ECO mode FORD MUSTANG 1969 Volume One Chassis

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

02-02-18

Brake System

02-02-18

the brake hose connector
and
bracket

assembly.

3.
Remove
the two
bolts retaining

the brake hose bracket
and
caliper
as-

sembly
to the
spindle. Take care
to

avoid loosening
the
bridge bolts that

hold
the two
halves
of the
caliper
to-

gether.

4.
Lift
the
caliper assembly
off the

rotor
and
place
it on the
bench.

Installation

1.
If the
caliper assembly
is to be

replaced, transfer
the
steel tubing
and

the bleeder screw
to the new
caliper.

2.
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 pistons into
the
cylinder

bores
to
obtain clearance between
the

shoe
and
lining assembly
and the

rotor.
The
shoe
and
lining assemblies

should
be
seated properly
on the

bridges.

3.
Install
the
caliper
to
spindle
re-

taining bolts
and
torque them
to
spec-

ification. Check
to
insure that
the

rotor runs squarely
and
centrally
be-

tween
the two
halves
of the
caliper.

These should
be
approximately 0.090-

0.120 inch clearance between
the
cali-

per
and the
rotor outside diameter

(Fig.
6).

4.
Position
the
steel transfer tube

brake hose bracket
and
caliper assem-

bly
to the
spindle. Install
the
retaining

bolts then torque them
to
specifica-

tion.

5.
Connect
the
front wheel steel

transfer tube from
the
caliper
to the

front brake hose connector. Check
the

hose
for
proper installation
(Fig. 21).

6. Bleed
the
brake system
and cen-

tralize
the
differential valve
as out-

lined
in
Part
2-1.
Check
the
master

cylinder fluid level
and add the
speci-

fied fluid,
as
required. Pump
the

brake pedal several times
to
actuate

the piston seals
and to
position
the

shoe
and
lining assemblies.

7.
Install
the
wheel
and
tire assem-

bly
and the
wheel cover.

8. Road test
the
vehicle.

DISC BRAKE SHOE
AND

LINING

ALL MODELS EXCEPT

LINCOLN CONTINENTAL

Removal

1.
Remove
the
wheel
and
tire from
the
hub and
rotor assembly.

2.
Remove
the
caliper from
the ve-

hicle following
the
procedures outlined

under Disc Brake Caliper Assembly.

3.
To
facilitate removal
of the
cali-

per assemblies,
the
piston
may
have
to

be pushed into
its
bore. Apply
a

steady inward pressure against
the

inner shoe
and
lining assembly. Main-

tain
the
pressure
for at
least
a
minute.

4.
Slide
the two
outer shoe retain-

ing clips
off the
retaining pins
(Fig.

23).

5.
Remove
the two
retaining pins

from
the
outer shoe, then remove
the

shoe from
the
stationary caliper.

6. Slide
the
inner brake shoe
out-

ward until
it is
free
of the
hold-down

springs, then remove
the
brake shoe.

7.
Remove
the
caliper locating pins

and stabilizer attaching bolts, then
re-

move
and
discard
the
stabilizer
or sta-

bilizers.

8. Remove
the
locating
pin
insula-

tors from
the
anchor plate.

Installation

When installing
new
shoes
and lin-

ings
it
will
be
necessary
to
force
the

piston
to the
bottom
of its
bore.

Apply sufficient pressure
to
overcome

the grip
of the
piston seal
on the pis-

ton.

1.
Install
new
caliper locating
pin

insulators
in the
anchor plate.

2.
Position
the
caliper assembly
in

the anchor plate.

3.
Position
the new
stabilizer
or

stabilizers
and
install
the
caliper locat-

ing pins
to
engage approximately four

threads.

If
the
caliper locating pins
are
rust-

ed
or
corroded they should
be re-

placed.

Apply water
or
isopropyl alcohol
to

the caliper locating pins before instal-

lation.
Oil or
grease must
not be
used

on
the
locating pins.

4.
Position
the
outer brake shoe
on

the caliper
and
install
the two
retain-

ing pins
and
clips.

5.
Install
the
inner brake shoe
so

that
the
ears
of
shoe
are on top of the

anchor plate bosses
and
under
the

shoe hold-down springs.

6. Position
the
shoe
and
lining

assemblies
so
that
the
caliper assem-

bly
can be
placed over
the
rotor.
Ro-

tate
a
hammer handle between
the lin-

ings
to
reset
the
stabilizers.

