mustang FORD MUSTANG 1969 Volume One Chassis

01-01-03
Vehicle Identification
01-01-03

BODY SERIAL AND STYLE CODES-(continued)

MONTEGO

Body

Serial

Code

01

02

06

07

10

11

12

11

12

10

11
Body

Style

Code

65A

54A

54B

65B

54D

65D

76D

65 E

76B

54C

65C
Body Type

2-Door Hardtop-formal

(Sports Coupe)®

4-Door Sedan (Sports)®

4-Door Sedan®

2-Door Hardtop-Formal®

4-Door Sedan®

2-Door Hardtop-Formal®

Convertible®

2-Door Hardtop-Formal©

Convertible®

4-Door Sedan®

2-Door Hardtop-Formal®
Model

Comet

Montego

Montego MX

Montego MX

Montego MX Brougham
MUSTANG

15
63A
2-Door Hardtop Fastback®

(GT Appearance Opt.®) Cyclone

15
63C
2-Door Hardtop Fastback®

16
63H
2-Door Hardtop Fastback®

(Sports Appearance Opt.©) Cyclone CJ

03
71B
Montego®

08
71C
Montego MX®

08
71A
Montego MX (Woodgrain)®
Station Wagons-4 Door

©Bench Seat ©Split Bench ©Bucket Seats

THUNDERBIRD

Body Body

Serial Style

Code Code

Body Type
Model

83
65A
2-Door Hardtop®

83
65C
2-Door Hardtop®

84
65B
2-Door Landau
®

84
65D
2-Door Landau
®

87
57B
4-Door Landau
©

87
57C
4-Door Landau
®

©Bench Seat ©Split Bench ©Bucket Seats ©Blind Quarter Roof

FALCON

Body

Serial

Code

10

11

20

22

21

12

23
Body

Style

Code

62A

54A

62B

62C

54B

71A

71B

©Bench Seat
Body Type

2-Door Sedan®

4-Door Sedan®

2-Door Sedan®

2-Door Sports Coupe®

4-Door Sedan©

Standard©

Futura©

©Split Bench
Model

Standard

Futura

Station Wagons

-4 Door

©Bucket Seat
Body

Serial

Code

01

02

03

01

02

03

01

01

01

02
Body

Style

Code

65A

63A

76A

65B

63B

76B

65C

65D

65E

63C

©Bench Seat
Body Type

2-Door Hardtop©©

2-Door Fastback©®

Convertible®®

2-Door Hardtop®®

2-Door Fastback®©

Convertible©®

2-Door Hardtop®

2-Door Hardtop®

2-Door Hardtop©

2-Door Fastback®
Model

Standard

Luxury

Standard

Luxury

Grand

Machl

©Split Bench ©Bucket Seats ©Hi-Back Bucket

FORD

Body

Serial

Code

50

51

52

53
Body

Style

Code

62E

54 E

62B

54B
Body Type

2-Door Sedan®

4-Door Sedan®

2-Door Sedan®

4-Door Sedan®
Model

Custom

Custom 500

54
54A
4-Door Sedan®

55
63B
2-Door Hardtop-Fastback®

58
65C
2-Door Hardtop-Formal®
Galaxie 500

56

57

60

61

64

62

66
57B

76A

63C

76B

54C

65A

57F
4-Door Hardtop®

Convertible®

2-Door Hardtop-Fastback®®

Convertible®©

4-Door Sedan®®

2-Door Hardtop-Formal®®

4-Door Hardtop®©
Ford XL

Ford LTD

70
71D
Ranchwagon-6 Passenger©

71
71H
Custom 500 Ranchwagon-

6 Passenger©

72
71J
Custom 500 Ranchwagon-

Dual Face Rear©

73
71B
Country Sedan-6 Passenger®

74
71C
Country Sedan-Dual Face Rear®

75
71E
Country Squire—6 Passenger®

76
71A
Country Squire-Dual Face Rear®
Station Wagons-4 Door

©Bench Seat ©Split Bench ©Bucket Seatsprocarmanuals.com

01-01-04

Vehicle Identification
01-01-04

BODY SERIAL AND STYLE CODES-(continued)

