mustang FORD MUSTANG 1969 Volume One Chassis

02-02-03
Brake System

02-02-03

DESCRIPTION

Disc brakes are available as option-

al equipment for the front wheels on

Ford, Mercury, Meteor, Fairlane,

Montego, Falcon, Mustang and Cou-

gar models and are standard on Thun-

derbird, Continental Mark III, and

Lincoln Continental models. The

dual-master cylinder equipped hydrau-

lic brake system employs single an-

chor, internal expanding and
self-

adjusting drum brake assemblies on

the rear wheels of vehicles with disc

brakes, and on the front and rear

wheels of all others.

A vacuum booster is used with the

power disc brake system.

DUAL MASTER CYLINDER

BRAKE SYSTEM

The dual-master cylinder brake sys-

tem has been incorporated in all mod-

els to provide increased safety. The

system consists of a dual-master cylin-

der (Fig. 1), pressure differential valve

assembly and a switch (Fig. 2). The

switch on the differential valve acti-

vates a dual-brake warning light, lo-

cated on the instrument panel.
DISC BRAKE

The disc brake consists of a venti-

lated rotor and caliper assembly. The

caliper used on all models except Lin-

coln Continental is a single piston

floating caliper (Fig. 3). The caliper

used on Lincoln Continental models is

a four piston fixed caliper (Fig. 4).

A proportioning valve in the rear

hydraulic circuit provides balanced

braking action between front and rear

brakes.

On all models except Lincoln a

pressure impulse valve located at the

primary inlet of the pressure differen-

tial valve prevents brake fluid surge

back to the master cylinder reservoir.

On Lincoln Continental models a

metering valve, in the hydraulic line

between the differential valve and the

front wheel disc brakes, prevents the

front brakes from applying until ap-

proximately 125 psi is obtained in the

system (Fig. 21). This delaying action

is required to prevent the front brakes

from performing all the braking ac-

tion on low speed stops and thereby

increasing the rate of lining wear.
FLOATING CALIPER—

ALL MODELS EXCEPT

LINCOLN CONTINENTAL

The caliper asseml.y is made up of

a floating caliper housing assembly

and an anchor plate. The anchor plate

is bolted to .the wheel spindle arm by

two bolts. The floating caliper is at-

tached to the anchor plate by steel

stabilizers on Ford, Mercury, Meteor,

Thunderbird and Continental Mark

III models and by one stabilizer on

Fairlane, Montego, Falcon, Mustang

and Cougar models. The floating cali-

per slides on two locating pins which

also attach to the stabilizers. The

floating caliper contains the single cyl-

inder and piston assembly. The cylin-

der bore contains a piston with a

molded rubber dust boot to seal the

cylinder bore from contamination

(Fig. 5). A square section rubber pis-

ton seal is positioned in a groove in

the cylinder bore and is used to pro-

vide sealing between the cylinder and

piston (Fig. 7).

The outer brake shoe and lining as-

sembly is longer than the inner assem-

bly, and the shoe and lining

DISC BRAKES

RETURN SPRING

(SECONDARY)

RETAINER

PRIMARY SYSTEM BRAKE

FLUID RESERVOIR

BOOT

PUSH ROD

TUBE SEAT |

(SECONDARY)

BRAKE OUTLET

PORT
RESIDUAL \ ^

CHECK \

VALVE \

SECONDARY PISTON

ASSEMBLY
(PRIMARY)

BRAKE OUTLET

PORT
PRIMARY PISTON

ASSEMBLY
H 1545-A

FIG.
I
—
Dual
Master Cylinder—Typicalprocarmanuals.com

02-02-10
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

PRESSURE IMPULSE

VALVE

TUBE-2A040

TUBE-2B253
TUBE-2263 ASSY R.H.

2264 ASSY L.H.

TUBE-2267

PRESSURE

DIFFERENTIAL

VALVE

TUBE-2265

PROPORTIONING

VALVE

TUBE-2B112 \ TUBE-2263

L.H. FENDER APRON REF.

