-TYPICAL H 1857.). CUSTOM CAR LIGHT CAR FIG. 7 Disc Brake ~oior Minimum Thickness Marking Location FIG. 8 D,isc Brake Rotor Gauge General Hydraulic Brake Service
The finished braking surface of the rotor and caliper assemblies should be contaminated with oil, grease or brake rotor must be flat and parallel within done in a way to avoid deformation of fluid. Replace lining in axle sets. Prior 0.0007 inch; lateral runout must not the brake rotor and nicking or to replacement of lining, the drum exceed 0.003 inch on custom vehicles scratching of brake linings. diameter should be checked to and 0.002 inch on light vehicles total 2. If a caliper piston is removed determine if oversize linings must be indicator reading, braking surface are for any reason, the piston seal must be installed. to be 80/15 micro inches. replaced. 4. Check the condition of brake On all models, the minimum limit 3. During removal and installa- shoes, retracting springs, hold-down ing dimension from the inboard tion of a wheel assembly, exercise care springs, and drum for signs of bearing cup to the inboard rotor face not to interfere with and damage the overheating. If the shoes have a slight and the minimum rotor thickness caliper splash shield or the bleeder blue coloring, indicating overheating, dimension, must be observed when screw fitting. replacement of the retracting and removing material from the rotor 4. Front wheel- bearing end play hold-down springs is strongly re- braking surfaces. Rotor minimum is critical and must be within commended. Overheated springs lose thickness is shown on each rotor (Fig. specifications. their pull and could cause the new 7). If the rotor thickness is less than 5. Be sure the vehicle is centered lining to wear prematurely, if they are that shown on the rotor, either on the hoist before servicing any front not replaced. If the brake drums are through wear or after refinishing, the end components, to avoid bending or heat spotted, indicating a overheated rotor must be replaced. A ball and damaging the rotor splash shitld on condition, they should be replaced. gage bar (Rotunda Kit FRE-70170) is full right or left wheel turns. 5. If the vehicle has 30,000 or to be used when checking minimum 6. Riding of the brake pedal more miles of operation on the brake dimensions (Fig. 8). (common on left foot applications) linings or signs of overheating are When the runout check is finished should be avoided during vehicle present when relining brakes, the be sure to adjust the bearings as operation. wheel cylinders should be disassem- outlined in Group 11-02 in order to 7. The wheel and tire must be bled and inspected for wear and prevent bearing failure. removed separately from the brake entrance of dirt into the cylinder. The 6. Check the rotor for scoring. rotor, unlike drum brakes where the cylinder cups should be replaced, thus Minor scores can be removed with a wheel, tire and drum are removed as a avoiding future problems. . fine emery clotii. If the rotor. is unit. 6. Inspect all other brake parts excessively scored, refinish it as 8. On floating caliper type disc and replace any that are worn or outlind in step 5 or replace the rotor, brakes, whenever the caliper is re damaged. if required. moved the caliper locating pins should 7. Inspect the brake drum and, if 7. Visually check the caliper. If be inspected for wear or damage. necessary, refinish. Brake dnim max- the caliper housing is leaking it should 9. On floating caliper type disc imum Inside diameter is shown on be replaced. If a seal is leaking the brakes, the caliper assembly must be each drum (Fig. 9). If the maximum caliper must be disassembled and new removed from the spindle prior to inside diameter shown on the drum is seals installed. If a piston is seized in removal of the shoe and lining exceeded either by wear or refinishing, the bore a new caliper housing is assemblies. the drum must be replaced. Refer* to required. 10. On floating caliper type disc Part 12-02. for refinishing. Check the brake hoses for signs of brakes the calipers must not be cracking, leaks or abrasion. Replace interchanged from one side to the BRAKE BOOSTER them if necessary. other. When the caliper is installed on its proper anchor plate and spindle, Check the booster operation as Disc Brake Service the bleeder screw will point to the rear noted in Part 12-01. Power Brake Precautions of the vehicle. If a caliper is installed Functional Test. If the brake booster is 1. Grease or any other foreign on the wrong side of the vehicle, it is damaged or inoperative replace it with material must be kept off the caliper not possible to bleed the system a new booster. The brake booster is assembly, surfaces of the rotor and properly. serviced only as an assembly. external surfaces of the hub during 11. Do not attempt to clean or service operations. Handling of the restore oil or grease soaked brake HYDRAULIC LINES linings. When contaminated linings are found, brake linings must be replaced Steel tubing is used throughout the in complete axle sets. brake system with the exception of the BRAKE DRUM-TYPICAL flexible hoses at the front wheels and DRUM BRAKES at the rear axle housing brake tube connection. 1. Remove the wheel from the Always bleed the applicable pri- drum, and remove the drum as mary or secondary brake system after outlined in Part 12-02. primary or secondary brake system 2. Brush all dust from. the hose or line replacement. Centralize backing plates and interior of the the pressure differential valve after brake drums. bleeding the system. 3. Inspect the brake sho&, for Brake Tubing excessive lining wear or shoe damage. If the lining is worn within 1/32 inch If a section of the brake tubing. of the rivet heads or if the shoes are becomes ,&maged, the entire section FIG. 9 Brake Drum Maximum damaged, they must be replaced. should be replaced with tubing of the \,Inside Diameter Marking Location . Replace any lining !hat had been same type, size, shape and length. 12-01-08 General Hydraulic Brake Service 12-01 -08
Copper tubing should not be used in a Brake Hose A rear brake hose should be hydraulic system. When bending brake A flexible brake hose should be installed so that it does not touch the tubing to fit undkbody or rear axle replaced if it shows signs of softening, mumer outlet pipe or shock absorber. contours, be careful not to kink or cracking, or other damage. Thread the hose into the rear brake crack the tube. When installing a new front brake tube connector. Engage the front end All brake tubing should be double hose, position the hose to avoid of the hose to the bracket on the flared properly to provide good contact with other chassis parts. Place frame. Install the horseshoe-type leakproof connections. Clean the brake a new copper gasket over the hose retaining clip, and connect the tube to tubing by flushing with clean brake fitting and thread the hose assembly the hose with the tube fitting nut. fluid before installation. into the front wheel cylinder. Engage When connecting a tube to a hose, the opposite end of the hose to the tube connector, or brake cylinder, bracket on the frame. Install the tighten the tube fitting nut to specified horseshoe-type retaining clip, and torque with Milbar Tool 11 12144 or connect the tube to the hose with the equivalent. tube fitting nut.
