differential FORD MUSTANG 1969 Volume One Chassis
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Page 12 of 413
02-01-01
02-01-01
GROUP
2
PART
2-1
PAGE
General Brake Service 02-01-01
PART
2-2
Brake System 02-02-01
PART
2-3
Specifications
PAGE
02-03-01
Part
2-1
General Brake Service
COMPONENT INDEX
ANTI SKID CONTROL SYSTEM
Tests
BRAKE BOOSTER
Adjustments
Cleaning
and
Inspection
Tests
BRAKE PEDAL
Free Height Test
Total Travel Test
DISC BRAKES
Cleaning
and
Inspection
Service Precautions
DRUM BRAKES
Cleaning
and
Inspection
HYDRAULIC SYSTEM BLEEDING
PARKING BRAKE CONTROL
Vacuum Release Test
PARKING BRAKE LINKAGE
Adjustment
PRESSURE DIFFERENTIAL VALVE
Adjustment (Centralize)
MODEL APPLICATION
All
Models
01-04
01-07
01-02
01-01
01-01
01-07
01-07
01-08
01-05
01-07
Ford
N/A
01-03
01-03
Mercury
N/A
01-03
01-03
Meteor
N/A
01-03
01-03
Cougar
N/A
N/A
01-03
Fairlane
N/A
N/A
01-03
F
alcon
N/A
N/A
01-03
Montego
N/A
N/A
01-03
Mustang
N/A
N/A
01-03
Lincoln-
Continental
N/A
01-03
01-04
Thunderbird
01-03
01-03
01-04
Continental-
Mark III
01-03
01-03
01-04
A page number indicates that the item
is for the
vehicle listed
at
the head
of the
column.
N/A indicates that the item
is not
applicable
to
the vehicle listed.
1 BRAKE SYSTEM TESTS
Always check
the
fluid level
in the
master cylinder before performing
the
test procedures.
If the
fluid level
is not
within
1/4
inch
of the top of the mas-
ter cylinder reservoirs,
add
Ford
Brake Fluid
—
Extra Heavy Duty —
Part Number C6AZ-19542-A
(ESA-
M6C25-A)
or
equivalent
for all
brake
applications.
The
extra heavy duty
brake fluid
is
colored blue
for
identifi-
cation purposes.
Do not mix low tem-
perature brake fluids with
the
speci-
fied brake fluid.
Should
one of the
wheel brakes
be
locked
and the
vehicle must
be
moved,
open
the
bleeder screw long enough
to
let
out a few
drops
of
brake fluid.
This bleeding operation will release
the brakes
but
will
not
correct
the
cause
of
trouble.
BRAKE PEDAL FREE
HEIGHT
AND
TRAVEL
MEASUREMENTS
With
the
engine running
for
full
power brake operation, measure
the
brake pedal free height,
and
check
the
brake pedal travel with
the use of the
Brake Pedal Pressure Gauge, Tool
WRE-5OO-5O
as
follows:
BRAKE PEDAL FREE HEIGHT
MEASUREMENT
1.
Insert
a
slender, sharp pointed
prod through
the
carpet
and
sound
deadener
to the
dash panel metal
and
measure
the
distance
to the
brake
pedal
(Fig. 1).
2.
If the
position
of the
pedal
is not
within specification, check
the
brake
pedal linkage
for
missing, worn,
or
damaged bushings,
or
loose attaching
bolts
and
replace them,
if
required.
3.
If the
pedal free height
is
still
out
of
specification, check
the
brake
pedal booster
or
master cylinder
to be
sure
the
correct parts
are
installed.
Replace
the
worn
or
damaged parts
as
necessary.
BRAKE PEDAL TRAVEL
MEASUREMENT
1.
Install
a
Brake Pedal Effort
Gauge
on the
brake pedal
pad
(Fig. 2).
2.
Hook
a
steel measuring tape
to
the brake pedal
as
shown
in Fig. 1.
