wheels FORD MUSTANG 1969 Volume One Chassis

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

02-01-07
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

02-02-03
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

02-02-07
Brake System

02-02-07

ANTI-SKID CONTROL SYSTEM

RELEASE PAWL CAM PIN

RELEASE PAWL CAM LEVER

RELEASE CABLE

H
1636-
A

FIG. 10—Parking Brake Control Assembly

With Manual Release—Typical

power unit with mounting bracket is

riveted to the control assembly. The

vacuum actuated piston within the

unit is connected by a rod to the

upper end of the release lever (Fig. 9).

The lower end of the release lever ex-

tends out for alternate manual release
in the event of vacuum power failure

or for optional manual release at any

time.

Hoses connect the power unit and

the engine manifold to a vacuum re-

lease valve in the transmission neutral

safety switch.
The anti-skid control system con-

sists of three major components (Fig.

39).
Mechanically driven electromag-

netic sensors at each rear wheel; an

electronic control module mounted

under the glove box; a vacuum pow-

ered actuator attached to a bracket on

the inside of the right front frame rail

under the toe board.

The sensors consist of steel rings

having teeth on their outer diameters,

pressed on each axle shaft just out-

board of the wheel bearing. The teeth

rotate past corresponding teeth on the

inside diameter of stationary steel

rings mounted in the bearing retain-

ers.
Also mounted in the retainers, are

ring-shaped permanent magnets and

coils of wire. Two wires from each

sensor connect the sensors to the con-

trol module.

The control module consists of solid

state electronic components sealed in

a container. It is connected to the sen-

sors and to a solenoid on the actuator.

The actuator is similar to a vacuum

brake booster and consists of three

parts.
A chamber divided by a vacuum

suspended diaphragm; a hydraulic cyl-

inder connected to the diaphragm; and

a solenoid connected electrically to the

control module.

IN-VEHICLE ADJUSTMENTS AND REPAIRS

After any brake service work, ob-

tain a firm brake pedal before moving

the vehicle. Riding the brake pedal

(common on left foot application)

should be avoided when driving the

vehicle.

BRAKE SHOE ADJUSTMENTS—

DRUM BRAKES

The hydraulic drum brakes are

self-adjusting and require a manual

adjustment only after the brake shoes

have been relined, replaced, or when

the length of the adjusting screw has

been changed while performing some

other service operation. The manual

adjustment is performed with the

drums removed, using the tool and the

procedure detailed below.

When adjusting the rear brake

shoes,
check the parking brake cables

for proper adjustment. Make sure that

the equalizer operates freely.
To adjust the brake shoes:

1.
Use Rotunda Tool HRE 8650,

(Fig. 11) to determine the inside diam-

eter of the drum braking surface.

2.
Reverse the tool as shown in Fig.

11 and adjust the brake shoe diameter

to fit the gauge. Hold the automatic

adjusting lever out of engagement

while rotating the adjusting screw, to

prevent burring the screw slots. Make

sure the adjusting screw rotates freely.

If necessary, lubricate the adjusting

screw threads with a thin, uniform

coating of MIC-100-A.

3.
Rotate Tool HRE 8650 around

the brake shoes to be sure of the set-

ting.

4.
Apply a small quantity of high

temperature grease to the points

where the shoes contact the backing

plate, being careful not to get the lu-

bricant on the linings.

5. Install the drums. Install Tinner-

man nuts and tighten securely.

6. Install the wheels on the drums
and tighten the nuts to specification.

7.
Complete the adjustment by

applying the brakes several times with

a minimum of 50 lbs 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 direction.

WHEEL CYLINDER REPAIR-

DRUM BRAKE

Wheel cylinders should not be di-

sassembled 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.procarmanuals.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

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

02-02-36
Brake System

02-02-36

locating stripe on the cable is midway

between the retaining clips and tighten

all retaining clip screws.

4.
Position the left cable, retaining

clip and screw on the left lower sus-

pension arm. Compress the prongs on

the left cable and position the cable

through the frame side-member. The

prongs must be securely locked in

place.

5.
Insert the ball ends of the cables

into the equalizer assembly.

6. Install the rear drum(s) and

tighten the three Tinnerman nuts and

secure the drum. Install the wheel and

tire and the wheel cover.

