Manual 12672416

Manual 12672416
GROUP INDEX
1969
CAR
SHOP
MANUAL
VEHICLE IDENTIFICATION
BRAKES
SUSPENSION, STEERING WHEELS AND TIRES
REAR AXLE
MANUAL SHIFT TRANSMISSION
AUTOMATIC TRANSMISSION
WHEELS and TIRES, SUSPENSION, STEERING, BRAKES,
CLUTCH and TRANSMISSION, REAR AXLE
M FIVE
FIRST PRINTING-NOVEMBER, 1968
© 1968 FORD MOTOR COMPANY, DEARBORN, MICHIGAN
4
DRIVE SHAFT AND CLUTCH
VOLUME ONE
CHASSIS
SERVICE PUBLICATIONS
2
SPECIFICATIONS AND SPECIAL SERVICE TOOLS
AT END OF EACH GROUP
6
Copyright © 2006, Forel Publishing Company, LLC, Woodbridge, Virginia
All Rights Reserved. No part of this book may be used or reproduced in any manner
whatsoever without written permission of Forel Publishing Company, LLC. For
information write to Forel Publishing Company, LLC, 3999 Peregrine Ridge Ct.,
Woodbridge, VA 22192
1969 Ford Car Shop Manual
ISBN: 0-9673211-6-6
EAN: 978-0-9673211-6-5
Forel Publishing Company, LLC
3999 Peregrine Ridge Ct.
Woodbridge, VA 22192
Email address: webmaster@ForelPublishing.com
Website: http://www.ForelPublishing.com
Disclaimer
Although every effort was made to ensure the accuracy of this book, no representations or warranties of
any kind are made concerning the accuracy, completeness or suitability of the information, either expressed
or implied. As a result, the information contained within this book should be used as general information
only. The author and Forel Publishing Company, LLC shall have neither liability nor responsibility to any
person or entity with respect to any loss or damage caused, or alleged to be caused, directly or indirectly by
the information contained in this book. Further, the publisher and author are not engaged in rendering legal
or other professional services. If legal, mechanical, electrical, or other expert assistance is required, the
services of a competent professional should be sought.
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 performed, such as frequently performed adjustments and repairs, invehicle 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 specifications or design, without notice and without incurring obligation.
SERVICE PUBLICATIONS
GENERAL INFORMATION
Individual carline shop manuals have been combined in one Car
Shop Manual divided into five volumes for 1969.
The 1969 Car Shop Manual has been organized into general
Groups as in previous shop manuals. All Groups are listed in the Group
index on the first page of each Volume. Groups not contained in a
given Volume are listed with a solid gray background.
To locate the beginning page of any particular Group, first select
the Volume containing that Group. Bend the manual until the black
mark on the first page of the Group can be seen in line with the Group
title on the first page of the Volume.
The first page of each Group lists the material contained in the
Group under Part headings and also lists the beginning page of each
Part.
On the beginning page of each Part, there is a Part index which
lists in detail all information appearing in the Part, the page where
the information is given, and the vehicles to which the information
applies.
All pages carry a six-digit number which indicates the Group,
Part and Page number.
For Example:
Page 03-02-01 indicates
Group 3, Part 2, Page 1
Part Indexes will use only the Part and Page reference numbers.
For Example: Page 03-02-01 will appear in the Part Index as 02-01.
Each Part will start with Page 01.
01-01-02
01-01-02
Vehicle Identification
VEHICLE WARRANTY NUMBER
COUGAR
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.
Body Body
Serial Style
Code Code
Model
Body Type
91
92
65A
76A
2-Door Hardtop©
Convertible©
Standard
93
94
65B
76B
2-Door Hardtop©
Convertible®
XR-7 Luxury
VEHICLE DATA
91
65C
2-Door Hardtop®
Standard
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 twodigit 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).
® Bench Seat
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
Code
Letter
A
B
C
D
E
F
G
H
J
K
Code
Letter
.,
Atlanta
Oakville (Canada)
Ontario Truck
Dallas
Mahwah
Dearborn
Chicago
Lorain
Los Angeles
Kansas City
L
N
P
R
S
T
U
W
X
Y
Z
Michigan Truck
Norfolk
Twin Cities
San Jose
. (Pilot). ...Allen Park
Metuchen
Louisville
Wayne
St. Thomas
Wixom
St. Louis
©Split Bench
©Bucket Seats
MERCURY
Body Body
Serial Style
Code Code
Model
Body Type
Monterey
44
46
48
45
54A
65A
57A
76A
4-Door Sedan©
2-Door Hardtop-Formal®
4-Door Hardtop®
Convertible®
40
41
42
53M
65M
57M
CANADA ONLY
4-Door Hardtop Sedan®
2-Door Hardtop-Formal®
4-Door Hardtop®
54
56
58
54C
65B
57B
4-Door Sedan®
2-Door Hardtop-Formal®
4-Door Hardtop®
Monterey-Custom
63
66
68
65
53F
65F
57 F
76F
4-Door Hardtop Sedan®©
2-Door Hardtop-Formal®©
4-Door Hardtop®®
Convertible®®
Marquis
63
66
68
53C
65C
57C
4-Door Hardtop Sedan©
2-Door Hardtop-Formal©
4-Door Hardtop©
Brougham (Option)
60
61
63G
63H
2-Door Hardtop (Tunnel Roof)®© Marauder
2-Door Hardtop (Tunnel Roof)®®©
72
72
71B
71C
4-Door 2 Seat®
4-Door 3 Seat (Side Facing)®
Monterey Wagoi
74
74
71F
71G
4-Door 2 Seat®
4-Door 3 Seat (Side Facing)®
Monterey-Custom Wagon
76
76
71E
71A
4-Door 2 Seat®©
4-Door 3 Seat (Side Facing)®©
Marquis Colony Park
©Bench Seat
©Split Bench
Marquis
©Bucket Seats
METEOR (CANADA)
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 conjunction 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
82
80
53A
65A
Body Type
4-Door Sedan
2-Door Hardtop
CONTINENTAL MARK III
Body Body
Serial Style
Code Code
89
65A
Body Type
2-Door Hardtop
Body Body
Serial Style
Code Code
Body Type
Model
20
54A
4-Door Sedan®
Rideau
21
23
54B
65B
4-Door Sedan®
2-Door Hardtop-Formal®
Rideau 500
30
35
35
33
34
34
54C
65C
65E
57C
76C
76E
4-Door Sedan®
Montcalm
2-Door Hardtop-Formal®
2-Door Hardtop-Formal{5-33)®®
4-Door Hardtop®
Convertible®
Convertible (S-33)®®
24
27
65F
57F
2-Door Hardtop-Formal®©
4-Door Hardtop®®
LeMoyne
28
29
38
39
71B
71C
71E
71A
Rideau 500-6 Passenger®
Rideau 500-Dual Face Rear®
Mo ntcalm-6 Passenger®
Montcalm-Dual Face Rear®
Station Wagons.