7.
Install
the
caliper assembly over

the rotor
and on the
spindle. Install

the
two
caliper attaching bolts,
and

torque them
to
specifications.
The

upper bolt must
be
tightened first.
In-

stall
the
safety wire
and
twist
the
ends
at least five turns. Push
the
wire ends

against
the
spindle
to
avoid interfer-

ence with
the
brake hose
and the

steering stop.

8. With moderate pressure applied

to
the
brake pedal, torque
the
stabiliz-

er attaching screws
and
caliper locat-

ing pins
to
specification.

LINCOLN CONTINENTAL

Removal

1.
Remove
the
wheel
and
tire
as-

sembly from
the hub and
rotor assem-

bly.
Be
careful
to
avoid damage
or in-

terference with
the
caliper splash

shield, bleeder screw fitting
or
transfer

tube.

2.
Remove
the two
bolts that retain

the caliper splash shield,
and
remove

the shield
(Fig. 4).

3.
To
facilitate removal
and
instal-

lation
of the
shoe
and
lining assem-

blies,
the
pistons must
be
pushed into

their bores. Apply
a
steady inward

pressure against each shoe
and
lining

assembly toward
its
respective caliper

housing
on
each side
of the
rotor
(Fig.

6).
Maintain
the
pressure
for at
least

a minute.
If the
pistons will
not go ifi

easily, force them
in
with water pump

pliers.

4.
Grasp
the
metal flange
on the

outer
end of the
shoe with
two
pairs

of pliers
and
pull
the
shoe
out of the

caliper (Fig.
25).

Installation

1.
Position
a new
shoe
and
lining

assembly
on
each side
of the
rotor
so

that
the
lining faces
the
rotor.
Be
sure

AB

AB

USE SECOND

PAIR
OF

PLIERS HERE

H 1651
A

FIG. 25—Removing Disc Brake

Shoe
and
Lining Assembly—

Lincoln Continentalprocarmanuals.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

02-02-39
Brake System

02-02-39

MAJOR REPAIR OPERATIONS

BRAKE DRUM REFINISHING

Minor scores on a brake drum can

be removed with sandpaper. A drum

that is excessively scored or shows a

total indicator runout of over 0.007

inch should be turned down. Remove

only enough stock to eliminate the

scores and true up the drum. The refi-

nished diameter must not exceed 0.060

inch oversize.

Check the inside diameter of the

brake drum with a brake drum mi-

crometer (Tool FRE-14^1).

If the drum diameter is less than

0.030 inch oversize after refinishing^

standard lining may be installed. If

the drum diameter is 0.030—0.060

inch oversize after refinishing, oversize

lining must be installed.

After a drum is turned down, wipe

the refinished surface with a cloth

soaked in clean denatured alcohol. If

one drum is turned down, the opposite

drum on the same axle should also be

cut down to the same size.

ROTOR REFINISHING

Rotunda Disc Brake Attachment,

FRE-2249-2, is the only recommended

tool to refinish the disc brake rotors.

The step-by-step resurfacing procedure

provided with the tool must be ad-

hered to.

The finished braking surfaces of the

rotor must be flat and parallel within

0.0007 inch; lateral runout must not

exceed 0.003 inch total indicator read-

ing, and the surface finish of the brak-

ing surfaces are to be 80/15 micro

inches. The minimum limiting dimen-

sions (Figs. 11 and 12, Part 2-1) from

the inboard bearing cup to the out-

board rotor face and from the inboard

bearing cup to the inboard rotor face

must be observed when removing ma-

terial from the rotor braking surfaces.

On all models except Lincoln Con-

tinental, the limiting dimensions are to

be measured with a ball and gage bar

(Rotunda Kit FRE-70160).

BRAKE SHOE RELINING

Brake linings that are worn to with-

in 1/32 inch of the rivet head or are

less than 0.030 inch thick (bonded lin-

ing) or have been contaminated with

brake fluid, grease or oil must be re-

placed. Failure to replace worn linings

will result in a scored drum. When it
is necessary to replace linings, they

must also be replaced on the wheel on

the opposite side of the vehicle.

Inspect brake shoes for distortion,

cracks, or looseness. If this condition

exists,
the shoe must be discarded. Do

not attempt to repair a defective brake

shoe.

1.
Wash the brake shoes thoroughly

in a clean solvent. Remove all burrs

or rough spots from the shoes.