FAIRLANE

Body

Serial

Code

30

31

34

35

33

36

35

33

36

40

41

42

44

43

42

44

43

46

46

45

45

32

37

38

47

48

48

49

49
Body

Style

Code

65A

54A

54B

63B

65B

76B

63E

65E

76E

65C

54C

63F

65F

76F

63D

65D

76D

63B

63E

65A

65E

71D

71B

71E

66A

66B

66B

(Opt.)

66C

66D

©Bench Seat
Body Type

2-Door
Hardtop-formal®

4-Door
Sedan®

4-Door
Sedan®

2-Door
Hardtop—Fastback®

2-Door
Hardtop-formal®

Convertible®

2-Door
Hardtop—Fastback©

2-Door
Hardtop-Formal©

Convertible®

2-Door
Hardtop-Formal®

4-Door
Sedan®

r t

2-Door
Hardtop—FastbackCD

2-Door
Hardtop-Formal®

Convertible®

2-Door
Hardtop—Fastback®

2-Door
Hardtop-Formal®

Convertible®

2-Door
Hardtop-Fastback®

2-Door
Hardtop-Fastback®

2-Door
Hardtop-Formal®

2-Door
Hardtop-formal®

Fairlane®

Fairlane 500®

Fairlane Torino Squire®

Ranchero®

Ranchero 500®

Ranchero 500®

Ranchero®

Ranchero®
Model

Fairlane

Fairlane 500

Fairlane 500

Torino

Torino GT

Torino GT

Cobra

Station Wagons-4 Door

Ranchero

Ranchero

Ranchero GT

©Split Bench ©Bucket Seats

REAR AXLE RATIO CODES

Conventional
Limited-Slip

Ratio

1
J
2.50:1

2
K
2.75:1

3
L
2.79:1

4
M 2.801

5
N
2.83:1

6
0
3.00:1

7
P
3.10:1

8
Q
3.20:1

9
R
3.25:1

A
S
3.50:1

B
T
3.07:1

C
U
3.08:1

D
V
3.91:1

E
W
4.30:1

TRANSMISSION CODES

Code Type

1
3-Speed
Manual

5 4-Speed Manual-wide ratio (2.78 1st Gear)

6 4-Speed Manual-close ratio (2.32 1st Gear)

W Automatic (C4) (XP-3)

U Automatic (C6) (XPL)

Y Automatic (MX)

X Automatic (FMX)

Z Automatic (C6 Special) (XPL, Special)®

©For Police & trailer towing
-
Not available with bucket seats
ENGINE CODES

Code

U
6Cyl.

T
6Cyl.

2
6 Cyl.®

L 6 Cyl.

3
6 Cyl CD

V
6
Cyl."

5
.
6 Cyl CD

B .6
Cyl.

E
6
Cyl.

F
8
Cyl.

6 8 Cyl.®

D 8
Cyl.

H 8 Cyl.

M 8 Cyl.

Y 8
Cyl.

X 8 Cyl.©

S 8 Cyl.©

P 8 Cyl.®

8 Cyl.

8 Cyl.®

K 8
Cyl.

N
8
Cyl.

A 8
Cyl.

