specifications FORD MUSTANG 1969 Volume One Chassis

FOREWORD

The five volumes of
this
shop manual provide the Service Technician

with complete information for the proper servicing of all the 1969 line

of Ford Passenger Cars.

The information is grouped according to the type of work being per-

formed,
such as frequently performed adjustments and repairs, in-

vehicle adjustments, major repair, etc. Specifications, maintenance

information and recommended special tools are
included.

The descriptions and specifications in this manual were in effect at the

time this manual was approved for printing. Ford Motor Company

reserves the right to discontinue models at any time, or change specifi-

cations
or design, without notice and without incurring obligation.

SERVICE PUBLICATIONSprocarmanuals.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

02-02-09
Brake System

02-02-09

REMOVAL AND INSTALLATION

FRONT BRAKE DRUM

REMOVAL

1.
Raise the vehicle until the wheel

and tire clear the floor. Remove the

wheel cover or hub cap, and remove

the wheel and tire from the drum.

2.
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.

3.
Pull the drum off the wheel

spindle.

4.
If the drum will not come off,

pry the rubber cover from the brake

backing plate. Insert a narrow screw-

driver through the slot and disengage

the adjusting lever from the adjusting

screw. While holding the adjusting

lever away from the screw, back off

the adjusting screw with the brake ad-

justing tool (Fig. 13). Be very careful

not to burr, chip, or damage the

notches in the adjusting screw; other-

wise the self-adjusting mechanism will

not function properly.

INSTALLATION

1.
If the drum is being replaced, re-

move the protective coating from the

new drum with carburetor degreaser.

Then, use sandpaper to insure that no

residue remains. Wipe the drum with

a cloth soaked with denatured alcohol.

Install new bearings and grease seal.

Pack the wheel bearings, install the

inner bearing cone and roller assembly

RUBBER PLUG

REMOVED

'MOVE HANDLE UPWARD

TO RETRACT BRAKE SHOES
in the inner cup, and install the new

grease seal see Part 3-5, Section 4.

If the original drum is being in-

stalled, make sure that the grease in

the hub is clean and adequate.

2.
Adjust the brakes and install the

drum assembly as outlined under

Brake Shoe Adjustments in this sec-

tion.

3.
Install the outer wheel bearing,

washer and adjusting nut.

4.
Adjust the wheel bearing as out-

lined in Part 3-7, Section 2, then in-

stall the grease cap. Install the wheel

and hub cap.

REAR BRAKE DRUM

REMOVAL

1.
Raise the vehicle so that the tire

is clear of the floor.

2.
Remove the hub cap and wheel.

Remove the three Tinnerman nuts and

remove the brake drum. If the drum

will not come off, pry the rubber

cover from the backing plate. Insert a

narrow screwdriver through the hole

in the backing plate, and disengage

the adjusting lever from the adjusting

screw. While holding the adjusting

lever away from the adjusting screw,

back off the adjusting screw with the

brake adjusting tool (Fig. 13). Be very

careful not to burr, chip, or damage

the notches in the adjusting screw;

otherwise, the self-adjusting mecha-

nism will not function properly.

INSTALLATION

1.
Remove the protective coating

from a new drum with carburetor de-

greaser; then sand lightly and wipe

with a cloth soaked with denatured al-

cohol.

HI 590-A
H1390-A

FIG. 73—Backing Off Brake

Adjustment
FIG. 14—Retracting Spring

Removal
2.
Adjust the brakes as outlined

under Brake Shoe Adjustments in this

section. Place the drum over the brake

assembly and into position.

3.
Install the three Tinnerman nuts

and tighten securely. Install the wheel

on the axle shaft flange studs against

the drum, and tighten the attaching

nuts to specifications.

BRAKE SHOES AND

ADJUSTING SCREW-

DRUM BRAKES

REMOVAL

1.
With the wheel and drum re-

moved install a clamp over the ends of

the brake cylinder as shown in Fig.

14.

