trans FORD MUSTANG 1969 Volume One Chassis
[x] Cancel search | Manufacturer: FORD, Model Year: 1969, Model line: MUSTANG, Model: FORD MUSTANG 1969Pages: 413, PDF Size: 75.81 MB
Page 5 of 413
01-01-01
01-01-01
1
I 9Y82A848000
|
Y89A848000
rMMUNTrNUMBW
I 53A
A IA I8H 34 4
^J MODEL YEAR CODE
2)
ASSEMBLY PLANT CODE
5)
BODY SERIAL CODE
T)
ENGINE CODE
T)
CONSECUTIVE UNIT
NO.
T)
BODY TYPE CODE
(7)
COLOR CODE
0 TRIM CODE
® DATE CODE
(JO) DISTRICT-SPEC. EQUIP. CODE
(lT) REAR AXLE CODE
(12) TRANSMISSION CODE
W1001-A
Fig.
1—Warranty
Plates—Passenger Cars
9Y83NI0000I
Fig. 2—Typical Vehicle Identification Number
(VIN) Tab
W
1002-Aprocarmanuals.com
Page 6 of 413
01-01-02
Vehicle Identification
01-01-02
VEHICLE WARRANTY NUMBER
The vehicle warranty number is the first line of numbers and
letters appearing on the Warranty Plates (Fig. 1). The Warranty
Plate is riveted to the left front door lock face panel. The first
number indicates the model year. The letter following the model
year number indicates the manufacturing assembly plant. The next
two numbers designate the Body Serial Code followed by a letter
expressing the Engine Code. The group of six digits remaining on
the first line indicate the Consecutive Unit Number.
VEHICLE DATA
The vehicle data appears on the second or lower line on the
Warranty Plate. The first two numbers and a letter identify the
Body Style. A letter or a number appears next indicating the
Exterior Paint Color followed by a number-letter combination
designating the Interior Trim. To the right of this code appears the
Date Code indicating the date the car was manufactured. A two-
digit number next designates the district in which the car was
ordered and may appear in conjunction with a Domestic Special
Order or Foreign Special Order number when applicable. The final
two spaces indicate the Rear Axle Ratio (numbers for regular axles,
letters for locking-types) and the Transmission type (numbers for
manual,
letters for automatic).
OFFICIAL VEHICLE IDENTIFICATION NUMBER
The official Vehicle Identification Number (VIN) for title and
registration purposes is stamped on an aluminum tab that is riveted
to the instrument panel close to the windshield on the driver's side
of the car and is visible from outside (Fig. 2).
MODEL YEAR CODE
The number 9 designates 1969.
ASSEMBLY PLANT CODES
COUGAR
Code
Letter
Code
Letter
A
B
C
D
E
F
G
H
J
K
Atlanta
L
Oakville (Canada)
N
Ontario Truck
P
Dallas
R
.,
Mahwah
S
Dearborn
T
Chicago
U
Lorain
W
Los Angeles
X
Kansas City
Y
Z
Michigan Truck
Norfolk
Twin Cities
San Jose
.
(Pilot). ...Allen Park
Metuchen
Louisville
Wayne
St. Thomas
Wixom
St. Louis
BODY SERIAL AND STYLE CODES
The two-digit numeral which follows the assembly plant code
identifies the body series. This two-digit number is used in con-
junction with the Body Style Code, in the Vehicle Data, which
consists of a two-digit number with a letter suffix. The following
chart lists the Body Serial Codes, Body Style Codes and the model.