©Low Compression

©High Performance
Type

170
Cu.
In.
(IV)

200
Cu.
In.
(IV)

200
Cu.
In.
(IV)

250
Cu.
In.
(IV)

250
Cu.
In.
(IV)

240
Cu.
In.
(IV)

240
Cu.
In.
(IV)

240 Cu. In. (IV) Police

240 Cu. In. (IV) Taxi

302
Cu.
In.
(2V)

302
Cu.
In.
(2V)

302 Cu. In. (2V) Police & Taxi

351
Cu.
In.
(2V)

351
Cu.
In.
(4V)

390
Cu.
In.
(2V)

390Cu.ln.(2V)

390
Cu.
In.
(4V)

428 Cu. In. (4V) Police Interceptor

428
Cu.
In.
(4V)
CJ

428
Cu.
In.
(4V)
CJ

429
Cu.
In.
(2V)

429
Cu.
In.
(4V)

460
Cu.
In.
(4V)

©Premium Fuel ©Improved Performance

©Ram Air Induction

CONSECUTIVE UNIT NUMBER

Starting Serial Numbers—1969 Passenger Cars

100,001—Ford, Fairlane, Falcon, Mustang, Thunderbird

500,001 -Mercury, Montego,
Cougar,
Meteor

848,000—Lincoln Continental & Continental Mark
III

EXTERIOR PAINT COLOR CODES

Code
Reference

Number
Color

A

B

c

D

E

F

G

H

|

J

K

L
. .

M

N

p

Q

R

S.
.. .

T

u

v

W

X

Y

z

2.
..

3

4

6.
. .

7

8
..
1724-A
1

3059-A

3197-A

3303-A

3191-A

3065-A
. .

3203-A

..
,.2067-A

2041-A

3080-A

3204-A

3060-A

1619-A
..

921-A

3064-A

1624-A

3198-A
. .

3199-A

2008-A

1070-A

3201-A

3120-A

3061-A
. . .

3202-A

2044-A

3071-A
. .

1730-A

3230-A

.
3077-A

3193-A

3190-A

..M6J-49B..

....M6J-50B.
Black

Maroon

Dk. Ivy Green Met.

Pastel Gray

Lt. Aqua

Dk. Aqua Met. (Brt.)

Med.
Orchid Met.

Lt. Green

Med.
Lime Met.

Dk. Aqua Met.

Dk. Orchid Met.

Lt. Gray Met.

White

Platinum

Med.
Blue Met.

Med.
Blue Met.

Lt. Gold

Med.
Gold Met.

Red

Med.
Aqua Met.

Lt. Aurora Copper IVIet.

Yellow

Dk. Blue Met.

Burnt Orange Met.

Dk. Grey Met.

Lt. Ivy Yellow

Calypso Coral

Med.
Emerald Met.

Med.
Blue Met. (Brt)

Lt. Emerald Green Met.

Lt. Blue

Red Primer

Grey Primerprocarmanuals.com

01-01-05
Vehicle Identification

01-01-05

INTERIOR TRIM CODES

Code Trim Schemes

1A Black Vinyl (Cougar, Falcon)

1A Black Cloth & Vinyl

IB Med. Blue Cloth/Lt. Blue Vinyl

IB Med. or Lt. Blue Vinyl

IB Dk. Blue Cloth & Vinyl

(Lincoln,
T-Bird, Mark III, Mercury)

IB Lt. Blue Cloth & Vinyl

(Ford,
Montego, Meteor)

ID Dk. Red Cloth and Vinyl

IF Med. Saddle Vinyl (Cougar)

1G Dk. Ivy Gold Cloth & Vinyl

1G Lt. Ivy Gold Vinyl (Cougar)

IK Lt. Aqua Cloth and/or Vinyl

IP
Med.
Grey Cloth & Vinyl (Mark III)

1Y Lt. Nugget Gold Vinyl (Cougar-Falcon)

1Y Lt. Nugget Gold Cloth & Vinyl

2A Black Vinyl

2A Black Leather & Vinyl (Lincoln)

2A Black Leather (Mark III)

2B Dk. or Lt. Blue Vinyl

2B Dk. Blue Leather & Vinyl (Lincoln)

2B Dk. Blue Leather (Mark III)

2D Dk. Red Vinyl

2D Dk. Red Leather & Vinyl (Lincoln)

2D Dk. Red Leather (Mark III)