2.
Remove the secondary shoe to

anchor spring with the tool shown in

Fig. 14. With the same tool remove

the primary shoe to anchor spring and

unhook the cable eye from the anchor

pin.

3.
On Ford, Mercury, Meteor,

Thunderbird, Continental Mark III

and Lincoln Continental models, re-

move the shoe guide (anchor pin)

plate (Fig. 8).

4.
Remove the shoe hold-down

springs, shoes, adjusting screw, pivot

nut, socket and automatic adjustment

parts.

5.
On rear brakes, remove the

parking brake link and spring. Dis-

connect the parking brake cable from

the parking brake lever.

*>.
After removing the rear brake

secondary shoe, disassemble the park-

ing brake lever from the shoe by re-

moving the retaining clip and spring

washer (Fig. 8).

INSTALLATION

1.
Before installing the rear brake

shoes,
assemble the parking brake

lever to the secondary shoe and secure

with the spring washer and retaining

clip.

2.
Apply a light coating of high-

temperature grease at the points

where the brake shoes contact the

backing plate.

3.
Position the brake shoes on the

backing plate and secure the assembly

with the hold down springs. On the

rear brake, install the parking brake

link and spring, back off the parkingprocarmanuals.com

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

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

02-02-22
Brake System

02-02-22

BRAKE VACUUM BOOSTER -2005

AUTOMATIC I

TRANSMISSION

HAIR PIN RETAINER

330699-S2

SPACER

STOP LIGHT SWITCH-13480

STANDARD

TRANSMISSION
BUSHING
BUSHING

PUSH ROD

BRAKE PEDAL ASSEMBLY
CLUTCH

PEDAL

ASSEMBLY

H 1557-C

FIG. 30—Master Cylinder Installation—Power Brake-

Fairlane, Montego and Falcon

ASSIST

SPRING BRACKET CLUTCH ASSIST

\ SPRING

BRAKE PEDAL

SHAFT

CLUTCH

PEDAL

CLUTCH PEDAL

TO EQUALIZER ROD

HI643-
A

FIG. 31—Master Cylinder Installation-

Power Brake—Mustang and Cougar
6. Bleed the dual-master cylinder

and the primary and secondary brake

systems. Centralize the pressure dif-

ferential valve. Refer to H>draulic

System Bleeding and Centralizing of

the Differential Valve, Part 2-1, Sec-

tion 2 for the proper procedure.

7.
Operate the brakes several times,

then check for external hydraulic

leaks.

PRESSURE DIFFERENTIAL

VALVE AND PROPORTIONING

VALVE ASSEMBLY

REMOVAL

1.
Disconnect the brake warning

light wire from the pressure differen-

tial valve assembly switch (Figs. 17

thru 21). To prevent damage to the

brake warning switch wire connector,

expand the plastic lugs to allow re-

moval of the shellwire connector from

the switch body.

2.
Loosen the tube nuts connecting

the primary and secondary inlet and

outlet tubes at the pressure differential

valve assembly and remove the tubes.

3.
Remove the screw or screws re-

taining the pressure differential valve

assembly to the chassis and remove

the valve assembly.

4.
On disc brake equipped vehicles,

place the pressure differential valve

assembly and mounting bracket in a

vise.
Loosen the proportioning valve

tube nuts at the differential valve and

at the proportioning valve. Remove

the proportioning valve from the

mounting bracket.

5.
If the differential valve is to be

replaced, remove the brake warning

lamp switch and install the switch in

the new differential valve. The pres-

sure differential valve assembly, the

brake warning lamp switch, and the

proportioning valve are separate units

and each is serviced as a separate as-

sembly only.

INSTALLATION

1.
On disc brake equipped vehicles,

connect the proportioning valve inlet

and outlet tubes to the proportioning

valve and differential valve bodies.

Tighten the tube nuts to specification.

2.
Mount the pressure differential

valve assembly on the chassis and in-

stall the attaching screw or screws.