©Bench Seat
©Splite Bench
©Bucket Seats
01-01-03
Vehicle Identification
01-01-03
BODY SERIAL AND STYLE CODES-(continued)
MONTEGO
MUSTANG
Body Body
Serial Style
Code Code
Model
Body Type
02
54A
2-Door Hardtop-formal
(Sports Coupe)®
4-Door Sedan (Sports)®
06
07
54B
65B
4-Door Sedan®
2-Door Hardtop-Formal®
Montego
10
11
12
54D
65D
76D
4-Door Sedan®
2-Door Hardtop-Formal®
Convertible®
Montego MX
11
12
65 E
76B
2-Door Hardtop-Formal©
Convertible®
Montego MX
10
11
54C
65C
4-Door Sedan®
2-Door Hardtop-Formal®
Montego MX Brougham
15
63A
01
15
16
65A
Comet
2-Door Hardtop Fastback®
(GT Appearance Opt.®)
63C 2-Door Hardtop Fastback®
63H 2-Door Hardtop Fastback®
(Sports Appearance Opt.©)
03
08
08
71B
71C
71A
©Bench Seat
Montego®
Montego MX®
Montego MX (Woodgrain)®
©Split Bench
Body Body
Serial Style
Code Code
Body Type
Model
01
02
03
65A
63A
76A
2-Door Hardtop©©
2-Door Fastback©®
Convertible®®
Standard
01
02
03
65B
63B
76B
2-Door Hardtop®®
2-Door Fastback®©
Convertible©®
Luxury
01
65C
2-Door Hardtop®
Standard
01
65D
2-Door Hardtop®
Luxury
01
65E
2-Door Hardtop©
Grand
02
63C
2-Door Fastback®
Machl
©Bench Seat
©Split Bench
©Bucket Seats
©Hi-Back Bucket
Cyclone
Cyclone CJ
Station Wagons-4 Door
FORD
Body Body
Serial Style
Code Code
©Bucket Seats
Model
Body Type
50
51
62E
54 E
2-Door Sedan®
4-Door Sedan®
Custom
52
53
62B
54B
2-Door Sedan®
4-Door Sedan®
Custom 500
54
55
58
56
57
54A 4-Door Sedan®
63B 2-Door Hardtop-Fastback®
65C 2-Door Hardtop-Formal®
57B 4-Door Hardtop®
76A Convertible®
60
61
63C
76B
2-Door Hardtop-Fastback®®
Convertible®©
Ford XL
64
62
66
54C
65A
57F
4-Door Sedan®®
2-Door Hardtop-Formal®®
4-Door Hardtop®©
Ford LTD
70
71
Station Wagons-4 Door
71D Ranchwagon-6 Passenger©
71H Custom 500 Ranchwagon6 Passenger©
71J Custom 500 RanchwagonDual Face Rear©
71B Country Sedan-6 Passenger®
71C Country Sedan-Dual Face Rear®
71E Country Squire—6 Passenger®
71A Country Squire-Dual Face Rear®
THUNDERBIRD
Body Body
Serial Style
Code Code
83
83
84
84
87
87
65A
65C
65B
65D
57B
57C
©Bench Seat
Body Type
2-Door
2-Door
2-Door
2-Door
4-Door
4-Door
Model
Hardtop®
Hardtop®
Landau ®
Landau ®
Landau ©
Landau ®
©Split Bench
©Bucket Seats
©Blind Quarter Roof
72
73
74
75
76
FALCON
Body Body
Serial Style
Code Code
©Bench Seat
Body Type
Model
10
11
62A
54A
2-Door Sedan®
4-Door Sedan®
Standard
20
22
21
62B
62C
54B
2-Door Sedan®
2-Door Sports Coupe®
4-Door Sedan©
Futura
12
23
71A
71B
Standard©
Futura©
Station Wagons
- 4 Door
©Bench Seat
©Split Bench
©Bucket Seat
©Split Bench
Galaxie 500
©Bucket Seats
01-01-04
01-01-04
Vehicle Identification
BODY SERIAL AND STYLE CODES-(continued)
ENGINE CODES
FAIRLANE
Type
Code
Body Body
Serial Style
Code Code
Body Type
Model
30
31
65A
54A
2-Door Hardtop-formal®
4-Door Sedan®
Fairlane
34
35
33
36
54B
63B
65B
76B
4-Door Sedan®
2-Door Hardtop—Fastback®
2-Door Hardtop-formal®
Convertible®
Fairlane 500
35
33
36
63E
65E
76E
2-Door Hardtop—Fastback©
2-Door Hardtop-Formal©
Convertible®
Fairlane 500
40
41
65C
54C
2-Door Hardtop-Formal®
4-Door Sedan®
Torino
r
t
U
T
6Cyl.
6Cyl.
2
6 Cyl.®
L
3
V
5 .
6 Cyl.
6 Cyl CD
6 Cyl."
6 Cyl CD
B
.6 Cyl.
E
F
6
D
H
M
Y
X
S
P
6 Cyl.
8 Cyl.
8 Cyl.®
8 Cyl.
8 Cyl.
8 Cyl.
8 Cyl.
8 Cyl.©
8 Cyl.©
8 Cyl.®
8 Cyl.
8 Cyl.®
8 Cyl.
8 Cyl.
8 Cyl.
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)
42
44
43
63F
65F
76F
2-Door Hardtop—FastbackCD
2-Door Hardtop-Formal®
Convertible®
Torino GT
42
44
43
63D
65D
76D
2-Door Hardtop—Fastback®
2-Door Hardtop-Formal®
Convertible®
Torino GT
46
46
45
45
63B
63E
65A
65E
2-Door
2-Door
2-Door
2-Door
Cobra
32
37
38
71D
71B
71E
Fairlane®
Fairlane 500®
Fairlane Torino Squire®
Station Wagons-4 Door
CONSECUTIVE UNIT NUMBER
47
48
66A
66B
Ranchero®
Ranchero 500®
Ranchero
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
48
66B Ranchero 500®
(Opt.)
Ranchero
49
49
66C
66D
Ranchero GT
©Bench Seat
Hardtop-Fastback®
Hardtop-Fastback®
Hardtop-Formal®
Hardtop-formal®
Ranchero®
Ranchero®
©Split Bench
K
N
A
©Low Compression
©High Performance
©Bucket Seats
Reference
Number
Code
Limited-Slip
Ratio
1
2
3
4
J
K
L
M
2.50:1
2.75:1
2.79:1
2.801
5
6
7
8
N
0
P
Q
2.83:1
3.00:1
3.10:1
3.20:1
9
A
R
S
3.25:1
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
5
6
W
U
Y
X
Z
3-Speed Manual
4-Speed Manual-wide ratio (2.78 1st Gear)
4-Speed Manual-close ratio (2.32 1st Gear)
Automatic (C4) (XP-3)
Automatic (C6) (XPL)
Automatic (MX)
Automatic (FMX)
Automatic (C6 Special) (XPL, Special)®
©For Police & trailer towing - Not available with bucket seats
©Improved Performance
EXTERIOR PAINT COLOR CODES
REAR AXLE RATIO CODES
Conventional
©Premium Fuel
©Ram Air Induction
A
B
c
D
E
F
G
H
|
J
K
L
M
N
p
.
.
Q
R
S.
T
.. .
u
v
W
X
Y
z2 .
..
3
4
6.
.
7
8
.
.. 1724-A
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.
Color
.
.
.
.
.