9 SPECIAL SERVICE TOOLS
SPECIAL SE~ICETOOLS Tool No. Description Tool No. Description Rotunda WRE-500-50 Brake Pedal Effort Gauge Rotunda FRE.70370 Ball and Bar Gauge Rotunda ARE-345 Vacuum and Fuel Pump Tester Gauge Rotunda.FRE-1432 Brake Drum Micrometer Rotunda 1436 Diaphragm Type Bleeder Rotunda-FRE-1466-B Disc Brake Lathe Tool 4201-C Universal Dial Indicator and Bracket Milbar 1112-144 Inch Pound Torque Wrench CH1860.A 12-02-01 Drum Brakes-Sinale Cylinder, Dual Piston 12-02-01
PART 12-02 Drum Brakes- Single Cylinder, Dual Piston 1
COMPONENT INDEX Applies to Models As Indicated
BRAKE SHOES
1 DESCRIPTION
The drum brake system employs routed along the webb of the A vacuum booster is used with the single anchor, internal expanding and secondary brake shoe by mearis of the power drum brake system. self adjusting brake assemblies. cable guide. The adjuster spring is
The self-adjusting brake mecha- ' hooked to the primary brake shoe and DUAL MASTER CYLINDER BRAKE ', nism consists of a cable, cable guide, to the' lever. The automatic adjuster SYSTEM \b adjusting lever, adjusting screw as- operates only when the brakg are sembly, and adjuster spring (Fig. 1). applied while the vehicle is moving The dual-master cylinder brake The cable is hooked over the anchor rearward and only when the secondary system has been incorporated in all pin at the top and is connected to the shoe is free to move toward the drum models to provide increased safety. \\lever at the bottom. The cable is beyond a predetermined point. The system consists of a dual-master \ 12-02-02 Drum Brakes-Sinale Cvlinder. Dual Piston 12-02-02
FIG. 1 Self-Adjusting Brake Assemblies
SECONDARY BRAKE RETAINER
PRIMARY SYSTEM BRAKE FLUID RESERVOIR
RETURN SPRING (PRIMARY)
BRAKE OUTLET SECONDARY PISTON BRAKE OUTLET PRIMARY PISTON PORT ASSEMBLY PORT ASSEMBLY H 1545-A
FIG. 2 Dual Master Cylinder- Typical 12-02-03 Drum Brakes-Single Cylinder, Dual Piston . + '
cylinder (Fig. 2), pressure differential BRAKE WARNING LAMP SWITCH FRONT BRAKE valve assembly and a switch (Fig. 3). I INLET The switch on the differential valve activates a dual-brake warning light, REAR BRAKE FRONT BRAKE RIGHT located on the instrument panel. INLET FROM INLET FROM BRAKE RAKE OUTLET 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 atmos- pheric pressure. for its power. NORMAL POSITION Adjustment of the push rod ~d REAR BRAKES (CENTERED) OUTLET TO (CENTERED) replacement of the check valve and RIGHT FRONT BRAKE grommet are the only services per- LIGHT CAR CUSTOM CAR H1698-0 mitted on the brake booster. The booster unit is to be exchanged when FIG. 3 Pressure Differential Valve and Brake Warning Light Switch it is inspected, checked and found to be inoperative. The valve body is step bored to tapered shoulder groove in the center accommodate a sleeve and seal of the piston. In this position the PRESSURE DIFFERENTDAL VALVE installed over the piston and into the electrical continuity through the larger valve body bore in the front switch is interrupted and the brake A self centering pressure differen- brake system area. The brake warning warning lamp on the instrument panel tial valve assembly is used on all light switch is mounted at the center is out. (Fig. 3) vehicles having power or non-power of the valve body and the spring drum type brakes. loaded switch plunger fits into a
3 ADJUSTMENTS
After any brake service work, obtain a firm brake pedal before moving the vehicle. Riding the brake pedal (common on left foot applica- tion) should be avoided when driving the vehicle.
BRAKE SHOE ADJUSTMENTS 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 brake cables for proper adjustment. Make sure that the equalizer operates freely. To adjust the brake shoes: 1. Use Rotunda Tool HRE 8650, (Fig. 4) to determine the inside diameter of the drum braking surface. 2. Reverse the tool as shown in I I JUST SET TO DRUM FIND CORRECT BRAKE Fig. 4 and adjust the brake shoe DIAMETER HERE. . diameter to fit the gauge. Hold the . SHOE DIAMETER HERE H14,6-A automatic adjusting lever out of engagement while rotating the ad- 'justing screw, to prevent burring the FIG. 4 Adjusting Brake Shoes Using Tool HRE-8650 12-02-04 Drum Brakes-Single Cylinder, Dual Piston 12-02-04. screw slots. Make sure the adjusting screw rotates freely. If necessary, BOOT lubricate the adjusting screw threads BOOT CUP with a thin, uniform coating of CIAZ 19590-B Moly Dysulfide. 3. Rotate Tool HRE 8650 around the brake shoes to be sure of the setting. 4. Apply a small quantity of high temperature grease to the points where PISTON the shoes contact the backing plate, 2197 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 FIG. 5 Brake Wheel Cylinder- Typical drums and tighten the nuts to specification. and overhaul the cylinder. Removal is 5. Inspect the cylinder bore for 7. Complete the adjustment by necessary only when the cylinder is score marks or rust. If either condition applying the brakes several times with damaged or scored beyond repair. is present the cylinder bore must be a minimum of 50 lbs pressure on the Disassembly honed. However, the cylinder should pedal while backing the vehicle. After 1. Remove the links and the not be honed more than 0.003 inch each stop the vehicle must be .moved rubber boots from the ends of the beyond its original diameter. forward. brake cylinder. Remove the pistons, 6. Check the bleeder hole to be 8. After the brake shoes have cups, and return spring and expander sure that it is open. been properly adjusted, check the assembly (cup expanders are an Assembly operation of the brakes by making integral part of the return spring on 1. Apply a light coating of several stops while operating in a Ford, Mercury, Meteor, Lincoln heavyduty brake fluid to all internal forward direction. Continental, Continental Mark I11 and parts. Thunderbird Models) from the cyl- 2. Thread the bleeder screw into WHEEL CYLINDER REPAIR inder bore (Fig. 5). the cylinder and tighten securely. 2. Remove the bleeder screw 3. Insert the return spring and Wheel cylinders should not be from the cylinder. expander assembly, cups, and pistons disassembled unless they are leaking or 3. Wash all parts in clean brake into their respective positions in the unless new cups and boots are to be fluid. Dry with compressed air. cylinder bore (Fig. 5). Place a boot installed. It is not necessary to remove 4. Replace scored pistons. Al- over each end of the cylinder. Bleed the brake cylinder from the backing ways replace the rubber cups and dust the brake system. plate to disassemble, inspect, or hone boots.
4 REMOVAL AND INSTALLATION
back off the adjusting screw with the FRONT BRAKE DRUM brake adjusting tool (Fig. 6). Be very careful not to burr, chip, or damage Removal the notches in the adjusting screw; 1. Raise the vehicle until the otherwise the self-adjusting mecha- wheel and tire clear the floor. Remove nism will not function properly. the wheel cover or hub cap, and Installation remove the wheel and tire from the 1. If the drum is being replaced, drum. remove the protective coating from the 2. Remove the grease cap from new drum with carburetor degreaser. the hub. Remove the cotter pin, nut Then, use sandpaper to insure that no lock, adjusting nut, and flat washer residue remains. Wipe the drum with a from the spindle. Remove the outer cloth soaked with denatured alcohol. bearing cone and roller assembly. Install new bearings and grease seal. 3. Pull the drum off the wheel Pack the wheel bearings, install the HANDLE UPWARD RACT BRAKE SHOES spindle. inner bearing cone and roller assembly 4. If the drum will not come off, in the inner cup, and install the new pry the rubber cover from the brake grease seal see Part 11-02. backing plate. Insert, a narrow If the original drum is being ~1590-A screwdriver through the slot and installed, make sure that the grease in disengage the adjusting lever from the the hub is clean and adequate. adjusting screw. While holding the 2. Adjust the brakes and install FIG. 6 Backing Off Brake adjusting lever away from the screw, the drum assembly as outlined under Adjustment 12-02-05 Drum Brakes-Sinale Cylinder, Dual Piston
Brake Shoe Adjustments in this section. BRAKE SHOES AND ADJUSTING 3. Install the outer wheel bearing, SCREW washer and adjusting nut. 4. Adjust the wheel bearing as Removal outlined in Part 11-02, then install the 1. With the wheel and drum grease cap. Install the wheel and hub removed a Over the ends cap. of- the brake cylinder as shown in Fig. I. 2. Remove the secondary shoe to REAR BRAKE DRUM anchor spring with the tool shown in Fig. 7. With the same tool remove the . Removal primary shoe to anchor spring and unhook the cable eye from the anchor 1. Raise the vehicle so that the pin. FIG. 8 Retracting Spring tire is clear of the floor. , 3. On Ford, Mercury, Meteor, Installation 2. Remove the hub cap and Thunderbird, Continental Mark 111 wheel. Remove the three Tinnerman and Lincoln Continental models, anchor spring with the tool shown in nuts and remove the brake drum. If remove the shoe guide (anchor pin) Fig. 8. the drum will not come off, pry the plate (Fig. 1). Be certain that the cable eye is not rubber cover from the backing 'plate. 