VIEWP

FOR POWER DISC BRAKES

TUBE-2B253

TUBE-

TUBE-22 64

TUBE-2B269
VIEWX

427 & 428 ENGINES 382410-S2

ALL EXCEPT

200 ENGINE

TUBE-2267

HOSE-2A448

TUBE-2265
TUBJ,-2268

VIEWY

ALL EXCEPT 200 ENGINE

PRESSURE DIFFERENTIAL

VALVE -2B257

VIEWS L&M //

BODY CROSSMEMBER

TUBE-2265

L.H. FENDER APRON REF.

VIEWR

FOR DRUM BRAKES
VIEW IN CIRCLE V

TYPICAL 4 PLACES
HOSE-2A448

VIEW IN CIRCLE U
VIEWW

VIEW IN CIRCLE T

VIEW IN CIRCLE S

TYPICAL 4 PLACES
VIEWN

H1640-A

FIG. 19—Service Brake System—Mustang and Cougarprocarmanuals.com

02-02-17
Brake System

02-02-17

CALIPER PARTS

2B120 R.H.

2B121 L.H.

CALIPER ASS'Y

2B118 R.H.

2BU9L.H.

INSULATOR

CUP
2B2"

2B164
STABILIZER

2B295

FAIRLANE, MONTEGO, FALCON,

MUSTANG AND COUGAR
SEAL

2B115

2207

BOOT
20310-S

34806 S \ INNER BEARING

w CONE AND ROLLER

1201

CUP
ANCHOR PLATE

2B293 L.H.

2B292 R.H.

CONE AND ROLLER

1216

GREASE SEAL

1190

ADJUSTING NUT

374504-S
3105-R.H.

3106-L.H.

ROTOR SPLASH SHI

2K004-R.H.

2K005-L.H.

COVER-1130

1102

H 1670-A

FIG. 23—Disc Brake—Disassembled—All Models Except Lincoln

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.

5. Install the wheel and tire assem-

bly and the wheel cover.

6. Road test the vehicle.
LINCOLN CONTINENTAL

Removal

Refer to Fig. 24.

1.
Remove the front wheel cover.
Remove the wheel and tire assembly

from the hub and rotor assembly. Be

careful to avoid damage or interfer-

ence with the caliper splash shield,

bleeder screw fitting or transfer tube.

2.
Disconnect the steel brake line

transfer tube from the caliper (Fig.

21).
Leave the steel tube connected to

CALI PER PARTS-2B120-R.H. -2B121-L.H.

CALIPER ASSEMBLY

*2B118-R.H.

•2B119-L.H.
34811-S

SPINDLE
379726-S
INBOARD HOUSING

PISTON SEALS (4)-2B115

/PISTONS (4) -2196 OUTBOARD HOUSING

T BOOTS (4) 2207
CLIP

34806-S
INNER BEARING

CONE AND ROLLER

1201

GASKET

3105-R.H.
2B16°

3106-L.H.

ROTOR SPLASH
SHI
EL

1102
SHOE AND LINING

ASSEMBLIES -2018

COVER-US'!

H 1650-A

FIG. 24—Disc Brake Disassembled—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

02-02-21
Brake System

02-02-21

INSTALLATION

CLUTCH ASSIST

SPRING

MASTER CYLINDER

2140

FIG. 28 —Dual Master Cylinder Installation—

Non Power Brake—Mustang and Cougar

inch of the top of the dual reservoirs.

Use Ford Brake Fluid- Extra Heavy

Duty-Part Number C6AZ-19542-A

for all brake applications. The brake

fluid is colored blue for identification.

Do not mix low temperature brake

fluids with the specified fluid for the

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 the proper procedure.

9. Operate the brakes several times,

then check for external hydraulic

leaks.

DUAL MASTER CYLINDER-

POWER BRAKES

REMOVAL

1.
Remove the brake tubes from

the primary and secondary outlet

ports of the master cylinder (Figs. 29

thru 33).

2.
Remove the two nuts and two

lock washers attaching the master cyl-

inder to the brake booster assembly.

3.
Slide the master cylinder forward

and upward from the vehicle.
SHAFT

AUTOMATIC

TRANSMISSION

CLUTCH PEDAL

BUMPER STOP
H1638-A
1.
Before installing the mater cyl-

inder, check the distance t; m the

outer end of the booster ass;. ,ihi\

push rod to the master .>',nder

mounting surface. Turn the nu->h rod

adjusting screw in or out as required

to obtain the specified length. Refer to

Part 2-1, Section 2. Power Brake

Master Cylinder Push Rod Adjust-

ment for the proper procedure.