2.
Check the inside diameter of the

brake drum with a brake drum mi-

crometer (tool FRE-1431). If the di-

ameter is less than 0.030 inches over-

size,
standard lining may be installed.

If the diameter is 0.030—0.060 inches

oversize, oversize lining should be in-

stalled.

3.
Position the new lining on the

shoe.
Starting in the center, insert and

secure the rivets, working alternately

towards each end. Replacement lin-

ings are ground and no further grind-

ing is required.

4.
Check the clearance between the

shoe and lining. The lining must seat

tightly against the shoe with not more

than 0.008 inch clearance between any

two rivets.

RETAINER - 2B245
DUAL MASTER CYLINDER

DISASSEMBLY

1.
Clean the outside of the master

cylinder and remove the filler cover

and diaphragm. Pour out any brake

fluid that remains in the cylinder. Dis-

card the old brake fluid.

2.*
Remove the secondary piston

stop bolt from the bottom of the cyl-

inder (Figs. 40 and 41).

3.
Remove the bleed screw, iL re-

quired.

4.
Depress the primary piston and

remove the snap ring from the retain-

ing groove at the rear of the master

cylinder bore (Fig. 42). Remove the

push rod and the primary piston as-

sembly from the master cylinder bore.

Do not remove the screw that retains

the primary return spring retainer, re-

turn spring, primary cup and protec-

tor on the primary piston. This assem-

bly is factory pre-adjusted and should

not be disassembled.

5.
Remove the secondary piston as-

sembly. Do not remove the outlet tube

seats,
outlet check valves and outlet

SECONDARY SYSTEM

BRAKE OUTLET
COVER -2166

GASKET-2167

MASTER CYLINDER -2155

SNAP RING -7821

BOOT

PUSH ROD

PRIMARY PISTON

ASSEMBLY - 2169

tTUBE SEAT-

2B220
* SECONDARY PISTON

ASSEMBLY - 2A502

• NOT USED ON POWER BRAKE EQUIPPED VEHICLES

fNOT SERVICED

•REPLACE AS AN ASSEMBLY ONLY

H 1499-B

FIG. 40— Dual Master Cylinder Disassembled—Except Disc Brakesprocarmanuals.com

02-02-40
Brake System

02-02-40

RETAINER - 2B245

PRIMARY PISTON

ASSEMBLY-2169

GASKET-2167

RETURN SPRING

RETAINER

\ CUP

\\PROTECTOR

^\i # PISTON
fNOT SERVICED

* REPLACE AS

ASSEMBLY ONLY

*O-RING

PUMPING CUP

tVALVE

2175

SECONDARY

BRAKE SYSTEM

OUTLET
*SECONDARY PISTON

ASSEMBLY-2A502

H 1550-B

FIG. 41—Dual Master Cylinder Disassembled—Disc Brakes

check valve springs from the master

cylinder body.
open and free of foreign matter. Use

an air hose to blow out dirt and clean-

ing solvent. Place all parts on a clean

pan or paper.

3.
Inspect the master cylinder bore

for signs of etching, pitting, scoring or

rust. If it is necessary to hone the

master cylinder bore to repair dam-

age,
do not exceed allowable hone

specifications.

ASSEMBLY

1.
Dip all parts except the master

cylinder body in clean Rotunda Extra

Heavy Duty Brake Fluid.

2.
Carefully insert the complete

secondary piston and return spring as-

sembly in the master cylinder bore.

3.
Install the primary piston assem-

bly in the master cylinder bore.

4.
Depress the primary piston and

install the snap ring in the cylinder

bore groove.

5.
Install the push rod, boot and re-

tainer on the push rod, if so equipped.

Install the push rod assembly into the

primary piston. Make sure the retain-

er is properly seated and holding the

push rod securely.

6. Position the inner end of the

push rod boot (if so equipped) in the

master cylinder body retaining groove.

7.
Install the secondary piston stop

INSPECTION AND REPAIR

1.
Clean all parts in clean isopropyl

alcohol, and inspect the parts for

chipping, excessive wear or damage.

When using a master cylinder repair

kit, install all the parts supplied.

