Ford 1966 Thunderbird Shop Manual

1966 FORD
SHOP MA
Copyright © 2009, 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
1966 Ford Thunderbird Shop Manual
EAN: 978-1-60371-016-9
ISBN: 1-60371-016-7
Forel Publishing Company, LLC
3999 Peregrine Ridge Ct.
Woodbridge, VA 22192
Email address: [email protected]
Website: http://www.ForelPublishing.com
This publication contains material that is reproduced and distributed under a license from Ford
Motor Company. No further reproduction or distribution of the Ford Motor Company material is
allowed without the express written permission of Ford Motor Company.
Note from the Editor
This product was created from the original Ford Motor Company’s publication. Every effort has
been made to use the original scanned images, however, due to the condition of the material;
some pages have been modified to remove imperfections.
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
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services of a competent professional should be sought.
GROUP INDEX
CHICLE IDENTIFICATION
Imrnf^k
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DRIVE SHAFT AND CLUTCH
MANUAL SHIFT TRANSMISSION (Not Applicable)
AUTOMATIC TRANSMISSION
ENGINE
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\WL%\mjB/nKmKKMmmmmMm^
mm.
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IGNITION SYSTEM
BB
FUEL SYSTEM
1^
ITS1
121
MM
COOLING SYSTEM
EXHAUST SYSTEM
J^Mj
CHARGING SYSTEM
STARTING SYSTEM
UGHTJNG SYSTEM, HORNS AND INSTRUMENTS
VENTILATING, HEATING AND ACCESSORIES
BODY, DOORS AND WINDOWS
TRIM, SEATS AND CONVERTIBLE TOP
fTTI
haWaaal
MAINTENANCE SCHEDULE
MAINTENANCE OPERATIONS
20
LUBRICATION CHARTS AND SPECIFICATIONS
SCHEMATICS
^J5^)SERVICE
FIRST
PUBLICATIONS
PRINTING
AUGUST,
1965 FORD MOTOR COMPANY.
Reproduced under
SPECIFICATIONS AND SPECIAL SERVICE TOOLS
AT END OF EACH GROUP
1985
DEARBORN, MICHIGAN
License # 5008 from Ford Motor
Company May
-
2000
FOREWORD
This shop
the Service Technician
manual provides
information for the
complete
proper
with
servicing of the
1966 Thunderbird
The information is
work
being
frequently
grouped
such
performed,
according to the type of
as
diagnosis
performed adjustments and repairs,
adjustments,
etc.
overhaul,
mended special
Refer to the
tools
are
Specifications
testing,
and
in-vehicle
recom
and
included.
opposite page
for important
vehicle
identi
fication data.
The descriptions
in
effect at
ing.
specifications
the time this
The Ford Motor
discontinue
or
and
design,
models
at
manual were
manual was approved
Company
any time,
reserves
for
the
print
right
to
or change specifications
without notice and without
^d
in this
SERVICE
incurring obligation,
PUBLICATIONS
1-1
\/ri iif*i p
GROUP
IDENTIFICATION
1
EXTERIOR PAINT COLOR
BODY STYLE
(2 DOOR HARDTOP)
AXLE RATIO CODE
(26TH DAY AUGUST)
\
\
(3.00:1 AXLE
INTERIOR TRIM
SILVER MINK
TRIIVUJ
BODY// COLORJ
63A
DATE CODE
(WHITE)
RATIO)
dso/
U AXLE ILTRANS
'
M.'
21
N
33
26H
(C6 DUAL
RANGE AUTOMATIC)
DETROIT DISTRICT
DATE//
TRANSMISSION CODE
N j
VEHICLE WARRANTY NUMBER
\\OT \pR
TITLE Q
>N PURPOSES
.
,
IEWS MANUFACTURED UNDER UNITED STATES
D
CTOEI&N PATENTS AND PATENT APPLICATIONS
A P\\ODl\VT OF
y
lt^^
MOTOR COMPANY
-\-
MODEL YEAR
(1966)
ASSEMBLY PLANT
(WIXOM)
BODY SERIAL CODE (2-DOOR
CONSECUTIVE UNIT NUMBER
^ENGINE CODE (8 CYL. 390 CID ENGINE)
HARDTOP)
M 1087-D
Fig. 1 -Thunderbird Warranty Plate
Figure 1 illustrates a Thunderbird Warranty plate. The warranty plate is attach
to the rear (lock) face of the left door.
The official Vehicle Identification Number for title and registration purposes is
stamped on the hood support top surface to the right of the hood lock plate
(Fig. 2). Do not use the Vehicle Warranty Number which appears on the war
ranty plate for title or registration purposes.
ed
letter. The next code gives the district in which the
two numbers. The next to the last code is the
Axle Ratio Code and is designated by a number for a conventional axle or a
letter for an Equa-Lock axle. The last code in the vehicle data is the Transmis
sion Code and consists of one number. The charts that
follow, list in detail the
various vehicle data codes.
sists of
two numbers
and a
car was ordered and consists of
VEHICLE WARRANTY NUMBER
The
vehicle
ing
on
warranty number is the second line of numbers and letters appear
the Warranty Plate (Fig. 1). The first number indicates the model year.
The letter following the model year indicates the assembly plant at which the
The
next two numbers designate the Body Serial Code.
Body Serial Code designates the Engine Code. The re
maining numbers indicate the Consecutive Unit Number. Thecharts that follow,
list the various Vehicle Warranty Number codes.
car was manufactured.
M 1088-C
The letter
following
BODY
SERIAL AND STYLE CODES
the
The two-digit numeral which follows the assembly plant code identifies the
body
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
series.
Fig. 2 -Vehicle Identification
Number Location
VEHICLE
DATA
The vehicle data appears in a line across the top of the warranty plate (Fig. 1).
The first two letters and a number identify the Body Style. The following one
of two
or two letters identify the Exterior Paint Color. The next code consisting
interior Trim. The Date Code
numbers, or a letter and a number, identifies the
conthe date the car was manufactured, follows the Trim Code and
showing
body
type.
Body Serial
Body Style
Code
Code
83
81
87
85
63A
63C
63D
76A
Body Type
2-Door Hardtop (Conventional
Roof)
2-Door Hardtop (Blind Quarter
Roof-Painted)
2-Door Landau (Blind Quarter Roof-Vinvh
Convertible
1}
GROUP
12
1-
VEHICLE IDENTIFICATION
EXTERIOR PAINT COLOR CODES
INTERIOR TRIM CODES
Code
Trim Schemes
M-32J
Number
Code
A
B
12
16
21
22
23
24
25
26
27
28
42
46
51
52
53
54
55
56
57
58
62
65
66
ID
40
B2
B3
B4
B6
B7
B8
B9
Gl
G2
G3
G4
G6
G7
G8
G9
K2
K3
K4
K6
K7
K8
K9
L2
L3
L4
L6
L7
L8
L9
PI
P2
P3
P4
P6
P7
P8
P9
Dk. Blue Cloth and Dk. Blue Vinyl
Black Cloth and Black Vinyl
Silver Mink Vinyl
Dk. Blue Vinyl
Burgundy Vinyl
Emberglo Vinyl
Red Vinyl
Black Vinyl
Aqua Vinyl
Ivy Gold Vinyl
Dk. Blue Cloth and Dk. Blue Vinyl
Black Cloth and Black Vinyl
Silver Mink Vinyl
Dk. Blue Vinyl
Burgundy
Emberglo
Red Vinyl
H
K
L
M
N
P
Black Vinyl
Aqua Vinyl
Ivy Gold Vinyl
Dk. Blue Leather
Red Leather
Black Leather
Parchment Cloth and Parchment Vinyl
Parchment Cloth and Parchment Vinyl
Blue and Parchment Vinyl
1624-A
1879-A
2008-A
1070-A
1921 A
1632-A
1915-A
1920-A
1907-A
R
T
U
V
X
Z
1
2
letters for the month are preceded by a numeral to show the day of
the Thunderbird was completed. The second year code letters
to be used if model production exceeds 12 months.