Measure
and
record
the
distance from
the brake pedal free height position
to
the reference point, which
is at the six
procarmanuals.com
Page 13 of 413
02-01-02
Brakes
02*01-02
STEERING
WHEEL RIW
TOEBOARD
OR
DASH
METAL
CHECKING
POINTS
STEERING
COLUMN-
STEEL
MEASURING TAPE
VEHICLE
FORD,
MERCURY AND METEOR
FORD,
MERCURY AND METEOR
FORD,
MERCURY AND METEOR
FORD,
MERCURY AND METEOR
FAIRLANE,
MONTEGO AND FALCON
FAIRLANE,
MONTEGO AND FALCON
MUSTANG
AND COUGAR
MUSTANG
AND COUGAR
THUNDERBIRD
CONTINENTAL
MARK III
LINCOLN
CONTINENTAL
TYPE
NON-POWER
DRUM
POWER
DRUM & DISC
NON-POWER
DISC
POLICE
POWER DISC
NON-POWER
DRUM
POWER
DISC
NON-POWER
DRUM
POWER
DISC
POWER
DISC
POWER
DISC
POWER
DISC
PEDAL
FREE
HEIGHT-A
8.09-7.17
6.18-5.99
8.65-7.82
7.58-6.72
8.13-6.91
7.25-5.71
7.49-6.43
6.25-5.56
PEDAL
FREE
HEIGHT-B"
5.96-5.04
5.96-5.04
6.50-5.50
PEDAL
TRAVEL-C
3.10
3.27
2.18
3.27
2.90
2.35
2.58
1.75
3.00
3.00
2.25
NOTE:AgB
DIMENSION TO BE MEASURED TO SHEET METAL
C
DIMENSION TO BE MEASURED PARALLEL TO THE VERTICAL CENTERLINE OF THE
STEERING
COLUMN WITH A 50 POUND LOAD APPLIED TO THE CENTERLINE OF THE
BRAKE
PEDAL PAD. (CHECKS ON POWER BRAKE VEHICLES MADE WITH ENGINE RUNNING
H1630-A
FIG. 1 — Brake Pedal Height and Travel Measurements
Tool-WRE-l
HI525-A
FIG.
2—Brake Pedal Effort Gauge Installed
o'clock position on the steering wheel
rim.
3.
With the steel tape still hooked
to the brake pedal depress the brake
pedal by pressing downward on the
brake pedal effort gauge. Apply a 50
pound load to the center of the pedal
by observing the pressure gauge, and
measure the distance from the brake
pedal to the fixed reference point on
the steering wheel rim parallel to the
centerline of the steering column.
4.
The difference between the brake
pedal free height and the depressed
pedal measurement under a 50 pound
load should be within the specified
maximum pedal travel service specifi-
cation B in Fig. I.
5.
If the pedal travel is more than
the specified maximum shown in Fig.
1,
dimension C, make several sharp
reverse stops (equivalent to 50 pounds
pedal pressure) with a forward stop
before each. Move the vehicle in rev-
erse and forward for a distance of ap-
proximately ten feet; then, apply the
brakes sharply and hold the brake
pedal down until the vehicle is com-
pletely stopped. This will actuate the
brake self-adjusters. If these stops do
not bring the brake pedal travel within
specification, make several additional
forward and reverse stops as outlined
above.
6. If the second series of stops do
not bring the brake pedal travel within
specification, remove the brake drums
and check the brake adjusters to make
sure they are functioning. Check the
brake linings for wear or damage. Re-
pair or replace all worn or damaged
parts and non-functioning adjusters.
Adjust the brake lining outside diame-
ter to the approximate inside diameter
of the brake drum with Rotunda Tool
HRE-8650 (Fig. 12, Part 2-2).
7.
If all the brake adjusters, brake
drums and linings are functional and
the brake travel is not within specifi-
cations, check the pedal linkage for
missing or worn bushings, or loose at-
tachments. Bleed the brakes and cen-
tralize the differential valve.
POWER BRAKE
FUNCTIONAL TEST
1.
Check the hydraulic brake sys-
tem for leaks or insufficient fluid.
2.
With the transmission in neutral,
stop the engine and apply the parking
brake. Depress the brake pedal several
times to exhaust all vacuum in the
system.
3.
