Demounted on a Emery Cloth Or Fine Steel Wool

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

1970 Ford Car Shop Manual ISBN: 0-9673211-7-4 EAN: 978-0-9673211-7-2

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.

IDENTIFICATION

INDEX end lDENTlFlCATlON ...... 20

IGUlTlON SYSTEM

STARTING SYSTEM ...... 2)

INDEX md IDENTIFICATION...... 3 CHARGING SYSTEM ...... 31 EXTERIOR LIGHTS, HEADLIGHT DIMMER, TURN SIGNALS, HORN . . . . . 32 INTERIOR LIGHTS, INSTRUMENTS, INSTRU.

MIRRORS, Etr...... 35 WIRING, CIRCUIT PROTECTION, BULB CHARTS , ...... 38 VACUUM SYSTEMS ...... 37 SPEED CONTROL, ANTI-SKID CONTROL . . . 38

INDEX and lDENTlFlCATloN...... 48 and DRIVESHAFT

TRANSFER, VINYL ROOFS, PAINT . . . 46 INTERIOR TRIM ...... 47 BODY SHELL, EXTERIOR TRIM, FRAMES, UNDERBODY ...... 88

FIRST PRINTING - SEPTEMBER, 1969 PUBLICATloNS @I969 FORD MOTOR COMPANY, DEARBORN. MICHIGAN

I ... - FOREWORD

This manual is divided into five volumes: I - Chassis, 2 - Engine, 3 - Electrical, 4 - Body, 5 - Maintenance and Lubrication These volumes should provide Service Technicians with complete information covering normal service repairs on all 1970 model passenger cars built by Ford Motor Company in the US. and Canada. As changes in the product occur, this information will be updated by Technical Service Bulletins. When issued, TSB information always supersedes that published here.

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. " That page will contain an index to ')arts" and the first page of each "part" contains a detailed index which gives page location for each service operation covered. Page numbers are consecutive in each 'Bart. "

Those who have previously used Ford Shop Manuals will find a major change this year in the division of information into "groups" and ')arts." To make reference easier, information has been broken down into smaller units so that essentially there is now one "part" for each component or system. Group numbers have been changed so that the first digit of the number indicates the volume in which thi. group may be found.

Example:

36 - 05 - 13 Volume 3 - Group 6 - Part 5 - Page 13

We hope that this change in indexing willmake it easier and quicker to locate desired information within these manuals

The descriptions and specifications.in this manual were in effect at the time this manual was approved for printing. Ford Motor Company reserves the right to'dis- continue models at any time, or change specifications or design, without notice and without incurring obligation.

SERVICE PUBLICATIONS

5006 July 1997 Warranty identification of the vehicle. The first number indicates the model year. The letter following the model year number indicates the manufacturing assembly plant. The next two numbers designate the Body Serial Code followed by a letter expressing the Engine Code. The last six digits of the Vehicle ldentification Num- ber indicate the Consecutive Unit Number. The remaining information on the V.C. Label consists of certinent vehicle identification codes. The BODY code is two numerals and a letter identifying the body style. The COL (color) code is a number or letter (or both) indicating the exterior Fig. I - Typical Vehicle ldentification Number paint color code. The TRIM code consists of a number-letter combination des- ignating the interior trim. The Axle code NUFACTURED BY 100001 is a number or letter indicating the rear RD MOTOR COMPANY axle ratio and standard or rocking type axles. The TRNS. code is a number or letter indicating the type of transmission. numerals for manual and letters for automatic or semi-automatic. The DSO code consisting of two numbers designates the district in which the car was ordered a'nd may appear in conjunction with a Dom- estic Special Order or Foreign Special Order number when applicable. Ford of Canada DSO codes consist of a letter and a number except for export codes which are designated by two numbers.

MODEL YEAR CODE

The number 0 designates 1970.

CONSECIJl IVE UN:T NO REAR AXLE CODE

@ OODY SERiAL CODE @ COLOR CODE

0MODEL YEAR CODE @ BODY TYPE CODE a ASSEMBLY DLANT CODE I( D:STRlCT SPEC EQUIP CODE 0 ASSEMBLY PLANT CODES @ ENGINE CODE @ TRANSMlSS:ON CODE W 1009.A Code TRIM CODE Letter @ W 1009.A A ...... Atlanta FIG. 2 - Vehicle Certification Label B ...... Oakville (Canada) D ...... Dallas E ...... Mahwah F ...... Dearborn G ...... Chicago H ...... Lorain J ...... Los Angeles OFFICIAL VEHICLE VEHICLE CERTIFICATION LABEL K ...... Kansas City IDENTIFICATION NUMBER N ...... Norfolk The Vehicle Certification Label (V.C. P ...... Twin Cities The official Vehicle ldentification Num- Label) is attached to the rear face of the R ...... San Jose ber (VIN) for title and registration pur- driver's door. The upper half of the label S ...... Allen Park poses is stamped on an aluminum tab contains the name of the manufacturer. T ...... Metuchen that is riveted to the instrument panel the month and, year of manufacture and U ...... Louisville close to the windshield on the driver's the certification,.statement. The V.C. label W ...... Wayne X ...... St. Thomas side of the car and is visible from outside also contains the Vehicle Identification Y ...... Wixom (Fig. I). Number. This number is also used lor * 10-0 1-02 Index and Vehicle Identification 1 0-0 1 -02

BODY SERlAL ANDSTYLE CODES MERCURY (Cont'd.) Body Body The two-digit numeral which follows the assembly plant code identifies the Code Code Body Type Model body series. This two-digit number is used in conjunction with the Body Style 4 - Door 2 Sea.t @ MontereyXustom Code, inthe Vehicle Data, which consists '>74 71G 4- Door 3 Seat (Side Facing)@ Wagon of a two-digit number with a letter suffix. 71E 4 - Door 2 Seat 00 Marquis Colony Park The following chart lists the Body Serial 4- Door 3 Seat (S~deFacing)@@ Codes. Body Style Codes and the model. @ Bucket Seats

LINCOLN CONTINENTAL

Body Type 4 Door Sedan 181 65A 2. Door Hardtop 1 METEOR (CANADA) Body Body Serial Style MARK Ill Code Code Body Type Model Body Body 20 54A 4 . Door Sedan@ Rideau Serial Style 22 54B 4. Door Sedan0 Rideau 500 Code Code Body Type 23 658 2 . Door Hardtop-Formal@ 89 65A 2 - Door Hardtop 25 54C 4 - Door Sedan@@ Montcalm 26 65C 2 - Door Hardtop@@ :'26 65E 2.DoorHardtop@@ 27 57C 4 - Door Hardtop @ @ 28 76C Convertible @@ COUGAR "28.-. 76E.- Convertible @O Body Body 34 65F 2 - Door Hardtop-Formal 00 LeMoyne Serial Style 35 57F 2. Door Hardtoo@@ Code Code Body Type Model - 36 718 Rideau 5006 Passenger @ St at ion Wagons- 91 65A 2. Door Hardtop @ Standard 37 71C Rideau 5004ual Face Rear@ 4 Door 92 76A Convert ible'@ 38 71E .Montcalmb Passenger @, 93 658 2 - Door Hardtop@ XR-7 Luxury 39 71A -Montcalm4ual 94 768 Convertible@ DBench Seat @ Split Bench @Bench Seat @Split Bench - @Bucket Seats *Merchandised as Options

MERCURY - Body Body Serial Style MONTEGO Code Code Body Type Model 44 54A 4. Door Sedan@ Monterey 46 65A 2 - Door Hardtop@ 48 57A 4 - Door Hardtop @ 2. Door Hardtop @ --45 76A Convertible @ 4 - Door Sedan @ CANADA ONLY 4 - Door Sedan @ Montego MX 40 53M. 4 . Door Hardtop Sedan @ Marquis 658 2 . Door Hardtop@ 41 65M 2 . Door Hardtop-Formal @ 54D 4 . Door ~edanc Montego MX 42 57M 4-DoorHardtopO 65D 2 - Door Hardtop @ Brougham 54 54C 4. Door Sedan@ MontereyXustom 12 570 --4 - Door Hardtop@ 56 658 2 - Door Hardtop@ 1 ':07 65E 2. Door tiardto~@ Montego MX I 158~ - 57B 4 - Door Hardtoo@. - 63 53F 4 . Door Hardtop Sedan 00 Marquis 1- i1 i:::i:,':: z Cyclone 66 65F 2. Door Hardtop@@ :::I5 65F 2 - Door Hardtop @ 68 57F 4 - Door Hardtop@@ 65 76F Convertible @@ 17 65G 2. Dbor Hardtop @ -62 53C 4. Door Hardtop Sedan @ Brougham 16 65H 2- Door Hardtop @ Cyclone GT 64 65C 2. Door Hardtop@ (08 71C Montego MX@ Stat~onWagon- I 57C . 4 . Door ~ardtob@ 63G . 63H 2 - Door Hardtop (Tunnel Roof) @Bench Seat @Split Bench @ Bucket Seats XlOO 300 "Merchandised as Options

72 718 4 - Door 2 Seat @ Monterey Wagon , . :::72 71C 4. Door 3 Seat (Side Facing) @ Index and Vehicle Identification

THUNDERBIRD FORD (Cont'd.) Body Body Body Body Serial Style Serial Style Code Code Body Type Model Code Code Bodv Tvoe Model ':83 65A 2 - Door ~ardtop@ Galaxie 500 83 65C 2 - Door Hardtop @ 2 - Door Hardtop Fastback @ '>84 658 2 - Door Landau @ 58 2 - Door Hardtop Formal @ 84 650 2 - Door Landau @ 56 578 4. Door Hardtop@ ':87 578 4 - Door Landau O 60 63C 2- Door Hardtop Fastback@@ Ford XL 87 57C 4. Door Landau @ 61 768 Convertible @@- - @Benchseat OSplitBench @Bucket Seats 64 54C 4- Door Sedan@@ Ford LTD ;>Merchandised as Options : 62 65A 2 - Door Hardtoo Formal @@ 1 66 57F 4. Door ~ardth@@ I 70 71D Ranchwagon4 Passenger0 Station Wagon 71 71H Custom 500 Ranchwagon- 6 Passenger @ FALCON 72 71J Custom 500 Ranchwagon- Dual Face Rear @ Serial Style 73 718 Country Sedan4 Passenger @ 74 71C Country Sedan-Dual Face Rear @ 75 71E Country Squired Passenger @ 76 7:A Country Squire-Dual Face Rear@

4. Door~ ~ Sedan o @Benchseat OSolitBench @Bucket Seats 628- 2 - Door Sedan 0 Futura 548 4 - Door Sedan @ 4 - Door Standard @ Station Wagon pi$--4 - Door Fut ura @ @Bench Seat OS~litBench @Bucket Seats

MAVERICK Body Body Serial Style FAIRLANE Code Code Body Type Model Body Boy 91 62A 2 - Door Sedan Standard Serial Style Code Code Body Type Model 28 548 4. Door Sedan@ Fairlane 500 --29 658 2 - Door Hardtop@ 30 65C 2. Door Hardtop@ Torino MUSTANG 31 54C 4- Door Sedan@ I Body Body 32 57C 4 - Door Hardtop@ Serial Style "30 65C 2 - Door Hardtop @ Torino Code Code Body Type Model 33 65E 2 . Door Hardtop. Formal @ Torino Brougham 65A 2.. Door Hardtop@ Standard 36 57E 4 - Door Hardtop@ LF 63A 2 . Door Fastback @ 35 63F 2- Door Hardtop. Fastback@ Torino GT 03 76A - Convertible @ 37 76F Convertible@ Wl 65B 2. Door Hardtop@ Flair ---- "'02 "35 63F 2. Door Hardtop - Fastback@ Torino GT 638 2 - Door Fastback @ "37 76F Convertible @ ':'03 76B Convertible @ 38 63H 2- Door Hardtoo - Fastback @ Cobra 04 65E 2. Door Hardtop@ "Grande" --- "38 63H 2- Door Hardtop - Fastback @ Cobra 05 63C 2 - Door Fastback @ "Mach I" , 41 718 Fairlane 500@ Station Wagon @Bench Seat .@Split Bench @ Bucket Seats 42 71C Torino @ 4. Door "Merchandised as Options 43 71E Torino Squire (Brougham) @ 46 66A Ranchero @ Ranchero 47 668 Ranchero 500@ "47 668 Ranchero 500 @ Ranchero FORD 48 66C RancheroGTO Ranchero Body Body $48 66C RancheroGTa 49 66E Ranchero Squire@ Code Code Body Type Model "49 66E Ranchero Squire @ 4 - Door Sedan@ Custom @Bench Seat @Split Bench @Bucket Seats 548 4 - Door Sedan@ Custom 500 OMerchandised as Options - i Index and Vehicle Identification 1 0-0 1 -04

:REAR AXLE RATIO CODES EXTERIOR PAINT COLOR COOES - INTERIOR TRIM CODES-- l~onventional Limited-Slip Ratio I Color M-32.1 Color Code Trim Schemes Number 1A ...... Black Vinyl 1A ...... Black Cloth & Vinyl A ..... 1724.A ...... Black B ..... 3316.A ...... Dk.Maroon 1A ...... Black Cloth & Black Vinyl C ..... 3323.A ...... Dk. Ivy Green Met. 1A ...... Black Knit & Vinyl D ..... 3470-A ...... Brt. Yellow-Competition 1B ...... Med./Lt. Blue Vinyl Yellow. 1B ...... Dk. Blue Cloth & Vinyl E ..... 1906.A ...... Lt.Blue 1B ...... Dk. Blue Knit & Vinyl F ..... 3065-A ...... Dk. Aqua Met (Brt.)-Dk. 1B ...... Med. Blue Vinyl Aqua Met. 1B ...... Med. Blue Cloth & Vinyl G ..... 3075-A ...... Med. Avacado Met.-Med. 1D ...... Dk. Red Vinyl Lime Met. 1D ...... Dk. Red Knit & Vinyl -.. 1 ...... 3204-A ...... ~k.Orchid Met. 1D ...... Dk. Red Cloth and/or Dk. Red Vinyl J ...... 3320.A ...... Brt. Blue Met. (Astra)- 1F ...... Med. Ginger Vinyl Deep Blue Met. 1F ...... Med. Ginger Cloth & Vinyl K ..... 3340-A ...... Yellow Met.drt. Gold 1G ...... Dk. Ivy Green Cloth & Vinyl Met. (Freudian GiltIMav. 1G ...... Med. Ivy Green Vinyl erick):Deeo Gold Met. 1G ...... Med. Ivy Green Cloth & Vinyl ...... 1G ...... Med. Green Cloth & Vinyl M .... 1619-A ...... White 1G ...... Dk. Ivy Green Knit & Vinyl TRANSMISSION CODES N ..... 921.A ..; ...... Platinum-Pastel Blue 0 ..... 3202.A ...... Burnt Orange Met.- 1P ...... Med. Grey Cloth & Vinyl Code Type (Original CLnnamon/Mav- 1Y ...... Lt. Nugget Gold Vinyl erici) 1Y ...... Lt. Nugget .Gold Cloth & Vinyl 1...... 3 . Speed Manual P ...... 3401.A ...... Med. Ivy Green Met. 1Y ...... Lt. Gold Cloth & Vinyl 5 ...... 4. S eed Manual -wide ratio Q ..... 3319.A ...... Med.BlueMet. 1Z ...... Dk. Tabacco Vinyl 6 ...... 4 . %peed Manual - close ratio R ..... 3342-A ...... Dk.BrownMet. V ...... Semi .Automatic Stick Shift 1Z ...... Dk. Tabacco Knit & Vinyl S ..... 3199-A ...... Nug et Gold Met.-Med. 2A ...... Black Vinyl W ...... Automatic (C4) ~olf~et. U ...... Automatic (C6) T ..... 2008-A ...... Red 2A ...... Black Leather & Vinyl X ...... Automatic (FMX) U ..... 1070-A ...... Med.AquaMet. 2A ...... White& Black Cloth & Black Vinyl Z ...... Automatic (C6 Special) W .... 3341-A ...... Yellow 2A ...... Black Knit & Vinyl - X ..... 3063-A ...... Dk. Blue 28 ...... Dk. & Lt. Blue Vinyl Y ...... 3347-A ...... Chestnut Met.-Chestnut 28 ...... Dk. Blue Leather & Vinyl Bronze Met-Med. Bronze 28 ...... Med. Blue Vinyl Met. I 28 ...... Dk. Blue Knit & Vinyl ENGINE CODES Z ..... 3346-A ...... Dk. Slate Gray Met.-Dk. 28 ...... Med. Blue & Black Cloth & Med. Gray Met. Blue Vinyl Code Type 1 ...... 1730-A ...... Calypso Coral-Vermilion -Competition Orange 2D ...... Dk. Red Vinyl 2 ...... 3071-A ...... Lt. Ivy Yellow , 20 ...... Dk. Red Leather & Vinyl U 6 Cyl. 170 Cu. In. (1V) 2D ...... Dk. Red & Black Cloth & Dk. Red T 6 Cyl. 200 Cu. In. (1V) 5 ...... 3564.A ...... Ginger Met.-Med. Brown 2 6 Cyl. o 200 Cu. In. (1V) Met. Vinyl L 6 Cyl. 250 Cu. In. (1V) 6 ...... 3077-A ...... Med. Brt. Blue Met.- 2F ...... Med. Ivy Green Vinyl 3 6 Cyl. O 250 Cu. In. (11) Bright Blue Met.4ulla 2F ...... Med. Ginger Vinyl V 6 Cyl. 240 Cu. In. (1V) BlueJMaverick 2F ...... Med. Brown Vinyl 5 6 Cyl. O 240 Cu. In. (1V) 7 ...... 3812-A ...... Med. Peppermint Met.- 2F ...... Med. Ginger Leather & Vinyl B 6Cyl. 240 Cu. In. (1V) Police (Anti-Establishment Mint /Maverick) 2G ...... Dk. Ivy Green Vinyl E . 6 Cyl. 240 Cu. In. (1V) Taxi 2G ...... Med. Green Vinyl F 8 Cyl. 302 Cu. In. (2V) 2G ...... Dk. Ivy Green Knit & Vinyl 6 8 Cyl. O 302 Cu. In. (2V) D 8 Cyl. 302 Cu. In. (2V) Taxi 2G ...... Dk. Ivy Green Leather & Vinyl G 8 Cyl. 302.4V HO 2K ...... Lt. Aqua Leather & Vinyl H 8 Cyl. 351 Cu. In. (2V) GLAMOUR PAINTS4pt. 2P ...... Med. Grey Leather & Vinyl M 8 Cyl. 351 Cu. In. (4V) 2W ...... White Vinyl 2W ...... White Leather & Vinyl Y 8 Cyl. 390 Cu. In. 2V) Regular 19 ... 3595-A ...... Ivy Bronze Met.4reen 8 Cyl. 428 Cu'. In. (1V) CJ Fire4reen Stardust 2W ...... White Vinyl With Black 1 8Cyl @ 428 Cu In. (4V) CJ Ram AI 09 ... 3597-A ...... Olive Bronze Met.4live 2W ...... White Knit & Vinyl P 8Cyl. @ 428 Cu. In. (4V) Police 2Y ...... Lt. Gold Vinyl K 8 Cyl. 429 Cu. In. (2V) Firealive Stardust N 8 Cyl. 429 Cu. In. (4V) 89 ... 3333-A ...... Fall Bronze Met. -Bronze 2Y ...... Lt. Nugget Gold Vinyl C 8Cyl. 429 - 4V. CJ Firedronze Stardust 2Y ...... Lt. Nugget Gold Leather & Vinyl Z 8Cyl. 429.4V. HO 59 ... 3275-A ...... Med. Red Met. -Burgundy 2Y ...... Lt. Nugget & Black Cloth & Lt. J 8 Cyl. 429 - 4V CJ Ram Air Fire-Red Stardust Nugget Gold Vinyl A 8 Cyl. 460 Cu. In. (4V) 22 ...... Dk. Tobacco Leather & Vinyl Vendor= Grabber Paints 3A ...... Black Vinyl With Red Strip O Low Compression O Premium Fuel 3A ...... Black Cloth & Vinyl O Improved Performance J ...... 0470 ...... Grabber Blue (Med.)- 3A ...... Black Leather & Vinyl O High Performance O Ram Air Induction Competition Blue 3A ...... Med. Blue Cloth & Vinyl . U ..... 6166 ...... Grabberoran e (Dk ) 38 ...... Med. Blue Knit & Vinyl Competition [old ' - 38 ...... Med. Blue Cloth & Vinyl Z ..... 4359 ...... Grabber Green (Med.)- 38 ...... Dk. Blue Cloth & Vinyl CONSECUTIVE UNIT NUMBER Competition Green Starting Serial Numbers - 1970 Passenger Cars 3B ...... Dk. Blue Leather & Vinyl 100,001 -Ford, Fairlane, Falcon, Mustang, 38 ...... Med. Blue Cloth & Lt. Blue Vinyl Thunder bird, Maverick 3B ...... Med. Blue Vinyl 500,001 - Mercury, Meteor, Montego, Cougar 30 ..: ..... Dk. Red Cloth & Vinyl 800.001 - Lincoln Continental & Mark II I 3D ...... Dk. Red Leather & Vinyl 3E ...... Vermilion Vinyl Index and Vehicle Identification

INTERIOR TRlM CODES-(continued)-- INTERIOR TRlM CODES-(continued) INTERIOR TRlM CODES-(continued) Code Trim khemes Code Trim Schemes Code Trim Schemes 3E ...... Vermilion Knit & Vinyl 6F ...... Med. Ginger Vinyl AK ...... Lt. Aqua Cloth & Vinyl 3F ...... Med. Brown Cloth & Vinyl 6F ...... Med. Ginger Grain Leather AP ...... Med. Grey Cloth & Vinyl 3F ...... Med. Ginger Knit & Vinyl 6G ...... Med. Ivy Green Vinyl AY ...... Lt. Nugget Cloth & Vinyl 3F ...... Med. Ginger Leather & Vinyl 6G ...... Med. Ivy Green Grain Leather AZ ...... White With Tobacco 3F ...... Med. Ginger Vinyl 6G ...... Med. Green Vinyl BA ...... Black Vinyl 3F ...... Med. Ginger Cloth & Vinyl 6G ...... Med. Green Cloth & Vinyl BA...... Black Cloth& Vinyl 3G ...... Med. Ivy Green Knit & Vinyl 6W ...... White Cloth & Vinyl BB ...... Lt. Blue Vinyl 3G ...... Med. Ivy Green Leather & Vinyl 6W ...... White Vinyl With Black BB ...... Med. Blue Vinyl 3G ...... Med. Ivy Green Vinyl 6Y ...... Lt. Nugget Gold Vinyl BD ...... Dk. Red Cloth & Vinyl 3G ...... Med. Ivy Green Cloth & Vinyl 6Y ...... Lt. Nugget Gold Cloth & Vinyl BE ...... Vermilion Vinyl 3G ...... Dk. Ivy Green Cloth & Vinyl 62 ...... Dk. Tobacco Grain Leather BF ...... Med. Ginger Vinyl 3K ...... Lt. Aqua Leather & Vinyl 62 ...... Dk. Tobacco Vinyl BG ...... Med. Ivy Green 3K ...... Lt. Aqua Cloth & Lt. Aqua Vinyl 6Z ...... Dk. Tobacco Grain Lether &/or Vinyl BW..: ..... White Vinyl 3P ...... Med. Grey Leather & Vinyl 62 ...... Dk. Brown Leather & Vinyl BW ...... White Vinyl With Black 3W ...... White Leather & Vinyl 7A ...... Black Vinyl CA ...... Black Cloth & Vinyl 3W ...... White With Black Knit & Vinyl 7A ...... Black Cloth & Vinyl CA ...... Black Knit & Vinyl 3Y ...... Lt. Nugget Leather & Vinyl 7A ...... Black Leather & Vinyl CB ...... Med. Blue Knit & Vinyl 3Y ...... Lt. Nugget Gold Cloth & Vinyl 78 ...... Dk. Blue Leather & Vinyl CB ...... Med. Blue Cloth & Vinyl 32 ...... Dk. Tobacco Leal her & Vinyl 7B ...... Med. Blue Cloth & Vinyl CD ...... Dk. Red Cloth & Vinyl 4A ...... Black Vinyl 78 ...... Med. Blue Vinyl CD ...... Dk. Red Knit & Vinyl 4A ...... Black Cloth & Vinyl 70 ...... pk. Red Leather & Vinyl CE ...... VermilionCloth & Vinyl 4A ...... Dk. Black Knit & Vinyl 7F ...... Med. Ginger Cloth & Vinyl CF ...... Med. Ginger Cloth & Vinyl 48 ...... Dk. Blue Knit & Vinyl 7F ...... Med. Ginger Vinyl CF ...... Med. Ginger Knit & Vinyl 48 ...... Dk./Lt. Blue Vinyl 7F ...... Med. Brown Cloth & Vinyl CG ...... Med. Ivy Green Cloth & Vinyl 4B ...... Med. Blue Cloth & Vinyl 7G ...... Med. Ivy Green Vinyl CY ...... Lt. Nugget Gold Cloth & Vinyl 48 ...... Med. Blue Vinyl 7G ...... Dk. Ivy Green Leather & Vinyl DA ...... Black Cloth & Vinyl 40 ...... Dk. Red Vinyl 7G ...... Med. Ivy Green Cloth & Vinyl DA ...... Black Vinyl 4F ...... Med. Ginger Vinyl 7W ...... White Leather & Vinyl DB ...... Med. Blue Cloth & Vinyl 4F ...... Med. Brown Vinyl 7Y ...... Lt. Nugget Gold Cloth & Vinyl DB ...... Med. Blue Vinyl 4G ...... Dk. Ivy Green Knit &Vinyl 8A ...... Black Vinyl DD ...... Dk. Red Cloth & Vinyl 4G ...... Dk. Ivy Green Vinyl 8A ...... Black Knit & Pewter Vinyl DD ...... Dk. Red Vinyl 4W ...... White Vinyl 8A ...... Black Grain Leather DE ...... Med. Ginger Cloth & Vinyl 4W ...... White Knit & Vinyl With Black 8A ...... Black Knit & Vinyl DF ...... Med. Ginger Cloth & Vinyl 4Y ...... Lt. Gold Cloth & Vinyl 8A ...... Black Grain Leather &/or Vinyl DG ...... Med. Ivy Green Cloth & Vinyl 4Y ...... Lt. Nugget Gold Cloth & Vinyl 88 ...... Med. Blue Knit & Vinyl DG ...... Med. Ivy Green Vinyl 4Y ...... Lt. Nugget Gold Vinyl 8B ...... Med. Blue Vinyl DK ...... Lt. Aqua Cloth & Vinyl 5A ...... Black Knit & Vinyl 80 ...... Dk. Red Vinyl DW ...... WhiteYityl Wiih Black 5A ...... Black Cloth and/or Black Vinyl 80 ...... Dk. Red Grain Leather BY ...... Lt. Nugget Gold Cloth & Vinyl 5A ...... Black Vinyl 80 ...... Dk Red Knit &Yi@ DY ...... Lt. Nugget Gold Vinyl 58 ...... Med. Blue Cloth & Vinyl 80 ...... LTk. Red Grain Leather &/or Vinyl EA ...... Black Cloth & Vinyl 5B ...... Med. Blue Knit & Vinyl 8F ...... Med. Brown Vinyl EA ...... Black Knit & Vinyl 58 ...... Med. Blue Vinyl 8F ...... Med. Ginger Grain Leather &/or Vinyl EA ...... White & Black Vinyl 5B ...... Dk. Blue Cloth & Vinyl 8F ...... Med. Ginger Vinyl EB ...... Med. Blue Knit & Vinyl 50 ...... Dk. Red Cloth & Vinyl 8F ...... Med. Ginger Grain Leather EB ...... Med. Blue Cloth & Vinyl 50 ...... Dk. Red Knit & Vinyl 8F ...... Med. Ginger Knit & Vinyl ED ...... Dk. Red Cloth & Vinyl 50 ...... Dk. Red Vinyl 8G ...... Med. Ivy Green Knit & Vinyl EF ...... Med. Ginger Cloth & Vinyl 5F ...... Med. Brown Vinyl 8G ...... Med. Ivy Green Vinyl EG ...... Dk. Ivy Green Knit & Vinyl 5F ...... Med. Ginger Knit & Vinyl 8W ...... White Vinyl With Black EG ...... Med. Ivy Green Cloth & Vinyl 5F ...... Med. Ginger Vinyl 8W ...... White Knit & Vinyl EW ...... White Knit & Vinyl 5G ...... Med. Ivy Green Cloth & Vinyl 8W ...... White Knit & Vinyl With Black EW ...... White w/Black Knit & Vinyl 5G ...... Dk. Green Cloth & Vinyl 9A ...... Black Vinyl EY ...... Lt. Nugget Gold Cloth & Vinyl 5G ...... Med. Ivy Green Knit & Vinyl 9A ...... Black Cloth & Vinyl FA ...... Black Vinyl 5G ...... Med. Green Vinyl &/or Cloth 9B ...... Med. Blue Vinyl FA ...... White Vinyl With Black 5K ...... Lt. Aqua Cloth & Vinyl 98 ...... Med. Blue Cloth & Vinyl FA ...... White With Black Leather w/Vinyl 5K ...... Lt. Aqua Knit & Vinyl 90 ...... Dk. Red Vinyl FB ...... Med. Blue Vinyl 5Y ...... Lt. Nugget Gold Cloth & Vinyl 90 ...... Dk. Red Cloth & Vinyl FB ...... White Vinyl With Blue 5Y ...... Lt. Gold Cloth & Vinyl 9F ...... Med. Ginger Vinyl FD ...... Dk. Red Vinyl 5Y ...... Lt. Nugget Gold Knit & Vinyl 9G ...... Med. Ivy Green Cloth & Vinyl FD ...... White Vinyl With Red 52 ...... Dk. Tobacco Knit & Vinyl 9G ...... Med. Ivy Green Vinyl FD ...... Dk. Red Cloth & Vinyl 52 ...... Dk. Tobacco Cloth & Vinyl 9K ...... Lt. Aqua Cloth & Vinyl FF ...... White Vinyl With Ginger 6A ...... Black Knit R Vinyl 9Y ...... Lt. Nugget Gold Cloth & Vinyl FF ...... Med. Ginger Vinyl 6A ...... Black Vinyl A4 ...... White Vinyl With Black Vinyl FG ...... Med. Ivy Green Vinyl 6A ...... Black Grain Leather AA ...... Black Vinyl With Black Vinyl FG ...... White Vinyl With Dk. Ivy 6A ...... Black Grain Leather &/or Vinyl A4 ...... Black Cloth & Vinyl FY ...... Lt. Nugget Gold Cloth & Vinyl 6B ...... Med. Blue Grain Leather With Vinyl AB ...... White Vinyl With Blue Vinyl FZ ...... White Vinyl With Tobacco 6B ...... Med. Blue Grain Leather AB ...... Blue Cloth With Blue Vinyl GA ...... Black Vinyl 6B ...... Med. Blue Vinyl AD ...... White Vinyl GB ...... Med. Blue Vinyl 60 ...... Dk. Red Cloth & Vinyl AD ...... Dk. Red Cloth & Vinyl GD ...... Dk. Red Vinyl 60 ...... Dk. Red Vinyl AE ...... Vermilion Cloth & Vinyl GF ...... Med. Ginger Vinyl 60 ...... Dk. Red Grain Leather AF ...... Med. Ginger Cloth & Vinyl G F ...... Med. Brown Vinyl 60 ...... : Dk. Red Grain Leather &/or Vinyl AF ...... White Vinyl With Ginger GW ...... White Vinyl With Black 6F ...... Med. Brown Leather With Vinyl AG ...... White Vinyl With Ivy Gold HA ...... Black Cloth & Vinyl 6F ...... Med. Brown Vinyl AG ...... Med. Ivy Green Cloth & Vinyl HA ...... Black Knit & Vi'nyl Index and Vehicle Identification

