light FORD MUSTANG 1969 Volume One Chassis

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

02-02-22
Brake System

02-02-22

BRAKE VACUUM BOOSTER -2005

AUTOMATIC I

TRANSMISSION

HAIR PIN RETAINER

330699-S2

SPACER

STOP LIGHT SWITCH-13480

STANDARD

TRANSMISSION
BUSHING
BUSHING

PUSH ROD

BRAKE PEDAL ASSEMBLY
CLUTCH

PEDAL

ASSEMBLY

H 1557-C

FIG. 30—Master Cylinder Installation—Power Brake-

Fairlane, Montego and Falcon

ASSIST

SPRING BRACKET CLUTCH ASSIST

\ SPRING

BRAKE PEDAL

SHAFT

CLUTCH

PEDAL

CLUTCH PEDAL

TO EQUALIZER ROD

HI643-
A

FIG. 31—Master Cylinder Installation-

Power Brake—Mustang and Cougar
6. Bleed the dual-master cylinder

and the primary and secondary brake

systems. Centralize the pressure dif-

ferential valve. Refer to H>draulic

System Bleeding and Centralizing of

the Differential Valve, Part 2-1, Sec-

tion 2 for the proper procedure.

7.
Operate the brakes several times,

then check for external hydraulic

leaks.

PRESSURE DIFFERENTIAL

VALVE AND PROPORTIONING

VALVE ASSEMBLY

REMOVAL

1.
Disconnect the brake warning

light wire from the pressure differen-

tial valve assembly switch (Figs. 17

thru 21). To prevent damage to the

brake warning switch wire connector,

expand the plastic lugs to allow re-

moval of the shellwire connector from

the switch body.

2.
Loosen the tube nuts connecting

the primary and secondary inlet and

outlet tubes at the pressure differential

valve assembly and remove the tubes.

3.
Remove the screw or screws re-

taining the pressure differential valve

assembly to the chassis and remove

the valve assembly.

4.
On disc brake equipped vehicles,

place the pressure differential valve

assembly and mounting bracket in a

vise.
Loosen the proportioning valve

tube nuts at the differential valve and

at the proportioning valve. Remove

the proportioning valve from the

mounting bracket.

5.
If the differential valve is to be

replaced, remove the brake warning

lamp switch and install the switch in

the new differential valve. The pres-

sure differential valve assembly, the

brake warning lamp switch, and the

proportioning valve are separate units

and each is serviced as a separate as-

sembly only.

INSTALLATION

1.
On disc brake equipped vehicles,

connect the proportioning valve inlet

and outlet tubes to the proportioning

valve and differential valve bodies.

Tighten the tube nuts to specification.

2.
Mount the pressure differential

valve assembly on the chassis and in-

stall the attaching screw or screws.

3.
Connect the primary and second-

ary inlet and outlet tubes to the pres-

sure differential valve assembly and

tighten the tube nuts to specifications.procarmanuals.com

02-02-24
Brake
System

02-02-24

proportioning valve to the fender

apron and remove the proportioning

valve.

Installation

1.
Position the proportioning valve

to the fender apron.

2.
Connect the two brake lines at

the proportioning valve. Do not tight-

en.

3.
Install the bolt retaining the pro-

portioning valve to the fender apron.

4.
Tighten the brake line tube nuts

at the proportioning valve to specifica-

tions.

5.
Bleed the brakes and centralize

pressure differential valve.

THUNDERBIRD AND

CONTINENTAL MARK III

Removal

Refer to Fig. 20.

1.
Disconnect the two hydraulic

brake lines at the master cylinder.

2.
Remove the two nuts retaining

the master cylinder to the booster and

remove the master cylinder for clear-

ance.

3.
Disconnect the two brake lines at

the proportioning valve.

4.
Remove the bolt and nut retain-

ing the proportioning valve to the

pressure differential valve bracket and

remove the proportioning valve assem-

bly.

Installation

1.
Transfer the bracket to the new

proportioning valve.

2.
Position the proportioning valve

assembly to the pressure differential

valve bracket.

3.
Connect the two brake lines to

the proportioning valve. Do not tight-

en.

4.
Install the bolt and nut retaining

the proportioning valve to the pressure

differential valve bracket.