3.
Connect the primary and second-

ary inlet and outlet tubes to the pres-

sure differential valve assembly and

tighten the tube nuts to specifications.procarmanuals.com

02-02-23
Brake System

02-02-23

BOOSTER ASSEMBLY- 2005

NUT-34444-S7

HOSE 2A047

MASTER CYLINDER

IDENTIFICATION

BRAKE TUBE-2263

BRAKE TUBE -2264

PRESSURE DIFFERENTIAL

VALVE ASSEMBLY-2B257
BRAKE TUBE-2B255

H 15S3-B

FIG. 32—Master Cylinder Installation-

Thunderbird and Continental Mark III

FLUID LEVEL IN MASTER

CYLINDER MUST 3E FULL

TO 1/4 INCH FROM TOP
BUSH

SLEEVE

BOLT

BRAKE SWITCH

13480

NUT (4 REQUIRED) -55768-S2

WASHER"(4 REQUIRED) -44726-S8

BOOSTER

ASSEMBLY 2005

MASTER CYLINDER 2WO

HOSE-2A047

BUSHING DIP IN

S.A.E. 10W MOTOR OIL

BEFORE ASSEMBLY

PEDAL ASSEM6LY-2455

COVER

BRAKE TUBE-2A040

REAR BRAKE TUBE -2B329

PRESSURE DIFFERENTIAL

VALVE ASSEMBLY-2B328

FRONT BRAKE TUBE-2B162

PROPORTIONING VALVE

MASTER CYLINDER

IDENTIFICATION

H 1530-C

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

to the brake warning lamp switch.

Make sure the plastic lugs on the con-

nector hold the connector securely to

the switch.

5. Bleed the brakes and centralize

the pressure differential valve.

PROPORTIONING VALVE

FORD, MERCURY

AND METEOR

On Ford, Mercury and Meteor

models, the proportioning valve must

be removed with the pressure differen-

tial valve. Use the procedure shown

above for replacement of the propor-

tioning valve.

FAIRLANE, MONTEGO

AND FALCON

Removal

Refer to Fig. 18.

1.
Disconnect the two brake lines at

the proportioning valve.

2.
Remove the bolt retaining the

pressure differential valve bracket to

the fender apron.

3.
Lift the proportioning valve

bracket from behind the pressure dif-

ferential valve bracket and remove the

proportioning valve from the vehicle.

Installation

1.
Position the proportioning valve

and bracket to the fender apron with

the proportioning valve bracket be-

tween the pressure differential valve

bracket and the fender apron.

2.
Connect the two brake lines at

the proportioning valve. Do not tight-

en.

3.
Install the bolt retaining the two

valve brackets to the fender apron.

4.
Tighten the two brake line tube

nuts at the proportioning valve to

specifications.

5.
Bleed the brakes and centralize

the pressure differential valve.

MUSTANG AND COUGAR

Removal

Refer to Fig. 19.

1.
Disconnect the two brake lines at

the proportioning valve.

2.
Remove the bolt retaining theprocarmanuals.com

02-02-24
Brake
System

02-02-24

proportioning valve to the fender

apron and remove the proportioning

valve.

Installation

1.
Position the proportioning valve

to the fender apron.

2.
Connect the two brake lines at

the proportioning valve. Do not tight-

en.

3.
Install the bolt retaining the pro-

portioning valve to the fender apron.

4.
Tighten the brake line tube nuts

at the proportioning valve to specifica-

tions.

5.
Bleed the brakes and centralize

pressure differential valve.

THUNDERBIRD AND

CONTINENTAL MARK III

Removal

Refer to Fig. 20.

1.
Disconnect the two hydraulic

brake lines at the master cylinder.

2.
Remove the two nuts retaining

the master cylinder to the booster and

remove the master cylinder for clear-

ance.

3.
Disconnect the two brake lines at

the proportioning valve.

4.
Remove the bolt and nut retain-

ing the proportioning valve to the

pressure differential valve bracket and

remove the proportioning valve assem-

bly.