INTERIOR TRIM CODES (continued) INTERIOR TRIM CODES (continued) DATE CODES Code Trim Schemes Code Trim Schemes A number signifying the date preceeds the month code letter. A second-year code HB ...... Med. Blue Cloth & Vinyl RG ...... Med. Green Vinyl ...... Med. Ivy Green Knit & Vinyl letter will be used if the model exceeds I2 HD ...... Dk. Red Cloth & Vinyl RG months. HG ...... Med. Green Cloth & Vinyl RW ...... White Vinyl With Black HY ...... Lt. Nugget Gold Cloth & Vinyl RW ...... White'Knit & Vinyl With Black HY ...... Lt. Nugget Gold Knit & Vinyl RZ ...... Dk. Tobacco Leather & Vinyl JA ...... Black Vinyl SA ...... Black Vinyl JA ...... Black Knit & Vinyl SA ...... Black & White, Cloth & Black Vinyl Month Code Code JB...... Med. Blue Cloth & Vinyl SB ...... Med. Blue Vinyl First Year Second JB ...... Med. Blue Vinyl SD ...... Red & Black Cloth & Red Vinyl Year JD ...... Dk. Red Vinyl SD ...... Dk. Red Vinyl SF ...... Med. Ginger Vinyl January ...... A ...... N JF ...... Med. Ginger Vinyl February ...... B ...... P JG ...... Med. Ivy Green Vinyl SG ...... Med. Ivy Green Vinyl March ...... C ...... JW ...... White Vinyl SW ...... White Vinyl With Black . Apiil ...... D ...... ! JW ...... White Knit & Vinyl . TA ...... Black Cloth & Vinyl May ...... E ...... S JW ...... White Vinyl WIBlack TA ...... Black Knit & Vinyl June ...... F ...... T JY ...... Lt. Nugget Gold Vinyl TA ...... Black & White Cloth & Black Vinyl July ...... G ...... U KA ...... Black Vinyl TB ...... Med. Blue Knit & Vinyl August ...... H ...... V KA ...... Black Knit & Vinyl TD ...... Dk. Red Cloth & Vinyl September ...... J ...... W KA ...... Black Cloth & Vinyl TD ...... Dk. Red & Black Cloth & Dk. Red Vinyl October ...... K ...... X Dk. Red Knit & Vinyl November ...... L ...... Y KA ...... Black Leather& Vinyl TD ...... December ...... M ...... Z KB ...... Med. Blue Cloth & Vinyl TF ...... Med. Ginger Cloth & Vinyl KB ...... Dk. Blue Leather & Vinyl . TF ...... Med. Brown Cloth & Vinyl KD ...... Dk. Red Cloth & Vinyl TG ...... Med.& Lt. Ivy Green Knit & Vinyl KD ...... Dk. Red Leather &Vinyl TW ...... White Knit & Vinyl DISTRICT CODES (DSO) KF ...... Med. Ginger Leather & Vinyl TW ...... White With Black Knit & Vinyl Units built on a Domestic Special Or- KG ...... Med. Ivy Green Cloth & Vinyl TY ...... Lt. Nugget Gold Knit & Vinyl der, Foreign Special Order, or other Spe- KG ...... Dk. Ivy Green Leather & Vinyl UA ...... Black Knit & Vinyl cial orders will have the completc order KK ...... Lt. Aqua Leather & Vinyl UA ...... Black Vinyl number in this space. Also to appear in KP ...... Med. Grey Leather & Vinyl UA ...... Black Grain Leather this space is the two-digit code number of KW ...... White Knit & Vinyl With Black UB ...... Med. Blue Vinyl the District which ordered the unit. If the KW ...... White Leather & Vinyl UD ...... Dk. Red Grain Leather unit is a regular production unit, only the KY ...... Lt. Nugget Leather & Vinyl UE ...... Vermilioncloth & Vinyl District code number will appear. KY ...... Lt. Nugget Gold Vinyl UF ...... Med: Ginger Cloth & Ginger Vinyl KY ...... Lt. Nugget Gold Knit & Vinyl UW ...... White Knit & Vinyl With Black FORD KY ...... Lt. Nugget Gold Cloth & Vinyl UW ...... White Vinyl KY ...... Lt. Gold Vinyl UY ...... Lt. Gold Vinyl Code District KZ ...... Dk. Tobacco Cloth & Vinyl UY ...... Lt. Nugget Gold Knit & Vinyl KZ ...... Dk. Tobacco Leather & Vinyl UY ...... Lt. Nugget Gold Vinyl 11 ...... Boston LE ...... Lt & Med. Beige Vinyl UZ ...... Dk. Tobacco Grain Leather 13 ...... New York MA...... Black Vinyl VA ...... Black Knit & Vinyl 15 ...... Newark MA ...... Black & White Cloth & Black Vinyl 16 ...... Philadelphia VA ...... Black Vinyl 17 ...... Washington MB ...... Med. Blue Vinyl VB ...... Med. Blue Vinyl 21 ...... Atlanta MD ...... Dk. Red Vinyl VD ...... Dk. Red Cloth & Vinyl 22 ...... Charlotte MD ...... Red & Black Cloth & Red Vinyl VD ...... Dk. Red Vinyl 24 ...... Jacksonville MF ...... Med. Ginger Vinyl VF ...... Med. Brown Vinyl 25 ...... Richmond NA ...... Black Vinyl VF ...... Med. Ginger Vinyl & Cloth 28 ...... Louisville NA ...... Black Knit & Vinyl VF ...... Med. Ginger Vinyl 32 ...... Cleveland NB ...... Med. Blue Vinyl VF ...... Med. Ginger Knit & Vinyl 33 ...... Detroit NF ...... Med. Ginger Knit & Vinyl VG Med. Ivy Green Vinyl 35 ...... Lansing ...... 37 ...... Buffalo NY ...... Lt. Nugget Gold Vinyl VW ...... White Vinyl 38 ...... Pittsburgh PA ...... Black Vinyl WA ...... BlackKnit & Vinyl 41 ...... Chicago PA ...... Black Cloth & Vinyl WA ...... Black Vinyl 43 ...... Milwaukee PB ...... Lt. Blue Vinyl WA ...... Black Cloth & Vinyl 44 ...... Twin Cities PB ...... Lt. Blue Cloth & Vinyl WB ...... Med. Blue Cloth & Vinyl 46 ...... Indianapolis PD ...... Dk. Red Cloth & Vinyl WD ...... Dk. Red Cloth & Vinyl 47 ...... Cincinnati PF ...... Med. Ginger Cloth & Vinyl WF ...... Med. Ginger Cloth & Vinyl 51 ...... Denver PY ...... Lt. Nugget .Gold Vinyl WF ...... Med. Brown Cloth & Vinyl 53 ...... Kansas City PY ...... Lt. Nugget Gold Cloth & Vinyl 54 ...... Omaha WG ...... Med. Ivy Green Cloth & Vinyl 55 ...... St.Louls QA ...... Black Knit & Vinyl WW ...... White Knit & Vinyl With Black 56 ...... Davenport QB ...... Med. Blue Knit & Vinyl WY ...... Lt. Nugget Gold Vinyl 61 ...... Dallas QD'...... Dk. Red Knit & Vinyl WY ...... Lt. Nugget Gold Knit & Vinyl 62 ...... Houston QW...... White Knit & Vinyl With Black YA ...... Black Knit & Vinyl 63 ...... Memphis RA ...... Black Vinyl YA ...... Bla'ck Cloth & Vinyl 64 ...... New Orleans RA ...... Black Grain Leather Vinyl YB ...... Med. Blue Knit & Vinyl 65 ...... Oklahoma C~ty RA ...... Black Knit & Vinyl YD ...... Dk. Red Knit & Vinyl 7 1...... Los Angeles RA ...... Black & White Cloth & Black Vinyl ;YF ...... Med. Ginger Knit & Vinyl 72 ...... San Jose RB ...... Med. Blue Vinyl 73 ...... Salt Lake City YG ...... Med. Ivy Green Cloth & Vinyl 74 ...... Seattle RB ...... Med. Blue Knit & Vinyl YG ...... Med. Ivy Green Knit & Vinyl 75 ...... Phoenix RD ...... Dk. Red Vinyl YW ...... White Knit & Vinyl With Black 83 ...... Government RD ...... Red & Black Cloth & Red Vinyl W ...... Lt. Nugget Gold Cloth & Vinyl 84 ...... Home Office Resewe RD ...... Dk. Red Knit & Vinyl ZA ...... Black Cloth & Vinyl 85 ...... American Red Cross RF ...... Med. Ginger Vinyl ZG ...... Dk. Ivy Green Cloth & Vinyl 89 ...... Transportation Sewices RF ...... Med. Brown Vinyl ZG ...... Med. Green Cloth & Vinyl 90-99 ...... Export 10-0 1-07 Index and Vehicle Identification 10-0 1-07

LINCOLN-MERCURY FORD OF'CANADA - Code District Code District 11...... B6ston B1 ...... Central 15 ...... New York 82...... Eastern 16 ...... Philadelphia 63...... Atlantic 17 ...... Washington I1 thru I7 ...... Export 21 ...... Altanta 64...... Midwestern 22 ...... Dallas 66...... Western 23 ...... Jacksonville 67 ...... Pacific . . 26 ...... Memphis 31...... Buffalo Note: Canadian Lincoln-Mercury units use prefix 32 ...... Cincinnati "A in place of "6" 33 ...... Cleveland 34 ...... Detroit 41 ...... Chicago 42 ...... St. Louis 46 ...... Twin Cities 51 ...... Denver 52 ...... Los Angeles 53 ...... Oakland 54 ...... Seattle 84 ...... Home Office Resene 90 ...... Export GROUP

PART 11-01 PAGE PART 1 1-03 PAGE General Wheels and Tires Tires ...... 1 1-03-0 1 Service ...... 11-01-01 PART 1 1-02 Wheels ...... 1 1-02-0 1

PART 11-01 General Wheels and Tires Service

COMPONENT INDEX COMPONENT INDEX All All 'This Information Applies This information Applies Models Models to All Models to All Models

FRONT WHEEL BEARING WHEEL BALANCING 01-01 MAINTENANCE 01-01 WHEEL INSPECTION 01-01 TI RE INSPECTION 01-02

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.

1 COMMON ADJUSTMENTS AND REPAIRS

WHEEL BALANCING

See the instructions provided with the Rotunda Wheel Balancer. Make certain that the brakes are not dragging before attempting to spin the wheels. Push the brake shoes into the caliper to free the rotor.

WHEEL INSPECTION drum and lumps of mus or grease can FRONT WHEEL BEARING unbalance a wheel and tire. MAINTENANCE Wheel hub nuts should be inspected Check for damage that would af- and tightened to specification at pre- fect the runout of the wheels. Wobble Wheel bearings are adjustable to delivery. Loose wheel hub nuts may or shimmy caused by a damaged correct for bearing and spindle shoul- cause shimmy and vibration. Elongat- wheel will eventually damage the der wear. Satisfactory operation and ed stud holes in the wheels may also wheel bearings. Inspect the wheel long life of bearings depend on proper result from loose hub nuts. rims for dents that could permit air adjustment and correct' lubrication. If Keep the wheels and hubs clean. to leak from the tires. bearings are adjusted too tightly, they Stones wedged between the wheel and will overheat and wear rapidly. An General Wheels And Tires Service

adjustment that is excessively loose the mileageltime periods indicated in will cause pounding and contribute to the maintenance schedule. TIRE INSPECTION uneven tire wear, steering difficulties New hub grease seals should be in- and inefficient brakes. The bearing stalled when the hub is removed. An Incorrect wheel alignment can adjustment should be checked at reg- imperfect seal may permit bearing lu- cause tire wear. Abnormal or exces- ular inspecthn intervals. bricant to reach the brake linings re- sive tire wear can also be caused by Front hhbs and bearings should be sulting in faulty brake operation and wheelltire unbalance or incorrect tire cleaned, inspected and lubricated necessitating premature cleaning or pressure. Typical tire wear patterns whenever the hubs are removed or at replacement of linings. are shown in Fig. 1. 11-01-03 General Wheels And Tires Service - 11-01-03

STONE BRUISE

STONE BRUISE UNDERINFLATION ROCK CUT

BRUISE HEAT BRUISE

NG. I-Tire Wear Conditions 1 1-02-01 ,- Wheels 11-02-01 -

ART 11-02 Wheels COMPONENT INDEX Applies To Models As Indicated

I 1-1 - FRONT HUB AND DRUM I I ASSEMBLY 111 Removal and Installation 02-05 1 FRONT HUB AND ROTOR ASSEMBLY Removal and Installation 02-05 02-05 FRONT WHEEL ASSEMBLY Description 02-0 1 FRONT WHEEL BEARING ' ADJUSTMENT 0242 FRONT WHEEL GREASE SEAL AND BEARING I Removal. Ihstallation. Re~ackine10243 1 I I HOISTING INSTRUCTIONS 10242 1 1 REARWHEEL ASSEMBLY I I I Description 102-01 1 WHEEL AND TIRE (CONVEN- 1 1 I

Removal and Installation 102-031 I I I I I A page number indicates that the item is for the vehicle(s) isted at the head of the column. I N/A indicates that the item is not applicable to the ;ehicle(s) listed. 1 DESCRIPTION

FRONT WHEEL ASSEMBLY

Each front wheel and tire is bolted to its respective front hub and brake drum or rotor assembly. Two op- posed tapered roller bearings are in- ' stalled ii each hub. A 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 spihdle by the adjusting nut, nut lock and cotter pin (Figs. I and 2). r. REAR WHEEL ASSEMBLY

The rear wheel hub and brake drum assembly is attached to studs on the rear axle shaft flange by three speed nuts. The wheel and tire mounts on the same rear axle shaft flange studs and is held against the hub and drum by the wheel nuts. The rear wheel bearing is pressed onto the axle shaft just inside the shaft flange, and the entire assembly is retained to the rear axle housing by the bearing retainer plate which is bolted to the housing flange. FIG. I-Front Hub, Bearing and Grease Retainer Drum Brakes 1 1-02-02 Wheels 1 1-02-02

F1416-A FIG. 2-Front Hub and Rotor Bearing and Grease Retainer Disc Brakes-Typical

2 IN-VEHICLE ADJUSTMENTS AND REPAIRS

HOISTING INSTRUCTIONS

Damage to steering linkage components and front suspension struts may occur if care is not exercised when positioning the hoist adapters of 2 post hoists prior to lifting the vehicle. If a 2 post hoist is used to lift the vehicle, place the adapters under the lower arms or the No. I crossmemb- WITH WHEEL ROTATING BACK ADJUSTING TIGHTEN ADJUSTING INSTALLSL~CK T(I1QUE ADJUSTING NU+, NUT OFF 1/2 TURN NUT TO 1 Cb15 IN..LBS. AND A NEW C.OTTER PIN er. Do not allow the adapters to con- TO 17-25 FT. LBS. tact steering linkage. If the adapters are placed under the crossmember, a piece of wood (2x4~16inches) should be placed on the hoist channel be- FIG. 3-Front Wheel Bearing Adjustment tween the' adapters. This will prevent the adapters from damaging the front end of the spindle, and remove the If the wheel rotates properly, install suspension struts. cotter pin and nut lock. the grease cap and the hub cap or 4. While rotating the wheel, hub, wheel cover. If the wheel still rotates FRONT WHEEL BEARING and drum assembly, torque the ad- - roughly or noisily, clean, inspect or APJUSTMENT justing nut to 17-25 ft-lbs to seat the replace the bearings and cups as re- . . bearings (Fig. 3). quired. The front wheel bearings should be 5. Locate the nut lock on the ad- adjusted 'if the wheel is loose on the justing nut so that the castellations on DISC BRAKES spindle or if the wheel does not rotate the lock are aligned with the cotter freely. The following procedures will pin hole in the spindle. 1. Raise the vehicle until the wheel bring the! bearing adjustment to speci- 6. Using a 1 t/8-inch box wrench, and tire clear the floor. fication. back off the adjusting nut one half 2. Pry off the wheel cover and turn. Retighten the adjusting nut to remove the grease cap (Fig. 2) from DRUM BRAKES 10-15 in-lbs with a torque wrench or the hub. finger tight. 3. Wipe the excess grease from the ,. 1. Raise the vehicle until the wheel 7. Position the lock on the adjust- end of the spindle, and remove the and tire clear the floor. ing nut and install a new cotter pin. adjusting nut cotter pin and nut lock. 2.- Pry off the hub cap or wheel Bend the ends of the cotter pin ar- 4. Loosen the bearing adjusting nut cover and remove the grease cap (Fig. ound the castellated flange of the nut three turns. Then, rock the 'wheel, 1) from the hub. lock. hub, and rotor assembly in and-out 3. Wipe the.excess grease from the 8. Check the front wheel rotation. several times to push' the shoe and Wheels

linings away from the rotor. justing nut so that the castellations on the grease cap and the hub cap or 5. While rotating the wheel, hub, the lock are aligned with the cotter wheel cover. If the wheel still rotates and rotor assembly, torque the adjust- pin hole in the spindle. roughly or noisily, clean or replace ing nut to 17-25 ft-lbs to seat the 8. Install a new cotter pin, and the bearings and cups as required. bearings (Fig. 3). bend the ends of the cotter pin ar- 10. Before driving the vehicle, 6. Back the adjusting nut off one ound the castellated flange of the nut pump the brake pedal several times to half turn. Then, -retighten the. adjust- lock: obtain normal brake lining to rotor ing nut to 10-15 in-lbs with a torque 9. Check. the front wheel rotation. clearance and restore normal brake , wrench or finger tight. If the wheel rotates properly, install . pedal travel. 7. Locate the nut lock on the ad-

3 REMOVAL AND INSTALLATION

HOISTING INSTRUCTIONS vent the adapters from damaging the tire from hub and drum. front suspension struts. Damage to steering linkage compo- WHEEL AND TIRE nents and front suspension struts may WHEELS AND TIRES INSTALLATION occur if care is not exercised when positioning the hoist adapters of 2 WHEEL AND TIRE 1. Clean all dirt from the hub and post hoists prior to lifting the vehicle. REMOVAL drum. If a 2 post hoist is used to lift the 2. Position the wheel and tire on vehicle, place the adapters under the 1. Pry off the wheel hub -cap or the hub and drum. Install the wheel lower arms or the No. I crossmemb- wheel cover. Loosen but do not re- hub nuts and tighten them alternately er. Do not allow the adapters to con- move the wheel hub nuts. to draw the wheel evenly against the tact the steering linkage. If the adapt- 2. Raise the vehicle until the wheel hub and drum. ers are placed under the crossmemb- and tire clear the floor. 3. Lower the vehicle to the floor, er; a piece of wood (2x4~16inches) 3. Remove the wheel hub nuts and torque the hub nuts to specifica- should be placed on the hoist channel from the bolts, and pull the wheel and tion. between the adapters. This will pre-

4 MAJOR REPAIR OPERATIONS

HOISTING INSTRUCTIONS eliminate looseness or rough . and and outer bearing cups with solvent noisy operation, the hub and bearings and inspect the cups for scratches, Damage to steering linkage compo- should be cleaned, inspected, and re- pits, excessive wear, and other dam- nents and front suspension struts may packed with specified wheel grease. If age. If the cups are worn or damaged, occur .if care is not exercised when 'the bearing cups or the cone and roll- remove them with Tool T69L- 1102-A positioning the hoist adapters of 2 er assemblies are worn or damaged, (Fig. 4). post hoists prior to lifting the vehicle. they should be repladed. 6. Thoroughly clean the inner and If a 2 post hoist is used to lift the outer bearing cone and roller assem- vehicle, place the adapters under the DRUM BRAKES blies with solvent and dry them thor- lbwer arms or the No. I crossmemb- oughly. Do not spin the bearings with er. Do not allow the adapters to con- 1. Raise the vehicle until the wheel compressed air. tact the stkring linkage. If the adapt- and tire clear the floor. Inspect the cone and roller assem- ers are placed under the crossmemb- 2. Remove the wheel cover or hub blies for wear or damage, and replace er, a piece of wood (2x4~16inches) cap. Remove the grease cap from the them if necessary. The cone and roller should be placed on the hoist channel hub. Remove the cotter pin, nut lock, assemblies and the bearing cups between the adapters. This will pre- adjusting nut, and flat washer from .should be replaced as a unit if dam- vent the adapters from damaging the the spindle. Remove the outer bearing age to either is encountered. front suspension struts. cone and roller assembly (Fig. I). 7. Thoroughly clean the spindle 3. Pull the wheel, hub, and drum and the inside of the hub with solvent FRONT WHEEL GREASE SEAL AND assembly off the wheel spindle. to remove all old lubricant. BEARING REMOVAL, 4. Remove the grease retainer with Cover the spindle with a clean INSTALLATION AND/OR Tool 1175AB and discard: Remove cloth, and brush all loose dust and REPACKING the inner bearing cone and roller, as- dirt from the brake assembly. To pre- sembly from the hub. vent getting dirt on the spindle, care- If bearing adjustment will. not 5.. Clean the lubricant off the inner fully remove the cloth from the Wheels

spindle. with wheel bearing grease. A bearing and tire clear the floor. 8. If the inner and/or outer bear- packer is desirable for this operation. 2. Remove the wheel cover or hub ing cup(s) were removed, install the If a packer is not available, work as cap from the wheel. replacement cup(s) in the hub with much lubricant as possible between 3. Remove the wheel and tke f~om the tool shown in Fig, 5. Be sure to the rollers and cages. Lubricate the the hub and rotor. seat the cups properly in the hub. cone surfaces with grease. 4. Remove 2 bolts and washers 9. Pack the inside of the hub with 11. Place the inner bearing cone that attach the caliper to the spindle. specified wheel bearing grease. Add and roller assembly in the inner cup. Remove the caliper from the rotor lubricant to the hub only until the Apply a light film of grease to the and wire it to the underbody to pre- grease is flush with the inside diame- lip(s) of the grease retainer and install vent damage to the brake hose. ter of both bearing cups (Fig. 6). the new grease retainer with the rev- 5. Remove the grease cap from the 10. All old grease should be com- erse end of the tool shown in Fig. 5. hub. Remove the cotter pin, nut lock, pletely cleaned from the bearings and Be sure that the retainer is properly adjusting nut, and flat washer from surrounding surfaces before repacking seated. the spindle. Remove the outer bearing them with new grease (CIAZ- 12. Adjust the brake shoes as out- cone and roller assembly (Fig. 2). 19590-B). The new lithium base lined in Group 12. 6. Pull the hub and rotor assembly grease is not compatible with sodium 13. Install the wheel, hub, and off the wheel spindle. base grease which may have been drum assembly on the wheel spindle. 7. Remove and discard the old present on the bearing surfaces. Pack Keep the hub centered on the spindle grease retainer and the inner bearing the bearing cone and roller assemblies to prevent damage to the grease re- cone and roller assembly from the tainer or the.spindle threads. hub. 14. Install the outer bearing cone 8. Clean the lubricant off the inner and roller assembly and the flat wash- and outer bearing cups with solvent er on the spindle, then install the ad- and inspect the cups for scratches, justing nut (Fig. 1). pits, excessive wear, and other dam- 15. Adjust the wheel bearings as age. If the cups are-worn or damaged, outlined in Section 2, and install a remove them with Tool T69L- 1102-A new cotter pin. Bend the ends of the (Fig. 4). cotter pin around the castellations of 9. Thoroughly clean the inner and the nut lock to prevent interference outer bearing cones and rollers with with the radio static collector in the cleaning solvent, and dry them thor- grease cap. Install the grease cap. oughly. Do not spin the bearings dry 16. Install the hub cap or wheel with compressed air. cover. Inspect the cones and rollers for wear or damage, and replace them if DISC BRAKES necessary. The cone and roller assemblies and the bearing cups should be 1. Raise the vehicle until the wheel replaced as a set if damage to either is encountered. 10. Thoroughly, ,-clthn the spindle and the inside..,of"ihe hub with solvent to remove .@old lubricant. Cover, ,;the spindle with a clean cloth, aid brush all loose dust and dirt from the dust shield. To prevent getting dirt on the spindle carefully remove the cloth from the spindle. 11. If the inner and/or outer bear- FIG. 4-Removing Front Wheel ing cup(s) were removed, install the Bearing Cups-Disc (Drum-Type replacement cup(s) in the hub with Similar) the tools shown in Fig. 7. Be sure to seat the cups properly in the hub. 12. Pack the inside of the hub with the specified wheel bearing grease. Add lubricant to the hub only until the grease is flush with the inside diameter of both bearing cups. It is important that all old grease be removed from the wheel bearings and surrounding surfaces because the new Lithium base grease ClAZ- 19590-B is not compatible with Sodi- INNER CUP OUTER CUP um base grease which ,may already be INSTALLATION INSTALLATION present on the bearing surfaces. 13. Pack the bearing cone and roller assemblies with wheel bearing FIG. 5-Installing Front Wheel FIG. 6-Front Wheel Hub grease. A bearing packer is desirable Bearing Cups-Drum Lubrication 1 1-02-05 Wheels