5.
Tighten the two brake line tube

nuts at the proportioning valve to

specifications.

6. Position the master cylinder to

the booster and install the nuts retain-

ing the master cylinder to the booster.

7.
Connect the two brake lines at

the master cylinder and tighten the

tube nuts to specifications.

8. Bleed the brakes and centralize

the pressure differential valve.
LINCOLN CONTINENTAL

Removal

Refer to Fig. 21.

1.
Disconnect the two brake lines at

the proportioning valve.

2.
Loosen the bolt and nut on the

bracket retaining the proportioning

valve to the chassis.

3.
Remove the proportioning valve

from the bracket.

Installation

- 1. Position the proportioning valve

in the bracket and connect the two

brake lines. Do not tighten.

2.
Tighten the bolt and nut on the

bracket.

3.
Tighten the tube nuts on the

brake lines at the proportioning valve

to specifications.

4.
Bleed the brakes and centralize

the pressure differential valve.

PRESSURE METERING VALVE—

LINCOLN CONTINENTAL

REMOVAL

Refer to Fig. 21.

1.
Loosen the tube nuts connecting

the inlet and outlet tubes at the me-

tering valve, and remove the tubes.

2.
Remove the two screws retaining

the metering valve to the frame

crossmember, and remove the me-

tering valve. The metering valve is ser-

viced as an assembly only.

INSTALLATION

1.
Position the metering valve to

the frame crossmember, and install

the retaining screws.

2.
Connect the inlet and outlet

tubes to the metering valve, and tight-

en the tube nuts to specification.

BRAKE BOOSTER

REMOVAL

1.
Working from inside the\ vehicle

below the instrument panel, disconnect

the booster push rod from the brake

pedal assembly. To do this, proceed as

follows:

Disconnect the stop light switch

wires at the connector. Remove the

hairpin retainer. Slide the stop light
switch off from the brake pedal pin

just far enough for the switch outer

hole to clear the pin, and then remove

the switch from the pin and booster

push rod. Be careful not to damage

the switch during removal. Slide the

booster push rod and the nylon wash-

ers and bushing off the brake pedal

pin (Figs. 29 thru 33).

2.
Open the hood and remove the

master cylinder from the booster. Se-

cure it to one side without disturbing

the hydraulic lines. It is not necessary

to disconnect the brake lines, but care

should be taken that the brake lines

are not deformed. Permanent defor-

mation of brake lines can lead to tube

failure.

3.
Disconnect the manifold vacuum

hose or hoses from the booster unit.

4.
Remove the booster-to-dash

panel attaching nuts or bolts (Figs. 29

thru 33). Remove the booster and

bracket assembly from the dash panel,

sliding the push rod link out from the

engine side of the dash panel.

5.
On Fairlane, Montego, and Fal-

con models, remove the push rod link

boot from the dash panel.

INSTALLATION

1.
On Fairlane, Montego and Fal-

con models, install the push rod link

boot in the hole in the dash panel as

shown in Fig. 23. Install the four

spacers on the mounting studs.

2.
Mount the booster and bracket

assembly to the dash panel by insert-

ing the push rod or push rod link in

through the hole and boot in the dash

panel. Install the bracket-to-dash

panel attaching lock nuts or bolts

(Figs.
29 thru 33).

3.
Connect the manifold vacuum

hose or hoses to the booster.

4.
Before installing the master cyl-

inder, check the distance from the

outer end of the booster assembly

push rod to master cylinder surface.

Turn the screw in or out to obtain the

specified length. Refer to Part 2-1,

Section 2, Power Brake Master Cylin-

der Push Rod Adjustment. Install the

master cylinder and torque the attach-

ing nuts to specifications.

5.
Working from inside the vehicle

below the instrument panel, connect

the booster push rod link to the brake

pedal assembly. To do this, proceed as

follows:

Install the inner nylon washer, the

booster push rod, and the bushing on

the brake pedal pin. Position the

switch so that it straddles the push

rod with the switch slot on the pedal

pin and the switch outer hole justprocarmanuals.com

02-02-25
Brake System

02-02-25

clearing the pin. Slide the switch com-

pletely onto the pin, and install the

nylon washer as shown in Figs. 29

thru 33. Be careful not to bend or de-

form the switch. Secure these parts to

the pin with the hairpin retainer. Con-

nect the stop light switch wires to the

connector, and install the wires in the

retaining clip.