Installation

1.
Transfer the bracket to the new

proportioning valve.

2.
Position the proportioning valve

assembly to the pressure differential

valve bracket.

3.
Connect the two brake lines to

the proportioning valve. Do not tight-

en.

4.
Install the bolt and nut retaining

the proportioning valve to the pressure

differential valve bracket.

5.
Tighten the two brake line tube

nuts at the proportioning valve to

specifications.

6. Position the master cylinder to

the booster and install the nuts retain-

ing the master cylinder to the booster.

7.
Connect the two brake lines at

the master cylinder and tighten the

tube nuts to specifications.

8. Bleed the brakes and centralize

the pressure differential valve.
LINCOLN CONTINENTAL

Removal

Refer to Fig. 21.

1.
Disconnect the two brake lines at

the proportioning valve.

2.
Loosen the bolt and nut on the

bracket retaining the proportioning

valve to the chassis.

3.
Remove the proportioning valve

from the bracket.

Installation

- 1. Position the proportioning valve

in the bracket and connect the two

brake lines. Do not tighten.

2.
Tighten the bolt and nut on the

bracket.

3.
Tighten the tube nuts on the

brake lines at the proportioning valve

to specifications.

4.
Bleed the brakes and centralize

the pressure differential valve.

PRESSURE METERING VALVE—

LINCOLN CONTINENTAL

REMOVAL

Refer to Fig. 21.

1.
Loosen the tube nuts connecting

the inlet and outlet tubes at the me-

tering valve, and remove the tubes.

2.
Remove the two screws retaining

the metering valve to the frame

crossmember, and remove the me-

tering valve. The metering valve is ser-

viced as an assembly only.

INSTALLATION

1.
Position the metering valve to

the frame crossmember, and install

the retaining screws.

2.
Connect the inlet and outlet

tubes to the metering valve, and tight-

en the tube nuts to specification.

BRAKE BOOSTER

REMOVAL

1.
Working from inside the\ vehicle

below the instrument panel, disconnect

the booster push rod from the brake

pedal assembly. To do this, proceed as

follows:

Disconnect the stop light switch

wires at the connector. Remove the

hairpin retainer. Slide the stop light
switch off from the brake pedal pin

just far enough for the switch outer

hole to clear the pin, and then remove

the switch from the pin and booster

push rod. Be careful not to damage

the switch during removal. Slide the

booster push rod and the nylon wash-

ers and bushing off the brake pedal

pin (Figs. 29 thru 33).

2.
Open the hood and remove the

master cylinder from the booster. Se-

cure it to one side without disturbing

the hydraulic lines. It is not necessary

to disconnect the brake lines, but care

should be taken that the brake lines

are not deformed. Permanent defor-

mation of brake lines can lead to tube

failure.

3.
Disconnect the manifold vacuum

hose or hoses from the booster unit.

4.
Remove the booster-to-dash

panel attaching nuts or bolts (Figs. 29

thru 33). Remove the booster and

bracket assembly from the dash panel,

sliding the push rod link out from the

engine side of the dash panel.

5.
On Fairlane, Montego, and Fal-

con models, remove the push rod link

boot from the dash panel.

INSTALLATION

1.
On Fairlane, Montego and Fal-

con models, install the push rod link

boot in the hole in the dash panel as

shown in Fig. 23. Install the four

spacers on the mounting studs.

2.
Mount the booster and bracket

assembly to the dash panel by insert-

ing the push rod or push rod link in

through the hole and boot in the dash

panel. Install the bracket-to-dash

panel attaching lock nuts or bolts

(Figs.
29 thru 33).

3.
Connect the manifold vacuum

hose or hoses to the booster.

4.
Before installing the master cyl-

inder, check the distance from the

outer end of the booster assembly

push rod to master cylinder surface.