from the new hub and drum with carburetor degreaser. 6. Pack the inside of the hub with specified wheel bearing grease. Add lubricant to the hub only until the grease is flush with the inside diameter of both bearing cups (Fig. 6). 7. All old grease should be completely cleaned from the bearings before repacking them with new grease. Pack the bearing cone and roller assemblies with wheel bearing grease. A bearing packer is desirable for this operation. If a packer is not available, work as much lubricant as possible between the rollers and cages. Lubricate the cone surfaces with grease. 8. Place the inner bearing cone and FIG. 7-Installing Front Wheel roller assembly in the inner cup, and Bearing Cup-Disc install the new grease retainer with the reverse end of the tool shown in new cotter pin. Bend the ends of the Fig. 5. Be sure that the retainer is cotter pin around the castellations of properly seated. the nut lock to prevent interference 9. Adjust the brake shoes as out- with the radio static colletor in the lined in Group 12. grease cap. Install the grease cap. 10. Install the new hub and drum 18. Install the caliper to the spindle assembly on the wheel spindle. Keep and torque the attaching bolt; to spe- the hub centered on the spindle to cifications as detailed in Group 2. prevent damage to the grease retainer. 19. Install the wheel and tire on 11. Install the outer bearing cone the .hub. and roller assembly and the flat wash- 20. Install the hub cap or wheel er on the spindle; then, install the ad- cover. justing nut (Fig. I). 21. Before driving the vehicle. 12. Position the wheel and tire on pump the brake pedal several times to the new hub and drum assembly. In- obtain normal brake lining to rotor stall the wheel hub nuts and tighten clearance and restore normal brake them alternately in order to draw the pedal travel. wheel evenly against the hub and drum. F1443-A FRONT HUB AND DRUM 13. Adjust the wheel bearings as FIG. 8-Installing hiease ASSEMBLY REMOVAL AND outlined in Section 2, and install a Retainer-Disc INSTALLATION new cotter pin. Bend the ends of the cotter pin around the castellations of for this operation. If a packer is not When the hub and drum assembly the nut lock to prevent interference available, work as much lubricant as is replaced, new bearings and a grease with the radio static co~~dctorin the possible between the rollers and retainer must be installed in the new grease cap. Install the grease cap. cages. Lubricate the cone surfaces assembly. The new grease retainer 14. Install the hub cap or wheel with grease. should be soaked in light engine oil at cover. 14. Place the inner bearing cone least 30 minutes before installation. and roller assembly in the inner cup. 1. Raise the vehicle until the wheel FRONT HUB AND ROTOR Apply a light film of grease to the and tire clears the floor. Pry off the ASSEMBLY REMOVAL AND lips of the grease retainer and install hub cap or wheel cover, and remove INSTALLATION the new grease retainer with the tool the wheel and tire from the hub and shown in Fig. 8. Be sure the retainer drum assembly. When the hub and rotor assembly is properly seated. 2. Remove the grease cap from the is replaced, new bearings and a grease 15. Install the hub and rotor as- hub. Remove the cotter pin, nut lock retainer must be installed in the new sembly on the wheel spindle. Keep the adjusting nut, and flat washer from assembly.' hub centered on the spindle to ptevent the spindle. Remove the outer bearing 1. Raise the vehicle until the wheel damage to the grease retainer or the cone and roller assembly (Fig. I). and tire clear the floor. Pry off the spindle threads. 3. Pull the hub and drum assembly hub cap or wheel cover, and remove 16. Install the outer bearing cone off the wheel spindle. the wheel and tire from the hub and and roller assembly and the flat wash- 4. Remove the grease retainer and rotor assembly. er on the spindle, then install the ad- the inner bearing cone.and roller as- 2. Remove 2 bolts and washers justing nut. sembly from the hub with Tool that attach the caliper to the spindle. 17. Adjust the wheel bearings as 1175AB. Remove the caliper from the rotor outlined in Section 2. and install a 5. Remove the protective coating and wire it to the underbody to pre- 1 1-02-06 Wheels 1 1-02-06

vent damage to the brake hose. and install the grease retainer. evenly against the hub and rotor. 3. Remove the grease cap from the 7. Install the new hub and rotor 11. Adjust the wheel bearings as hub. Remove the cotter pin, nut lock, assembly to the wheel spindle. Keep outlined in Section 2, and install a adjusting nut, and flat washer from the hub centered on the spindle to new cotter pin. Eend the ends of the the spindle; then, remove the outer prevent damage to the grease retainer. cotter pin around the castellations of bearing cone and roller assembly, 8. Install the outer bearing cone the nut lock to prevent interference (Fig. 2). and roller assembly and the flat wash- with the radio static collector in the 4. Pull the hub and rotor off the er on the spindle; then, install the ad- grease cap. lnstall the grease cap. spindle. justing nut. 12. lnstall the hub cap or wheel 5. Remove the protective coating 9. lnstall the caliper to the spindle cover. from the new hub and rotor with car- and tighten the attaching bolts to spe- 13. Before driving the vehicle, buretor degreaser. cifications as detailed in Group 12. pump the brake pedal several times to 6. Grease and install the inner 10. Position the wheel and tire on obtain normal brake lining to rotor bearing cone and roller assembly in the new hub and rotor. Install the clearance and restore normal brake the inner bearing cup. Apply a light wheel hub nuts and tighten them al- pedal travel. film of grease on the grease retainer ternately in order to draw the wheel

5 SPECIAL SERVICE TOOLS

Tool No. Description ~EE.AB Grease Seal Remover (Head Only)

b-'l102-~ Front Wheel Bearing Remover CF1540-A 1 1 -03-01 Tires 1 1-03-0 1

_/ PART 11-03 Tires

Installation N/A N/A N/A N/A N/A N/A N/A N/A N/A 03-03 03-03 03-03 Removal N/A N/A N/A N/A N/A N/A N/A N/A N/A 03-03 03-03 03-03 Repairs N/A N/A N/A N/A N/A N/A N/A N/A N/A 03-04 03-04 03-04

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.

1 DESCRIPTION

LIFE GUARD TIRE

The Goodyear Power Cushion Tire (available on Thunderbird, Lincoln and Continental Mark I11 models) fitted with the Life Guard Safety Spare provides a tire within a tire with two separate air chambers (Fig. I). If the outer tire casing should be punctured or otherwise damaged causing it to go flat, the Life Guard Safety Spare will carry the load of the vehicle and will allow driving at. speeds up to 40 mph with good control up to a distance of 40 miles. A ~afeti-~i~nalbuilt into the Life Guard tread produces a lope or vibration indicating the outer tire has lost FIG. I-Life Guord Sofety pressure. Tire-Sectionol View

2 IN-VEHICLE ADJUSTMENTS AND REPAIRS

HOISTING INSTRUCTIONS vehicle, place the adapters under the the adapters from damaging the front lower arms or the No. I crossmemb- suspension struts. Damage to steering linkage compo- er. Do not allow the adapters to con- nents and front suspension struts may tact steering linkage.If the adapters BALANCING LlFE occur if care is not exercised when are placed under the crossmember, a GUARD TlRE positioning the- hoist adapters of 2 piece of wood (2x4~16inches) should post hoists prior to lifting the vehicle. be placed on the hoist channel be- Tires fitted with the Life Guard If a 2 post hoist is used to lift the tween the adapters. This will prevent Safety Spare are balanced in the 1 1-03-02 Tires 1 1-03-02

deflate both air chambers. incorrect pressure relationship be- 2. Install the core housing. tween the inner and outer air cham- 3. Unseat the beads of tire with the bers that may cause the life guard to bead breakers away from the valve shift position within the tire. The fol- stem as shown in Fig. 2. lowing procedure should be used to 4. Rotate tire casing 90 degrees on correct vibration and shake condi- the wheel rim. tions: 5. Rotate the tire casing back and 1. Check pressure of the inner and forth on the rim to center the valve. outer air chambers on all four tires. 6. Inflate both chambers of the tire 2. If the inner chamber has at least following steps 13 through 15 of the five psi more pressure than the outer Tire Installation procedure. chamber the pressures should be ad- 7. Balance the tire in the normal justed and the tires rebalanced if manner. necessary. NG. 2-Breaking Top Bead of 3. If the pressures of the inner'and Tire From Wheel Rim CORRECTING VIBRATION outer air chambers are equal the Air AND SHAKE- Container is leaking. To repair the same manner as conventional tires. If LIFE GUARD TlRE leaking air container the recommend- an excessive out of balance condition ed procedures for the removal, repair exists the following procedure can be The condition of excessive vibration of air container, mounting, and bal- used to correct the'condition: and shake is generally the result of an ancing should be followed. 1. Remove the core housing and

3 REMOVAL AND INSTALLATION

HOISTING INSTRUCTIONS tire irons with rounded edges or irons designed for removing tubeless tires. Damage to steering linkage compo- 4. Leave one tire iron in position, nents and front suspension struts may and pry the rest of the bead over the occur if care is not exercised when rim with the other iron. Take small positioning the hoist adapters of 2 bites with the iron around the tire in post hoists prior to lifting the vehicle. order to avoid damaging the sealing If a 2 post hoist is used to lift the surface of the tire bead. vehicle, place the adapters under the 5. Stand the wheel and tire upright lower arms or the No. 1 crossmemb- with the tire outer bead in the drop er. Do not allow the adapters to con- center well at the bottom of the tact the steering linkage. If the adapt- wheel. Insert the tire iron between the ers are placed under the cros'smemb- bead and the edge of the wheel rim, er, a piece of wood (2x4~16inches) and pry the wheel out of the tire. F1414 A should be placed on the hoist channel FIG. 3-Bead Loosening Tool between the adapters. This will pre- MOUNTING CONVENTIONAL vent the adapters from damaging the ., TlRE TO WHEEL front suspension struts. 1. If a used tire is being installed REMOVING CONVENTIONAL TlRE remove all dirt from the tire. FROM WHEEL If a tire is being mounted to the original wheel, clean the rim with The tire can be demounted on a emery cloth or fine steel wool. Check mounting machine. Be sure that the the rim for dents. outer side of the wheel is positioned If a new wheel is being installed, FIG. 4-Tubeless Tire Mounting downward. If tire irons are used, coat a new valve with RUGLYDE or Band follow the procedure given here. similar rubber lubricant and position 1. Remove the valve cap and core, the valve to the new wheel. Use a to force the beads over the rim. and deflate the tire completely. rubber hammer or a valve replacing 3. Align the balance mark on the 2. With a bead loosening tool, tool to seat the valve firmly against tire with the valve on the wheel. break loose the tire side walls from the inside of the rim. 4. Hold the beads against bhe tim the wheel (Fig. 3). 2. Apply RUGLYDE or a similar flanges by positioning a tire mounting 3. Position the outer side of the rubber lubricant to the sealing surface band over the tire (Fig. 4). If a wheel downward, and insert two tire on both tire beads. With the outer mounting band is not available, tie a irons about eight inches apart be- side of the wheel down, pry the beads tourniquet of heavy cord around the tween the tire inner bead and the over the wheel rim with two tire circumference and in the center of the back side of the wheel rim. Use only irons. Do not use a hammer or mallet tire. Tighten the cord with a tire iron. 1 1-03-03 Tires 1 1-03-03

7. Lift the lower bead over the wheel rim to remove the tire. 8. Remove the rubber valve hous- AIR CONTAINER ing from the wheel rim.

CORE HOUSING RIDGE INSTALLING LlFE GUARD TlRE ON WHEEL

I. Apply Silicone Lubricant (COAZ-19553-A) as the, anti-friction VE GROOVES treatment uniformly over the crown F 1382 - A and shoulder area inside the tire or outside the life guard. FIG. 5-Core Housing Disassembled 2. Fold the life guard as shown in Fig. 7. 3. Insert life guard into tire casing. 4. Install a new rubber valve housing on the air container valve stem and thread the core housing into place. It is not necessary to install a new core housing. 5. Insert air container into the life guard with the valve grooves to the outboard side of the tire. Place the valve at the valve stem location marked on the sidewall during removal as shown in Fig. 8. 6. Apply a soap solution to the beads and the rubber valve housing. 7. Place the wheel on the mounting FIG. 6-Removing! Air Container FIG. 9-Valve Installation machine with the valve hole away Valve Stem from bead breakers. Remove all burrs Center the tire on the wheel with a and sharp edges from valve hole in rubber mallet. rim. 5. Give the tire a few quick bursts 8. Mount first tire bead exercising of air to seat the beads properly, then care not to'pinch air container. inflate the tire to 40 psi pressure. 9. Start valve through hole in rim. Check to see. that the bead posi- Do not pull valve housing into place tioning rings (outer rings near the side at this time. walls) are evenly visible just above the 10. Mount the second bead starting rim flanges all the way around the just past the valve so the last portion tire. If the rings are not even, deflate of the bead goes over the rim at the the tire completely and inflate. it valve. again. 11. Rotate the tire back and forth 6. When the rings are properly po- to center the valve housing. sitioned. deflate the tire to the recom- 12. Pull the valve housing into mended' pressure. place. Make certain that the iubber FIG. 7-Folding Life Guard For valve ridge is visible around the valve Installation in Tire REMOVING LIFE GUARD TIRE housing (Fig. 9). FROM WHEEL 13. Tighten the core housing lightly using pliers. I. Mark the valve stem location on 14. Thread the Inflate-Chek adapt- the tire sidewall. er onto the core housing. 2. Remove the core housing (Fig. 15. Inflate the inner chamber to 5) and deflate both air chambers. seat the tire beads exercising care, not 3. Unseat the beads of the tire with to exceed 45 psi pressure. Adjust this the bead breakers working away from inner chamber air pressure to 15 psi the valve stem (Fig. 2). higher than the recommended tire 4. Starting at the valve stem, work pressure. (he top bead of the tire over the rim 16. Remove the Inflate-Chek of the wheel. adapter and adjust tire (outer cham- 5. Pull the air container valve stem ber) pressure to the recommended out of the rubber valve housing (Fig. pressure. 6). 17. Recheck inner chamber pres- FIG. 8-Aligning Valve with 6. Remove the air container before sure. Reference Mark on Tire attempting to remove the tire from 18. Install valve cap. the wheel. 1 1-03-04 Tires 1 1-03-04

MAJOR REPAIR OPERATIONS

HOISTING INSTRUCTIONS front suspension struts. rubber solvent. 2. Buff the inside area of the tire. Damage to steering linkage compo- LIFE GUARD 3. Apply a hot cure patch only. nents and front suspension struts may TIRE REPAIRS occur if care is not exercised when REPAIR OF AIR positioning the hoist adapters of 2 REPAIR OF OUTER TIRE CONTAINER post hoists prior to lifting the vehicle. If a 2 post hoist is used to lift the Outside Repairs Air containers are repaired in the vehicle, place the adapters under the same manner as conventional inner lower arms or the No. 1 crossmemb- All outside repairs are made in the tubes. er. Do not allow the adapters to con- same manner as on conventional tact the steering linkage. If the adapt- tubeless tires. REPAIR OF LIFE GUARD ers are placed under the crossmember, a piece of wood (2x4~16inches) Inside Repairs A damaged life guard that may should be placed on the hoist channel pinch the air container should be re- between the adapters. This will pre- 1. Remove the anti-friction treat- placed. No repairs are reqyired for vent the adapters from damaging. the ment on the inside of the tire with small punctures in the life guard. PART 12-0 1 PAGE PART 12-03 PAGE General Brake Service ...... 12-01-01 Disc Brakes ...... 1 2-03-0 1 PART 12-02 PART 12-04 Drum Brakes ...... 12-02-0 1 Parking Brakes ...... 1 2-04-0 1

Part 12-01 General Brake Service I COMPONENT INDEX -vl .L m w ;L Applies To Models >. M As Indicated

PARKINGBRAKE CONTROL o 1-02 Vacuum Release Test 0 1-02

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. 12-01-02 . .., General Brake Service

i. BRAKE SYSTEM TESTS

. . Always check the fluid level in the the brake pedal free height position to stop the eng& a:nd apply the parkirig ,, master cylinder before performing the the reference point, which is at the six brake. .Depress:the brake peaai sever- test procedures. If the fluid level is o'clock. position on the steering wheel al times .to exhaust all vacuum in the not within t/4 inch of the top of the rim. system. master cylinder reservoirs, add Ford 3. With the steel tape still hooked 3. With the engine sh:ut off sind'all Brake Fluid - Extra Heavy Duty-P- to the brake pedal depress the brake vacuum in the. system exhausted, dep- art Number C6AZ-19542-A (ESA- pedal by pressing downward on the ress the,pedal, 'and hold, it irirthe ap- M6C25-A) or equivalent for all brake brake pedal effort gauge. Apply a 50 plied position. Stari the engine.,If,,the applications. The extra heavy duty pound load to the center of the pedal vacuum 'system is oper&ting,the pdal brake fluid is colored blue for identif- by observing the pressure gauge, and will tend to fall away under foot pies- ication purposes. Do not mix low measure the distance from' the brake sure arid less. pressure will be required temperature brake fluids with the pedal to the fixed reference, paint on to hold the pedal in the applied posi- specified brake fluid. the steering wheel rim parallel to the tion. If .no action is fglf,. ;the'vacuum Should one of the wheel brakes be centerline of the steering ,column. booster system is not functioning. locked and the vehicle must be 4. The difference between the If' the. brake pedal:-movement feels moved, open the bleeder screw long brake 'pedal free height ,and the de- spongy, bleed the hydraulic system to enough to let out a few drops of pressed. pedal measurement under a remove air from the-syste@- Refer to brake fluid. This bleeding operation 50 pound load should' be within the Hydraulic System Bleeding;, in this will release the brakes but will not specified maximum pedal travel serv- Part. correct the cause of trouble. ice specification B in Fig. I. 5. If the pedal travel is more than VACUUM TEST S-VACUUM BRAKE PEDAL FREE the specified maximum shown in Fig. RELEASE PARKING BRAKES HEIGHT AND T RAVEL I, dimension C, make. several sharp MEASUREMENTS reverse stops (equivalent'to 50 pounds V'isually check the operation, of the pedal pressure) with a forward stop brake lin'kage as the brake; pedal. is With, the engine running for full before each. 'Move the vehicle in rev- depressed. Then, check,;$e:;operation power brake operation and the .park- erse and forward for a distance of ap- of.the brake linkage when the manual ing,brake fully released, measure the proximately ten feet; then, apply the release lever is activated. These

brake bdal free height, and check the brakes sharply and hold the brake checks , should indicate whether the brake pedal travel with the use of the pedal down until the vehicle is com- manual' parking brake control,linkage Brake Pedal Pressure Gauge, Tool pletely stopped. This will actuate the is operating properly or requires, re- WRE-500-50 as follows: brake self-adjusters. If these stops do pair or adjustment due to..inability-of not bring the brake pedal travel with- the parking brake to titiold against BRAKE PEDAL FREE HEIGHT in specification, make several addi- moderate vehicle- movenient. Perform MEASUREMENT tional forward and reverse stops as tests of the parking brake system and outlined above. controls after -making certain the, link- 1. Insert a slender, sharp pointed 6. If the second series of stops do age, and manual controls operate prod through the carpet and sound not bring the brake pedal travel with- properly. deadener to the dash panel metal and in specification, remove the brake When testing .a parking br.&kevacu- measure the distance to the brake drums and check the brake adjusters um, releasesystem, a minimum of 10 pedal (Fig. 1). to make sure they are functioning. inches of vacuum (Hg.). should be 2. If the position of the pedal is Check the brake linings for wear or available at all points where vacuum not within specification, check the damage. Repair or replace all worn is applied. This can be checked ,with a brake pedal linkage for missing, or damaged parts and non-functioning Rotunda Fuel Pump Tester Gauge worn, or damaged bushings, or loose adjusters. Adjust the brake lining out- (ARE345) and two Distr.itiutor Tester attaching bolts and replace them, if side diameter to the approximate in- hose adapters (Marked, Q) connected required. side diameter of the' brake drum with together. with a coupling. This ,allows 3. If the-pedal free height is still Rotunda Tool HRE-8650 described in the Fuel Pump Tester Gauge hose to out of specification, check the brake Part 12-02. be adapted to any other vacuum hose pedal booster or master cylinder to be 7. If all the brake adjusters, brake or rubber connector in the vacuum sure the correct parts are installed. drums and. linings are functional and systems. Replace the worn or damaged parts the brake travel is not within specifi- Failure to maintain 10 ,inches of as necessary. cations, check the pedal linkage for vacuum (Hg.) during vacuum system missing or worn bushings, or loose at- tests could be caused by a loose hose BRAKE PEDAL TRAVEL tachments. Bleed the brakes and cen- connection, resulting in a vacuum MEASUREMENT tralize the differential valve. leak. When checking for vacuum between two points, trace the hose along I. Install a Brake Pedal Effort POWER BRAKE the entire routing to be sure it is not Gauge on the brake pedal pad (Fig. FUNCTIONAL TEST crossed with another hose and con- . 2). nected to the wrong connection. 2. Hook a steel measuring tape to 1. Check the hydraulic brake All of the vacuum parking brake the brake pedal as shown in Fig. 1. system for leaks or insufficient fluid. control checks are to be performed Measure and record the distance from 2. With the transmission in neutral, with the engine running at idle speed. General Brake Service

LINCOLN. MARK 111 - T'BIRD MEASURED FROM CENTER LINE OF CURVED PEDAL

& \;n STEEL MEASURING TAPE

SURFACE FORD. MERCURY - METEOR - - MAVERICK

PEDAL FREE HEIGHT- B TRAVEL-C VEHICLE TYPE PEDALFGET-1 I HEIGHT-A EERCURYANDMETEOR I NON~RDRW 1 8.09.7.17 1 1 3.10 I

FORD, MERCURY AND METEOR NOH-POWER DISC 8.65 7.82

FORD,MERCURYANDMETEOR POLICE POWER DISC 7.58-6.72

FAIRLANE AND MONTEGO NON-POWER DRW 8.32 7.02 FAIRLANE AND MONTEGO POWER DISC 7.67- 6.52

MUSTANG AND COUGAR NON-POWER DRW 7.49.6.43

MUSTANGANDCOUGAR POWER DISC 6.55-5.88

THUNDERBIRD POWER DISC MONTEGO - FAIRLANE - FALCON CONTINENTAL MARK Ill POWER DISC LINCOLN CONTINENTAL POWER DISC 7.39 - 6.62 3.27 % MAVERICK STD. DRUM 7.42 6.45 2.90

MDNTEGO POLICE DRUM 7.67 6.52 2.20

MONTEGO POLICE DISC 8.40 7.25 2.80

FALCON STO. DRUM 8.13 6.91 2.90

NOTE: A 8 B DIMENSION TO BE MEASURED TOSHEET METAL

C 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 MADE WlTH ENGINE RUNNING)

MUSTANG - COUGAR

FIG. I-Brake Pedal Height and Travel Measurements 12-0 1-04 General Brake Service

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 must be replaced.

PARKING BRAKE OPERATION

Check the operation of the parking brake. With the vehicle on a hoist and the parking brake fully released, the cables should not have any slack. Also, the rear brakes should not drag FIG. 2-Brake Pedal Effort Gauge Installed when the wheels are turned. If either of the above'conditions exist, adjust Leaks in the parking brake hoses parking brake pedal to see that the as required. or a disconnected or improperly con- pedal moves upward and the parking nected hose can usually. be\fourtd. by brake releases. If the parking brake ROAD TEST listening for a hissing sound along the releases. the parking brake vacuum hose routines. Under no circumstanc- control is working properly. A road test should be conducted es should air pressure be -applied to 2. If the parking brake does not re- only when the operator is sure the the yacuum system as th6.actuator di- lease, test for vacuum at the back-up brakes will stop the vehicle. aphragm in the parking brake vacu- light switch mounted on the steering If the road test reveals one or more um motor may be damaged. column and the vacuum lines to the problem conditions, correct all mal- 1. Start the engine and. run it at parking brake release vacuum motor. functions of the vacuum system, idle speed. With the transmission shift Use the Rotunda Vacuum and Fuel brake booster and hydraulic system control in neutral, depress the parking Pump Tester 345. This can be accom- prior to removing brake drums, brake brake pedal to apply the parking plished by removing the hose from calipers, brake shoes and linings or brake. Move the transmission shift each component and: attaching it to backing plates. control to D range and observe the . 2 COMMON ADJUSTMENTS AND REPAIRS

POWER BRAKE MASTER ment is necessary, the push rod length CYLINDER PUSH ROD may be verified with a push rod #I6 ADJUSTMENT length gauge and measured with the U.S.S. GAUGE SHEET STEEL Q engine running to apply vacuum to b-2-7.'6"-4 q+ The push rod is provided with an the booster (Fig. 3). adjustment screw to maintain the cor- The push rod length verification rect relationship between the booster and adjustment of Midland-Ross control valve plunger and the master power brake booster assemblieb must cylinder. If the plunger is too long it be done according to the following will prevent the master cylinder piston procedure: from completely releasing hydraulic I. Disconnect the master cylinder pressure and can cause the brakes to from the booster assembly and secure drag. If the plunger is too short it will it away from the booster without dis- result in excess pedal travel and an connecting the brake tubes. H1087-E undesirable clunk in the booster area. 2. Reinstall. the air filter assembly FIG. 3-Push Rod Gauge Dimen- The adjustment-screw is set to the on the booster if it was removed with sions correct height at the time of original the master cylinder (Fig. 4). assembly of the power' unit. Under 3. Install and tighten the master master cylinder mounting surface of normal service the adjustment screw cylinder retaining nuts to retain the the air filter assembly. does not require any further attention air filter assembly securely against the 5. Adjust the push rod screw to providing the original push rod as- booster body and to seal the booster provide a slight tension against the sembly remains in the original unit. bellows against air leaks. inner edge of the adjustment gauge If a check of the push rod adjust- 4. Place the gauge against the slot. (Approximately 5 pounds of ten- General Brake Service

MANIFOLD CHECK VALVE-2365 19.25 IN. LB.