BRAKE PEDAL

FORD, MERCURY

AND METEOR

Removal

1.
Disconnect the stop light switch

wires at the connector.

2.
Remove the hairpin retainer.

Slide the stop light switch off the

brake pedal pin just far enough for

the switch outer hole to clear the pin,

and then lift the switch straight up-

ward from the pin. Be careful not to

damage the switch during removal.

Slide the master cylinder or booster

push rod and the nylon washers and

bushing off the brake pedal pin (Figs.

26 and 29).

3.
Remove the hairpin type retainer

and washer from the brake pedal

shaft, then remove the shaft, the brake

pedal and the bushings from the pedal

support bracket.

Installation

1.
Apply a coating of SAE 10 En-

gine oil to the bushings and locate

bushings in their proper places on the

pedal assembly and pedal support

bracket (Figs. 26 and 29).

2.
Position the brake pedal assem-

bly to the support bracket, then install

the pedal shaft through the support

bracket and brake pedal assembly. In-

stall the retainer.

3.
Install the inner nylon washer,

the master cylinder or booster push

rod, and the bushing on the brake

pedal pin. Position the switch so that

it straddles the push rod with the

switch slot on the pedal pin and the

switch outer hole just clearing the pin.

Slide the switch completely onto the

pin, and install the nylon washer as

shown in Figs. 26 and 29. Be careful

not to bend or deform the switch. Se-

cure these parts to the pin with the

hairpin retainer.

4.
Connect the stop light switch

wires to the connector, and install the

wires in the retaining clip.
5.
Check the Brake Pedal Free

Height and Travel Measurements,

Part 2-1, Section 1.

FAIRLANE, MONTEGO AND

FALCON—MANUAL-SHIFT

TRANSMISSION

Removal

1.
Remove the clutch pedal assist

spring.

2.
Disconnect the clutch pedal-

to-equalizer rod at the clutch pedal by

removing the retainer and bushing.

3.
Disconnect the stop light switch

wires at the connector.

4.
Remove the switch retainer, and

slide the stop light switch off the

brake pedal pin just far enough for

the switch outer hole to clear the pin.

Then lower the switch away from the

pin.

5. Slide the master cylinder or

booster push rod and the nylon wash-

ers and bushing off from the brake

pedal pin (Figs. 27 and 30).

6. Remove the self-locking pin and

washer from the clutch and brake

pedal shaft, then remove the clutch

pedal and shaft assembly, the brake

pedal assembly, and the bushings from

the pedal support bracket (Figs. 27

and 30).

Installation

1.
Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

bushings in their proper places on the

clutch and brake pedal assemblies.

2.
Position the brake pedal to the

support bracket, then install the clutch

pedal and shaft assembly through the

support bracket and brake pedal as-

sembly. Install the spring clip (Figs.

27 and 30).

3.
Install the clutch pedal assist

spring.

4.
Connect the clutch pedal-

to-equalizer rod to the clutch pedal

assembly with the bushing and the

spring clip retainer. Apply SAE 10

engine oil to the bushing.

5.
Install the inner nylon washer,

the master cylinder or booster push

rod, and the bushing on the brake

pedal pin. Position the switch so that

it straddles the push rod with the

switch slot on the pedal pin and the

switch outer hole just clearing the pin.

Slide the switch completely onto the

pin, and install the outer nylon washer

as shown in Figs. 27 and 30. Secure

these parts to the pin with the
self-

locking pin.
6. Connect the stop light switch

wires to the connector, and install the

wires to the retaining clip.

7.
Adjust the clutch pedal free play

(Group 5) to specification, if required.

8. Check the Brake Pedal Free

Height and Travel Measurements

(Part 2-1, Section 1).

MUSTANG AND COUGAR—

MANUAL-SHIFT

TRANSMISSION

Removal

1.
Disconnect the battery ground

cable from the battery.

2.
Remove the steering column.

Refer to Part 3-4, Section 2 for pro-

cedure.