Turn the screw in or out to obtain the

specified length. Refer to Part 2-1,

Section 2, Power Brake Master Cylin-

der Push Rod Adjustment. Install the

master cylinder and torque the attach-

ing nuts to specifications.

5.
Working from inside the vehicle

below the instrument panel, connect

the booster push rod link to the brake

pedal assembly. To do this, proceed as

follows:

Install the inner nylon washer, the

booster push rod, and the bushing on

the brake pedal pin. Position the

switch so that it straddles the push

rod with the switch slot on the pedal

pin and the switch outer hole justprocarmanuals.com

02-02-26
Brake System

02-02-26

14.
Remove the clutch pedal assist

spring.

15.
On non-power brakes, remove

the retainer clip from the clutch and

brake pedal shaft, then remove the

clutch pedal and shaft assembly, the

brake pedal assembly, and the bush-

ings from the pedal support bracket.

On power brakes, remove the retainer

nut from the brake pedal shaft then

remove the pedal shaft, the brake

pedal assembly and the bushings from

the pedal support bracket.

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

bushings in their proper places on the

clutch and brake pedal assemblies.

2.
On non-power brakes, position

the brake pedal to the pedal support

bracket, then install the clutch pedal

and shaft assembly through the sup-

port bracket and brake pedal assem-

bly. On power brakes position the

brake pedal to the pedal support

bracket, then install the pedal shaft

and nut.

3.
Install the clutch pedal assist

spring and pivot the clutch pedal

against its bumper stop. Secure the

pedal to the stop with a small C-

clamp as shown in Figs. 28 and 31.

4.
Position the pedal support

bracket assembly to the dash panel,

and to the steering column retainer

studs.

5.
Align the pedal support bracket

holes with the holes in the dash panel

and install the two attaching sheet

metal screws. On power brakes install

the nuts on the brake booster studs.

6. Install the two cap screws at-

taching the pedal support bracket to

the upper cowl bracket.

7. Install the cap screw attaching

the pedal support bracket to the top

inner cowl bracket (Figs. 28 and 31).

8. Install the inner nylon washer,

the master cylinder push rod, and the

bushing on the brake pedal pin. Posi-

tion the stop light switch so that it

straddles the push rod with the switch

slot on the pedal pin and the switch

outer hole just clearing the pin. Slide

the switch completely onto the pin,

and install the outer nylon washer as

shown in Figs. 28 and 31. Secure

these parts to the pin with the
self-

locking retainer.

9. Connect the stop light switch

wires to the connector.

10.
Connect the clutch pedal-

to-equalizer rod to the clutch pedal

assembly with the bushing and the

spring clip retainer. Apply SAE 10
engine oil to the bushing. Remove the

C-clamp from the clutch pedal.

11.
Working from the engine side

of the dash panel, on non-power

brakes, install the two cap screws at-

taching the pedal support bracket to

the dash panel. Then install the two

screws attaching the master cylinder

to the dash panel. On power brakes

install the cap screws retaining the

brake booster to the dash panel.

12.
Install the steering column.

Refer to Part 3-4, Section 2 for pro-

cedure.

13.
Adjust the clutch pedal free

play (Group 5) to specification, if re-

quired.

14.
Check the Brake Pedal Free

Height and Travel Measurements

(Part 2-1, Section 1).

15.
Connect the ground cable to the

battery.

FAIRLANE, MONTEGO,

FALCON, MUSTANG

AND COUGAR-

AUTOMATIC TRANSMISSION

Removal

1. Disconnect the stop light switch

wires at the connector.

2.
Remove the self-locking pin and

slide the stop light switch off the

brake pedal pin just far enough for

the switch outer hole to clear the pin.

Then lower the switch away from the

pin. Slide the master cylinder or

booster push rod and the nylon wash-

ers and bushing off from the brake

pedal pin (Figs. 27, 28, 30 and 31).

