differential FORD MUSTANG 1969 Volume One Chassis

02-01-01

02-01-01

GROUP

2

PART
2-1
PAGE

General Brake Service 02-01-01

PART
2-2

Brake System 02-02-01
PART
2-3

Specifications
PAGE

02-03-01

Part
2-1
General Brake Service

COMPONENT INDEX

ANTI SKID CONTROL SYSTEM

Tests

BRAKE BOOSTER

Adjustments

Cleaning
and
Inspection

Tests

BRAKE PEDAL

Free Height Test

Total Travel Test

DISC BRAKES

Cleaning
and
Inspection

Service Precautions

DRUM BRAKES

Cleaning
and
Inspection

HYDRAULIC SYSTEM BLEEDING

PARKING BRAKE CONTROL

Vacuum Release Test

PARKING BRAKE LINKAGE

Adjustment

PRESSURE DIFFERENTIAL VALVE

Adjustment (Centralize)
MODEL APPLICATION
All
Models

01-04

01-07

01-02

01-01

01-01

01-07

01-07

01-08

01-05

01-07
Ford
N/A

01-03

01-03
Mercury
N/A

01-03

01-03
Meteor
N/A

01-03

01-03
Cougar
N/A

N/A

01-03
Fairlane
N/A

N/A

01-03
F

alcon
N/A

N/A

01-03
Montego
N/A

N/A

01-03
Mustang
N/A

N/A

01-03
Lincoln-
Continental
N/A

01-03

01-04
Thunderbird
01-03

01-03

01-04
Continental-
Mark III
01-03

01-03

01-04

A page number indicates that the item
is for the
vehicle listed
at
the head
of the
column.

N/A indicates that the item
is not
applicable
to
the vehicle listed.

1 BRAKE SYSTEM TESTS

Always check
the
fluid level
in the

master cylinder before performing
the

test procedures.
If the
fluid level
is not

within
1/4
inch
of the top of the mas-

ter cylinder reservoirs,
add
Ford

Brake Fluid
—
Extra Heavy Duty —

Part Number C6AZ-19542-A
(ESA-

M6C25-A)
or
equivalent
for all
brake

applications.
The
extra heavy duty

brake fluid
is
colored blue
for
identifi-

cation purposes.
Do not mix low tem-

perature brake fluids with
the
speci-

fied brake fluid.

Should
one of the
wheel brakes
be

locked
and the
vehicle must
be
moved,

open
the
bleeder screw long enough
to

let
out a few
drops
of
brake fluid.

This bleeding operation will release

the brakes
but
will
not
correct
the

cause
of
trouble.
BRAKE PEDAL FREE

HEIGHT
AND
TRAVEL

MEASUREMENTS

With
the
engine running
for
full

power brake operation, measure
the

brake pedal free height,
and
check
the

brake pedal travel with
the use of the

Brake Pedal Pressure Gauge, Tool

WRE-5OO-5O
as
follows:

BRAKE PEDAL FREE HEIGHT

MEASUREMENT

1.
Insert
a
slender, sharp pointed

prod through
the
carpet
and
sound

deadener
to the
dash panel metal
and

measure
the
distance
to the
brake

pedal
(Fig. 1).

2.
If the
position
of the
pedal
is not

within specification, check
the
brake
pedal linkage
for
missing, worn,
or

damaged bushings,
or
loose attaching

bolts
and
replace them,
if
required.

3.
If the
pedal free height
is
still

out
of
specification, check
the
brake

pedal booster
or
master cylinder
to be

sure
the
correct parts
are
installed.

Replace
the
worn
or
damaged parts
as

necessary.

BRAKE PEDAL TRAVEL

MEASUREMENT

1.
Install
a
Brake Pedal Effort

Gauge
on the
brake pedal
pad
(Fig. 2).

2.
Hook
a
steel measuring tape
to

the brake pedal
as
shown
in Fig. 1.

Measure
and
record
the
distance from

the brake pedal free height position
to

the reference point, which
is at the six
procarmanuals.com

02-01-02
Brakes

02*01-02

STEERING
WHEEL RIW

TOEBOARD
OR

DASH
METAL
CHECKING
POINTS

STEERING
COLUMN-

STEEL
MEASURING TAPE

VEHICLE

FORD,
MERCURY AND METEOR

FORD,
MERCURY AND METEOR

FORD,
MERCURY AND METEOR

FORD,
MERCURY AND METEOR

FAIRLANE,
MONTEGO AND FALCON

FAIRLANE,
MONTEGO AND FALCON

MUSTANG
AND COUGAR

MUSTANG
AND COUGAR

THUNDERBIRD

CONTINENTAL
MARK III

LINCOLN
CONTINENTAL
TYPE

NON-POWER
DRUM

POWER
DRUM & DISC

NON-POWER
DISC

POLICE
POWER DISC

NON-POWER
DRUM

POWER
DISC

NON-POWER
DRUM

POWER
DISC

POWER
DISC

POWER
DISC

POWER
DISC
PEDAL
FREE

HEIGHT-A

8.09-7.17

6.18-5.99

8.65-7.82

7.58-6.72

8.13-6.91

7.25-5.71

7.49-6.43

6.25-5.56
PEDAL
FREE

HEIGHT-B"