With the engine shut off and all
vacuum in the system exhausted, dep-
ress the pedal, and hold it in the ap-
plied position. Start the engine If theprocarmanuals.com
Page 16 of 413
02-01-05
Brakes
02-01-05
1.
Disconnect the master cylinder
from the booster assembly and secure
away from the booster without discon-
necting the brake tubes.
2.
Reinstall the air filter assembly
on the booster if it was removed with
the master cylinder (Fig. 8).
3.
Install and tighten the master
cylinder retaining nuts to retain the
air filter assembly securely against the
booster body and to seal the booster
bellows against air leaks.
4.
Place the gauge against the
master cylinder mounting surface of
the air filter assembly.
5.
Adjust the push rod screw to
provide a slight tension against the
inner edge of the adjustment gauge
slot. (Approximately 5 pounds of ten-
sion against the push rod is required
to assure that the push rod is firmly
seated in the booster assembly.)
6. Remove the retaining nuts from
the booster master cylinder mounting
studs.
7.
Install the master cylinder on the
brake booster and tighten the retain-
ing nuts to the specified torque.
The push rod length verification of
the Bendix power brake booster
assemblies is accomplished as follows:
1.
Disconnect the master cylinder
from the booster assembly and secure
away from the booster without discon-
necting the brake tubes.
2.
Adjust the push rod screw to
provide a slight tension against the
inner edge of the adjustment gauge
slot. (Approximately 5 pounds of ten-
sion against the push rod is required
to assure that the push rod is firmly
seated in the booster assembly.) See
Figure 8.
3.
Install the master cylinder on the
brake booster and tighten the retain-
ing nuts to the specified torque.
Do not set up side forces on the
push rod as it may break the valve
plunger.
This is an approximate adjustment
only. To verify the adjustment, look
through the make-up (rear) port of the
master cylinder when installing the
master cylinder to the booster. The
master cylinder piston should not
move more than 0.015 inch as it con-
tacts the push rod. No movement
(exact contact) is ideal.
HYDRAULIC SYSTEM BLEEDING
AND CENTRALIZING OF THE
DIFFERENTIAL VALVE
When any part of the hydraulic sys-
tem has been disconnected for repair
or replacement, air may enter the sys-
tem and cause spongy pedal action.
Bleed the hydraulic system after it has
been properly connected, to be sure
that all air is expelled.
MANUAL BLEEDING
The Lincoln Continental hydraulic
brake system is to be bled only with
pressure bleeding equipment.
The primary and secondary (front
MANIFOLD CHECK VALVE-2365 19-25 IN. LB.
TIGHTEN RETAINING NUTS
TO SECURE AIR FILTER
AGAINST BOOSTER BODY
AND BELLOWS
ADJUST PUSH ROD SCREW TO
PROVIDE A SLIGHT TENSION
(APPROXIMATELY 5 LBS.)
AGAINST THE GAUGE
PUSH ROD GAUGE
and rear) hydraulic brake systems are
individual systems and are bled separ-
ately. Bleed the longest line first on
the individual system being serviced.
During the complete bleeding opera-
tion,
DO NOT allow the reservoir to
run dry. Keep the master cylinder res-
ervoirs filled with Ford Fluid—Extra
Heavy Duty — Part Number C6AZ-
19542-A (ESA-M6C 25-A). The extra
heavy duty brake fluid is colored blue
for identification purposes. Do not
mix low temperature brake fluids with
the specified fluid during the bleeding
operations. Never re-use brake fluid
which has been drained from the hy-
draulic systems.
1.
If the master cylinder is
equipped with a bleed screw, loosen
the bleed screw. Push the brake pedal
down slowly through its full travel.
Close the bleeder fitting and return
the pedal to the fully released posi-
tion. Repeat this operation until fluid
is free of air bubbles, then tighten the
bleeder screw. Do not use the second-
ary piston stop screw, located on the
bottom of the master cylinder to bleed
the brake system. Loosening or re-
moving this screw could result in dam-
age to the secondary piston or stop
screw.
2.
To bleed the secondary (rear)
brake system, position a suitable 3/8
inch box wrench (Fig. 9) on the bleed-
er fitting on the brake wheel cylinder.
