lock FORD MUSTANG 1969 Volume One Chassis

01-01-02
Vehicle Identification
01-01-02

VEHICLE WARRANTY NUMBER

The vehicle warranty number is the first line of numbers and

letters appearing on the Warranty Plates (Fig. 1). The Warranty

Plate is riveted to the left front door lock face panel. The first

number indicates the model year. The letter following the model

year number indicates the manufacturing assembly plant. The next

two numbers designate the Body Serial Code followed by a letter

expressing the Engine Code. The group of six digits remaining on

the first line indicate the Consecutive Unit Number.

VEHICLE DATA

The vehicle data appears on the second or lower line on the

Warranty Plate. The first two numbers and a letter identify the

Body Style. A letter or a number appears next indicating the

Exterior Paint Color followed by a number-letter combination

designating the Interior Trim. To the right of this code appears the

Date Code indicating the date the car was manufactured. A two-

digit number next designates the district in which the car was

ordered and may appear in conjunction with a Domestic Special

Order or Foreign Special Order number when applicable. The final

two spaces indicate the Rear Axle Ratio (numbers for regular axles,

letters for locking-types) and the Transmission type (numbers for

manual,
letters for automatic).

OFFICIAL VEHICLE IDENTIFICATION NUMBER

The official Vehicle Identification Number (VIN) for title and

registration purposes is stamped on an aluminum tab that is riveted

to the instrument panel close to the windshield on the driver's side

of the car and is visible from outside (Fig. 2).

MODEL YEAR CODE

The number 9 designates 1969.

ASSEMBLY PLANT CODES
COUGAR

Code

Letter
Code

Letter

A

B

C

D

E

F

G

H

J

K
Atlanta
L

Oakville (Canada)
N

Ontario Truck
P

Dallas
R

.,
Mahwah
S

Dearborn
T

Chicago
U

Lorain
W

Los Angeles
X

Kansas City
Y

Z
Michigan Truck

Norfolk

Twin Cities

San Jose

.
(Pilot). ...Allen Park

Metuchen

Louisville

Wayne

St. Thomas

Wixom

St. Louis

BODY SERIAL AND STYLE CODES

The two-digit numeral which follows the assembly plant code

identifies the body series. This two-digit number is used in con-

junction with the Body Style Code, in the Vehicle Data, which

consists of a two-digit number with a letter suffix. The following

chart lists the Body Serial Codes, Body Style Codes and the model.

LINCOLN CONTINENTAL

Body Body

Serial Style

Code Code Body Type

82
53A
4-Door Sedan

80
65A
2-Door
Hardtop

CONTINENTAL MARK
III

Body Body

Serial Style

Code Code Body Type

89
65A
2-Door
Hardtop
Body

Serial

Code

91

92

93

94

91
Body

Style

Code

65A

76A

65B

76B

65C

® Bench Seat

MERCURY

Body

Serial

Code

44

46

48

45

40

41

42

54

56

58

63

66

68

65

63

66

68

60

61

72

72

74

74

76

76
Body

Style

Code

54A

65A

57A

76A

53M

65M

57M

54C

65B

57B

53F

65F

57 F

76F

53C

65C

57C

63G

63H

71B

71C

71F

71G

71E

71A

©Bench Seat
Body
Type

2-Door
Hardtop©

Convertible©

2-Door
Hardtop©

Convertible®

2-Door
Hardtop®
Model

Standard

XR-7 Luxury

Standard

©Split Bench ©Bucket Seats

Body Type

4-Door Sedan©

2-Door
Hardtop-Formal®

4-Door Hardtop®

Convertible®

CANADA ONLY

4-Door Hardtop Sedan®

2-Door
Hardtop-Formal®

4-Door Hardtop®

4-Door Sedan®

2-Door
Hardtop-Formal®

4-Door Hardtop®

4-Door Hardtop Sedan®©

2-Door
Hardtop-Formal®©

4-Door Hardtop®®

Convertible®®

4-Door Hardtop Sedan©

2-Door
Hardtop-Formal©

4-Door Hardtop©
Model

Monterey

Marquis

Monterey-Custom

Marquis

Brougham (Option)

2-Door
Hardtop (Tunnel Roof)®© Marauder

2-Door
Hardtop (Tunnel Roof)®®©

4-Door 2 Seat®

4-Door 3 Seat (Side Facing)®

4-Door
2
Seat®

4-Door 3 Seat (Side Facing)®

4-Door 2 Seat®©

4-Door 3 Seat (Side Facing)®©
Monterey Wagoi

Monterey-Custom Wagon

Marquis Colony Park

©Split Bench ©Bucket Seats

METEOR (CANADA)

Body

Serial

Code

20

21

23
Body

Style

Code

54A

54B

65B
Body Type

4-Door Sedan®

4-Door Sedan®

2-Door
Hardtop-Formal®
Model

Rideau

Rideau 500

30
54C
4-Door Sedan®

35
65C
2-Door
Hardtop-Formal®

35
65E
2-Door
Hardtop-Formal{5-33)®®

33
57C
4-Door Hardtop®

34
76C
Convertible®

34
76E
Convertible (S-33)®®
Montcalm

24
65F
2-Door
Hardtop-Formal®©

27
57F
4-Door Hardtop®®
LeMoyne

28
71B
Rideau 500-6 Passenger®

29
71C
Rideau 500-Dual Face Rear®

38
71E
Mo ntcalm-6 Passenger®

39
71A
Montcalm-Dual Face Rear®
Station Wagons.