1Black
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 Primer
01-01-05
Vehicle Identification
INTERIOR TRIM CODES
01-01-05
INTERIOR TRIM CODES-(continued)
Code
Trim Schemes
Code
Trim Schemes
1A
1A
IB
IB
IB
Black Vinyl (Cougar, Falcon)
Black Cloth & Vinyl
Med. Blue Cloth/Lt. Blue Vinyl
Med. or Lt. Blue Vinyl
Dk. Blue Cloth & Vinyl
(Lincoln, T-Bird, Mark III, Mercury)
Lt. Blue Cloth & Vinyl
(Ford, Montego, Meteor)
Dk. Red Cloth and Vinyl
Med. Saddle Vinyl (Cougar)
Dk. Ivy Gold Cloth & Vinyl
Lt. Ivy Gold Vinyl (Cougar)
Lt. Aqua Cloth and/or Vinyl
Med. Grey Cloth & Vinyl (Mark III)
Lt. Nugget Gold Vinyl (Cougar-Falcon)
Lt. Nugget Gold Cloth & Vinyl
Black Vinyl
Black Leather & Vinyl (Lincoln)
Black Leather (Mark III)
Dk. or Lt. Blue Vinyl
Dk. Blue Leather & Vinyl (Lincoln)
Dk. Blue Leather (Mark III)
Dk. Red Vinyl
Dk. Red Leather & Vinyl (Lincoln)
Dk. Red Leather (Mark III)
Med. Saddle Vinyl (Cougar)
Med. Saddle Leather & Vinyl (Lincoln)
Med. Saddle Leather (Mark III)
Lt. or Dk. Ivy Gold Vinyl
Dk. Ivy Gold Leather & Vinyl (Lincoln)
Dk. Ivy Gold Leather (Mark III)
Lt. Aqua Vinyl
Lt. Aqua Leather & Vinyl (Lincoln)
Lt. Aqua Leather (Mark III)
Med. Grey Leather (Mark III)
Pastel Parchment w/Black Leather (Mark III)
Whitew/Black Vinyl
White w/Black Leather & Vinyl (Lincoln)
Whitew/Black Leather (Mark III)
Lt. Nugget Gold Vinyl
Lt. Nugget Gold Leather & Vinyl (Lincoln)
Lt. Nugget Gold Leather (Mark III)
Black w/Red Knit and/or Vinyl (Mustang,
Montego)
Black Knit and/or Vinyl
Black Cloth & Vinyl
Black Leather & Vinyl (Lincoln)
5D
5D
5F
5G
5G
5G
5K
5K
5K
5W
5W
5Y
5Y
Dk. Red Knit and/or Vinyl
Dk. Red Leather & Vinyl (Lincoln)
Med. Saddle Leather & Vinyl (Lincoln)
Dk. Ivy Gold Knit and/or Vinyl
Dk. Ivy Gold Cloth & Vinyl
Dk. Ivy Gold Leather & Vinyl (Lincoln)
Lt. Aqua Cloth & Vinyl (Montego)
Lt. Aqua Vinyl
Lt. Aqua Leather & Vinyl (Lincoln)
White w/Black Knit and/or Vinyl
White w/Black Leather & Vinyl (Lincoln)
Lt. Nugget Gold Cloth & Vinyl
Lt. Nugget Gold Knit and/or Vinyl (Mustang,
Fairlane)
Lt. Nugget Gold Leather & Vinyl (Lincoln)
Black Knit and/or Vinyl
Black Cloth & Vinyl (Lincoln)
Black Leathe; & Vinyl (Cougar)
Dk. or Lt. Blue Vinyl
Dk. Blue Leather & Vinyl (Cougar)
Dk. Red Knit and/or Vinyl
Dk.Red Leather & Vinyl (Cougar)
Med. Saddle Leather I Vinyl
Dk. Ivy Gold Vinyl
Dk. Ivy Gold Leather & Vinyl (Cougar)
Lt. Aqua Vinyl
Lt. Aqua Leather & Vinyl (Cougar)
White w/Black Vinyl
Lt. Nugget Gold Vinyl
Lt. Nugget Gold Leather & Vinyl (Cougar)
Black Vinyl
Black Cloth & Vinyl (Fairlane)
Black Leather & Vinyl (Lincoln)
Lt. Blue Vinyl (Cougar, Montego, Ford)
Dk. Blue Cloth & Vinyl
Dk. Blue Leathe; & Vinyl (Lincoln)
Dk. Red Vinyl (Mustang)
Dk. Red Cloth & Vinyl
Dk. Ivy Gold Cloth and/or Vinyl
Dk. Ivy Gold Leather & Vinyl (Lincoln)
Lt. Aqua Cloth & Vinyl
White w/Black Vinyl
White Leather & Vinyl (Lincoln)
Lt. Nugget Gold Cloth & Vinyl
Lt. Nugget Gold Vinyl
(Ford, Meteor, Mustang)
Black Knit and/or Vinyl
Black Leather & Vinyl (T-Bird)
Dk. or Lt. Blue Knit and/or Vinyl
Dk. Red Knit and/or Vinyl
Med. Saddle Knit and/or Vinyl
Dk. Ivy Gold Knit and/or Vinyl
Lt. Aqua Knit and/or Vinyl
White w/Black and/or Vinyl
White w/Black Leather & Vinyl (T-Bird)
Lt. Nugget Gold Knit and/or Vinyl
Black Knit and/or Vinyl
Black Cloth & Vinyl (Ford, Meteor)
Lt. Blue Knit and/or Vinyl
Dk. Blue Cloth & Vinyl (Ford, Meteor)
Dk. Red Knit and/or Vinyl
Dk. Red Cloth & Vinyl (Ford-Meteor)
Dk. Ivy Gold Cloth & Vinyl
Lt. Aqua Cloth & Vinyl
Lt. Nugget Gold Cloth and/or Vinyl
Lt. Nugget Gold Knit and/or Vinyl
White Vinyl With Black (Cougar)
Black Cloth & Vinyl (Lincoln)
White Vinyl With Blue (Cougar)
Lt. Blue Cloth & Vinyl (Lincoln)
White Vinyl With Red (Cougar)
White Vinyl With Ivy Gold (Cougar)
Lt. Ivy Gold Cloth & Vinyl (Lincoln)
White Vinyl With Aqua (Cougar)
Lt. Aqua Cloth & Vinyl (Lincoln)
Lt. Silver Cloth & Vinyl (Lincoln)
Lt. Nugget Gold Cloth & Vinyl (Lincoln)
White Vinyl With Nugget Gold (Cougar)
White Vinyl With Black (Cougar)
Black Vinyl (Fairlane)
White Vinyl With Blue (Cougar)
IB
ID
IF
1G
1G
IK
IP
1Y
1Y
2A
2A
2A
2B
2B
2B
2D
2D
2D
2F
2F
2F
2G
2G
2G
2K
2K
2K
2P
2U
2W
2W
2W
2Y
2Y
2Y
3A
3A
3A
3A
3B
3B
3B
3B
3B
3B
3D
3D
3G
3G
3K
3W
3W
3Y
3Y
4A
4A
4B
4B
4D
4G
4G
4K
4W
4Y
5A
5A
5A
5B
5B
5B
5B
5D
Lt. Blue Knit and/or Vinyl
Lt. or Dk. Blue Cloth & Lt. Blue Vinyl
Lt. Blue Cloth & Vinyl
(Fairlane, Ford, Montego, Meteor)
Med. Blue Cloth & Lt. Blue Vinyl
Dk. Blue Cloth & Vinyl (T-Bird, Mercury)
Dk. Blue Leather & Vinyl (Lincoln)
Dk.Red Cloth & Vinyl
Dk. Red Knit and/or Vinyl
Dk. Ivy Gold Cloth & Vinyl
Dk. Ivy Gold Leather & Vinyl (Lincoln)
Lt. Aqua Cloth & Vinyl
White w/Black Knit and/or Vinyl
Whitew/Black Leather & Vinyl (Lincoln)
Lt. Nugget Gold Cloth & Vinyl
Lt. Nugget Gold Knit and/or Vinyl (T-Bird)
Black Cloth & Vinyl
Black Knit and/or Vinyl
Dk. Blue Vinyl
Dk. or Lt. Blue Vinyl
Dk.Red Vinyl
Dk. Ivy Gold Cloth & Vinyl
Dk. Ivy Gold Vinyl
Lt. Aqua Vinyl
White w/Black Vinyl
Lt. Nugget Gold Knit and/or Vinyl
Black Cloth & Vinyl
Black Knit and/or Vinyl
Black Leather & Vinyl (Lincoln)
Lt. Blue Cloth and/or Vinyl
Lt. Blue Knit and/or Vinyl