Attach a rubber drain tube to the
bleeder fitting. The end of the tube
should fit snugly around the bleeder
fitting.
APPROXIMATELY 45°
PUSH ROD ADJUSTMENT-MIDLAND-ROSS
FIG. 8—Brake Booster Push Rod Measurement
PUSH ROD ADJUSTMENT-BENDIX
H1589-A
H1300-B
. 9—Wrench for Bleeding
Brake Hydraulic System
3.
Submerge the free end of the
tube in a container partially filled with
clean brake fluid, and loosen the
bleeder fitting approximately 3/4 turn.
4.
Push the brake pedal down slow-
ly through its full travel. Close the
bleeder fitting, then return the pedal
to the full-released position. Repeat
this operation until air bubbles cease
to appear at the submerged end of the
bleeder tube.
5.
When the fluid is completely free
of air bubbles, close the bleeder fitting
and remove the bleeder tube.
6. Repeat this procedure at the
brake wheel cylinder on the oppositeprocarmanuals.com
Page 17 of 413
02-01-06
Brakes
02-01-06
side.
Refill the master cylinder reser-
voir after each wheel cylinder is bled
and install the master cylinder cover
and gasket. Be sure the diaphragm
type gasket is properly positioned in
the master cylinder cover. When the
bleeding operation is completed, the
fluid level should be filled to within
1/4 inch of the top of the reservoirs.
7. If the primary (front brake) sys-
tem is to be bled. Repeat steps 2
through 6 at the right front brake cal-
iper or cylinder and ending at the left
front brake caliper or cylinder.
8. On disc brake equipped models
be sure that the front brake pistons
are returned to their normal positions
and that the shoe and lining assem-
blies are properly seated by depressing
the brake pedal several times until
normal pedal travel is established.
9. Centralize the pressure differen-
tial valve. Refer to the Centralizing
the Pressure Differential Valve proce-
dures which follow.
PRESSURE BLEEDING
The Lincoln Continental hydraulic
brake system is to be bled only with
pressure bleeding equipment.
Bleed the longest lines first. The
bleeder tank should contain enough
new Ford Brake Fluid to complete the
bleeding operation. Use Ford Brake
Fluid — Extra Heavy Duty — Part
Number C6AZ-19542-A (ESA-
M6C25-A) or equivalent for all brake
applications. The brake fluid is col-
ored blue for identification purposes.
Do not mix low temperature brake
fluid with the specified brake fluid
during the bleeding operations. Never
re-use brake fluid that has been
drained from the hydraulic system.
The tank should be charged with ap-
proximately 10 to 30 pounds of air
pressure. Never exceed 50 pounds
pressure.
1.
Clean all dirt from the master
cylinder reservoir cover.
2.
Remove the master cylinder res-
ervoir cover and rubber gasket, and
fill the master cylinder reservoir with
the specified brake fluid. Install the
pressure bleeder adapter tool to the
master cylinder, and attach the bleed-
er tank hose to the fittng on the
adapter.
Master cylinder pressure bleeder
adapter tools can be obtained from
the various manufacturers of pressure
bleeding equipment. Follow the in-
structions of the manufacturer when
installing the adapter.
3.
If the master cylinder is
equipped with a bleed screw, loosen
the bleed screw and bleed the master
cylinder until the fluid is free of air
bubbles; then, tighten the bleed screw.
Do not use the secondary piston stop
screw, located on the bottom of the
master cylinder, to bleed the master
cylinder.
4.
If the rear wheel cylinders, the
secondary brake system, are to be
bled, position a 3/8 inch box wrench
(Fig. 9) on the bleeder fitting on the
right rear brake wheel cylinder. At-
tach a bleeder tube to the bleeder fit-
ting. The end of the tube should fit
snugly around the bleeder fitting.
5. Open the valve on the bleeder
tank to admit pressurized brake fluid
to the master cylinder reservoir.
6. Submerge the free end of the
tube in a container partially filled with
clean brake fluid, and loosen the
bleeder fitting.
7.
When air bubbles cease to ap-
pear in the fluid at the submerged end
of the bleeder tube, close the bleeder
fitting and remove the tube.