©Bench Seat ©Splite Bench ©Bucket Seatsprocarmanuals.com

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

02-01-03
Brakes

02-01-03

vacuum system is operating, the pedal

will tend to fall away under foot pres-

sure and less pressure will be required

to hold the pedal in the applied posi-

tion. If no action is felt, the vacuum

booster system is not functioning.

If the brake pedal movement feels

spongy, bleed the hydraulic system to

remove air from the system. Refer to

Hydraulic System Bleeding, Part 1,

Section 2.

VACUUM TESTS—VACUUM

RELEASE PARKING BRAKES

Visually check the operation of the

brake linkage as the brake pedal is

depressed. Then, check the operation

of the brake linkage when the manual

release lever is activiated. These

checks should indicate whether the

manual parking brake control linkage

is operating properly or requires re-

pair or adjustment due to inability of

the parking brake to hold against

moderate vehicle movement. Perform

tests of the parking brake system and

controls after making certain the link-

age and manual controls operate

properly.

When testing a parking brake vacu-

um release system, a minimum of 10

inches of vacuum (Hg.) should be

available at all points where vacuum is

applied. This can be checked with a

Rotunda Fuel Pump Tester Gauge

(ARE345) and two Distributor Tester

hose adapters (Marked Q) connected

together with a coupling. This allows

the Fuel Pump Tester Gauge hose to
be adapted to any other vacuum hose

or rubber connector in the vacuum

systems.

Failure to maintain 10 inches of

vacuum (Hg.) during vacuum system

tests could be caused by a loose hose

connection, resulting in a vacuum

leak. When checking for vacuum be-

tween two points, trace the hose along

the entire routing to be sure it is not

crossed with another hose and con-

nected to the wrong connection.

All of the vacuum parking brake

control checks are to be performed

with the engine running at idle speed.

Leaks in the parking brake hoses or

a disconnected or improperly con-

nected hose can usually be found by

listening for a hissing sound along the

hose routings. Under no circumstances

should air pressure be applied to the

vacuum system as the actuator dia-

phragm in the parking brake vacuum

motor may be damaged.

1.
Start the engine and run it at

idle speed. With the transmission shift

control in neutral, depress the parking

brake pedal to apply the parking

brake. Move the transmission shift

control to D range and observe the

parking brake pedal to see that the

pedal moves upward and the parking

brake releases. If the parking brake

releases, the parking brake vacuum

control is working properly.

2.
If the parking brake does not re-

lease, test for vacuum at the steering

column neutral switch port in the

junction block, vacuum lines and the

parking brake release vacuum motor.

Use the Rotunda Vacuum and Fuel
Pump Tester 345. This can be accom-

plished by removing the hose from

each component and attaching it to

the vacuum gauge. Connect two dis-

tributor tester vacuum hose adapters

together with a coupling as a connec-

tor to attach the gauge. A minimum

of ten inches of vacuum is required to

actuate the parking brake vacuum

motor. Do not remove any of the vac-

uum hoses from the junction block

unless the junction block is being re-

placed, as the plastic nipples are thin

and very brittle and damage may re-

sult. If a minimum reading is not

present when checking each of the

aforementioned components, they

must be replaced.

ROAD TEST

A road test should be conducted

only when the operator is sure the

brakes will stop the vehicle.

If the road test reveals one or more

problem conditions, correct all mal-

functions of the vacuum system, brake

booster and hydraulic system prior to

removing brake drums, brake calipers,

brake shoes and linings or backing

plates.

ANTI-SKID CONTROL

SYSTEM TESTS

No adjustments or repairs are to be

performed on the skid control system.

Damaged or worn parts are to be re-

placed.

Refer to Ford Car and Truck Diag-

nosis Manual for Testing procedures.

COMMON ADJUSTMENTS AND REPAIRS

PARKING BRAKE LINKAGE

ADJUSTMENT

FORD, MERCURY, METEOR,

FAIRLANE, MONTEGO,

FALCON, MUSTANG

AND COUGAR

Check the parking brake cables

when the brakes are fully released. If1

the cables are loose, adjust them as

follows:

1.
Fully release the parking brake

pedal by pulling the release lever.