5.96-5.04

5.96-5.04

6.50-5.50
PEDAL

TRAVEL-C

3.10

3.27

2.18

3.27

2.90

2.35

2.58

1.75

3.00

3.00

2.25

NOTE:AgB
DIMENSION TO BE MEASURED TO SHEET METAL

C
DIMENSION TO BE MEASURED PARALLEL TO THE VERTICAL CENTERLINE OF THE

STEERING
COLUMN WITH A 50 POUND LOAD APPLIED TO THE CENTERLINE OF THE

BRAKE
PEDAL PAD. (CHECKS ON POWER BRAKE VEHICLES MADE WITH ENGINE RUNNING

H1630-A

FIG. 1 — Brake Pedal Height and Travel Measurements

Tool-WRE-l

HI525-A

FIG.
2—Brake Pedal Effort Gauge Installed
o'clock position on the steering wheel

rim.

3.
With the steel tape still hooked

to the brake pedal depress the brake

pedal by pressing downward on the

brake pedal effort gauge. Apply a 50

pound load to the center of the pedal

by observing the pressure gauge, and

measure the distance from the brake

pedal to the fixed reference point on

the steering wheel rim parallel to the

centerline of the steering column.

4.
The difference between the brake

pedal free height and the depressed

pedal measurement under a 50 pound

load should be within the specified

maximum pedal travel service specifi-

cation B in Fig. I.

5.
If the pedal travel is more than

the specified maximum shown in Fig.

1,
dimension C, make several sharp

reverse stops (equivalent to 50 pounds

pedal pressure) with a forward stop

before each. Move the vehicle in rev-

erse and forward for a distance of ap-

proximately ten feet; then, apply the

brakes sharply and hold the brake

pedal down until the vehicle is com-

pletely stopped. This will actuate the

brake self-adjusters. If these stops do

not bring the brake pedal travel within

specification, make several additional

forward and reverse stops as outlined

above.

6. If the second series of stops do

not bring the brake pedal travel within

specification, remove the brake drums

and check the brake adjusters to make

sure they are functioning. Check the

brake linings for wear or damage. Re-

pair or replace all worn or damaged

parts and non-functioning adjusters.

Adjust the brake lining outside diame-

ter to the approximate inside diameter

of the brake drum with Rotunda Tool

HRE-8650 (Fig. 12, Part 2-2).

7.
If all the brake adjusters, brake

drums and linings are functional and

the brake travel is not within specifi-

cations, check the pedal linkage for

missing or worn bushings, or loose at-

tachments. Bleed the brakes and cen-

tralize the differential valve.

POWER BRAKE

FUNCTIONAL TEST

1.
Check the hydraulic brake sys-

tem for leaks or insufficient fluid.

2.
With the transmission in neutral,

stop the engine and apply the parking

brake. Depress the brake pedal several

times to exhaust all vacuum in the

system.

3.
With the engine shut off and all

vacuum in the system exhausted, dep-

ress the pedal, and hold it in the ap-

plied position. Start the engine If theprocarmanuals.com

02-01-05
Brakes

02-01-05

1.
Disconnect the master cylinder

from the booster assembly and secure

away from the booster without discon-

necting the brake tubes.

2.
Reinstall the air filter assembly

on the booster if it was removed with

the master cylinder (Fig. 8).

3.
Install and tighten the master

cylinder retaining nuts to retain the

air filter assembly securely against the

booster body and to seal the booster

bellows against air leaks.

4.
Place the gauge against the

master cylinder mounting surface of

the air filter assembly.

5.
Adjust the push rod screw to

provide a slight tension against the

inner edge of the adjustment gauge

slot. (Approximately 5 pounds of ten-

sion against the push rod is required

to assure that the push rod is firmly

seated in the booster assembly.)

6. Remove the retaining nuts from

the booster master cylinder mounting

studs.

7.
Install the master cylinder on the

brake booster and tighten the retain-

ing nuts to the specified torque.

The push rod length verification of

the Bendix power brake booster

assemblies is accomplished as follows:

1.
Disconnect the master cylinder

from the booster assembly and secure

away from the booster without discon-

necting the brake tubes.

2.
Adjust the push rod screw to

provide a slight tension against the

inner edge of the adjustment gauge

slot. (Approximately 5 pounds of ten-
sion against the push rod is required

to assure that the push rod is firmly

seated in the booster assembly.) See

Figure 8.

3.
Install the master cylinder on the

brake booster and tighten the retain-

ing nuts to the specified torque.

Do not set up side forces on the

push rod as it may break the valve

plunger.

This is an approximate adjustment

only. To verify the adjustment, look

through the make-up (rear) port of the

master cylinder when installing the

master cylinder to the booster. The

master cylinder piston should not

move more than 0.015 inch as it con-

tacts the push rod. No movement

(exact contact) is ideal.