2F Med. Saddle Vinyl (Cougar)

2F
Med.
Saddle Leather & Vinyl (Lincoln)

2F Med. Saddle Leather (Mark III)

2G Lt. or Dk. Ivy Gold Vinyl

2G Dk. Ivy Gold Leather & Vinyl (Lincoln)

2G Dk. Ivy Gold Leather (Mark III)

2K Lt. Aqua Vinyl

2K Lt. Aqua Leather & Vinyl (Lincoln)

2K Lt. Aqua Leather (Mark III)

2P
Med.
Grey Leather (Mark III)

2U Pastel Parchment w/Black Leather (Mark III)

2W Whitew/Black Vinyl

2W White w/Black Leather & Vinyl (Lincoln)

2W Whitew/Black Leather (Mark III)

2Y Lt. Nugget Gold Vinyl

2Y Lt. Nugget Gold Leather & Vinyl (Lincoln)

2Y Lt. Nugget Gold Leather (Mark III)

3A Black w/Red Knit and/or Vinyl (Mustang,

Montego)

3A Black Knit and/or Vinyl

3A Black Cloth & Vinyl

3A Black Leather & Vinyl (Lincoln)

3B Lt. Blue Knit and/or Vinyl

3B Lt. or Dk. Blue Cloth & Lt. Blue Vinyl

3B Lt. Blue Cloth & Vinyl

(Fairlane,
Ford,
Montego, Meteor)

3B Med. Blue Cloth & Lt. Blue Vinyl

3B Dk. Blue Cloth & Vinyl (T-Bird, Mercury)

3B Dk. Blue Leather & Vinyl (Lincoln)

3D Dk.Red Cloth & Vinyl

3D Dk. Red Knit and/or Vinyl

3G Dk. Ivy Gold Cloth & Vinyl

3G Dk. Ivy Gold Leather & Vinyl (Lincoln)

3K Lt. Aqua Cloth & Vinyl

3W White w/Black Knit and/or Vinyl

3W Whitew/Black Leather & Vinyl (Lincoln)

3Y Lt. Nugget Gold Cloth & Vinyl

3Y Lt. Nugget Gold Knit and/or Vinyl (T-Bird)

4A Black Cloth & Vinyl

4A Black Knit and/or Vinyl

4B Dk. Blue Vinyl

4B Dk. or Lt. Blue Vinyl

4D Dk.Red Vinyl

4G Dk. Ivy Gold Cloth & Vinyl

4G Dk. Ivy Gold Vinyl

4K Lt. Aqua Vinyl

4W White w/Black Vinyl

4Y Lt. Nugget Gold Knit and/or Vinyl

5A Black Cloth & Vinyl

5A Black Knit and/or Vinyl

5A Black Leather & Vinyl (Lincoln)

5B Lt. Blue Cloth and/or Vinyl

5B Lt. Blue Knit and/or Vinyl

5B Dk. Blue Leather & Vinyl (Lincoln)

5B Dk. Blue Cloth & Vinyl (Mercury)

5D Dk.Red Cloth & Vinyl (Montego)
INTERIOR TRIM CODES-(continued)

Code Trim Schemes

5D Dk. Red Knit and/or Vinyl

5D Dk. Red Leather & Vinyl (Lincoln)

5F
Med.
Saddle Leather & Vinyl (Lincoln)

5G Dk. Ivy Gold Knit and/or Vinyl

5G Dk. Ivy Gold Cloth & Vinyl

5G Dk. Ivy Gold Leather & Vinyl (Lincoln)

5K Lt. Aqua Cloth & Vinyl (Montego)

5K Lt. Aqua Vinyl

5K Lt. Aqua Leather & Vinyl (Lincoln)

5W White w/Black Knit and/or Vinyl

5W White w/Black Leather & Vinyl (Lincoln)