8. Repeat steps 3 through 7 at the
left rear wheel cylinder.
9. If the vehicle is equipped with
disc brakes, repeat steps 4 through 7,
starting at the right front disc caliper
and ending at the left front disc cali-
per.
On Lincoln Continental models the
front wheel and tire assemblies must
be removed to gain access to the
bleeder fittings on the calipers. Also
on Lincoln Continental models the
metering valve release rod must be
pulled outward and held a minimum
of 1/16 inch (Fig. 10) while bleeding
the primary brake system.
10.
If the vehicle contains drum-
type front brakes and the primary
(front) brake system is to be bled, re-
peat steps 4 through 7, starting at the
right front wheel cylinder ending at
the left front wheel cylinder.
11.
When the bleeding operation is
completed, close the bleeder tank
valve and remove the tank hose from
the adapter fitting.
12.
On disc brake equipped ve-
hicles,
be sure that the front brake
pistons are returned to their normal
positions and that the shoe and lining
assemblies are properly seated by dep-
ressing the brake pedal several times
until normal pedal travel is esta-
blished.
13.
Remove the Pressure Bleeder
Adapter Tool. Fill the master cylinder
reservoirs to within 1/4 inch of the
top.
Install the master cylinder cover
and gasket. Be sure the Diaphragm
type gasket is properly positioned in
the master cylinder cover.
14.
Centralize the pressure differen-
tial valve as follows.
METERING VALVE
BLEEDER RETAINER
SEE
VIEW A
RELEASE ROD
FIG. 10—Disc Brake Metering Valve—Lincoln Continental
HI 644-Aprocarmanuals.com
Page 18 of 413
02-01-07
Brakes
02-01-07
CENTRALIZING THE
PRESSURE DIFFERENTIAL
VALVE
After a failure of the primary (front
brake) or secondary (rear brake) sys-
tem has been repaired and bled, the
dual-brake warning light will usually
continue to be illuminated due to the
pressure differential valve remaining in
the off-center position.
To centralize the pressure differen-
tial valve and turn off the warning
light after a repair operation, a pres-
sure differential or unbalance condi-
tion must be created in the opposite
brake system from the one that was
repaired or bled last.
1.
Turn the ignition switch to the
ACC or ON position. Loosen the dif-
ferential valve assembly brake tube
nut at the outlet port on the opposite
side of the brake system that was
wheel balanced, repaired and/or bled
last. Depress the brake pedal slowly to
build line pressure until the pressure
differential valve is moved to a cen-
tralized position and the brake warn-
ing light goes out; then, immediately
tighten the outlet port tube nut.
2.
Check the fluid level in the mas-
ter cylinder reservoirs and fill them to
within 1/4 inch of the top with the
specified brake fluid, if necessary.
3.
Turn the ignition switch to the
OFF position.
4.
Before driving the vehicle, check
the operation of the brakes and be
sure that a firm pedal is obtained.
CLEANING AND INSPECTION
DISC BRAKES
1.
Remove the wheel and tire and
the shoe and lining assemblies as out-
lined in Part 2-2, Section 2.
2.
On all models except Lincoln
Continental, make thickness measure-
ments with a micrometer across the
thinnest section of the shoe and lining.
If the assembly has worn to a thick-
ness of 0.230-inch (shoe and lining to-
gether) or 0.030-inch (lining material
only) at any one of three measuring
locations or if there is more than
0.125 taper from end to end or if lin-
ing shows evidence of brake fluid con-
tamination, replace all (4) shoe and
lining assemblies on both front wheels.
On Lincoln Continental brakes
make three thickness measurements
with a micrometer across the middle
section of the shoe and lining. Take
one reading at each side and one in
the center. If the assembly has worn
to a thickness of 0.231 inch (shoe and
lining together) or 0.066 inch (lining
material only) at any one of the three
measuring locations, replace all (4)
shoe and lining assemblies on both
front wheels.
3.
Check the caliper to spindle at-
taching bolts torque. Torque them to
specification, if required.
4.
To check rotor runout, first
eliminate the wheel bearing end play
by tightening the adjusting nut. After
tightening the nut, check to see that
the rotor can still be rotated.