2.
Check all recesses, openings and

internal passages to be sure they are

Snap Ring Pliers

SNAP RING

H1477-C

FIG. 42—Removing Snap

Ring—Typical
INNER BRAKE

SHOE AND LINING

ASSEMBLY-2019
OUTER SHOE

RETAINING CLIPS

2066

STABILIZER

2B295

LOCATING PIN

2B296

ANCHOR PLATE

2B293(L.H.)

2B292 (R.H.)
MOVABLE CALIPER

2B119(L.H.)

2B118(R.H.)

H 1573-C

FIG. 43—Caliper Assembly—Disassembled-

All Models Except Lincoln Continentalprocarmanuals.com

02-02-41
Brake System

02-02-41

bolt and G-ring in the bottom of the

master cylinder.

8. Install the bleed screw (if so

equipped). Install the gasket (dia-

phragm) in the master cylinder filler

cover. Position the gasket as shown in

Figs.
40 and 41. Make sure the gasket

is securely seated.

9. Install the cover and gasket on

the master cylinder and secure the

cover into position with the retainer.

DISC BRAKE CALIPER

ALL MODELS EXCEPT

LINCOLN CONTINENTAL

Disassembly

1.
Remove the caliper assembly

from the vehicle as outlined in Section

2.

2.
Remove the caliper locating pins

from the caliper assembly and lift the

anchor plate from the caliper.

3.
Slide the two outer shoe retain-

ing clips off the retaining pins (Fig.

43).

4.
Remove the two retaining pins,

then remove the outer brake shoe

from the caliper.

5.
Slide the inner brake shoe out-

ward until it is free of the hold-down

springs, then remove the brake shoe.

6. Apply air pressure to the fluid

port in the caliper with a rubber

tipped nozzle (Tool 7000-DD) as

shown in Fig. 44 to remove the piston.

Place a cloth over the piston before

applying air pressure to prevent dam-

age to the piston. If the piston is

seized and cannot be forced from the

FIBER

BLOCK

CALIPER

PISTON

H 1574-B

FIG. 44 —Removing Piston From

Caliper —
All
Models Except

Lincoln Continental
caliper, tap lightly around the piston

while applying air pressure. Care

should be taken because the piston

can develop considerable force due to

pressure build-up.

7.
Remove the dust boot from the

caliper assembly.

8. Remove the rubber piston seal

from the cylinder and discard it.

Cleaning and Inspection

Clean all metal parts with isopropyl

alcohol or a suitable solvent. Use

clean, dry, compressed air to clean out

and dry the grooves and passage ways.

Be sure that the caliper bore and com-

ponent parts are completely free of

any foreign material.

Check the cylinder bore and piston

for damage or excessive wear. Replace

the piston if it is pitted, scored, or the

chrome plating is worn off.

Assembly

1.
Apply a film of clean brake fluid

to the new caliper piston seal and in-

stall it in the cylinder bore. Be sure

the seal does not become twisted and

that it is seated fully in the groove.

2.
Install a new dust boot by setting

the flange squarely in the outer groove

of the caliper bore.

3.
Coat the piston with the speci-

fied fluid and install the piston in the

cylinder bore. Spread the dust boot

over the piston as it is installed. Seat

the dust boot in the piston groove.

4.
Position the inner brake shoe so

that the ears of the shoe rests on the

top of the anchor plate bosses and be-

neath the hold-down springs.

5.
Install new caliper locating pin

insulators in the anchor plate.

6. Position the caliper on the an-

chor plate.

7.
Apply water or isopropyl alcohol

to the caliper locating pins and install

them loosely in the anchor plate. Be

sure the guide pins are free of oil,

grease or dirt.

8. Install the caliper on the spindle

as outlined under Disc Brake Caliper

Assembly.

LINCOLN CONTINENTAL

Disassembly

Do not remove the bridge bolts that

hold the two halves of the caliper to-

gether. The two caliper housings are

shown separated in Fig. 46 for illus-

tration purposes only.
1.
Remove the caliper assembly

from the car as outlined in Section 2.

2.
Remove the two attaching bolts

and the caliper splash shield (Fig. 46).

3.
Remove the two shoe and lining

assemblies.

4.
Remove the flexible brake hose

from the caliper.

5.
Remove the external transfer

tube.

6. Remove the four dust boots from

the caliper housings and piston

grooves.

7.
Clamp the caliper in a vise and

secure it by the mounting flanges on

the inboard housing (Fig. 45).