5Y Lt. Nugget Gold Cloth & Vinyl

5Y Lt. Nugget Gold Knit and/or Vinyl (Mustang,

Fairlane)

5Y Lt. Nugget Gold Leather & Vinyl (Lincoln)

6A Black Knit and/or Vinyl

6A Black Cloth & Vinyl (Lincoln)

6A Black Leathe; & Vinyl (Cougar)

6B Dk. or Lt. Blue Vinyl

6B Dk. Blue Leather & Vinyl (Cougar)

6D Dk. Red Knit and/or Vinyl

6D Dk.Red Leather & Vinyl (Cougar)

6F
Med.
Saddle Leather I Vinyl

6G Dk. Ivy Gold Vinyl

6G Dk. Ivy Gold Leather & Vinyl (Cougar)

6K Lt. Aqua Vinyl

6K Lt. Aqua Leather & Vinyl (Cougar)

6W White w/Black Vinyl

6Y Lt. Nugget Gold Vinyl

6Y Lt. Nugget Gold Leather & Vinyl (Cougar)

7A Black Vinyl

7A Black Cloth & Vinyl (Fairlane)

7A Black Leather & Vinyl (Lincoln)

7B Lt. Blue Vinyl (Cougar, Montego, Ford)

7B Dk. Blue Cloth & Vinyl

7B Dk. Blue Leathe; & Vinyl (Lincoln)

7D Dk. Red Vinyl (Mustang)

7D Dk. Red Cloth & Vinyl

7G Dk. Ivy Gold Cloth and/or Vinyl

7G Dk. Ivy Gold Leather & Vinyl (Lincoln)

7K Lt. Aqua Cloth & Vinyl

7W White w/Black Vinyl

7W White Leather & Vinyl (Lincoln)

7Y Lt. Nugget Gold Cloth & Vinyl

7Y Lt. Nugget Gold Vinyl

(Ford,
Meteor, Mustang)

8A Black Knit and/or Vinyl

8A Black Leather & Vinyl (T-Bird)

8B Dk. or Lt. Blue Knit and/or Vinyl

8D Dk. Red Knit and/or Vinyl

8F Med. Saddle Knit and/or Vinyl

8G Dk. Ivy Gold Knit and/or Vinyl

8K Lt. Aqua Knit and/or Vinyl

8W White w/Black and/or Vinyl

8W White w/Black Leather & Vinyl (T-Bird)

8Y Lt. Nugget Gold Knit and/or Vinyl

9A Black Knit and/or Vinyl

9A Black Cloth & Vinyl (Ford, Meteor)

9B Lt. Blue Knit and/or Vinyl

9B Dk. Blue Cloth & Vinyl (Ford, Meteor)

9D Dk. Red Knit and/or Vinyl

9D Dk. Red Cloth & Vinyl (Ford-Meteor)

9G Dk. Ivy Gold Cloth & Vinyl

9K Lt. Aqua Cloth & Vinyl

9Y Lt. Nugget Gold Cloth and/or Vinyl

9Y Lt. Nugget Gold Knit and/or Vinyl

AA(1W)
White Vinyl
With Black (Cougar)

AA Black Cloth & Vinyl (Lincoln)

AB(1W) White Vinyl With Blue (Cougar)

AB Lt. Blue Cloth & Vinyl (Lincoln)

AD(1W) White Vinyl With Red (Cougar)

AG(1W) White Vinyl With Ivy Gold (Cougar)

AG Lt. Ivy Gold Cloth & Vinyl (Lincoln)

AK (1W) White Vinyl With Aqua (Cougar)

AK Lt. Aqua Cloth & Vinyl (Lincoln)

AL Lt. Silver Cloth & Vinyl (Lincoln)

AY Lt. Nugget Gold Cloth & Vinyl (Lincoln)

AY(1W) White Vinyl With Nugget Gold (Cougar)

BA(2W) White Vinyl With Black (Cougar)

BA Black Vinyl (Fairlane)

BB(2W) White Vinyl With Blue (Cougar)procarmanuals.com

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

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

02-01-03
Brakes

02-01-03

vacuum system is operating, the pedal

will tend to fall away under foot pres-

sure and less pressure will be required

to hold the pedal in the applied posi-

tion. If no action is felt, the vacuum

booster system is not functioning.