4. Remove the shoe hold-down cocked or binding on the anchor pin Insert a narrow screwdriver through springs, shoes, adjusting screw, pivot when installed. All parts should be flat the hole in the backing plate, and nut, socket and automatic adjustment on the anchor pin. Remove the brake disengage the adjusting lever from the parts. cylinder clamp. adjusting screw. While holding the 5. On rear brakes, remove the 9. Apply high-temperature grease adjusting lever away from the ad- parking brake link and spring. CIAZ 19590-B Moly Dysulfide to the justing screw, back off the adjusting Disconnect the parking brake cable threads and the socket end of the screw with the brake adjusting tool from the parking brake lever. adjusting screw. Turn the adjusting (Fig. 6). Be very careful not to burr, 6. After removing the rear brake screw into the adjusting pivot nut to chip, or damage the notches in the secondary shoe, disassemble the the limit of the threads and then back adjusting screw; otherwise, the self- parking brake lever from the shoe by off 1/2 turn. adjusting mechanism will not function removing the retaining clip and spring Interchanging the brake shoe properly. washer (Fig. 1). adjusting screw assemblies from one Installation Installation side of the vehicle to the other would 1. Before installing the rear brake cause the brake shoea to retract rather 1. Remove the protective coating shoes, assemble the parking brake than expand each time the automatic from a new drum with carburetor lever to the secondary shoe and secure adjusting mechanism operated. To degreaser; then sand lightly and wipe with the spring washer and retaining prevent installation on the wrong side with a cloth soaked with denatured -1:- Gllp. of the vehicle, the socket end of the i alcohol. 2. Apply a light coating of adjusting screw stamped with an 2. Adjust the brakes as outlined is R hightemperature grease at the points or L (Fig. 9). The adjusting pivot nuts under Brake Shoe Adjustments in this where the brake shoes contact the section. Place the drum over the brake cnn be distinguished by the number of backing plate. grooves machined around the body of assembly and into position. 3. Position the brake shoes on the 3. Install the three Tinnerman the nut. Two grooves on the nut backing plate and secure the assembly indicate a right thread; one groove nuts and tighten securely. Install the with the hold down springs. On the wheel on the. axle shaft flange studs indicates a left thread. rear brake, install the parking brake 10. Place the adjusting socket on against the drum, and tighten the link and spring, back off the parking attaching nuts to specifications. the screw and install this assembly brake adjustment then connect the between the shoe ends with the parking brake cable to the parking adjusting screw toothed wheel nearest brake lever (Fig. 1). the secondary shoe. 4. Install the shoe guide (anchor 11. Hook the cable hook into the pin) plate on the anchor pin when so hole in the adjusting lever. The equipped. adjusting levers are stamped with an R 5. Place the cable eye over the or L to indicate their installation on anchor pin with the crimped side right or left brake assembly (Fig. 9). toward the backing plate; 12. Position the hooked end of 6. Install the primary shoe to the adjuster spring completely into the anchor spring (Fig. 8). large hole in the primary shoe web. 7. Install the cable guide. on the The last coil of the spring should be at secondary shoe web with the flanged the edge of the hole. Connect the loop hole fitted into the hole in the end of the spring to the adjuster lever secondary shoe web. Th'read'the cable hole. around the cable guide groove (Fig. 1). 13. Pull. the adjuster lever, cable It is imperative that the cable be and automatic adjuster spring down positioned in this groove and not and toward the rear to engage the \ ', FIG. 7 Retracting Spring between the guide and the shoe web. pivot hook in the large hole in the. 'i.Removal 8. Install the secondary shoe to secondary shoe web (Fig. 1). i 12-02-06 Drum Brakes:Single Cylinder, Dual Piston
14. After installation, check the anchor to the end of the cable hook. washers and attaching bolts. Torque action of the adjuster by pulling the c. Check the cable guide for them to specifications. section of the cable between the cable damage. The cable groove should be On Ford, Mercury and Meteor guide and the anchor pin toward the parallel to the shoe web, and the body models, to install a front wheel secondary shoe web far enough to lift of the guide should lie flat against the cylinder, position the cylinder on the the lever past a tooth on the adjusting web. Replace the guide if it shows anchor pin against the backing plate. screw wheel. The lever should snap damage. Install the washer and cylinder into position behind the next tooth, d, Check the pivot hook on the attaching nut on the anchor pin, and and release of the cable should cause lever. The hook surfaces should be torque it to specification. Lock the the adjuster spring to return the lever square with the body of the lever for washer retainer securely. to its original position. This return proper pivoting. Replace the lever if 2. Install a new copper gasket action of the lever will turn the the hook shows damage. over the hose fitting. Thread the hose adjusting screw one tooth. e. See that the adjusting screw into the cylinder and tighten it to If pulling the cable does not socket is properly seated in the notch specified torque. produce the action described, or if the in the shoe web. 3. Engage the opposite end of the lever action is sluggish instead of hose to the bracket on the frame. positive and sharp, check the position WHEEL CYLINDER Install the horseshoe-type retaining of the lever on the adjusting screw clip, and connect the brake tube to the toothed wheel. With the brake in a Removal hose with the tube fitting nut. Tighten vertical position (anchor at the top), 1. Remove the wheel and the the nut to specification with tool the lever should contact the adjusting drum. 11 12-144. wheel 3/16 inch (plus or minus 1/32 2. Remove the brake shoe as- 4. To install a rear wheel inch) above the centerline of the semblies, following. procedures out- cylinder, place the rear wheel cylinder screw. If the contact point is below lined in this section. into position. Enter the tubing into the this centerline, the lever will not lock 3. Disconnect the brake line from cylinder, and start the tube fitting nut on the teeth in the adjusting screw the brake cylinder. On a vehicle with a into the threads of the cylinder. wheel, and the screw will not be vacuum brake booster, be sure the 5. Secure the cylinder to the turned as the lever is actuated by the engine is stopped and there is no backing plate by installing the cable. vacuum in the booster system before attaching bolts and lock washers. To determine the cause of this disconnecting the hydraulic lines. 6. Tighten the tube fitting nut to condition: To disconnect the hose at a front specification with tool 11 12-144. a. Check the cable end fittings. The cylinder, loosen the tube fitting that 7. Install the links in the ends of cable should completely fill or extend connects the opposite end of the hose the wheel cylinder, install the shoes slightly beyond the crimped section of to the brake tube at a bracket on the and adjuster assemblies, and adjust the the fittings. If it does not meet this frame. Remove the horseshoe-type shoes as outlined in this section. specification, possible damage is retaining clip from the hose and 8. Adjust the brakes as described indicated and the cable assembly bracket, disengage the hose from the in this part. Install the brake drum should be replaced. bracket, then unscrew the entire hose and wheel. Bleed the brakes and b. Check the cable length. On assembly from the front wheel centralize the differential valve as Ford, Mercury, Meteor, Thunderbird, cylinder. outlined in Part 12-01. Continental Mark 111, and Lincoln At a rear cylinder, unscrew the Continental models, the cable should tube fitting that connects the tube to BRAKE BACKING PLATE measure 11 1/8 inches (plus or minus the cylinder. Do not pull the metal 1/64 inch) from the end of the cable tube away from the cylinder. Pulling Removal anchor to the end of the cable hook. the tube out of the cylinder connection 1. Remove the wheel and brake On Torino, Montego, Mustang, and will bend the metal tube and make drum. Disconnect the brake line from Cougar models the cable should installation difficult. The tube will the brake cylinder. measure 8 13/32 inches on 9 inch separate from the cylinder when the 2. Remove the brake shoe and brakes or 9 3/4 inches on 10 inch cylinder is removed from the backing adjuster assemblies and the wheel brakes from the end of the cable plate. cylinder as outlined in this section. On 4. On all except the front wheels the rear wheels, disconnect the ,DJUSTING LEVER on Ford, Mercury, and Meteor parking brake lever from the cable. models, remove the wheel cylinder 3. If the rear backing plate is attaching bolfs and lock washers and being replaced, remove the axle shaft remove the cylinder. On the front from the applicable rear axle as wheel of Ford, Mercury and Meteor outlined in Group 15 and disengage models, remove the nut and washer the parking brake cable retainer from SOCKET that attaches the cylinder to the backing plate. Remove the backing anchor pin. Remove the cylinder from plate and gasket. the anchor pin. If the front backing plate is being Installation replaced, remove the bolts and nuts \a ADJUSTING SCREW Wipe the end(s) of the hydraulic that secure the backing plate to the IDENTIFICATION LINES line to remove any foreign matter front wheel spindle and remove the before making connections. plate and gasket. H1143-C 1. On all models except Ford, Installation Mercury and Meteor, to install a front If a rear backing plate is to be FIG. 9 Adjusting Screw and wheel cylinder, position the cylinder to replaced, position a new rear backing Lever Identification the backing plate. Install the two lock plate and gasket on the attaching bolts 12-02-07 Drum Brakes-Single 'cylinder, Dual Fiston 12-02-07
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 15 for the proper installation procedure. UPPER STUD SHAFT (AUT0,WTIC 1. If the front brake backing plate is to be replaced, position a new front backing plate 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 as outlined in this section, and install the brake drums and wheels. Bleed the brake system and centralize the .differential valve as outlined in Part 1201.