8. Remove the four pistons from

the cylinder bores with the special tool

shown in Fig. 45. To prevent cocking

with consequent damage to the piston

or bore, rotate the piston with the tool

while pulling it outward at the same

time.
Be careful to avoid scratching or

damaging the outside diameter surface

or dust boot retaining groove of the

piston. Such damage causes poor seal-

ing.

If a piston is so completely seized in

the cylinder bore that it can not be re-

moved with the special tool, the cali-

per housing must be replaced, by posi-

tioning two screwdrivers in the piston

dust boot retaining groove and prying

outward. To prevent cocking, tap the

end of the piston lightly around the

circumference with a hammer, while

the prying force is being applied. Be

careful to avoid damaging the dust

boot retainer in the caliper housing

(Fig. 46). If this method of removal is

used, the pistons must be replaced.

If the caliper dust boot retainer or

retaining groove is damaged or

scratched, pry the retainer out of the

caliper housing with screwdrivers.

Too/-T65P-2
J
18- A

H 1652-A

FIG. 45—Removing or Installing

Pistons —
Lincoln
Continentalprocarmanuals.com

03-05-01
Steering Columns And Linkage

03-05-01

PART 3-5 Steering
Columns
and Linkage

COMPONENT INDEX

ADJUSTING SLEEVE (LINKAGE)

Removal and Installation

CENTER LINK (LINKAGE)

Removal and Installation

LOCKING LEVER (TILT-AWAY COLUMN)

Removal and Installation

PITMAN ARM (LINKAGE)

Removal and Installation

SPINDLE CONNECTING ROD ASSEMBLY

(Inner and Outer Ends)

Removal and Installation

STATIONARY STEERING COLUMNS

Description

STEERING COLUMN

Alignment

Removal and Installation

STEERING COLUMN SHIFT TUBE

Removal and Installation

STEERING COLUMN UPPER BEARING

Removal and Installation

STEERING IDLER ARM AND BRACKET

ASSEMBLY

Removal and Installation

STEERING WHEEL

Removal and Installation

Spoke Position Adjustment

TILT-AWAY STEERING COLUMN

Description

TILT STEERING COLUMN

Description

TILT WHEEL STEERING COLUMN

STEERING SHAFT

Removal and Installation

VACUUM MOTOR (TILT-AWAY COLUMN)

Removal and Installation

VACUUM RELEASE VALVE (TILT-AWAY

COLUMN)

Removal and Installation
MODEL APPLICATION
All
Models

05-19

05-20

05-20

05-01

05-14

05-02

05-20

05-02

05-02
Ford
N/A

05-19

N/A

05-08

N/A

05-01

05-16

N/A

N/A
Mercury
N/A

05-19

N/A

05-08

N/A

05-01

05-16

N/A

N/A
Meteor
N/A

05-19

N/A

05-08

N/A

05-01

05-16

N/A

N/A
Cougar
05-06

05-19

N/A

05-10

05-02

N/A

N/A

05-05

05-05
Fairlane
N/A

05-19

N/A

05-09

N/A

N/A

N/A

N/A

N/A
Falcon
N/A

05-19

N/A

05-09

N/A

N/A

N/A

N/A

N/A
Montego
N/A

05-19

N/A

05-09

N/A

N/A

N/A

N/A

N/A
Mustang
05-06

05-19

N/A

05-10

05-02

N/A

N/A

05-05

05-05
Lincoln-
Continental
N/A

05-19

05-06

05-11

N/A

05-01

05-16

N/A

N/A
Thunderbird
05-06

05-19

05-07

05-14

05-02

N/A

N/A

05-05

05-05
Continental-
Mark
III
N/A

05-19

05-06

05-11

N/A

05-01

05-16

N/A

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.

1 DESCRIPTION

STATIONARY STEERING COLUMNS

The steering column is of the col-

lapsible type to lessen the possibility

of injury to the driver of the vehicle

should he become involved in an acci-
dent. The lower end of the steering

column tube at the bellows area will

collapse approximately six inches

upon a hard impact.

The shift tube and the steering shaft

are provided with plastic dowels and
will shear and allow them to collapse

in proportion to the outer tube upon

impact.

Once the steering column has been

collapsed, a complete new column

must be installed with new brackets
procarmanuals.com

03-05-02
Steering Columns
And
Linkage

03-05-02

which also will shear away during
im-

pact.