If the brake pedal movement feels

spongy, bleed the hydraulic system to

remove air from the system. Refer to

Hydraulic System Bleeding, Part 1,

Section 2.

VACUUM TESTS—VACUUM

RELEASE PARKING BRAKES

Visually check the operation of the

brake linkage as the brake pedal is

depressed. Then, check the operation

of the brake linkage when the manual

release lever is activiated. These

checks should indicate whether the

manual parking brake control linkage

is operating properly or requires re-

pair or adjustment due to inability of

the parking brake to hold against

moderate vehicle movement. Perform

tests of the parking brake system and

controls after making certain the link-

age and manual controls operate

properly.

When testing a parking brake vacu-

um release system, a minimum of 10

inches of vacuum (Hg.) should be

available at all points where vacuum is

applied. This can be checked with a

Rotunda Fuel Pump Tester Gauge

(ARE345) and two Distributor Tester

hose adapters (Marked Q) connected

together with a coupling. This allows

the Fuel Pump Tester Gauge hose to
be adapted to any other vacuum hose

or rubber connector in the vacuum

systems.

Failure to maintain 10 inches of

vacuum (Hg.) during vacuum system

tests could be caused by a loose hose

connection, resulting in a vacuum

leak. When checking for vacuum be-

tween two points, trace the hose along

the entire routing to be sure it is not

crossed with another hose and con-

nected to the wrong connection.

All of the vacuum parking brake

control checks are to be performed

with the engine running at idle speed.

Leaks in the parking brake hoses or

a disconnected or improperly con-

nected hose can usually be found by

listening for a hissing sound along the

hose routings. Under no circumstances

should air pressure be applied to the

vacuum system as the actuator dia-

phragm in the parking brake vacuum

motor may be damaged.

1.
Start the engine and run it at

idle speed. With the transmission shift

control in neutral, depress the parking

brake pedal to apply the parking

brake. Move the transmission shift

control to D range and observe the

parking brake pedal to see that the

pedal moves upward and the parking

brake releases. If the parking brake

releases, the parking brake vacuum

control is working properly.

2.
If the parking brake does not re-

lease, test for vacuum at the steering

column neutral switch port in the

junction block, vacuum lines and the

parking brake release vacuum motor.

Use the Rotunda Vacuum and Fuel
Pump Tester 345. This can be accom-

plished by removing the hose from

each component and attaching it to

the vacuum gauge. Connect two dis-

tributor tester vacuum hose adapters

together with a coupling as a connec-

tor to attach the gauge. A minimum

of ten inches of vacuum is required to

actuate the parking brake vacuum

motor. Do not remove any of the vac-

uum hoses from the junction block

unless the junction block is being re-

placed, as the plastic nipples are thin

and very brittle and damage may re-

sult. If a minimum reading is not

present when checking each of the

aforementioned components, they

must be replaced.

ROAD TEST

A road test should be conducted

only when the operator is sure the

brakes will stop the vehicle.

If the road test reveals one or more

problem conditions, correct all mal-

functions of the vacuum system, brake

booster and hydraulic system prior to

removing brake drums, brake calipers,

brake shoes and linings or backing

plates.

ANTI-SKID CONTROL

SYSTEM TESTS

No adjustments or repairs are to be

performed on the skid control system.

Damaged or worn parts are to be re-

placed.

Refer to Ford Car and Truck Diag-

nosis Manual for Testing procedures.