Dk. Blue Leather & Vinyl (Lincoln)
Dk. Blue Cloth & Vinyl (Mercury)
Dk.Red Cloth & Vinyl (Montego)
5Y
6A
6A
6A
6B
6B
6D
6D
6F
6G
6G
6K
6K
6W
6Y
6Y
7A
7A
7A
7B
7B
7B
7D
7D
7G
7G
7K
7W
7W
7Y
7Y
8A
8A
8B
8D
8F
8G
8K
8W
8W
8Y
9A
9A
9B
9B
9D
9D
9G
9K
9Y
9Y
AA(1W)
AA
AB(1W)
AB
AD(1W)
AG(1W)
AG
AK (1W)
AK
AL
AY
AY(1W)
BA(2W)
BA
BB(2W)
01-01-06
INTERIOR TRIM CODES-(continued)
Code
BB
BB
BD(2W)
BG(2W)
BG
BK(2W)
BY(2W)
BY
CA
CA
CB
CB
CD
CD
CG
CG
CK
CY
CY
DA
DA(4W)
DA
DB
DB
DB(4W)
DD(4W)
DD
DD
DG
DG
DK
DW
DY
DY
EA
EA
EB
ED
EG
EK
EW
EY
FA
FA(6W)
FB
FB(6W)
FD
FD(6W)
FG
FG(6W)
FK(6W)
FW
FY
FY(6W)
GA
GB
GD
GG
GY
HA
HA(8W)
HA
HB
HB (8W)
HD
HD
HD(8W)
HG
HG(8W)
HK
HK(8W)
HW
HW
01-01-06
Vehicle Identification
Trim Schemes
Lt. Blue Vinyl (Fairlane)
Lt. Blue Leather & Vinyl (Lincoln)
..White Vinyl With Red (Cougar)
White Vinyl With Ivy Gold (Cougar)
Lt. Ivy Gold Leather & Vinyl (Lincoln)
White Vinyl With Aqua (Cougar)
White Vinyl With Lt. Nugget Gold (Cougar)
Lt. Nugget Gold Vinyl (Fairlane)
Black Cloth & Vinyl
Black Vinyl (Montego)
Dk. Blue Cloth & Vinyl
Lt. Blue Vinyl (Montego)
Dk. Red Cloth & Vinyl
Dk. Red Vinyl
Dk. Ivy Gold Cloth & Vinyl
Lt. Ivy Gold Leather & Vinyl (Lincoln)
Lt. Aqua Cloth & Vinyl
Lt. Nugget Gold Cloth & Vinyl
Lt. Nugget Gold Vinyl (Montego)
Black Cloth & Vinyl
White Vinyl With Black (Cougar)
Black Knit and/or Vinyl
Dk. Blue Cloth & Vinyl
Dk. Blue Vinyl (Mercury)
White Vinyl With Blue (Cougar)
White Vinyl With Red (Cougar)
Dk. Red Knit and/or Vinyl
Dk. Red Cloth & Vinyl
Dk. Ivy Gold Vinyl
Dk. Ivy Gold Cloth & Vinyl
Lt. Aqua Cloth & Vinyl
White w/Black Knit and/or Vinyl
Lt. Nugget Gold Cloth & Vinyl
Lt. Nugget Gold Vinyl (Mercury)
Black Knit and/or Vinyl
Black Cloth & Vinyl
Dk. Blue Cloth & Vinyl
Dk. Red Cloth & Vinyl
Dk. Ivy Gold Cloth & Vinyl
Lt. Aqua Cloth & Vinyl
White w/Black Knit and/or Vinyl
Lt. Nugget Gold Cloth & Vinyl
Black Knit and/or Vinyl
White Vinyl With Black (Cougar)
Lt. or Dk. Blue Vinyl
White Vinyl With Blue (Cougar)
Dk. Red Knit and/or Vinyl
White Vinyl With Red (Cougar)
Dk. Ivy Gold Vinyl
White Vinyl With Ivy Gold (Cougar)
White Vinyl With Lt. Aqua (Cougar)
White w/Black Knit and/or Vinyl
Lt. Nugget Gold Vinyl
White Vinyl With Nugget Gold (Cougar)
Black Vinyl
Lt. Blue Vinyl
Dk. Red Vinyl
Dk. Ivy Gold Vinyl
Lt. Nugget Gold Vinyl
Black Knit and/or Vinyl
White Vinyl With Black (Cougar)
Black Leather & Vinyl (Mercury)
Lt. Blue Vinyl
White Vinyl With Blue (Cougar)
Dk. Red Vinyl
Dk. Red Leathe; & Vinyl (Mercury)
White Vinyl With Dk. Red (Cougar)
Dk. Ivy Gold Vinyl
White Vinyl With Ivy Gold (Cougar)
Lt. Aqua Vinyl
White Vinyl With Lt. Aqua (Cougar)
White w/Black Leather & Vinyl (Mercury)
White w/Black Vinyl (Fairlane)
INTERIOR TRIM CODES-(contlnuad)
Code
Trim Schemes
HY(8W)
HY
JA
JB
JG
JW
JY
JY
KA
KA
KA
KB
KB
KB
KD
KG
KG
KL
KW
KY
KY
LA
LA
LB
LB
LD
LE
LG
LW
LW
LY
MA
MB
MD
MW
NA
White Vinyl With Nugget Gold (Cougar)
Lt. Nugget Gold Knit and/or Vinyl
Black Knit and/or Vinyl
Lt. Blue Cloth & Vinyl (Lincoln)
Lt. Ivy Gold Cloth & Vinyl
.....White w/Black Knit and/or Vinyl
Lt. Nugget Gold Knit and/or Vinyl
Lt. Nugget Gold Cloth & Vinyl (Lincoln)
Black Knit and/or Vinyl
Black Cloth & Vinyl (Ford-Mercury-Meteor)
Black Leather & Vinyl (Lincoln)
Dk. Blue Cloth & Vinyl
.....Med. Blue Cloth & Lt. Blue Vinyl (Ford-Montego)
Dk. Blue Leather & Vinyl (Lincoln)
Dk. Red Cloth & Vinyl
Dk. Ivy Gold Leather & Vinyl (Lincoln)
Dk. Ivy Gold Cloth & Vinyl
Lt. Silver Leather & Vinyl (Lincoln)
White W/Black Leather & Vinyl (Lincoln)
Lt. Nugget Gold Knit and/or Vinyl
Lt. Nugget Gold Cloth & Vinyl
Black Knit and/or Vinyl
Black Leather & Vinyl (Lincoln)
Lt. Blue Knit and/or Vinyl
Dk. Blue Leather & Vinyl (Lincoln)
Dk. Red Knit and/or Vinyl
Lt. & Med. Beige Vinyl
Dk. Ivy Gold Leather & Vinyl (Lincoln)
White w/Black Knit and/or Vinyl
White w/Black Leather & Vinyl (Lincoln)
Lt. Nugget Gold Knit and/or Vinyl
Black Vinyl
Lt. Blue Vinyl
Dk Red Vinyl
White w/Black Vinyl
Black Knit and/or Vinyl
NB
NY
PA
PB
PY
QA
)B
JW
RA
RB
RD
RD
RW
RW
RY
SB
SG
TG
VA
VB
VG
VW
VY
WA
WW
WY
YA
YB
YD
YG
YK
YY
ZA
ZB
ZG
Lt. Blue Vinyl
.
Lt. Nugget Gold Knit and/or Vinyl
Black Vinyl
Lt. Blue Vinyl
Lt. Nugget Gold Vinyl
Black Knit and/or Vinyl
Lt Blue Vinyl
White Knit and/or Vinyl
Lt. Nugget Gold Vinyl
Black Knit and/or Vinyl
Black Leather & Vinyl
Lt. Blue Knit and/or Vinyl
Dk. Red Knit and/or Vinyl
Dk. Red Leather & Vinyl
White w/Black Leather & Vinyl
White W/Black Knit and/or Vinyl
Lt. Nugget Gold Knit and/or Vinyl
Lt. Blue Leather & Vinyl (Lincoln)
Lt. Ivy Gold Leather & Vinyl (Lincoln)
Lt. Ivy Gold Leather & Vinyl (Lincoln)
Black Knit and/or Vinyl
Dk Blue Vinyl
Dk. Ivy Gold Vinyl
White w/Black Knit and or Vinyl
Lt. Nugget Gold Vinyl
Black Knit and/or Vinyl
White w/Black Knit and/or Vinyl
Lt. Nugget Gold Knit and/or Vinyl
Black Cloth & Vinyl
Dk. Blue Cloth & Vinyl
Dk. Red Cloth & Vinyl
Dk. Ivy Gold Cloth & Vinyl
Lt. Aqua Cloth & Vinyl
Lt. Nugget Gold Cloth & Vinyl
Black Cloth & Vinyl
Dk. Blue Cloth & Vinyl
Dk. Ivy Gold Cloth & Vinyl
01-01-07
01-01-07
Vehicle Identification
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.