The
code
the
month when
are
First
Model Year
Emberglo and Parchment Vinyl
Blackand Parchment Vinyl
Turquoise and Parchment Vinyl
Gold and Parchment Vinyl
Palomino and Parchment Vinyl
Silver Mink and White Pearl Vinyl
Blue and White Pearl Vinyl
January
February
Burgundy and White Pearl Vinyl
August
Emberglo and White Pearl Vinyl
Black and White and White Pearl Vinyl
Turquoise and White Pearl Vinyl
Gold and White Pearl Vinyl
Palomino and White Pearl Vinyl
Blue and Parchment Vinyl
Burgundy and Parchment Vinyl
Emberglo and Parchment Vinyl
Blackand Parchment Vinyl
Turquoise and Parchment Vinyl
Gold and Parchment Vinyl
Palomino and Parchment Vinyl
Blue and Parchment Leather
Burgundy and Parchment Leather
Emberglo and Parchment Leather
Blackand Parchment Leather
Turquoise and Parchment Leather
Gold and Parchment Leather
Palomino and Parchment Leather
Silver Mink and White Pearl Vinyl
Blue and White Pearl Vinyl
Burgundy and White Pearl Vinyl
Emberglo and White Pearl Vinyl
Black and White and White Pearl Vinyl
Turquoise and White Pearl Vinyl
Gold and White Pearl Vinyl
Palomino and White Pearl Vinyl
September
C6.
3 Speed Dual Range Automatic
Cruise-O-Matic
Yellow
DATE CODES
Month
Type
Ivy
White
Platinum
Med. Palomino Met.
Med. Blue Met.
Dk. Green Met.
Red
Med. Turquoise Met.
Emberglo Met.
Maroon Met.
Med. Sage Gold Met.
Rose Met.
Dk. Turquoise Met.
921-A
Burgundy and Parchment Vinyl
Code
Lt. Blue
Brite Blue Met.
Lt. Beige
Dk. Blue Met.
1910-A
Q
Vinyl
TRANSMISSION CODE
4
E
F
G
Vinyl
Color
Black
Lt. Beige Met.
Med. Silver Mink Met.
1724-A
1911 A
1446-A
1226-A
1905-A
1912-A
1903-A
1917-A
1619-A
Second
Model Year
N
P
A
B
C
D
E
F
G
H
J
K
L
M
March
April
May
June
July
October
November
December
Q
R
S
T
U
V
W
X
Y
Z
DISTRICT CODES (DSO)
Thunderbirds built to a Domestic Special Order, Foreign Special Order, or PreApproved Order have the complete order number recorded in this space. Also
appearing in this space is the two digit code number of the District which or
dered the
unit.
If the
unit
is
regular
production, only the District code number
will appear.
Code
11
12
13
14
15
21
22
23
24
25
26
31
32
33
34
35
36
41
42
43
44
District
Boston
Buffalo
New York
Pittsburgh
Newark
Atlanta
Charlotte
Philadelphia
Jacksonville
Richmond
Washington
Cincinnati
Cleveland
Detroit
Indianapolis
Lansing
Louisville
Chicago
Fargo
Rockford
Twin Cities
Code
45
51
52
53
54
55
61
62
63
64
65
71
72
73
74
81
83
84
85
89
90-99
District
Davenport
Denver
Des Moines
Kansas City
Omaha
St. Louis
Dallas
Houston
Memphis
New Orleans
Oklahoma City
Los Angeles
San Jose
Salt Lake City
Seattle
Canada
Government
Home Office Reseive
American Red Cioss
Transportation Services
Ford
of
Expoit
PART 1-VEHICLE IDENTIFICATION
REAR AXLE RATIO CODE
ASSEMBLY PLANT CODES
Code
Ratio
1
3.00:1
3.20:1
2.80:1
3
6
ENGINE CODES
Code
Z
Q
1-3
Type
8 Cylinder 390 Cubic Inch (4 barrel)
8 Cylinder 428 Cubic Inch (4 barrel)
CONSECUTIVE UNIT NUMBER
The assembly plant, with each model year, begins with
ber 100001 and continues on for each unit built.
consecutive unit num
Code
Assembly
Code
Assembly
Letter
Plant
Letter
Plant
Atlanta
N
p
R
S
T
U
W
Y
A
B
C
D
E
G
H
J
K
L
Oakville Passenger
Ontario Truck
Dallas
Mahwah
Chicago
Lorain
Los Angeles
Kansas City
Michigan Truck
MODEL YEAR
The number 6 designates 1966
Z
Norfolk
Twin Cities
San Jose
Pilot Plant
Metuchen
Louisville
Wayne
Wixom
St. Louis
2-1
GROUP
PART 2-1
GENERAL BRAKE SERVICE
.
2-1
.
PAGE
PART 2-3
PAGE
SPECIFICATIONS
2.22
.
PART 2-2
2-7
BRAKE SYSTEM
PART
2-1
GENERAL BRAKE SERVICE
Section
Page
1 Diagnosis
Section
Preliminary Tests
2-1
Road Test
2-1
Disc Brake Trouble Symptoms and
Possible Causes
Drum Brake Trouble Symptoms and
Possible Causes
2 Common Adjustments and Repairs
Page
2-4
Parking Brake Linkage Adjustment
Power Brake Master Cylinder Push Rod
2-1
Testing
and
2-4
Adjustment
2-4
Hydraulic System Bleeding
3 Cleaning and Inspection
Disc Brakes
Drum Brakes
Booster Unit
2-2
2-3
2-4
2-5
2-6
2-6
2-6
DIAGNOSIS AND TESTING
PRELIMINARY TESTING
brake. Depress the
several
1. Check
master
R103-A
level in the
Rotunda
fluid
the
cylinder,
and
add
Super
Heavy Duty brake
fluid (B7AZ-19542-A) if required.
2. Push the brake
far
it
as
running
and
go
will
or
while
vacuum
travels to a point
pedal
brake
adjustment
system
still.
If the
check
the
the automatic
and
adjusters.
To
tion,
brake
check rear
check
components
installation
the
adjuster opera
shoes and
the adjuster
for binding or improper
follow the procedure
and
Brake Shoe
under
described
justments in Part 2-2, Section 2.
Make
several reverse
brake
ensure uniform adjustment at
Ad
Then, depress
hold it in the
Start the
engine.
the
applied
If the
pedal
in
pedal
position.
is operating, the pedal will tend to fall
under foot pressure
and less
pressure will be required to hold the
pedal in the applied position. If no ac
tion is felt, the vacuum booster system
is not functioning.
stops
the
4. With the engine shut off, ex
haust all vacuum in the system.
Depress the brake pedal and hr'd it in
the applied position. Ifthepc
ually falls away under thi?
the hydraulic system is lea!.
all
tubing,
cylinders,
hoses,
to
rear
adjustment
is
brakes,
a
the automatic
permanent
built-in
feature.
and connections
transmission
engine and
in neutral,
apply the parking
few drops
a
for leaks.
the
cause of
ROAD TEST
The
car should
if the brakes
will
be
preliminary
symptoms
eliminate
tests.
For
the
causes
or
surge,
tirely
locked
open
and
the car
the bleeder
must
screw
long enough
to
of
check
which
check
the
and
are also
for brake
apply the brakes
air
from the lines and
See Hydraulic System Bleed
ing, Section 2. Also, check for leaks
or insufficient fluid.
brakes be
be moved,
each
encountered,
or surge will
remove
car.
the
chatter
feels
tested only
brakes at a speed of 25-30
mph to check for the existence of
the
trouble symptoms listed in Table
1,
with
the exception of brake chatter
and those symptoms resolved in
the
Apply
Chatter
the
road
safely stop the
spongy, bleed the hydraulic system to
of
brake fluid.
the trouble.
lightly
pedal movement
one
of
bleeding operation will release
brakes, but it will not correct the
at
5. Should
3. With the
out
listed in Table 1. To
calipers,
cylinder.