5.
Clamp a dial indicator to the
caliper housing so that the stylus con-
tact the rotor at a point approximate-
ly 1 inch from the outer edge. Rotate
the rotor and take an indicator read-
ing. If the reading exceeds 0.003 inch
total lateral runout on the indicator,
replace or resurface the disc brake
rotor. The following requirement must
be met when resurfacing disc brake
rotors:
Rotunda Disc Brake Attachment
FRE-2249-2 is the only approved tool
to be used to refinish the disc brake
rotors.
The step-by-step resurfacing
procedure provided with the tool must
be adhered to.
The finished braking surface of the
rotor must be flat and parallel within
0.0007 inch; lateral runout must not
exceed 0.003 inch total indicator
reading, braking surface are to be 80/15
micro inches.
On all models except Lincoln Con-
tinental the minimum limiting dimen-
sion from the inboard bearing cup to
the inboard rotor face and the mini-
mum rotor thickness dimension, must
be observed when removing material
from the rotor braking surfaces. A
ball and gage bar (Rotunda Kit FRE
70160) is to be used when checking
minimum dimensions (Fig. 11).
FALCON-FAIRLANE
MUSTANG-COUGAR
MONTEGO
.046 MAX-**
.119
MAX.
FORD-MERCURY
METEOR - THUNDERBIRD
875
MIN
H1633-A
1.12
MIN.-^
??
— Disc Brake Rotor
Service Limits—All Models Except
Lincoln Continental
On Lincoln Continental models the
minimum limiting dimension (Fig. 12)
from the inboard bearing cup to the
inboard rotor face (dimension B)
and the outboard rotor surface and
the inboard bearing cup (dimension
A),
must be observed when remov-
ing material from the rotor braking
surfaces.
When the runout check is finished
be sure to adjust the bearings as out-
lined in Group 3, in order to prevent
bearing failure.
6. Check the rotor for scoring. Mi-
nor scores can be removed with a
fine emery cloth. If the rotor is ex-
cessively scored, refinish it as out-
lined in step 5 or replace the rotor,
if required.
7.
Visually check the caliper. If the
caliper housing is leaking it should be
replaced. If a seal is leaking the cali-
per must be disassembled and new
.seals installed. If a piston is seazed
in the bore a new caliper housing is
required.
On Lincoln Continental models the
two halves of the caliper assembly
should never be separated. Damage or
failure of one requires replacement of
both as a unit.
Check the brake hoses for signs of
cracking, leaks or abrasion. Replace
them if necessary.
DISC BRAKE SERVICE
PRECAUTIONS
1.
Grease or any other foreign ma-
terial must be kept off the caliper as-
sembly, surfaces of the rotor and ex-
ternal surfaces of the hub during serv-
ice operations. Handling of the rotor
and caliper assemblies should be done
in a way to avoid deformation of the
brake rotor and nicking or scratching
of brake linings.
2.
If a caliper piston is removed for
any reason, the piston seal must be re-
placed.
3.