COMMON ADJUSTMENTS AND REPAIRS

PARKING BRAKE LINKAGE

ADJUSTMENT

FORD, MERCURY, METEOR,

FAIRLANE, MONTEGO,

FALCON, MUSTANG

AND COUGAR

Check the parking brake cables

when the brakes are fully released. If1

the cables are loose, adjust them as

follows:

1.
Fully release the parking brake

pedal by pulling the release lever.

2.
Depress the parking brake pedal

until it is engaged in the first notch of

the control. On a vacuum release

brake, the first notch will be approxi-

mately two inches of pedal travel.

3.
Raise the vehicle. With the

transmission in neutral, turn the ad-

justing nut forward against the equal-

izer (Figs. 3 and 4) until there is 100
L.H. REAR WHEEL CABLE -2A809> 2A791 (2 REQUIRED)

EQUALIZER-TO-ACTUATOR CABLE-2A815

R.H. REAR WHEEL CABLE-2A635

ADJUSTING NUT-2A812

H 1537-C

FIG. 3—Parking Brake Adjustment—Ford, Mercury, Meteor,

Thunderbird and Continental Mark IIIprocarmanuals.com

02-01-04
Brakes

02-01-04

ft-lb breakaway torque.
The
breaka-

way torque
is the
torque required
to

turn
the
rear wheels
the
direction
of

forward rotation with
a
torque wrench

and tool shown
in Fig. 5. The
torque

measurement must
be
made relative
to

the center line
of the
wheel.

4.
Release
the
parking brake,
and

check
to
make sure that
the
brake

shoes return
to the
fully released posi-

tion.

5.
Depress
the
parking brake pedal

to
the
third notch. Under normal
con-

ditions, this will hold
the
vehicle satis-

factorily.

6. Release
the
parking brake again,

and check
as in
step
4.

7.
If the
rear brakes
do not
fully

release, check
the
cables
for
kinks
or

binds.
Free
the
cables
as
required.

8. Lower
the
vehicle. Remove
the

torque wrench
and
tool. Install
the

wheel attaching nuts
and
torque them

to specification. Install
the
wheel

cover.

RETAINER-*^ REAR WHEEL

(CABLE ASSEMBLY

EQUALIZER
NUT

PARKING

BRAKE CABLE

AND CONDUIT

ASSEMBLY-2853
SPRING-2A651

SPRING SEAT-2A616
JAM NUT

H1631-A

FIG. 4—Parking Brake Linkage

Adjustment—Fairlane, Montego,

Falcon,
Mustang
and
Cougar
THUNDERBIRD,

CONTINENTAL MARK
III,

AND LINCOLN

CONTINENTAL

Check
the
parking brake cables

when
the
brakes
are
fully released.
If

the cables
are
loose, adjust them
as

follows:

1.
Fully release
the
parking brake

pedal
by
pushing down
the
manual
re-

lease lever.

2.
Depress
the
parking brake pedal

1
1/4
inch from
its
normal released

position.

3.
Raise
the
vehicle with
the
trans-

mission
in
neutral.

4.
Loosen
the
lock
nut and
turn
the

adjusting
nut
forward against
the

equalizer (Figs.
3 and 6)
until there
is

100 ft-lbs breakaway torque.
The

breakaway torque
is the
torque
re-

quired
to
turn
the
rear wheels
the di-

rection
of
forward rotation with
a tor-

que wrench
and
tool shown
in Fig. 5.

The torque measurement must
be

made relative
to the
centerline
of the

wheel. Tighten
the
lock
nut.

5.
Release
the
parking brake,
and

check
to
make sure that
the
brake

shoes return
to the
fully released posi-

tion.

6. Depress
the
parking brake pedal

until
it is
fully engaged.

7.
Release
the
parking brake again,

and check
as in
step
5.

8. Depress
the
pedal
1/2
inch.
The

brakes should
not
drag.

9.
If the
rear brakes
do not
fully

release, check
the
cables
for
kinks
or

binds.
Free
the
cables
as
required.