2.
Depress the parking brake pedal

until it is engaged in the first notch of

the control. On a vacuum release

brake, the first notch will be approxi-

mately two inches of pedal travel.

3.
Raise the vehicle. With the

transmission in neutral, turn the ad-

justing nut forward against the equal-

izer (Figs. 3 and 4) until there is 100
L.H. REAR WHEEL CABLE -2A809> 2A791 (2 REQUIRED)

EQUALIZER-TO-ACTUATOR CABLE-2A815

R.H. REAR WHEEL CABLE-2A635

ADJUSTING NUT-2A812

H 1537-C

FIG. 3—Parking Brake Adjustment—Ford, Mercury, Meteor,

Thunderbird and Continental Mark IIIprocarmanuals.com

02-01-04
Brakes

02-01-04

ft-lb breakaway torque.
The
breaka-

way torque
is the
torque required
to

turn
the
rear wheels
the
direction
of

forward rotation with
a
torque wrench

and tool shown
in Fig. 5. The
torque

measurement must
be
made relative
to

the center line
of the
wheel.

4.
Release
the
parking brake,
and

check
to
make sure that
the
brake

shoes return
to the
fully released posi-

tion.

5.
Depress
the
parking brake pedal

to
the
third notch. Under normal
con-

ditions, this will hold
the
vehicle satis-

factorily.

6. Release
the
parking brake again,

and check
as in
step
4.

7.
If the
rear brakes
do not
fully

release, check
the
cables
for
kinks
or

binds.
Free
the
cables
as
required.

8. Lower
the
vehicle. Remove
the

torque wrench
and
tool. Install
the

wheel attaching nuts
and
torque them

to specification. Install
the
wheel

cover.

RETAINER-*^ REAR WHEEL

(CABLE ASSEMBLY

EQUALIZER
NUT

PARKING

BRAKE CABLE

AND CONDUIT

ASSEMBLY-2853
SPRING-2A651

SPRING SEAT-2A616
JAM NUT

H1631-A

FIG. 4—Parking Brake Linkage

Adjustment—Fairlane, Montego,

Falcon,
Mustang
and
Cougar
THUNDERBIRD,

CONTINENTAL MARK
III,

AND LINCOLN

CONTINENTAL

Check
the
parking brake cables

when
the
brakes
are
fully released.
If

the cables
are
loose, adjust them
as

follows:

1.
Fully release
the
parking brake

pedal
by
pushing down
the
manual
re-

lease lever.

2.
Depress
the
parking brake pedal

1
1/4
inch from
its
normal released

position.

3.
Raise
the
vehicle with
the
trans-

mission
in
neutral.

4.
Loosen
the
lock
nut and
turn
the

adjusting
nut
forward against
the

equalizer (Figs.
3 and 6)
until there
is

100 ft-lbs breakaway torque.
The

breakaway torque
is the
torque
re-

quired
to
turn
the
rear wheels
the di-

rection
of
forward rotation with
a tor-

que wrench
and
tool shown
in Fig. 5.

The torque measurement must
be

made relative
to the
centerline
of the

wheel. Tighten
the
lock
nut.

5.
Release
the
parking brake,
and

check
to
make sure that
the
brake

shoes return
to the
fully released posi-

tion.

6. Depress
the
parking brake pedal

until
it is
fully engaged.

7.
Release
the
parking brake again,

and check
as in
step
5.

8. Depress
the
pedal
1/2
inch.
The

brakes should
not
drag.

9.
If the
rear brakes
do not
fully

release, check
the
cables
for
kinks
or

binds.
Free
the
cables
as
required.

10.
Lower
the
vehicle. Remove
the

torque wrench
and
tool. Install
the

wheel attaching nuts
and
torque them

to specification. Install
the
wheel

cover.

Tool-T59L
4204-A,

T65K
4204-A,

T66L-4204-A,

OR

Tool-4421UA

E1897-A
POWER BRAKE MASTER

CYLINDER PUSH
ROD

ADJUSTMENT

The push
rod is
provided with
an

adjustment screw
to
maintain
the cor-

rect relationship between
the
booster

control valve plunger
and the
master

cylinder.
If the
plunger
is too
long
it

will prevent
the
master cylinder piston

from completely releasing hydraulic

pressure
and can
cause
the
brakes
to

drag.
If the
plunger
is too
short
it
will

result
in
excess pedal travel
and an

undesirable clunk
in the
booster area.

The adjustment screw
is set to the

correct height
at the
time
of
original

assembly
of the
power unit. Under

normal service
the
adjustment screw

does
not
require
any
further attention

providing
the
original push
rod
assem-

bly remains
in the
original unit.

If
a
check
of the
push
rod
adjust-

ment
is
necessary,
the
push
rod
length

may
be
verified with
a
push
rod
length

gauge
and
measured with
the
engine

running
to
apply vacuum
to the
boost-

er (Fig.
7).