7.
Adjust the parking brake linkage

as outlined in Part 2-1, Section 2. Ad-

just the rear brakes, as required (Part

2-1,
Section 2).

FAIRLANE, MONTEGO,

MUSTANG AND COUGAR—

EXCEPT STATION WAGON

Removal

1.
Remove the equalizer lock nut

and adjusting nut, equalizer, spring

and spring seat.

2.
With the cables slack, discon-

nect the ball-ends from the connector

(Figs.
35 and 36).

3.
Remove the cable from the re-

tainer hooks (station wagon models)

and the underbody guide (convertible

models) if required.

4.
Remove the hairpin lock retain-

ing the cable housing to the side rail

bracket.

5.
Remove the wheel cover, wheel

and tire and the rear brake drum as

outlined in Section 2.

6. Remove self-adjuster springs to

allow clearance to remove cable re-

tainer from the backing plate. Discon-

nect the rear end of the cable from the

parking brake lever on the brake shoe.

Disengage the cable housing retaining

grommet or steel-pronged Hi-Hat

from the backing plate and withdraw

the cable and housing from the in-

board side of the backing plate.

7.
Slide the cable and housing out

of the side rail bracket.

Installation

1.
Insert the rear end of the cable

through the side rail bracket and pull

the cable and housing into position.

2.
Insert the rear end of the cable

and housing through the hole in the

backing plate from the inboard side.

3.
Connect the cable to the parking
brake lever on the brake shoe and in-

stall the cable housing retaining grom-

met or steel-pronged Hi-Hat in the

backing plate.

4.
Install the self-adjuster springs.

Position the cable housing in the side

rail bracket and install the hairpin

type retainer.

5.
Install rear hub and drum as-

sembly, wheel and tire assemblies and

wheel cover as outlined in Section 2.

6. Position the cable retainer hooks

(station wagon models) in the under-

body guide (convertible models) and

install the connector, thus hooking the

two cables together.

7.
Insert the cable into the equaliz-

er and install the equalizer, spring

seat, spring, adjusting nut and lock

nut to the front, parking brake control

cable.

8. Adjust the parking brake^as di-

rected in Part 2-1, Section 2.

FAIRLANE AND MONTEGO

STATION WAGONS AND

FALCON PASSENGER

MODELS

Removal and Installation

Refer to Fig. 35.

Generally follow the procedure

given above, omitting separation of

the cables, since the parking brake

rear cable assemblies supplied for

these models is in one piece. Removal

and installation of both rear wheels,

tires and drums will also be required.

LINCOLN CONTINENTAL

Removal

1.
Raise the car. Remove the rear

wheel cover. Remove the wheel and

tire as an assembly.

2.
Remove the three Tinnerman

nuts that hold the brake drum in

place, and remove the drum.

3.
Remove the brake shoe retract-

ing springs.

4.
Loosen the equalizer rod adjust-

ing nut and disconnect the cable from

the equalizer (Fig. 38).

5.
Remove the hairpin-type retainer

clip that secures the cable housing to

the body bracket, and pull the cable

and housing out of the bracket (Fig.

38).

6. Remove the cable to underbody

clamp attaching nuts and the clamp.

Disengage the cable housing from the

hook-type retainer at the spring U-

bolt.
7.
Working on the wheel side of the

backing plate (Fig. 38), compress the

prongs on the cable retainer so that it

can pass through the hole in the back-

ing plate. Draw the cable retainer out

of the hole.

8. With the spring tension off the

parking brake lever, lift the cable out

of the slot in the lever and remove it

through the backing plate hols.

Installation

1.
Pull enough of the cable through

the cable housing so that the end of

the cable may be inserted through the

backing plate hole from the inner side

and engage the cable end with the slot

in the parking brake lever.

2.
Pull the excess slack from the

cable and insert the cable housing into

the backing plate access hole (Fig.

38).
The prongs must be securely

locked in place.

3.
Install the brake shoe retracting

springs.

4.
Position the cable to the under-

body and install the retaining clamp

so that the cable conduit armor ex-

tends forward of the clamp as shown

in Fig. 38. Install the clamp retaining

nuts.

5.
Hook the cable housing to the

retainer at the spring U-bolt.

6. Engage the forward end of the

cable housing with the frame bracket

and secure it with the hairpin-type

clip.

7.
Insert the ball end of the cable

into the equalizer.