DUAL MASTER CYLINDER- NON PUSH ROD POWER BRAKES Ford, Mercury and Meteor H 1556C Removal 6 Refer to Fig. 10. FIG. 11 Master Cylinder Installation-Non Power Brake--Torino and 1. Disconnect the stoplight switch wires at the connector. Remove Montego the spring retainer. Slide the stop light ' switch off the brake pedal pin just far from the pin. Use care to avoid switch rod and the nylon washers and enough to clear the end of the pin, damage during removal. bushings off the brake pedal pin. then lift the switch straight upward 2. Slide the master cylinder push 3. Remove the brake tube from the primary and secondary outlet ports of the master cylinder. 4. Remove the cap screws and lockwashers that secure the master cylinder to the dash panel and lift the cylinder forward and upward from the vehicle. Installation 1. Position the boot on the push MASTER rod and secure-the boot to 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 at the dash panel and torque them to . specification. 3. Coat the nylon bushings with SAE 10W oil. Install the nylon washer 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 RETAINER them in bsition with the spring BUSHING retainer. STOPLIGHT SWITCH 5. Connect the wires at the stop 13480 "la"* light switch connector. 6. Connect the brake lines to the FIG. 10 Master Cylinder Installation-Non Power Brakes-Ford, Mercury, master cylinder leaving the brake line and Meteor fittings loose. \ \ Drum Brakes-Sinale Cylinder, Dual Piston
7. Fill the master cylinder with the specified brake fluid to within 1/4 inch of the top of the dual reservoirs. Use Ford Brake Fluid-Extra Heavy Duty-Part Number C6AZ-19542-A CLIP (ESA-M6C25-A) or equivalent for all drum brake applications. The extra heavy duty brake system fluid is colored blue for identification. Do not mix low temperature brake fluids with VACUUM BOOSTER 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 MASTER CYLINDER differential valve. Refer to Hydraulic System Bleeding and Centralizing of the Differential Valve, Part 12-01, for proper procedure. 9. Operate the brakes several times, then check for external hy- draulic leaks. BRAKE PEDAL Torino, Montego, Maverick, Mustang and Cougar SWITCH 13480 SPACER Removal Refer to Figs. 11 and 12. 1. Working from inside the vehicle below the instrument panel, H I~~Z-A disconnect the master cylinder push rod from the brake pedal assembly. FIG. 13 Master Cylinder Installo -Power Brake-Ford, Mercury and The push rod cannot be removed from the master cylinder. Meteor 2. ~iscbnnect the stoplight just far enough to clear the end of the 3. Slide the master cylinder push switch wires at the connector. Remove pin, then lift the switch straight rod and the nylon washers and the hairpin retainer. Slide the stop upward from the pin. Use care to bushings off the brake pedal pin. light switch off the brake pedal pin avoid switch damage during removal. 4. Remove the brake tubes from the primary and secondary outlet ports of the master cylinder. LOCKNUT. '\ la~e.o~.sioo~/ 5. Remove the lock nuts or cap 120-240 LB. IN screw and lockwashers that secure the master cylinder to the dash panel and lift the cylinder forward and upward from the car. Installation Refer to Figs. 1 1 and 12. 1. Position the boot on the push rod and secure the boot to the master cylinder. Carefully insert the master BRAKE PEDJ\L " 2A188 WASHER 28129 PEDAL SUPPORT I ASSY. 2455 (2 REQD.) A:SY. cylinder push rod and boot through the dash panel opening. 2. On Torino or Montego mod- els, position the gasket and master cylinder on the mounting studs on the dash panel. Install the lock nuts on the MASTER CYLINDER studs at the dash panel and torque them to specification. 3. On Mustang or Cougar mod- els, position the master cylin der on the dash panel. Install the retaining screws and torque them to specifica- INCHES FROM TOP D.) BRAKE P tion. Coat the nylon bushings with . FT. ASSY. 2 H 1862-A SAE 10W oil. Install the nylon washer and bushing on the brake ~edal in. 4. POS~.ion the stop liiht switch FIG. 12 Master Cylinder Installation-Non Power Brake-Mustang and and master cylinder push rod on the Cougar brake pedal pin, install the nylon Drum Brakes-Single Cylinder, Dual Piston . . 12-02-09
bushing and washer and secure them in position with the spring retainer. . PEDAL,SUPPORT ASSY. 5. Connect the wires at the stop light switch connector. 6. Connect the brake lines to the master cylinder and tighten to specified torque. 7. Fill the master cylinder with the specified brake fluid to within 1/4 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. Do 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 PEDAL SUPPORT ASSY. 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 hy- draulic leaks. PART OF 2140 ASSY.