3.
On non-power brakes, remove

the two cap screws retaining the mas-

ter cylinder to the dash panel and re-

move the two cap screws retaining the

brake pedal support bracket to the

dash panel. On power brakes remove

the two cap screws retaining the

booster to the dash panel.

4.
Working inside the vehicle, se-

cure the clutch pedal against the

bumper stop with a small C-clamp as

shown in Figs. 28 and 31.

5.
Disconnect the clutch pedal-

to-equalizer rod at the clutch pedal by

removing the retainer and bushing.

6. Disconnect the stop light switch

wires at the connector.

7.
Remove the switch retainer and

slide the stop light switch off the

brake pedal pin just far enough for

the switch outer hole to clear the pin.

Then lower the switch away from the

pin.
Remove the master cylinder or

booster push rod, bushing and nylon

washer from the brake pedal pin.

8. Remove the screw retaining the

pedal support bracket to the top inner

cowl bracket (Figs. 28 and 31).

9. Remove the two sheet metal

screws retaining the pedal support

bracket to the dash panel. On power

brakes remove the nuts from the

brake booster studs.

10.
Remove the two screws retain-

ing the pedal support bracket to the

upper cowl brace and lower the pedal

support bracket away from the steer-

ing column studs.

11.
Remove the pedal support

bracket assembly from the vehicle.

12.
Position the pedal and support

bracket assembly in a vise.

13.
Remove the C-clamp to release

the clutch pedal from its bumper stop

and pivot the pedal away from the

bumper.procarmanuals.com

02-02-26
Brake System

02-02-26

14.
Remove the clutch pedal assist

spring.

15.
On non-power brakes, remove

the retainer clip from the clutch and

brake pedal shaft, then remove the

clutch pedal and shaft assembly, the

brake pedal assembly, and the bush-

ings from the pedal support bracket.

On power brakes, remove the retainer

nut from the brake pedal shaft then

remove the pedal shaft, the brake

pedal assembly and the bushings from

the pedal support bracket.

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

bushings in their proper places on the

clutch and brake pedal assemblies.

2.
On non-power brakes, position

the brake pedal to the pedal support

bracket, then install the clutch pedal

and shaft assembly through the sup-

port bracket and brake pedal assem-

bly. On power brakes position the

brake pedal to the pedal support

bracket, then install the pedal shaft

and nut.

3.
Install the clutch pedal assist

spring and pivot the clutch pedal

against its bumper stop. Secure the

pedal to the stop with a small C-

clamp as shown in Figs. 28 and 31.

4.
Position the pedal support

bracket assembly to the dash panel,

and to the steering column retainer

studs.

5.
Align the pedal support bracket

holes with the holes in the dash panel

and install the two attaching sheet

metal screws. On power brakes install

the nuts on the brake booster studs.

6. Install the two cap screws at-

taching the pedal support bracket to

the upper cowl bracket.

7. Install the cap screw attaching

the pedal support bracket to the top

inner cowl bracket (Figs. 28 and 31).

8. Install the inner nylon washer,

the master cylinder push rod, and the

bushing on the brake pedal pin. Posi-

tion the stop light switch so that it

straddles the push rod with the switch

slot on the pedal pin and the switch

outer hole just clearing the pin. Slide

the switch completely onto the pin,

and install the outer nylon washer as

shown in Figs. 28 and 31. Secure

these parts to the pin with the
self-

locking retainer.

9. Connect the stop light switch

wires to the connector.

10.
Connect the clutch pedal-

to-equalizer rod to the clutch pedal

assembly with the bushing and the

spring clip retainer. Apply SAE 10
engine oil to the bushing. Remove the

C-clamp from the clutch pedal.

11.
Working from the engine side

of the dash panel, on non-power

brakes, install the two cap screws at-

taching the pedal support bracket to

the dash panel. Then install the two

screws attaching the master cylinder

to the dash panel. On power brakes

install the cap screws retaining the

brake booster to the dash panel.

12.
Install the steering column.

Refer to Part 3-4, Section 2 for pro-

cedure.

13.
Adjust the clutch pedal free

play (Group 5) to specification, if re-

quired.

14.
Check the Brake Pedal Free

Height and Travel Measurements

(Part 2-1, Section 1).