3.
On all vehicles except Mustang

and Cougar with power brakes, re-

move the self-locking pin and washer

from the brake pedal shaft, then re-

move the shaft, the brake pedal as-

sembly and the bushings from the

pedal support bracket. On Mustang

and Cougar vehicles with power

brakes, remove the locknut and bolt

from the pedal. Remove the pedal as-

sembly from the support bracket (Fig.

3).

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

the bushings in their proper places on

the pedal assembly and pedal support

bracket (Figs. 27, 28, 30 and 31).

2.
Position the brake pedal assem-

bly to the support bracket, then install

the pedal shaft or bolt through the

support bracket and brake pedal as-

sembly. Install the retainer or locknut.
3.
Install the inner nylon washer,

the master cylinder or booster push

rod, and the bushing on the brake

pedal pin. Position the switch so that

it straddles the push rod with the

switch slot on the pedal pin, and the

switch outer hole just clearing the pin.

Slide the switch completely onto the

pin, and install the outer nylon washer

as shown in Figs. 27, 28, 30 and 31.

Secure these parts to the pin with the

self-locking pin.

4.
Connect the stop light switch

wires to the connector, and install the

wires in the retaining clip.

Check the Brake Pedal Free Height

and Travel Measurements, Part 2,

Section 1.

THUNDERBIRD
AND

CONTINENTAL MARK
III

Removal

1.
Loosen the booster mounting

nuts.

2.
Disconnect the stop light switch

wires at the connector.

3.
Remove the hairpin retainer.

Slide the stop light switch off from

the brake pedal pin just far enough

for
the
switch outer hole
to
clear
the

pin,
and then lift the switch straight

upward from the pin. Slide the master

cylinder push rod and the nylon wash-

ers and bushing off from the brake

pedal pin (Fig. 32).

4.
Remove the pivot bolt and nut

that holds the pedal to the pedal sup-

port bracket. Remove the brake pedal

assembly from the pedal support

bracket, and remove the bushings.

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

the bushings in their proper places on

the pedal assembly (Fig. 32).

2.
Install the brake pedal assembly

and bushings to the support bracket,

and then install the pivot bolt through

the support bracket and brake pedal

assembly. Install the pivot bolt nut

and torque to specifications.

3.
Install the inner nylon washer,

the master cylinder push rod, and the

bushing on the brake pedal pin. Posi-

tion the switch so that it straddles the

push rod with the switch slot on the

pedal pin and the switch outer hole

just clearing the pin. Slide the switch

completely onto the pin, install the

outer nylon washer as shown in Fig.

32.
Secure these parts to the pin with

the hairpin retainer.procarmanuals.com

02-02-27
Brake System

02-02-27

4.
Connect the stop light switch

wires to the connector, and install the

wires in the retaining clip.

5.
Torque the booster mounting

nuts to specifications.

LINCOLN CONTINENTAL

Removal

1.
Disconnect the battery ground

cable from the battery.

2.
It is necessary to obtain clear-

ance to remove vacuum hoses and the

electrical connector to the temperature

heat control box. Remove the two

screws retaining the relay to the fend-

er and push the relay aside. Discon-

nect the vacuum hoses and connector

at the heat control box.

3.
Working under the instrument

panel, disconnect the vacuum hoses,

wires and retaining clip from the tem-

perature heat control box. Remove the

two screws securing the temperature

control box to the dash panel.

4.
Remove the lower control hous-

ing retaining screws (6). Disconnect

the wire harnesses at the lower control

panel and place the panel aside. Re-

move the wire harness shield. Remove

the wire harness clip. Position the

wire harness aside. Remove the tem-

perature control box and position it

aside.

5.
Remove the hair-pin type retain-

er. Slide the stop light switch off the

brake pedal pin just far enough for

the switch outer hole to clear the pin.

Lift the switch upward from the pin.

Slide the master cylinder push rod,

nylon washers and bushing off the

brake pedal pin.

6. Remove the pivot bolt and nut

that holds the pedal to the pedal sup-

port bracket. Remove the brake pedal

assembly from the support bracket

and remove the bushings.