TILT STEERING COLUMNS

The steering column
is of the col-

lapsible type
to
lessen
the
possibility

of injury
to the
driver
of the
vehicle

should
he
become involved
in an
acci-

dent.
The
lower
end of the
steering

column tube
at the
bellows area will

collapse approximately
six
inches

upon
a
hard impact.

The shift tube
and the
steering shaft

are provided with plastic dowels
and

will shear
and
allow them
to
collapse

in proportion
to the
outer tube upon

impact.

Once
the
steering column
has
been

collapsed,
a
complete
new
column
must
be
installed.

The tilt column features nine driv-

ing positions (four
up and
four down

from
a
center position).
The
.column

also features
a
turn signal switch with

a lane-changer position turn indicating

position
and
emergency warning flash-

er control.

TILT-AWAY STEERING COLUMNS

The tilt-away steering column
fea-

tures nine driving positions (four
up

and four down from
a
center position)

and
a
tilt-away position that
is
auto-

matically accomplished
on
Mustang

and Cougar models when
the
ignition

key
is
turned
to the
OFF
position
and

the left door
is
opened.
On
Thunder-

bird models,
the
tilt-away occurs when
the shift lever
is
placed
in
PARK
and

the driverns door
is
opened.

The steering column
is of the col-

lapsible type
to
lessen
the
possibility

of injury
to the
driver
of the
vehicle

should
he
become involved
in an
acci-

dent.
The
lower
end of the
steering

column tube
at the
bellows area will

collapse approximately
six
inches

upon
a
hard impact.

The shift tube
and the
steering shaft

are provided with plastic dowels
and

will shear
and
allow them
to
collapse

in proportion
to the
outer tube upon

impact.

Once
the
steering column
has
been

collapsed,
a
complete
new
column

must
be
installed along with mounting

brackets which will also shear away

during impact.

IN-VEHICLE ADJUSTMENTS
AND
REPAIRS

STEERING WHEEL SPOKE

POSITION ADJUSTMENT

When
the
steering gear
is on the

high point,
the
front wheels should
be

in
the
straight-ahead position
and the

steering wheel spokes should
be in

their normal position with
the
Pitman

arm pointing directly forward.
If the

spokes
are not in
their normal posi-

tion, they
can be
adjusted without
dis-

turbing
the
toe-in adjustment (Part

3-1).

STEERING WHEEL

REPLACEMENT

1.
Disconnect
the
negative cable

from
the
battery.

2.
Working from
the
underside
of

the steering wheel spoke, remove
the

crash
pad
attaching screws. Lift
the

crash
pad
from
the
wheel.
(On
Conti-

nental Mark
III
models,
pry out the

crash
pad
insert
and
remove
the two

screws that secure
the
crash
pad. Re-

move
the
crash
pad. On
models

equipped with steering wheel mounted

speed controls, refer
to
Group
16 for

removal instructions). Remove
the

horn ring
(if so
equipped)
by
turning

it counterclockwise.

3.
Remove
the
steering wheel
nut,

and then remove
the
steering wheel

with tool T67L-3600-A
(Fig. 1). Do

not
use a
knock-off type steering

wheel puller
or
strike
the end of the

steering shaft with
a
hammer. Striking

the puller
or
shaft will damage
the

bearing
or the
collapsible column.

4.
Transfer
all
serviceable parts
to

the
new
steering wheel.

5.
Position
the
steering wheel
on

the shaft
so
that
the
alignment mark
on
the hub of the
wheel
is
adjacent
to

the
one on the
shaft. Install
a new

locknut
and
torque
it to
specifications.

6. Install
the
horn ring
(if so

equipped)
and
crash
pad.

STEERING COLUMN UPPER

BEARING REPLACEMENT

STATIONARY COLUMNS

Removal

1. Disconnect
the
horn wire
and the

turn indicator wires
at the
connector.

2.
Working from
the
underside
of

the steering wheel spoke, remove
the

two crash
pad
attaching screws. Lift

the crash
pad
from
the
wheel.
(On

Continental Mark
III
models,
pry out

the crash
pad
insert
and
remove
the

two screws that secure
the
crash
pad.

Remove
the
crash
pad. On
models

equipped with steering wheel mounted

speed controls, refer
to
Group
16 for

7oo/-T67L-3600-A
removal instructions). Remove
the

horn ring
(if so
equipped)
by
turning

it counterclockwise.

3.
Remove
the
steering wheel
at-

taching
nut.
Remove
the
steering

wheel using tool T67L-3600-A
(Fig.