1/8 MAX. 8 FULL WIDTH OF CLAMP DUAL MASTER CYLINDER- ON HOSE INSTALLATION BUSHING 2A309 13480 POWER BRAKES VIEW A VIEW B H 1863-A Removal FIG. 15 Master Cylinder Installation-Power Brake-Mustang and Cougar 1. Remove the brake tubes from the primary and secondary outlet ports of the master cylinder (Figs. 13 thru 15). BRAKE VACUUM BOOSTER -2005 1 2. Remove the two nuts and two lock washers attaching the master cylinder to the brake booster assembly. 3. Slide the master cylinder forward and upward from the vehicle. Installation 1." Before installing the master cylinder, check the distance from the outer end of the booster assembly push rod to the master cylinder mounting surface. Turn the push rod adjusting screw in or out as required to obtain the specified length. Refer to Part 12-0 1, Power Brake 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 booster assembly. (Figs. 13 thru 15). 3. Install the attaching nuts and lock washers and torque them to specifications. 4. Install the front and rear brake tubes to the master cylinder outlet fittings. 5. Fill the master cylinder with the specified brake fluid to within 1/4 inch of the top of the dual reservoirs. Use Ford Brake Fluid-Extra Heavy Duty-Part Number C6AZ- 19542-A 'FIG. 14 Master Cylinder lnstall'ation-power Brake-Torino and Montego (ESA-M6C25-A) for all brake appli- \ \.. Drum Brakes-Single Cylinder, Dual Piston
cations. The extra heavy duty brake booster push rod and the nylon connector, and install the wires in the fluid is colored blue for identification. washers and bushing off the brake retaining clip. Do not mix low temperature brake pedal pin (Figs 13 thru 15). fluids with the specified fluids for the 2. Open the hood and remove the BRAKE PEDAL disc brake system. master cylinder from the booster. 6. Bleed the dual-master cylinder Secure it to one side without and the primary and secondary brake disturbing the hydraulic lines. It is not Ford, Mercury and systems. Centralize the pressure necessary to disconnect the brake Meteor differential valve. Refer to Hydraulic lines, but care should be taken that the Removal System Bleeding and Centralizing of brake lines are not deformed. Per- 1. Disconnect the stop light the Differential Vahe, Part 12-01, for manent deformation of brake lines can switch wires at the connector. the proper procedure. lead to tube failure. 2. Remove the hairpin retainer. 7. Operate the brakes several 3. Disconnect the manifold Slide the stop light switch off the times, then check for external hy- vacuum hose or hoses from the brake pedal pin just far enough for the draulic leaks. booster unit. switch outer hole to clear the pin, and 4. Remove the booster-to-dash then lift the switch straight upward PRESSURE DIFFERENTIAL VALVE panel attaching nuts or bolts (Figs. 13 from the pin. Be careful not to damage ASSEMBLY thru 15). Remove the booster and the switch during removal. Slide the bracket assembly from the dash panel, master cylinder or booster push rod Removal sliding the push rod link out from the and the nylon washers and bushing off The pressure differential valve engine side of the dash panel. the brake pedal pin (Figs. 10 and 15). assembly is sewiced as an assembly 5. On Torino and Montego 3. Remove the hairpin-type re- only. Do not attempt to repair this models, remove the push rod link boot tainer and washer from the brake unit. from the dash panel. pedal shaft, then remove the shaft, the 1. Disconnect the brake warning Installation brake pedal and the bushings from the light connector from the warning light 1. On Torino and Montego pedal support bracket. switch. models, install the push rod link boot Installation 2. Disconnect the front inlet and in the hole in the dash panel as shown 1. Apply a coating of SAE 10 rear outlet tubes from the valve in Fig. 14. Install the four spacers on Engine oil to the bushings and locate assembly (Fig. 3). the mounting studs. bushings in their proper places on the 3. Remove the two attaching nuts 2. Mount the booster and bracket pedal assembly and pedal support and bolts from the valve bracket on assembly to the dash panel by bracket (Figs. 10 and 15). the underside of the fender apron and inserting the push rod or push rod link 2. Position the brake pedal remove the valve assembly and bracket in through the hole and boot in the assembly to the support bracket, then from the vehicle. dash panel. Install the bracket-to-dash install the pedal shaft through the Installation panel attaching lock nuts or bolts support bracket and brake pedal 1. Position the valve assembly (Figs. 13 thru IS). assembly. Install the retainer. and bracket to the fender apron. 3. Connect the manifold vacuum 3. Install the inner nylon washer, Install the attaching nuts and bolts: hose or hoses to the booster. the master cylinder or booster push torque them to specifications. 4. Before installing the master rod, and the bushing on the brake 2. Install the front inlet and rear cylinder, check the distance from the pedal pin. Position the switch so that outlet tubes to the valve assembly. outer end of the booster assembly push it straddles the push rod with the Torque them to specifications. rod to master cylinder surface. Turn switch slot on the pedal pin and the 3. Connect the brake warning the screw in or out to obtain the switch outer hole just clearing the pin. light connector to the warning light specified length. Refer to Part 12-01, Slide the switch completely onto the switch. Power Brake Master Cylinder Push pin, and install the nylon washer as 4. Bleed the system and cen- Rod Adjustment. Install the master shown in Figs. 10 and 13. Be careful tralize the pressure differential valve cylinder and torque the attaching nuts not to bend or deform the switch. following the procedures in Central- to specifications. Secure these parts to the pin with the izing the Pressure Differential Valve. 5. Working from inside the hairpin retainer. vehicle below the instrument panel, 4. Connect the stop light switch BRAKE BOOSTER connect the booster push rod link to wires to the connector, and install the the brake pedal assembly. To do this, wires in the retaining clip. Removal proceed as follows: 5. Check the Brake Pedal Free 1. Working from inside the Install the inner nylon washer, the Height and Travel Measurements, vehicle below the instrument panel, booster push rod, and the bushing on Part 12-01. disconnect the booster push rod from the brake pedal pin. Position the the brake pedal assembly. To do this, switch so that it straddles the push rod Torino, Montego and proceed as follows: with the switch slot on the pedal pin Maverick- Disconnect the stop light switch and the switch outer hole just clearing Manual-Shift wires at the connector. Remove the the pin. Slide the switch completely Transmission hairpin retainer. Slide the stop light onto the pin, and install the nylon Removal switch off from the brake pedal pin washer as shown in Figs. 13 thru 15. 1. Remove the clutch pedal assist just far enough for the switch outer Be careful not to bend or deform the spring. hole to clear the pin, and then remove switch. Secure these parts to the pin 2. Disconnect the clutch pedal- the switch from the pin and booster with the hairpin retainer. Connect the to-equalizer rod at the clutch pedal by push rod. Be careful not to damage stop light switch wires to the removing the retainer and bushing. the switch during removal. Slide the 12-02- 1 1 Drum Brakes-Single Cylinder, Dual Piston
pedal shaft, then remove the clutch wires to the connector, and install the tang and Cougar vehicles, remove the pedal and shaft assembly, the brake wires to the retaining clip. locknut and bolt from the pedal pedal assembly, and the bushings from 7. Adjust the clutch pedal free support. Remove the pedal assembly the pedal support bracket (Figs. 11 play (Group 16-02) to specification, if from the support bracket. and 14). required. Installation Installation 8. Check the Brake Pedal Free 1. Apply a coating of SAE 10 1. Apply a coating of SAE 10 Height and Travel Measurements engine oil to the bushings and locate engine oil to the bushings and locate (Part 12-01, Section 1). all the bushings in their proper places all bushings in their proper places on on the pedal assembly and pedal Torino, Montego, the clutch and brake pedal assemblies. support bracket (Figs. 1 1, 12, 14 and Maverick, Mustang 2. Position the brake pedal to the 15). and support bracket, then install the clutch 2. Position the brake pedal Cougar-Automatic pedal and shaft assembly through the assembly to the support bracket, then Transmission or support bracket and brake pedal install the pedal shaft or bolt through Mustang and Cougar assembly. Install the spring clip (Figs. the support bracket and brake pedal with Standard 1 1 and 14). assembly. Install the retainer or Transmission 3. Install the clutch pedal assist locknut. spring. Removal 3. Install the inner nylon washer, 4. Connect the clutch .pedalto- 1. Disconnect the stop light the master cylinder or booster push equalizer rod to the clutch pedal switch wires at the connector. rod, and the bushing on the brake assembly with the bushing and the 2. Remove the self-locking pin pedal pin. Position the switch so that spring clip retainer. Apply SAE 10 and slide the stop light switch off the it straddles the push rod with the engine oil to the bushing. brake pedal pin just far epough for the switch slot on the pedal pin, and the 5. Install the inner nylon washer, switch outer hole to clear the pin. switch outer hole just clearing the pin. the master cylinder or booster push Then lower the switch away from the Slide the switch completely onto the rod, and the bushing on the brake pin. Slide the master cylinder or pin, and install the outer nylon washer pedal pin. Position the switch so that booster push rod and the nylon as shown in Figs. 11, 12, 14 and 15. it straddles the push rod with the washers and' bushing off from the Secure these parts to the pin with the sw/tch slot on the pedal pin and the brake pedal pin (~igs.11, 12, 14 and self-locking pin. switch outer hole just clearing the pin. 15). 