15.
Connect the ground cable to the

battery.

FAIRLANE, MONTEGO,

FALCON, MUSTANG

AND COUGAR-

AUTOMATIC TRANSMISSION

Removal

1. Disconnect the stop light switch

wires at the connector.

2.
Remove the self-locking pin and

slide the stop light switch off the

brake pedal pin just far enough for

the switch outer hole to clear the pin.

Then lower the switch away from the

pin. Slide the master cylinder or

booster push rod and the nylon wash-

ers and bushing off from the brake

pedal pin (Figs. 27, 28, 30 and 31).

3.
On all vehicles except Mustang

and Cougar with power brakes, re-

move the self-locking pin and washer

from the brake pedal shaft, then re-

move the shaft, the brake pedal as-

sembly and the bushings from the

pedal support bracket. On Mustang

and Cougar vehicles with power

brakes, remove the locknut and bolt

from the pedal. Remove the pedal as-

sembly from the support bracket (Fig.

3).

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

the bushings in their proper places on

the pedal assembly and pedal support

bracket (Figs. 27, 28, 30 and 31).

2.
Position the brake pedal assem-

bly to the support bracket, then install

the pedal shaft or bolt through the

support bracket and brake pedal as-

sembly. Install the retainer or locknut.
3.
Install the inner nylon washer,

the master cylinder or booster push

rod, and the bushing on the brake

pedal pin. Position the switch so that

it straddles the push rod with the

switch slot on the pedal pin, and the

switch outer hole just clearing the pin.

Slide the switch completely onto the

pin, and install the outer nylon washer

as shown in Figs. 27, 28, 30 and 31.

Secure these parts to the pin with the

self-locking pin.

4.
Connect the stop light switch

wires to the connector, and install the

wires in the retaining clip.

Check the Brake Pedal Free Height

and Travel Measurements, Part 2,

Section 1.

THUNDERBIRD
AND

CONTINENTAL MARK
III

Removal

1.
Loosen the booster mounting

nuts.

2.
Disconnect the stop light switch

wires at the connector.

3.
Remove the hairpin retainer.

Slide the stop light switch off from

the brake pedal pin just far enough

for
the
switch outer hole
to
clear
the

pin,
and then lift the switch straight

upward from the pin. Slide the master

cylinder push rod and the nylon wash-

ers and bushing off from the brake

pedal pin (Fig. 32).

4.
Remove the pivot bolt and nut

that holds the pedal to the pedal sup-

port bracket. Remove the brake pedal

assembly from the pedal support

bracket, and remove the bushings.

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

the bushings in their proper places on

the pedal assembly (Fig. 32).

2.
Install the brake pedal assembly

and bushings to the support bracket,

and then install the pivot bolt through

the support bracket and brake pedal

assembly. Install the pivot bolt nut

and torque to specifications.

3.
Install the inner nylon washer,

the master cylinder push rod, and the

bushing on the brake pedal pin. Posi-

tion the switch so that it straddles the

push rod with the switch slot on the

pedal pin and the switch outer hole

just clearing the pin. Slide the switch

completely onto the pin, install the

outer nylon washer as shown in Fig.

32.
Secure these parts to the pin with

the hairpin retainer.procarmanuals.com

02-02-27
Brake System

02-02-27

4.
Connect the stop light switch

wires to the connector, and install the

wires in the retaining clip.

5.
Torque the booster mounting

nuts to specifications.

LINCOLN CONTINENTAL

Removal

1.
Disconnect the battery ground

cable from the battery.

2.
It is necessary to obtain clear-

ance to remove vacuum hoses and the

electrical connector to the temperature

heat control box. Remove the two

screws retaining the relay to the fend-

er and push the relay aside. Discon-

nect the vacuum hoses and connector

at the heat control box.

3.
Working under the instrument

panel, disconnect the vacuum hoses,

wires and retaining clip from the tem-

perature heat control box. Remove the

two screws securing the temperature

control box to the dash panel.

4.
Remove the lower control hous-

ing retaining screws (6). Disconnect

the wire harnesses at the lower control

panel and place the panel aside. Re-

move the wire harness shield. Remove

the wire harness clip. Position the

wire harness aside. Remove the tem-

perature control box and position it

aside.