HYDRAULIC SYSTEM BLEEDING

AND CENTRALIZING OF THE

DIFFERENTIAL VALVE

When any part of the hydraulic sys-

tem has been disconnected for repair

or replacement, air may enter the sys-

tem and cause spongy pedal action.

Bleed the hydraulic system after it has

been properly connected, to be sure

that all air is expelled.

MANUAL BLEEDING

The Lincoln Continental hydraulic

brake system is to be bled only with

pressure bleeding equipment.

The primary and secondary (front

MANIFOLD CHECK VALVE-2365 19-25 IN. LB.

TIGHTEN RETAINING NUTS

TO SECURE AIR FILTER

AGAINST BOOSTER BODY

AND BELLOWS

ADJUST PUSH ROD SCREW TO

PROVIDE A SLIGHT TENSION

(APPROXIMATELY 5 LBS.)

AGAINST THE GAUGE

PUSH ROD GAUGE
and rear) hydraulic brake systems are

individual systems and are bled separ-

ately. Bleed the longest line first on

the individual system being serviced.

During the complete bleeding opera-

tion,
DO NOT allow the reservoir to

run dry. Keep the master cylinder res-

ervoirs filled with Ford Fluid—Extra

Heavy Duty — Part Number C6AZ-

19542-A (ESA-M6C 25-A). The extra

heavy duty brake fluid is colored blue

for identification purposes. Do not

mix low temperature brake fluids with

the specified fluid during the bleeding

operations. Never re-use brake fluid

which has been drained from the hy-

draulic systems.

1.
If the master cylinder is

equipped with a bleed screw, loosen

the bleed screw. Push the brake pedal

down slowly through its full travel.

Close the bleeder fitting and return

the pedal to the fully released posi-

tion. Repeat this operation until fluid

is free of air bubbles, then tighten the

bleeder screw. Do not use the second-

ary piston stop screw, located on the

bottom of the master cylinder to bleed

the brake system. Loosening or re-

moving this screw could result in dam-

age to the secondary piston or stop

screw.

2.
To bleed the secondary (rear)

brake system, position a suitable 3/8

inch box wrench (Fig. 9) on the bleed-

er fitting on the brake wheel cylinder.

Attach a rubber drain tube to the

bleeder fitting. The end of the tube

should fit snugly around the bleeder

fitting.

APPROXIMATELY 45°

PUSH ROD ADJUSTMENT-MIDLAND-ROSS

FIG. 8—Brake Booster Push Rod Measurement
PUSH ROD ADJUSTMENT-BENDIX

H1589-A
H1300-B

. 9—Wrench for Bleeding

Brake Hydraulic System

3.
Submerge the free end of the

tube in a container partially filled with

clean brake fluid, and loosen the

bleeder fitting approximately 3/4 turn.

4.
Push the brake pedal down slow-

ly through its full travel. Close the

bleeder fitting, then return the pedal

to the full-released position. Repeat

this operation until air bubbles cease

to appear at the submerged end of the

bleeder tube.

5.
When the fluid is completely free

of air bubbles, close the bleeder fitting

and remove the bleeder tube.

6. Repeat this procedure at the

brake wheel cylinder on the oppositeprocarmanuals.com

02-01-06

Brakes

02-01-06

side.
Refill the master cylinder reser-

voir after each wheel cylinder is bled

and install the master cylinder cover

and gasket. Be sure the diaphragm

type gasket is properly positioned in

the master cylinder cover. When the

bleeding operation is completed, the

fluid level should be filled to within

1/4 inch of the top of the reservoirs.

7. If the primary (front brake) sys-

tem is to be bled. Repeat steps 2

through 6 at the right front brake cal-

iper or cylinder and ending at the left

front brake caliper or cylinder.

8. On disc brake equipped models

be sure that the front brake pistons

are returned to their normal positions

and that the shoe and lining assem-

blies are properly seated by depressing

the brake pedal several times until

normal pedal travel is established.

9. Centralize the pressure differen-

tial valve. Refer to the Centralizing

the Pressure Differential Valve proce-

dures which follow.

PRESSURE BLEEDING

The Lincoln Continental hydraulic

brake system is to be bled only with

pressure bleeding equipment.

Bleed the longest lines first. The

bleeder tank should contain enough

new Ford Brake Fluid to complete the

bleeding operation. Use Ford Brake

Fluid — Extra Heavy Duty — Part

Number C6AZ-19542-A (ESA-

M6C25-A) or equivalent for all brake

applications. The brake fluid is col-

ored blue for identification purposes.

Do not mix low temperature brake

fluid with the specified brake fluid

during the bleeding operations. Never

re-use brake fluid that has been

drained from the hydraulic system.

The tank should be charged with ap-

proximately 10 to 30 pounds of air

pressure. Never exceed 50 pounds

pressure.

1.
Clean all dirt from the master

cylinder reservoir cover.