On front disc
let
This
vacuum system
away
If the brake
wheels.
stop the
system.
and
brake
all vacuum
less than 1
from the floor pan,
inch
as
the engine is
is in the
is standing
the car
down
pedal
the
service
times to exhaust
approximately 50
apply
mph.
almost en
to rear brakes only.
For booster
removal
and
installa
tion
procedures, refer to Part 2-2, Sec
tion 3. No service
repairs, other than
adjustment of the push
rod, are made
Replace the
assembly
booster is determined to be
onjhfcrfco-oster.
Avlien the
defective.
GROUP 2
2-2
TABLE 1 Front (Disc) Brake Trouble Symptoms
and
-BRAKES
Possible Causes
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T3
oo
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C
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>
t-
ed
2
H
>
CC
ha
H
>
"5
o
<l>
Piston and Shoe
or Positioned
Air Leak
or
or
Bearing
Lining Assembly
>
o
not
or
Caliper
Excessively
Frozen
Brake
Shoe
out of
Fluid, Oil
or
Lining Worn
and
of
on
Linings
with
Rotor
Increase
or
X
X
cQ
a
CO
8
X
UJ
Caliper
Shoe Hold Down Clips
Improperly
of
Parallel
CQ
Urn
-J
Ua
00
c
12
15
CQ
Ua
X)
CQ
CQ
>
O
O
Z
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Missing
or
X
or
X
Positioned
X
X
X
the Cylinder Bore or on the Piston
Surface
X
X
Bleeder Screw Still Open
Caliper Out
CQ
CKJ
o
X
Brake Pedal
Build-Up in
rt
o
>>
_:
o
3
a.
Scores in the Cylinder Bore
Corrosion
u
CQ
ha
oo
c
(/>
c
Decrease Pedal Effort
and
Riding
>
u
V
X
Excessive Clearance Between Shoe
Between Shoe and Splash Shield
Operator
08
X
Below Specifications
Alignment
Slightly
da
13
X
Loose Caliper Attachment
Need to
V
X
Rotor
Booster Inoperative
Caliper Out
a
>
u
c
U
"O
</>
UJ
c
">
X
Parallel
Grease
"5
X
Seized Pistons
or
o.
X
Improper Booster Push Rod Adjustment
Rotor
Q
i>
c
Properly Seated
Worn Caliper Piston Seal
of
3
<
C
or
Adjustment
Excessive Lateral Run-Out
ii
OQ
a>
X
Insufficient Fluid in System
Loose Wheel
Damaged
and
Cornering
UJ
V
H
Violent
<.
ca
a.
after
O
</>
</>
J
S3
and Lining Knock-back
Rough Road Travel
o
0-
o
Shoe
u
00
3
u
POSSIBLE CAUSES OF TROUBLE
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00
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o
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U
with
Rotor
X
PART 2-1
2 Rear
TABLE
(Drum) Brake
and
-GENERAL
2-3
BRAKE SERVICE
General System Trouble Symptoms
and
Possible Causes
ha
0
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00
C/5
0
(U
c/l
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00
>
rt
i/5
a.
ha
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10
00
>
u.
ca
ha
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CC
ha
O
POSSIBLE CAUSES OF TROUBLE
Mechanical Resistance
Pedal
at
or
Leaks
or
CQ
rt
ha
ca
O
c
H
O
X
rt
-a
u
0T3
<
X
X
X
X
X
T3
0>
00
c
o
a
on
Improperly
of
Adjusted Brake Shoe
Round
Lining Glazed
Oil
Grease
or
or
on
X
X
o
"3
u
x:
"rt
-0
u
Oa
"w
(/I
u
cu
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(/5
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ft.
ha
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0
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X
X
X
X
X
X
X
Worn
Lining
X
"rt
3
0
ca
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0
IS
X)
0
<
ca
ha
z
c
0
0
</)
"rt
X
0
u
rt
UJ
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X
X
ha
X
X
X
X
X
X
X
X
X
X
>-.
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u
CO
J*
'5
z
CC
-n
00
rt
ha
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Loose Front Suspension
Left by Drum
Shoes Sideways
X
X
to Drum Contact
Cracked Drum
a
0
X
Tire Tread Worn
Threads"
0
ha
0
(U
X
X
Operating
Insufficient Shoe-to-Carrier Plate Lubrication
Lining
X
X
Master Cylinder
Self Adjusters Not
0
X
Air in Hydraulic System
Poor
CU
<*-
Drum-Lining Surface
Brake Fluid
Faulty
>
a
<
X
Faulty Brake Cylinder
Dirty
c
>>
a
X
Lining
on
ha
>>
Scored Drum
Dirt
CQ
00
c
un
u
0
s
X
X
X
Loose Carrier Plate
Loose
u
rt
0
X
Faulty Retracting Spring
Drum Out
0
X
Insufficient Fluid
or
0
0
rt
X
Improper Tire Pressure
Distorted
.X
-J
ha
ft.
Shoes
Brake Line Restricted
C9
ha
Q
J
u
c
00
cu
u
-X
Turning
Tool Pulls
X
X
.
X
GROUP 2
24
-BRAKES
COMMON ADJUSTMENTS AND REPAIRS
PARKING BRAKE LINKAGE
ADJUSTMENT
Check
the
the
cables
brake
parking
the brakes are
when
fully
loose,
are
U-CLIP
cables
released.
If
them as
adjust
follows:
1.
the parking brake
down the manual
Fully release
by pushing
pedal
lever.
release
2. Raise the
3. Adjust
against
cable
CABLE HOUSING END
car.
the
lever
equalizer
LEVER-TO-CABLE
SPRING SEAT
ADJUSTING NUT
the cable spring on the pedal
the
dimension shown in
to
CABLE SPRING
Fig. 1.
4. Loosen the adjusting
in front
nut
turns
nut on the
rod, and then turn the lock
equalizer
the
of
equalizer several
EQUALIZER
ROD
forward.
brake
5. Depress
the
parking
1 3/4 inches from its
pedal
EQUALIZER LEVER
CABLES TO
normal
REAR WHEELS
H1307-A
released position.
6. While turning the
in
a
direction,
rearward
justing
drag is felt
7. When
the
wheels
turn the ad
the equalizer until
nut against
a moderate
rear
(Fig.
cables
1).
are
properly
adjusted, tighten the lock nut
the
against
equalizer.
to
shoes
return
and
brake
the
fully
the
to
brake,
that
sure
make
released
the
9. Depress
inches.
pedal
two
conditions, this
parking
Under
brake
normal
satisfactorily hold
will
the car.
brake
parking
then depress the pedal 1/2
and
the
inch. The brakes
the
not
for kinks
rod
push
surface of
be
should
micrometer
of
height
the
provide
between
the
screw
set
gauge
a
to a dimen
0.380 0.995 inch, or with a
in Fig. 2. The
SCREW
a
height
gauge are
the
unit.
providing the
rod,
hold the
with
rod
cross-
or
shorten,
out
to
After
cylinder
cup in
should just
ton
hole
port
a
the
clear
master
This
pis
cylinder
compensating
the unit is in the
when
placing
hydraulic
the
released position.
over
the
of
assembly
to the power section, the
can
few drops
of
be
fully
checked
brake fluid
the
compensating port and ap
plying light air pressure to the output
port of the master cylinder. If air bub
piston
is
port
cup
open.