Code
First Year
Month
January
February
March
April
May
June
July
August
September
October
November
December
Code
Second Year
....A..
...B..
...C.
...D..
...E..
. . . F..
. . . G.
...H.
...J..
.. K.
. ...L.
...M.
LINCOLN-MERCURY
Code
District
Code
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...
District
...
..
..
...
Detroit
Chicago
St. Louis
Twin Cities
Denver
Los Angeles
Oakland
Seattle
Home Office Reserve
Export
FORD OF CANADA
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.
Code
District
Code
Bl
B2
B3
Central
Eastern
Atlantic
Export
B4.
B6.
B7.
I I thru 17..
District
Midwestern
Western
. Pacific
Note: Canadian Lincoln-Mercury units use prefix " A " in place of«"B".
FORD
Code
District
Boston
11...
13 . . . . . . N e w York
Newark
15...
1 6 . . . ...Philadelphia
17...
Washington
21...
Atlanta
Charlotte
22 . . .
2 4 . . . ...Jacksonville
Richmond
25...
2 8 . . . . ...Louisville
3 2 . . . . . ...Cleveland
3 3 . . . . . . . Detroit
Lansing
35...
3 7 . . . ...Buffalo
3 8 . . . . . . . .Pittsburgh
Chicago
41...
Milwaukee
43...
Twin Cities
44...
4 6 . . . . ...Indianapolis
47...
Cincinnati
Code
District
. . . Denver
51
.. .Kansas City
53
54
.. Omaha
55
...St. Louis
.. Davenport
56
.. Dallas
61
. . . Houston
62
.. Memphis
63
.. New Orleans
64
65
.. .Oklahoma City
71
. . . Los Angeles
72
...San Jose
...Salt Lake City
73
...Seattle
74
.. .Phoenix
75
.. Government
83
84
. . . Home Office Reserve
85
.. American Red Cross
89
...Transportation Services
90's .. ...Export
Brakes
02-01-02
02*01-02
STEERING WHEEL RIW
CHECKING POINTS
STEERING COLUMNSTEEL MEASURING TAPE
TOEBOARD OR
DASH METAL
VEHICLE
TYPE
PEDAL FREE
HEIGHT-A
PEDAL FREE
HEIGHT-B"
PEDAL
TRAVEL-C
FORD, MERCURY AND METEOR
NON-POWER DRUM
8.09-7.17
3.10
3.27
FORD, MERCURY AND METEOR
POWER DRUM & DISC
6.18-5.99
FORD, MERCURY AND METEOR
NON-POWER DISC
8.65-7.82
2.18
FORD, MERCURY AND METEOR
POLICE POWER DISC
7.58-6.72
3.27
FAIRLANE, MONTEGO AND FALCON
NON-POWER DRUM
8.13-6.91
2.90
FAIRLANE, MONTEGO AND FALCON
POWER DISC
7.25-5.71
2.35
MUSTANG AND COUGAR
NON-POWER DRUM
7.49-6.43
2.58
MUSTANG AND COUGAR
POWER DISC
6.25-5.56
THUNDERBIRD
POWER DISC
5.96-5.04
3.00
MARK III
POWER DISC
5.96-5.04
3.00
LINCOLN CONTINENTAL
POWER DISC
6.50-5.50
2.25
CONTINENTAL
1.75
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
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 specification 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 reverse and forward for a distance of approximately ten feet; then, apply the
brakes sharply and hold the brake
pedal down until the vehicle is completely 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. Repair or replace all worn or damaged
parts and non-functioning adjusters.
Adjust the brake lining outside diameter 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 specifications, check the pedal linkage for
missing or worn bushings, or loose attachments. Bleed the brakes and centralize the differential valve.
POWER BRAKE
FUNCTIONAL TEST
HI525-A
FIG. 2—Brake Pedal Effort Gauge Installed
1. Check the hydraulic brake system 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, depress the pedal, and hold it in the applied position. Start the engine If the
02-01-03
vacuum system is operating, the pedal
will tend to fall away under foot pressure and less pressure will be required
to hold the pedal in the applied position. 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
r e l e a s e lever is activiated. These
checks should indicate whether the
manual parking brake control linkage
is operating properly or requires repair 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 linkage and manual controls operate
properly.
When testing a parking brake vacuum 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
Brakes
02-01-03
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 between two points, trace the hose along
the entire routing to be sure it is not
crossed with another hose and connected 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 connected 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 diaphragm 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 release, 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 accomplished by removing the hose from
each component and attaching it to
the vacuum gauge. Connect two distributor tester vacuum hose adapters
together with a coupling as a connector 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 vacuum hoses from the junction block
unless the junction block is being replaced, as the plastic nipples are thin
and very brittle and damage may result. 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 malfunctions 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 replaced.
Refer to Ford Car and Truck Diagnosis Manual for Testing procedures.
COMMON ADJUSTMENTS AND REPAIRS
PARKING BRAKE LINKAGE
ADJUSTMENT
L.H. REAR WHEEL CABLE - 2 A 8 0 9 >
2A791 (2 REQUIRED)
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 approximately two inches of pedal travel.
3 . R a i s e the vehicle. With the
transmission in neutral, turn the adjusting nut forward against the equalizer (Figs. 3 and 4) until there is 100
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 III
02-01-04
ft-lb breakaway torque. The breakaway 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 position.
5. Depress the parking brake pedal
to the third notch. Under normal conditions, this will hold the vehicle satisfactorily.
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
NUT
EQUALIZER
SPRING-2A651
02-01-04
Brakes
JAM NUT
PARKING
SPRING SEAT-2A616
BRAKE CABLE
AND CONDUIT
ASSEMBLY-2853
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 release lever.
2. Depress the parking brake pedal
1 1/4 inch from its normal released
position.
3. Raise the vehicle with the transmission 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 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 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 position.
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.
POWER BRAKE MASTER
CYLINDER PUSH ROD
ADJUSTMENT
The push rod is provided with an
adjustment screw to maintain the correct 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 assembly remains in the original unit.
If a check of the push rod adjustment 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 booster (Fig. 7).
The push rod length verification and
adjustment of Midland-Ross power
brake booster assemblies must be
done according to the following procedure:
REAR WHEEL ADJUSTING NUT
CABLES
EQUALIZER
SPRING
CABLE ASSEMBLY
Tool-T59L 4204-A,
T65K 4204-A,
T66L-4204-A,
OR
Tool-4421UA
H1632-A
FIG. 6—Parking Brake Linkage
Adjustment—Lincoln Continental
#16 U.J>.S.
\
0.980"
0.995"
GAUGE SHEET STEEL
i
1
H1087-E
E1897-A
FIG. 5—Checking Parking Brake Breakaway Torque
FIG. 7—Push Rod Gauge
Dimensions
02-01-05
Brakes
1. Disconnect the master cylinder
from the booster assembly and secure
away from the booster without disconnecting the brake tubes.
2. Reinstall the air filter assembly
on the booster if it was removed with
the master cylinder (Fig. 8).
3. Install and tighten the master
cylinder retaining nuts to retain the
air filter assembly securely against the
booster body and to seal the booster
bellows against air leaks.
4. Place the gauge against the
master cylinder mounting surface of
the air filter assembly.
5. Adjust the push rod screw to
provide a slight tension against the
inner edge of the adjustment gauge
slot. (Approximately 5 pounds of tension against the push rod is required
to assure that the push rod is firmly
seated in the booster assembly.)
6. Remove the retaining nuts from
the booster master cylinder mounting
studs.
7. Install the master cylinder on the
brake booster and tighten the retaining nuts to the specified torque.