2.
Remove the master cylinder res-

ervoir cover and rubber gasket, and

fill the master cylinder reservoir with

the specified brake fluid. Install the

pressure bleeder adapter tool to the

master cylinder, and attach the bleed-

er tank hose to the fittng on the

adapter.

Master cylinder pressure bleeder

adapter tools can be obtained from

the various manufacturers of pressure

bleeding equipment. Follow the in-

structions of the manufacturer when

installing the adapter.

3.
If the master cylinder is

equipped with a bleed screw, loosen
the bleed screw and bleed the master

cylinder until the fluid is free of air

bubbles; then, tighten the bleed screw.

Do not use the secondary piston stop

screw, located on the bottom of the

master cylinder, to bleed the master

cylinder.

4.
If the rear wheel cylinders, the

secondary brake system, are to be

bled, position a 3/8 inch box wrench

(Fig. 9) on the bleeder fitting on the

right rear brake wheel cylinder. At-

tach a bleeder tube to the bleeder fit-

ting. The end of the tube should fit

snugly around the bleeder fitting.

5. Open the valve on the bleeder

tank to admit pressurized brake fluid

to the master cylinder reservoir.

6. Submerge the free end of the

tube in a container partially filled with

clean brake fluid, and loosen the

bleeder fitting.

7.
When air bubbles cease to ap-

pear in the fluid at the submerged end

of the bleeder tube, close the bleeder

fitting and remove the tube.

8. Repeat steps 3 through 7 at the

left rear wheel cylinder.

9. If the vehicle is equipped with

disc brakes, repeat steps 4 through 7,

starting at the right front disc caliper

and ending at the left front disc cali-

per.

On Lincoln Continental models the

front wheel and tire assemblies must
be removed to gain access to the

bleeder fittings on the calipers. Also

on Lincoln Continental models the

metering valve release rod must be

pulled outward and held a minimum

of 1/16 inch (Fig. 10) while bleeding

the primary brake system.

10.
If the vehicle contains drum-

type front brakes and the primary

(front) brake system is to be bled, re-

peat steps 4 through 7, starting at the

right front wheel cylinder ending at

the left front wheel cylinder.

11.
When the bleeding operation is

completed, close the bleeder tank

valve and remove the tank hose from

the adapter fitting.

12.
On disc brake equipped ve-

hicles,
be sure that the front brake

pistons are returned to their normal

positions and that the shoe and lining

assemblies are properly seated by dep-

ressing the brake pedal several times

until normal pedal travel is esta-

blished.

13.
Remove the Pressure Bleeder

Adapter Tool. Fill the master cylinder

reservoirs to within 1/4 inch of the

top.
Install the master cylinder cover

and gasket. Be sure the Diaphragm

type gasket is properly positioned in

the master cylinder cover.

14.
Centralize the pressure differen-

tial valve as follows.

METERING VALVE

BLEEDER RETAINER

SEE

VIEW A

RELEASE ROD

FIG. 10—Disc Brake Metering Valve—Lincoln Continental
HI 644-Aprocarmanuals.com

02-01-07
Brakes

02-01-07

CENTRALIZING THE

PRESSURE DIFFERENTIAL

VALVE

After a failure of the primary (front

brake) or secondary (rear brake) sys-

tem has been repaired and bled, the

dual-brake warning light will usually

continue to be illuminated due to the

pressure differential valve remaining in

the off-center position.

To centralize the pressure differen-

tial valve and turn off the warning
light after a repair operation, a pres-

sure differential or unbalance condi-

tion must be created in the opposite

brake system from the one that was

repaired or bled last.

1.
Turn the ignition switch to the

ACC or ON position. Loosen the dif-

ferential valve assembly brake tube

nut at the outlet port on the opposite

side of the brake system that was

wheel balanced, repaired and/or bled

last. Depress the brake pedal slowly to

build line pressure until the pressure
differential valve is moved to a cen-

tralized position and the brake warn-

ing light goes out; then, immediately

tighten the outlet port tube nut.

2.
Check the fluid level in the mas-

ter cylinder reservoirs and fill them to

within 1/4 inch of the top with the

specified brake fluid, if necessary.

3.
Turn the ignition switch to the

OFF position.

4.
Before driving the vehicle, check

the operation of the brakes and be

sure that a firm pedal is obtained.

CLEANING AND INSPECTION

DISC BRAKES

1.
Remove the wheel and tire and

the shoe and lining assemblies as out-

lined in Part 2-2, Section 2.

2.
On all models except Lincoln

Continental, make thickness measure-

ments with a micrometer across the

thinnest section of the shoe and lining.

If the assembly has worn to a thick-

ness of 0.230-inch (shoe and lining to-

gether) or 0.030-inch (lining material

only) at any one of three measuring

locations or if there is more than

0.125 taper from end to end or if lin-

ing shows evidence of brake fluid con-

tamination, replace all (4) shoe and

lining assemblies on both front wheels.