FIG. 5-Wrench for Bleeding Brake Hydraulic System

down slowly through its full travel. Close the bleeder fitting and return the pedal to the fully released position. Repeat this operation until fluid is free of air bubbles, then tighten the bleeder screw. Do not use the secondary piston stop screw, located on the bottom of the master cylinder to bleed the brake system. Loosening or removing this screw could result in damage to the secondary piston or stop screw. \ PUSH ROD ADJUSTMENTMIDLAND- ROSS PUS+^ mD ADJUSTMENT-BENMX 2. To bleed the secondary (rear) brake system, position a suitable 318 inch box wrench (Fig. 5) on the FIG. 4-Brake Booster Push Rod Measurement bleeder fitting on the brake wheel cylinder. Attach a rubber drain tube to sion against the push rod is required the bleeder fitting. The end of the to assure that the push rod is firmly HYDRAULIC SYSTEM BLEEDING tube should fit snugly around the seated in the booster assembly). bleeder fitting. 6. Remove the retaining nuts from When any part of the hydraulic 3. Submerge the free end of the the booster master cylinder mounting system has been disconnected for re- tube in a container partially filled studs. pair or replacement, air may enter the with clean brake fluid, and loosen the 7. Install the master cylinder on system and cause spongy pedal ac- bleeder fitting approximately 314 the brake booster and tighten the re- tion. Bleed the hydraulic system after turn. taining nuts to the specified torque. it has been properly connected, to be 4. Push the brake pedal down The push rod length verification of sure that all air is expelled. slowly through its full travel. Close the Bendix power brake booster the bleeder fitting, then return the assemblies is accomplished as follows: MANUAL BLEEDING pedal to the full-released position. 1. Disconnect the master cylinder Repeat this operation until air from the booster assembly and secure The Ford, Mercury, Meteor, Conti- bubbles cease to appear at the sub- away from the booster without dis- nental Mark 111, Lincoln Continental, merged end of the bleeder tube. connecting the brake tubes. Thunderbird models equipped with 5. When the fluid is completely 2. Adjust the push rod screw to disc brakes must be bled with pres- free of air bubbles, close the bleeder provide a slight tension against the sure bleeding equipment. fitting and remove the bleeder tube. inner edge of the adjustment gauge The primary and secondary (front 6. Repeat this procedure at the slot. (Approximately 5 pounds of ten- and rear) hydraulic brake systems are brake wheel cylinder on the opposite sion against the push rod is required individual systems and are bled separ- side. Refill the master cylinder reser- to assure that the push rod is firmly ately. Bleed the longest line first on voir after each wheel cylinder is bled seated in the booster assembly). See the individual system being serviced. and install the master cylinder cover Figure 4. During the complete bleeding opera- and gasket. Be sure the diaphragm 3. Install the master cylinder on tion. DO NOT allow the reservoir to type gasket is properly positioned in the brake booster and tighten the re- run dry. Keep the master cylinder res- the master cylinder cover. When the taining nuts to the specified torque. ervoirs filled with Ford Fluid-Extra bleeding operation is completed, the Do not set up side forces on the Heavy Duty-Part Number C6AZ- fluid level should be filled to within push rod as it may break the valve 19542-A (ESA-M6C 25-A). The extra 114 inch of the top of the reservoirs. plunger. heavy duty brake fluid is colored blue 7. If the primary (front brake) This is an approximate adjustment for identification purposes. Do not system is to be bled. Repeat steps 2 only. To verify the adjustment, look mix low temperature brake fluids through 6 at the right front brake cal- through the make-up (rear) port of with the specified fluid during the iper or cylinder and ending at the left the master cylinder when installing bleeding operations. Never re-use front brake caliper or cylinder. the master cylinder to the booster. brake fluid which has been drained 8. On disc brake equipped models The master cylinder piston should not from the hydraulic systems. be sure that the front brake pistons move more than 0.015 inch as it con- 1. If the master cylinder is are returned to their normal positions tacts the push rod. No movement equipped with a bleed screw, loosen and that the shoe and lining assem- (exact contact) is ideal. the bleed screw. Push the brake pedal blies are properly seated by depress- 1 2-0 1-06 General Brake Service

ing the brake pedal several times until the specified brake fluid. Install the with clean brake fluid, and loosen the normal pedal travel is established. pressure bleeder adapter tool to the bleeder fitting. 9. Centralize the pressure differen- master cylinder, and attach the bleed- 7. When air bubbles cease to ap- tial valve. Refer to centralizing the er tank hose, to the fitting on the pear in the fluid at the submerged end Pressure Differential Valve proce- adapter. of the bleeder tube, close the bleeder dures. Master cylinder pressure bleeder fitting and remove the tube. adapter tools can be obtained from 8. Repeat steps 3 through 7 at the PRESSURE BLEEDING ALL the various manufacturers of pressure left rear wheel cylinder. MODELS bleeding equipment. Follow the in- 9. If the vehicle is equipped with structions of the manufacturer when disc brakes, repeat steps 4 through 7, Bleed the longest lines first. The installing the adapter. starting at the right front disc caliper bleeder tank should contain enough 3. If the master cylinder is and ending at the left front disc cali- new Ford Brake Fluid to complete equipped with a bleed screw, loosen per. the bleeding operation. Use Ford the bleed screw and bleed the master On Ford? Mercury, Meteor, Conti- Brake Fluid - Extra Heavy Duty - cylinder until the fluid is free of air nental Mark Ill, Lincoln Continental Part Number C6AZ-19542-A (ESA- bubbles; then, tighte'n the bleed ,screw. and Thunderbird models the metering M6C25-A) or equivalent for all brake Do not use the secondary piston stop valve release rod must be pulled out- applications. The brake fluid is col- screw, located on the bottom of the ward and held a minimum of 1/16 ored blue for identification purposes. master cylinder, to bleed the master inch (Fig. 6) while bleeding the pri- Do not mix low temperature brake cylinder. niayy brake system. fluid with the specified brake fluid 4. If the rear wheel cylinders, the 10. If the vehicle contains drum- during the bleeding operations. Never secondary brake system, are to be type front brakes and the primary re-use brake fluid that has been bled, position a 318 inch box wrench (front) brake system is to be bled, re- drained from the hydraulic system. . (Fig. 5) on the bleeder fitting on the peat steps 4 through 7, starting at the The tank should be charged with ap- right rear brake wheel cylinder. At- right front wheel cylinder ending at proximately 10 to 30 pounds of air tach a bleeder tube to the bleeder fit- the left front wheel cylinder. pressure. Never exceed 50 pounds ting. The end of the tube should fit 11. When the bleeding operation is pressure. snugly around the bleeder fitting. completed, close the bleeder tank , . 1. Clean all dirt from the master 5. Open the valve on the bleeder valve and remove the tank hose from cylinder reservoir cover. tank to admit pressurized brake fluid the adapter fitting. 2. Remove the master cylinder res- to the master cylinder reservoir. 12. On disc brake equipped ve- ervoir cover and rubber gasket, and 6. Submerge the free end of the hicles, be sure that the front brake fill the master cylinder reservoir with tube in a container partially filled pistons are returned to their normal positions and that the shoe and lining assemblies are properly seated by depressing the brake pedal several times until normal pedal travel is established. 13. Remove the Piessure ' Bleeder Adapter Tool. Fill the master cylinder reservoirs to within 114 inch of the top. Install the master cylinder cover and gasket. Be sure the Diaphragm type gasket is properly positioned in FORD-MERCURY-METEOR the master cylinder cover. THUNDERBIRD AND MARK Ill 14. Centralize the pressure differential valve. Refer to Centralizing the Pressure Differential Valve procedures.

CENTRALIZIN G THE COMPRESS TOOL AND PRESSURE DIFFEREN'I-I AL POSITION AND/OR PRESSURE ONTO VALVE. RELEASE TO CONTROL VALVE ALLOW SPRING ACTION TO After any repair or bleeding of the FORCE primary (front brake) or secondary ROD OUT (rear brake) system, the dual-brake warning light will usually continue to be illuminated due to.the pressure differential valve remaining in the off- center position. To centralize the pressure differen- RELEASE ROD H164.4-8 tial valve and turn off the warning FIG. 6-Disc Brake Metering Valve-Ford, Mercury, Meteor, Lincoln light after a repair operation: Continental, Continental Mark Ill and Thunderbird 1. Turn the ignition switch to the ACC or ON position. General Brake Service

2. Check the fluid level in the repaired or bled last. warning light goes out; then, immedi- master cylinder reservoirs and fill 1. Turn the ignition switch to the ately tighten the outlet port tube nut. them to within 114 inch of the top ACC or ON position. Loosen the dif- 2. Check the fluid level in the mas- with the specified brake fluid, if nec- ferential valve assembly brake tube ter cylinder reservoirs and fill them to essary. nut at the outlet port on the opposite within 1.14 inch of the top with the 3. Depress the brake pedal and the side of the brake system that was specified brake fluid, if necessary. piston will center itself causing the wheel balanced, repaired and/or bled 3. Turn the ignition switch to the brake warning light to go out. last. Depress the brake pedal slowly OFF position. 4. Turn the ignition switch to the to build line pressure until the pres- 4. Before driving the vehicle, check OFF position. sure differential valve is moved to a the operation of the brakes and be 5. Before driving the vehicle. check centralized position and the brake sure that a firm pedal is obtained.

3 CLEANING AND INSPECTION

DlSC BRAKES and 0.002 inch on light vehicles total FAIRLANE MUSTANGCOUGAR 4k '875 MIN' indicator reading, braking surface are MONTECO 1. Remove the wheel and tire and to be 80115 micro inches. the shoe and lining assemblies as out- On all models the minimum limit- lined in Part 12-03. ing dimension from the inboard bear- 2. On all models make the thick- ing cup to the inboard rotor face and ness measurements with a micrometer the minimum rotor thickness dimen- across the thinnest section of the shoe sion, must be observed when remov- and lining. If the assembly has worn ing material from the rotor braking to a thickness of 0.230-inch (shoe and surfaces. A ball and gage bar (Rotun- lining together) or 0.030-inch (lining da Kit FRE-70160) is to be used material only) at any one of three when checking minimum dimensions measuring locations or if there is (Fig. 7). more than 0.125 taper from end to When the runout check is finished end or if lining shows evidence of be sure to adjust the bearings as out- brake fluid contamination, replace all lined in Croup 11-02 in order to prevent bearing failure. THUNDERBIRD-CONTINENTAL (4) shoe and lining assemblies on both MARK Ill-LINCOLN front wheels. 6. Check the rotor for scoring. CONTINENTAL 11) YIN.4 ~16w-~ 3. Check the caliper to spindle at- Minor scores can be removed with a taching bolts torque. Torque them to fine emery cloth. If the rotor is cx- FIG. 7-Disc Brake Rotor Service specification, if required. cessively scored, refinish it as outlined Limits-All Models 4. To check rotor runout, first in step 5 or replace the rotor, if re- eliminate the wheel bearing end play quired. any reason, the piston seal must be by tightening the adjusting nut. After 7. Visually check the caliper. If the replaced. tightening the nut, check to see that caliper housing is leaking it should be 3. During removal and installation the rotor can still be rotated. replaced. If a seal is leaking the cali- of a wheel assembly, exercise care not 5. Clamp a dial indicator to the per must be disassembled and new to interfere with and damage the cali- caliper housing so that the pointer seals installed. If a piston is seized in per splash shield or the bleeder screw contact the rotor at a point approxi- the bore a new caliper housing is re- fitting. mately I inch from the outer edge. quired. 4. Front wheel bearing end play is Rotate the rotor and take an indica- Check the brake hoses for signs of critical and must be within specifica- tor reading. If the reading exceeds cracking, leaks or abrasion. Replace tions. 0.003 inch on custom vehicles and them if necessary. 5. Be sure the vehicle is centered 0.002 inch on light vehicles total lat- on the hoist before servicing any front eral runout on the indicator, replace end components, to avoid bending or or resurface the disc brake rotor. The DlSC BRAKE SERVICE damaging the rotor splash shield on following requirement must be met PRECAUTIONS full right or left wheel turns. when resurfacing disc brake rotors: 6. Riding of the brake pedal (com- Rotunda Disc Brake Attachment 1. Grease or any other foreign ma- mon on left foot applications) should FRE-2249-2 is the only approved tool terial must be kept off the caliper as- be avoided during vehicle operation. to be used to refinish the disc brake sembly, surfaces of the rotor and ex- 7. The wheel and tire must be rotors. The step-by-step resurfacing ternal surfaces of the hub during serv- removed separately from the brake procedure provided with the tool must ice operations. Handling of the rotor rotor, unlike drum brakes where the be adhered to. and caliper assemblies should be done wheel, tire and drum are removed as The finished braking surface of the in a way to avoid deformation of the a unit. rotor must be flat and parallel within brake rotor and nicking or scratching 8. On floating caliper type disc 0.0007 inch: lateral runout must not of brake linings. brakes whenever the caliper is re- exceed 0.003 inch on custom vehicles 2. If a caliper piston is removed for moved the caliper locating pins should General Brake Service

be inspected for wear or damage. replacement of the retracting and BRAKE TUBING 9. On floating caliper type disc hold-down springs is strongly recom- brakes. the caliper assembly must be mended. Overheated springs lose their If a section of the brake tubing be- removed from the spindle prior to re- pull and could cause the new lining to comes damaged, the entire section moval of the shoe and lining assem- wear prematurely, if they are not re- should be replaced with tubing of the blies. placed. If the brake drums are heat same type, size, shape and length. 10. On floating caliper type disc spotted, indicating a overheated con- Copper tubing should not be used in a brakes the calipers must not be inter- dition, they should be replaced. hydraulic system. When bending changed from one side to the other. 5. If the vehicle has 30,000 or more brake tubing to fit underbody or rea; When the caliper is installed on its miles of operation on the brake lin- axle contours, be careful not to kink proper anchor plate and spindle, the ings or signs of overheating are pres- or crack the tube. bleeder screw will point to the rear of ent when relining brakes, the wheel All brake tubing should be double the vehicle. If a caliper is installed on cylinders should be disassembled and flared properly to provide good leak- the wrong side of the vehicle. it is not inspected for wear and entrance of proof connections. Clean the brake possible to bleed the system properly. dirt into the cylinder. The cylinder tubing by flushing with clean brake 11. Do not attempt to clean or cups should be replaced, thus avoiding fluid before installation. restore oil or grease soaked brake lin- future problems. When connecting a tube to a hose, ings. When contaminated linings are 6. Inspect all other brake parts and tube connector, or brake cylinder, found. brake linings must be replaced replace any that are worn or dam- tighten the tube fitting nut to speci- in complete axle sets. aged. fied torque with Milbar Tool 11 12- 7. Inspect the brake drum and, if 144 or equivalent. necessary, refinish. Refer to Part DRUM BRAKES 12-02 for refinishing. BRAKE HOSE

1. Remove the wheel from the BRAKE BOOSTER A flexible brake hose should be re- drum, and remove the drum as out- placed if it shows signs of softening, lined in Part 12-02. Check the booster operation as cracking, or other damage. 2. Brush all dust from the backing noted in Part 12-01. Power Brake When installing a new front brake plates and interior of the brake Functional Test. If the brake booster hose, position the hose to avoid con- drums. is damaged or inoperative replace it tact with other chassis parts. Place a 3. Inspect the brake shoes for ex- with a new booster. The brake boost- new copper gasket over the hose fit- cessive lining wear or shoe damage. If er is serviced only as an assembly. ting and thread the hose assembly the lining is worn within 1/32 inch of into the front wheel cylinder. Engage the rivet heads or if the shoes are HYDRAULIC LINES the opposite end of the hose to the damaged, they must be replaced. Re- bracket on the frame. Install the hor- place any lining that had been con- Steel tubing is used throughout the seshoe-type retaining clip, and contaminated with oil, grease or brake brake system with the exception of nect the tube to the hose with the fluid. Replace lining in axle sets. the flexible.hoses at the front wheels tube fitting nut. Prior to replacement of lining, the and at the rear axle housing brake A rear brake hose should be in- drum diameter should be checked to tube connection. stalled so that it does not touch the determine if oversize linings must be Always bleed the applicable pri- muffler outlet pipe or shock absorber. installed. mary or secondary brake system after Thread the hose into the rear brake 4. Check the condition of brake primary or secondary brake system tube connector. Engage the front end shoes, retracting springs, hold-down hose or line replacement. Centralize of the hose to the bracket on the springs, and drum for signs of ov- the pressure differential valve after frame. Install the horseshoe-type re- erheating. If the shoes have a slight bleeding the.system. taining clip, and connect the tube to blue coloring, indicating overheating, the hose with the tube fitting nut. 1 2-0 1 -09 General Brake Service 1 2-0 1-09

3 SPECIAL TOOLS

SPEC1 AL TOOLS * Ford Tool No. Description

Rotunda WRE-500.50 Brake Pedal Effort Gauge

Rotunda ARE-345 Vacuum and Fuel Pump Tester Gauge

Rotunda 1436 Diaphragm Type Bleeder

Tool 4201-C Universal Dial Indicator and Bracket

Rotunda FRE.70160 Ball and Bar Gauge

Rotunda-FRE-1432 Brake Drum Micrometer Rot unda-2249-2 Disc Brake ~ttachment . Milbar 1112.144 Inch Pound Torque Wrench 1 2-02-0 1 Drum Brakes 1 2-02-0 1

PART 12-02 Drum Brake

COMPONENT INDEX 12-02-02 Drum Brakes 12-02-02

1 DESCRIPTION

The drum brake system employs system has been incorporated in all single anchor, internal expanding and models to provide increased safety. PRESSURE DIFFERENTIAL VALVE self adjusting brake assemblies. The system consists of a dual-master The self-adjusting brake mechanism cylinder (Fig. 2). pressure differential A self centering pressure differen- consists of a cable, cable guide, ad- valve assembly and a switch (Fig. 3). tial valve assenibly is used on all ve- justing lever, adjusting screw assem- The switch on the differential valve hicles having power or non-power bly, and adjuster spring (Fig. I). The activates a dual-brake warning light, drum type brakes. cable is hooked over the anchor pin at located on the instrument panel. The valve body is step bored to ac- the top and is connected to the lever commodate a sleeve and seal installed at the bottom. The cable is routed over the piston and into the larger along the webb of the secondary BRAKE BOOSTER SYSTEM valve body bore in the front brake brake shoe by means of the cable system area. The brake warning light guide. The adjuster spring is hooked This diaphragm-type brake booster switch is mounted at the center of the to the primary brake shoe and to the is a self-contained vacuum-hydraulic valve body and the spring loaded lever. The automatic adjuster operates braking unit mounted on the engine switch plunger fits into a tapered only when the brakes are applied side of the dash panel. shoulder groove in the center of the while the vehicle is moving rearward The brake booster is of the vacuum piston. In this position the electrical and only when the secondary shoe is suspended-type which utilizes engine continuity through the switch is inter- free to move toward the drum beyond intake manifold vacuum and armos- rupted and the brake warning lamp a predetermined point. pheric pressure for its power. on the instrument panel is out. (Fig. A vacuum booster is used with the Adjustment of the push rod and re- 3) power drum brake system. placement of the check valve and grommet are the only services permit- DUAL MASTER CYLINDER ted on the brake booster. The booster BRAKE SYSTEM unit is to be exchanged when it is inspected, checked and found to be ino- The dual-master cylinder brake perative.

SHOF GUIDE (ANCHOR PIN) PLATE SHOE WIDE (ANCHOR PIN) PLATE PRIMARY SHOE.TO.ANCHOR

AUJUb I INb AND HOUSING SPRING SCREW

FIG. 7-Self-Adjusting Brake Assemblies 12-02-03 Drum Brakes 1 2-02-03

PRIMARY SYSTEM BRAKE FLUID RESERVOIR

RETURN SPRING (PRIMARY)

ASSEMBLY 9G. 2-Dual Master Cylinder-Typical

BRAKE WARNING LAMPSWITCH FRONT BRAKE I INLET

REAR BRAKE FRONT BRAKE RIGHT FRONT INLET FROM RAKE OUTLET

NORMAL POSITION REAR BRAKES (CENTERED) OUTLET TO (CENTERED) RIGHT FRONT BRAKE LIGHT CAR CUSTOmCAR H1698-8 FIG. 3-Pressure Differential Valve and Brake Warning Light Switch

2 IN-VEHICLE ADJUSTMENTS AND REPAIRS

After any brake service work, have been -relined, replaced, or when obtain a firm brake pedal before BRAKE SHOE ADJUSTMENTS the length of the adjusting screw has moving the vehicle. Riding the brake been changed while performing some pedal (common on left foot applica- The hydraulic drum brakes are other service operation. The manual tion) should be avoided when driving self-adjusting and require a manual adjustment is performed with the the vehicle. adjustment only after the brake shoes drums removed, using the tool and 12-02-04 Drum Brakes

6. Install the wheels on the drums and tighten the nuts to specification. 7. Complete the adjustment by applying the brakes several times with a minimum of 50 Ibs pressure on the pedal while backing the vehicle. After each stop the vehicle must be moved forward. 8. After the brake shoes have been properly adjusted, check the operation of the brakes by making several stops while operating in a forward direc- tion.

WHEEL CYLINDER REPAIR

Wheel cylinders should not be disassembled unless they are leaking or unless new cups and boots are to be installed. It is not necessary to remove the brake cylinder from the backing plate to disassemble, inspect, or hone and overhaul the cylinder. Removal is necessary only when the cylinder is damaged or scored beyond repair.

FIND CORRECT -BRAKE DISASSEMBLY SHOE DIAMETER HERE 1. Remove the links and the rubber boots from the ends of the brake cyl- FIG. 4-Adjusting Brake Shoes Using Tool HRE-8650 inder. Remove the pistons, cups, and return spring from the cylinder bore (Fig. 5). 2. Remove the bleeder screw from BOOT CUP the cylinder. 1 1 CUP INSPECTION

1. Wash all parts in clean brake fluid. Dry with compressed air. 2. Replace scored pistons. Always PISYON I replace the rubber cups and dust CYLINDER boots. 3. Inspect the cylinder bore for H1385-B score marks or rust. If either condition is present the cylinder bore must FIG. 5-Brake Wheel ~~linder-~~~ical be honed. However, the cylinder should not be honed more than 0.003 the procedure detailed below. slots. Make sure the adjusting screw inch beyond its original diameter. When adjusting the rear brake rotates freely. If necessary, lubricate 4. Check the bleeder hole to be shoes, check the parking brake cables the adjusting screw threads with a sure that it is open. for proper adjustment. Make sure thin, uniform coating of CIAZ that the equalizer operates freely. 19590-B Moly Dysulfide. ASSEMBLY To adjust the brake shoes: 3. Rotate Tool HRE 8650 around 1. Use Rotunda Tool HRE 8650, the brake shoes to be sure of the set- 1. Apply a light coating of heavy- (Fig. 4) to determine the inside diam- ting. duty brake fluid to all internal parts. eter of the drum braking surface. 4. Apply a small quantity of high 2. Thread the bleeder screw into 2. Reverse the tool as shown in temperature grease to the points the cylinder and tighten securely. Fig. 4 and adjust the brake shoe di- where the shoes contact the backing 3. Insert the return spring, cups, ameter to fit the gauge. Hold the au- plate, being careful not to get the lu- and pistons into their respective posi- tomatic adjusting lever out of en- bricant on the linings. tions in the cylinder bore (Fig. 12). gagement while rotating the adjusting 5. Install the drums. Install Tinner- Place a boot over each end of the cyl- screw, to prevent burring the screw man nuts and tighten securely. inder. Bleed the brake system. 12-02-05 Drum Brakes - 12-02-05

3 REMOVAL AND INSTALLATION

FRONT BRAKE DRUM is clear of the floor. RUBBER PLUG 2. Remove the hub cap and wheel. REMOVAL Remove the three Tinnerman nuts and remove the brake drum. If the 1. Raise the vehicle until the wheel drum will not come off, pry the rub- and tire clear the floor. Remove the ber cover from the backing plate. In- wheel cover or hub cap, and remove sert a narrow screwdriver through the the wheel and tire from the drum. hole in the backing plate, and disen- 2. Remove the grease cap from the gage the adjusting lever from the ad- hub. Remove the cotter pin, nut lock, justing screw. While holding the ad- adjusting nut, and flat washer from justing lever away from the adjusting the spindle. Remove the outerbearing screw, back off the adjusting screw cone and roller assembly. with the brake adjusting tool (Fig. 6). 3. Pull the drum off the wheel Be very careful not to burr, chip, or OVE HANDLE UPWARD spindle. damage the notches in the adjusting RETRACT BRAKESHOES 4. If the drum will not come off, screw; otherwise, the self-adj,usting pry the rubber cover from the brake mechanism will not function properly. backing plate. Insert a narrow screw; driver through the slot and disengage INSTALLATION ' / H1590-A the adjusting lever from the adjusting FIG. 6-Backing Off Brake screw. While holding the adjusting 1. Remove the protective coating Adiustment lever away from the screw, back, off from a new drum with carburetor de- the adjusting screw with the brake ad- greaser; then sand lightly and wipe justing tool (Fig. 6). Be very careful with a cloth soaked with denatured not to burr, chip, or damage the alcohol. notchesin the adjusting screw; other- 2. Adjust the brakes as outlined wise the self-adjusting mechanism will under Brake Shoe Adjustments in this not function properly. section. Place the drum over the H1590-A 2 1116~2 112 brake assembly and into position. 3. Install the three Tinnerman nuts INSTALLATION and tighten securely. Install the wheel on the axle shaft flange studs against 1. If the drum is being replaced, the drum, and tighten the attaching remove the protective coating from nuts to specifications. the new drum with carburetor degreaser. Then, use sandpaper to in- BRAKE SHOESAND ADJUSTING sure that no residue remains. Wipe SCREW the drum with a cloth coaked with FIG. 7-Retracting Spring denatured alcohol. Install new bear- REMOVAL Removal ings and grease seal. Pack the wheel bearings, install the inner bearing 1. With the wheel and drum re- 6. After removing the rear brake cone and roller assembly in the inner moved install a clamp over the ends secondary shoe, disassemble the park- cup, and install the new grease seal of the brake cylinder as shown in Fig. ing brake lever from the shoe by re- see Part 11-02. 7. moving the retaining clip and spring If the original drum is being in- 2. Remove the secondary shoe to washer (Fig. I). stalled, make sure that the grease in anchor spring with the tool shown in the hub is clean and adequate. Fig. 7. With the same tool remove the 2. Adjust the brakes and install the primary shoe to anchor spring and drum assembly as outlined under unhook the cable eye from the anchor 1. Before installing the rear brake Brake Shoe Adjustments in this sec- pin. shoes, assemble the parking brake tion. 3. On Ford, Mercury, Meteor. lever to the secondary shoe and secure 3. Install the outer wheel bearing, Thunderbird, Continental Mark I11 with the spring washer and retaining washer and adjusting nut. and Lincoln Continental models, re- clip. 4. Adjust the wheel bearing as out- move the shoe . guide (anchor pin) 2. Apply a light coating of high- lined in Part 11-02, then install the plate (Fig. I). temperature grease at the points grease cap. Install the wheel and hub 4. Remove the shoe hold-down where the brake shoes contact the cap. springs, shoes, adjusting screw, pivot backing plate. nut, socket and automatic adjustment 3. Position the brake shoes on the REAR BRAKE DRUM parts. backing plate and secure the assembly 5. On rear brakes, remove the with the hold down springs. On the REMOVAL parking brake link and spring. Dis- rear brake, install the parking brake connect the parking brake cable from link and spring, back off the parking 1. Raise the vehicle so that the tire the parking brake lever. brake adjustment then connect the Drum Brakes