The push rod length verification of
the Bendix power b r a k e booster
assemblies is accomplished as follows:
1. Disconnect the master cylinder
from the booster assembly and secure
away from the booster without disconnecting the brake tubes.
2. Adjust the push rod screw to
provide a slight tension against the
inner edge of the adjustment gauge
slot. (Approximately 5 pounds of ten-
02-01-05
sion against the push rod is required
to assure that the push rod is firmly
seated in the booster assembly.) See
Figure 8.
3. Install the master cylinder on the
brake booster and tighten the retaining nuts to the specified torque.
Do not set up side forces on the
push rod as it may break the valve
plunger.
This is an approximate adjustment
only. To verify the adjustment, look
through the make-up (rear) port of the
master cylinder when installing the
master cylinder to the booster. The
master cylinder piston should not
move more than 0.015 inch as it contacts the push rod. No movement
(exact contact) is ideal.
HYDRAULIC SYSTEM BLEEDING
AND CENTRALIZING OF THE
DIFFERENTIAL VALVE
When any part of the hydraulic system has been disconnected for repair
or replacement, air may enter the system and cause spongy pedal action.
Bleed the hydraulic system after it has
been properly connected, to be sure
that all air is expelled.
MANUAL BLEEDING
The Lincoln Continental hydraulic
brake system is to be bled only with
pressure bleeding equipment.
The primary and secondary (front
MANIFOLD CHECK VALVE-2365 19-25 IN. LB.
and rear) hydraulic brake systems are
individual systems and are bled separately. Bleed the longest line first on
the individual system being serviced.
During the complete bleeding operation, DO NOT allow the reservoir to
run dry. Keep the master cylinder reservoirs filled with Ford Fluid—Extra
Heavy Duty — Part Number C6AZ19542-A (ESA-M6C 25-A). The extra
heavy duty brake fluid is colored blue
for identification purposes. Do not
mix low temperature brake fluids with
the specified fluid during the bleeding
operations. Never re-use brake fluid
which has been drained from the hydraulic systems.
1. If t h e m a s t e r c y l i n d e r is
equipped with a bleed screw, loosen
the bleed screw. Push the brake pedal
down slowly through its full travel.
Close the bleeder fitting and return
the pedal to the fully released position. Repeat this operation until fluid
is free of air bubbles, then tighten the
bleeder screw. Do not use the secondary piston stop screw, located on the
bottom of the master cylinder to bleed
the brake system. Loosening or removing this screw could result in damage to the secondary piston or stop
screw.
2. To bleed the secondary (rear)
brake system, position a suitable 3/8
inch box wrench (Fig. 9) on the bleeder fitting on the brake wheel cylinder.
Attach a rubber drain tube to the
bleeder fitting. The end of the tube
should fit snugly around the bleeder
fitting.
APPROXIMATELY 45°
TIGHTEN RETAINING NUTS
TO SECURE AIR FILTER
AGAINST BOOSTER BODY
AND BELLOWS
H1300-B
ADJUST PUSH ROD SCREW TO
PROVIDE A SLIGHT TENSION
(APPROXIMATELY 5 LBS.)
AGAINST THE GAUGE
. 9—Wrench for Bleeding
Brake Hydraulic System
PUSH ROD GAUGE
PUSH ROD ADJUSTMENT-MIDLAND-ROSS
PUSH ROD ADJUSTMENT-BENDIX
H1589-A
FIG. 8—Brake
Booster Push Rod Measurement
3. Submerge the free end of the
tube in a container partially filled with
clean brake fluid, and loosen the
bleeder fitting approximately 3/4 turn.
4. Push the brake pedal down slowly through its full travel. Close the
bleeder fitting, then return the pedal
to the full-released position. Repeat
this operation until air bubbles cease
to appear at the submerged end of the
bleeder tube.
5. When the fluid is completely free
of air bubbles, close the bleeder fitting
and remove the bleeder tube.
6. Repeat this procedure at the
brake wheel cylinder on the opposite
02-01-06
side. Refill the master cylinder reservoir after each wheel cylinder is bled
and install the master cylinder cover
and gasket. Be sure the diaphragm
type gasket is properly positioned in
the master cylinder cover. When the
bleeding operation is completed, the
fluid level should be filled to within
1/4 inch of the top of the reservoirs.
7. If the primary (front brake) system is to be bled. Repeat steps 2
through 6 at the right front brake caliper or cylinder and ending at the left
front brake caliper or cylinder.
8. On disc brake equipped models
be sure that the front brake pistons
are returned to their normal positions
and that the shoe and lining assemblies are properly seated by depressing
the brake pedal several times until
normal pedal travel is established.
9. Centralize the pressure differential valve. Refer to the Centralizing
the Pressure Differential Valve procedures which follow.
PRESSURE BLEEDING
The Lincoln Continental hydraulic
brake system is to be bled only with
pressure bleeding equipment.
Bleed the longest lines first. The
bleeder tank should contain enough
new Ford Brake Fluid to complete the
bleeding operation. Use Ford Brake
Fluid — Extra Heavy Duty — Part
Number
C6AZ-19542-A
(ESAM6C25-A) or equivalent for all brake
applications. The brake fluid is colored blue for identification purposes.
Do not mix low temperature brake
fluid with the specified brake fluid
during the bleeding operations. Never
re-use brake fluid that has been
drained from the hydraulic system.
The tank should be charged with approximately 10 to 30 pounds of air
pressure. Never exceed 50 pounds
pressure.
1. Clean all dirt from the master
cylinder reservoir cover.
2. Remove the master cylinder reservoir cover and rubber gasket, and
fill the master cylinder reservoir with
the specified brake fluid. Install the
pressure bleeder adapter tool to the
master cylinder, and attach the bleeder tank hose to the fittng on the
adapter.
Master cylinder pressure bleeder
adapter tools can be obtained from
the various manufacturers of pressure
bleeding equipment. Follow the instructions of the manufacturer when
installing the adapter.
3 . If t h e m a s t e r c y l i n d e r is
equipped with a bleed screw, loosen
Brakes
02-01-06
the bleed screw and bleed the master
cylinder until the fluid is free of air
bubbles; then, tighten the bleed screw.
Do not use the secondary piston stop
screw, located on the bottom of the
master cylinder, to bleed the master
cylinder.
4. If the rear wheel cylinders, the
secondary brake system, are to be
bled, position a 3/8 inch box wrench
(Fig. 9) on the bleeder fitting on the
right rear brake wheel cylinder. Attach a bleeder tube to the bleeder fitting. The end of the tube should fit
snugly around the bleeder fitting.
5. Open the valve on the bleeder
tank to admit pressurized brake fluid
to the master cylinder reservoir.
6. Submerge the free end of the
tube in a container partially filled with
clean brake fluid, and loosen the
bleeder fitting.
7. When air bubbles cease to appear in the fluid at the submerged end
of the bleeder tube, close the bleeder
fitting and remove the tube.
8. Repeat steps 3 through 7 at the
left rear wheel cylinder.
9. If the vehicle is equipped with
disc brakes, repeat steps 4 through 7,
starting at the right front disc caliper
and ending at the left front disc caliper.
On Lincoln Continental models the
front wheel and tire assemblies must
be removed to gain access to the
bleeder fittings on the calipers. Also
on Lincoln Continental models the
metering valve release rod must be
pulled outward and held a minimum
of 1/16 inch (Fig. 10) while bleeding
the primary brake system.
10. If the vehicle contains drumtype front brakes and the primary
(front) brake system is to be bled, repeat steps 4 through 7, starting at the
right front wheel cylinder ending at
the left front wheel cylinder.
11. When the bleeding operation is
completed, close the bleeder tank
valve and remove the tank hose from
the adapter fitting.
12. On disc brake equipped vehicles, be sure that the front brake
pistons are returned to their normal
positions and that the shoe and lining
assemblies are properly seated by depressing the brake pedal several times
until normal pedal travel is established.