2.
Position the master cylinder as-

sembly over the booster push rod and

onto the two studs on the booster as-

sembly (Figs. 29 thru 37).

3.
Install the attaching nuts and

lock washers and torque them to spec-

ifications.

4.
Install the front and rear brake

tubes to the master cylinder outlet fit-

tings.

5.
Fill the master cylinder with the

specified brake fluid to within 1/4

inch of the top o\ the dual reservoirs.

Use Ford Brake Fluid Fxtra Heavy

Duty Part Number C6AZ-19542-A

(ESA-M6C25-A) for all brake appli-

cations. The extra htaw duty brake

fluid is colored blue for identification.

Do not mix low temperature brake

fluids with the specified fluids for the

disc brake svstem.

CLIP

W
'0 AIR CONDITIONING

BUSHING

SHAFT

BUSHING

BRAKE PEDAL

SPACER

H 1642-A

FIG. 29—Master Cylinder Installation-

Ford,
Mercury and Meteor
-Power Brake-procarmanuals.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

02-02-23
Brake System

02-02-23

BOOSTER ASSEMBLY- 2005

NUT-34444-S7

HOSE 2A047

MASTER CYLINDER

IDENTIFICATION

BRAKE TUBE-2263

BRAKE TUBE -2264

PRESSURE DIFFERENTIAL

VALVE ASSEMBLY-2B257
BRAKE TUBE-2B255

H 15S3-B

FIG. 32—Master Cylinder Installation-

Thunderbird and Continental Mark III

FLUID LEVEL IN MASTER

CYLINDER MUST 3E FULL

TO 1/4 INCH FROM TOP
BUSH

SLEEVE

BOLT

BRAKE SWITCH

13480

NUT (4 REQUIRED) -55768-S2

WASHER"(4 REQUIRED) -44726-S8

BOOSTER

ASSEMBLY 2005

MASTER CYLINDER 2WO

HOSE-2A047

BUSHING DIP IN

S.A.E. 10W MOTOR OIL

BEFORE ASSEMBLY

PEDAL ASSEM6LY-2455

COVER

BRAKE TUBE-2A040

REAR BRAKE TUBE -2B329

PRESSURE DIFFERENTIAL

VALVE ASSEMBLY-2B328

FRONT BRAKE TUBE-2B162

PROPORTIONING VALVE

MASTER CYLINDER

IDENTIFICATION

H 1530-C

FIG. 33—Master Cylinder Installation—Lincoln Continental
4.
Connect the shell-wire connector

to the brake warning lamp switch.

Make sure the plastic lugs on the con-

nector hold the connector securely to

the switch.

5. Bleed the brakes and centralize

the pressure differential valve.

PROPORTIONING VALVE

FORD, MERCURY

AND METEOR

On Ford, Mercury and Meteor

models, the proportioning valve must

be removed with the pressure differen-

tial valve. Use the procedure shown

above for replacement of the propor-

tioning valve.

FAIRLANE, MONTEGO

AND FALCON

Removal

Refer to Fig. 18.

1.
Disconnect the two brake lines at

the proportioning valve.

2.
Remove the bolt retaining the

pressure differential valve bracket to

the fender apron.

3.
Lift the proportioning valve

bracket from behind the pressure dif-

ferential valve bracket and remove the

proportioning valve from the vehicle.

Installation

1.
Position the proportioning valve

and bracket to the fender apron with

the proportioning valve bracket be-

tween the pressure differential valve

bracket and the fender apron.

2.
Connect the two brake lines at

the proportioning valve. Do not tight-

en.

3.
Install the bolt retaining the two

valve brackets to the fender apron.

4.
Tighten the two brake line tube

nuts at the proportioning valve to

specifications.

5.
Bleed the brakes and centralize

the pressure differential valve.

MUSTANG AND COUGAR

Removal

Refer to Fig. 19.

1.
Disconnect the two brake lines at

the proportioning valve.

2.
Remove the bolt retaining theprocarmanuals.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