FORD MUSTANG 1969 Volume One Chassis
Manufacturer: FORD, Model Year: 1969, Model line: MUSTANG, Model: FORD MUSTANG 1969Pages: 413, PDF Size: 75.81 MB
Page 31 of 413
02-02-12
Brake System
02-02-12
TUBE ASSY. REF.
2 A 040
TUBE ASSY. REF.
2B113-B
PRESSURE
IMPULSE VALVE
PROPORTIONING
TUBE
>Y.
2B253 ASSY REF TUBE
/W W '
Kth#
2263 ASSY. R.H. REF.
TUBE
2B112-E
2264 ASSY. L.H. REF.
2B329
ASSY. REF.
HOSE
C8OA-2B218-C ASSY.L.H.
C80A-26171-D ASSY.R.H.
2B269 ASSY. REF.
VIEWZ
INSTALLATION-DISC BRAKE ONLY
BEND CLIP TO RETAIN
TUBE AS SHOWN
-TUBE
VIEW IN CIRCLE T
382365-S36
WASHER
8M-2149
TUBE-2A040
INSTALLATION-DISC BRAKES SAME AS
DRUM BRAKES AND MAIN VIEW
EXCEPT AS SHOWN
TUBE-2267 R.H.
TUBE-2B253
TUBE 2B329
PRESSURE DIFFERENTIAL
VALVE
TUBE 2B329
VIEW IN
CIRCLE U
TYPICAL ^,
CES^^
CLI
BOLT-
VIEW IN CIRCLE N
WASHER
34808-S8
PART OF AXLE
VENT ON STATION
WAGON ONLY
VENT ASSEMBLY
TUBE ASSEMBLY-2265
STANDARD AND POWER DRUM
3RAKES TUBE ASSEMBLY-2B1T2
POWER DISC BRAKES
MANUAL DISC
TUBE-2263 R.H.
3 REQUIRED
BOLT- 3 REQUIRED
CHECK BRAKE HOSE CLEARANCE „
TO ALL COMPONENTS IN
2A448"
METAL/METAL JOUNCE AND
METAL/METAL REBOUND-
TUBE-2267
ARMOR-390, 428 ENGINES ONLY
8 CYLINDER ENGINE REAR AXLE ONLY
TUBE ASSEMBLY-2268 L.H.
PRESSURE DIFFERENTIAL
VALVE
- GROMMET- 2
jl^REQUIRED
EWYN
TUBE
VIEW P
ROUTING FOR STATION WAGON ONLY
TUBE-22.S5
TUBE-2263 R.H. 2264 L.H.
VIEW IN CIRCLE Y
TYPICAL 2 PLACES
CHECK BRAKE HOSE CLEARANCE TO ALL
COMPONENTS IN METAL/METAL JOUNCE,
METAL/METAL REBOUND AND FULL
INSIDE AND OUTSIDE TURNS
VIEWX
TYPICAL 2 PLACES
DRUM BRAKES
TUBE-2263 R.H
2264 L.H.
VIEW IN CIRCLE U
TYPICAL 4 PLACES
HOSE-2A448
BRAKE HOSE-2078
GASKET-2149 2 REQUIRED
VIEW IN CIRCLE W
TYPICAL 2 PLACES
DRUM BRAKES
LIP
REINFORCEMENT ASSEMBLY-2B222
APPLY ESB-M4632-A SEALER AROUND
STUDS AND SCREW HOLE ON
FLOOR PAN SIDE
TUBE
TUBE ASSEMBLY-226J)
VIEW R
TUBE
VIEW IN CIRCLE M
POWER DISC BRAKES
BRAKE HOSE MUST BE ASSEMBLED
WITH WHEELS STRAIGHT AHEAD.
STRIPE ON HOLE HOSE ASSEMBLY
MUST SHOW NO EVIDENCE OF TWIST.
H 1559-C
—Service Brake
System—Fairlane,
Montego
and
Falconprocarmanuals.com
Page 32 of 413
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
Page 33 of 413
TUBE ASSEMBLY-2B255
VIEW IN CIRCLES V
FUEL LINE
CLIP (4 REQUfRED)
PART OF AXLE ASSEMBLY
HOSE ASSEMBLY-2A448
FRAME
TUBE ASSEMBLY-2267
CHECK BRAKE HOSE
CLEARANCE TO ALL
COMPONENTS IN
METAL/METAL JOUNCE
AND METAL/METAL
REBOUND.