LINCOLN CONTINENTAL
Body Body
Serial Style
Code Code Body Type
82
53A
4-Door Sedan
80
65A
2-Door
Hardtop
CONTINENTAL MARK
III
Body Body
Serial Style
Code Code Body Type
89
65A
2-Door
Hardtop
Body
Serial
Code
91
92
93
94
91
Body
Style
Code
65A
76A
65B
76B
65C
® Bench Seat
MERCURY
Body
Serial
Code
44
46
48
45
40
41
42
54
56
58
63
66
68
65
63
66
68
60
61
72
72
74
74
76
76
Body
Style
Code
54A
65A
57A
76A
53M
65M
57M
54C
65B
57B
53F
65F
57 F
76F
53C
65C
57C
63G
63H
71B
71C
71F
71G
71E
71A
©Bench Seat
Body
Type
2-Door
Hardtop©
Convertible©
2-Door
Hardtop©
Convertible®
2-Door
Hardtop®
Model
Standard
XR-7 Luxury
Standard
©Split Bench ©Bucket Seats
Body Type
4-Door Sedan©
2-Door
Hardtop-Formal®
4-Door Hardtop®
Convertible®
CANADA ONLY
4-Door Hardtop Sedan®
2-Door
Hardtop-Formal®
4-Door Hardtop®
4-Door Sedan®
2-Door
Hardtop-Formal®
4-Door Hardtop®
4-Door Hardtop Sedan®©
2-Door
Hardtop-Formal®©
4-Door Hardtop®®
Convertible®®
4-Door Hardtop Sedan©
2-Door
Hardtop-Formal©
4-Door Hardtop©
Model
Monterey
Marquis
Monterey-Custom
Marquis
Brougham (Option)
2-Door
Hardtop (Tunnel Roof)®© Marauder
2-Door
Hardtop (Tunnel Roof)®®©
4-Door 2 Seat®
4-Door 3 Seat (Side Facing)®
4-Door
2
Seat®
4-Door 3 Seat (Side Facing)®
4-Door 2 Seat®©
4-Door 3 Seat (Side Facing)®©
Monterey Wagoi
Monterey-Custom Wagon
Marquis Colony Park
©Split Bench ©Bucket Seats
METEOR (CANADA)
Body
Serial
Code
20
21
23
Body
Style
Code
54A
54B
65B
Body Type
4-Door Sedan®
4-Door Sedan®
2-Door
Hardtop-Formal®
Model
Rideau
Rideau 500
30
54C
4-Door Sedan®
35
65C
2-Door
Hardtop-Formal®
35
65E
2-Door
Hardtop-Formal{5-33)®®
33
57C
4-Door Hardtop®
34
76C
Convertible®
34
76E
Convertible (S-33)®®
Montcalm
24
65F
2-Door
Hardtop-Formal®©
27
57F
4-Door Hardtop®®
LeMoyne
28
71B
Rideau 500-6 Passenger®
29
71C
Rideau 500-Dual Face Rear®
38
71E
Mo ntcalm-6 Passenger®
39
71A
Montcalm-Dual Face Rear®
Station Wagons.
©Bench Seat ©Splite Bench ©Bucket Seatsprocarmanuals.com
Page 8 of 413
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
Page 11 of 413
01-01-07
Vehicle Identification
01-01-07
DATE CODES
A number signifying the date precedes the month code letter. A
second-year code letter will be used if the model exceeds 12 months.
Month
Code
First Year
Code
Second Year
January
February
March
April
May
June
July
August
September
October
November
December
....A..
...B..
...C.
...D..
...E..
...
F..
...
G.
...H.
...J..
..
K.
. ...L.
...M.
DISTRICT CODES (DSO)
Units built on a Domestic Special Order, Foreign Special Order,
or other special orders will have the complete order number in
this space. Also to appear in this space is the two-digit code number
of the District which ordered the unit. If the unit is a regular
production unit, only the District code number will appear.
FORD
Code
District
Code
District
11...
13
...
15...
16...
17...
21...
22
...
24...
25...
28...
32....
33...
35...
37...
38....
41...
43...
44...
46....
47...
Boston
...New York
Newark
...Philadelphia
Washington
Atlanta
Charlotte
...Jacksonville
Richmond
. ...Louisville
. ...Cleveland
.... Detroit
Lansing
...Buffalo
... .Pittsburgh
Chicago
Milwaukee
Twin Cities
...Indianapolis
Cincinnati
51
53
54
55
56
61
62
63
64
65
71
72
73
74
75
83
84
85
89
90's
..