1).
Do not use a
knock-off type steer-

ing wheel puller
or
strike
the end of

the steering shaft with
a
hammer.

Striking
the
puller
or
shaft will
dam-

age
the
bearing
or the
collapsible
col-

umn.

4.
Remove
the
turn indicator lever.

5.
Remove
the
turn signal switch

attaching screws. Lift
the
switch over

the
end of the
steering shaft
and
place

it
to one
side.

6. Remove
the
snap ring from
the

top
of the
steering shaft.

7.
Loosen
the two
flange-to-steering

column tube attaching bolts
to
disen-

gage them from
the
tube.

8. Raise
the
flange upward while

BEARING
AND

INSULATOR

Spacer

G 1502 -B

FIG.
1—Removing
Steering Wheel
G 1497-A

FIG. 2—Installing Upper Bearingprocarmanuals.com

03-05-20
Steering Columns And Linkage

03-05-20

placed if it becomes worn or damaged

(Figs.
18 through 21). Do not attempt

to straighten the sleeve if damaged.

1.
Remove the spindle connecting

rod end assemblies as described in the

previous sub-section.

2.
Screw the spindle rod end assem-

blies into the new sleeve the same

number of turns as the ends that were

removed. Do not tighten the clamp

bolts at this time.

3.
Position the sleeve and end as-

sembly on the center link and the

spindle arm. Install the attaching nut,

torque it to specification, and install

the cotter pin.

4.
Check and, if necessary, adjust

toe-in (Part 3-1). After toe-in is

checked and adjusted, oil the sleeve

clamp bolts then torque them to speci-

fication. The sleeve clamp must be in-

stalled as shown in Figs. 18 through

21.

CENTER LINK

REPLACEMENT

The center link connecting the Pit-

man arm and the idler arm is non-

adjustable and is provided with ta-

pered holes to accommodate the ball

studs (Figs. 18 through 21). The link

should be replaced when damaged or

when worn at the ball studs. On Lin-

coln Continental models, the link

should be replaced if excessive loose-

ness is noticed in either ball stud sock-

et.

REMOVAL

1.
Raise the vehicle on a hoist and

position safety stands.

2.
Remove the cotter pins and nuts

that attach both inner connecting rod

ends to the center link (Figs. 18

through 21).

3.
Disconnect the inner connecting

rod ends from the center link using

Tool 3290-C (Fig. 22).

4.
Remove the cotter pin and nut

attaching the idler arm to the center

link. Disconnect the idler arm from

the center link using Tool 3290-C for

Lincoln Continental models only.

5.
Remove the cotter pin and nut

attaching the Pitman arm to the cen-

ter link. Disconnect the Pitman arm

from the center link (use Tool 3290-C)

and remove the center link. On ve-

hicles equipped with the non-integral

power steering system, remove the

center link from the control valve as

detailed in Part 3-7.

INSTALLATION

1.
Replace the rubber seals on the
spindle connecting rod ends, if re-

quired.

2.
Position the center link to the

Pitman arm and idler arm and install

the attaching nuts loosely. On all ve-

hicles except Lincoln Continental

models, place the idler arm and the

front wheels in the straight ahead po-

sition to insure keeping the steering

wheel aligned and to prevent bushing

damage after the attaching nuts have

been torqued. On Lincoln Continental

models, insure that the seal is properly

installed on the center link. Torque

the nuts to the low end of the specifi-

cation. Continue to tighten each nut

until the slots in the nut align with the

hole in the stud. Then install a new

cotter pin.

3.
Position the spindle connecting

rod ends to the center link and install

the attaching nuts. Torque the nuts to

the low end of the specification. Con-

tinue to tighten each nut until the

slots in the nut align with the hole in

the stud. Then, install a new cotter

pin.

4.
Remove the safety stands, lower

the vehicle, check and adjust toe-in to

specification (Part 3-1).

STEERING IDLER ARM

AND BRACKET ASSEMBLY

REPLACEMENT

REMOVAL

If the idler arm bushings are worn

the complete idler arm assembly must

be replaced. In Lincoln Continental

models, if the socket at the idler

bracket is excessively loose, replace

the complet assembly.

1.
Remove the cotter pin and nut

attaching the steering center link at

the idler arm (Figs. 18 through 21).

2.
Disconnect the center link from

the idler arm (on Lincoln Continental

models, use Tool 3290-C).