On Lincoln Continental brakes

make three thickness measurements

with a micrometer across the middle

section of the shoe and lining. Take

one reading at each side and one in

the center. If the assembly has worn

to a thickness of 0.231 inch (shoe and

lining together) or 0.066 inch (lining

material only) at any one of the three

measuring locations, replace all (4)

shoe and lining assemblies on both

front wheels.

3.
Check the caliper to spindle at-

taching bolts torque. Torque them to

specification, if required.

4.
To check rotor runout, first

eliminate the wheel bearing end play

by tightening the adjusting nut. After

tightening the nut, check to see that

the rotor can still be rotated.

5.
Clamp a dial indicator to the

caliper housing so that the stylus con-

tact the rotor at a point approximate-

ly 1 inch from the outer edge. Rotate

the rotor and take an indicator read-

ing. If the reading exceeds 0.003 inch

total lateral runout on the indicator,

replace or resurface the disc brake

rotor. The following requirement must

be met when resurfacing disc brake

rotors:
Rotunda Disc Brake Attachment

FRE-2249-2 is the only approved tool

to be used to refinish the disc brake

rotors.
The step-by-step resurfacing

procedure provided with the tool must

be adhered to.

The finished braking surface of the

rotor must be flat and parallel within

0.0007 inch; lateral runout must not

exceed 0.003 inch total indicator

reading, braking surface are to be 80/15

micro inches.

On all models except Lincoln Con-

tinental the minimum limiting dimen-

sion from the inboard bearing cup to

the inboard rotor face and the mini-

mum rotor thickness dimension, must

be observed when removing material

from the rotor braking surfaces. A

ball and gage bar (Rotunda Kit FRE

70160) is to be used when checking

minimum dimensions (Fig. 11).

FALCON-FAIRLANE

MUSTANG-COUGAR

MONTEGO

.046 MAX-**

.119
MAX.

FORD-MERCURY

METEOR - THUNDERBIRD
875
MIN

H1633-A

1.12
MIN.-^

??
— Disc Brake Rotor

Service Limits—All Models Except

Lincoln Continental

On Lincoln Continental models the

minimum limiting dimension (Fig. 12)

from the inboard bearing cup to the
inboard rotor face (dimension B)

and the outboard rotor surface and

the inboard bearing cup (dimension

A),
must be observed when remov-

ing material from the rotor braking

surfaces.

When the runout check is finished

be sure to adjust the bearings as out-

lined in Group 3, in order to prevent

bearing failure.

6. Check the rotor for scoring. Mi-

nor scores can be removed with a

fine emery cloth. If the rotor is ex-

cessively scored, refinish it as out-

lined in step 5 or replace the rotor,

if required.

7.
Visually check the caliper. If the

caliper housing is leaking it should be

replaced. If a seal is leaking the cali-

per must be disassembled and new

.seals installed. If a piston is seazed

in the bore a new caliper housing is

required.

On Lincoln Continental models the

two halves of the caliper assembly

should never be separated. Damage or

failure of one requires replacement of

both as a unit.

Check the brake hoses for signs of

cracking, leaks or abrasion. Replace

them if necessary.

DISC BRAKE SERVICE

PRECAUTIONS

1.
Grease or any other foreign ma-

terial must be kept off the caliper as-

sembly, surfaces of the rotor and ex-

ternal surfaces of the hub during serv-

ice operations. Handling of the rotor

and caliper assemblies should be done

in a way to avoid deformation of the

brake rotor and nicking or scratching

of brake linings.

2.
If a caliper piston is removed for

any reason, the piston seal must be re-

placed.

3.
During removal and installation

of a wheel assembly, exercise care not

to interfere with and damage the cali-procarmanuals.com

02-02-02

Brake
System
02-02-02

COMPONENT INDEX

DISC BRAKE SHOE AND LINING

Cleaning and Inspection
-
See
Part 2-1

Removal and Installation

DRUM BRAKE

Description

DUAL BRAKE SYSTEM

Description

HYDRAULIC LINES

Removal
and
Installation (Hose)

Removal
and
Installation (Tube)