4. Connect the stop light switch Slide the switch completely onto the 3. On all vehicles except Mustang wires to the connector, ind install the pin, and install the outer nylon washer and Cougar, re move the self-locking wires in the retaining clip. as shown in Figs. 11 and 14. Secure pin and washer from the brake pedal Check the Brake Pedal Free these parts to the pin with the shaft, then remove the shaft, the brake Height and Travel Measurements, self-locking pin. pedal assembly and the bushings from Part 1201. 6. Connect the stop light switch the pedal support bracket. On Mus-
5 MAJOR REPAIR OPERATlOPlS
3. Position the new lining on the BRAKE DRUM REFINISHING BRAKE SHOE RELINING shoe. Starting in the center, insert and secure the rivets, working alternately Minor scores on a brake drum can Brake linings that are worn to towards each end. Replacement linings be removed with sandpaper. A drum within 1/32 inch of the rivet head or are ground and no further grinding is that is excessively scored or_ shows a are less than 0.030 inch thick (bonded required. total indicator runout of over 0.007 lining) or have been contaminated 4. Check the clearance between inch should be turned down. Remove with brake fluid, grease or oil must be only enough stock to eliminate the replaced. Failure to replace worn scores and true up the drum. Brake linings will rbult in a scored drum. drum maximum inside diameter is When it is necessary to replace BRAKE DRUM-TYPICAL shown on each drum (Fig. 16). If the linings, they must also be replaced on maximum inside diameter shown on the wheel on the opposite side of the the drum is exceeded either through vehicle. wear or refinishing, the drum must be Inspect brake shoes for distortion, replaced. cracks, or looseness. If this condition Check the inside diameter of the exists, the shoe must be discarded. Do brake drum with a brake drum not attempt to repair a damaged brake micrometer (Tool FRE-1432). shoe, After a drum is turned down, wipe 1. Wash the brake shoes thor- < MAXIMUM DIAMETER x the refinished surface with a cloth oughly in a clean solvent. Remove all (OPTIONAL LOCATION) H 1859-A ,, soaked in clean denatured alcohol. If burrs or rough spots from the shoes. ' one drum is turned down, the opposite 2. Check the inside diameter of drum on the same axle should also be the brake drum with a brake drum FIG. 16 Brake Drum Maximum cut down to the same size. micrometer (Tool FRE-1432). Inside Diameter Marking Location \ / 12-02- 12 Drum Brakes-Single Cylinder, Dual Piston
the shoe and lining. The lining must master cylinder bore (Fig. 18). Snap Ring Pliers seat tightly against the shoe with not Remove the push rod and the primary more than 0.008 inch clearance piston assembly from the master between any two rivets. cylinder bore. Do not remove the SNAP RlNG screw that retains the primary return DUAL MASTER CYLINDER spring retainer, return spring, primary cup and protector on the primary When a repair is necessary on the piston. This assembly is factory master cylinder, it is required practice pre-adjusted and should not be during the warranty period to replace disassembled. the cylinder as a unit instead of 5. Remove the secondary piston overhauling the cylinder with a service assembly. Do not remove the outlet repair kit. tube seats, outlet check valves and Disassembly outlet check valve springs from the 1. Clean the outside of the master master cylinder body. cylinder and remove the filler cover 6. Clean all parts in clean isopro and diaphragm. Pour out any brake pyl alcohol, and inspect the parts for fluid that remains in the cylinder. chipping, excessive wear or damage. Discard the old brake fluid. When using a master cylinder repair 2. Remove the secondary piston kit, install all the parts supplied. FIG. 18 Removing Snap Ring- stop bolt from the bottom of the 7. Check all recesses, openings Typical cylinder (Fig. 17). and internal passages to be sure they 3. Remove the bleed screw, if are open and free of foreign matter. bore for signs of etching, pitting, required. Use an air hose to blow out dirt and scoring or rust. If it is necessary to 4. Depress the primary piston cleaning solvent. Place all parts on a hone the master cylinder bore to and remove the snap ring from the clean pan or paper. repair damage, do not exceed allow- retaining groove at the rear of the 8. Inspect the master cylinder able hone specifications. Assembly 1. Dip all parts except the master RETAINER - 28245 cylinder body in clean Rotunda Extra Heavy Duty Brake Fluid. 2. Carefully insert the complete secondary piston and return spring assembly in the master cylinder bore. 3. Install the ' primary piston MASTER CYLINDFR - 2155 assembly in the master cylinder bore. SNAP RlNG - 7821 4. Depress the primary piston and install the snap ring in the
0 PUSH ROD cylinder bore groove. 5. Install the push rod, boot and retainer on the push rod, if so
0 RETAINER equipped. Install the push rod assembly into the primary piston. Make sure the retainer is properly seated and holding the push rod securely. 6. Position the inner end of the push rod boot (if so equipped) in the * PRIMARY PISTON master cylinder body retaining groove. ASSEMBLY - 2169 7. Install the secondary piston * SECONDARY PISTON ASSEMBLY - 2A502 stop bolt and O-ring in the bottom of the master cylinder. t TUBE SEAT - 28220 0 NOTUSEDON POWERBRAKE EWIPPEDVEHICLES 8. Install the bleed screw (if so tNOT SERVICED equipped). Install the gasket (dia- *REPLACE AS AN ASSEMBLY ONLY phragm) in the master cylinder filler cover. Position the gasket as shown in - Fig. 17. Make sure the gasket is se curely seated. 9. Install the cover and gasket on FIG. 17 Dual Master Cylinder Disassembled the master cylinder and secure the cover into position with the retainer. 12-02-1 3 Drum Brakes-Single Cylinder, Dual Piston 12-02- 13
9 .SPECIFICATIONS APdD SPECIAL SERVICE TOOLS
DRUM BRAKE LINING DIMENSIONS (INCHES) FORD.MERCURY-METEOR BRAKE LINING SIZE@ MODELS POSITION COLOR CODE SIZE FRONT REAR Mercury passenger car - 351 Monterey & Monterey Primary Black-Yellow 11 2.50 x 9.34 2.25 x 9.34 Custom. Ford-Meteor passenger car. 240-302-351-CID - All except LTD & Lemoyne. Secondary Blue-Black 11 2.50 x 12.12 2.25 x 12.12 390 & 400 CID Ford - All except LTD. . Ford-Mercury-Meteor Passenger Car. Primary Black-Yellow 11 3.00 x 3.34 2.25 x 9.34 400 CID - all Meteor except Lemoyne 400 & 429 Secondary Blue.Black 11 3.00 x 12.12 2.25 x 12.12 CID - All Mercury 429 CID - All Ford and Meteor except LTD and Lemoyne. 240-302CID New York Taxi - Ford. Primary Black.Yellow 11 NA 2.25 x 9.34 I Without AIC - 429 Police Interceptor - Ford. Secondary Blue-Black 11 NA 2.25 x 12.12 Ford LTD - All Engines Mercury Police - All Engines except Police Primary Black-Yellow 11 NA 2.25 x 9.34 Interceptor - 429 CID Secondary Blue-Black 11 NA 2.25 x 12.12 Mercury Police Interceptor - 429 ClD Primary Yellow-Yellow 11 NA 2.50 x 9.34 Secondary Green-Green 11 NA 2.50 x 12.12 Ford-Mercury-Meteor Station Wagons. Primary Black-Yellow 11 3.00 x 9.34 2.25 x 9.34 302-351 CID - All Ford-Meteor except Squire. 390 Secondary Blue-Black 11 3.00 x 12.12 2.25 x 12.12 and 400 w/o A/C - All Ford-Rideau-Monterey M71B. Ford-Mercury-Meteor Station Wagons. Primary Black-Yellow 11 NA 2.25 x 9.34 I 400 CID without A/C - ~ontcalm& All Mercury except secondary Blue-Black 11 NA 2.25 x 12.12 Monterey M71B. 400 CID Meteor and Mercury with A/C. A11 429 CID Meteor and Mercurv. 390 & 400 CID Ford with AIC. 429 . All Ford. Ford Squire - All Engines. 1 I I TO~~~NI~.MONTEGO 250 & 302 CID Torino.Montego Sedan and Hardtop. Primary Yellow-Black 10 2.25 x 8.43 2.00 x 8.43 Secondary Blue-Blue 10 2.25 x 10.82 2.00 x 10.82 250& 302 Torino-Monteno Conv. Primary Yellow-Black 10 2.50 x 8.43 2.00 x 8.43 250 & 302 ~orino-~ontegoSta. Wag. 351 & 429 CID Secondary Blue-Blue 10 2.50 x 10.82 Fairlane-Montego Sedan & Hdtop. and 351 Conv. 250, 302.3 351 Torino-Monteo LPO Police-Maximum Fade Resistant. 250-302& 351 Montego Police LPD Maximum Wear Primary Yellow-Black Resistant (Bonded) 2.50 x 10.75 2.00 x 10.75 351 & 429 CID Torino-Montego Station Wagons.