3.
Remove the two bolts that attach

the idler arm and bracket assembly to

the frame.

INSTALLATION

1.
Secure the new idler arm and

bracket assembly to the frame with

the two attaching bolts (nuts and flat

washers as shown in Figs. 18, 19 and

21).

2.
On all vehicles except Lincoln

Continental models, place the idler

arm and the front wheels in the

straight ahead position to insure keep-

ing the steering wheel aligned and to
prevent bushing damage after the at-

taching nut has been torqued. Insert

the center link stud through the hole

in the end of the idler arm and install

the nut and washer.

On Lincoln Continental models, in-

sert the center link stud through the

hole in the end of the idler arm insur-

ing that the seal is properly installed

on the center link.

3.
Torque the idler arm rod nut to

specification and install a new cotter

pin.

PITMAN ARM

REPLACEMENT

REMOVAL

1.
Remove the cotter pin from the

castellated nut that attaches the steer-

ing center link to the Pitman arm.

Remove the castellated nut.

2.
Disconnect the steering center

link from the Pitman arm with tool

3290-C.

3.
Remove the Pitman arm attaching

nut and lock washer.

4.
Position the front wheels in the

straight ahead position. Remove the

Pitman arm with tool T64P-3590-F

(Fig. 23).

INSTALLATION

1.
With the front wheels in the

straight ahead position, place the Pit-

man arm on the sector shaft making

sure it is pointing forward.

2.
Install the nut and lock washer.

Torque the nut to specification.

G1663-A

FIG. 23— Removing Pitman

Arm—Typicalprocarmanuals.com

04-01-02
General Axle Service

04-01-02

COMPONENT INDEX
MODEL APPLICATION

o

3
I

i

Ji

LUBRICANT LEVEL CHECK

01-10

PINION RETAINER

01-10

Cleaning and Inspection

01-10

SHIM AND BACKLASH CHANGES
01-03

Integral Carrier

Removable Carrier
01-04
N/A

01-04
01-04

01-04

01-04
01-04
01-04

N/A
N/A
N/A

U-JOINT FLANGE
01-10

Cleaning and Inspection
01-10

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
COMMON ADJUSTMENTS
AND
REPAIRS

IDENTIFICATION

The AXLE code on the vehicle

Warranty Plate (Fig. 1) identifies the

rear axle type (conventional or

limited-slip differential) and gear

ratio.

A metal tag (Fig. 2) stamped with

the model designation and gear ratio

is secured to one of the rear cover-

to-housing bolts (integral carrier-type)

or to one of the carrier-to-housing

bolts (removable carrier-type).

The spaces on the top line provide

the axle model identification code.

This code, such as WDT-AN4,

WDC-AS4, WEG-C2, etc. indicates a

specific combination of the following

factors: conventional or limited slip

differential; diameter of ring gear;

small or large wheel bearings; and the

gear ratio. Refer to the specifications

group of this manual for the car-line

rear axle ratios, gear and code
identif-

ication.

The second line on the tag is used

for gear ratio, the production date

code and the production plant identifi-

cation code.
It is important to use the model

designation when obtaining correct re-

placement parts.

LIMITED-SUP
OR

TRACTION-LOK DIFFERENTIAL

OPERATION CHECK

A limited-slip or Traction-Loc dif-
ferential can be checked for proper

operation without removing the carrier

from the axle housing.

Jack up one rear wheel and remove

the wheel cover. Install the tool on the

axle shaft flange studs as shown in

Fig. 3.

AXLE MODEL

PLANT CODING

DATE (YEAR, MONTH, WEEK)

RATIO (CONVENTIONAL)

(LIMITED SLIP WOULD
BE
3L00)

E 1918-A

FIG.
2—Rear
Axle Model Identification
Tag

NOT
FOR
TITLE
OR
REGISTRATION

9G5IVI0000I
WARRANTY NUMBER

E1917-A
CONVENTIONAL

2

3

4
.

5

6

7

A

c
LIMITED SLIP

K

L

M

/

/

p
_ —

R
— —

c

—
u

V
RATIO

2.75:1

2.79:1

— 2.80:1

2.83:1

-
3.00:1

3.10:1

—
3.25:1

3.50:1

3.08:1

3.91:1

— 4.30:1

FIG.
1
— Rear Axle Gear Ratio
and
Type Identificationprocarmanuals.com