The push
rod
length verification
and

adjustment
of
Midland-Ross power

brake booster assemblies must
be

done according
to the
following proce-

dure:

REAR WHEEL ADJUSTING NUT

CABLES

EQUALIZER

SPRING

CABLE ASSEMBLY H1632-A

FIG. 6—Parking Brake Linkage

Adjustment—Lincoln Continental

FIG. 5—Checking Parking Brake Breakaway Torque
#16
U.J

\

0.980"

0.995"

FIG. 7—Push

Dimensions
>.S. GAUGE SHEET

i

1
STEEL

H1087-E

Rod Gaugeprocarmanuals.com

02-02-09
Brake System

02-02-09

REMOVAL AND INSTALLATION

FRONT BRAKE DRUM

REMOVAL

1.
Raise the vehicle until the wheel

and tire clear the floor. Remove the

wheel cover or hub cap, and remove

the wheel and tire from the drum.

2.
Remove the grease cap from the

hub.
Remove the cotter pin, nut lock,

adjusting nut, and flat washer from

the spindle. Remove the outer bearing

cone and roller assembly.

3.
Pull the drum off the wheel

spindle.

4.
If the drum will not come off,

pry the rubber cover from the brake

backing plate. Insert a narrow screw-

driver through the slot and disengage

the adjusting lever from the adjusting

screw. While holding the adjusting

lever away from the screw, back off

the adjusting screw with the brake ad-

justing tool (Fig. 13). Be very careful

not to burr, chip, or damage the

notches in the adjusting screw; other-

wise the self-adjusting mechanism will

not function properly.

INSTALLATION

1.
If the drum is being replaced, re-

move the protective coating from the

new drum with carburetor degreaser.

Then, use sandpaper to insure that no

residue remains. Wipe the drum with

a cloth soaked with denatured alcohol.

Install new bearings and grease seal.

Pack the wheel bearings, install the

inner bearing cone and roller assembly

RUBBER PLUG

REMOVED

'MOVE HANDLE UPWARD

TO RETRACT BRAKE SHOES
in the inner cup, and install the new

grease seal see Part 3-5, Section 4.

If the original drum is being in-

stalled, make sure that the grease in

the hub is clean and adequate.

2.
Adjust the brakes and install the

drum assembly as outlined under

Brake Shoe Adjustments in this sec-

tion.

3.
Install the outer wheel bearing,

washer and adjusting nut.

4.
Adjust the wheel bearing as out-

lined in Part 3-7, Section 2, then in-

stall the grease cap. Install the wheel

and hub cap.

REAR BRAKE DRUM

REMOVAL

1.
Raise the vehicle so that the tire

is clear of the floor.

2.
Remove the hub cap and wheel.

Remove the three Tinnerman nuts and

remove the brake drum. If the drum

will not come off, pry the rubber

cover from the backing plate. Insert a

narrow screwdriver through the hole

in the backing plate, and disengage

the adjusting lever from the adjusting

screw. While holding the adjusting

lever away from the adjusting screw,

back off the adjusting screw with the

brake adjusting tool (Fig. 13). Be very

careful not to burr, chip, or damage

the notches in the adjusting screw;

otherwise, the self-adjusting mecha-

nism will not function properly.

INSTALLATION

1.
Remove the protective coating

from a new drum with carburetor de-

greaser; then sand lightly and wipe

with a cloth soaked with denatured al-

cohol.

HI 590-A
H1390-A

FIG. 73—Backing Off Brake

Adjustment
FIG. 14—Retracting Spring

Removal
2.
Adjust the brakes as outlined

under Brake Shoe Adjustments in this

section. Place the drum over the brake

assembly and into position.

3.
Install the three Tinnerman nuts

and tighten securely. Install the wheel

on the axle shaft flange studs against

the drum, and tighten the attaching

nuts to specifications.

BRAKE SHOES AND

ADJUSTING SCREW-

DRUM BRAKES

REMOVAL

1.
With the wheel and drum re-

moved install a clamp over the ends of

the brake cylinder as shown in Fig.

14.

2.
Remove the secondary shoe to

anchor spring with the tool shown in

Fig. 14. With the same tool remove

the primary shoe to anchor spring and

unhook the cable eye from the anchor

pin.

3.
On Ford, Mercury, Meteor,

Thunderbird, Continental Mark III

and Lincoln Continental models, re-

move the shoe guide (anchor pin)

plate (Fig. 8).

4.
Remove the shoe hold-down

springs, shoes, adjusting screw, pivot

nut, socket and automatic adjustment

parts.

5.
On rear brakes, remove the

parking brake link and spring. Dis-

connect the parking brake cable from

the parking brake lever.

*>.
After removing the rear brake

secondary shoe, disassemble the park-

ing brake lever from the shoe by re-

moving the retaining clip and spring

washer (Fig. 8).

