FORD MUSTANG 1969 Volume One Chassis

01-01-07
Vehicle Identification

01-01-07

DATE CODES

A number signifying the date precedes the month code letter. A

second-year code letter will be used if the model exceeds 12 months.

Month
Code

First Year
Code

Second Year

January

February

March

April

May

June

July

August

September

October

November

December
....A..

...B..

...C.

...D..

...E..

...
F..

...
G.

...H.

...J..

..
K.

. ...L.

...M.

DISTRICT CODES (DSO)

Units built on a Domestic Special Order, Foreign Special Order,

or other special orders will have the complete order number in

this space. Also to appear in this space is the two-digit code number

of the District which ordered the unit. If the unit is a regular

production unit, only the District code number will appear.

FORD

Code
District
Code

District

11...

13
...

15...

16...

17...

21...

22
...

24...

25...

28...

32....

33...

35...

37...

38....

41...

43...

44...

46....

47...
Boston

...New York

Newark

...Philadelphia

Washington

Atlanta

Charlotte

...Jacksonville

Richmond

. ...Louisville

. ...Cleveland

.... Detroit

Lansing

...Buffalo

... .Pittsburgh

Chicago

Milwaukee

Twin Cities

...Indianapolis

Cincinnati
51

53

54

55

56

61

62

63

64

65

71

72

73

74

75

83

84

85

89

90's
..
... Denver

.. .Kansas City

.. Omaha

...St. Louis

.. Davenport

.. Dallas

... Houston

.. Memphis

.. New Orleans

.. .Oklahoma City

... Los Angeles

...San Jose

...Salt Lake City

...Seattle

.. .Phoenix

.. Government

... Home Office Reserve

.. American Red Cross

...Transportation Services

...Export
LINCOLN-MERCURY

Code
District

Code
District

11

15

16

17

21

22

23

26

31

32

33
Boston

New York

Philadelphia

Washington

Altanta

Dallas

Jacksonville

Memphis

Buffalo

Cincinnati

Cleveland
34

41

42

46

51

52

53

54

84

90's...
... Detroit

.. Chicago

..
St.
Louis

... Twin Cities

Denver

Los Angeles

Oakland

Seattle

Home Office Reserve

Export

FORD
OF
CANADA

Code
District
Code
District

Bl

B2

B3

II thru
17..
Central

Eastern

Atlantic

Export
B4.

B6.

B7.
Midwestern

Western

. Pacific

Note:
Canadian Lincoln-Mercury units use prefix
"A" in
place of«"B".procarmanuals.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

02-01-05
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

02-01-08
Brakes

02-01-08

BEARING CUP

DIMENSION "B"

0.755 MINIMUM

DIMENSION "A'

0.395 MINIMUM

H1532-B

FIG. 12—Disc Brake Rotor Service

Limits—Lincoln Continental

per splash shield or the bleeder screw

fitting.

4.
Front wheel bearing end play is

critical and must be within specifica-

tions.

5.
Be sure the vehicle is centered on

the hoist before servicing any front

end components, to avoid bending or

damaging the rotor splash shield on

full right or left wheel turns.

6. The proportioning valve should

not be disassembled or adjustments

attempted on it.

7.
Riding of the brake pedal (com-

mon on left foot applications) should

be avoided during vehicle operation.

8. The wheel and tire must be re-

moved ' separately from the brake

rotor, unlike drum brakes where the
wheel, tire and drum are removed as a

unit.

9. On floating caliper type disc

brakes whenever the caliper is re-

moved the caliper locating pins should

be inspected for wear or damage.

10.
On floating caliper type disc

brakes, the caliper assembly must be

removed from the spindle prior to re-

moval of the shoe and lining assem-

blies.

11.
On floating caliper type disc

brakes the calipers must not be inter-

changed from one side to the other.

When the caliper is installed on its

proper anchor plate and spindle, the

bleeder screw will point to the rear of

the vehicle (Fig. 22). If a caliper is in-

stalled on the wrong side of the vehi-

cle,
it is not possible to bleed the sys-

tem properly.

12.
Do not attempt to clean or re-

store oil or grease soaked brake lin-

ings.
When contaminated linings are

found, brake linings must be replaced

in complete axle sets.

DRUM BRAKES

1.
Remove the wheel from the

drum, and remove the drum as out-

lined in Part 2-2, Section 2.

2.
Brush all dust from the backing

plates and interior of the brake

drums.

3.
Inspect the brake shoes for ex-

cessive lining wear or shoe damage. If

the lining is worn within 1/32 inch of

the rivet heads or if the shoes are

damaged, they must be replaced. Re-

place any lining that had been con-

taminated with oil, grease or brake
fluid. Replace lining in axle sets. Prior

to replacement of lining, the drum di-

ameter should be checked to deter-

mine if oversize linings must be in-

stalled.

4.
Check the condition of brake

shoes,
retracting springs, hold-down

springs, and drum for signs of over-

heating. If the shoes have a slight blue

coloring, indicating overheating, re-

placement of the retracting and hold-.

down springs is strongly recommended.

Overheated springs lose their pull and

could cause the new lining i:o wear

prematurely, if they are not replaced.

5. If the vehicle has 30,000 or more

miles of operation on the brake linings

or signs of overheating are present

when relining brakes, the wheel cylin-

ders should be disassembled and in-

spected for wear and entrance of dirt

into the cylinder. The cylinder cups

should be replaced, thus avoiding fu-

ture problems.

6. Inspect all other brake parts and

replace any that are worn or dam-

aged.

7.
Inspect the brake drum and, if

necessary, refinish. Refer to Part 2-2,

Section 4 for refinishing.

BRAKE BOOSTER

Check the booster operation as

noted in Part 2-1, Section 1, Power

Brake Functional Test. If the brake

booster is damaged or defective, re-

place it with a new booster. The brake

booster is serviced only as an assem-

bly.procarmanuals.com

02-02-01
Brake System

02-02-01

Part 2-2 Brake
System

COMPONENT INDEX

ANTI SKID CONTROL SYSTEM

Description

ANTI SKID CONTROL ACTUATOR

Removal and Installation

ANTI SKID CONTROL MODULE

Removal and Installation

ANTI SKID CONTROL SENSOR

Removal and Installation

BRAKE BACKING PLATE (DRUM)

Removal and Installation

BRAKE BOOSTER

Cleaning and Inspection
-
See Part 2-1

Description

Removal and Installation

BRAKE DRUM

Cleaning and Inspection
-
See Part 2-1

Refinishing

Removal and Installation (Front)

Removal and Installation (Rear)

BRAKE PEDAL

Removal and Installation

BRAKE SHOES (DRUM)

Adjustments

Relining

Removal and Installation

DISC BRAKE

Description

DISC BRAKE CALIPER

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

DISC BRAKE ROTOR AND HUB

Cleaning and Inspection
—
See Part 2-1

Refinishing

Removal and Installation

DISC BRAKE ROTOR SPLASH SHIELD

Removal and Installation

DISC BRAKE SERVICE PRECAUTIONS

—
See Part 2-1
MODEL APPLICATION
All
Models

02-16

02-06

02-24

02-39

02-09

02-09

02-07

02-39

02-09

02-03

02-39

02-19

02-19
Ford
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Mercury
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Meteor
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Cougar
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Fairlane
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Falcon
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Montego
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Mustang
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A

02-27

02-42

02-41

02-17
Thunderbird
02-07

02-36

02-38

02-38

N/A

02-26

04-41

02-41

02-16
Continental-
Mark
III
02-07

02-36

02-38

02-38

N/A

02-26

02-41

02-41

02-16

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