If the
overlaps the com
will
be
no
flow
through the compensating port.
condition
this
the
ad
exists,
of air
HI 086- A
-Push
Rod Adjustment
If
justment
the
screw should
be turned into
push rod a slight amount or until
the compensating port
is
open.
a
HYDRAULIC SYSTEM BLEEDING
to
When any part of the hydraulic sys
has been disconnected for repair
The
the
tem
ad
or
rod
does
assembly
re-
and
cause
air
FIG. 3-Push Rod Gouge
Dimensions
may
spongy
Bleed the hydraulic
H1087-C
not
attention
replacement,
lines
correct
assembly
Under normal
further
push
to
bles appear, the
FIG. 2
with
and
to the
adjustment screw
any
in
primary
at the time of original
power
push
the
of
pliers and turn the adjustment
screw
by
Push Rod
Gauge
the
end
lengthen.
body
with
gauge as shown
details for making
given in Fig. 3.
milled
relationship
piston
piston.
is
either
#15 OR #16 U.S.S. GAUGE SHEET STEEL
screw
correct
cylinder
master
justment
is designed
booster
to the
the booster
rechecked
depth
from the
screw
adjust
serrated
2-7/8".
adjustment
self-locking
require
mounting
the distance
adjustment
or
cables as required.
ROD ADJUSTMENT
service
unit,
fully
MASTER CYLINDER PUSH
the
assembly is transferred to
the
To
However,
used or the
pensating port, there
do
brakes
rear
binds. Free the
height
another
is
inch.
check the cables
release,
of
rod
rod
drag with
should not
the pedal depressed 1/2
The
push
original unit.
push
new
ADJUSTMENT
10. Release
If
in the
a
of
Brake Adjustments
Parking
when
sion
position.
again,
mains
end
8. Release the parking
check
FIG. 1
get
into the
pedal action.
system after
it has
properly connected to be sure
that all air is expelled from the brake
been
cylinders,
lines.
disc
brake
calipers,
and
PART 2-1
The hydraulic
or
manually
system
with
be bled
can
bleeding
pressure
3. Push
fitting,
With disc brakes, more pumping of
pedal
is required and more
frequent checking of the master
fully-released
cylinder
be
may
while
necessary
bleeding.
Remove the front
in
semblies
bleeder
fittings
wheel and tire as
to
order
gain access
appear
master
with
cylinder
5. Repeat
Rotunda
new
Never
in
filled
should
R103-A
Extra
been drained from the hydraulic
a
gasket
has
installed.
3/8-inch box
fitting
wrench
the right rear
on
(Fig. 4).
cylinder
the bleeder
on
brake
Attach
a
drain tube to the bleeder fitting. The
end
the
of
around
tube
should
fit
cutting
a
seated
on the
master cylinder or
at
se
sealed
leakage
will
3. Position
on
the
brake
bleeding
the
3/8 inch of the top
The diaphragm-type
should
6. Be
that the front brake pis
sure
are
their
to
returned
normal
positions and that the shoe and
assemblies are
7. Before
operation
properly
lining
4. Open the
tank
is
that a firm pedal
obtained.
the
of
end
partially filled
fluid, and loosen
with
container
the
bleeder fitting.
6. When
bubbles
air
in the fluid
to ap
cease
at the submerged end
drain tube,
of the
close the
bleeder fit
and remove the tube.
ting
7. Repeat
in
wheel
front.
cylinder
caliper at each
Refill
front,
right
the
after
reservoir
the
on
procedure
disc
left rear,
order:
left
and
this
cylinder or
cylinder
snugly
cylinder reservoir.
brake
clean
brake
the brakes and be sure
brake fluid
5. Submerge the free
tube in a
bleeder
on the
valve
to admit pressurized
to the master
seated.
the car, check the
driving
of
(Fig. 4). Attach
drain tube to the bleeder fit
ting. The end of the tube should fit
snugly around the bleeder fitting.
The fluid level
completed.
fitting
wheel cylinder
wrench
on the right rear
a rubber
master
each
after
and when
3/8-inch box
a
the bleeder
master
brake
each
is bled.
the bleeder fitting.
APPROXIMATELY
8. When the
Bleed the longest lines first. Never
brake
fluid which has been
drained from the hydraulic
bleeder
The
tank
it
300- A
HI
Bleeder Wrench
-Brake
2. Submerge
the
a container
free
end
of
partially filled
with
fluid, and loosen the
fitting approximately 3/4
bleeder
with
10-30
dirt from the
master
charged
pounds of air pressure.
1. Clean
all
2. Remove the
ervoir
the
install
cap,
reservoir,
adapter
3/8 inch from the top
of
refill
cap,
to within
the reservoir.
diaphragm-type
gasket is properly positioned in the res
ervoir cap, and then install the cap.
that
sure
10. Be
the
sure that the
are
returned
front brake
to
their
an
adapter
attach
fitting
on
properly
cap to
the bleeder
the adapter
11. Before
pis
normal
positions and that the shoe and
assemblies are
cap.
turn.
the tank hose from
fitting.
master cylinder reservoir
Be
is
tank
lining
master cylinder res
and
hose to the
tank
the
tons
cylinder reservoir cap.
the
brake
be
should
remove
the adapter
operation
bleeder
the
9. Remove the
contain
heavy-duty brake fluid to
the bleeding operation, and
complete
valve and
system.
should
enough new
FIG. 4
bleeding
close
45
use
in
be
must
completely
curely
completed,
tube
and
fitting
a
cap and soldering
the hole. The adapter cap
PRESSURE BLEEDING
clean
center of a res
ervoir
pear
wheel
rubber
front,
right
Refill
within
the
be properly positioned
in the reservoir cap before the cap is
sys
formed
specially
be
the
tons
1. Position
is
on
calipers at each
left rear,
the reservoir.
of
disc
reservoir
reservoir
tem.
of the
by
be fabricated
cap can
hole in the
adapter
brake
procedure
front.
is bled
operation
which
this
order:
left
Keep
brake fluid
use
to
drain tube.
cylinders or
cylinder
Heavy Duty brake fluid during
bleeding operation.
cease
end
submerged
and remove the
cylinder
the
the
this
4. When the fluid is completely free
of air bubbles, close the bleeder fitting
and
Bleed the longest lines first.
Repeat
bubbles
air
to the
pedal
position.
until
at
the
return
An
slow
tube.
wheel
MANUAL BLEEDING
down
occur.
brake
calipers.
then
operation
disc brake
the
on
to the
pedal
thru its full travel. Close the bleeder
ly
equipment.
the
brake
the
25
BRAKE SERVICE
-GENERAL
seated.
driving
the car, check
the brakes and be
the
operation
sure
that a firm pedal is obtained.
of
CLEANING AND INSPECTION
ing. Take
FRONT BRAKES
one
1. Remove
the
tire,
and
shield, and the shoe and
caliper splash
linings
wheel
as outlined
in Part
2-2, Section
2.
worn
to
and
inch
of
urements
the middle
three
with
a
section
thickness
micrometer
meas
front
at each side and
If the assembly has
thickness of 0.231 inch
a
(lining
the
reading
center.
(Shoe
lining together)
material
three
place all
2. Make
one
in the
(4)
only)
at
or
0.066
any
one
measuring locations, re
shoe and linings on both
stalled,
the
a
feeler
and rotor.
gauge
If the
between
clearance
is not within 0.002-0.010 inch, check
for shoe and lining assemblies not
being
properly
bridges, for
the cylinder
or
wheels.
insert
lining
for
a
seated
on
the caliper
piston pushed
bore, for
a seized
back in
piston,
malfunction of a piston seal.
across
of the shoe and
lin
3. With
the
shoe
and
linings in
Ordinarily,
the clearance should
be
2-6
GROUP 2 -BRAKES
0.002-0.010 inch. However, if
was
stopped
just
prior
by
drag slightly.
check
eliminate
the car
application
or seized pistons
rotor
the wheel
by tightening
the
bearing
adjusting
the nut check
tightening
the rotor can
still
5.