parking brake cable to the parking off t 2 turn. To determine the cause of this con- brake lever (Fig. 1). InI erchanging the brake sboe addition: 4. Install the shoe guide (anchor justing screw assemblies from one a. check the cable end fittings. pin) plate on the anchar pin when so side of the vehicle to the other would The cable should completely fill or equipped. cause the brake shoes to retract ratH- extend slightly beyond the crimped 5. Place the cable eye over the an- er than ekpPnd each time the auto- section of the fittings. If it does not chor pin with the crimped side toward matic adjusting mechanism operated. meet this specification, possible dam- the backing plate. To prevent installation on the wrong age is indicated and the cable assem- 6. Install the primary shoe to an- side of the vehicle, the socket end of bly should be replaced. chor spring (Fig. 8). the adjusting screw is stamped with b. Check the cable length. On 7. Install the cable guide on the an R or L (Fig. 9). The adjusting Ford, Mercury, Meteor, Thunderbird, secondary shoe web with the flanged pivot nuts can be distinguished by thC Continental Mark 111, and Lincoln hole fitted into the hole in the second- number of grooves machined around Continental models, the cable should ary shoe web. Thread the cable the body of the nut. Two grooves on measure 11 t/8 inches (plus or minus around the cable guide groove (Fig. the nut indicate a right thread; one f/64 inch) from the end of the cable 1). groove indicates a left thread. anchor to the end of the cable hook. It is imperative that the cable be 10. Place the adjusting socket ofi On Fairlane, Montego, Falcod, positioned in this groove and not be- the screw and install this assembly Mustaw, and Cougar models the tween the guide and the shoe .web. between the shoe ends with the ad- cable should measure 8 13/32 inches 8. Install the secondary shoe to an- justing screw toothed wheel nearest on 9 inch brakes or 9 314 inches on chor spring with the tool shown in the secondary shoe. 10 inch brakes from the end of the Fig. 8. 11. Hook the cable hook into the cable anchor to the end of the cable Be certain that the cable eye is not hole in the adjusting lever. The ad- hook. cocked or binding on the anchor pin justing levers are stamped with an R C. Check the cable guide for dam- when installed. All parts should be or L to indicate their installation on age. The cable groove should be par- flat on the anchor pin. Remove the right or left brake assembly (Fig. 9), allel to the shoe web, and the body of brake cylinder clamp. 12. Position the hooked end of the the guide should lie flat against the 9. Apply high-temperature grease adjuster spring completely ,into the web. Replace the guide if it shows CIA2 19590-B Moly Dysulfide to the large hole in the primary shoe web. damage. threads and the socket end of the ad- The last coil of the spring should be d. Check the pivot hook on the justing screw. Turn the adjusting at the edge of the hole. Connect the lever. The hook surfaces should be screw into the adjusting pivot nut to loop end of the spring to the adjuster square with the body of the lever for the limit of the threads and then back proper pivoting. Replace the lever if lever13. h"$Pu the adjuster lever, cable the hook shows damage. and automatic adjuster spring down e. See that the adjusting screw and toward the rear to engage the socket is properly seated in the notch pivot hook in the large hole in the in the shoe web. secondary shoe web (Fig. 1). 14. After installation, check the ac- WHEEL CYLINDER 'tion of the adjuster by pulling the section of the cable between the cable REMOVAL guide and the anchor pin toward the secondary shoe web far enough to lift 1. Remove the wheel and the the lever past a tooth on the adjusting drtim. screw wheel. The lever should snap 2. Remove the brake shoe assem- into position behind the next tooth, blies, following procedures outlined in and release of the cable should cause this section. FIG. 8-Retracting Spring the adjuster spring to return the lever 3. Disconnect the brake line from Installation to its original position. This return the brake cylinder. On a vehicle with action of the lever will turn the ad- a vacuum brake booster, be sure the justing screw one tooth. engine is stopped and there is no vac- If pulling the cable does not pro- uum in the booster system before dis- duce the action described, or if the connecting the, hydraulic lines. lever action is sluggish instead of pos- To disconnect the hose at a front itive and sharp, check the position of cylinder, loosen the tube fitting that the lever on the adjusting screw connects the opposite end of the hose toothed wheel. With the brake in a to the brake tube at a bracket on the vertical position (anchor at the top), frame. Remove the horseshoe-type re- the lever should contact the adjusting taining clip from the hose and brack- wheel 3/16 inch (plus or minus 1/32 et, disengage the hose from the ADJUSTING SCREW inch) above the centerline of the bracket, then unscrew the entire hose IDENTlFlCATlON LINES screw. If the contact point is below assembly from the front wheel cylin- HllU-C this centerline, the lever will not lock der. on the teeth in the adjusting screw At a rear cylinder, unscrew the FIG. 9-Ad'usting Serew and wheel, and the screw will not be tube fitting that connects the tube to Lever ldenti 1ication turned as the lever is actuated by the the cylinder. Do not pull the metal cable. tube away from the cylinder. Pulling Drum Brakes 1 2-02-07

the tube out of the cylinder connec- BRAKE BACKING PLATE is to be replaced, position a new front tion will bend the metal tube and backing plate and gasket to the wheel make installation difficult. The tube REMOVAL spindle and install the attaching bolts will separate from the cylinder when and nuts. the cylinder is removed from the I. Remove the wheel and brake 2. Install the wheel cylinder and backing plate. drum. Disconnect the brake line from connect the brake line as outlined in 4. On all except the front wheels the brake Fylinder. this section. on Ford, Mercury, and Meteor mod- 2. Remove the brake shoe and 3. Install the brake shoe and ad- els, remove the wheel cylinder attach- adjuster assemblies and the wheel cyl- juster assemblies as outlined in this ing bolts and lock washers and re- inder as outlined in this section. On section. On a rear brake, connect the move the cylinder. On the front wheel the rear wheels, disconnect the park- parking brake cable to the lever. of Ford, Mercury and Meteor mod- ing brake lever from the cable. 4. Adjust the brake shoes as out- els, remove the nut and washer that 3. If the rear backing plate is being lined in this section, and install the attaches the cylinder to the anchor replaced, remove the axle shaft from brake drums and wheels. Bleed the pin. Remove the cylinder from the the applicable rear axle as outlined in brake system and centralize the dif- ' anchor pin. Group 15, Part 2 or 3, Rear, Axle, ferential valve as outlined in Part 12- Section 2, disengage parking brake 0 1. 1NSTALLATION cable retainer from backing plate. Remove the backing plate and gasket. DUAL MASTER CYLINDER- Wipe the end(s) of the hydraulic If the front backing plate is being NON POWER BRAKES line to remove any foreign matter bef- replaced, remove the bolts and nuts ore making connections. that secure the backing plate to the FORD, MERCURY 1. On all models except Ford, front wheel spindle and remove the AND METEOR Mercury and Meteor, to install a plate and gasket. front wheel cylinder, position the cyl- Removal inder to the backing plate. Install the two lock washers and attaching bolts. Refer to Fig. 10. Torque them to specifications. If a rear backing plate,is to be re- I. Disconnect -the stoplight switch On Ford, Mercury and Meteor placed, position a new rear backing wires at the connector. Remove the models, to install a front -wheel cylin- plate and gasket on the attaching spring retainer. Slide the stop light der, position the cylinder on the an- bolts in the axle housing flange. In- switch off the brake pedal pin just far chor pin against the backing plate. sert parking brake cable into backing enough to clear the end of the pin, Install the washer and cylinder at- plate and secure retaining fingers. In- then lift the switch straight upward taching nut on the anchor pin, and stall the rear axle shaft tor applicable from the pin. Use care to avoid torque it to specification. Lock the rear axle. Refer to Group 15 Part 2 switch damage during removal. washer retainer securely. or' 3 Rear Axle, Section 2 for the 2. Slide the master cylinder push 2. Install a new copper gasket over proper installation procedure. rod and the nylon washers and bush- the hose fitting. Thread the hose into 1. If the front brake backing plate ings off the brake pedal pin. the cylinder and tighten it to specified torque. BUSHING 3. 'Engage the opposite end of the hose to the bracket on the frame. In- stall the horseshoe-type retaining clip, and connect the brake tube to the hose with the tube fitting nut. Tighten the nut to specification with tool 11 12-144. 4. To install a rear wheel cylinder, place the rear wheel cylinder into position. Enter the tubing into the cylinder, and start the tube fitting nut into the threads of the cylinder. 5. Secure the cylinder to the backing plate by installing the attaching bolts and lock washers. 6. Tighten the tube fitting nut to specification with tool 11 12-144. 7. Install the links in the ends of the wheel cylinder, install the shoes and adjuster assemblies, and adjust the shoes as outlined in this section. 8. Adjust the brakes as described in this part. Install the brake drum and wheel. Bleed the brakes and cen- STOPLIGHT SWITCH tralize the differential valve as out- 13480 H1637-A lined in Part 12-01. FIG. 10-Dual Master cyIinde; Installation-Non Power Brbkes-Ford, Mercury, and Meteor 12-02-08 Drum Brakes 12-02-08

Installation

1. Position the boot on the push rod and secure the boot to the master UPPER STUD SHAFT (AUTWTIC 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 them in position with the spring retainer. 5. Connect the wires at the stop light switch connector. STOP LITE BRA;(€PEDAL 6. Connect the brake lines to the BUSHING SWITCH master cylinder leaving the brake line 13180 LOWER STUD 'I MASTER CYLINDER fittings loose. PUSH ROD 7. Fill the master cylinder with the specified brake fluid to within k/4 inch of the top of the dual reservoirs. FIG. 7 1-Dual Master Cylinder Installation-Non Power Use Ford Brake Fluid-Extra Heavy BrakeiFairlane, Montego, and Falcon Duty-Part Number C6AZ- 19542-A (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 the specified fluid for the power disc brake system. 8. Bleed the dual-master cylinder and the primary and secondary brake systems. Centralize the pressure differential valve. Refer to Hydraulic System Bleeding and Centralizing of the Differential Valve, Part 12-01, for proper procedure. 9. Operate the brakes several CLUTCH times, then check for external hydraulic leaks. FAIRLANE, MONTEGO, MAVERICK, FALCON, MUSTANG.AND COUGAR

Removal

Refer to Figs. I l land 12. 1. Working from inside the vehicle AUTOMATIC TRANSMISSION below the instrument panel, discon- 2140 nect the master cylinder push rod STOP LIGHT CLUTCHPEDAL SWITCH 13480 BUMPER STOP H163BA from the brake pedal assembly. The push rod cannot be removed from the FIG. 12-Dual Master cylinder Installation-Non Power master cylinder. Brake-Mustang and Cougar 2. Disconnect the stoplight switch wires at the connector. Remove the 3. Remove the brake tube from the lockwashers that secure the master hairpin retainer. Slide the stop light primary and secondary outlet ports of cylinder to the dash panel and lift the switch off the brake pedal pin just far the master cylinder. cylinder forward and upward from enough to clear the end of the pin, 4. Remove the cap screws and the vehicle. then lift the switch straight upward. Drum Brakes 12-02-09

from the pin. Use care to avoid DUAL MASTER CYLINDER- lock washers and torque them to switch damage during removal. POWER BRAKES specifications. 3. Slide the master cylinder push 4. Install the front and rear brake rod and the nylon washers and bush- REMOVAL tubes to the master cylinder outlet fit; ings off the brake pedal pin. tings. 4. Remove the brake tubes from 1. Remove the brake tubes from 5. Fill the master'cylinder with the the primary and secondary outlet the primary and secondary outlet specified brake fluid to, within 1/4 ports of the master cylinder. ports of the master cylinder (Figs. 13 inch of the top of the dual reservoirs. 5. Remove the lock nuts or cap thiu 15). Use Ford Brake Fluid-Extra Heavy screw and lockwashers that secure the 2. Remove the two nuts and two Duty-Part Number C6AZ-19542-A master cylinder to the dash panel and lock washers attaching the master (ESA-M6C25-A) for all brake appli- lift the cylinder forward and upward cylinder to the brake booster assem- cations. The extra heavy duty brake from the car. bly. fluid is coloredblue for identification. 3. Slide the master cylinder for- Do not mix low temperature brake Installation ward and upward from the vehicle. fluids with the specified fluids for the disc brake, system. Refer to Figs. l 1 and 12. INSTALLATION 6. Bleed the dual-master cylinder 1. Position the boot on the push and the primary and secondary brake rod and secure the boot to the master 1. Before installing the master systems. Centralize the pressure dif- cylinder. Carefully insert the master cylinder, check the distance from the ferential valve. Refer to Hydraulic cylinder push rod and boot through outer end of the booster assembly System Bleeding and Centralizing of the dash panel opening. push rod to the master cylinder the rdfferential Valve, Part 12-01, for 2. On Fairlane, Falcon or Montego mounting surface. Turn the push rod the proper procedure. models, position the gasket and adjusting screw in or out as required 7. Operate the brakes several master cylinder on the mounting to obtain the specified length. Refer times, then check for external hydrau- studs on the dash panel. Install the to Part 12-01. Power Brake Master lic leaks. lock nuts on the studs at the dash Cylinder Push Rod Adjustment for panel and torque them to specifica- the proper procedure. PRESSURE DIFFERENTIAL VALVE tion. 2. Position the master cylinder ASSEMBLY 3. On Mustang or Cougar models, assembly over the booster push rod position the gasket and master cylin- and onto the two studs on the booster REMOVAL der on the dash panel. Install the re- assembly (Figs. 13 thru 15). taining screws and torque them to 3. Install the attaching nuts and The pressure differential ' valve specification. 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 them in position with the spring retainer. W.10 AIR CONDITIONING 5. Connect the wires at the stop I BUSHING light switch connector. 6. Connect the brake lines to the VbCUUM BOOSTER master cylinder and tighten to specified torque. 7. Fill the master cylinder with the specified brake fluid to within t/4 inch of the top of the dual reservoirs. MASTER CYLINDER 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 differential valve. Refer to Hydraulic STOP LIGHT \ System Bleeding and Centralizing of SWITCH 13480 SPACER the Differential Valve, Part 2-1, Sec- tion 2 for the proper procedure. 9. Operate the brakes several times, then check for external hydrau- H 1642A lic leaks. FIG. 13-Master Cylinder Installation-Power Brake-Ford, Mercury and Meteor 1 2-02- 10 Drum Brakes

BRAKE VACUUM BOOSTER -2005 1 sembly (Fig. 3). 3. Remove the two attaching nuts and bolts from the valve bracket on the underside of the fender apron and remove the valve assembly and bracket from the vehicle.

INSTALLATION

I. Position the valve assembly and bracket to the fender apron. Install the attaching nuts and bolts: torque them to specifications. 2. Install the front inlet and rear outlet tubes to the valve assembly. Torque them to specifications. 3. Connect the brake warning light connector to the warning light switch. 4. Bleed the system and centralize the pressure differential valve following the procedures in Centralizing the Pressure Differential Valve. BRAKE BOOSTER . REMOVAL

H 1557-C 1. Working from inside the vehicle below the instrument panel, discon- NG. 14-Master Cylinder Installation-Power Brake-Fairlane, nect the booster push rod from the Montego and Falcon brake pedal assembly. To do this, proceed as follows: Disconnect the stop light switch wires at the connector. Remove the hairpin retainer. Slide the stop light ASSIST switch off from the brake pedal pin SPRING BRACKET CLUTCH ASSIST just far enough for the switch outer 1 SPRING hole to clear the pin, and then remove BUSHING / BRA,KJnLFDAL --.* - I - -- \ the switch, from the pin and booster push rod. Be careful not to damage the switch during removal. Slide the CLUTCH booster push rod and the nylon wash- PEDAL ers and bushing off the brake pedal pin (Figs 13 thru 15). VACUUM 2. Open the hood and remove the HOSE master cylinder from the booster. Se- cure it to one side without disturbing the hydraulic lines. It is not necessary to disconnect the brake lines, but care should be taken that the brake lines HAIRPIN / are not deformed. Permanent defor- BUSHING I mation of brake lines can lead to tube UG STOPLIGHT CLUTCH PEDAL failure. SWITCH 17460 TO EQUALIZER ROD 3. Disconnect the manifold vacuum I BOOSTER I 2005 hose or hoses from the booster unit. MASTER CYLINDER 4. Remove the booster-to-dash 2140 panel attaching nuts or bolts (Figs. 13 thru 15). Remove the booster and FIG. 15-Master Cylinder Installation-Power Brake-Mustang and bracket assembly from the dash Cougar panel, sliding the push rod link out from the engine side of the dash assembly is serviced as an assembly light connector from the warning light panel. only. Do not attempt to repair this switch. 5. On Fairlane, Montego, and Fal- unit. 2. Disconnect the front inlet and con models, remove the push rod link 1. Disconnect the brake warning rear outlet tubes from the valve as- boot from the dash panel. Drum Brakes

INSTALLATION 3. Remove the hairpin-type retain- pedal assembly, and the bushings - er and washer from the brake pedal from the pedal support bracket (Figs. 1. On Fairlane, Montego and Fal- shaft, then remove the shaft, the I l and 14). con models, install the push rod link brake pedal and the bushings from boot in the hole in the dash panel as the pedal support bracket. shown in Fig. 14. Install the four Installation spacers on the mounting studs. Installation 2. Mount the booster and bracket I. Apply a co.ating of SAE 10 assembly to the dash panel by insert- I. Apply a coating of SAE 10 engine oil to the bushings and locate ing the push rod or push rod link in Engine oil to the bushings and locate all bushings in their proper places on through the hole and boot in the dash bushings in their proper places on the the clutch and brake pedal assem- panel. Install the bracket-to-dash pedal assembly and pedal support blies. panel attaching lock nuts or bolts bracket (Figs. 10 and 15). '2. Position the brake pedal to the (Figs. 13 thru 15). 2. Position the brake pedal assem- support bracket, then install the 3. Connect the manifold vacuum bly to the support bracket, then in- clutch pedal and shaft assembly hose or hoses to the booster. - stall the pedal shaft through' the sup- through the support bracket and 4. Before installing the master pori bracket and brake pedal assem- brake pedal assembly. Install the cylinder, check the dist~ncefrom the bly. Install the retainer. spring clip (Figs. I I and 14). outer end of the booster assembly 3. Install the inner nylon washer, 3. Install the clutch pedal assist push rod to master cylinder surface. the master cylinder or booster push spring. Turn the screw in or out to obtain the rod, and the bushing on the brake 4. Connect the clutch pedal- specified length. Refer to Part 12-01, pedal pin. Position the switch so that to-equalizer rod to the clutch pedal Power Brake Master Cylinder Push it straddles the push rod with the assembly with the bushing and the Rod Adjustment. Install the master switch slot on the pedal pin and the spring clip retainer. Apply SAE 10 cylinder and torque the attaching nuts switch outer hole just clearing the pin. engine oil to the bushing. to specifications. Slide the switch completely onto the 5. Install the inner nylon washer, 5. Working from inside the vehicle pin, and install the nylon washer as the master cylinder or booster push befow the instrument panel, connect shown in Figs. 10 and 13. Be careful rod, and the bushing on the brake the booster push rod link to the brake not to bend or deform the switch. Se- pedal pin. Position the switch so that pedal assembly. To do this, proceed cure these parts to the pin with the it straddles the push rod with the as follows: hairpin retainer. switch slot on the pedal pin and the Install the inner nylon washer, the 4. Connect the stop light, switch switch outer hole just clearing the pin. booster push rod, and the bushing on wires to the connector, and install the Slide the switch completely onto the the brake pedal pin. Position the wires in the retaining clip. pin, and install the outer nylon wash- switch so that it straddles the push 5. Check the Brake Pedal Free er as shown in Figs. I I and 14. Se- - rod with the switch slot on the pedal Height and Travel Measurements, cure these parts to the pin with the pin and the switch outer hole just Part 12-01. self-locking pin. clearing the pin. Slide the switch 6. Connect the stop light switch , completely onto the pin, and install wires to the connector, and install the the nylon washer as shown in Figs. 13 FA[ RLANE, MONTECO, wires to the retaining clip. thru 15. Be careful not to bend or de- MAVERICK AND 7. Adjust the clutch pedal free play form the switch. Secure these parts to FALCON-MAN UAL-SHIFT (Group 16-02) to specification, if re- the pin with the hairpin retainer. TRANSMISSION quired. Connect the stop light switch wires to 8. Check the Brake Pedal Free the connector, and install the wires in Removal Height and Travel Measurements the retaining clip. (Part 12-01, Section I). 1. Remove the clutch pedal assist BRAKE PEDAL spring. 2. Disconnect the clutch pedal- MUSTANG AND COUCAR- FORD, MERCURY to-equalizer rod at the clutch pedal by MANUAL-SHIFT AND METEOR removing the retainer and bushing. TRANSMISSION 3. Disconnect the stop light switch Removal wires at the connector. Removal 4. Remove the switch retainer, and I. Disconnect the stop light switch slide the stop light switch off the I. Disconnect the battery ground wires at the connector. brake pedal pin just far enough for cable from the battery. 2. Remove the hairpin retainer. the switch outer hole to clear the pin. 2. Remove the steering column. Slide the stop light switch off the Then lower the switch away from the Refer to Part 13-02 for procedure. brake pedal pin just far enough for pin. . 3. On non-power brakes, remove the switch outer hole to clear the pin, 5. Slide the master cylinder or the two cap screws retaining the mas- and then lift the switch straight up- booster push rod and the nylon wash- ter cylinder to the dash panel and ward from the pin. Be careful not to ers and bushing off from the brake remove the two cap screws retaining damage the switch during removal. pedal pin (Figs. I l and 14). the brake pedal support bracket to Slide the master cylinder or booster 6. Remove the self-locking ,pin and the, dash panel. On power brakes re- push rod and the nylon washers and washer from the clutch and brake move the two cap screws retaining the bushing off the brake pedal pin (Figs. pedal shaft, then remove the clutch booster to the dash panel. 10 and 15). pedal and shaft assembly, the brake 4. Working inside the vehicle, se- Drum Brakes

cure the clutch pedal against the bly. On power brakes position the FAIRLANE, MONTEGO, bumper stop with a small C-clamp as brake pedal to the pedal support FALCON, MAVERICK, shown in Figs. 12 and IS. bracket, then install the pedal shaft MUSTANG AND 5. D sconnect the clutch peda! and nut. COUGAR-AUTOMATIC to-equalizer rod at the clutch pedal by 3. Install the clutch pedal assist TRANSMISSION removing the retainer and bushing. spring and pivot the clutch pedal 6. Disconnect the stop light switch against its bumper stop. Secure the Removal wires at the connector. pedal to the stop with a small C- 7. Remove the switch retainer and clamp as shown in Figs. 12 and 15. 1. Disconnect the stop light switch slide the stop light switch off the 4. Position the pedal support wires at the connector. brake pedal pin just far enough for bracket assembly to 'the dash panel, 2. Remove the self-locking pin and the switch outer hole to clear the pin. and to the steering column retainer slide the stop light switch off the Then lower the switch away from the studs. brake pedal pin just far enough for I pin. Remove the master cylinder or 5. Align the pedal support bracket the switch outer hole to clear the pin. booster push rod, bushing and nylon holes with the holes in the dash panel Then lower the switch away from the washer from the brake pedal pin. and install the two attaching sheet pin. Slide the master cylinder or 8. Remove the screw retaining the metal screws. On power brakes install booster push rod and the nylon wash- pedal support bracket to the top inner the nuts on the brake booster studs. ers and bushing off from the brake cowl bracket (Figs. I2 and 15). 6. Install the two cap screws at- pedal pin (Figs. 1 1, 12, 14 and 15). 9. Remove the two sheet metal taching the pedal support bracket to 3. On all vehicles except Mustang screws retaining the pedal support the upper cowl bracket. and Cougar with power brakes, re- bracket to the dash panel. On power 7. Install the cap screw attaching move the self-locking pin and washer brakes remove the nuts from the the pedal support bracket to the top from the brake pedal shaft, then re- brake booster studs. inner cowl bracket (Figs. 12 and 15). move the shaft, the brake pedal 10. Remove the two screws retain- 8. Install the inner nylon washer, assembly and the bushings from the ing the pedal support bracket to the the master cylinder push rod, and the pedal support bracket. On Mustang upper cowl brace and lower the pedal bushing on the brake pedal pin. Posi- and Cougar vehicles with power support bracket away from the steer- tion the stop light switch so that it brakes, remove the locknut and bolt ing column studs. straddles the push rod with the switch from the pedal. Remove the pedal as- 11. Remove the pedal support slot on the pedal pin and the switch sembly from the support bracket (Fig. bracket assembly from the vehicle. outer hole just clearing the pin. Slide 15). 12. Position the pedal and support the switch completely onto the pin, bracket assembly in a vise. and install the outer nylon washer as Installation 13. Remove the C-clamp to release shown in Figs. 12 and 15. Secure the clutch pedal from its bumper stop these parts to the pin with the self- 1. Apply a coating of SAE 10 and pivot the pedal away from the locking retainer. engine oil to the bushings and locate bumper. 9. Connect the stop light switch all the bushings in their proper places 14. Remove the clutch pedal assist wires to the connector. on the pedal assembly and pedal sup- spring. 10. Connect the clutch pedal- port bracket (Figs. 11, 12, 14 and 15). 15. On non-power brakes, remove to-equalizer rod to the clutch pedal 2. Position the brake pedal assem- the retainer clip from the clutch and assembly with the bushing and the bly to the support bracket, then in- brake pedal shaft, then remove the spring clip retainer. Apply SAE 10 stall the pedal shaft or bolt through clutch pedal and shaft assembly,; the engine oil to the bushing. Remove the the support bracket and brake pedal brake pedal assembly, and the bush- C-clamp from the clutch pedal. assembly. Install the retainer or lock- ings from the pedal support bracket. 11. Working from the engine side nut. On power brakes, remove the retainer of the dash panel, on non-power 3. Install the inner nylon washer, nut from the brake pedal shaft then brakes, install the two cap screws at- the master cylinder or booster push remove the pedal shaft, the brake taching the pedal support bracket to rod, and the bushing on the brake pedal assembly and the bushings from the dash panel. Then install the two pedal pin. Position the switch so that the pedal support bracket. screws attaching the master cylinder it straddles the push rod with the to the dash panel. On power brakes switch slot on the pedal pin, and the install the cap screws retaining the switch outer hole just clearing the pin. Installation brake booster to the dash panel. Slide the switch completely onto the 12. Install the steering column. pin, and install the outer nylon wash- 1. Apply a coating of SAE 10 Refer to Part 13-02 for procedure. er as shown in Figs. 11, 12, 14 and engine oil to the bushings and locate 13. Adjust the clutch pedal free IS. Secure these parts to the pin with all bushings in their proper places on play (Group 16-02) to specification, if the self-locking pin. the clutch and brake pedal assem- required. 4. Connect the stop light switch blies. 14. Check the Brake Pedal Free wires to the connector, and install the 2. On non-power brakes, position Height and Travel Measurements wires in-the retaining clip. the brake pedal to the pedal support Part 12-01. Check the Brake Pedal Free Height bracket, then install the clutch pedal 15. Connect the ground cable to and Travel Measurements, Part 12- and shaft assembly through the sup- the battery. 01. port bracket and brake pedal assem- , 1 2-02- 1 3 Drum Brakes . 1 2-02- 1 3

4 MAJOR REPAIR OPERATIONS

BRAKE DRUM REFINISHING RETAINER - 28245 Minor scores on a brake drum can be removed with sandpaper. A drum that is excessively scored or shows a total indicator runout of over 0.007 inch should be turned down. Remove GASKET - 2167 SECONDARY SYSTEM MASTER CYLINDER - 2155 only enough stock to eliminate the BRAKE OUTLET scores and true up the drum. The re- SNAP RING - 7821 finished diameter must not exceed

0.060 inch oversize. PUSH ROD Check the inside diameter of the brake drum with a brake drum mi-

crometer (Tool FRE- 143 l). RETAINER If the drum diameter is less than 0.030 inch oversize after refinishing, standard lining may be installed. If the drum diameter is 0.030-0.060 inch oversize after refinishing, oversize lining must be installed. After a drum is turned down, wipe the refinished surface with a cloth soaked in clean denatured alcohol. If * SECONDARY PISTON ASSEMRLY - 2A502 one drum is turned down, the opposite drum on the same axle should t TUBE SEAT - also be cut down to the same size. 28220 NOT USED ON POWER BRAKE EWlPPED VEHICLES tNOT SERVICED BRAKE SHOE RELINING *REPLACE AS AN ASSEMBLY ONLY

Brake linings that are worn to within 1./32 inch of the rivet head or are less than 0.030 inch thick (bonded FIG. 16-Dual Master Cylinder Disassembled lining) or have been contaminated S.rop Ring Pliers with brake fluid, grease or oil must shoe ,and lining. The lining must seat be replaced. Failure to replace worn tightly against 'the shoe with not more / linings will result in a scored drum. than -0.608 inch clearance between When it is necessary to replace lin- any two rivets. ings, they must also be replaced on the wheel on the opposite side of the DUAL MASTER CYLINDER vehicle. Inspect brake shoes for distortion, When a repair is necessary on the cracks, or looseness. .If this condition master cylinder, it is required practice exists, the shoe must be discarded. DO during the warranty period to replace not attempt to repair a defective brake shoe. the cylinder as a unit instead of over- 1. Wash the brake shoes thorough- hauling the cylinder with a service re- ly in a clean solvent. Remove all pair kit. burrs or rough spots from the shoes. 2. Check the inside diameter of the DISASSEMBLY brake drum with a brake drum micrometer (tool FRE-1431). If the 1. Clean the outside of the master diameter is less than 0.030 inches cylinder and remove the filler cover oversize, standard lining may be in- and diaphragm. Pour out any brake FIG. 17-Removing Snap stalled. If the diameter is fluid that remains in the cylinder. Ring-Typical 0.030-0.060 inches oversize, oversize Discard the old brake fluid. lining should be installed. 2. Remove the secondary piston cylinder bore (Fig. 17). Remove the 3. Position the new lining on the stop bolt from the bottom of the cyl- push rod and the primary piston as- shoe. Starting in the center, insert inder (Fig. 16). sembly from the master cylinder bore. and secure the rivets, working alter- 3. Remove the bleed screw, if re- Do not remove the screw that retains nately towards each end. Replace- quired. the primary return spring retainer, re- ment linings are ground and no fur- 4. Depress the primary piston and turn spring, primary cup and protec- ther grinding is required. remove the snap ring from the retain- tor on the primary piston. This as- 4. Check the clearance between the ing groove at the rear of the master semhly is factory pre-adjusted and Drum Brakes

should not be disassembled. for signs of etching, pitting, scoring equipped. Install the push rod assem- 5. Remove the secondary piston or rust. If it is necessary to hone the bly into the primary piston. Make assembly. DO not remove the outlet master cylinder bore to repair dam- sure the retainer is properly seated tube seats, outlet check valves and age, do not exceed allowable hone and holding the push rod securely. outlet check valve springs from the specifications. 6. Position the inner end of the master cylinder body. push rod boot (if so equipped) in the ASSEMBLY master cylinder body retaining INSPECTION AND REPAIR groove. 1. Dip all parts except the master 7. Install the secondary piston stop 1. Clean all parts in clean isopro- cylinder body in clean Rotunda Extra bolt and O-ring in the bottom of the pyl alcohol, and inspect the parts for Heavy Duty Brake Fluid. master cylinder. chipping, excessive wear or damage. 2. Carefully insert the complete 8. Install the bleed screw (if so When using a master cylinder repair secondary piston and return spring equipped). Install the gasket (dia- kit, install all the parts supplied. assembly in the master cylinder bore. phragm) in the master cylinder filler 2. Check all recesses, openings and 3. Install the primary piston as- cover. Position the gasket as shown in internal passages to be sure they are sembly in the master cylinder bore. Fig. 16. Make sure the gasket is se- open and free of foreign matter. Use 4. Depress the primary piston and curely seated. an air hose to blow out dirt and install the snap ring in the cylinder 9. Install the cover and gasket on cleaning solvent. Place all parts on a bore groove. the master cylinder and secure the clean pan or paper. 5. Install the push rod, boot and cover into position with the retainer. 3. Inspect the master cylinder bore retainer on the push rod, if so 12-02- 15 Drum Brakes 12-02- 15

5 SPECIFICATIONS

LINING DIMENSIONS -DRUM BRAKES -INCHES

1 Vehicle...... I Position I Front Rear FORD, MERCURY, METEOR Ford, Meteor Passenger (Riveted Primary 2.50 x 9.34 2.25 x 9.34 Lining) Except 390, 429 ClD Galaxie 500XL, Ford LTD, LeMoyne. . Secondary 2.50 x 12.12 2.25 x 12.12 Ford, Mercury, Meteor with Disc Primary N/A 2,25 x 9.34 Brakes. Secondary N/A 2.25 x 12.12 Mercury Passenger, Sta. Wag. andp Conv. Ford Meteor Station Wagon Primary 3.00 x 9.34 2.25 x 9.34 and Convertible. 390, 429 ClD Galaxie 500 XL, Ford LTD, LeMoyne. Secondarv 3.00 x 12.12 2.25 x 12.12 Ford, Meteor 240, 302 CID Taxi Only (Bonded Lining) Max Wear Resistance. MONTEGO, FAIRLANE Passenger 250, 302 CID E xcept Primary 2.25x8.43 2.00x8.43 Convertible Secondary 2.25 x 10.82 2.00 x 10.82 Station Wagon, Ranchero and Convertible 250. 302 CID. I Primary 1 2.50 13.43 1 2.061 8.43 ' I Passenger and convertible 351, 390, 428 Cl D. Station Wagon and Ranchero 351, 390,428 CI D.