8. Make a preliminary brake ad-

justment with the use of Tool HRA-

8650 (Fig. 11).

9. Install the rear drum. Tighten

the three Tinnerman nuts that secure

the drum. Install the wheel and wheel

cover.

10.
Adjust the parking brake link-

age.

11.
Lower the vehicle.

ANTI-SKID CONTROL

ACTUATOR

REMOVAL

Refer to Fig. 39.

1.
Working in the passenger com-

partment, under the glove box, remove

the screw that attaches the forward

end of the control module retainer to

the support assembly. Lower the for-

ward end of the control module re-

tainer and remove the module assem-

bly.procarmanuals.com

02-02-38
Brake System

02-02-38

2.
Disconnect the actuator solenoid

and warning switch harness connectors

from the control module.

3.
Remove the two wiring harness

grommets from the dash panel and

push the wiring harness and connec-

tors through the openings in the dash

panel.

4.
Working in the engine compart-

ment loosen the hose clamp and re-

move the air hose from the air filter.

5.
Remove the engine air cleaner-

Loosen the hose clamp and remove

the vacuum hose from the vacuum

manifold fitting.

6. Raise the vehicle on a hoist.

7.
Disconnect the exhaust pipes

from the exhaust manifold and sup-

port with wire to provide access to the

actuator assembly.

8. Remove the bolt retaining the

actuator ground wire to the rear outer

corner of the engine right bank.

9. Loosen the tube nuts and discon-

nect the brake system hydraulic tubes

from the hydraulic valve housing.

10.
Remove the three nuts retaining

the actuator assembly to the actuator

support bracket.

11.
Remove the three bolts that re-

tain the actuator mounting bracket to

the side rail and remove the mounting

bracket.

12.
Remove the actuator assembly

from the vehicle and place it on a

bench.

13.
Remove the air and vacuum

hoses from the actuator.

INSTALLATION

1.
Install the air and vacuum hoses

on the new actuator.

2.
Place the actuator assembly into

position under the vehicle, routing the

air and vacuum hoses up between the

engine and fender apron and inserting

the solenoid leads through the holes in

the firewall.

3.
Position the ground wire to the

rear of the engine block and install re-

taining bolt.

4.
Position the actuator mounting

bracket to the frame side rail and in-

stall the three retaining bolts.

5.
Position the actuator assembly

to the mounting bracket and install

the three retaining nuts.

6. Connect the hydraulic tubes to

the hydraulic valve assembly and

tighten the tube nuts to specifications.

7.
Connect the exhaust pipes to the

exhaust manifolds.

8. Lower the vehicle.

9. Pull the actuator solenoid and

brake warning switch wiring harness
through the two holes in the dash

panel from inside the car. Seat the

wiring harness grommets in the dash

panel.

10.
Connect the actuator solenoid

and brake warning switch wiring har-

ness connectors to the control mo-

dules.
'

11.
Position the control module in

the bracket under the glove box and

install the retaining screw.

12.
In the engine compartment con-

nect the air hose to the air filter and

position the hose clamp.

13.
Connect the vacuum hose to the

engine vacuum manifold fitting. In-

stall the engine air cleaner.

14.
Bleed the rear brake system and

centralize the pressure differential

valve.

15.
Raise the rear wheels. Apply

the brakes with the rear wheels turn-

ing to verify proper operation of the

anti-skid control system.

ANTI-SKID CONTROL MODULE

REMOVAL

Refer to Fig. 39.

1.
Remove the retaining strap hold-

ing the harnesses.

2.
Remove the screw that attaches

the forward end of the control module

retainer to the support assembly.

3.
Lower the forward end of the

control module and retainer from the

support assembly; move the module

and retainer forward slightly until the

flange clears the slot in the support

assembly.

4.
Disconnect the five wiring har-

ness plugs from the control module.

5.
Remove the control module from

the vehicle.

INSTALLATION

1.
Connect the five wiring harness

plugs to the control module. Only one

arrangement is possible.

2.
Position the control module in

the retainer, orienting the module per

the markings on it, and insert the re-

tainer flange into the slot at the rear

of the support assembly.

3.
Pivot the retainer and control

module upward and align the screw

hole in the forward end of the retainer

with the hole in the support bracket

assembly. Install the retaining screw.

4.
Test the vehicle on the hoist to

verify correct operation of the skid

control system.
5.-
Secure the wiring to the module

support extension with the retaining

strap.