MASTER CYLINDER

Cleaning
and
Inspection

Disassembly
and
Overhaul

Removal
and
Installation - Non-Power

Removal
and
Installation - Power

PARKING BRAKE

Description

PARKING BRAKE ACTUATOR
TO

CONTROL CABLE

Removal
and
Installation

PARKING BRAKE ACTUATOR
TO

EQUALIZER CABLE

Removal
and
Installation

PARKING BRAKE CONTROL

Removal
and
Installation

PARKING BRAKE EQUALIZER
TO

CONTROL CABLE

Removal
and
Installation

PARKING BRAKE EQUALIZER
TO

REAR WHEEL CABLE

Removal
and
Installation

PRESSURE DIFFERENTIAL VALVE

Removal
and
Installation

PRESSURE METERING VALVE

Removal
and
Installation

PROPORTIONING VALVE

Removal
and
Installation

WHEELCYLINDER

Cleaning
and
Inspection

Disassembly
and
Overhaul

Removal
and
Installation
MODEL APPLICATION
All
Models

02-05

02-03

02-08

02-08

02-40

02-39

02-21

02-06

02-22

02-08

02-07

02-10
Ford
02-18

02-19

02-34

02-35

02-27

N/A

02-35

N/A

02-23
Mercury
02-18

02-19

02-34

02-35

02-27

N/A

02-35

N/A

02-23
Meteor
02-18

02-19

02-34

02-35

02-27

N/A

02-35

N/A

02-23
Cougar
02-18

02-20

N/A

N/A

02-30

02-34

02-36

N/A

02-23
Fairlane
02-18

02-20

N/A

N/A

02-27

02-34

02-36

N/A

02-23
Falcon
02-18

02-20

N/A

N/A

02-27

02-34

02-36

N/A

02-23
Montego
02-18

02-20

N/A

N/A

02-27

02-34

02-36

N/A

02-23
Mustang
02-18

02-20

N/A

N/A

02-30

02-34

02-36

N/A

02-23
Lincoln-
Continental
02-18

N/A

N/A

N/A

02-30

02-35

02-36

02-24

02-24
Thunderbird
02-18

N/A

02-34

02-35

02-30

N/A

02-35

N/A

02-24
Continental-
Mark III
02-18

N/A

02-34

02-35

02-30

N/A

02-35

N/A

02-24

A page number indicates that the item
is for
the vehicle listed
at
the head
of
the column.

N/A indicates that the item is
not
applicable
to
the vehicle listed.
procarmanuals.com

02-02-03
Brake System

02-02-03

DESCRIPTION

Disc brakes are available as option-

al equipment for the front wheels on

Ford, Mercury, Meteor, Fairlane,

Montego, Falcon, Mustang and Cou-

gar models and are standard on Thun-

derbird, Continental Mark III, and

Lincoln Continental models. The

dual-master cylinder equipped hydrau-

lic brake system employs single an-

chor, internal expanding and
self-

adjusting drum brake assemblies on

the rear wheels of vehicles with disc

brakes, and on the front and rear

wheels of all others.

A vacuum booster is used with the

power disc brake system.

DUAL MASTER CYLINDER

BRAKE SYSTEM

The dual-master cylinder brake sys-

tem has been incorporated in all mod-

els to provide increased safety. The

system consists of a dual-master cylin-

der (Fig. 1), pressure differential valve

assembly and a switch (Fig. 2). The

switch on the differential valve acti-

vates a dual-brake warning light, lo-

cated on the instrument panel.
DISC BRAKE

The disc brake consists of a venti-

lated rotor and caliper assembly. The

caliper used on all models except Lin-

coln Continental is a single piston

floating caliper (Fig. 3). The caliper

used on Lincoln Continental models is

a four piston fixed caliper (Fig. 4).

A proportioning valve in the rear

hydraulic circuit provides balanced

braking action between front and rear

brakes.

On all models except Lincoln a

pressure impulse valve located at the

primary inlet of the pressure differen-

tial valve prevents brake fluid surge

back to the master cylinder reservoir.

On Lincoln Continental models a

metering valve, in the hydraulic line

between the differential valve and the

front wheel disc brakes, prevents the

front brakes from applying until ap-

proximately 125 psi is obtained in the

system (Fig. 21). This delaying action

is required to prevent the front brakes

from performing all the braking ac-

tion on low speed stops and thereby

increasing the rate of lining wear.
FLOATING CALIPER—

ALL MODELS EXCEPT

LINCOLN CONTINENTAL

The caliper asseml.y is made up of

a floating caliper housing assembly

and an anchor plate. The anchor plate

is bolted to .the wheel spindle arm by

two bolts. The floating caliper is at-

tached to the anchor plate by steel

stabilizers on Ford, Mercury, Meteor,

Thunderbird and Continental Mark

III models and by one stabilizer on

Fairlane, Montego, Falcon, Mustang

and Cougar models. The floating cali-

per slides on two locating pins which

also attach to the stabilizers. The

floating caliper contains the single cyl-

inder and piston assembly. The cylin-

der bore contains a piston with a

molded rubber dust boot to seal the

cylinder bore from contamination

(Fig. 5). A square section rubber pis-

ton seal is positioned in a groove in

the cylinder bore and is used to pro-

vide sealing between the cylinder and

piston (Fig. 7).

The outer brake shoe and lining as-

sembly is longer than the inner assem-

bly, and the shoe and lining

DISC BRAKES

RETURN SPRING

(SECONDARY)

RETAINER

PRIMARY SYSTEM BRAKE

FLUID RESERVOIR

BOOT

PUSH ROD

TUBE SEAT |

(SECONDARY)

BRAKE OUTLET

PORT
RESIDUAL \ ^

CHECK \

VALVE \

SECONDARY PISTON

ASSEMBLY
(PRIMARY)

BRAKE OUTLET

PORT
PRIMARY PISTON

ASSEMBLY
H 1545-A

FIG.
I
—
Dual
Master Cylinder—Typicalprocarmanuals.com

BRAKE WARNING LAMP SWITCH

PISTON
BRAKE WARNING LAMP SWITCH

BRAKE WARNING LAMP SWITCH

PLUNGER IN THE ON POSITION

CONNECTOR
BRAKE WARNING LAMP SWITCH

PLUNGER IN OFF POSITION

VALVE PISTON HAS MOVED

TO LOW PRESSURE AREA.