Clamp a
caliper housing
be
first
runout,
end
nut.
play
After
dial
8. If
indicator to the
so that the stylus con
removal and
upon
disassembly
the caliper
is found to be distorted or damaged,
if the cylinder bores are scored or
or
the
replace
worn,
excessively
as
sembly.
to see that
rotated.
indicate
disassembly.
to checking the clearance,
the brakes may
4. To
brake
a
The two halves
sembly
Damage
should
failure of
of both as a
or
placement
the caliper as
of
be
never
separated.
1 inch from the
the
outer edge.
indicator read
ing. If the reading exceeds 0.002 inch
total
indicator runout, replace the
rotor. Do not attempt to refinish a
rotor that indicates runout in excess
of specification.
When the
be
sure
prevent
to
adjust
the
in
Group 3,
bearing failure.
outlined
sively
7.
scored replace
it
should
and
lined in
a
if
check the caliper.
If it is
leakage is evident,
be replaced. Slight leakage
excess
from the
wheel
the drum as out
Part 2-2, Section 2. Wash
the parts except the brake shoes in
dry
and
with
com
to
all
dust from the
interior
5. If the
ings,
ent
of the
carrier
brake drum.
3. Inspect the brake
shoes
for
ex
lining wear or shoe damage. If
lining is worn to within 1/32 inch
car
the
rivet
heads
or
if the
be
shoes are
replaced.
Rep
lace any lining that has been oil
rated. Replace the lining in axle
satu
Prior to
the
new
they
or signs of
when
lose
lin
are
for
be
brakes,
must
replacement of the
sets.
lining,
the
more
are pres
the wheel
be disassembled and
and
dirt in the
wear
cylinder cups and other
contained
should
future
The
or
brake lin
the
on
overheating
relining
should
cylinders
parts
has 30,000
operation
of
miles
in the
overhaul
kit
thus
avoiding
brake
parts and
replaced,
problems.
cessive
the
springs
springs
prematurely if
wear
cylinder.
2. Brush
hold down
pull and could cause
inspected
pressed air.
of
it.
the
cleaning fluid
and
Overheated
necessary.
not replaced.
remove
damaged, they
Visually
cracked or
1. Remove
drum,
drum
overheating, replacement of
is
ing
plate and
6. Check the rotor for scoring.
Minor scores can be removed with a
fine emery cloth. If the rotor is exces
indicating
unit.
REAR BRAKES
and
springs,
retracting
shoes,
the brake
condition of
for signs of overheating. If the shoes
have a slight blue coloring, or if the
springs show a change in free length,
their
all
is finished
bearings as
in order to
runout check
4. Check the
the retracting
Rotate
rotor and take an
installed.
one requires re
tacts the rotor at a point approximate
ly
drum diameter should be checked to
determine if oversize linings must be
6. Inspect
replace
any
all other
that
are
worn
or
da
maged.
7. Inspect the brake drums and, if
refinish. Refer to Part 2-2,
necessary,
Section 4 for
refinishing.
2-7
PART
2-2
BRAKE SYSTEM
Section
Page
Description
and
Operation
Disc Brake Assemblies
Hydraulic
Self-
Adjusting
Brake System
Booster System
In-Car Adjustments
Disc Brake Caliper
Front Wheel Hub
and
Repairs
Assembly
Rotor
and
Assembly
Brake Carrier Plate Replacement
2-15
2-7
Hydraulic Lines
2-15
2-8
Brake Tube Replacement
Brake Hose Replacement
2-15
Installation
2-16
2-9
Removal
2-10
Master Cylinder
2-11
Booster Unit
and
Brake Pedal
-
2-11
2-12
Disc Brakes
Disc Brake Rotor Splash Shield
-
-
2-17
Automatic Transmission
2-18
Assembly
2-19
Brake Vacuum Power Unit
Brake Equalizer to Control Cable
2-19
Brake Equalizer to Rear Wheel Cable
2-19
2-12
2-13
Major Repair Operations
Adjusting Screw
Disc Brake Shoe and Lining Replacement
2-13
Brake Drum
Wheel Cylinder Repair
2-13
2-14
Brake Shoe Relining
Master Cylinder
Wheel Cylinder Replacement
2-15
and
2-16
2-17
Brake Shoe Adjustments
Rear Brake Drum
Brake Shoes
2-15
Power Brakes
Brake Control
Parking
Parking
Parking
Parking
2-12
Valve
Proportioning
2-7
2-9
Brake
Parking
Page
Section
2-20
2-20
Refinishing
2-20
2-20
DESCRIPTION AND OPERATION
The 1966 Thunderbird brake system
disc brakes on the front
employs
anchor, internal ex
self-adjusting brake as
wheels and single
panding
and
semblies
on
tem
is
the rear wheels.
powered
by
a vacuum
The sys
booster
master cylinder converts physi
force from the brake pedal and
pressure
hydraulic
into
booster
the pistons in the calipers
against
cal
(front
(rear
turn
convert
into
physical
brake
wheel
the
in
The pistons in
hydraulic pressure back
wheels)
cylinders
movement
or
force
at
the
discs
and
of
caliper.
the disc
either
The
caliper as
two
of
caliper
housings bolted together with each
half containing two cylinder bores of
1
15/16 inch diameter. Each
tached
molded
the
seal
piston
grooves
in the
an
at
dust boot to
bore from con
seals
Square-section
are positioned
cylinder
in
bores.
seals perform
piston
cylinder
with
rubber
(Fig. 2).
rubber
The
piston
cylinder
tamination*
three im
tasks:
portant
1.
a
contains
or
wheels).
the
consists
sembly
bore
as standard equipment.
The
lateral
(rotor)
They
provide
between the
hydraulic sealing
cylinders and pistons.
shoes.
2.
They
released
pressure
DISC BRAKE ASSEMBLIES
-FRONT
the
return
position,
is
to
pistons
when
hydraulic
rect
RELATION AND FUNCTION
They
maintain the shoes
adjustment
to
the
at all times
automatic
in
tilated
disc type,
draulic
system
a
fixed caliper,
ven
non-energized,
actuated
(Fig.
by
a
1). There is
hy
no
cylinders
(compar
adjusters
draulically by
sages
in the
external
halves
connected
means of
caliper
the
internal
housings
transfer tube
of
FIG. 1
caliper
hypas
and an
between the two
assembly.
Brake
Disc
in
bleeder
are
H1368-B
cor
drum-type brakes.
The
piston,
EXTERNAL TRANSFER
released.
OF COMPONENT PARTS
The disc brake is
SCREW
HUB AND ROTOR ASSEMBLY
3.
WHEELS
able
opposed
DER
CALIPER
SPLASH SHIELD
One
screw and
Assembly
fluid inlet
fitting
is
provided on each caliper assembly.
The
shoe and
lining
located in between
assemblies are
parallel machined
abutments within the caliper, and
are
supported
tabs on
radially
by
the
2-8
GROUP 2
-BRAKES
When the brakes
CALIPER TO ROTOR CLEARANCE
CALIPER HOUSING
TRANSFER TUBE
to the
pressure
fluid
-ROTOR
A
brake
front
By
of
to
applied
the
PISTON OUST BOOT
RETAINING GROVE
the
high
when
brakes
the
under a wide
(Fig. 16).
conditions
the hydraulic pressure
rear
limits
valve
bal
between
action
braking
regulating
the
and
wheel cylinder provides
and the rear
range
by
located
valve
cylinder
master
braking
anced
because the
master cylinder
proportioning
between the
rear
no
residual check valve.
the
passes
is
calipers
the
source at
in the unap
hydraulic
are
there
position,
plied
wheel
rear
action
required
are
pressures
cylinders,
braking
at
the front brakes. In this manner, pre
is
skid
wheel
rear
mature
prevented.