CLIP (3 REQUIRED)
TUBE ASSEMBLY-2267
BRAKE BOOSTER-2B195
HOSE-2A047
TUBE ASSEMBLY-2B255
TUBE ASSEM3LY-2420
[
TUBE-2263-C *
TUBE ASSEMBLY BRAKE TUBE
2268 ASSEMBLY
2267 R.R. BRAKE TUBE
ASSEMBLY
TUBE ASSEMBLY
2263
VIEW IN CIRCLES X
COVER-2A487
PEDAL PAD-2457
BRAKE PEDAL-2455
USE EXISTING NUTS
TUBE ASSEMBLY
2325r
TUBE ASSEMBLY
2264 L.H. 2263 R.H.
TUBE ASSEMBLY
2B171-C R.H.
23218-C L.H.
BOLT-381877-S2
(3REQUIRED)
CLIP-382088-S2
(3 REQUIRED)
ALL CONNECTIONS, TUBES, MASTER
CYLINDER AND FITTINGS MUST BE
FREE OF FLUID LEAKAGE WHEN
CHECKED AFTER ROAD TEST.
TUBE ASSY.-2A040
TUBE ASSY.-2B253
PRESSURE IMPULSE
VALVE
ALL BRAKE LINES, FITTINGS AND
FLEXIBLE HOSES MUST BE KEPT FREE
OF FOREIGN MATERIAL BEFORE
AND DURING ASSEMBLY OPERATIONS.
TUBE ASSEMBLY
2B255
PROPORTIONING
VALVE-2B328
GASKET-2149
(4 REQUIRED)
#LUBRICATE PIVOTS
CLIP-381799-S2
2REQUIRED
180°APART
BE LEAKPROOF
TUBE ASSEMBLY-2B255
6
w
Q
7T
3
CHECK BRAKE HOSE
CLEARANCE TO ALL COMPONENTS
IN METAL/METAL JOUNCE
METAL/METAL REBOUND AND FULL
INSIDE AND OUTSIDE TURNS.
BOLT
2 REQUIRED
TUBE ASSY. -2264
BRACKET ASSY.-2B328
O
6
H 1540-C
FIG. 20—Service Brake System—Thunderbird, Continental Markprocarmanuals.com
Page 34 of 413
BOLT-381877
TUBE-2267
BRACKET-2A448
TUBE-2268
VIEW IN CIRCLE X
TYPICAL 3 PLACES
TUBE ASSEMBLY-2B162
TUBE ASSEMBLY-2264
TUBE ASSEMBLY-2263
TUBE-2267
BEND CLIPS TO RETAIN
TUBES AT ASSEMBLY
5 PLACES
CHECK BRAKE HOSE CLEARANCE
TO ALL COMPONENTS IN METAL/METAL
JOUNCE AND METAL/METAL REBOUND
TUBE-2268
PROPORTIONING
VALVE ASSEMBLY
BRACKET-2B266
BOOSTER ASSEMBLY-2B195
PULLOUT WHILE BLEEDING
BRAKE SYSTEM-USE CARE
NOT TO BEND PIN
TUBE-2420
DIFFERENTIAL VALVE-C8VA
VIEW IN CIRCLE M
TUBE-2A280
TUBE-2A280
PRESSURE DIFFERENTIAL
VALVE ASSEMBLY-C8VA-2B328-C
TUBE ASSEMBLY-2264
BRACKET-2082 R.H.
-2AO56 L.H.
CLIP-97502
2 REQUIRED
357444-S 2 REQUIRED
TO CALIPER ASSEMBLY
HOSE-2B171 R.H.
-2B218 L.H.
VIEWN
HOSE-2A448
TUBE-2A280
VIEWP
SHIELD-2A337
VIEW IN CIRCLE S
TYPICAL 4 PLACES
TUBE-2A280
VIEWR
V1EWU
VIEWV
WASHER-2149 2 REQUIRED
TUBE-2B166 R.H.
-2B168 L.H.