During removal and installation
of a wheel assembly, exercise care not
to interfere with and damage the cali-procarmanuals.com
Page 21 of 413
02-02-02
Brake
System
02-02-02
COMPONENT INDEX
DISC BRAKE SHOE AND LINING
Cleaning and Inspection
-
See
Part 2-1
Removal and Installation
DRUM BRAKE
Description
DUAL BRAKE SYSTEM
Description
HYDRAULIC LINES
Removal
and
Installation (Hose)
Removal
and
Installation (Tube)
MASTER CYLINDER
Cleaning
and
Inspection
Disassembly
and
Overhaul
Removal
and
Installation - Non-Power
Removal
and
Installation - Power
PARKING BRAKE
Description
PARKING BRAKE ACTUATOR
TO
CONTROL CABLE
Removal
and
Installation
PARKING BRAKE ACTUATOR
TO
EQUALIZER CABLE
Removal
and
Installation
PARKING BRAKE CONTROL
Removal
and
Installation
PARKING BRAKE EQUALIZER
TO
CONTROL CABLE
Removal
and
Installation
PARKING BRAKE EQUALIZER
TO
REAR WHEEL CABLE
Removal
and
Installation
PRESSURE DIFFERENTIAL VALVE
Removal
and
Installation
PRESSURE METERING VALVE
Removal
and
Installation
PROPORTIONING VALVE
Removal
and
Installation
WHEELCYLINDER
Cleaning
and
Inspection
Disassembly
and
Overhaul
Removal
and
Installation
MODEL APPLICATION
All
Models
02-05
02-03
02-08
02-08
02-40
02-39
02-21
02-06
02-22
02-08
02-07
02-10
Ford
02-18
02-19
02-34
02-35
02-27
N/A
02-35
N/A
02-23
Mercury
02-18
02-19
02-34
02-35
02-27
N/A
02-35
N/A
02-23
Meteor
02-18
02-19
02-34
02-35
02-27
N/A
02-35
N/A
02-23
Cougar
02-18
02-20
N/A
N/A
02-30
02-34
02-36
N/A
02-23
Fairlane
02-18
02-20
N/A
N/A
02-27
02-34
02-36
N/A
02-23
Falcon
02-18
02-20
N/A
N/A
02-27
02-34
02-36
N/A
02-23
Montego
02-18
02-20
N/A
N/A
02-27
02-34
02-36
N/A
02-23
Mustang
02-18
02-20
N/A
N/A
02-30
02-34
02-36
N/A
02-23
Lincoln-
Continental
02-18
N/A
N/A
N/A
02-30
02-35
02-36
02-24
02-24
Thunderbird
02-18
N/A
02-34
02-35
02-30
N/A
02-35
N/A
02-24
Continental-
Mark III
02-18
N/A
02-34
02-35
02-30
N/A
02-35
N/A
02-24
A page number indicates that the item
is for
the vehicle listed
at
the head
of
the column.
N/A indicates that the item is
not
applicable
to
the vehicle listed.
procarmanuals.com
Page 22 of 413
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
Page 23 of 413
BRAKE WARNING LAMP SWITCH
PISTON
BRAKE WARNING LAMP SWITCH
BRAKE WARNING LAMP SWITCH
PLUNGER IN THE ON POSITION
CONNECTOR
BRAKE WARNING LAMP SWITCH
PLUNGER IN OFF POSITION
VALVE PISTON HAS MOVED
TO LOW PRESSURE AREA.
WARNING LAMP SWITCH
PLUNGER IS DEPRESSED,
LIGHTING THE BRAKE
WARNING LAMP
LOW PRESSURE SIDE
U
VALVE PISTON IS
CENTRALIZED. PRIMARY
AND SECONDARY SYSTEM
PRESSURES ARE EQUALIZED
BRAKE WARNING LAMP
SWITCH PLUNGER IN
OFF POSITION
HIGH PRESSURE SIDE
DRUM BRAKES
TJ
CONNEiCTOR
BRAKE FLUID
BRAKE WARNING LAMP I
SWITCH PLUNGER IN
ON POSITION
REAR BRAKE INLET
CONNECTOR
FRONT BRAKE
INLET
FRONT BRAKE
OUTLET
VALVE PISTON IS CENTRALIZED.
PRIMARY AND SECONDARY SYSTEM
PRESSURES ARE EQUALIZED
OUTLET TO
PROPORTIONING VALVE
DISC BRAKES
\
REAR BRAKE
PROPORTIONING
VALVE IS BYPASSED
VALVE PISTON HAS MOVED TO LOW
PRESSURE AREA. WARNING LAMP SWITCH PLUNGER IS
DEPRESSED, LIGHTING THE BRAKE WARNING LAMP H1634-A
FIG. 2—Pressure Differential Valve and Brake Warning Light Switch
CALIPER ASSEMBLY
BLEEDER
SCREW
EXTERNAL
TRANSFERTU3E
H1567-B
HUB
AND
ROTOR
ASSEMBLY
H 1647-A
FIG. 3—Disc Brake Assembly-
Floating Caliper—All Models
Except Lincoln Continental
FIG. 4—Disc Brake Assembly—
Fixed Caliper—Lincoln
Continental
blies are not interchangable (Fig. 23).