The proportioning valve is serviced
an assembly and is never adjusted
PISTON SEAL
as
or
overhauled.
FIG. 2
Assembly Sectional
Caliper
View
SELF-ADJUSTING BRAKE
ASSEMBLIES-REAR WHEELS
outer
ends
the
of
(Fig. 21). The
shoe
shoes
the caliper abutments
tabs which
(bridges)
assemblies
axially in
slide
by
means of the
ledges
hydraulic pressure is
on
ride
when
machined
(Fig. 7). A
applied to the piston
shoe
assembly consists of fric
tion material bonded to a metal plate
lining
and
the
called
It is
shoe.
Brake torque is
unit.
the
of
mating
shoe
is
retain
against
the
to
attached
to
caliper
end
the
as
by
(Fig. 21). A
caliper abutments
shield
replaced
absorbed
a
the
the
splash
top
of
the
lining
shoe and
assemblies and reduce contamination.
The
front
the
assembly is
caliper
mounted on
wheel spindle to the rear of
the wheel vertical centerline.
The
ed
cast
type
rotor
is
iron disc is
fins
incorporating forty
staked
.87
design increases cooling
resulting in
rotor
brake. A
of the
the
spindle
prevent
tacting
surfaces
more
rapid
splash shield
is
used
the inboard
for
volving
rotor
During brake
ber
seal
in
piston
braking action.
to effect
application, the
rub
each piston stretches as
moves
the
against
(Fig. 3). When the hydraulic
the
shoe
pressure
is released, the seal
back. This roll-back
against the piston
or
relaxes
rolls
action pulls the piston
shoe
relieve
the
approximately
the force of the
rotor
required
herent
and,
against
provide
clearance.
Also, in
rotor runout contributes
of
running
adjustment
is
the
to the
clearance.
achieved
by
sliding in the seals out
from the cylinder bores. The pis
pistons
ward
ton
lining
thereby,
running
maintenance
the
away from the
0.005 inch to
gradually
ative
to the
changes
seal
as
its
the
position rel
lining
wears
thus, maintains the correct
justment location at all times.
and,
ad
ing lever,
cable,
the
is
and
top
over
adjust
assembly,
(Fig. 4).
The
the anchor pin at
connected to the
bottom. The
at the
is
cable
lever
connected
to the secondary brake shoe
by
means
the cable guide. The adjuster spring
of
is hooked to the primary brake shoe
to the lever. The automatic ad
and
juster
are
operates
applied
shoe
only
is free to
drum beyond
when
the
and
rearward
dary
only
while
when
car moving
brakes applied, the
forces
shoe
the
upper
against
of
the
brakes
is moving
the
secon
toward the
a predetermined point.
action of the shoes
tion
car
move
With the
the
rearward and
wrap-around
following
end
of
the
drum
the primary
the anchor pin. The ac
the wheel cylinder moves the
upper end of
PISTON
spring
is hooked
cable
mechanism
guide,
screw
adjusting
adjuster
and
cable
the secondary shoe away
t
CALIPER
HOUSING
cooling
bolted to
primarily
rotor
(Fig. 8). The
The self-adjusting brake
consists of a
the
through
air
The force
assemblies.
the linings against both sides of the re
area and per
road contaminants
protection
the
of
circulation
mits
lining
and
the pistons against the shoes moves
of
Automatic
of the ventilat
to, and rotates with, the
wheel hub. The outside diameter of
inches and the inside
the rotor is 1 1
diameter is 7.875 inches. This type of
and
shoe
from
and
to
con
lining
wheel provides
the outboard surface of
rotor.
OPERATION
As
the
hydraulic
cylinder
caliper
brake
pedal
pressure
forces the
bores
is depressed,
from
the
master
pistons out of
against
their
the
respective
BRAKES RELEASED
BRAKES APPLIED
FIG. 3
-Function
of
Piston
Seal
HI 370- A
PART 2-2
2-9
SYSTEM
-BRAKE
BOOSTER SYSTEM
FORWARD
DESCRIPTION
ANCHOR PIN
PARKING BRAKE LEVER
The tandem diaphragm type Master
is a self-contained vacuum hy
draulic power braking unit. It is of the
RETAINING CLIP
Vac
WASHER
LEVER
intake
engine
PARKING BRAKE
LINK
CABLE GUIDE
type which utilizes
suspended
vacuum
PARKING BRAKE
atmospheric
pressure
Adjustment
the
of
for its
LINK SPRING
when
is the
this booster.
is to be
unit
power.
rod
push
service permitted on
only
The booster
and
vacuum
manifold
exchanged
it is determined to be defective.
PARKING BRAKES
An independent foot-operated
brake
ing
(Fig.
control
5)
park
actuates
brake shoes through a
linkage. The operating cable is
routed from the parking brake control
the rear wheel
cable
assembly to the equalizer lever which
is attached to the equalizer assembly.
CABLE
The
PRIMARY SHOE
CABLE HOOK
cables
the
connect
assembly to the parking
lever at each rear secondary
brake
(Fig.
shoe
PIVOT HOOK
brake
rear
equalizer
1, Part 2-1
and
Fig.
18).
PARKING BRAKE CABLE
When the
HOUSING RETAINER
ADJUSTING LEVER
AUTOMATIC
PIVOT NUT
by
AND HOUSING
A
vacuum
Assembly
Rear Wheel
power
parking
when the
Adjusting Broke
applied position
the engagement of a spring-loaded
the
Self
are
in the
control as
sembly.
H1384-A
Thunderbird
rear
unit
brakes
will
release
automatically
lever is
transmission selector
into any drive position
running. The brakes
moved
the engine
from
The
the anchor pin.
not
movement
pull
justing
travel
The
star-wheel.
screw
of
increases
the lever
wear
increases.
move
upward
far enough, it
can
the end of the tooth and engages
tooth.
downward
lever
wheel
The
to
as
spring
in
the
VACUUM POWER
PISTON LINK
are
pulls
the
star-
the
causing
and expand
the shoes.
is turned
one tooth at
the
linings
progressively
car
moving forward
star-wheel
time
a
turn
brakes
the
is
passes
over
adjuster
lever
lining
When the lever
When
selector
will
however,
automatically,
upward
as
the
released, the
the
with
PEDAL MOUNT
the adjusting lever upward and
against the end of a tooth on the ad
to
release
when
the secondary shoe causes the cable
of
sec
forced
brake drums. The
pawl with a ratchet
PARKING BRAKE CABLE
FIG. 4
is depressed the
shoes
is held in the
pedal
ADJUSTING SCREW
the
against
ADJUSTER SPRIl'G
pedal
brake
ondary
wear.
With the
the
brakes
shoe
is
applied,
the
and
secondary
against the anchor pin and the
primary shoe is
drum. Therefore,
moved
the
toward
adjuster
the
RELEASE LEVER
does
not operate.
The
conventional
lever, link,
rear
and
brake. The
spring
parking
are used
anchor pins are
and non-adjustable.
LEFT SIDE
brake
in the
H1312-A
fixed
FIG. 5
Parking
Brake Control
Assembly
2-10
GROUP 2
neutral
gine
or
the en
park position with
in any
or
running,
position with
the lever through a slot and rivet pin
power
(Fig. 5).
thus created
the engine off.
The
The parking brake control assembly
mounted to the left cowl side panel
(Fig. 18). The pedal assembly pivots
is
on a
A
spring-loaded
lever
are
pawl
is
mount.