5.
Remove the hair-pin type retain-

er. Slide the stop light switch off the

brake pedal pin just far enough for

the switch outer hole to clear the pin.

Lift the switch upward from the pin.

Slide the master cylinder push rod,

nylon washers and bushing off the

brake pedal pin.

6. Remove the pivot bolt and nut

that holds the pedal to the pedal sup-

port bracket. Remove the brake pedal

assembly from the support bracket

and remove the bushings.

7.
If required, remove the brake

pedal pad retaining nuts and remove

the brake pedal pad.

Installation

1.
If the brake pedal pad was re-

moved, position the pad on the pedal.

Install the pad retaining nuts and tor-

que them to specification.

2.
Apply SAE 10 engine oil to the

bushings and locate all the bushings in

their proper places on the pedal as-

sembly.

3.
Install the brake pedal assembly

and bushings to the support bracket,

and then install the pivot bolt through
the support bracket and pedal assem-

bly. Install the pivot bolt nut and tor-

que it to specification.

4.
Install the inner nylon washer,the

master cylinder push rod link, and the

bushing on the brake pedal pin. Posi-

tion the switch so that it straddles the

push rod link with the switch slot on

the pedal and the switch outer hole

just clearing the pin. Install the outer

nylon washer as shown in Fig. 33. In-

stall the hair-pin type retainer on the

brake pedal pin.

5.
Connect the stop light switch

wires to the connector, and install the

wires in the retaining clip.

6. Position the wire harness and

clip on the temperature control box

and install the retaining screw. Posi-

tion the temperature control box to

the dash panel and install the two re-

taining bolts.

7.
Connect the vacuum lines and

the electrical connector to the control

box. Position the wire harness to the

control box and install the retaining

clip.

8. Position the wire harness shield

and install two retaining bolts.

9. Connect the wire harnesses to

the lower control panel and install the

retaining screws.

10.
Working within the engine

compartment, connect the wire con-

nector to the temperature heat control

box.

11.
Position the relay to the fender

apron and install the retaining bolts.

12.
Connect the ground cable to the

battery.

13.
Check the brakes and light

switch for proper operation. Close the

hood.

PARKING BRAKE CONTROL

ASSEMBLY

FORD, MERCURY

AND METEOR

Removal

Refer to Fig. 34.

1.
Make sure the parking brake is

fully released.

2.
Remove all tension from the rear

cables by backing off the adjusting nut

from the equalizer.

3.
Remove the roll pin that secures

the release knob to the cable and re-

move the knob.

4.
Remove the nut that secures the

release cable to the instrument panel
and remove the cable from the rear of

the instrument panel.

5.
Remove the two nuts attaching

the control assembly to the dash

panel.

6. Remove the cap screw attaching

the control assembly to the cowl side

bracket.

7.
Disconnect the hose to the park-

ing brake vacuum unit, if so equipped.

8. Remove the front cable assembly

retainer clip from the cable assembly

and disconnect the cable ball from the

control clevis.

9. Remove the control assembly

from the vehicle.

Installation

1.
Position the control assembly in

the vehicle.

2.
Fit the cable assembly through

its mounting hole and install the re-

taining clip. Connect the cable ball to

the control clevis.

3.
Connect the vacuum hose to the

parking brake unit, if so equipped.

4.
Install the attaching cap screw to

the cowl side bracket. Do not tighten.

5.
Install the two control assemb-

ly-to-dash panel nuts. Tighten the nuts

and the cap screw to specifications.

6. Insert the release cable into the

instrument panel and install the re-

taining nut.

7.
Install the release knob on the

cable with the roll pin.

8. Check the operation of the park-

ing brake. Adjust the parking brake

as required.

FAIRLANE, MONTEGO

AND FALCON

Removal

Refer to Fig. 35.

1.
Make sure the parking brake is

completely released.

2.
Remove all tension from the rear

cables by backing off the jam nut and

adjusting nut from the equalizer.

3.
Working inside the vehicle, re-

move the four bolts and one nut re-

taining the left air vent and cable as-

sembly to the dash and instrument

panels. Remove the vent assembly.

4.
Remove the parking brake front

cable ball retaining clip from the clev-

is.