WARNING LAMP SWITCH

PLUNGER IS DEPRESSED,

LIGHTING THE BRAKE

WARNING LAMP

LOW PRESSURE SIDE
U
VALVE PISTON IS

CENTRALIZED. PRIMARY

AND SECONDARY SYSTEM

PRESSURES ARE EQUALIZED

BRAKE WARNING LAMP

SWITCH PLUNGER IN

OFF POSITION
HIGH PRESSURE SIDE

DRUM BRAKES
TJ
CONNEiCTOR

BRAKE FLUID

BRAKE WARNING LAMP I

SWITCH PLUNGER IN

ON POSITION

REAR BRAKE INLET

CONNECTOR

FRONT BRAKE

INLET

FRONT BRAKE

OUTLET
VALVE PISTON IS CENTRALIZED.

PRIMARY AND SECONDARY SYSTEM

PRESSURES ARE EQUALIZED
OUTLET TO

PROPORTIONING VALVE

DISC BRAKES
\
REAR BRAKE

PROPORTIONING

VALVE IS BYPASSED

VALVE PISTON HAS MOVED TO LOW

PRESSURE AREA. WARNING LAMP SWITCH PLUNGER IS

DEPRESSED, LIGHTING THE BRAKE WARNING LAMP H1634-A

FIG. 2—Pressure Differential Valve and Brake Warning Light Switch

CALIPER ASSEMBLY

BLEEDER

SCREW
EXTERNAL

TRANSFERTU3E

H1567-B
HUB

AND

ROTOR

ASSEMBLY

H 1647-A

FIG. 3—Disc Brake Assembly-

Floating Caliper—All Models

Except Lincoln Continental
FIG. 4—Disc Brake Assembly—

Fixed Caliper—Lincoln

Continental
blies are not interchangable (Fig. 23).

The outboard shoe and lining is fixed

to the floating caliper and is retained

by two pins and spring clips. The shoe

and lining assembly consists of fric-

tion material bonded to a metal plate

called the shoe. It is replaced as a

unit.

FIXED CALIPER

LINCOLN CONTINENTAL

The caliper assembly is bolted di-

rectly to the wheel spindle arm by two

bolts.
The caliper assembly consists of

two caliper housings bolted together

with each half containing two cylinder

bores of 1.938 inch diameter. Each

cylinder bore contains a piston with

an attached molded rubber dust boot

to seal the cylinder bore from contam-

ination (Fig. 6). Square-section rubberprocarmanuals.com

02-02-08
Brake System

02-02-08

Tool-HRE-8650

JUST SET TO DRUM

DIAMETER HERE . . .
FIND CORRECT BRAKE

SHOE DIAMETER HERE

H1416-A

FIG.
7
7—Adjusting Brake Shoes Using Tool HRE-8650

BOOT

BOOT

PISTON
. BLEEDER .

CYLINDER
SCREW RETURN SPRING PIST0N

H1385-B

FIG. 72—Brake Wheel Cylinder—Typical

DISASSEMBLY

1.
Remove the links and the rubber

boots from the ends of the brake cyl-

inder. Remove the pistons, cups, and

return spring from the cylinder bore

(Fig. 12).

2.
Remove the bleeder screw from

the cylinder.

INSPECTION

1.
Wash all parts in clean brake

fluid. Dry with compressed air.

2.
Replace scored pistons. Always

replace the rubber cups and dust

boots.
3.
Inspect the cylinder bore for

score marks or rust. If either condi-

tion is present the cylinder bore must

be honed. However, the cylinder

should not be honed more than 0.003

inch beyond its original diameter.

4.
Check the bleeder hole to be sure

that it is open.

ASSEMBLY

1.
Apply a light coating of heavy-

duty brake fluip! to all internal parts.

2.
Thread the bleeder screw into the

cylinder and tighten securely.

3.
Insert the return spring, cups,

and pistons into their respective posi-

tions in the cylinder bore (Fig. 12).
Place a boot over each end of the cyl-

inder. Bleed the brake system.

HYDRAULIC LINE REPAIR

Steel tubing is used throughout the

brake system with the exception of the

flexible hoses at the front wheels and

at the fear axle housing brake tube

connection (Figs. 17 thru 21).

Always bleed the applicable pri-

mary or secondary brake system after

primary or secondary brake system

hose or line replacement. Centralize

the pressure differential valve after

bleeding the system.

BRAKE TUBE

REPLACEMENT

If a section of the brake tubing be-

comes damaged, the entire section

should be replaced with tubing of the

same type, size, shape and length.