... Denver
.. .Kansas City
.. Omaha
...St. Louis
.. Davenport
.. Dallas
... Houston
.. Memphis
.. New Orleans
.. .Oklahoma City
... Los Angeles
...San Jose
...Salt Lake City
...Seattle
.. .Phoenix
.. Government
... Home Office Reserve
.. American Red Cross
...Transportation Services
...Export
LINCOLN-MERCURY
Code
District
Code
District
11
15
16
17
21
22
23
26
31
32
33
Boston
New York
Philadelphia
Washington
Altanta
Dallas
Jacksonville
Memphis
Buffalo
Cincinnati
Cleveland
34
41
42
46
51
52
53
54
84
90's...
... Detroit
.. Chicago
..
St.
Louis
... Twin Cities
Denver
Los Angeles
Oakland
Seattle
Home Office Reserve
Export
FORD
OF
CANADA
Code
District
Code
District
Bl
B2
B3
II thru
17..
Central
Eastern
Atlantic
Export
B4.
B6.
B7.
Midwestern
Western
. Pacific
Note:
Canadian Lincoln-Mercury units use prefix
"A" in
place of«"B".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 14 of 413
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
Page 15 of 413
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
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 24 of 413
02-02-05
Brake System
02-02-05
piston seals are positioned in grooves
in the cylinder bores and are used to
provide hydraulic sealing between the
cylinders and pistons (Fig. 7).
The cylinders are connected hydrau-
lically by means of internal passages
in the caliper housings and an external
transfer tube between the two halves
of the caliper assembly. One bleeder
screw and fluid inlet fitting is provided
on each caliper assembly.
The shoe and lining assemblies are
located in between parallel machined
abutments within the caliper, and are
supported radially by tabs on the
o'uter ends of the shoe assemblies (Fig.
46).
The shoes slide axially in the cali-
per abutments by means of the tabs
which ride on machined ledges (bridg-
es) when hydraulic pressure is applied
to the piston (Fig. 6). A shoe and lin-
ing assembly consists of friction mate-
rial riveted to a metal plate called the
shoe.
It is replaced as a unit. Clips are
attached to the top of the caliper to
retain the shoe and lining assemblies.
The caliper assembly is mounted on
the front wheel spindle to the rear of
the wheel vertical centerline.
ROTOR
The cast iron disc is of the ventilat-
ed rotor-type incorporating forty fins
and is attached to, and rotates with
the wheel hub. A splash shield bolted
to the spindle is used primarily to pre-
vent road contaminants from contact-
ing the inboard rotor and lining sur-
faces.
The wheel provides protection
for the outboard surface of the rotor.
DRUM BRAKE
The drum brake system employs
single anchor, internal expanding ancj
self adjusting brake assemblies.
The self-adjusting brake mechanism
consists of a cable, cable guide, ad-
justing lever, adjusting screw assem-
bly, and adjuster spring (Fig. 8). The
cable is hooked over the anchor pin at
the top and is connected to the lever
at the bottom. The cable is routed
along the webb of the secondary brake
shoe by means of the cable guide. The
adjuster spring is hooked to the pri-
mary brake shoe and to the lever. The
automatic adjuster operates only when
the brakes are applied while the vehi-
cle is moving rearward and only when
the secondary shoe is free to move
toward the drum beyond a predeter-
mined point.
CALIPER
HOUSING
PISTON
SHOE
LINING
PISTON SEAL
FIG. 5—Floating Caliper Assembly—Sectional View
CALIPER
TO
ROTOR
CLEARANCE
CALIPER
HOUSING
PISTON
SHOE
LINING
PISTON SEAL
H 1568-B
TRANSFER
TUBE
PISTON DUST BOOT
RETAINING
GROVE
CALIPER
DUST
BOOT
RETAINER
H 1648-A
FIG.