INSTALLATION

1.
Before installing the rear brake

shoes,
assemble the parking brake

lever to the secondary shoe and secure

with the spring washer and retaining

clip.

2.
Apply a light coating of high-

temperature grease at the points

where the brake shoes contact the

backing plate.

3.
Position the brake shoes on the

backing plate and secure the assembly

with the hold down springs. On the

rear brake, install the parking brake

link and spring, back off the parkingprocarmanuals.com

02-02-10
Brake System

02-02-10

brake adjustment then connect the

parking brake cable to the parking

brake lever (Fig. 8).

4.
Install the shoe guide (anchor

pin) plate on the anchor pin when so

equipped.

5.
Place the cable eye over the an-

chor pin with the crimped side toward

the backing plate.

6. Install the primary shoe to an-

chor spring (Fig. 15).

H1391-A

FIG. 75—Retracting Spring

Installation

7.
Install the cable guide on the

secondary shoe web with the flanged

hole fitted into the hole in the second-

ary shoe web. Thread the cable

around the cable guide groove (Fig.

8).

It
is
imperative that
the
cable
be

positioned
in
this groove
and not be-

tween
the
guide
and the
shoe
web.

8.
Install the secondary shoe to an-

chor spring with the tool shown in

Fig. 15.

Be certain that
the
cable
eye is not

cocked
or
binding
on the
anchor
pin

when installed.
All
parts should
be
flat

on
the
anchor
pin.
Remove
the
brake

cylinder clamp.

9. Apply high-temperature grease

(MIC-100-A) to the threads and the

socket end of the adjusting screw.

Turn the adjusting screw into the ad-

justing pivot nut to the limit of the

threads and then back off 1/2 turn.

Interchanging
the
brake shoe
ad-

justing screw assemblies from
one
side

of
the
vehicle
to the
other would cause

the brake shoes
to
retract rather than

expand each time
the
automatic
ad-

justing mechanism operated.
To pre-

vent installation on the wrong side of

the vehicle, the socket end of the ad-

justing screw is stamped with an R or

L (Fig. 16). The adjusting pivot nuts

can be distinguished by the number of

grooves machined around the body of

the nut. Two grooves on the nut indi-

cate a right thread; one groove indi-

cates a left thread.
10.
Place the adjusting socket on

the screw and install this assembly be-

tween the shoe ends with the adjusting

screw toothed wheel nearest the sec-

ondary shoe.

11.
Hook the cable hook into the

hole in the adjusting lever. The adjust-

ing levers are stamped with an R or L

to indicate their installation on right

or left brake assembly (Fig. 16).

12.
Position the hooked end of the

ADJUSTING LEVER

IDENTIFICATION LINES

H1143-C

FIG. 16—Adjusting Screw
and

Lever Identification

adjuster spring completely into the

large hole in the primary shoe web.

The last coil of the spring should be at

the edge of the hole. Connect the loop

end of the spring to the adjuster lever

hole.

13.
Pull the adjuster lever, cable

and automatic adjuster spring down

and toward the rear to engage the

pivot hook in the large hole in the sec-

ondary shoe web (Fig. 8).

14.
After installation, check the ac-

tion of the adjuster by pulling the sec-

tion of the cable between the cable

guide and the anchor pin toward the

secondary shoe web far enough to lift

the lever past a tooth on the adjusting

screw wheel. The lever should snap

into position behind the next tooth,

and release of the cable should cause

the adjuster spring to return the lever

to its original position. This return ac-

tion of the lever will turn the adjusting

screw.one tooth.

If pulling the cable does not pro-

duce the action described, or if the

lever action is sluggish instead of posi-

tive and sharp, check the position of

the lever on the adjusting screw

toothed wheel. With the brake in a

vertical position (anchor at the top),

the lever should contact the adjusting

wheel 3/16 inch (plus or minus 1/32

inch) above the centerline of the

screw. If the contact point is below

this centerline, the lever will not lock

on the teeth in the adjusting screw

wheel, and the screw will not be turned
as the lever is actuated by the cable.

To determine the cause of this con-

dition:

a. Check the cable end fittings. The

cable should completely fill or extend

slightly beyond the crimped section of

the fittings. If it does not meet this

specification, possible damage is indi-

cated and the cable assembly should

be replaced.

b.
Check the cable length. On

Ford, Mercury, Meteor, Thunderbird,

Continental Mark III, and Lincoln

Continental models, the cable should

measure 11 1/8 inches (plus or minus

1/64 inch) from the end of the cable

anchor to the end of the cable hook.