The outboard shoe and lining is fixed
to the floating caliper and is retained
by two pins and spring clips. The shoe
and lining assembly consists of fric-
tion material bonded to a metal plate
called the shoe. It is replaced as a
unit.
FIXED CALIPER
LINCOLN CONTINENTAL
The caliper assembly is bolted di-
rectly to the wheel spindle arm by two
bolts.
The caliper assembly consists of
two caliper housings bolted together
with each half containing two cylinder
bores of 1.938 inch diameter. Each
cylinder bore contains a piston with
an attached molded rubber dust boot
to seal the cylinder bore from contam-
ination (Fig. 6). Square-section rubberprocarmanuals.com
Page 27 of 413
02-02-08
Brake System
02-02-08
Tool-HRE-8650
JUST SET TO DRUM
DIAMETER HERE . . .
FIND CORRECT BRAKE
SHOE DIAMETER HERE
H1416-A
FIG.
7
7—Adjusting Brake Shoes Using Tool HRE-8650
BOOT
BOOT
PISTON
. BLEEDER .
CYLINDER
SCREW RETURN SPRING PIST0N
H1385-B
FIG. 72—Brake Wheel Cylinder—Typical
DISASSEMBLY
1.
Remove the links and the rubber
boots from the ends of the brake cyl-
inder. Remove the pistons, cups, and
return spring from the cylinder bore
(Fig. 12).
2.
Remove the bleeder screw from
the cylinder.
INSPECTION
1.
Wash all parts in clean brake
fluid. Dry with compressed air.
2.
Replace scored pistons. Always
replace the rubber cups and dust
boots.
3.
Inspect the cylinder bore for
score marks or rust. If either condi-
tion is present the cylinder bore must
be honed. However, the cylinder
should not be honed more than 0.003
inch beyond its original diameter.
4.
Check the bleeder hole to be sure
that it is open.
ASSEMBLY
1.
Apply a light coating of heavy-
duty brake fluip! to all internal parts.
2.
Thread the bleeder screw into the
cylinder and tighten securely.
3.
Insert the return spring, cups,
and pistons into their respective posi-
tions in the cylinder bore (Fig. 12).
Place a boot over each end of the cyl-
inder. Bleed the brake system.
HYDRAULIC LINE REPAIR
Steel tubing is used throughout the
brake system with the exception of the
flexible hoses at the front wheels and
at the fear axle housing brake tube
connection (Figs. 17 thru 21).
Always bleed the applicable pri-
mary or secondary brake system after
primary or secondary brake system
hose or line replacement. Centralize
the pressure differential valve after
bleeding the system.
BRAKE TUBE
REPLACEMENT
If a section of the brake tubing be-
comes damaged, the entire section
should be replaced with tubing of the
same type, size, shape and length.
Copper tubing should not be used in a
hydraulic system. When bending
brake tubing to fit underbody or rear
axle contours, be careful not to kink
or crack the tube.
All brake tubing should be double
flared properly to provide good leak-
proof connections. Clean the brake
tubing by flushing with clean brake
fluid before installation.
When connecting a tube to a hose,
tube connector, or brake cylinder,
tighten the tube fitting nut to specified
torque with Milbar tool 1112-144 or
equivalent.
BRAKE HOSE
REPLACEMENT
A flexible brake hose should be re-
placed if it shows signs of softening,
cracking, or other damage.
When installing a new front brake
hose,
position the hose to avoid con-
tact with other chassis parts. Place a
new copper gasket over the hose fit-
ting and thread the hose assembly into
the front wheel cylinder. Engage the
opposite end of the hose to the brack-
et on the frame. Install the horsesho-
e-type retaining clip, and connect the
tube to the hose with the tube fitting
nut (Figs. 17 thru 21).
A rear brake hose should be in-
stalled so that it does not touch the
muffler outlet pipe or shock absorber.
Thread the hose into the rear brake
tube connector. Engage the front end
of the hose to the bracket on the
frame. Install the horseshoe-type re-
taining clip, and connect the tube to
the hose with the tube fitting nut.procarmanuals.com
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