' FALCON - MAVERICK Sedan 6-Cylinder.

Station Wagon 6-Cylinder. Primary

I Sedan 8.Cyli nder. Secondary 2.25 x 10.82 2.00 x 10.82 . Station Wagon 8-Cylinder. Primary 2.50 x 8.43 2.00 x 8.43 ' Secondary 2.50 x 10.82 2.00 x 10.75 MUSTANG, COUGAR 200 CI D Engine. Primary 2.25 x 7.62 1.50 x 7.62 Secondary 2.25 x 9.77 1.50 x 9.77 250, 302 CI DSngines. Primary 2.25 x 8.43 1.75 x 8.43 Secondary 2.25 x 10.82 1.75 x 10.82 351, 390, 4 28 Cl D Engines. Primary 2.50 x. 8.43 2.00 x 8.43 Secondarv 2.50~10.82 2.00 x 10.82 I I I THUNDERBIRD, CONTINENTAL MARK Ill Primarv N/A 2.25 x 9.34 Secondjy N/A 2.25 x 12.12 LINCOLN CONTINENTAL Primary N/A 2.50 x 9.34 I I 1 Secondarv I N /A 2.50 x 12.12 1 Wear Limits Riveted: 1/32 inchfrom top of rivets. Bonded: 0.030 inch total lining thickness. 12-02-16 Drum Brakes 12-02- 1 6

BORE DIAMETERS-BRAKE DRUM, WHEEL CYUNDER AND MASTER CYUNDER Brake D~~~ Wheel Cylinder Bore Muter Cylinder Bore Dia. Dia. Models Inside BoringLirnit With Power Less Power Diameter (Max.)$) FrontO Rear@ Brake@ Brake@ Ford, Taxi and Station Wagon 11.030 11.090 1.094 0.938 1.000 1.000 Mercury I and Meteor Other 11.030 11.090 1.125 0.938 1.000 1.000 Pass. except Conv. 250, 302 ClD Engines 10.000 10.060 1.125 0.906 0.9375 1.000 I I I I I I MOmetO Pass. and Conv. 351, 390, 428 Cl D Eng. 1 10.000 1 10.060 1 1.125 0.906 0.9375 1.000 I l and Convertible 250, 302 CID Engines 10.000 10.060 1.125 0.906 0.9375 1.000 Fair lane Station and Ranchero 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 Falcon 10 Inch Brake - Station~ Wanon" 10.000 10.060 1.125 0.968 0.9375 1.000 10 Inch Brake - Passenger Car 10.000 10.060 1.125 0.875 0.9375 1.000 Mustang 200 CI D Engine 9.000 9.060 1.0620 0.8440 1.000 1.000 351, 390, 428 ClD 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 11.030 11.090 NIA 0.938 NIA N/A Continental Mark Ill 11.030 11.090 NIA 0.938 N /A NIA Lincoln Continental 11.090 11.130 NIA 0.938 NIA N/A @Max. Runout 0.007 @Front Wheel Cylinder cannot be honed on Falcon or Mustang with 9 inch @Max. Allowable Hone 0.003 Brakes 12-02- 17 Drum Brakes 1 2-02- 1 7

TORQUE LIMITSGENERAL4T-LBS Fairlane- Thunderbird Ford-Mercur y Montego Mustang- Continental Lincoln Meteor Falcon 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 13i25 , 13-25 'loin. Brake 10 in. Brake Wheel Cylinder to Backing Plate Screws 10-20 10-20 10-20 10.20 10.20 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 25-40 20-35 20-35 Pressure Differential 7-11 7-11 7.11 7-11 7.11 Valve Bracket Bolts and Nuts 32-650 32-650 Wheel Cylinder Bleeder Screw 6.15 I Inch-lb. Inch-lb. .6.15 6-15 Brake Hose Connection to front Wheel Cylinder 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 Hydraulic Tube Connections@ 318 x 24 10-15 10-15 10-15 10.15 10-15 7/18 x 24 10-15 10-15 10-15 10-15 10-15 112 x 20 10.17 10-17 10-17 10-17 10-17 9/16 x 18 10-17 10-17 10-17 10-17 10-17 4 lug 4 lug Wheel to Hub and Drum 55-85 55-85 70-115 5 lug 5 lug 70-115 70-115 70-115 70-115 @All hydraulic lines must be tightened to the specified torque value and be free of fluid leakage.

SPECIAL~ - TOOLS~- Ford Tool No. Former No. Description Rotunda HRE 8650 Brake Adjusting Gage LM 119 Brake Cylinder Retaining Clamp

2162 Adapter Cap 2035N Brake Shoe R & R Spring Tool 7000-00 Rubber Tipped Air Nozzle Tool 33621 33621 Internal Snap Ring Pliers

1 1112-144 I Inch Pound Torque Wrench Tool 4235-C 1 4235-C I Axle Shaft Remover I I Rotunda FRE 1431 I I Brake Drum Micrometer 1 Disc Brake

BART 12-03 Disc Brake

COMPONENT INDEX. Applies To Models As Indicated 12-03-02 Disc Brake 12-03-02

1 DESCRIPTION

Disc brakes are available as option- cylinder equipped hydraulic brake DUAL MASTER CYLINDER al equipment for the front wheels on system employs single anchor, inter- BRAKE SYSTEM Ford, Mercury, Meteor, Fairlane, nal expanding and self-adjusting drum Montego, Mustang and Cougar mod- brake assemblies on the rear wheels The dual-master cylinder brake els and are standard on Thunderbird, of vehicles with disc brakes. system has been incorporated in all Continental Mark 111, and Lincoln The disc brake consists of a venti- models to provide increased safety. Continental models. The dual-master lated rotor and caliper assembly. The The system consists of a dual-master caliper used is a single piston floating cylinder (Fig. 2), pressure differential INNER BRAKE SHOE OUTER BRAKE SHOE caliper (Fig. I). valve assembly and' a switch (Fig. 3). HOLD DOWN CLIPS RETAINING CLIPS A pressure control valve provides The switch on the differential valve 20164 2066 balanced braking action between front activates a dual-brake warning light, and rear brakes. located on the instrument panel. On Ford, Mercury, ~eteor,"~onti- nental Mark 111, Lincoln Continental and Thunderbird models a metering FLOATING CALIPER valve, in the hydraulic line between the differential valve and the front The caliper assembly -is made up of wheel disc brakes, prevents the front a floating caliper housing assembly brakes from applying until approxi- and an anchor plate. The anchor plate- mately 125 psi is obtained in the sys- is bolted to the wheel spindle arm by tem (Fig. I). This delaying action is two bolts. The floating caliper is at- required to prevent the front brakes tached to the anchor plate by steel from performing all the braking ac- stabilizers on Ford, Mercury, Meteor, 2~118R.H. tion on low speed stops and thereby Lincoln Continental, Thunderbird and 201 19L.H. increasing the rate of lining wear, and Continental Mark I11 models and by H 1690.~ from- locking on ice and slippery one stabilizer on Fairlane, Montego, A pavement. Mustang and Cougar models. The FIG. 7-Disc Brake Assembly- A vacuum booster is used with the floating caliper slides on two locating Floating Caliper power disc brake system. pins which also attach to the stabilizers. The floating caliper contains the

SECONDARY BRAKE FLUID RESERVOIR

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 12-03-03 Disc Brake 12-03-03

- single cylinder and piston assembly. The cylinder bore contains a piston NORMAL POSITION with 'a molded rubber dust boot. to CENTERED seal the cylinder bore from contamination (Fig. 4). A'square section rubber piston seal is positioned in a groove in the cylinder bore and is T OUTLET used to provide sealing between the cylinder and piston (Fig. 5). The outer brake shoe and lining assembly islonger 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 the shoe. It is replaced as a unit.

LIGHT CAR CUSTOM CAR The cast iron disc is of the ventilat- ed rotor-type incorporating forty fins niro7.e and is attached to, and rotates with the wheel hub. A splash shield bolted FIG. 3-Pressure Differential and Pressure Control Valve and Brake to the spindle is used primarily to Warning Light Switch prevent road contaminants from con- tacting the inboard rotor and lining surfaces. The wheel provides protection for the outboard surface of the rotor. CALIPER HOUSING BRAKE BOOSTER SYSTEM PISTON- This diaphragm-type brake booster is a self-contained vacuum-hydraulic braking unit mounted on the engine SHOE - side of the dash panel. LINING- The brake booster is of the vacuum suspended-type which utilizes engine intake manifold vacuum and atmos- pheric pressure for its power. Adjustment of the push rod and replacement of the check valve and grommet are the only services permit- PISTON-SEAL ANCHOR PLATE ted on the brake booster. The booster unit is to be exchanged when it is in- H 1568-8 spected, checked and found to be ino- FIG. 4-Floating Caliper Assembly-Sectional View perative. 12-03-04 Disc Brake 12-03-04

PISTON SEAL DISTORTED PISTON SEA,L RELAXED

CALIPER HOUSING BRAKES APPLIED BRAKES RELEASED H1569-8

FIG. 5-Function of Piston Seal

2 REMOVAL AND INSTALLATION

DlSC BRAKE CALIPER ASSEMBLY dirt. Torque the caliper, locating pins BLEEDER SCREW FACING THIS D~REC~ON~ to specifications. 'REMOVAL 3. Install the stabilizer to anchor plate attaching screws and torque to I. Remove the wheel and tire specifications. assembly from the hub. Use care to 4. Remove the cap from the brake avoid damage or interference with the hose fitting. Install a new copper bleeder screw fitting during removal. yasher on each side of the hose fit- 2. Disconnect the brake hose from ting a d install' the brake hose to the the caliper. Cap the hose fitting to caliper. Torque the attaching bolt to prevent brake system contamination specifications. and loss of brake fluid from the mas- 5. Bleed the brake system and ter cylinder. Mark the left and right centralize the brake pressure differen- caliper assemblies with chalk prior to tial valve as outlined in Part 12-01. removal from the vehicle. 6. Fill the master cylinder as re- 3. Remove the caliper locating pins quired to within t/4 inch of the top and lower stabilizer attaching bolts of the reservoir. and discard the stabilizer (Figs. 3 and 7. Install the wheel and tire assem- 0FROHT ROTOR SPLASH SHIELD 6). bly and torque the wheel nuts to spec- Hl64LB 4. Lift the caliper from the anchor ifications. FIG. 6-Floating Caliper plate. 8. Apply the brake pedal prior to Installed-Rear View moving the vehicle to position the INSTALLATION brake linings. full. Discard this fluid. 9. Road test vehicle. 2. Remove the wheel and tire I. Install the caliper assembly over assembly from the hub. Be careful to the rotor with the outer brake shoe DlSC BRAKE SHOE AND LINING avoid damage or interference with the against the rotor braking surface dur- caliper splash shield or bleeder screw ing installation in the anchor plate to FORD, MERCURY, METEOR, fitting. prevent pinching the piston boot be- THUNDERBIRD, 3. Remove the inner shoe hold tween the inner brake shoe and the CONTINENTAL MARK Ill, down clips (Fig. 3). piston. Check that the correct caliper LINCOLN CONTINENTAL 4. Place a small screwdriver under is installed on the correct anchor the outer shoe retaining clip tang and plate as marked during disassembly. Removal lift away from the pin groove and 2. Position the new stabilizer (sup- slide the clip from the shoe retaining plied in the brake kit). Apply water I. Remove the master cylinder cap pin. Remove the other brake shoe re- to the locating pins and attach the and check the fluid level in the pri- taining clip. See Fig. 3 and remove stabilizer to the caliper. Be sure the mary (large) reservoir. Remove the outer brake shoe. locating pins are free of oil, grease or enough fluid until the reservoir is half 5. Remove the caliper locating pins Disc Brake

(Fig. 6). in the caliper with the brake shoe lan- plate. 6. Remove the upper stabilizer to ces positioned in the slots in the cali- 7. Position the upper stabilizer and anchor plate attaching bolt and re- per outer legs and retract the piston install the stabilizer to Anchor plate move the upper stabilizer to avoid in- (Fig. 7). attaching bolt. Be careful to, properly terference with the brake hose during The piston retracting tool can be position the tab at the tower bolt caliper removal (Fig. 6). fabricated from a discarded outer location. Torque the attaching bolt to 7. Lift the caliper assembly from brake shoe and a threaded rod. Refer specifications. the anchor plate and remove the outer to Fig. 8 for tool fabricating details. 8. Install the caliper locating pins shoe and retaining pins from the cali- When using the piston retracting and torque to specifications (Fig. 6). per assembly. tool, turn the threaded rod one half 9. Add fluid in the master cylinder 8. Suspend the caliper from the turn at a time and pause to permit as required until the fluid level is vehicle upper control arm with a wire the piston to move in the seal. Reduce within t/4 inch of the top of the res- hooked through the upper caliper lo- the time interval as the piston nears ervoir. cating pin hole. the bottom of the cylinder bore to en- 10. Install the wheel and tire as- 9. Remove the caliper locating pin sure bottoming of the piston. If the sembly and torque the wheel nuts to insulators (Fig. 3). piston is not fully bottomed, the spac- specifications. 10. Remove the inner shoe and lining between the linings will be insuffi- 11. Pump the brake pedal prior to ing assembly and inspect both rotor cient to position the brake shoe and moving the vehicle 'to position the braking surfaces. caliper assembly over the rotor. brake linings. Inspect the piston dust boot for 12. Road test the vehicle. Installation cracks due to overheating and replace as required (Part 12-03, Section 4). 1. Install the inner shoe and lining 4. Turn the tool handle clockwise FAIRLANE. MONTEGO, assembly in the anchor plate, then in- with one hand and guide the ram into MUSTANG, COUGAR stall new locating pin insulators (sup- the piston cavity with the other until plied in the shoe and lining kit). Use the piston is bottomed in the cylinder Removal a cloth to protect the insulators dur- bore. Remove the tool. ing installation (Fig. 3). Check that 5. Install the outer brake shoe and 1. Remove the wheel and tire both insulator flanges straddle the an- lining assembly, then install the re- assembly from the hub. Be careful to cho'r plate. taining pins and retainer clips (Fig. avoid damage or interference with the 2. Install the inner brake shoe hold 3). caliper splash shield or bleeder screw down clips and torque the retaining 6. Remove the caliper assembly fitting. bolts to specifications. from the upper control arm and insert 2. Remove the caliper from the 3. Install the piston retracting tool the caliper assembly in the anchor vehicle following the procedures outlined under Disc Brake Caliper As- sembly. 3. Remove the inner brake shoe hold down clips from the anchor plate, remove the locating pin insulators from the anchor plate and remove the inboard brake shoe and lining assembly. 4. To remove the outer brake shoe. place a small screwdriver under the outer brake shoe retaining clip tang

WELD SECURELY TO THREADED RO

1/2-13 THREADED

TO BRAKE SHOE

n l693.A FIG. 8-Piston Retracting Tool FIG. 7-Installing Piston Retracting Tool Dimensions 12-03-06 Disc Brake 12-03-06

and lift away 'from the pin groove and 4. Install the new outer brake shoe hub. Remove the cotter pin, nut lock, slide the clip from the brake shoe re- and lining assembly on the caliper adjusting nut, and flat washer from taining pin. Remove the other brake and install the outer brake shoe re- the spindle. Remove the outer bearing shoe retai-ning clip. See Fig. 3 and retaining clips. Hold the retaining pins cone and roller assembly. move the outer brake shoe. in position with an allen wrench or 4. Remove the hub . and rotor bolt while installing the retaining assembly from the spindle. Installation clips. 5. Install the caliper on the vehile INSTALLATION 1. To install a new inner brake following the procedures outlined shoe in the anchor plate, install new under Disc Brake Caliper Assembly. 1. If the rotor is being replaced, caliper locating pin insulators (sup- remove the protective coating from plied in the brake shoe and lining FRONT WHEEL HUB AND ROTOR the new rotor with carburetor de- kit). Use a cloth to protect the insula- ASSEMBLY ' greaser. Pack a new set of bearings tors during assembly. Check that both with specified grease (M- IC75B), and insulator flanges straddle the anchor REMOVAL install the inner bearing cone and plate (See Fig. 3). roller assembly in the inner cup. Pack 2. Install the inner brake shoe hold I. Remove the wheel and tire from grease lightly between the lips of a down clips and torque the retaining the hub. Be careful to avoid damage new grease seal and install the seal screws to specifications. or interference with the bleeder screw (Fig. 9). 3. Install the piston retracting tool fitting. If the original rotor is being in- in the caliper with the brake shoe lan- 2. Remove the caliper assembly stalled, make sure that the grease in ces positioned in the slots in the cali- from the spindle and the rotor. If the the hub is clean and adequate, that per outer legs and retract the piston. caliper does not require servicing, it is the inner bearing and grease seal are The piston retracting tool can be fa- not necessary to disconnect the brake lubricated and in good condition, and bricated from a discarded outer brake hose or remove the caliper from the that the rotor braking surfaces are shoe and a threaded rod. Refer to vehicle. Position the .caliper out of the clean. Fig. 8 for tool fabricating details. way, and support it with a wire to 2. Install the hub and rotor assem- When using the piston retracting tool, avoid damaging the caliper or stretch- bly on the spindle. turn the threaded rod one half turn at ing the hose. Insert a clean cardboard 3. Lubricate and install the outer a time and pause to permit the piston spacer between the linings to prevent wheel bearing, washer and adjusting to move in the seal. Reduce the time the piston from coming out of the nut. interval to ensure bottoming of the cylinder, bore while the caliper is 4. Adjust the wheel bearings to piston. If the piston is not fully bot- removed. specification, and then install the nut tomed, the spacLng between the' lin- Handle the rotor and caliper lock, cotter pin, and grease cap. The ings is insufficient - to assemble the assemblies in such a way as to avoid wheel bearing adjustment is especially brake shoe and caliper assembly over deformation of the rotor and nicking, important with disc brakes. the .rotor. Use a cloth to catch brake scratching or contamination of the 5. Mount the caliper assembly on fluid from the caliper bore (See Fig. brake linings. the spindle following the Disc Brake 7). '3. Remove the grease cap from the Caliper Assembly Installation proce-

CALIPER PARTS

ff K?>R.* h< PIN 28118 R H FAIRLANE, MONTEGO, FALCON, 281 I9 L H MUSTANG AND COUGAR

34806.5 ...a. b.. W...,.,,." A \CONE AND ROLLER m?$$7 :LATE* SHOEI SHOEI - 2019 20 18 CONE AND ROLLER

3105'~.~. 28160 3106-L.H.

ROTOR SPLASH SHIELD 2KWd-R.H. / II Tt 2KOO5-L.H. GREASE SI:AL .I .-Inl

FIG. 9-Disc Brake is assembled 12-03-07 . Disc Brake 12-03-07

dure in this section.

DISC BRAKE ROTOR CLIP SPLASH SHIELD

W '0 AIR CONDITIONING REMOVAL I 1 BUSHING I. Remove the caliper and the hub and rotor assembly as outlined under Removal in the foregoing procedure (it is not necessary to disconnect hydraulic connections). 2. Remove the three bolts that attach the splash shield to the spindle, and remove the shield (Fig. 9). 3. Remove and discard the splash shield to spindle gasket.

INSTALLATION

1. Install a new splash 'shield to spindle gasket. 2. If the shield is bent, straighten it out before installation. Position the STOP LIGHT \ SWITCH 13480 SPACER shield to the mounting bracket, install the attaching bolts, nuts and torque them to specification. 3. Install the hub and rotor assembly and the caliper as outlined under Installation in the foregoing proce- FIG. 10-Master Cylinder Installation-Power Brake-Ford, Mercury and dure. Meteor DUAL MASTER CYLINDER- POWER BRAKES

BRAKE VACUUM BOOSTER -2OAj I REMOVAL

1. Remove the brake tubes from the primary and secondary outlet ports of the master cylinder (Figs. 29 thru 33). 2. Remove the two nuts and two lock washers attaching the master JOOT-2A02 1 cylinder to the brake booster assembly. 3. Slide the master cylinder for- MASTER ward and upward from the vehicle. CYLINDER ASSEMBLY 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 STOP LIGHT SWITCH-134 to Part 12-01, Section 2, Power Brake Master Cylinder Push Rod ASSEMBLY Adjustment for the proper procedure. 2. Position the master cylinder TRANSMISSION assembly over the booster push rod BRAKE PEDALASSEMBLY and onto the two studs on the booster H 1557-C assembly (Figs. 10 thru 14). FIG. 1 ]-Master Cylinder Installation-Power Brake-Fairlane, 3. Install the attaching nuts and Montego lock washers and torque them to specifications. 12-03-08 Disc Brake 12-03-08

(ESA-~6~25-A)for all biake applications. The extra heavy duty brake fluid is colored blue for identification. Do not mix low temperature brake fluids with the specified fluids,for the disc brake system. 6. Bleed the dual-master cylinder and the primary and secondary brake systems. Centralize the pressure differential valve. Refer to Hydraulic System Bleeding and ,Centralizing of the Differential Valve, Part 2-1, Sec- tion 2 for the proper procedure. 7. Operate the brakes several times, then check for external hydraulic leaks.

PRESSURE DIFFERENTIAL AND PRESSURE CONTROL VALVE

SWITCH l74EO TO EQUALIZER ROD REMOVAL I 2005 MASTER CYLINDER Refer to Fig. 2. 2140 The Brake and/or Pressure Differ- ential and Pressure Control Valve assembly is serviced as an assembly FIG. 12-Master Cylinder Installation-Power Brake-Mustang and only. Do not attempt to repair this Cougar unit. 1. Disconnect the brake warning light connector from the warning light switch. SOOSTER ASSEMBLY- 2005 2. Disconnect the front inlet and / rear outlet tubes from the valve assembly (Fig. 2). 3. Remove the two attaching nuts and bolts from the valve bracket on the underside of the fender apron and remove the valve assembly and bracket from the vehicle.

INSTALLATION

1. ~os.ition the valve assembly and bracket to the fender apron. Install the attaching nuts and bolts. Torque them to specifications. 2. Install the front inlet and rear outlet tubes to the valve assembly. Torque them to specifications. BUSHING 3. Connect the brake warning light I connector to the warning light switch. MASTER CYLINDER I BRAKE LIGHT SWITCH-I3480 4. Bleed the system and centralize 2140 the pressure differential valve following the procedures in Centraliz~ng the Pressure Differential Valve..

PRESSURE METERING FIG. 13-Master Cylinder Instollation-Thunderbird and Continental VALVE-FORD, MERCURY, Mark Ill METEOR, CONTINENTAL MARK I Ill, THUNDERBIRD, LINCOLN CONTINENTAL

REMOVAL 4. Install the front and rear brake specified brake fluid to within 114 tubes to the master cylinder outlet fit- inch of the top of the dual reservoirs. Refer to Fig. 15. tings. Use Ford Brake Fluid-Extra Heavy 1. Loosen the tube nuts connecting 5. Fill the fnaster cylinder with the Duty-Part Number C6AZ-19542-A the inlet and outlet tubes at the me- Disc Brake

tering valve, and remove the tubes. 2. Remove the two screws retaining the metering valve to the frame crossmember, and remove the metering valve. The metering valve is serviced as an assembly only.

INSTALLATION NUT (4 REQUIRED) -557685 WASHER (4 REQUIRED) -4472658 I. Position the metering valve to the frame crossmember, and install the retaining screws. 2. Connect the inlet and outlet tubes to the metering valve, and tight-

3EFORE ASSE en the tube nuts to specification. 3. Pressure Bleed the system.