The
it
teeth
ratchet
ing
motion
to
release,
stationary
the
pedal
is
the apply
when
the pedal starts
pawl
the
engages
locks the brakes in
Since the release
thus
and
A
will slide over
as
stops and
the
release
pedal.
the ratchet
pawl contacts
depressed; however,
ratchet
a
assembled to the
at such an angle that
the
and
to the
assembled
ratchet
(Fig. 5).
pedal mount
stationary
the applied position.
lever
pivots against the
a slight
pawl,
lever
movement of the release
from the
dis
will
engage
the
lowing
the brakes to
lever is actuated
release.
release
release
handle
connected
pawl
by
is
which
ratchet al
The
a manual
to
-BRAKES
vacuum
power
bracket
mounting
control assembly.
is
to the
riveted
The
with
unit
vacuum actuat
The
unit.
link to
pull
which,
in
differential
pressure
the piston and
cause
will
the manual release handle
the
actuates
turn,
release
lever.
is connected
link to the upper end of the
release
handle which actuates the
ed piston within the unit
by
a
lever to
release
move
the pawl out of
TO VACUUM
(Fig. 5).
POWER UNIT
engagement with the ratchet
The lower
extends
failure
for
in the
release
the release handle
manual
alternate
event of vacuum power
for
or
of
end
out
optional manual
release
NEUTRAL
SAFETY
SWITCH
(VACUUM
RELEASE
any time.
at
Hoses
the
VALVE)
connect
engine
release
the power unit and
to
manifold
in
valve
the
a
(Figs. 5
the transmission selector lever
into any drive
position with
will open
connect
engine
one side of
TO ENGINE
MANIFOLD
VACUUM
6).
safety
Moving
switch
4
vacuum
transmission
neutral
running
CONNECTS WITH
VENTILATION
SYSTEM
and
H1313-A
the engine
the release valve to
manifold
to
vacuum
6 Connections
FIG.
the actuating piston in the
Release
Brake
Parking
matic
For Auto
IN-CAR ADJUSTMENTS AND REPAIRS
brake
After any
service
ob
work,
tain a firm brake pedal before moving
the car. Riding the brake pedal (com
mon
be
left foot applications)
on
driving
avoided when
the
of
pliers and pull the shoe out of
caliper
the
(Fig. 7).
of
condition
boot
should
and
REMOVAL
1. Position
that the
hub
and
to
terference
wheel and tire
damage
the
with
shield, bleeder
or
caliper
fully
Be
splash
Remove
the
bolts that
two
move the shield
3. To facilitate
lation
their
lining
housing
at
least
not
a
each
pump
Grasp
end
minute.
in easily,
go
with water
outer
its
(Fig. 2). Maintain
rotor
4.
each
toward
on
the
of
a
be
as
pushed
shoe and
of
H 1366
-
A
the
pistons
FIG. 7
Shoe
seat
bridges
caliper
shield
splash
to
the
shield
caliper
1).
Pump
the
the shoe with two pairs
until
brake
the
a
firm
the shoe and
pedal
pedal
is
several
obtained
lining assemblies are
seated.
4. Install the
wheel and tire on
the
and rotor assembly.
Removing Disc Broke
and
5. Check
Lining Assembly
and
refill
the
master
cylinder reservoir with specified
fluid
brake
as required.
CLEANING AND INSPECTION
6. Road test the
When
on
the
two attaching bolts (Fig.
hub
force them in
flange
flanges
caliper
with
properly
ihe pressure
If the
rotor so
the rotor. Be sure
secure
and
respective
pliers.
metal
USE SECOND
PAIR OF
PLIERS HERE
steady in
side
the
lining
and
the
and
3.
instal
lining
and
Apply
against
assembly
caliper
for
bores.
pressure
ward
will
shoe
the pistons must
semblies,
into
the
of
and
lining faces
against
times
1).
removal
shoe
at
tach the caliper splash shield, and re
(Fig.
new
2. Install the
tube.
2.
dust
before in
(Fig. 7).
in
fitting or transfer
screw
a
on each side of
that the tabs on the shoe
from
assembly.
rotor
avoid
area
stalling.
car.
assembly
the
or cor
each
clean
surrounding
INSTALLATION
careful
inspect
and
for damage
Thoroughly
rosion.
FRONT (DISC) BRAKE SHOE
AND LINING REPLACEMENT
1. Remove the
boots,
the
each piston surface
the
semblies are
boots
from
shoe
and
lining
the
pistons.
as
It
should not
dust
the system
Check the
placement.
replaced, remove the
car.
be necessary to bleed
after a shoe and
lining
re
PART 2-2
DISC BRAKE CALIPER
be
should
ASSEMBLY
seated
hub
terference
lengths. Check
wheel and
rotor
with
tire
from
assembly.
damage
avoid
shield, bleeder
tube.
the
or
caliper
Be
in
splash
fitting or transfer
screw
2. Disconnect the front brake flex
ible hose from the brake tube at the
bracket
on
the
frame (Fig. 16).
3. Remove the two bolts that
at
runs
the
care
of
the
caliper
4. Lift the
to
avoid
loosening
the
together.
caliper
3. Connect
the
in
outlined
master
5.
brake
wheel
brake
the
Section
system
2-1.
as
Pump
the
brake
the
pedal
several
the piston seals and
actuate
position
to
shoe
and
lining
as
assembly (Fig. 8).
damage or in
avoid
the
with
shield, bleeder
screw
2. Remove
from the
caliper
the
or transfer
does
caliper
require
not
assembly
the rotor.
and
spindle
If the
servicing,
it is
necessary to disconnect the brake
hose or remove the caliper from the
not
Position
and
way,
the
it
the
spacer
the
prevent
the
of
caliper
is
of
a
wire
caliper
Insert
hose.
stretching
cardboard
out
with
the
damaging
avoid
to
caliper
support
a
the
to
or
clean
between the linings
from coming
pistons
bores
cylinder
while
the
removed.
Handle
semblies
the
in
rotor
such
deformation
of
or
of
scratching
a
the
and
caliper
as
way
to
rotor and
as
avoid
nicking
the brake linings.
3. Remove the
grease
hub. Remove the
cotter
adjusting nut, and flat
the spindle. Remove the
wheel and tire.
splash
caliper
fitting
tube.
Check the
fluid level, and the
brake fluid as required.
cylinder
7. Roadtest the
and mate
cap from the
pin, nut
lock,
washer
from
outer
bearing
cone and roller assembly.
car.
assembly on
the mounting bolt
caliper with
lining
front
rotor
and
caliper
those in the
It may be necessary to push
the caliper pistons into the cylinder
bores to obtain clearance between the
The
careful
car.
2).
semblies.
spindle.
and
hub
Be
out
6. Install the
1. Position the
of
centrally between
the caliper. There
routing.
off the
INSTALLATION
rotor.
rotor
flexible hose to the brake tube at the
bracket on the frame (Fig. 16). The
hose should be checked for correct
to
shoe
insure that the
the rotor outside diameter (Fig.
times to
holes in the
bolt
be approximately 0.090-0.120
between the caliper and
specified
assembly
rotor.
the rotor,
specifica
clearance
4. Bleed
bridge bolts that hold the two halves
spindle
in
and
halves
two
inch
to
squarely
should
tach the caliper to the spindle.
Take
to
caliper
retaining bolts and torque to
Note the difference
and
to
careful
the
tion.
1. Remove the
the
terference
2. Install
the
the
on
properly
bridges.
REMOVAL
2-11
SYSTEM
-BRAKE
assemblies
shoe and
lining
and
4. Remove the hub
sembly from the
FRONT WHEEL HUB AND
ROTOR ASSEMBLY
rotor
as
INSTALLATION
REMOVAL
1. If the
the
assemblies
and
spindle.
1. Remove the
wheel and tire
from
CALI PER PARTS
-2B120-R.H.
move
rotor
is
being
replaced,
the protective coating
re
from the
-2B121-L.H.
CALIPER ASSEMBLY
2B118-R.H.
2B119-L.H.
ROTOR SPLASH SHIELD
2K004.R.H.
2K005-L.H.