STOP LAMPS MUST LIGHT WITH MAXIMUM FOOT
PEDAL EFFORT OF 4 POUNDS AND WITHOUT AUDIBLE
SOUND FROM THE SWITCH UNDER NORMAL OPERATION.
ALL BRAKE LINES, FITTINGS AND FLEXIBLE HOSES
MUST BE KEPT FREE OF FOREIGN MATERIAL BEFORE
AND DURING ASSEMBLY OPERATIONS.
ALL CONNECT
IONS,
TUBES,
MASTER CYLINDER AND
FITTINGS MUST BE FREE OF FLUID LEAKAGE.
H 1528-C
FIG. 21—Service Brake System—Lincoln Continentalprocarmanuals.com
Page 35 of 413
02-02-16
Brake System
02-02-16
fitting that connects the tube to the
cylinder. Do not pull the metal tube
away from the cylinder. Pulling the
tube out of the cylinder connection
will bend the metal tube and make in-
stallation difficult. The tube will sepa-
rate from the cylinder when the cylin-
der is removed from the backing
plate.
4.
On all except the front wheels on
Ford, Mercury, and Meteor models,
remove the wheel cylinder attaching
bolts and lock washers and remove the
cylinder. On the front wheel of Ford,
Mercury and Meteor models, remove
the nut and washer that attaches the
cylinder to the anchor pin. Remove
the cylinder from the anchor pin.
INSTALLATION
Wipe the end(s) of the hydraulic
line to remove any foreign matter be-
fore making connections.
1.
On all models except Ford, Mer-
cury and Meteor, to install a front
wheel cylinder, position the cylinder to
the backing plate. Install the two lock
washers and attaching bolts. Torque
them to specifications.
On Ford, Mercury and Meteor
models, to install a front wheel cylin-
der, position the cylinder on the an-
chor pin against the backing plate. In-
stall the washer and cylinder attaching
nut on the anchor pin, and torque it
to specification. Lock the washer re-
tainer securely.
2.
Install a new copper gasket over
the hose fitting. Thread the hose into
the cylinder and tighten it to specified
torque.
3.
Engage the opposite end of the
hose to the bracket on the frame. In-
stall the horseshoe-type retaining clip,
and connect the brake tube to the
hose with the tube fitting nut. Tighten
the nut to specification with tool
1112-144.
4.
To install a rear wheel cylinder,
place the rear wheel cylinder into po-
sition. Enter the tubing into the cylin-
der, and start the tube fitting nut into
the threads of the cylinder.
5.
Secure the cylinder to the back-
ing plate by installing the attaching
bolts and lock washers.
6. Tighten the tube fitting nut to
specification with tool 1112-144.
7.
Install the links in the ends of
the wheel cylinder, install the shoes
and adjuster assemblies, and adjust
the shoes as outlined in this section.
8. Adjust the brakes (Part 2-2, Sec-
tion 2). Install the brake drum and
wheel. Bleed the brakes and centralize
the differential valve as outlined in
Part 2-1, Section 2.
BRAKE BACKING PLATE
DRUM BRAKE
REMOVAL
1.
Remove the wheel and brake
drum. Disconnect the brake line from
the brake cylinder.
2.
Remove the brake shoe and ad-
juster assemblies and the wheel cylin-
der as outlined in this section. On the
rear wheels, disconnect the parking
brake lever from the cable.
3.
If the rear backing plate is being
replaced, remove the axle shaft from
the applicable rear axle as outlined in
Group 4, Part 4-2— Rear Axle, Sec-
tion 2, disengage parking brake cable
retainer from backing plate. Remove
the backing plate and gasket.
If the front backing plate is being
replaced, remove the bolts and nuts
that secure the backing plate to the
front wheel spindle and remove the
plate and gasket.
INSTALLATION
If a rear backing plate is to be re-
placed, position a new rear backing
plate and gasket on the attaching
bolts in the axle housing flange. Insert
parking brake cable into backing plate
and secure retaining fingers. Install
the rear axle shaft for applicable rear
axle.
Refer to Group 4, Part 4-2 —
Rear Axle, Section 2 for the proper
installation procedure.
1.