BRAKE BOOSTER

REMOVAL

1. Working from inside the vehicle below the instrument panel, disconnect the booster push rod from the MASTER CYLINDER brake pedal assembly. To do this, IDENTIFICATION proceed as follows: Disconnect the stop light switch wires at the connector. Remove the hairpin retainer. Slide the stop light Him-0 switch off from the brake pedal pin just far enough for the switch outer FIG. 14-Master Cylinder Installation-Lincoln Continental hole to clear the pin, and then remove the switch from the pin and booster push rod. Be careful not to damage the switch during removal. Slide the booster push rod and the nylon washers and bushing off the brake pedal pin (Figs. 10 thru 14). 2. Open the hood and remove the master cylinder from the booster. Se- cure it to one side without disturbing the hydraulic lines. It is not necessary to disconnect the brake lines, but care FORDMERCURY-METEOR should be taken that the brake lines THUNDERBIRD AND MARK Ill are not deformed. Permanent deformation of brake lines can lead to tube METERING VALVE BLEEDER RETAINER failure. 3. Disconnect the manifold vacuum hose or hoses from the booster unit. 4. Remove the booster-to-dash COMPRESS TOOL AND panel attaching nuts or bolts (Figs. 10 POSITION thru 14). Remove the booster and ONTO VALVF. RELEASE TO bracket assembly from the dash ALLOW panel, sliding the push rod link out SPRING from the engine side of the dash ACTION TO FORCE panel. RWOUT 5. On Fairlane, Montego, and Fal- con models, remove the push rod link boot from the dash panel.

INSTALLATION

RELEASE ROD HIUB I. On Fairlane, Montego and Fal- - con models, install the push rod link boot in the hole in the dash panel as FIG. 15-Metering Valve Location shown in Fig. 11. Install the four spacers on the mounting studs. 12-03-1 0 Disc Brake 12-03- 10

2. Mount the booster and bracket Installation all bushings in their proper places on assembly to the dash panel by insert- the clutch and brake pedal assem- ing the push rod or push rod link in 1. Apply a coating of SAE 10 - blies. . through the hole and boot in the dash Engine oil to the bushings and locate 2. Position the brake pedal to the panel. lnstall the bracket-to-dash bushings in their proper places on the support bracket, then install the panel attaching lock nuts or bolts pedal assembly and pedal support clutch pedal and shaft assembly (Figs. 10 thru 14). bracket (Fig. 10). through the support bracket and 3. Connect the manifold vacuum 2. Position the brake pedal assem- brake pedal assembly. Install the hose or hoses to the booster. bly to the support bracket, then in- spring clip (Figs. 27 and 30). 4. Before installing the master stall the pedal sh-aft through the sup- 3. Install the clutch pedal assist cylinder, check the distance from the port bracket and brake pedal assem- spring. outer end of the booster assembly bly. Install the retainer. 4. Connect the clutch pedal- push rod to master cylinder surface. 3. Install the inner nylon washer, to-equalizer rod to the clutch pedal Turn the screw in or out to obtain the the master cylinder or booster push assembly with the bushing and the specified length. Refer to Part 12-01, rod, and the bushing on the brake spring clip retyiner. Apply SAE 10 Section 2, Power Brake Master Cyl- pedal pin. Position the switch so that engine oil to the bushing. inder Push Rod Adjustment. Install it straddles the push iod with the 5. Install the inner nylon washer, the master cylinder and torque the at- switch slot on the pedal pin and the the master cylinder or booster push taching nuts to specifications. switch outer hole just clearing the pin. rod,, and the bushing on the. brake 5. Working from inside the vehicle Slide the switch completely onto the pedal pin. Position the switch so that below the instrument panel, connect pin, and install the nylon washer as it sstraddles the push rod with the the booster push rod link to the brake shown in Fig. 10. Be careful not to switch slot on the pedal pin and the pedal assembly. To do this, proceed bend or deform the switch. Secure switch outer hole just clearing the pin. as follows: these parts to the pin with the hairpin Slide, the switch completely onto the lnstall the inner nylon washer, the retainer. pin, and install the outer nylon wash- booster push' rod, and the bushing on 4. Connect the stop light switch er as shown in Fig. I I. Secure these the brake pedal pin. Position the wires to the connector, and install the parts to the pin with the self-locking switch so that it straddles the push wires in the retaining clip. pin. rod with the switch slot on the pedal 5. Check the Brake Pedal Free 6. connect the stop light switch pin and the switch outer hole just Height. and Travel Measurements, wires to the connector, and install the clearing the- pin. Slide the switch Part 12-01, Section I. wires to the retaining clip. completely onto the pin, and install 7. Adjust thg clutch pedal free play the nylon washer as shown in Figs. 10 FAIRLANE, (Group 16-02) to specification, if re- thru 14. Be careful not to bend or de- MONTEGO-MANUAL- quired. form the switch. Secure these parts to SHIFT-TRANSMISSION 8. Check the Brake Pedal Free the pin with the hairpin retainer. Height and Travel Measurements Connect the stop light switch wires to Removal (Part 12-01, Section I). the connector, and install the wires in the retaining clip. 1. Remove the clutch pedal assist MUSTANG AND COUGAR- spring. MANUAL-SHIFT 2. Disconnect the clutch pedal- TRANSMISSION BRAKE PEDAL to-equalizer rod at the clutch pedal.by removing the retainer and bushing. ' Removal FORD, MERCURY 3. Disconnect the stop light switch AND METEOR wires at the connector. 1. Disconnect the battery ground 4. Remove the switch retainer, and cable .from the battery. Removal slide the stop light switch off the 2. Remove the steering column. brake pedal pin just far enough for Refer to Part 13-02 for procedure.. 1. Disconnect the stop light switch the switch outer hole to clear the pin. 2. Remove the two cap screws re- wires at the connector. Then lower the switch away from the taining the booster to the dash panel. 2. Remove the hairpin retainer. pin. 4. Working inside the vehicle, se- Slide the, stop light switch off the 5. Slide the master cylinder or cure. the clutch pedal against the brake pedal pin just far enough for booster push rod and the nylon wash- bumper stop with a small C-clamp as the switch outer hole to clear the pin, ers and bushing off from the brake shown in Fig. 12. and then lift the switch straight up- pedal pin (Fig. I I). 5. Disconnect the clutch pedal- ward from the pin. Be careful not to 6. Remove the self-locking pin and to-equalizer rod at the clutch pedal by damage the switch during removal. washer from the clutch and brake removing the retainer and bushing. Slide the master cylinder or booster pedal shaft, then remove the clutch 6. Disconnect the stop light switch push rod and the nylon washers and pedal and shaft assembly, the brake wires at the connector. bushing off the brake pedal pin (Fig. pedal assembly, and the bushings 7. Remove the switch retainer and 10). from the pedal support bracket (Fig. slide the stop light switch off the 3. Remove the hairpin-type retain- I I). brake pedal pin just far enough for er and washer from the brake. pedal the switch outer hole to clear the pin. shaft, then remove the shaft, the Installation Then lower the switch away from the brake pedal and the bushings from pin. -Remove the master, cylinder or the pedal support bracket. 1. Apply a coating of SAE 10 booster push rod, bushing and nylon engine oil to the bushings and locate washer from the brake pedal pin. Disc Brake

8. Remove the screw retaining the bushing on the brake pedal pin. Posi- on the pedal assembly and pedal sup- pedal support bracket to the top inner tion the stop light switch so that it port bracket (Fig. 12). cowl bracket (Fig. 12). straddles the push rod with the switch 2. Position the brake pedal assem- 9. Remove the two sheet metal slot on the pedal pin and the switch bly to the support bracket, then in- screws retaining the pedal support outer hole just clearing the pin. Slide stall the pedal shaft or bolt through bracket to the dash panel. On power the switch completely onto the pin, the support bracket and brake pedal brakes remove the nuts from the and install the outer nylon washer as assembly. Install the retainer or lock- brake booster studs. shown in Fig. 12. Secure these parts nut. 10. Remove the two screws retain- to the pin with the self-locking retain- 3. Install the inner nylon washer, ing the pedal support bracket to the er. the master cylinder or booster push upper cowl brace and lower the pedal 9. Connect the stop light switch rod, and the bushing on the brake support bracket away from the steer- wires to the connector. pedal pin. Position the switch so that ing column studs. 10. Connect the clutch pedal- it straddles the push rod with the 11. Remove the pedal support to-equalizer rod to the clutch pedal switch slot on the pedal pin, and the bracket assembly from the vehicle. assembly with the bushing and the switch outer hole just clearing the pin. 12. Position the pedal and support spring clip retainer. Apply SAE 10 Slide the switch completely onto the bracket assembly in a vise. engine oil to the bushing. Remove the pin, and install the outer nylon wash- 13. Remove the C-clamp to release C-clamp from the clutch pedal. er as shown in Fig. 12. Secure these the clutch pedal from its bumper stop 11. Working from the engine side parts to the pin with the self-locking and pivot the pedal away from the of the dash panel. Install the cap pin. bumper. screws retaining the brake booster to 4. Connect the stop light switch 14. Remove the clutch pedal assist the dash panel. wires to the connector, and install the spring. 12. Install the steering column. wires in the retaining clip. 15. Remove the clutch pedal and Refer to Part 13-02 for procedure. Check the Brake Pedal Free Height shaft assembly, the brake pedal as- 13. Adjust the clutch pedal free and Travel Measurements, Part 12- sembly, and the bushings from the play (Part 16-02) to specifications, if 0 1, Section I. pedal support bracket. Remove the required. retainer nut from the brake pedal 14. Check the Brake Pedal Free THUNDERBIRD AND shaft then remove the pedal shaft, the Height and Travel Measurements CONTINENTAL MARK 111 brake pedal assembly and the bush- (Part 12-01, Section I). ings from the pedal support bracket. 15. Connect the ground cable to Removal the battery. Installation I. Loosen the booster mounting FAIRLANE, MONTEGO, nuts. 1. Apply a coating of SAE 10 MUSTANG AND 2. Disconnect the stop light switch engine oil to the bushings and locate COUGAR-AUTOMATIC . wires at the connector. all bushings in their proper places on TRANSM ISSlON 3. Remove the hairpin retainer. the clutch and brake pedal assem- Slide the stop light switch off from blies. Removal the brake pedal pin just far enough 2. Install the clutch pedal and shaft for the switch outer hole to clear the assembly through the support bracket 1. Disconnect the stop light switch pin, and then lift the switch straight and brake pedal assembly. On power wires at the connector. upward from the pin. Slide the master brakes position the brake pedal to the 2. Remove the self-locking pin and cylinder push rod and the nylon wash- pedal support bracket, then install the slide the stop light switch off the ers and bushing off from the brake pedal shaft and nut. brake pedal pin just far enough for pedal pin (Fig. 13). 3. Install the clutch pedal assist the switch outer hole to clear the pin. 4. Remove the pivot bolt and nut spring and pivot the clutch pedal Then lower the switch away from the that holds the pedal to the pedal sup- against its bumper stop. Secure the pin. Slide the master cylinder or port bracket. Remove the brake pedal pedal to the stop with a small C- booster push rod and the nylon wash- assembly from the pedal support clamp as shown in Fig. 12. ers and bushing off from the brake bracket, and remove the bushings. 4. Position the pedal support pedal pin (Fig. 12). bracket assembly to the dash panel, 3. On all vehicles except Mustang Installation and to the steering column retainer and Cougar, remove the self-locking studs. pin and washer from the brake pedal 1. Apply a coating of SAE 10 5. Align the pedal support bracket shaft, then remove the shaft, the engine oil to the bushings and locate holes with the holes in the dash panel brake pedal assembly and the bush- all the bushings in their proper places and install the two attaching sheet ings from the pedal support bracket. on the pedal assembly (Fig. 13). metal screws. Install the nuts on the On Mustang and Cougar vehicles, re- 2. Install the brake pedal assembly brake booster studs. move the locknut and bolt from the and bushings to the support bracket, 6. Install the two cap screws at- pedal. Remove the pedal assembly and then install the pivot bolt through taching the pedal suRport bracket to from the support bracket (Fig. 12). the support bracket and brake pedal the upper cowl bracket. assembly. lnstall the pivot bolt nut 7. Install the cap screw attaching Installation and torque to specifications. the pedal support bracket to the top 3. Install the inner nylon washer, inner cowl bracket (Fig. 12). 1. Apply a coating of SAE 10 the master cylinder push rod, and the 8. lnstall the inner nylon washer, engine oil to the bushings and locate bushing on the brake pedal pin. Posi- the master cylinder push rod, and the all the bushings in their proper places tion the switch so that it straddles the Disc Brake 12-03-1 2

push rod with the switch slot on the the wire harness aside. Remove the bushing on the brake pedal pin. Posi- pedal pin and the switch outer hole temperature control box and position tion the switch so that it straddles the just clearing the pin. Slide the switch it aside. push rod link with the switch slot on completely onto the pin, install the 5. Remove the hair-pin type retain- the pedal and the switch outer hole outer nylon washer as shown in Fig. er. Slide the stop light switch off the just clearing the pin. Install the outer 13. Secure these parts to the pin with brake pedal pin just far enough for nylon washer as shown in Fig. 14. In- the hairpin retainer. the switch outer hole to clear the pin. stall the hair-pin type retainer on the 4. Connect the stop light switch Lift the switch upward from the pin. brake pedal pin. wires to the connector, and install the Slide the master cylinder push rod, 5. Connect the stop light switch wires in the retaining clip. nylon washers and bushing off the wires to the connector, and install the 5. Torque the booster mounting brake pedal pin. wires in the retaining clip. nuts to specifications. 6. Remove the pivot bolt and nut 6. Position the wire harness and that holds the pedal to the pedal sup- clip on the temperature control box LINCOLN CONTINENTAL port bracket. Remove the brake pedd and install the retaining screw. Posi- assembly from the support bracket tion the temperature control box to Removal and remove the bushings. the dash panel and install the two re- 7. If required, remove the brake taining bolts. 1. Disconnect the battery ground pedal pad retaining nuts and remove 7. Connect the vacuum lines and cable from the battery. the brake pedal pad. the electrical connector to the control 2. It is necessary to obtain clear- box. Position the wire harness to the ance to remove vacuum hoses and the Installation control box and install the retaining electrical connector to the tempera- clip. ture heat control box. Remove the I. If the brake pedal pad was 8. Position the wire harness shield two screws retaining the relay to the removed, position the pad on the and install two retaining bolts. fender and push the relay aside. Dis- pedal. lnstall the pad retaining nuts 9. Connect the wire harnesses to connect the vacuum hoses and con- and torque them to specification. the lower control panel and install the nector at the heat control box. 2. Apply SAE 10 engine oil to the retaining screws. 3. Working under the instrument bushings and locate all the bushings 10. Working within the engine panel, disconnect the vacuum hoses. in their proper places on the pedal as- compartment, connect the wire con- wires and retaining clip from the tem- sembly. nector to the temperature heat control perature heat control box. Remove 3. lnstall the brake pedal assembly box. the two screws securing -the tempera- and bushings to the support bracket. 11. Position the relay to the fender ture control box to the dash panel. and then install the pivot bolt through apron and install the retaining bolts. 4. Remove the lower control hous- the support bracket and pedal assem- 12. Connect the ground cable to ing retaining screws (6). Disconnect bly. Install the pivot bolt nut and tor- the battery. the wire harnesses at the lower con- que it to specification. 13. Check the brakes and light trol panel and place the panel aside. 4. Install the inner nylon washer,the switch for proper operation. Close the Remove the wire harness shield. Re- master cylinder push rod link, and the hood. move the wire harness clip. Position

3 MAJOR REPAIR OPERATIONS

After any service work, obtain a ish of the braking surfaces are to be brake rotors require refinishing. firm brake pedal before moving the 80/15 micro inches. The minimum Gauging of the rotor is accomplished vehicle. Riding the brake pedal (com- limiting dimensions (Fig. 16) from the on the bench prior to mounting in a mon on left foot application) should inboard bearing cup to the outboard rotor lathe. A controlled dimension be avoided when driving the vehicle. rotor face and from the inboard bear- notch machined in one edge of the ing cup to the inboard rotor face gauge bar identified custom car ROTOR REFINISHING must be observed when removing ma- (Ford, Mercury, Meteor and Thun- terial from the rotor braking surfaces. derbird, Continental Mark I11 and

Rotunda , Disc Brake Attachment, On ail models the limiting dimensions Lincoln Continental). The opposite --. FRE-2249-2, is the only recommend- are to be measured with the ball and raised center of the gauge bar is iden- ed tool to refinish the disc brake ro- gage bar (Rotunda Kit FRE-70160). tified light car (Montego, Fairlane. tors. The step-by-step resurfacing pro- Mustang and Cougar). Refer to cedure provided with the tool must be Fig. 16. adhered to. DISC BRAKE ROTOR CHECK Gauging of the rotor is accom- The finished braking surfaces of the plished accordi'ng to the following rotor must be flat and parallel within Refer to Fig. 16. procedure: 0.0007 inch; lateral runout must not A ball and gauge bar are required 1. Remove the inner bearing as- exceed 0.003 inch on Custom Vehicles to measure wear on the rotor inner sembly and grease retainer and thor- and 0.002 irich on Light Vehicles total braking surface and to determine the oughly clean the inner bearing cup indicator reading, and the surface fin- maximum stock removal limit when and hub bore. Disc Brake 12-03-1 3

FAIRIANE . '875 'IN' MUSTANGCOUGAR 4k

RETAINER - 28245

GASKET -2167

THUNDERBIRD-CONTINENTAL MARK Ill-LINCOLN CONTINENTAL 1 .I2 MlN.4 1-

FIG. 16-Disc Brake Rotor Service Limits

2. Carefully place the gauge ball in the inner bearing cup (Do not drop). 3. Position the gauge bar across the rotor inner braking surface and over the gauge ball (Fig, 16). Measure the distance between the gauge bar and ball. This clearance is equal to ASSEMBLY - 2A502 the maximum allowable stock removal. If the gauge bar touches the ball, no additional stock removal is al- FIG. 17-Dual Master Cylinder Disassembled lowed. If the gauge bar is below the top of the ball, the rotor must be re- the cylinder as a unit instead of over- Snop Ring Pliers placed. hauling the cylinder with,a service re- 4. The rotor thickness dimensions pair kit. after refinishing are limited to the SNAP RING minimum measurements shown DISASSEMBLY below. Ford, Mercury, Meteor, Thunderbird, Continental 1. Clean the outside of the master Mark 111 and Lincoln Continental cylinder and remove the filler cover 1.120-inch minimum. and diaphragm. Pour out any brake Fairlane, Montego, fluid that remains .in the cylinder. Mustang and Cougar Discard the old brake fluid. 0.875-inch minimum. 2. Remove the secondary piston Rotors having a thickness less than stop bolt from the bottom of the cyl- above specifications must be replaced inder (Fig. 17). , regardless of the ball and gauge bar 3. Remove the bleed screw, if re- measurement. quired. 5. The finished braking surface 4. Depress the primary piston and n1m-c must be flat and parallel within remove the snap ring from the retain- 0.0007 inch; lateral runout must not ing groove at the rear of the master FIG. 18-Removing Snap exceed 0.003 inch on Custom Vehicles cylinder bore (Fig. 18). Remove the Ring-Typical and 0.002 inch on Light Vehicles total push rod and the primary piston as- indicator reading, and the surface fin- sembly from the master cylinder bore. ish of the braking area is to be 80115 Do not remove the screw that retains INSPECTION AND REPAIR micro inches. the primary return spring retainer, re- The ball and gauge bar kit is avail- turn spring, primary cup and protec- 1. Clean all parts in clean isopro- able through Rotunda Equipment tor on the primary piston. This as- pyl alcohol, and inspect the parts for (Part No. FRE-70160). sembly is factory pre-adjusted and chipping, excessive wear or damage. should not be disassembled. When using a master cylinder repair DUAL MASTER CYLINDER 5. Remove the secondary piston kit, install all the parts supplied. assembly. DO not remove the outlet 2. Check all recesses, openings and When a repair is necessary on the tube seats, outlet check valves and internal passages to be sure they are master cylinder, it is required practice outlet check valve springs from the open and free of foreign matter. Use during the warranty period to replace master cylinder body. an air hose to blow out dirt and Disc Brake

cleaning solvent. Place all parts on a OUTER SHOE clean pan or paper. INNER BRAKE RETAINING CLIPS 3. Inspect the master cylinder bore SHOE &NO LINING 2066 ASSEMB,LY-2019 for signs of etching. pitting. scoring or rust. If it .is necessary to hone the master cylinder bore to repair damage. do not exceed allowable hone specifications.

ASSEMBLY

1. Dip all parts except the master cylinder body in clean Rotunda Extra Heavy Duty Brake Fluid. 2. Carefully insert the complete LOCATING PIN secondary piston and return spring assembly iri the master cylinder bore. 3. Install the primary piston assembly in the master cylinder bore. 4. Depress the primary piston and install the snap ring in the cylinder CFQT bore groove. 5. Install the push cod. boot and retainer on the push rod, if so 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 CLIP push rod boot (if so equipped) in the 20164 master cylinder body retaining groove. FIG. 19-Caliper Assembly-Disassembled 7. Install the secondary piston stop bolt and O-ring in the bottom of the ton. Place a cloth over the piston be- master cylinder. fore applying air pressure to prevent 8. Install the bleed screw (if so damage to the piston. If the piston is equipped). Install the gasket (dia- seized and cannot be forced from the phragm) in the master cylinder filler- caliper, tap lightly around the piston cover. Position the gasket as shown in while applying air pressure. Care Fig. 17. Make sure the gasket is se- should be taken because the piston curely seated. can develop considerable force due to 9. Install the cover and gasket on pressure build-up. the master cylinder and secure the 7. Remove the dust boot-from the cover into position with the retainer. caliper assembly. 8. Remove the rubber piston seal DISC BRAKE CALIPER from the cylinder and discard it. Disassembly > Cleaning and Inspection 1. Remove the caliper assembly from the vehicle ,as outlined in Sec- Clean all metal parts with isopropyl tion 2. alcohol or a suitable solvent. 'Use 2. Remove the caliper locating pins clean, dry, compressed air to clean from the caliper assembly and lift the out and dry the grooves and passage FIG. PO-Removing Piston From anchor plate from the caliper. ways. Be sure that the caliper bore Caliper 3. Slide the two outer shoe retain- and component parts are completely ing clips ,off the retaining' pins (Fig. free of any foreign material. and that it is seated fully in the 19). Check the cylinder bore and piston groove. 4. Remove the two retaining pins, for damage or excessive wear. Re- 2. Install a new dust boot by set- then remove the outer brake shoe place the piston if it is pitted, scored, ting the flange squarely in the outer from the caliper. or the chrome plating is worn off. groove of the caliper bore. 5. Slide the inner brake shoe out- 3. Coat the piston with the speci- ward uniil it is free of,the hold-down fied fluid and install the piston in the springs, then remove the brake shoe. cylinder bore. Spread the dust boot 6. Apply air pressure to the fluid 1. Apply a film of clean brake over the piston as it is installed. Seat port in the caliper with a rubber fluid to the new caliper piston seal the dust boot in the piston groove. tipped nozzle (Tool 7000-DD) as and install it in the cylinder bore. Be 4. Position the inner brake shoe so shown in Fig. 20 to remove the pis- sure the seal does not become twisted that the ear's of the shoe rests on the I 12-03-15 . Disc Brake 1 2-03- 1 5

top of the anchor plate bosses and be- chor plate. of oil, grease or dirt. neath the hold-down springs. 7. Apply water or isopropyl alco- 8. Install the caliper on the spindle 5. Install new caliper locating pin hol to the caliper locating pins and as outlined under Disc Brake Caliper insulators in the anchor plate. install them loosely in the anchor Assembly. 6. Position the caliper on the an- plate. Be sure the guide pins are free

4 SPECIFICATIONS

BORE DIAMETERS MASTER CYLINDER I Master Cylinder Bore Dia. With Power Models Brake@ Ford, Mercury Taxi and Station Wagon 1.000 and Meteor Other 1.000 Pass. except Conv. 250, 302 CID Engines 0.9375 Montego Pass. and Conv. 351, 390, 428 CID Eng. 0.9375 and Convertible 250, 302 Cl0 Engines 0.9375 Fair lane Station and Ranchero 0.9375 9 Inch' Brake Passenger Car N/A Falcon 10lnch Brake Station Wagon N/A 10 Inch Brake Passenaer Car N /A I Mustang 200 CID Enaine I 1.000 and Cougar 351, 390, 428 Cl D Engine 1.000 250, 302, CID Engine 1.000 Thunderbird Continental Mark Ill I I Lincoln Continental I 1 1.000 @Max.-Allowable Hone 0.003 02.755 for Ford, Mercury, Meteor with Disc Brakes 2.381for Fairlane, Montego, Mustang, Cougar with Disc Brakes CH1724-A 12-03- 16 Disc Brake- 12-03- 16

SHOEAND UNlNG DIMENSIONS- Dl% BRAKES -INCHES Ford, Mercury, Fair lane, Montego Meteor, Thunder. Mustang, Cougar bird, Continental Mark Ill, Lincoln Continental Lining Material Bonded Bonded Lining Size 7.38 x 2.27 Outer 6.82 x 1.80 Outer CALIPER CYLINDERBORE DIAMETER -INCHES 5.36 x 2.03 lnner 4.90 x 1.84 lnner IFord, Mercury, Meteor. Thunderbird. Continental Mark Ill I Lining Area - Square Inches 12.25 Outer 11.30 Outer Lincoln Continental 2.755 per Segment 8.44 l nner 8.80 Inner Mustang, Cougar, Fairlane and Montego 2.381 Lining Thickness Nominal 0.394 0.333 Outer 0.362 lnner Lining Wear Limit (Front Surface of Shoe) Max. 0.030 0.030

Lining-. Taper -Max. 0.125 0.125 I I Lining to Rotor Clearance (Brakes Released) 0.000-0.010 0.000-0.010

CH1725.A

TORQUE LIMITS -HUB TO SPINDLE Description Ft Lbs Hub and Drum or Rotor Pissembly Rotate hub while torquing to 17- to Front Wheel Spindle 25 ft-lbs. Back off the adjust. ROTOR DIMENSIONS ing nut 112 turn and retighten to 10-15 inch pounds while ro- Nom. Diameter tating wheel Selectively posi- Car Line Thickness Outside Inside tion nut retainer on adjusting Ford, Mercury, Meteor, nut .so that a set of slots are Lincoln Continental 1.180 11.72 7.785 in line with cotter pin hole. Ad- justing nut should not be rotated Thunder bird, Continental in this operation. Lock adjusting Mark Ill 1.180 11.72 7.785 nut and nut retainer with cotter Fairlane, Montego;Mustang pin so that the cotter pin end and Cougar 0.935 11.29 7.355 does not interfere with seating of wheel static collector in spindle hole.

ROTOR REFINISH I I The following requirements must be met when resurfacing disc on Custom vehicles and 0.002 inch on light vehicles total brake rotors: indicator reading, and the surface finish of the braking. surfaces Rotunda Disc Brake Attachment FRE-2249-2 is the only approv- are to be 80-15 micro inches. ed tool to be used to refinish the disc brake rotors. The step-by- On all models the limiting dimension from the inner bearing step resurfacing procedure provided with the tool must be adhered ,cup to the inner rotor face must be measured with a ball and to. gage bar (Rotunda FRE-70160). The finished braking surfaces .d the rotor must be flat and parallel within 0.0007 inch; lateral runout must not exceed 0.003 12-03- 17 Disc Brake 12-03- 17

Disc Brake Caliper to Spindle Bolts 12-03- 1 8 Disc Brake 12-03- 1 8

SPEb A1 TOOLS Ford Tool No. Former No. Description 2162 Adapter Cap Tool 7000.00 Rubber llpped Air Nozzle Rotunda 70160 Ball and Gage Bar Tool 33621 ,33621 Internal Snap Rinn Pliers Milbar 1112- 144 Inch Pound Torque Wrench 1 22742 (Kent Moore) Bleeder Valve Clip Spring Rotunda FR E 22492 Disc Brake Rotor Attachment CH1728-A 1 2-04-0 1 Parking Brakes 1 2-04-0 1

BART 12-04Barking Brake

-VI u Y - - COMPONENT INDEX = h 0 ;Lgg'=.-W=- =2 g: Applies To Models As Indicated E z 2 p f Q 8.; '2; 722~5EES~SIUCZE=z PARKING BRAKE 04-0I

the head of the column. N/A indicates that the item is not applicable to the vehicle(s) listed.