5.
Disconnect the cable ball from

the notch in the brake clevis.

6. Remove the three screws that at-

tach the control assembly to the left

cowl inner side panel.procarmanuals.com

02-02-30
Brake System

02-02-30

7.
Disconnect the wire lead at the

parking brake warning light switch

and remove the control assembly.

Installation

1.
Connect the wire lead to the

parking brake warning light switch.

2.
Position the control assembly to

the cowl inner side panel and install

the three attaching screws.

3.
Connect the ball-end of the park-

ing brake front cable assembly to the

control assembly, and install the hair-

pin retainer.

4.
Position the cable ball in the

notch in the brake clevis.

5.
Position the left air vent assem-

bly to the dash and instrument panels.

Install the four bolts and one nut re-

taining the air vent to the panels.

6. Check the operation of the park-

ing brake. Adjust the parking brake.

MUSTANG AND COUGAR

Removal

Refer to Fig. 36.

1.
Make sure the parking brake is

completely released,

2.
Remove all tension from the rear

cables by backing off the jam nut and

adjusting nut from the equalizer.

3.
Disconnect the wire lead at the

parking brake warning light switch (if

so equipped).

4.
Remove the parking brake front

cable ball retaining clip from the clev-

is.

5.
Remove the parking brake warn-

ing light switch and attaching screw (if

so equipped).

6. Disconnect the cable ball from

the notch in the brake clevis.

7.
Remove the three screws that at-

tach the control assembly to the left

cowl inner side panel.

8. Pull the control away from the

cowl, panel. Remove the hair-pin re-

tainer securing the front cable assem-

bly to the control assembly. Remove

the control assembly

Installation

1.
Connect the ball-end of the park-

ing brake front cable assembly to the

control assembly, and install the hair-

pin retainer.

2.
Position the control assembly to

the cowl inner side panel and install

the three attaching screws.
3.
Position the parking brake warn-

ing light switch and install the attach-

ing screw. Connect the parking brake

warning light switch wire lead (if vehi-

cle is so equipped).

4.
Position the cable ball in the

notch in the brake clevis.

5.
Check the operation of the park

ing brake. Adjust the parking brake.

THUNDERBIRD AND

CONTINENTAL MARK III

Removal

Refer to Fig. 37.

1.
Remove the two nuts retaining

the control to the dash panel.

2.
Remove two screws from the left

scuff plate.

3.
Remove one screw retaining the

left cowl trim panel and remove the

panel.

4.
Remove the two screws retaining

the left air duct and remove the air

duct.

5.
Remove the two screws retaining

the dimmer switch and position the

switch out of the way.

6. Remove the clip retaining the

cable assembly to the control.

7.
Disconnect the cable ball from

the control clevis.

8. Disconnect the vacuum hose at

the brake release.

9. Remove the bolt retaining the

control to the cowl side bracket and

remove the control.

Installation

1.
Position the parking brake con-

trol in the vehicle.

2.
Install the cable assembly in the

control and connect the cable ball to

the control clevis.

3.
Install the clip retaining the

cable to the control.

4.
Install the bolt retaining the con-

trol to the cowl side bracket.

5.
Connect the vacuum hose to the

parking brake release vacuum motor.

6. Position the dimmer switch and

install the retaining screws.

7.
Position the air duct and install

the retaining screws.

8. Position the cowl trim panel and

install the retaining screw.

9. Install the two scuff plate screws.

10.
Install the two nuts retaining

the control to the dash panel.

11.
Adjust the parking brakf
LINCOLN CONTINENTAL

Removal

Refer to Fig. 38.

1.
Raise the vehicle on a hoist.

2.
Loosen the parking brake cable

adjusting nut, remove the return

spring and remove the cable ball end

from the equalizer.

3.
Lower the vehicle.

4.
Disconnect the battery.

5.
Disconnect the wire harness con-

nector and two vacuum hoses at the

Automatic Temperature Control box.

6. Working inside the vehicle, re-

move the windshield wiper control

knob and bezel from the lower control

panel.

7.
Remove the screws retaining the

lower control panel. Lower the control

panel and disconnect wire harnesses

and vacuum hoses. Position the con-

trol panel aside.