Mustang Primary Yellow.Black 10 2.25 x 8.43 2.00 x 8.43 250 and 302 CID Secondary 2 Blue 10 2.25 x 10.82 2.00 x 10.82 351 and 429 CID Primary Yellow-Black 10 2.50 x 8.43 2.00 x 8.43 Mustang and Cougar Secondary Blue-Blue 10 2.50~10.82 2.00x10.82 MAVERICK AND COMET 200 & 250 CID Primary Red-Blue 9 2.25 x 7.62 1.50 x 7.62 Secondary Green 9 2.25 x 9.77 1.50 x 9.77 302 Cl D Primary % Yellow-Black 10 2.25 x 8.43, 1.75 x 8.43 Secondary Blue.Blue 10 2.25 x 10.82 1.75 x 10.82 LINCOLN CONTINENTAL. All Models Primary 1 Yellow-Black 1 11 , NA 2.50 x 9.34 Secondary 1. Blue-Blue I 11 NA 2.50 x 12.12 THUNDERBIRD AND CONTINENTAL MARK Ill All Models 1 Primary 1 Yellow-Black 1 11 1 NA 1 2.25 x 9.34 I I I I Secondary I Blue-Blue I 11 I NA 1 2.25 x 12.12 O Wear Llm~ts- R~veted:0.031 from top of r~vets.- Bonded: 0.030 total l~ningthickness. 12-02- 1 4 Drum Brakes-Sinale Cylinder. Dual Piston 12-02- 1 4
BORE DIAMETERSJRAKE DRUM, WHEEL CYLINDER AND MASTER CYLINDER ~~~k~ D~~~ Wheel Cylinder Bore Mastercylinder Bore Dia. Dia. r Models Inside Boring Limit With Power - Less Power Diameter (Max.)S Front@ Rear@ Brake@ Brake@ Ford, Tax1 and Station Wagon 11.030 11.090 1.093 0.938 1.000 1.000 Mercury and Meteor Dt her 11.030 11.090 1.125 0.938 1.000 i.000 Pass. except Conv. 250, 302 ClD Engines 10.000 10.060 1.125 0.906 0.9375 1.000 Mont ego Pass. and Conv. 351, 390, 429 CID Engines 10.000 10.060 1.125 0.906 0.9375 1,000 and - Convertible 250, 302 CID Engines 10 000 10.060 1.125 0.906 0.9375 1.000 Torino Station Wagon 10.000 10.060 1.125 0.968 0.9375 1.000 Maverick 9 Inch Brake - Passenger Car 9.000 9.060 1.0620 0.8440 0.9375 1.000 and Comet 10 Inch Brake - Passenger Car 10.000 10.060 1.125 0.875 0.9375 1.000 Mustang .- -. -. - - - ; 351, 429, 428 Cl D Engine 10.000 10.060 1.125 0.906 1.000 1.000 and Cougar 250, 302, CID Engine 10.000 10.060 1.125 0.875 1.000 1.000 Thunderbird All 11.030 11.090 N/A 0.938 1.000 N/A Continental Mark Ill All 1!.030 11.090 N/A 0.938 1.000 N/A Lincoln Continental AII 11.030 11.090 N/A 0.938 1.000 1 N/A @Max. Runout 0.007 0 Front Wheel Cylinder cannot be honed on Maverick or Mustang with @Max. Allowable Hone 0.003 9 inch Brakes. 1 2-02- 1 5 Drum Brakes-Single Cylinder, Dual Piston 12-02- 1 5
TORQUE 11 MI TS-G ENERALJT-LBS T~rioo Thunder bi r d Ford-Mercury Montego Mustang- Continental Lincoln Meteor Maverick Cougar Mark Ill Continental Master Cylinder to Dash Panel Screw 13-25 13.25 13-25 Master Cylinder to Booster 13.25 13.25 13.25 13.25 13-25 Booster to Dash Panel 13-25 13.25 13-25 13-25 13-25 10 in. Brake 10 in. Brake 10.20 10.20 10-20 10-20 10-20 Wheel Cylinder to Backing Plate Screws 9 in. Brake 9 in. Brake 5-7 5-7 Wheel Cylinder & Backing Plate Anchor Pin Nut 20-30 Rear Brake Backing Plate to Axle Housing: Removable Carrier 50-70 50-70 30-35 Integral Type 20-40 20-40 20.40 Front Brake Backing Plate to Spindle 25-45 20-35 . 20-35 Pressure Differential Valve Bracket Bolts and Nuts 7.11 i-11 * 7-11 7-11 7-11 32-65 32-65 6-15 6.15 Wheel Cylinder Bleeder Screw 6-15 Inch-lb. Inch.lb.
Wheel Cvlinder 12-20 12-20 12-20 Brake Line Connection to Rear Axle Housing: Removable Carrier 30-40 12-19 12-19 30-40 Integral Type 25.35 12.19 12- 19 Hydralilic Tube Connections@
. - 554 5545 Wheel to Hub and Drum 70-115 70-115 70-115 5 lug 5 lug -- 70.115 70-115 @All hydraulic lines must be tightened to the specified torque value and -be free of fluid leakage.
SERVICE TOOLS
Tool.. No. I Former No. I Description HRE 8650 (Rotunda) Brake Adjusting Gage BL-41-A (Snap-on) LM 119 Brake Cylinder Retaining Clamp B3404-B (Sna~-on) I . 2018-A I Brake Adjusting Tool
BT-11 (Snap-on) 2035N Brake Shoe R & R Spring Tool 7000-DE Rubber Tipped Air Nozzle Tool 33621 t 33621 Internal Snap Ring Pliers Milbar 1112-144 Inch Pound Torque Wrench T71P-4234-A (Ford) 4235-C Axle Shaft Remoyer Rotunda FRE 1432 Brake Drum Micrometer 12-20-0 1 Disc Brakes-Single Piston, Floating Caliper 12-20-0 1
PART12-20 Disc Brakes-Single Piston Floating Caliper
COMPONENT INDEX Applies to Models As Indicated
DISC BRAKE CALIPER Cleaning and Inspection 20-14 20-14 20-14 20-14 20-14 N/A N/A 20-14 20-14 20-14 20-14 20-14 Disassembly and Overhaul 20-13 20-13 20-13 20-13 20-13 N/A N/A 20-13 20-13 20-13 20-13 20-13 Removal and Installation 20-04 20-04 20-04 20-05 20-05 N/A N/A 20-05 20-05 20-04 20-04 20-04 DISC BRAKE ROTOR AND HUB Cleaning and Inspection - See Part 12-01! Refinishing 20-11 20-11 20-11 20-11 20-11 N/A N/A 20-11 20-11120-11 20-11 20-11 Removal and Installation 20L06 20,0_6 20-06 20-06 20,06 N/A N/A 20-06 20-06 20-06 20-a- 20-06 DlSC BRAKE ROTOR SPLASH SHIELD Removal and Installation 20-06 20-06 20-06 20-06 20-06 N/A N/A 20-06 20-06 20-06 20-06 20-06 DlSC BRAKE SERVICE PRECAUTIONS ' See Part 12-0 1 I I DlSC BRAKE SHOE AND LINING Cleaning and Inspection - See Part 12-01 Removal and Installation 20-04 20-04 20-04 20-04 20-04 N/A N/A 20-04 20-04 20-04 20-04 20-04 DUAL BRAKE SYSTEM Description 20-02 20-02 20-02 20-02 20-02 N/A N/A 20-02 20-02 20-02 20-02 120-02 MASTER CYLINDER Cleaning and Inspection 20-12 20-12 20-12 20-12 20-12 N/A N/A 20-12 20-12 20-12120-12 20-12 Disassembly and Overhaul 20-12 20-12 20-12 20-12 20-12 N/A N/A 20-12 20-12120-1220-12 20-12 Removal and Installation - Power 20-07 20-07 20-07 20-07 20-07 N/A N/A 20-07 20-07 20-07 20-07 20-07 PRESSURE DIFFERENTIAL AND I PRESSURE CONTROL VALVE . Removal and Installation 20-08 20-08 20-08 20-08 20-08 N/A N/A 20-08 20-08 20-08 20-08 120-08 PRESSURE METERING VALVE Removal and Installation 20-08 20-08 20-08 N/A N/A N/A N/A N/A N/A 20-08 20-08 20-08 SPECIFICATIONS AND SPECIAL SERVICE TOOLS 02- 15 A page number indicates that the item is for the vehicle(s) listed at the head of the column. N/A indicates that the item is not applicable to the vehicle(s) listed. 12-20-02 Disc Brakes-Single Piston, Floating Caliper 12-20-02