If the front brake backing plate
is to be replaced, position a new front
backing plate and gasket to the wheel
spindle and install the attaching bolts
and nuts.
2.
Install the wheel cylinder and
connect the brake line as outlined in
this section.
3.
Install the brake shoe and ad-
juster assemblies as outlined in this
section. On a rear brake, connect the
parking brake cable to the lever.
4.
Adjust the brake shoes (Section
2),
and install the brake drums and
wheels. Bleed the brake system and
centralize the differential valve as out-
lined in Part 2-1, Section 2.
DISC BRAKE CALIPER
ASSEMBLY
ALL MODELS EXCEPT
LINCOLN CONTINENTAL
Removal
Refer to Figs. 22 and 23.
BLEEDER SCREW FACING THIS DIRECTION^
BLEEDER SCREW
H 1641-A
FIG. 22—Floating Caliper
Installed
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 or
bleeder screw fitting.
2.
Disconnect the brake line from
the caliper. Cap the hose to prevent
*he brake fluid from leaking from the
master cylinder.
3.
Remove the safety wire and the
two bolts that attach the caliper as-
sembly to the spindle.
4.
Lift the caliper assembly off the
rotor and place it on the bench.
Installation
1.
Position the caliper assembly on
the rotor, and mate the mounting bolt
holes in the caliper with those in the
spindle. It may be necessary to push
the caliper piston into the cylinder
bore to obtain clearance between the
shoe and lining assembly and the
rotor.
2.
Install the caliper to spindle at-
taching bolts and torque them to spe-
cification. The upper bolt must be
tightened first. Install the safety wire
on the bolts and twist the wire ends at
least five turns. Push the wire ends
against the spindle to avoid interfer-
ence with the brake hose and the
steering stop. Check to insure that the
rotor runs squarely and centrally be-
tween the two brake shoes.
3.
Position the brake hose fitting
with a new copper washer on each
side of the fitting on the caliper as-
sembly. Install the bolts and torque to
specification.
4.
Bleed the brake system and cen-
tralize the differential valve as out-
lined in Part 2-1. Check the masterprocarmanuals.com
Page 36 of 413
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
Page 37 of 413
02-02-18
Brake System
02-02-18
the brake hose connector
and
bracket
assembly.
3.
Remove
the two
bolts retaining
the brake hose bracket
and
caliper
as-
sembly
to the
spindle. Take care
to
avoid loosening
the
bridge bolts that
hold
the two
halves
of the
caliper
to-
gether.
4.
Lift
the
caliper assembly
off the
rotor
and
place
it on the
bench.
Installation
1.
If the
caliper assembly
is to be
replaced, transfer
the
steel tubing
and
the bleeder screw
to the new
caliper.
2.
Position
the
caliper assembly
on
the rotor,
and
mate
the
mounting bolt
holes
in the
caliper with those
in the
spindle.
It may be
necessary
to
push
the caliper pistons into
the
cylinder
bores
to
obtain clearance between
the
shoe
and
lining assembly
and the
rotor.
The
shoe
and
lining assemblies
should
be
seated properly
on the
bridges.
3.
Install
the
caliper
to
spindle
re-
taining bolts
and
torque them
to
spec-
ification. Check
to
insure that
the
rotor runs squarely
and
centrally
be-
tween
the two
halves
of the
caliper.
These should
be
approximately 0.090-
0.120 inch clearance between
the
cali-
per
and the
rotor outside diameter
(Fig.
6).
4.
Position
the
steel transfer tube
brake hose bracket
and
caliper assem-
bly
to the
spindle. Install
the
retaining
bolts then torque them
to
specifica-
tion.
5.
Connect
the
front wheel steel
transfer tube from
the
caliper
to the
front brake hose connector. Check
the
hose
for
proper installation
(Fig. 21).
6. Bleed
the
brake system
and cen-
tralize
the
differential valve
as out-
lined
in
Part
2-1.
Check
the
master
cylinder fluid level
and add the
speci-
fied fluid,
as
required. Pump
the
brake pedal several times
to
actuate
the piston seals
and to
position
the
shoe
and
lining assemblies.
7.
Install
the
wheel
and
tire assem-
bly
and the
wheel cover.
8. Road test
the
vehicle.
