brakes FORD MUSTANG 1969 Volume One Chassis

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

02-02-24
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

02-02-36
Brake System

02-02-36

locating stripe on the cable is midway

between the retaining clips and tighten

all retaining clip screws.

4.
Position the left cable, retaining

clip and screw on the left lower sus-

pension arm. Compress the prongs on

the left cable and position the cable

through the frame side-member. The

prongs must be securely locked in

place.

5.
Insert the ball ends of the cables

into the equalizer assembly.

6. Install the rear drum(s) and

tighten the three Tinnerman nuts and

secure the drum. Install the wheel and

tire and the wheel cover.

7.
Adjust the parking brake linkage

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

just the rear brakes, as required (Part

2-1,
Section 2).

FAIRLANE, MONTEGO,

MUSTANG AND COUGAR—

EXCEPT STATION WAGON

Removal

1.
Remove the equalizer lock nut

and adjusting nut, equalizer, spring

and spring seat.

2.
With the cables slack, discon-

nect the ball-ends from the connector

(Figs.
35 and 36).

3.
Remove the cable from the re-

tainer hooks (station wagon models)

and the underbody guide (convertible

models) if required.

4.
Remove the hairpin lock retain-

ing the cable housing to the side rail

bracket.

5.
Remove the wheel cover, wheel

and tire and the rear brake drum as

outlined in Section 2.

6. Remove self-adjuster springs to

allow clearance to remove cable re-

tainer from the backing plate. Discon-

nect the rear end of the cable from the

parking brake lever on the brake shoe.

Disengage the cable housing retaining

grommet or steel-pronged Hi-Hat

from the backing plate and withdraw

the cable and housing from the in-

board side of the backing plate.

7.
Slide the cable and housing out

of the side rail bracket.

Installation

1.
Insert the rear end of the cable

through the side rail bracket and pull

the cable and housing into position.

2.
Insert the rear end of the cable

and housing through the hole in the

backing plate from the inboard side.

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

stall the cable housing retaining grom-

met or steel-pronged Hi-Hat in the

backing plate.

4.
Install the self-adjuster springs.

Position the cable housing in the side

rail bracket and install the hairpin

type retainer.

5.
Install rear hub and drum as-

sembly, wheel and tire assemblies and

wheel cover as outlined in Section 2.

6. Position the cable retainer hooks

(station wagon models) in the under-

body guide (convertible models) and

install the connector, thus hooking the

two cables together.

7.
Insert the cable into the equaliz-

er and install the equalizer, spring

seat, spring, adjusting nut and lock

nut to the front, parking brake control

cable.

8. Adjust the parking brake^as di-

rected in Part 2-1, Section 2.

FAIRLANE AND MONTEGO

STATION WAGONS AND

FALCON PASSENGER

MODELS

Removal and Installation

Refer to Fig. 35.

Generally follow the procedure

given above, omitting separation of

the cables, since the parking brake

rear cable assemblies supplied for

these models is in one piece. Removal

and installation of both rear wheels,

tires and drums will also be required.

LINCOLN CONTINENTAL

Removal

1.
Raise the car. Remove the rear

wheel cover. Remove the wheel and

tire as an assembly.

2.
Remove the three Tinnerman

nuts that hold the brake drum in

place, and remove the drum.

3.
Remove the brake shoe retract-

ing springs.

4.
Loosen the equalizer rod adjust-

ing nut and disconnect the cable from

the equalizer (Fig. 38).

5.
Remove the hairpin-type retainer

clip that secures the cable housing to

the body bracket, and pull the cable

and housing out of the bracket (Fig.

38).

6. Remove the cable to underbody

clamp attaching nuts and the clamp.

Disengage the cable housing from the

hook-type retainer at the spring U-

bolt.
7.
Working on the wheel side of the

backing plate (Fig. 38), compress the

prongs on the cable retainer so that it

can pass through the hole in the back-

ing plate. Draw the cable retainer out

of the hole.

8. With the spring tension off the

parking brake lever, lift the cable out

of the slot in the lever and remove it

through the backing plate hols.

Installation

1.
Pull enough of the cable through

the cable housing so that the end of

the cable may be inserted through the

backing plate hole from the inner side

and engage the cable end with the slot

in the parking brake lever.

2.
Pull the excess slack from the

cable and insert the cable housing into

the backing plate access hole (Fig.

38).
The prongs must be securely

locked in place.

3.
Install the brake shoe retracting

springs.

4.
Position the cable to the under-

body and install the retaining clamp

so that the cable conduit armor ex-

tends forward of the clamp as shown

in Fig. 38. Install the clamp retaining

nuts.

5.
Hook the cable housing to the

retainer at the spring U-bolt.

6. Engage the forward end of the

cable housing with the frame bracket

and secure it with the hairpin-type

clip.

7.
Insert the ball end of the cable

into the equalizer.

8. Make a preliminary brake ad-

justment with the use of Tool HRA-

8650 (Fig. 11).

9. Install the rear drum. Tighten

the three Tinnerman nuts that secure

the drum. Install the wheel and wheel

cover.

10.
Adjust the parking brake link-

age.

11.
Lower the vehicle.

ANTI-SKID CONTROL

ACTUATOR

REMOVAL

Refer to Fig. 39.

1.
Working in the passenger com-

partment, under the glove box, remove

the screw that attaches the forward

end of the control module retainer to

the support assembly. Lower the for-

ward end of the control module re-

tainer and remove the module assem-

bly.procarmanuals.com

FROM MASTER CYLINDER
ACTUATOR AIR FILTER

EXISTING SCREW

VIEW IN CIRCLE
W

SOLENOID

ACTUATOR TO REA

BRAKE TUBE

DIFFERENTIAL VALVE

UATORTUBE

VIEW IN CIRCLE T
FROM ACTUATOR

TO REAR BRAKES
GLOVE BOX

CONTROL MODULE

VIEW V

VIEW U

H1653-A

FIG. 39—Anti-Skid Control Systemprocarmanuals.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

02-02-39
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