10.
Lower
the
vehicle. Remove
the

torque wrench
and
tool. Install
the

wheel attaching nuts
and
torque them

to specification. Install
the
wheel

cover.

Tool-T59L
4204-A,

T65K
4204-A,

T66L-4204-A,

OR

Tool-4421UA

E1897-A
POWER BRAKE MASTER

CYLINDER PUSH
ROD

ADJUSTMENT

The push
rod is
provided with
an

adjustment screw
to
maintain
the cor-

rect relationship between
the
booster

control valve plunger
and the
master

cylinder.
If the
plunger
is too
long
it

will prevent
the
master cylinder piston

from completely releasing hydraulic

pressure
and can
cause
the
brakes
to

drag.
If the
plunger
is too
short
it
will

result
in
excess pedal travel
and an

undesirable clunk
in the
booster area.

The adjustment screw
is set to the

correct height
at the
time
of
original

assembly
of the
power unit. Under

normal service
the
adjustment screw

does
not
require
any
further attention

providing
the
original push
rod
assem-

bly remains
in the
original unit.

If
a
check
of the
push
rod
adjust-

ment
is
necessary,
the
push
rod
length

may
be
verified with
a
push
rod
length

gauge
and
measured with
the
engine

running
to
apply vacuum
to the
boost-

er (Fig.
7).

The push
rod
length verification
and

adjustment
of
Midland-Ross power

brake booster assemblies must
be

done according
to the
following proce-

dure:

REAR WHEEL ADJUSTING NUT

CABLES

EQUALIZER

SPRING

CABLE ASSEMBLY H1632-A

FIG. 6—Parking Brake Linkage

Adjustment—Lincoln Continental

FIG. 5—Checking Parking Brake Breakaway Torque
#16
U.J

\

0.980"

0.995"

FIG. 7—Push

Dimensions
>.S. GAUGE SHEET

i

1
STEEL

H1087-E

Rod Gaugeprocarmanuals.com

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

02-02-01
Brake System

02-02-01

Part 2-2 Brake
System

COMPONENT INDEX

ANTI SKID CONTROL SYSTEM

Description

ANTI SKID CONTROL ACTUATOR

Removal and Installation

ANTI SKID CONTROL MODULE

Removal and Installation

ANTI SKID CONTROL SENSOR

Removal and Installation

BRAKE BACKING PLATE (DRUM)

Removal and Installation

BRAKE BOOSTER

Cleaning and Inspection
-
See Part 2-1

Description

Removal and Installation

BRAKE DRUM

Cleaning and Inspection
-
See Part 2-1

Refinishing

Removal and Installation (Front)

Removal and Installation (Rear)

BRAKE PEDAL

Removal and Installation

BRAKE SHOES (DRUM)

Adjustments

Relining

Removal and Installation

DISC BRAKE

Description

DISC BRAKE CALIPER

Cleaning and Inspection

Disassembly and Overhaul

Removal and Installation

DISC BRAKE ROTOR AND HUB

Cleaning and Inspection
—
See Part 2-1

Refinishing

Removal and Installation

DISC BRAKE ROTOR SPLASH SHIELD

Removal and Installation

DISC BRAKE SERVICE PRECAUTIONS

—
See Part 2-1
MODEL APPLICATION
All
Models

02-16

02-06

02-24

02-39

02-09

02-09

02-07

02-39

02-09

02-03

02-39

02-19

02-19
Ford
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Mercury
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Meteor
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Cougar
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Fairlane
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Falcon
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Montego
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Mustang
N/A

N/A

N/A

N/A

02-09

02-25

02-41

02-41

02-16
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A

02-27

02-42

02-41

02-17
Thunderbird
02-07

02-36

02-38

02-38

N/A

02-26

04-41

02-41

02-16
Continental-
Mark
III
02-07

02-36

02-38

02-38

N/A

02-26

02-41

02-41

02-16

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

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