8. Remove the screw retaining the

plastic wire cover and place 'the cover

aside.

9. Disconnect three vacuum hoses

and the wiring harness at the Auto-

matic Temperature Control box.

10.
Remove the two screws retain-

ing the Automatic Temperature Con-

trol box to the dash panel and remove

the box for clearance.

11.
Disconnect the ball end of the

cable from the control clevis.

12.
Remove the four bolts retaining

the control to the dash panel and

lower instrument panel flange.

13.
Disconnect the vacuum release

hose from the control and remove the

control assembly from the vehicle.

Installation

1.
Position the control assembly to

the dash panel and instrument panel

flange and install the four retaining

screws.

2.
Connect the vacuum release hose

to the control assembly.

3.
Connect the cable ball to the

control clevis.

4.
Position the Automatic Temper-

ature Control box to the dash panel

and install the retaining screws.

5.
Connect the wiring harness and

vacuum hoses to the Automatic Tem-

perature Control box.

6. Position the plastic wire covei

and install the retaining screw.

7.
Connect the wire harnesses and

vacuum lines to the lower control

panel and position the panel to the inprocarmanuals.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

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

03-01-11
Suspension — Steering, Wheels And Tires — General Service

03-01-11

3.
Inspect the rotor, rollers, cam

ring, pressure plate, cover, and bush-

ing in the pressure plate for wear or

scoring. If damaged, replacement of

the pump (less housing) is required.

4.
Make sure the inner faces of the

cover and the housing are free of

paint, nicks, or burrs. Check all fluid

passages for restrictions.

5.
Inspect the valving surfaces

(areas where the rotor and rollers con-

tact) for wear or scoring. Replace the

pressure plate or the cover if worn or

scored. Inspect the bushing in the

pressure plate for wear or scoring, and

replace the plate if necessary.

6. Inspect the control valve for

scores, nicks, or burred edges. Re-

place the valve if damaged. Do not dis-

assemble the valve. Check the valve

for free movement in the housing

bore.

7.
Inspect the tube seat in the hous-

ing. If damaged, remove it with an

E-Z-Out and install a new seat.

SHOCK ABSORBER CHECKS

All vehicles are equipped with hy-

draulic shock absorbers of the direct-

acting type and are nonadjustable and

nonrefillable. They cannot be repaired.
Before replacing a shock absorber,

check the action of the shock absor-

bers as follows:

ON VEHICLE TESTS

1.
Check the shock absorber to be

sure it is securely and properly in-

stalled. Check the shock absorber in-

sulators for damage and wear.

Replace any defective insulators and

tighten attachments to the specified

torque (on a shock absorber which in-

corporates integral insulators, replace

the shock absorbers).

2.
Inspect the shock absorber for

evidence of fluid leakage. A light film

of fluid is permissible. Be sure any

fluid observed is not from sources

other than the shock absorber.

Replace the shock absorber if leak-

age is severe.

3.
Disconnect the lower end of the

shock absorber. Extend and compress

the shock absorber as fast as possible,

using as much travel as possible.

Action should become smooth and

uniform throughout each stroke.

Higher resistance on extension than

on compression is a normal condition.

Faint swish noises are also normal.

Remove the shock absorber for a

bench test if action is erratic. If the
action is smooth, but the shock absor-

bers are suspected of being weak fol-

low step 4:

4.
Repeat step 3 on the mating

shock absorber installed on the oppo-

site side of the vehicle, and compare

results of both tests. If the action is

similar, it is unlikely that either shock

absorber is defective. Reconnect both

shock absorbers.

Replace the shock absorber having

the lower resistance. Ensure that the

part number of the replacement is the

same as that of the original shock ab-

sorber. The replacement shock absor-

ber resistance will appear to be higher

than either original due to initial fric-

tion of the rod seal.

BENCH TEST

With the shock absorber right side

up (as installed in vehicle), extend it

fully. Then turn the shock absorber

upside down and fully compress it.

Repeat this procedure at least three

times to ensure that any entrapped air

has been expelled. Now place the

shock absorber right side up in a vise,

and hand stroke the shock absorber as

described in On Vehicle Tests, step 3.

If action is not now smooth and uni-

form, install a new shock absorber.procarmanuals.com