On Fairlane, Montego, Falcon,

Mustang, and Cougar models the

cable should measure 8 13/32 inches

on 9 inch brakes or 9 3/4 inches on

10 inch brakes from the end of the

cable anchor to the end of the cable

hook.

c. Check the cable guide for dam-

age.
The cable groove should be paral-

lel to the shoe web, and the body of

the guide should lie flat against the

web.
Replace the guide if it shows

damage.

d. Check the pivot hook on the

lever. The hook surfaces should be

square with the body of the lever for

proper pivoting. Replace the lever if

the hook shows damage.

e. See that the adjusting; screw

socket is properly seated in the notch

in the shoe web.

WHEEL CYLINDER

DRUM BRAKE

REMOVAL '

1.
Remove the wheel and the drum.

2.
Remove the brake shoe assem-

blies,
following procedures outlined in

this section.

3.
Disconnect the brake line from

the brake cylinder Figs. 17 thru 21.

On
a
vehicle with
a
vacuum brake

booster,
be
sure
the
engine
is
stopped

and there
is no
vacuum
in the
booster

system before disconnecting
the hy-

draulic lines.

To disconnect the hose at a front

cylinder, loosen the tube fitting that

connects the opposite end of the hose

to the brake tube at a bracket on the

frame. Remove the horseshoe-type re-

taining clip from the hose and brack-

et, disengage the hose from the brack-

et, then unscrew the entire hose as-

sembly from the front wheel cylinder.

At a rear cylinder, unscrew the tubeprocarmanuals.com

02-02-16
Brake System

02-02-16

fitting that connects the tube to the

cylinder. Do not pull the metal tube

away from the cylinder. Pulling the

tube out of the cylinder connection

will bend the metal tube and make in-

stallation difficult. The tube will sepa-

rate from the cylinder when the cylin-

der is removed from the backing

plate.

4.
On all except the front wheels on

Ford, Mercury, and Meteor models,

remove the wheel cylinder attaching

bolts and lock washers and remove the

cylinder. On the front wheel of Ford,

Mercury and Meteor models, remove

the nut and washer that attaches the

cylinder to the anchor pin. Remove

the cylinder from the anchor pin.

INSTALLATION

Wipe the end(s) of the hydraulic

line to remove any foreign matter be-

fore making connections.

1.
On all models except Ford, Mer-

cury and Meteor, to install a front

wheel cylinder, position the cylinder to

the backing plate. Install the two lock

washers and attaching bolts. Torque

them to specifications.

On Ford, Mercury and Meteor

models, to install a front wheel cylin-

der, position the cylinder on the an-

chor pin against the backing plate. In-

stall the washer and cylinder attaching

nut on the anchor pin, and torque it

to specification. Lock the washer re-

tainer securely.

2.
Install a new copper gasket over

the hose fitting. Thread the hose into

the cylinder and tighten it to specified

torque.

3.
Engage the opposite end of the

hose to the bracket on the frame. 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

1112-144.

4.
To install a rear wheel cylinder,

place the rear wheel cylinder into po-

sition. Enter the tubing into the cylin-

der, and start the tube fitting nut into

the threads of the cylinder.

5.
Secure the cylinder to the back-

ing plate by installing the attaching

bolts and lock washers.

6. Tighten the tube fitting nut to

specification with tool 1112-144.

7.
Install the links in the ends of

the wheel cylinder, install the shoes

and adjuster assemblies, and adjust

the shoes as outlined in this section.

8. Adjust the brakes (Part 2-2, Sec-

tion 2). Install the brake drum and

wheel. Bleed the brakes and centralize

the differential valve as outlined in

Part 2-1, Section 2.
BRAKE BACKING PLATE

DRUM BRAKE

REMOVAL

1.
Remove the wheel and brake

drum. Disconnect the brake line from

the brake cylinder.

2.
Remove the brake shoe and ad-

juster assemblies and the wheel cylin-

der as outlined in this section. On the

rear wheels, disconnect the parking

brake lever from the cable.

3.
If the rear backing plate is being

replaced, remove the axle shaft from

the applicable rear axle as outlined in

Group 4, Part 4-2— Rear Axle, Sec-

tion 2, disengage parking brake cable

retainer from backing plate. Remove

the backing plate and gasket.

If the front backing plate is being

replaced, remove the bolts and nuts

that secure the backing plate to the

front wheel spindle and remove the

plate and gasket.

INSTALLATION

If a rear backing plate is to be re-

placed, position a new rear backing

plate and gasket on the attaching

bolts in the axle housing flange. Insert

parking brake cable into backing plate

and secure retaining fingers. Install

the rear axle shaft for applicable rear

axle.
Refer to Group 4, Part 4-2 —

Rear Axle, Section 2 for the proper

installation procedure.

1.
If the front brake backing plate

is to be replaced, position a new front

backing plate and gasket to the wheel

spindle and install the attaching bolts

and nuts.

2.
Install the wheel cylinder and

connect the brake line as outlined in

this section.

3.
Install the brake shoe and ad-

juster assemblies as outlined in this

section. On a rear brake, connect the

parking brake cable to the lever.