13. Remove the Pressure Bleeder
Adapter Tool. Fill the master cylinder
reservoirs to within 1/4 inch of the
top. Install the master cylinder cover
and gasket. Be sure the Diaphragm
type gasket is properly positioned in
the master cylinder cover.
14. Centralize the pressure differential valve as follows.
METERING VALVE
BLEEDER RETAINER
SEE
VIEW A
RELEASE ROD
FIG. 10—Disc Brake Metering Valve—Lincoln Continental
HI 644-A
02-01-07
CENTRALIZING THE
PRESSURE DIFFERENTIAL
VALVE
After a failure of the primary (front
brake) or secondary (rear brake) system 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 differential valve and turn off the warning
Brakes
02-01-07
light after a repair operation, a pressure differential or unbalance condition 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 differential 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 centralized position and the brake warning light goes out; then, immediately
tighten the outlet port tube nut.
2. Check the fluid level in the master 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 outlined in Part 2-2, Section 2.
2. On all models except Lincoln
Continental, make thickness measurements with a micrometer across the
thinnest section of the shoe and lining.
If the assembly has worn to a thickness of 0.230-inch (shoe and lining together) 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 lining shows evidence of brake fluid contamination, 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 attaching 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 contact the rotor at a point approximately 1 inch from the outer edge. Rotate
the rotor and take an indicator reading. 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 Continental the minimum limiting dimension from the inboard bearing cup to
the inboard rotor face and the minimum 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
875 MIN
.046 MAX-**
inboard rotor face (dimension B)
and the outboard rotor surface and
the inboard bearing cup (dimension
A), must be observed when removing material from the rotor braking
surfaces.
When the runout check is finished
be sure to adjust the bearings as outlined in Group 3, in order to prevent
bearing failure.
6. Check the rotor for scoring. Minor scores can be removed with a
fine emery cloth. If the rotor is excessively scored, refinish it as outlined 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 caliper 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
.119 MAX.
FORD-MERCURY
METEOR - THUNDERBIRD
1.12 M I N . - ^
H1633-A
?? — 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
1. Grease or any other foreign material must be kept off the caliper assembly, surfaces of the rotor and external surfaces of the hub during service 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 replaced.
3. During removal and installation
of a wheel assembly, exercise care not
to interfere with and damage the cali-
02-01-08
Brakes
BEARING CUP
DIMENSION " B "
0.755 MINIMUM
DIMENSION " A '
0.395 MINIMUM
H1532-B
FIG. 12—Disc Brake Rotor Service
Limits—Lincoln Continental
per splash shield or the bleeder screw
fitting.
4. Front wheel bearing end play is
critical and must be within specifications.
5. Be sure the vehicle is centered on
the hoist before servicing any front
end components, to avoid bending or
damaging the rotor splash shield on
full right or left wheel turns.
6. The proportioning valve should
not be disassembled or adjustments
attempted on it.
7. Riding of the brake pedal (common on left foot applications) should
be avoided during vehicle operation.
8. The wheel and tire must be removed ' separately from the brake
rotor, unlike drum brakes where the
wheel, tire and drum are removed as a
unit.
9. On floating caliper type disc
brakes whenever the caliper is removed the caliper locating pins should
be inspected for wear or damage.
10. On floating caliper type disc
brakes, the caliper assembly must be
removed from the spindle prior to removal of the shoe and lining assemblies.
11. On floating caliper type disc
brakes the calipers must not be interchanged from one side to the other.
When the caliper is installed on its
proper anchor plate and spindle, the
bleeder screw will point to the rear of
the vehicle (Fig. 22). If a caliper is installed on the wrong side of the vehicle, it is not possible to bleed the system properly.
12. Do not attempt to clean or restore oil or grease soaked brake linings. When contaminated linings are
found, brake linings must be replaced
in complete axle sets.
DRUM BRAKES
1. Remove the wheel from the
drum, and remove the drum as outlined in Part 2-2, Section 2.
2. Brush all dust from the backing
plates and interior of the brake
drums.
3. Inspect the brake shoes for excessive lining wear or shoe damage. If
the lining is worn within 1/32 inch of
the rivet heads or if the shoes are
damaged, they must be replaced. Replace any lining that had been contaminated with oil, grease or brake
02-01-08
fluid. Replace lining in axle sets. Prior
to replacement of lining, the drum diameter should be checked to determine if oversize linings must be installed.
4. Check the condition of brake
shoes, retracting springs, hold-down
springs, and drum for signs of overheating. If the shoes have a slight blue
coloring, indicating overheating, replacement of the retracting and hold-.
down springs is strongly recommended.
Overheated springs lose their pull and
could cause the new lining i:o wear
prematurely, if they are not replaced.
5. If the vehicle has 30,000 or more
miles of operation on the brake linings
or signs of overheating are present
when relining brakes, the wheel cylinders should be disassembled and inspected for wear and entrance of dirt
into the cylinder. The cylinder cups
should be replaced, thus avoiding future problems.
6. Inspect all other brake parts and
replace any that are worn or damaged.
7. Inspect the brake drum and, if
necessary, refinish. Refer to Part 2-2,
Section 4 for refinishing.
BRAKE BOOSTER
Check the booster operation as
noted in Part 2-1, Section 1, Power
Brake Functional Test. If the brake
booster is damaged or defective, replace it with a new booster. The brake
booster is serviced only as an assembly.
02-02-01
Brake System
02-02-01
Part 2-2 Brake System
ContinentalMark III
Thunderbird
LincolnContinental
Fairlane
Mustang
Cougar
Montego
Meteor
N/A
N/A
N/A
N/A
N/A
N/A N/A
N/A N/A
02-07 02-07
N/A
N/A
N/A
N/A N/A
N/A N/A
N/A N/A
02-36 02-36
N/A
N/A
N/A
N/A N/A
N/A
N/A
N/A N/A
02-38 02-38
N/A
N/A
N/A
N/A
N/A
N/A
N/A N/A
02-38 02-38
N/A
Falcon
Mercury
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
Ford
COMPONENT INDEX
All Models
MODEL APPLICATION
02-16
02-06
02-24
02-39
02-09 02-09 02-09 02-09 02-09 02-09 02-09 02-09 02-09 N / A
02-09
N/A
N/A
02-25 02-25 02-25 02-25 02-25 02-25 02-25 02-25 02-27 02-26 02-26
02-07
02-39
02-09
02-03
02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-42 04-41 02-41
02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41
02-16 02-16 02-16 02-16 02-16 02-16 02-16 02-16 02-17 02-16 02-16
02-39
02-19
02-19
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.
02-02-02
02-02-02
Brake System
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
ContinentalMark III
Thunderbird
LincolnContinental
Mustang
Montego
Falcon
Fairlane
Cougar
Meteor
Mercury
Ford
COMPONENT INDEX
All Models
MODEL APPLICATION
02-18 02-18 02-18 02-18 02-18 02-18 02-18 02-18 02-18 02-18 02-18
02-05
02-03
02-08
02-08
02-40
02-39
02-19 02-19 02-19 02-20 02-20 02-20 02-20 02-20 N/A N/A N/A
02-21
02-06
02-34 02-34 02-34 N/A N/A N/A N/A N/A N/A 02-34 02-34
02-35 02-35 02-35 N/A N/A N/A N/A N/A N/A 02-35 02-35
02-27 02-27 02-27 02-30 02-27 02-27 02-27 02-30 02-30 02-30 02-30
N/A N/A N/A 02-34 02-34 02-34 02-34 02-34 02-35 N/A N/A
02-35 02-35 02-35 02-36 02-36 02-36 02-36 02-36 02-36 02-35 02-35
02-22
N/A N/A N/A N/A N/A N/A N/A N/A 02-24 N/A N/A
02-23 02-23 02-23 02-23 02-23 02-23 02-23 02-23 02-24 02-24 02-24
02-08
02-07
02-10
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.