1 DESCRIPTION

An independent foot-operated to the equalizer except on the Lincoln The lower end of the release lever ex- (hand-operated on Maverick) parking Continental. The rear brake cables tends out for alternate manual release brake control actuates the rear wheel connect the equalizer assembly to the in the event of vacuum power failure brake shoes through a cable linkage. parking brake lever at each rear sec- or for optional manual release at any On all models except Ford, Mercury, ondary shoe. Refer to Part 12-02. time. Meteor, Thunderbird, Coptinental On all vehicles except Maverick, Hoses connect the power unit and Mark 111 and Lincoln Continental. there are two types of foot-operated the engine manifold to a vacuum re- The operating cable is routed from parking brake controls used. The au- lease valve on the back-up light the parking brake control assembly to tomatic (vacuum) release type (Fig. I) switch. the equalizer. On Ford, Mercury. is used on the Mercury, Ford LTD, On a Maverick, the parking brake Meteor. Thunderbird, Continental Meteor LeMoyne. Thunderbird, Con- control is hand-operated. When the Mark 111 and Lincoln Continental the tinental Mark 111 and Lincoln Conti- handle is pulled the primary and sec- operating cable is routed from the nental models. All other models use ondary brake shoes are forced against parking brake control assembly to the the manual release-type (Fig. 2). the rear brake drums. The handle is actuator assembly. On Maverick, the On the automatic-type, the vacuum held in the applied position by the en- operating cable is routed from the power unit with mounting bracket is gagement of a spring loaded pawl parking brake control assembly ,to the riveted to the control assembly. The 'with a ratchet. Turning the handle equalizer pivot lever which is attached vacuum actuated piston within the counterclockwise disengages the pawl to the equalizer assembly. An inter- unit is connected by a rod to the from the ratchet to release the brakes. mediate cable connects the actuator upper end of the release lever (Fig. 9). 12-04-02 Parking Brakes 12-04-02

FIG. ]--Parking Brake Control Assembly with Automatic Release-Typical

RELEASE PAWL CAM PIN

L CAM LEVER

H 16SA FIG. 2-Parking Brake Control Assembly withMa:iual Release-Typical

2 IN-VEHICLE ADJUSTMENTS AND REPAIRS

PARKING BRAKE LINKAGE 2. Place the transmission :in neu- Then. loosen the adjusting nut until ADJUSTMENT tral. Raise the vehicle. the rear brakes are fully released. 3. Tighten the adjusting nut against There should be no brake drag. I. Make sure that the parking the cable equalizer (Fig. 3. 4. 5, 6. 7. 4. Lower the vehicle and check the brake is fully released. 8) to cause rear wheel brake drag. operation of the parking brake. Parking Brakes

3 REMOVAL AND INSTALLATION

PARNING BRAKE CONTROL FAIRLANE, MONTEGO ASSEMBLY AND FALCON 5. Remove the parking brake warning light switch and attaching FORD, MERCURY Removal screw (if so equipped). AND METEOR 6. Disconnect the cable ball from Refer to Fig. 4. the notch.in the brake clevis. Removal I. Make sure the parking brake is 7. Remove the three screws that at- completely released. tach the control assembly to the left Refer to Fig. 3. 2. Remove all tension from, the cowl inner side panel. 1. Make sure the parking brake is rear cables by backing off the jam nut 8. Pull the control away from the fully released. and adjustirig nut from the equalizer. cowl panel. Remove the hair-pin re- 2.- Remove all tension from the 3. Working inside the vehicle, tainer securing the front cable assem- rear cables by backing off the adjust- remove the four bolts and one nut re- bly to the control assembly. Remove ing nut from the equalizer. taining the left air vent and cable the control assembly. 3. Remove the roll pin that secures assembly to the dash and instrument the release knob to the cable and re- panels. Remove the vent assembly. Installation move the knob. 4. Remove the parking brake front 4. Remove the nut that secures the cable ball retaining clip from the clev- 1. Connect the ball-end of the release cable to the instrument panel is. parking brake front cable assembly to and remove the cable from the rear of 5. Disconnect the cable ball from the control assembly, and install the the instrument panel. the notch in the brake clevis. hair-pin retainer. 5. Remove the two nuts attaching 6. Remove the three screws that at- 2. Position the control asseinbly to the control assembly to the dash tach the control assembly to the left the cowl inner side panel and install panel. cowl inner side panel. the three attaching screws. 6. Remove the cap screw attaching 7. Disconnect the wire lead at the 3. Position the parking brake the control assembly to the cowl side parking brake warning light switch warning light switch and install the bracket. and remove the control assembly. attaching screw; Connect the parking 7. Disconnect the hose to the park- brake warning light switch wire lead ing brake vacuum unit, if so Installation (if vehicle is so equipped). equipped. 4. Position the cable ball in the 8. Remove the front cable assem- 1. Connect the wire. lead to the notch in the brake clevis. bly retainer clip from the cable as- parking brake warning light switch. 5. Check the operation of the park- sembly and disconnect the cable ball 2. Position the control assembly to ing brake. Adjust the parking brake. from the control clevis. the cowl inner side panel and install 9. Remove the control assembly the three attaching screws. MAVERICK from the vehicle. 3. Connect the ball-end of the parking brake front cable assembly to Removal Installation the control assembly, and install the hairpin retainer. Refer to Fig. 6. 1. Position the control assembly in 4. Position the cable ball in the 1. Remove the two screws that the vehicle. notch in the brake clevis. hold the control bracket on the in- 2. Fit the cable assembly through 5. Position the left air.vent assem- strument panel. its mounting hole and install the re- bly to the dash and instrument panels. 2. Remove the two nuts that secure taining clip. Connect the cable ball to Install the four bolts and one nut re- the control to the dash panel. the control clevis. taining the air vent to the panels. 3. Remove the hairpin clip and 3. Connect the vacuum hose to the 6. Check the operation of the park- clevis pin that secures the pulley to parking brake unit, if so equipped. ing brake. Adjust the parking brake. the control handle assembly. 4. Install the attaching cap screw 4. Disengage the locking pawl. to the cowl side bracket. Do not MUSTANG AND COUGAR Slide the rod forward and remove the tighten. ball on the cable from the slot on the 5. Install the two control assemb- Removal control assembly. ly-to-dash panel nuts. Tighten the 5. Remove the control from the nuts and the cap screw to specifica- Refer to Fig. 5. vehicle. tions. I. Make sure the parking brake is 6. Insert the release cable into the completely released. Installation instrument panel and install the re- 2. Remove all tension from the taining nut. rear cables by backing off the jam nut Refer to Fig. 6. 7. Install the release knob on the and adjusting nut from the equalizer. 1. Disengage the locking pawl. able with the roll pin. 3. Disconnect the wire lead at the Slide the rod forward and connect the 8. Check the operation of the park- parking brake warning light switch (if ball end of the cable to the slot in the ing brake. Adjust the parking brake so equipped). control assembly and pull. the rod as required. 4. Remove the parking brake front rearward, engaging the pawl in the cable ball retaining clip from the clev- ratchet. is. BRAKE PEDAL BRACKET CABLE MUST BE TIGHT ON -4 CROSSMEMBER

VlEW Z CABLE AND HOUSING R.H. VACUUM RELEASE

VlEW X

CABLE AND HOUSING L.H.

CLIP

INSTRUMENT PANEL CROSSMEMBER SUSPENSION ARM

ADJUSTING NUT

INTERMEDIATE CABLE CONTROL

LOCKED IN PLACE WITHIN BRAKE DRUM L.K SHOW R.H. TYPICAL VIEWY VlEW Z MANUAL RELEASE

FIG. 3-Parking Br,ake System-Ford, Mercury and Meteor 12-04-05 Parking Brakes 12-04-05 Parking Brakes' 12-04-06 -

Parking Brakes

CABLE ASSEMBLY 2853 PRONGS MUST BE SECURELY

CABLE ASSEMBLY 2A635 WEW Y

WASHER 381629-S WASHER?^^^

EQUALIZER LEVER 2Am5 EQUALIZER R CABLE 2A635

L.H. INSTALLATION SHOYN R.H. TYPICAL

CABLE ASSEMBLY 2A635 CABLE 2A635

VIEW U .-&

CABLE ASSEMBLY 2853 I CLEVIS PIN

PRONGS MU~TBE SECURELY LOCKED IN PLACE

VlEW T

INSTALLATION OF CABLE WITHIN BRAKE DRUM I SIDE RAIL REF L.H..6 R.H. TYPICAL CABLE ASSEMBLY 2853 VlEW IN CIRCLE B RETAINER VIE-W Z

FIG. 6-Maverick Parking Brake System FIG. 7-Parking Brake System-Thunderbird and Continental Mark Ill Parking Brakes

2. Assemble the pulley to the con- the cable to the frame. trol handle and the clevis pin. lnstall LINCOLN CONTINENTAL 5. From inside of passenger com- the clevis retainer. partment, remove spring clip that re- 3. Position the assembly against Removal tains the cable to the parking brake the dash panel and instrumentpanel. control. Disconnect the cable ball Secure the assembly to the instrument Refer to Fig. 8. from the control assembly. panel with the two screws. 1. Make sure that the parking 6. Remove the cable assembly 4. Working under the hood, install brake is fully released. from the vehicle. the two parking brake control-to-dash 2. Remove the two nuts from the panel attaching nuts. control assembly mounting studs on Installation 5. Check the parking brake for the engine compartment side of the proper operation. Adjust the parking dash panel. 1. Position the cable through the brake. 3. Working under the instrument provided openings and in the approxi- panel, remove the control assembly to mate final installation position. THUNDERBIRD .AND mounting bracket retaining screw. 2. Install the hairpin retainer on CONTINENTAL MARK 111 4. Disconnect the vacuum tube the cable at the frame crossmember. from the automatic release vacuum 3. Connect the ball end of the Removal servo motor. cable to the parking brake control. 5. Remove the retaining clip from lnstall the cable-to-control hairpin re- Refer to Fig. 7. the cable housing at the control as- taining clip. I. Remove the two nuts retaining sembly. 4. Position the .cable seal at the the control to the dash panel. 6. Disconnect the control cable ball dash panel, and slide the retaining 2. Remove two screws from the left end from' the control assembly cable clip upward to seal the cable at the scuff plate. clevis. dash opening. 3. Remove one screw retaining the 7. Remove the control assembly 5. Connect the ball end of the left cowl trim panel and remove the from the vehicle. cable to the clevis on the actuator panel. lever. 4. Remove the two screws retaining Installation 6. Adjust the parking brake. the left air duct and remove the air 7. Lower vehicle on hoist. duct. 1. Connect the vacuum tube to the 5. Remove the two screws retaining automatic release vacuum servo THUNDERBIRD AND the dimmer switch and position the motor. CONTINENTAL MARK Ill switch out of the way. 2. lnstall the control assembly 6. Remove the clip retaining the mounting studs through the holes in Removal cable assembly to the control. the dash panel and against the body 7. Disconnect the cable ball from mounting bracket. Refer to Fig. 7. the control clevis. 3. Assemble the control cable ball 1. Partially raise the vehicle. 8. Disconnect the vacuum hose at end 10 the control assembly cable 2. Back off the adjusting nut at the the brake release. clevis. equalizer to relieve the tension on the 9. Remove the bolt retaining the 4. lnstall the cable retaining clip at cable. control to the cowl side bracket and the control assembly. 3. Remove the spring at the actua- remove the control. 5. lnstall the control assembly- tor lever and disconnect the control to-mounting bracket retaining bolt cable from the clevis on the lever. Installation and torque them to specifications. 4. Remove the clip retaining the Torque them to 12-25 ft-lbs. control cable assembly to the frame 1. Position the parking brake con- 6. Install the nuts on the control bracket. trol in the vehicle. assembly mounting studs on the en- 5. Attach a length of wire to the 2. lnstall the cable assembly in the gine side of the dash panel and torque control cable. control and connect the cable ball to them to 10-20 fblbs. 6. Working inside the vehicle the control clevis. 7. Verify correct operation of the remove two screws retaining the left 3. lnstall the clip retaining the parking brake system. scuff plate. cable to the control. 7. Remove one screw and remove 4. lnstall the bolt retaining the PARKING BRAKE ACTUATOR- the left cowl side trim panel. control to the cowlside bracket. TO CONTROL CABLE 8. Remove the two screws retaining 5. Connect the vacuum hose to the the left air duct to the inner panel parking brake release vacuum motor. FORD, MERCURY and remove the air duct. 6. Position the, dimmer switch and AND METEOR 9. Remove the two screws retaining install the retainhg screws. the dimmer switch and position the 7. Position the air duct and install Removal dimmer switch back out of the way. the retaining screws. 10. Remove the clip retaining the 8. Position the cowl trim panel and 1. Raise the vehicle on a hoist. cable assembly to the :control and reinstall the retaining screw. 2. Loosen the actuator lever to move the cable ball from the control 9. Install the two scuff plate equalizer cable adjusting nut at the clevis. screws. equalizer (Fig. 3). 11. Pull the cable up through the 10. Install the two nuts retaining 3. Disconnect the cable ball from opening in the dash panel and remove the control to the dash panel. the clevis on the actuator lever. the cable'from the length of wire. 11. Adjust the parking brake. 4. Remove spring clip that retains BOLT ADJUSTMENT NUT 37403262 2A812

EQUALIZER ROD

CLl P PARKING BRAKE

10-20 LB. FT. 2 REQUIRED

-VIEW W

BOLT 381,877- S2 2 REQD.

PRONGS MUST BE SECURELY LOCKED IN PLACE L.H. SHOW (R.H. TYPICAL)

-nw T VlEW IN CIRCLES U -VlEW V

FIG. 8-Parking Brake System-Lincoln Continental Parking Brakes

lnstallation control and install the hairpin retain- trol assembly and install the clevis pin er. and hairpin retainer. 1. Attach the cable to the length of 4. Raise the vehicle. 8. Check the parking brake for wire and pull the cable down through 5. Position the cable in the body proper operation. Adjust the parking the opening in the dash panel. bracket and install the hairpin retain- brake. 2. Position the upper end of the er. control cable to the control. Connect 6. Position the spring, spring re- MUSTANG AND COUGAR the cable ball to the control clevis and tainer and equalizer on the cable and install the clip retaining the cable install the two nuts. Removal housing to,the control. 7. Adjust the parking brake. 3. Remove the length of wire from Refer to Fig. 5. the cable assembly and position the MAVERICK 1. Make certain the parking brake cable in the frame bracket. Install the is fully released. retainer. Removal 2. Raise the vehicle on a hoist. Re- 4. Connect the cable ball to the move the two nuts that attach the clevis on the actuator lever and install Refer to Fig. 6. cable to the equalizer. Remove the the actuator lever spring. 1. Remove the hairpin clip and equalizer spring seat and spring. 5. Adjust the parking brake. clevis pin that secures the cable pulley 3. Remove the hairpin retainer 6. Reposition the dimmer switch to the control handle assembly and holding the cable assembly to the and install the retaining screws. remove the pulley. body bracket and pull the cable out 7. Position the air duct to the inner 2. Disengage the locking pawl and of the side rail access holes. panel and'install the retaining screws. slide the control rod forward. Remove 4. Attach a wire to the end of the 8. Position the cowl side trim panel the cable ball from the slot in the cable to assist in routing new cable. and install the retaining screw. control rod. 5. Lower the vehicle. 9. Install the two screws in the 3. Remove the hairpin retainer 6. Remove the parking brake front scuff plate. from the dash panel bracket and di- cable ball retaining clip from the clev- sengage the cable from the bracket. is. PARKING BRAKE 4. Pull the cable and insulator tube 7. Disconnect the cable ball from EQUALIZER TO CONTROL down through the hole in the dash the notch in the brake clevis. CABLE panel. Remove the insulator tube 8. Remove the hairpin retainer and from the cable. remove the cable assembly from the FAIRLANE, MONTEGO 5. Raise the vehicle on a hoist. brake control assembly. AND FALCON 6. Remove the retaining screw and 9. Pull the cable assembly up clip from the cable on the chassis side through the opening in the floor and Removal rail. remove the wire from the end of the 7. Disengage the cable stepped-rod cable. Refer to Fig. 4. from the equalizer lever. 1. Make certain the parking brake 8. Remove the hairpin retainer lnstallation is fully released. from the cable housing at the 2. Raise the vehicle on a hoist. Re- crossmember. Refer to Fig. 5. move the two nuts that attach the 9. Pull the cable forward through 1. Connect the wire to the end of cable to the equalizer. Remove. the the crossmember and remove the the cable assembly and pull the cable equalizer, spring seat and spring. cable from the vehicle. down through the opening in the 3. Remove the hairpin retainer floor. Remove the wire. holding the cable assembly to the Installation 2. Connect the cable assembly to body bracket and remove the cable the brake control assembly and install from the slot in the bracket. Refer to Fig. 6. the hairpin retainer. 4. Lower the vehicle partially. 1. Pass the stepped-rod rearward 3. Position the ball end of the 5. Remove the hairpin retainer through the crossmember and connect cable in the notch of the brake clevis. which retains the cable assembly to it into the equalizer lever. 4. Raise the vehicle on a hoist. the control. 2. Install the hairpin retainer on 5. Pull the cable grommet into po- 6. Remove the cable bolt retaining the cable housing at the crossmember. sition and route the cable through the clip from the control clevis and dis- 3. Install the cable housing retain- access holes in the side rail and under connect the cable ball from the clevis. ing clip on the cable and install the the fuel line. 7. Pull the cable down through the retaining screw on the chassis side 6. Insert the cable into the body opening in the floor pan and frame rail. bracket and install the hairpin retain- side rail. 4. Install the insulator tube onto er. the upper end of the cable and push 7. Position the spring, spring seat. lnstallation the cable and insulator up through the and equalizer on the cable and install hole in the dash panel. the two nuts. 1. Route the new cable through the 5. Engage the upper end of the 8. Adjust the parking brake. frame side rail and up through the cable housing in the dash panel opening in the floor pan. Pull the bracket and install the hairpin retain- LINCOLN CONTlNENTAL cable up into position. er. 2. Connect the ca.ble ball in the 6. Connect the cable ball to the Removal control clevis. control rod. 3. Insert the cable housing into the 7. Assemble the pulley to the con- Refer to Fig. 8. Parking Brakes

1. Make sure that the parking equalizer. 2. Pull the excess slack from the brake is fully released. 3. Remove the cable end from the cable, and insert the cable housing 2. Raise the vehicle. equalizer. into the brake backing plate access 3. Loosen the parking brake cable 4. Unhook the cable from the actu- hole so that the retainer prongs ex- adjusting nut at the equalizer lever. ator, and remove from the vehicle. pand. The prongs must be securely 4. Lower the vehicle. locked in place. lnstall the automatic 5. Remove the cable housing re- lnstallation brake adjuster spring. taining clip and then disconnect the 3. Position the right hand cable control cable ball end from the con- 1. Insert new cable end into actua- and the two retaining clips and screws trol assembly clevis. tor. on the rear crossmember. Compress 6. Raise the vehicle. 2. Insert cable end into equalizer the prongs on the right cable and po- 7. Pull the cable and housing and tighten the adjusting nut snug. sition the cable in the retaining brack- downward through the .dash panel Install the lock nut. et on the frame side member. Be sure opening. 3. Adjust the parking brake. the lo.cating stripe on the cable is 8. Remove the retainer clip from 4. Lower the vehicle. midway between the retaining clips the cable housing at the number 3 and tighten all retaining clip screws. crossmember. PARKING BRAKE EQUALIZER 4. Position the left cable, retaining 9. Disconnect the cable ball end TO REAR WHEEL CABLE clip and screw on the left lower sus- from the parking brake cable clevis at pension arm. Compress the prongs on the actuator lever. FORD, MERCURY, the left cable and position the cable 10, Pull the parking brake cable METEOR, THUNDERBI RD through the frame side-member. The forward through. the holes in the AND CONTINENTAL prongs must be securely locked in number 3 crossmember and remove MARK Ill place. the cable and housing assembly from 5. Insert the ball ends of the cables the vehicle. Removal into the equalizer assembly. 6. Install the rear drum(s) and Installation 1. Raise the vehicle and loosen the tighten the three Tinnerman nuts and parking brake equalizer rod adjusting secure the drum. Install the wheel and 1. Push the rear end of the parking nut. Disconnect the equalizer from tire and the wheel cover. brake cable rearward through the the rear cables (Figs. 3 and 7). 7. Adjust the parking brake link- holes in the number 3 crossmember. 2. Compress the prongs on the left age. 2. Connect the cable ball end to cable-to-frame side member retainer the parking brake cable clevis at the so the prong can pass through the MAVERICK actuator lever. side-member. Remove the clip that 3. Install the retaining clip on the attaches the left cable to the left Removal cable housing at the number 3 lower arm. Pull the cable thru the crossmember. frame left side member. Refer to Fig. 6. 4. Push the forward end of the 3. Compress the prongs. on the 1. Completely release the parking cable and housing upward through the right cable-to-frame side member re- brake. dash panel opening. tainer bracket so the prong can pass 2. Raise the vehicle on a hoist. 5. Lower the vehicle. through the bracket. Remove the clips 3. Loosen the adjusting nut and 6. Connect the cable ball end to retaining the right cable to the frame remove rear parking brake cable ball the control assembly clevis and install crossmember. end from the connector. the retaining clip. 4. Remove the rear wheel cover 4. Remove the adjusting nut from 7. Raise the vehicle. and wheel. Remove the three Tinner- the equalizer rod and remove the 8. Adjust the parking brake. Refer man nuts that hold the brake drum in cable from the equalizer. to the Parking Brake Adjustment, place and remove the drum. 5. Compress the pronged retainer Procedures in this manual. 5. Working on the wheel side of at the rear spring front h.anger brack- 9. Lower the vehicle. the rear brake, remove the automatic et and pull the cable rearward 10. Verify correct operation of the brake adjuster spring. Compress the through the bracket. parking brake. prongs on the parking brake cable re- 6. Remove the wheel cover, wheel tainer so that they can pass through and, tire, and rear brake drum. PARKING BRAKE the hole in the brake backing plate. 7. Remove the self-adjuster springs ACTUATOR-TO-EQUALIZER Draw the cablt retainer through the to allow clearance to remove the CABLE hole. cable retainer from the backing plate. 6. With the spring tension off- the Disconnect the rear end of the cable FORD, MERCURY, parking brake lever, lift the cable out from the parking brake lever on the METEOR, THUNDERBI RD of the slot in the lever,and remove the secondary brake shoe. -- AND CONTINENTAL cable through the backing plate hole. 8. Compress the pronged retainer MARK III at the brake backing plate and pull the cable from the backing plate. Removal 9. Remove the screw from the re- 1. Pull .enough of the parking tainer on the rear spring. Remove the Refer to Figs. 3 and 7. brake cable through the housing so parking brake cable from the retainer 1. Raise the vehicle on a hoist. that the end of the cable may be in- and remove the cable from the vehi- 2. Remove the lock and adjusting serted over the slot .in the parking cle. nut which retains the cable to the brake lever on the rear brake shoe. Parking Brakes

Installation brake shoe. Disengage the cable hous- I. Raise the vehicle. ing retaining grommet or steel- 2. Loosen the parking brake ad- Refer to Fig. 6. pronged Hi-Hat from the backing justment nut and disconnect the rear I. Insert the forward end of the plate and withdraw the cable and brake cables from the equalizer. new parking brake cable through the housing from the inboard side of the 3. Remove the rear cable retaining hole in the rear spring front hanger backing plate. clips and pull the cables through the bracket. Pull the cable through until 7. Slide the cable and housing out left frame side member. the cable retainer prongs are firmly of the side rail bracket. 4. Remove the retaining clip that seated in the bracket hole. attaches the left rear cable to the 2. Push the cable rear end through Installation lower left arm. the hole in the brake backing plate 5. Remove the clips that retain the and pull into backing plate hole until I. Insert the rear end of the cable right rear cable to the number 4 cable retainer prongs are securely po- through the side rail bracket and pull crossmember and at the right frame sitioned in the backing plate cable the cable and housing into position. side rail. hole. 2. lnsert the rear end of the cable 6. Remove the rear wheel covers, 3. Connect the cable end to the and housing through the hole in the and the tire and wheel assemblies. parking brake lever on the rear brake backing plate from the inboard side. Remove the Tinnerman retaining nuts secondary shoe and install the brake 3. Connect the cable to the parking and remove the rear drums. self-adjuster spring. brake lever on the brake shoe and in- 7. Remove the automatic brake 4. lnstall the brake drum, wheel stall the cable housing retaining adjuster spring. and tire assembly and wheel cover. grommet or steel-pronged Hi-Hat in 8. Compress the parking brake 5. Position the parking brake cable the backing plate. cable housing retainer prongs and pull in the rear spring cable retainer, and 4. Install the self-adjuster springs. the retainer through the backing plate install and tighten the nut on the re- Position the cable housing in the side hole. tainer stud. rail bracket and install the hairpin 9. Relieve the spring tension and 6. Install the ball end of the cable type retainer. lift the cable end from the parking in the connector. 5. Install rear hub and drum as- brake lever. 7. Position the cable in the equaliz- sembly, wheel and tire assemblies and 10. Remove the parking brake er and install the equalizer rod adjust- wheel cover as outlined in Section 2. cable from the backing plate. ing nut. 6. Position the cable retainer hooks 8. Verify proper operation of the (station wagon models) in the under- lnstallation parking brake. body guide (convertible models) and 9. Adjust the parking brake. Refer install the connector, thus hooking I. Position the parking brake cable to "Parking Brake Adjustment". the two cables together. through the hole in the backing plate. 7. Insert the cable into the equaliz- 2. Relieve the spring tension and FAIRLANE, MONTEGO, er and install the equalizer, spring install the cable ball end in the park- MUSTANG AND COUGAR- seat, spring, adjusting nut and lock ing brake lever slot. Securely seat the EXCEPT STATION WAGON nut to the front, parking brake con- retainer prongs in the hole in the trol cable. backing plate. Removal 8. Adjust the parking brake. 3. Install the automatic brake adjuster spring. 1. Remove the equalizer lock, ,nut FA1 RLANE AND MONTEGO 4. Install the brake drum and the and adjusting nut, equalizer, spring STATION WAGONS AND Tinnerman retaining nuts. Install the and spring seat. FALCON PASSENGER wheel and tire assembly and wheel 2. With the cables slack, discon- MODELS cover. nect the ballends from the connector 5. Install the clips that attach the (Figs. 4 and 5). Removal and lnstallation right rear cable to the number 4 3. Remove the cable from the re- crossmember and the clip that retains tainer hooks (station wagon models) Refer to Fig. 4. the cable at the right frame side rail. and the underbody guide (convertible Generally follow the procedure 6. Install the cable clip that attach- models) if required. given above, omitting separation of es the left rear cable to the left lower 4. Remove the hairpin lock retain- the cables, since the parking brake arm. ing the cable housing to the side rail rear cable assemblies supplied for 7. Position the cables through the bracket. these models is in one piece. Removal left frame side member and install the 5. Remove the wheel cover, wheel and installation of both rear wheels, retaining clips. and tire and the rear brake drum as tires and drums will also be required. 8. Install the cable ends in the outlined in Part 12-02. equalizer lever. 6. Remove self-adjuster springs to LINCOLN CONTINENTAL 9. Adjust the parking brakes. Refer allow clearance to remove cable re- to the Parking Brake Adjustment tainer from the backing plate. Dis- Removal procedures in this manual. connect the rear end of the cable 10. Lower the vehicle. from the parking brake lever on the Refer to Fig. 8. 1 2-04- 14 Parking Brakes 1 2-04- 14

4 SPECIFICATIONS

TORQUE UMlrSGENERAL-fT4BS. Fairlane- Thunderbird Ford-Mercury Montego Mustang. Continental Lincoln Meteor Falcon Maverick Cougar Mark Ill Continental Parking Brake Control Assembly Cap Screw 12-25 Cap Screw 12-25 12-18 Dash Panel Mounting Nuts and Bolts 12-19 8-12 12-25 Nuts 7-11 Nuts 8-12 Inst. Panel 10-20 CH1730-A 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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