4.
Adjust the brake shoes (Section

2),
and install the brake drums and

wheels. Bleed the brake system and

centralize the differential valve as out-

lined in Part 2-1, Section 2.

DISC BRAKE CALIPER

ASSEMBLY

ALL MODELS EXCEPT

LINCOLN CONTINENTAL

Removal

Refer to Figs. 22 and 23.
BLEEDER SCREW FACING THIS DIRECTION^

BLEEDER SCREW

H 1641-A

FIG. 22—Floating Caliper

Installed

1.
Remove the front wheel cover.

Remove the wheel and tire assembly

from the hub and rotor assembly. Be

careful to avoid damage or interfer-

ence with the caliper splash shield or

bleeder screw fitting.

2.
Disconnect the brake line from

the caliper. Cap the hose to prevent

*he brake fluid from leaking from the

master cylinder.

3.
Remove the safety wire and the

two bolts that attach the caliper as-

sembly to the spindle.

4.
Lift the caliper assembly off the

rotor and place it on the bench.

Installation

1.
Position the caliper assembly on

the rotor, and mate the mounting bolt

holes in the caliper with those in the

spindle. It may be necessary to push

the caliper piston into the cylinder

bore to obtain clearance between the

shoe and lining assembly and the

rotor.

2.
Install the caliper to spindle at-

taching bolts and torque them to spe-

cification. The upper bolt must be

tightened first. Install the safety wire

on the bolts and twist the wire ends at

least five turns. Push the wire ends

against the spindle to avoid interfer-

ence with the brake hose and the

steering stop. Check to insure that the

rotor runs squarely and centrally be-

tween the two brake shoes.

3.
Position the brake hose fitting

with a new copper washer on each

side of the fitting on the caliper as-

sembly. Install the bolts and torque to

specification.

4.
Bleed the brake system and cen-

tralize the differential valve as out-

lined in Part 2-1. Check the masterprocarmanuals.com

02-02-19
Brake System

02-02-19

that the tabs on the shoe flanges seat

fully against the caliper bridges (Fig.

25).

2.
Install the caliper splash shield

and secure the shield to the caliper

with two retaining bolts (Fig. 4).

3.
Pump the brake pedal several

times until a firm pedal is obtained

and the shoe and lining assemblies are

properly seated.

4.
Install the wheel and tire assem-

bly on the hub and rotor assembly.

5.
Check and refill the master cyl-

inder reservoir with specified brake

fluid as required.

6. Road test the car.

It should not be necessary to bleed

the system after a shoe and lining re-

placement.

FRONT WHEEL HUB AND

ROTOR ASSEMBLY-

DISC BRAKES

REMOVAL

1.
Remove the wheel and tire from

the hub (Figs. 23 and 24). Be careful

to avoid damage or interference with

the bleeder screw fitting. On Lincoln

Continental models be careful to avoid

damage to the caliper splash shield or

transfer tube.

2.
Remove the caliper assembly

from the spindle and the rotor. If the

caliper does not require servicing, it is

not necessary to disconnect the brake

hose or remove the caliper from the

vehicle. Position the caliper out of the

way, and support it with a wire to

avoid damaging the caliper or stretch-

ing the hose. Insert a clean cardboard

spacer between the linings to prevent

the piston from coming out of the cyl-

inder bore while the caliper is re-

moved.

Handle the rotor and caliper assem-

blies in such a way as to avoid defor-

mation of the rotor and nicking,

scratching or contamination of the

brake linings.

3.
Remove the grease cap from the

hub.
Remove the cotter pin, nut lock,

adjusting nut, and flat washer from

the spindle. Remove the outer bearing

cone and roller assembly.

4.
Remove the hub and rotor as-

sembly from the spindle.

INSTALLATION

1.
If the rotor is being replaced, re-

move the protective coating from the

new rotor with carburetor degreaser.

Pack a new set of bearings with speci-
fied grease (M-1C75B), and install the

inner bearing cone and roller assembly

in the inner cup. Pack grease lightly

between the lips of a new grease seal

and install the seal (Figs. 23 and 24).

If the original rotor is being in-

stalled, make sure that the grease in

the hub is clean and adequate, that

the inner bearing and grease seal are

lubricated and in good condition, and

that the rotor braking surfaces are

clean.

2.
Install the hub and rotor assem-

bly on the spindle.

3.
Lubricate and install the outer

wheel bearing, washer and adjusting

nut.

4.
Adjust the wheel bearings to

specification, and then install the nut

lock, cotter pin, and grease cap. The

wheel bearing adjustment is especially

important with disc brakes.

5. Mount the caliper assembly on

the spindle following the Disc Brake

Caliper Assembly Installation proce-

dure in this section.