DISC BRAKE SHOE
AND
LINING
ALL MODELS EXCEPT
LINCOLN CONTINENTAL
Removal
1.
Remove
the
wheel
and
tire from
the
hub and
rotor assembly.
2.
Remove
the
caliper from
the ve-
hicle following
the
procedures outlined
under Disc Brake Caliper Assembly.
3.
To
facilitate removal
of the
cali-
per assemblies,
the
piston
may
have
to
be pushed into
its
bore. Apply
a
steady inward pressure against
the
inner shoe
and
lining assembly. Main-
tain
the
pressure
for at
least
a
minute.
4.
Slide
the two
outer shoe retain-
ing clips
off the
retaining pins
(Fig.
23).
5.
Remove
the two
retaining pins
from
the
outer shoe, then remove
the
shoe from
the
stationary caliper.
6. Slide
the
inner brake shoe
out-
ward until
it is
free
of the
hold-down
springs, then remove
the
brake shoe.
7.
Remove
the
caliper locating pins
and stabilizer attaching bolts, then
re-
move
and
discard
the
stabilizer
or sta-
bilizers.
8. Remove
the
locating
pin
insula-
tors from
the
anchor plate.
Installation
When installing
new
shoes
and lin-
ings
it
will
be
necessary
to
force
the
piston
to the
bottom
of its
bore.
Apply sufficient pressure
to
overcome
the grip
of the
piston seal
on the pis-
ton.
1.
Install
new
caliper locating
pin
insulators
in the
anchor plate.
2.
Position
the
caliper assembly
in
the anchor plate.
3.
Position
the new
stabilizer
or
stabilizers
and
install
the
caliper locat-
ing pins
to
engage approximately four
threads.
If
the
caliper locating pins
are
rust-
ed
or
corroded they should
be re-
placed.
Apply water
or
isopropyl alcohol
to
the caliper locating pins before instal-
lation.
Oil or
grease must
not be
used
on
the
locating pins.
4.
Position
the
outer brake shoe
on
the caliper
and
install
the two
retain-
ing pins
and
clips.
5.
Install
the
inner brake shoe
so
that
the
ears
of
shoe
are on top of the
anchor plate bosses
and
under
the
shoe hold-down springs.
6. Position
the
shoe
and
lining
assemblies
so
that
the
caliper assem-
bly
can be
placed over
the
rotor.
Ro-
tate
a
hammer handle between
the lin-
ings
to
reset
the
stabilizers.
7.
Install
the
caliper assembly over
the rotor
and on the
spindle. Install
the
two
caliper attaching bolts,
and
torque them
to
specifications.
The
upper bolt must
be
tightened first.
In-
stall
the
safety wire
and
twist
the
ends
at least five turns. Push
the
wire ends
against
the
spindle
to
avoid interfer-
ence with
the
brake hose
and the
steering stop.
8. With moderate pressure applied
to
the
brake pedal, torque
the
stabiliz-
er attaching screws
and
caliper locat-
ing pins
to
specification.
LINCOLN CONTINENTAL
Removal
1.
Remove
the
wheel
and
tire
as-
sembly from
the hub and
rotor assem-
bly.
Be
careful
to
avoid damage
or in-
terference with
the
caliper splash
shield, bleeder screw fitting
or
transfer
tube.
2.
Remove
the two
bolts that retain
the caliper splash shield,
and
remove
the shield
(Fig. 4).
3.
To
facilitate removal
and
instal-
lation
of the
shoe
and
lining assem-
blies,
the
pistons must
be
pushed into
their bores. Apply
a
steady inward
pressure against each shoe
and
lining
assembly toward
its
respective caliper
housing
on
each side
of the
rotor
(Fig.
6).
Maintain
the
pressure
for at
least
a minute.
If the
pistons will
not go ifi
easily, force them
in
with water pump
pliers.
4.
Grasp
the
metal flange
on the
outer
end of the
shoe with
two
pairs
of pliers
and
pull
the
shoe
out of the
caliper (Fig.
25).
Installation
1.
Position
a new
shoe
and
lining
assembly
on
each side
of the
rotor
so
that
the
lining faces
the
rotor.