02-02-03
02-02-03
Brake System
DESCRIPTION
Disc brakes are available as optional equipment for the front wheels on
Ford, Mercury, Meteor, Fairlane,
Montego, Falcon, Mustang and Cougar models and are standard on Thunderbird, Continental Mark III, and
L i n c o l n C o n t i n e n t a l models. The
dual-master cylinder equipped hydraulic brake system employs single anc h o r , i n t e r n a l expanding and selfadjusting drum brake assemblies on
the rear wheels of vehicles with disc
brakes, and on the front and rear
wheels of all others.
A vacuum booster is used with the
power disc brake system.
DUAL MASTER CYLINDER
BRAKE SYSTEM
The dual-master cylinder brake system has been incorporated in all models to provide increased safety. The
system consists of a dual-master cylinder (Fig. 1), pressure differential valve
assembly and a switch (Fig. 2). The
switch on the differential valve activates a dual-brake warning light, located on the instrument panel.
FLOATING CALIPER—
ALL MODELS EXCEPT
LINCOLN CONTINENTAL
DISC BRAKE
The disc brake consists of a ventilated rotor and caliper assembly. The
caliper used on all models except Lincoln Continental is a single piston
floating caliper (Fig. 3). The caliper
used on Lincoln Continental models is
a four piston fixed caliper (Fig. 4).
A proportioning valve in the rear
hydraulic circuit provides balanced
braking action between front and rear
brakes.
On all models except Lincoln a
pressure impulse valve located at the
primary inlet of the pressure differential valve prevents brake fluid surge
back to the master cylinder reservoir.
On Lincoln Continental models a
metering valve, in the hydraulic line
between the differential valve and the
front wheel disc brakes, prevents the
front brakes from applying until approximately 125 psi is obtained in the
system (Fig. 21). This delaying action
is required to prevent the front brakes
from performing all the braking action on low speed stops and thereby
increasing the rate of lining wear.
The caliper asseml.y is made up of
a floating caliper housing assembly
and an anchor plate. The anchor plate
is bolted to .the wheel spindle arm by
two bolts. The floating caliper is attached to the anchor plate by steel
stabilizers on Ford, Mercury, Meteor,
Thunderbird and Continental Mark
III models and by one stabilizer on
Fairlane, Montego, Falcon, Mustang
and Cougar models. The floating caliper slides on two locating pins which
also attach to the stabilizers. The
floating caliper contains the single cylinder and piston assembly. The cylinder bore contains a piston with a
molded rubber dust boot to seal the
cylinder bore from contamination
(Fig. 5). A square section rubber piston seal is positioned in a groove in
the cylinder bore and is used to provide sealing between the cylinder and
piston (Fig. 7).
The outer brake shoe and lining assembly is longer than the inner assembly, and the shoe and lining
DISC BRAKES
RETURN SPRING
(SECONDARY)
RETAINER
PRIMARY SYSTEM BRAKE
FLUID RESERVOIR
BOOT
PUSH ROD
RESIDUAL \
^
CHECK
\
TUBE SEAT |
VALVE
\
(SECONDARY)
(PRIMARY)
SECONDARY PISTON BRAKE OUTLET
BRAKE OUTLET
ASSEMBLY
PORT
PORT
FIG. I — Dual Master Cylinder—Typical
PRIMARY PISTON
ASSEMBLY
H 1545-A
BRAKE WARNING LAMP SWITCH
BRAKE WARNING LAMP SWITCH
BRAKE WARNING LAMP SWITCH
PLUNGER IN THE ON POSITION
BRAKE WARNING LAMP SWITCH
PLUNGER IN OFF POSITION
PISTON
CONNECTOR
VALVE PISTON HAS MOVED
TO LOW PRESSURE AREA.
WARNING LAMP SWITCH
PLUNGER IS DEPRESSED,
LIGHTING THE BRAKE
WARNING LAMP
LOW PRESSURE SIDE
HIGH PRESSURE SIDE
U
VALVE PISTON IS
CENTRALIZED. PRIMARY
AND SECONDARY SYSTEM
PRESSURES ARE EQUALIZED
DRUM BRAKES
CONNEiCTOR
TJ
BRAKE FLUID
BRAKE WARNING LAMP I
SWITCH PLUNGER IN
ON POSITION
REAR BRAKE INLET
BRAKE WARNING LAMP
SWITCH PLUNGER IN
OFF POSITION
CONNECTOR
FRONT BRAKE
INLET
FRONT BRAKE
OUTLET
VALVE PISTON IS CENTRALIZED.
PRIMARY AND SECONDARY SYSTEM
PRESSURES ARE EQUALIZED
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
\
OUTLET TO
PROPORTIONING VALVE
DISC BRAKES
FIG. 2—Pressure Differential Valve and Brake Warning Light Switch
CALIPER ASSEMBLY
BLEEDER
SCREW
EXTERNAL
TRANSFERTU3E
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 friction material bonded to a metal plate
called the shoe. It is replaced as a
unit.
FIXED CALIPER
LINCOLN CONTINENTAL
H1567-B
FIG. 3—Disc Brake AssemblyFloating Caliper—All Models
Except Lincoln Continental
HUB
AND
ROTOR
ASSEMBLY
H 1647-A
FIG. 4—Disc Brake Assembly—
Fixed Caliper—Lincoln
Continental
The caliper assembly is bolted directly 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 contamination (Fig. 6). Square-section rubber
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 hydraulically 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 caliper abutments by means of the tabs
which ride on machined ledges (bridges) when hydraulic pressure is applied
to the piston (Fig. 6). A shoe and lining assembly consists of friction material 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.
Brake System
02-02-05
CALIPER HOUSING
PISTON
SHOE
LINING
PISTON SEAL
H 1568-B
FIG. 5—Floating Caliper Assembly—Sectional View
TRANSFER TUBE
PISTON DUST BOOT
RETAINING GROVE
CALIPER TO ROTOR CLEARANCE
CALIPER HOUSING
PISTON
ROTOR
The cast iron disc is of the ventilated 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 prevent road contaminants from contacting the inboard rotor and lining surfaces. 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, adjusting lever, adjusting screw assembly, 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 primary brake shoe and to the lever. The
automatic adjuster operates only when
the brakes are applied while the vehicle is moving rearward and only when
the secondary shoe is free to move
toward the drum beyond a predetermined point.
SHOE
LINING
PISTON SEAL
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-B
19-04-40
Pre-Delivery And Maintenance Procedures
19-04-40
STEERING LINKAGE TORQUE LIMITS (FT-LBS)
Description
Cylinder Mounting Bracket to Underbody
or Frame
Cougar, Fairlane,
Ford,
Falcon, Montego,
Mercury,
Mark I I I ,
Lincoln
Meteor
Thunder bird
Continental
Mustang
(Side Hole)
28-35
-
-
-
(Bottom Hole)
35-43
-
-
-
18-24
-
-
-
3-5
-
-
-
Power Cylinder to Bracket
Power Cylinder to Bracket Lock Nut
Steering Tie Rod End to Spindle Arm
30-40®
35-47®
35-47®
40-55
28-35
28^5
28-35
20-30
Idler Arm Mounting Bracket to Underbody
or Frame
Pitman Arm to Control Valve (Power Steering)
35-47®
Steering Gear to Side Rail or Frame
50-65
Pitman Arm to Sector Shaft
150-225
-
-
-
50-65
50-65
50-65
150-225
150-225
150-200
Idler Arm to Pitman Arm-to-ldler Arm Rod
60-80®
60-80®
60-50®
40-55
Spindle Connecting Rod Clamp to Adjusting Sleeve
10-14
8-13
8-13
19-26
Pitman Arm to Steering Arm-to-ldler Arm Rod
35-47®
35^7®
35-47®
40-55
Steering Spindle Arm Connecting Rod to Arm-to-ldler Arm Rod
30-40®
35-47®
35-47®
40-55
©Torque to low limit of specification; then, tighten the nut to the nearest cotter pin slot and insert the cotter pin.
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