ANTI-SKID CONTROL SENSOR

REMOVAL

Refer to Fig. 39.

1.
Raise the vehicle on a hoist.

2.
Remove the rear wheel and tire

assembly.

3.
Remove the three Tinnerman

nuts (3) and remove the brake drum.

4.
Disconnect the sensor lead from

the rear wiring harness.

5.
Unseat the sensor lead grommet

pushing it to the inside of the brake

assembly.

6. Remove the four nuts that retain

the sensor to the backing plate and

pull the axle shaft, sensor assembly

and wheel bearing assembly from the

axle housing.

7.
Press the wheel bearing retainer

and wheel bearing off the axle shaft

(Refer to Part 4-2).

8. Remove the sensor assembly and

press the rotor off the shaft with tool

T69P-2B384-A Detail 2 and TOOL

1225-DA.

INSTALLATION

1.
Press a new rotor onto the axle

shaft. Install a new sensor assembly

on the shaft with tool T69P-

2B384-ADetail 1 and TOOL 1225-

DA, and press the bearing and bear-

ing retainer onto the shaft (Refer to

Part 4-2).

2.
Insert the axle shaft assembly in

the rear axle housing onto the four

backing plate retaining bolts, feeding

the sensor lead through the hole in the

backing plate.

3.
Seat the sensor lead grommet in

the backing plate.

4.
Install the four nuts on the re-

taining bolts and tighten to specifica-

tions.

5.
Connect the sensor lead to the

rear wiring harness and install two re-

taining straps.

6. Install the rear brake drum and

retain with the Tinnerrhan drum re-

taining nuts.

7.
Install the rear wheel and tire as-

sembly and tighten the wheel nuts to

specifications.

8. Test the vehicle on the hoist to

verify proper operation of the skid

control system.procarmanuals.com

03-01-01

PART
3-1
PAGE

Suspension,
Steering, Wheels and

Tires,
General Service 03-01-01

PART
3-2

Suspension 03-02-01

PART
3-3

Automatic
Air
Leveling System ....03-03-01

PART
3-4

Automatic
Air
Leveling System

Lincoln Continental 03-04-01

PART
3-5

Steering Columns and Linkage ... 03-05-01

PART
3-6

Manual Steering 03-06-01

PART
3-7

Ford Design Non-Integral Power

Steering System
03-07-01
PART
3-8
PAGE

Ford Design Integral Power

Steering Gear 03-08-01

PART
3-9

Saginaw Design Integral Power

Steering Gear 03-09-01

PART
3-10

Ford-Thompson Power Steering

Pump 03-10-01

PART
3-11

Eaton Power Steering Pump 03-1
1-01

PART 3-12

Wheels and Tires 03-1 2-01

PART
3-13

Specifications
03-13-01

PART
3-1
Suspension,Steering, Wheels
and

Tires—General Service

COMPONENT INDEX

CASTER AND CAMBER ADJUSTMENTS

FRONT
END
INSPECTION

FRONT WHEEL ALIGNMENT CHECKS

LUBRICANT CHECKING PROCEDURE

POWER STEERING GEAR CLEANING

AND INSPECTION

POWER STEERING PRELIMINARY TESTS

POWER STEERING PUMP

Cleaning
and
Inspection

Flow
and
Pressure Tests

POWER STEERING SYSTEM FLUSHING

SHOCK ABSORBER CHECKS

STEERING WHEEL SPOKE POSITION

Adjustment

TOE-IN ADJUSTMENT

WHEEL BALANCING
MODEL APPLICATION
All
Models

01-08

01-03

01-07

01-09

01-02

01-11

01-07

01-07

01-07
Ford
01-05

01-09

01-02

01-09
Mercury
01-05

01-09

01-02

01-09
Meteor
01-05

01-09

01-02

01-09
Cougar
01-06

01-09

01-02

01-09
Fairlane
01-06

01-09

01-02

01-09
Falcon
01-06

01-09

01-02

01-09
Montego
01-06

01-09

01-02

Gl-09
Mustang
01-06

01-09

01-02

01-09
Lincoln-
Continental
01-06

01-09

01-03

N/A
Thunderbird
01-05

01-09

01-02

01-09
Continental-
Mark
III
01-05

01-10

01-03

N/A

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