Be
sure
AB
AB
USE SECOND
PAIR
OF
PLIERS HERE
H 1651
A
FIG. 25—Removing Disc Brake
Shoe
and
Lining Assembly—
Lincoln Continentalprocarmanuals.com
Page 38 of 413
02-02-19
Brake System
02-02-19
that the tabs on the shoe flanges seat
fully against the caliper bridges (Fig.
25).
2.
Install the caliper splash shield
and secure the shield to the caliper
with two retaining bolts (Fig. 4).
3.
Pump the brake pedal several
times until a firm pedal is obtained
and the shoe and lining assemblies are
properly seated.
4.
Install the wheel and tire assem-
bly on the hub and rotor assembly.
5.
Check and refill the master cyl-
inder reservoir with specified brake
fluid as required.
6. Road test the car.
It should not be necessary to bleed
the system after a shoe and lining re-
placement.
FRONT WHEEL HUB AND
ROTOR ASSEMBLY-
DISC BRAKES
REMOVAL
1.
Remove the wheel and tire from
the hub (Figs. 23 and 24). Be careful
to avoid damage or interference with
the bleeder screw fitting. On Lincoln
Continental models be careful to avoid
damage to the caliper splash shield or
transfer tube.
2.
Remove the caliper assembly
from the spindle and the rotor. If the
caliper does not require servicing, it is
not necessary to disconnect the brake
hose or remove the caliper from the
vehicle. Position the caliper out of the
way, and support it with a wire to
avoid damaging the caliper or stretch-
ing the hose. Insert a clean cardboard
spacer between the linings to prevent
the piston from coming out of the cyl-
inder bore while the caliper is re-
moved.
Handle the rotor and caliper assem-
blies in such a way as to avoid defor-
mation of the rotor and nicking,
scratching or contamination of the
brake linings.
3.
Remove the grease cap from the
hub.
Remove the cotter pin, nut lock,
adjusting nut, and flat washer from
the spindle. Remove the outer bearing
cone and roller assembly.
4.
Remove the hub and rotor as-
sembly from the spindle.
INSTALLATION
1.
If the rotor is being replaced, re-
move the protective coating from the
new rotor with carburetor degreaser.
Pack a new set of bearings with speci-
fied grease (M-1C75B), and install the
inner bearing cone and roller assembly
in the inner cup. Pack grease lightly
between the lips of a new grease seal
and install the seal (Figs. 23 and 24).
If the original rotor is being in-
stalled, make sure that the grease in
the hub is clean and adequate, that
the inner bearing and grease seal are
lubricated and in good condition, and
that the rotor braking surfaces are
clean.
2.
Install the hub and rotor assem-
bly on the spindle.
3.
Lubricate and install the outer
wheel bearing, washer and adjusting
nut.
4.
Adjust the wheel bearings to
specification, and then install the nut
lock, cotter pin, and grease cap. The
wheel bearing adjustment is especially
important with disc brakes.
5. Mount the caliper assembly on
the spindle following the Disc Brake
Caliper Assembly Installation proce-
dure in this section.
DISC BRAKE ROTOR
SPLASH SHIELD
REMOVAL
1.
Remove the caliper and the hub
and rotor assembly as outlined under
Removal in the foregoing procedure
(it is not necessary to disconnect hy-
draulic connections).
2.
Remove the three bolts that at-
tach the splash shield to the spindle,
and remove the shield (Figs. 23 and
24).
3.
Remove and discard the splash
shield to spindle gasket.
INSTALLATION
1.
Install a new splash shield to
spindle gasket.
2.
If the shield is bent, straighten it
out before installation. Position the
shield to the mounting bracket, install
the attaching bolts, nuts and torque
them to specification.
3.
Install the hub and rotor assem-
bly and the caliper as outlined under
Installation in the foregoing proce-
dure.
DUAL MASTER CYLINDER—
NON POWER BRAKES
FORD, MERCURY
AND METEOR
Removal
Refer to Fig. 26.
BUSHING
HAIRPIN
RETAINER
BUSHING
STOPLIGHT SWITCH
13480
HI 637-A
FIG. 26—Dual Master Cylinder Installation— Non Power Brakes
Ford,
Mercury, and Meteorprocarmanuals.com
Page 39 of 413
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
Page 40 of 413
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