Copper tubing should not be used in a

hydraulic system. When bending

brake tubing to fit underbody or rear

axle contours, be careful not to kink

or crack the tube.

All brake tubing should be double

flared properly to provide good leak-

proof connections. Clean the brake

tubing by flushing with clean brake

fluid before installation.

When connecting a tube to a hose,

tube connector, or brake cylinder,

tighten the tube fitting nut to specified

torque with Milbar tool 1112-144 or

equivalent.

BRAKE HOSE

REPLACEMENT

A flexible brake hose should be re-

placed if it shows signs of softening,

cracking, or other damage.

When installing a new front brake

hose,
position the hose to avoid con-

tact with other chassis parts. Place a

new copper gasket over the hose fit-

ting and thread the hose assembly into

the front wheel cylinder. Engage the

opposite end of the hose to the brack-

et on the frame. Install the horsesho-

e-type retaining clip, and connect the

tube to the hose with the tube fitting

nut (Figs. 17 thru 21).

A rear brake hose should be in-

stalled so that it does not touch the

muffler outlet pipe or shock absorber.

Thread the hose into the rear brake

tube connector. Engage the front end

of the hose to the bracket on the

frame. Install the horseshoe-type re-

taining clip, and connect the tube to

the hose with the tube fitting nut.procarmanuals.com

02-02-12
Brake System

02-02-12

TUBE ASSY. REF.

2 A 040

TUBE ASSY. REF.

2B113-B

PRESSURE

IMPULSE VALVE

PROPORTIONING
TUBE

>Y.
2B253 ASSY REF TUBE

/W W '
Kth#
2263 ASSY. R.H. REF.

TUBE

2B112-E
2264 ASSY. L.H. REF.

2B329

ASSY. REF.

HOSE

C8OA-2B218-C ASSY.L.H.

C80A-26171-D ASSY.R.H.

2B269 ASSY. REF.

VIEWZ

INSTALLATION-DISC BRAKE ONLY
BEND CLIP TO RETAIN

TUBE AS SHOWN
-TUBE

VIEW IN CIRCLE T

382365-S36
WASHER

8M-2149

TUBE-2A040
INSTALLATION-DISC BRAKES SAME AS

DRUM BRAKES AND MAIN VIEW

EXCEPT AS SHOWN
TUBE-2267 R.H.

TUBE-2B253

TUBE 2B329

PRESSURE DIFFERENTIAL

VALVE

TUBE 2B329

VIEW IN

CIRCLE U

TYPICAL ^,

CES^^
CLI

BOLT-

VIEW IN CIRCLE N
WASHER

34808-S8

PART OF AXLE

VENT ON STATION

WAGON ONLY

VENT ASSEMBLY

TUBE ASSEMBLY-2265

STANDARD AND POWER DRUM

3RAKES TUBE ASSEMBLY-2B1T2

POWER DISC BRAKES

MANUAL DISC

TUBE-2263 R.H.
3 REQUIRED

BOLT- 3 REQUIRED

CHECK BRAKE HOSE CLEARANCE „

TO ALL COMPONENTS IN
2A448"

METAL/METAL JOUNCE AND

METAL/METAL REBOUND-
TUBE-2267

ARMOR-390, 428 ENGINES ONLY

8 CYLINDER ENGINE REAR AXLE ONLY

TUBE ASSEMBLY-2268 L.H.

PRESSURE DIFFERENTIAL

VALVE

- GROMMET- 2

jl^REQUIRED

EWYN

TUBE
VIEW P

ROUTING FOR STATION WAGON ONLY

TUBE-22.S5

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

VIEW IN CIRCLE Y

TYPICAL 2 PLACES
CHECK BRAKE HOSE CLEARANCE TO ALL

COMPONENTS IN METAL/METAL JOUNCE,

METAL/METAL REBOUND AND FULL

INSIDE AND OUTSIDE TURNS

VIEWX

TYPICAL 2 PLACES

DRUM BRAKES

TUBE-2263 R.H

2264 L.H.
VIEW IN CIRCLE U

TYPICAL 4 PLACES

HOSE-2A448

BRAKE HOSE-2078

GASKET-2149 2 REQUIRED

VIEW IN CIRCLE W

TYPICAL 2 PLACES

DRUM BRAKES
LIP
REINFORCEMENT ASSEMBLY-2B222

APPLY ESB-M4632-A SEALER AROUND

STUDS AND SCREW HOLE ON

FLOOR PAN SIDE

TUBE
TUBE ASSEMBLY-226J)

VIEW R

TUBE

VIEW IN CIRCLE M

POWER DISC BRAKES

BRAKE HOSE MUST BE ASSEMBLED

WITH WHEELS STRAIGHT AHEAD.

STRIPE ON HOLE HOSE ASSEMBLY

MUST SHOW NO EVIDENCE OF TWIST.

H 1559-C

—Service Brake
System—Fairlane,
Montego
and
Falconprocarmanuals.com