DISC BRAKE ROTOR

SPLASH SHIELD

REMOVAL

1.
Remove the caliper and the hub

and rotor assembly as outlined under
Removal in the foregoing procedure

(it is not necessary to disconnect hy-

draulic connections).

2.
Remove the three bolts that at-

tach the splash shield to the spindle,

and remove the shield (Figs. 23 and

24).

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

shield to the mounting bracket, install

the attaching bolts, nuts and torque

them to specification.

3.
Install the hub and rotor assem-

bly and the caliper as outlined under

Installation in the foregoing proce-

dure.

DUAL MASTER CYLINDER—

NON POWER BRAKES

FORD, MERCURY

AND METEOR

Removal

Refer to Fig. 26.

BUSHING

HAIRPIN

RETAINER

BUSHING

STOPLIGHT SWITCH

13480
HI 637-A

FIG. 26—Dual Master Cylinder Installation— Non Power Brakes

Ford,
Mercury, and Meteorprocarmanuals.com

02-02-20
Brake System

02-02-20

1.
Disconnect the stoplight switch

wires at the connector. Remove the

spring retainer. Slide the stop light

switch off the brake pedal pin just far

enough to clear the end of the pin,

then liftfthe switch straight upward

from the pin. Use care to avoid switch

damage during removal.

2.
Slide the master cylinder push

rod and the nylon washers and bush-

ings off the brake pedal pin.

3.
Remove the brake tube from the

primary and secondary outlet ports of

the master cylinder.

4.
Remove the cap screws and lock-

washers that secure the master cylin-

der to the dirSh panel and lift the cyl-

inder forward and upward from the

vehicle.

Installation

1.
Position the boot on the push

rod and secure the boot to the master

cylinder. Carefully insert the master

cylinder push rod and boot through

the dash panel opening and position

the master cylinder on the panel.

2.
Install the cap screws at the dash

panel and torque them to specifica-

tion.

3.
Coat the nylon bushings with

SAE 10W oil. Install the nylon wash-

er 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.

6. Connect the brake lines to the

master cylinder leaving the brake line

fittings loose.

7.
Fill the master cylinder with the

specified brake fluid to within 1/4

inch of the top of the dual reservoirs.

Use Ford Brake Fluid— Extra Heavy

Duty-Part Number C6AZ-19542-A

(ESA-M6C25-A) or equivalent for all

drum brake applications. The extra

heavy duty brake system fluid is col-

ored 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 dif-

ferential valve. Refer to Hydraulic

System Bleeding and Centralizing of

the Differential Valve, Part 2-1, Sec-

tion 2 for proper procedure.

9. Operate the brakes several times,

then check for external hydraulic

leaks.
FAIRLANE, MONTEGO,

FALCON, MUSTANG AND

COUGAR

Removal

Refer to Figs. 27 and 28.

1.
Working from inside the vehicle

below the instrument panel, disconnect

the master cylinder push rod from the

brake pedal assembly. The push rod

cannot be removed from the master

cylinder.

2.
Disconnect the stoplight switch

wires at the connector. Remove the

hairpin retainer. Slide the stop light

switch off the brake pedal pin just far

enough to clear the end of the pin,

then lift the switch straight upward

from the pin. Use care to avoid switch

damage during removal.

3.
Slide the master cylinder push

rod and the nylon washers and bush-

ings off the brake pedal pin.

4.
Remove the brake tubes from

the primary and secondary outlet

ports of the master cylinder.

5.
Remove the lock nuts or cap

screw and lockwashers that secure the

master cylinder to the dash panel and

lift the cylinder forward and upward

from the car.
Installation

Refer to Figs. 27 and 28.

1.
Position the boot on tie push

rod and secure the boot to the master

cylinder. Carefully insert the master

cylinder push rod and boot through

the dash panel opening.

2.
On Fairlane, Falcon or Montego

models, position the gasket and mas-

ter cylinder on the mounting studs on

the dash panel. Install the lock nuts

on the studs at the dash panel and

torque them to specification.

3.
On Mustang or Cougar models,

position the gasket and master cylin-

der on the dash panel. Install the re-

taining screws and torque them to

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.

5.
Connect the wires at the stop

light switch connector.

6. Connect the brake lines to the

master cylinder and tighten to speci-

fied torque.

7.
Fill the master cylinder with the

specified brake fluid to within 1/4

MASTER CYLINDER

IDENTIFICATION
UPPER STUD

SHAFT (AUTOf/lATIC

TRANSMISSION)

CLIP

BRAKE PEDAL

BUSHING SUPPORT

TUBE-2B253

TUBE-2A040
CLUTCH

PEDA_

LOWER STUD
STOP LITE

SWITCH

/ 13480

MASTER CYLINDER

PUSH ROD
BRAKE PEDAL

H 1556-C

FIG. 27—Dual Master Cylinder Installation—Non Power Brake

Fairlane, Montego, and Falconprocarmanuals.com