1 DESCRIPTION ..
Disc brakes are available as dual-master cylinder equipped hy- optional equipment for the front draulic brake system employs single DUAL MASTER CYLINDER BRAKE ./ wheels on Ford, Mercury,. Meteor, anchor, internal expanding and self- SYSTEM Torino, Montego, Mustang and Cou- adjusting drum brake assemblies on \ gar models and are standard on the rear wheels of vehicles with disc The dual-master cylinder brake Thunderbird, Continental Mark 111, brakes. system has been incorporated in all and Lincoln Continental models. The The disc brake consists of a models to provide increased safety. ventilated rotor and caliper assembly. The system consists of a dual-master The caliper used is a,single piston cylinder (Fig. 2), pressure differential floating caliper (Fig. 1). valve assembly and a switch (Fig. 3). INNER BRAKE SHOE OUTER BRAKE SHOE pressure control valve provides The switch on the differential valve HOLD DOWN CLIPS RETAINING CLIPS A 281 64 2066 balanced braking action between front activates a dual-brake warning light, and rear brakes. located on the instrument panel. On Ford, Mercury, Meteor, Con- Floating Caliper tinental Mark 111, Lincoln Continental The caliper assembly is made up of and Thunderbird models a metering a floating caliper housing assembly valve, in the hydraulic line between and an anchor plate. The anchor plate the differential valve and the front is bolted to the wheel spindle arm by wheel disc brakes, prevents the front two bolts. The floating caliper is brakes from applying until approxi- attached to the anchor plate by steel mately 125 psi is obtained in the stabilizers on Ford, Mercury, Meteor, system (Fig. 1). This delaying action is Lincoln Continental, Thunderbird and required to prevent the iiont brakes Continental Mark 111 models and by from performing all the braking action one stabilizer on Torino, Montego, CALIPER ASSEMBLY on low speed stops and thereby 281 18 R.H. Mustang and Cougar models. The 28119 L.H. increasing the rate of lining wear, and floating caliper slides on two locating H 1690.A from locking on ice and slippery pins which also attach to the pavement. stabilizers. The floating caliper con- FIG. 1 Disc Brake ~ssembly- A vacuum booster is used with the tains the single cylinder and piston Floating Caliper power disc brake system. assembly. The cylinder bore contains a
FILLER CAP / I
PRIMARY SYSTEM BRAKE FLUID RESERVOIR
RETURN SPRING (PRIMARY)
. - (SECONDARY) \ (PRIMARY) I BRAKE OUTLET SECONDARY PISTON BRAKE OUTLET PRIMARY PISTON ASSEMBLY PORT ASSEMBLY
Dual Master Cylinder- Typical 12-20-03 Disc Brakes-Single Piston, Floating Caliper 12-20-03
piston with a molded rubber dust boot to seal the cylinder bore from CALIPER HWSING contamination (Fig. 4). 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. 5). The outer brake shoe and lining assembly is longer than the inner assembly, and the shoe and lining assemblies are not interchangable. 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 ANCHOR PLATE the shoe. It is replaced as a unit. Rotor The cast iron disc is of the ventilated rotor-type incorporating FIG. 4 Floating Caliper Assernbly- Sectional View forty fins and is attached to, and braking unit mounted on the engine rotates with the wheel hub. A splash side of the dash pailel. shield bolted to the spindle is used The brake booster is of the vacuum primarily to prevent road contami- suspended-type which utilizes engine nants from contacting the inboard intake manifold vacuum and atmos- rotor and lining surfaces. The wheel pheric pressure for its power. provides protection for the outboard Adjustment of the Push rod and surface of the rotor. replacement of the check valve and grommet are the only services per- BRAKE BOOSTER SYSTEM mitted on the brake booster. The booster unit is to be exchanged when This diaphragm-type brake booster it is inspected, checked and found to is a self-contained vacuum-hydraulic be inoperative.
NORMAL POSITION CENTERED
LEFT FRONT FRONT INLET
GHT FRONT OUTLET BRAKE WARNING LIGHT SWITCH
REAR INLET
LIGHT CAR CUSTOM CAR
H1707-8
FIG. 3 Pressure Differential Valve and Brake Warning Light Switch 12-2044 Disc Brakes-Single Piston, Floating Caliper 12-2044
PISTON SEAL DISTORTED PISTON SEA\! RELAXED
CALIPER ~OUSING
BRAKES APPLIED BRAKES RELEASED H1569-B
FIG. 5 Function of Piston Seal
4 REMOVAL AND INSTALLATION
r bolts and discard the stabilizer (Figs. 3 8. Apply the brake pedal prior to DISC BRAKE CALIPER ASSEMBLY and 6). moving the vehicle to position the 4. Lift the caliper from the brake linings. Removal anchor plate. 9. Road test vehicle. 1. Remove the wheel and tire assembly from the hub. Use care to Installation DlSC BRAKE SHOE AND LINING avoid damage or interference with the 1. Install the caliper assembly bleeder screw fitting during removal. over the rotor with the outer b&e 2. Disconnect the brake hose shoe against the rotor braking snkface Ford, Mercury, Meteor, from the caliper. Cap the hose fitting during installation in the anchor plate Thunderbird, to prevent biake system contamination to prevent pinching the piston boot Continental Mark Ill, and loss of brake fluid from the master between the inner brake shoe and the Lincoln Continental cylinder. Mark the left and right piston. Check that the correct caliper caliper assemblies with chalk prior to is installed on the correct anchor plate Rembval removal from the vehicle. as marked during disassembly. 1. Remove the master cylinder 3. Remove the caliper locating 2. Position the new stabilizer cap and check the fluid level in the pins and lower stabilizer attaching (supplied in the brake kit). Apply primary (large) reservoir. Remoye water to the locating pins and attach emugh fluid until the reservoir is half the stabilizer to the caliper. Be sure full. Discard this fluid. the locating pins are free of oil, grease 2. Remove the wheel and tire or dirt. Torque the caliper locating assembly from the hub. Be careful to pins to specifications. avoid damage or interference with the 3. Install the stabilizer to anchor dper splash shield or bleeder screw plate attaching screws and torque to fitting. specifications. . 3. Remove the inner shoe hold 4. Remove the cap from the down clips (Fig. 1). brake hose fitting. Install a new copper 4. Place a small screwdriver washer on each side of the hose fitting under the outer shoe retaining clip and install the brake hose to the tang and lift away from the pin groove caliper. Torque the attaching bolt to and slide the clip from the shoe specifications. retaining pin. Remove the other brake 5.. Bleed the brake system and shoe retaining clip. See Fig. 1 and centralize the brake pressure differ- remove the outer brake shoe. ential valve as outlined in Part 12-01. 5. Remove the caliper locating 6. Fill the master cylinder as pins (Fig. 6). required to within 1/4 inch of the top 6. Remove the upper stabilizer to 4 FRONT ROTOR SPLASH SHIELD H1641-B of the reservoir. anchor plate attaching bolt and \\ 7. Install the wheel and tire remove 'the upper stabilizer to avoid \ FIG. 6 Floating Caliper assembly and torque the wheel nuts to interference with the brake hose '\ Installed- Rear View specifications. during .caliper removal (Fig. 6). 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, diagnostics, troubleshooting, overhaul, as well as the Our manuals are fully removal and installation of major components. Written approved and licensed by in an easy to understand format, this manual contains the Ford Motor Company 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.
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