6—Fixed
Caliper Assembly—Sectional View
PISTON
PISTON SEAL
RELAXED
CALIPER
HOUSING
BRAKES APPLIED
FIG. 7—Function of Piston Seal
BRAKES RELEASED
H1569-Bprocarmanuals.com
Page 26 of 413
02-02-07
Brake System
02-02-07
ANTI-SKID CONTROL SYSTEM
RELEASE PAWL CAM PIN
RELEASE PAWL CAM LEVER
RELEASE CABLE
H
1636-
A
FIG. 10—Parking Brake Control Assembly
With Manual Release—Typical
power unit with mounting bracket is
riveted to the control assembly. The
vacuum actuated piston within the
unit is connected by a rod to the
upper end of the release lever (Fig. 9).
The lower end of the release lever ex-
tends out for alternate manual release
in the event of vacuum power failure
or for optional manual release at any
time.
Hoses connect the power unit and
the engine manifold to a vacuum re-
lease valve in the transmission neutral
safety switch.
The anti-skid control system con-
sists of three major components (Fig.
39).
Mechanically driven electromag-
netic sensors at each rear wheel; an
electronic control module mounted
under the glove box; a vacuum pow-
ered actuator attached to a bracket on
the inside of the right front frame rail
under the toe board.
The sensors consist of steel rings
having teeth on their outer diameters,
pressed on each axle shaft just out-
board of the wheel bearing. The teeth
rotate past corresponding teeth on the
inside diameter of stationary steel
rings mounted in the bearing retain-
ers.
Also mounted in the retainers, are
ring-shaped permanent magnets and
coils of wire. Two wires from each
sensor connect the sensors to the con-
trol module.
The control module consists of solid
state electronic components sealed in
a container. It is connected to the sen-
sors and to a solenoid on the actuator.
The actuator is similar to a vacuum
brake booster and consists of three
parts.
A chamber divided by a vacuum
suspended diaphragm; a hydraulic cyl-
inder connected to the diaphragm; and
a solenoid connected electrically to the
control module.
IN-VEHICLE ADJUSTMENTS AND REPAIRS
After any brake service work, ob-
tain a firm brake pedal before moving
the vehicle. Riding the brake pedal
(common on left foot application)
should be avoided when driving the
vehicle.
BRAKE SHOE ADJUSTMENTS—
DRUM BRAKES
The hydraulic drum brakes are
self-adjusting and require a manual
adjustment only after the brake shoes
have been relined, replaced, or when
the length of the adjusting screw has
been changed while performing some
other service operation. The manual
adjustment is performed with the
drums removed, using the tool and the
procedure detailed below.
When adjusting the rear brake
shoes,
check the parking brake cables
for proper adjustment. Make sure that
the equalizer operates freely.
To adjust the brake shoes:
1.
Use Rotunda Tool HRE 8650,
(Fig. 11) to determine the inside diam-
eter of the drum braking surface.
2.
Reverse the tool as shown in Fig.
11 and adjust the brake shoe diameter
to fit the gauge. Hold the automatic
adjusting lever out of engagement
while rotating the adjusting screw, to
prevent burring the screw slots. Make
sure the adjusting screw rotates freely.
If necessary, lubricate the adjusting
screw threads with a thin, uniform
coating of MIC-100-A.
3.
Rotate Tool HRE 8650 around
the brake shoes to be sure of the set-
ting.
4.
Apply a small quantity of high
temperature grease to the points
where the shoes contact the backing
plate, being careful not to get the lu-
bricant on the linings.
5. Install the drums. Install Tinner-
man nuts and tighten securely.
6. Install the wheels on the drums
and tighten the nuts to specification.
7.
Complete the adjustment by
applying the brakes several times with
a minimum of 50 lbs pressure on the
pedal while backing the vehicle. After
each stop the vehicle must be moved
forward.
8. After the brake shoes have been
properly adjusted, check the operation
of the brakes by making several stops
while operating in a forward direction.
WHEEL CYLINDER REPAIR-
DRUM BRAKE
Wheel cylinders should not be di-
sassembled unless they are leaking or
unless new cups and boots are to be
installed. It is not necessary to remove
the brake cylinder from the backing
plate to disassemble, inspect, or hone
and overhaul the cylinder. Removal is
necessary only when the cylinder is
damaged or scored beyond repair.procarmanuals.com