7.
If required, remove the brake

pedal pad retaining nuts and remove

the brake pedal pad.

Installation

1.
If the brake pedal pad was re-

moved, position the pad on the pedal.

Install the pad retaining nuts and tor-

que them to specification.

2.
Apply SAE 10 engine oil to the

bushings and locate all the bushings in

their proper places on the pedal as-

sembly.

3.
Install the brake pedal assembly

and bushings to the support bracket,

and then install the pivot bolt through
the support bracket and pedal assem-

bly. Install the pivot bolt nut and tor-

que it to specification.

4.
Install the inner nylon washer,the

master cylinder push rod link, and the

bushing on the brake pedal pin. Posi-

tion the switch so that it straddles the

push rod link with the switch slot on

the pedal and the switch outer hole

just clearing the pin. Install the outer

nylon washer as shown in Fig. 33. In-

stall the hair-pin type retainer on the

brake pedal pin.

5.
Connect the stop light switch

wires to the connector, and install the

wires in the retaining clip.

6. Position the wire harness and

clip on the temperature control box

and install the retaining screw. Posi-

tion the temperature control box to

the dash panel and install the two re-

taining bolts.

7.
Connect the vacuum lines and

the electrical connector to the control

box. Position the wire harness to the

control box and install the retaining

clip.

8. Position the wire harness shield

and install two retaining bolts.

9. Connect the wire harnesses to

the lower control panel and install the

retaining screws.

10.
Working within the engine

compartment, connect the wire con-

nector to the temperature heat control

box.

11.
Position the relay to the fender

apron and install the retaining bolts.

12.
Connect the ground cable to the

battery.

13.
Check the brakes and light

switch for proper operation. Close the

hood.

PARKING BRAKE CONTROL

ASSEMBLY

FORD, MERCURY

AND METEOR

Removal

Refer to Fig. 34.

1.
Make sure the parking brake is

fully released.

2.
Remove all tension from the rear

cables by backing off the adjusting nut

from the equalizer.

3.
Remove the roll pin that secures

the release knob to the cable and re-

move the knob.

4.
Remove the nut that secures the

release cable to the instrument panel
and remove the cable from the rear of

the instrument panel.

5.
Remove the two nuts attaching

the control assembly to the dash

panel.

6. Remove the cap screw attaching

the control assembly to the cowl side

bracket.

7.
Disconnect the hose to the park-

ing brake vacuum unit, if so equipped.

8. Remove the front cable assembly

retainer clip from the cable assembly

and disconnect the cable ball from the

control clevis.

9. Remove the control assembly

from the vehicle.

Installation

1.
Position the control assembly in

the vehicle.

2.
Fit the cable assembly through

its mounting hole and install the re-

taining clip. Connect the cable ball to

the control clevis.

3.
Connect the vacuum hose to the

parking brake unit, if so equipped.

4.
Install the attaching cap screw to

the cowl side bracket. Do not tighten.

5.
Install the two control assemb-

ly-to-dash panel nuts. Tighten the nuts

and the cap screw to specifications.

6. Insert the release cable into the

instrument panel and install the re-

taining nut.

7.
Install the release knob on the

cable with the roll pin.

8. Check the operation of the park-

ing brake. Adjust the parking brake

as required.

FAIRLANE, MONTEGO

AND FALCON

Removal

Refer to Fig. 35.

1.
Make sure the parking brake is

completely released.

2.
Remove all tension from the rear

cables by backing off the jam nut and

adjusting nut from the equalizer.

3.
Working inside the vehicle, re-

move the four bolts and one nut re-

taining the left air vent and cable as-

sembly to the dash and instrument

panels. Remove the vent assembly.

4.
Remove the parking brake front

cable ball retaining clip from the clev-

is.

5.
Disconnect the cable ball from

the notch in the brake clevis.

6. Remove the three screws that at-

tach the control assembly to the left

cowl inner side panel.procarmanuals.com