H1371-A
FIG. 8
Disc
Broke Disassembled
2-12
GROUP 2
new
rotor
Pack
a
specified
cone
of
set
grease,
bearing
degreaser.
bearings with
install the inner
with carburetor
new
and
and
inner cup. Pack
between the lips of
the
retainer
assembly in
roller
new
a
sembly
der
hub
the
and
rotor
Installation
in
the
3. Position
as
and the caliper as outlined un
foregoing
tube.
procedure.
4. Bleed the brake
original
grease
the
retainer
make
PROPORTIONING VALVE
and
lubricated
in
rotor
grease retainer
good
condition,
braking
surfaces
are clean.
2. Install
hub
the
3. Lubricate
rotor
REAR WHEELS
The
as
1. Disconnect
washer
and
outer
adjusting
the
bearings
wheel
pin, and grease
cotter
cap.
proportioning
valve.
Working
fender, remove
the
underneath
left
the bolt that attaches
proportioning
and
the
valve
remove
to the fender
9).
important
brake
PROPORTIONING VALVE
hydraulic
rear
only
have been relined, rep
when the length of the adjust
shoes
bolts
to
necessary,
push
the
The
into
the
clearance
cylinder
bores
between the
shoe
seated
on
lining
and
Be
the
detailed below.
are
wheel
tool
as
gauge.
lever
while
shown
in
brake shoe
Hold the au
the
adjust
adjusting
ricate the
a
of
out
en
the
rotating
ad
thin,
adjusting
uniform
screw
threads
of
coating
with
CIAZ-
19590-B Grease.
correct routing.
6. Install the
hub
shoes:
justment screw, to prevent burring the
screw slots. Make sure the adjusting
screw rotates freely. If necessary, lub
the bridges. Check the flex
ible hose for
the
and
gagement
lining
that
brake
adjust the
tomatic
obtain
sure
per
the drums removed, us
tool
and
the procedure
with
diameter to fit the
If
assemblies
assemblies and the rotor.
the
to
shoe and
is
adjustment
manual
Fig. 10
pistons
caliper
service
Using Rotunda Tool HRE 8650,
(Fig. 10) determine the inside dia
meter of the
drum braking surface.
on
specification.
while
other
1.
two
the
torque
and
spindle
mounting
changed
some
2. Reverse
the
a
the
after
operation.
To
brakes.
assembly
require
adjustment
performing
adjustment
caliper
brakes
service
and
laced, or
ing screw has been
ing
RETAINING BOLT
with
5. Mount the
the
raised with
floor.
the
self-adjusting
formed
is especially
disc brakes. Refer to
Part 3-4 for specific instructions on
adjusting wheel bearings with disc
bearing
wheel
The
are
the valve through
nut
The
be
should
car
wheels off
manual
to
specification, and then install the
lock,
the
front-to-rear
2. Disconnect the
brake tube from the
the access hole (Fig.
4. Adjust
remove
cylinder-to-proportioning valve
brake tube (Fig. 16).
apron
nut.
and
master
3.
install the
and
bearing,
wheel
and
on the spindle.
sembly
-
REMOVAL
adequate, that
and
and
the
being in
that the grease in
sure
hub is clean
the inner bearing
that
is
rotor
the
and
system.
BRAKE SHOE ADJUSTMENTS
If the
are
brake
cylinder-to-proportioning valve
(Fig. 8).
stalled,
the master
and connect
lightly
grease
install
and
3. Install
-BRAKES
and tire on the
3. Rotate Tool HRE 8650
and rotor assembly.
around
the brake shoes to be sure of the set
ting.
DISC BRAKE ROTOR
SPLASH SHIELD
4.
Apply
REMOVAL
MOUNTING
1. Remove the
and
rotor
caliper and
assembly
Removal in the
2. Remove
foregoing
the
and remove
bolts
three
the shield (Fig.
3. Remove the
under
procedure.
shield to the
retain the splash
the hub
as outlined
that
1. From
apron.
2. If the
out
so
Install the gasket.
shield
is bent,
before installation.
shield
to
the
retaining bolts,
cation
(Fig. 8).
spindle,
straighten
it
Position the
install
the
and torque to specifi
Position the
that
the
fender,
proportioning
through the access
INSTALLATION
the left
underneath
the
high
points
brake
shoes contact the car
being
careful not to get the
plate,
on
the
linings.
5. Install the brake drum.
nuts
and tighten securely.
INSTALLATION
gasket.
of
the
6. Install the three Tinnerman
spindle,
8).
to
rier
lubricant
Valve
quantity
grease
where the
FENDER APRON H1365-A
FIG. 9 Removing or
Installing the Proportioning
install
1.
TANG
small
a
temperature
valve
hole in the fender
valve
mounting
tighten
the
extends
retaining bolt.
the
on
mounting
drum
nuts
to
by
ap
specification.
8. Complete the
plying the brakes
adjustment
several
times while
backing the car.
9. Check the
2. Connect the front-to-rear brake
16).
wheel
the
to the apron
tang
through the hole in the fender apron
Fig. 9. Install the
in
shown
as
tube to the valve (Fig.
7. Install
and
ward
direction.
by making
operating in a for
adjustment
several stops while
2-13
PART 2-2 -BRAKE SYSTEM
directed
Ad
Shoe
Brake
under
justments.
REAR BRAKE SHOE
REPLACEMENT
REMOVAL
1. Remove the wheel and the brake
drum and install a clamp over the
ends of the brake cylinder as shown in
Fig.
FIND CORRECT BRAKE
SHOE DIAMETER HERE
JUST SET TO DRUM
DIAMETER HERE
.
FIG. 10
-Using
.
.
Tool HRE-8650
REAR BRAKE DRUM
H
FIG. 12
i
Spring
ACCESS SLOT
1. Raise the
clear the
-Retracting
chor
with
spring
Fig. 13. With the
OUT)
car until the wheel and
the
floor.
2. Remove
nuts
the
wheel
cover
and
same
tool,
remove
shoe-to-anchor
secondary
3. Remove
the brake drum. If
adjusting hole in the car
rier plate, and disengage the ad
justing lever from the adjusting
While holding the adjusting
screw.
off
the
not
will
justment
in the adjusting screw;
other
self-adjusting mechanism
function properly. If the ad
was
changed,
that the adjuster lever
ed
secondary
MOVE HANDLE
UPWARDS
HI 144 -|
FIG. 1 1
in the
pin
plate
cable guide
from the
(Fig. 4).
the
shoe
hold-down
shoes, adjusting screw, pivot
nut, and socket.
6. Remove the parking brake link
Off
-Backing
shoe
5. Remove
springs,
and
spring.
brake
lever.
Brake Adjustment
from
make
certain
is properly
seat
shoe web.
a
new
drum
cable
Disconnect the parking
from the parking brake
carburetor
2. Adjust the brakes
as outlined un
der Brake Shoe Adjustments in this
section and
install the brake drum.
3. Install the three Tinnerman
on
the axle shaft
the
nuts
drum,
to
and
Install the
the
protective
coating
removing
the
secondary
flange
tighten
studs against
the
specifications.
4. Complete
lever from the
shoe
retaining clip
(Fig. 4).
and
spring
the
washer
retaining
Install
the
INSTALLATION
1. Before
shoes, back
adjustment
as
installing
off the
justment. Then
brake
by removing
nuts
wheel
wheel cover.
1. Remove
7. After
shoe, disassemble the parking brake
and tighten securely.
INSTALLATION
with
degreaser.
the
not
anchor
removed.
burr,
to
notches
wise,
only if the drum
Be very careful
chip, or damage the
adjustment
be
cannot
the
4. Remove the
a narrow screwdriver through
the brake
lever away from the adjusting screw,
back off the adjusting screw with the
brake adjusting tool (Fig. 11). Back
spring
from the an
and the anti-rattle clip.
the brake drum will not come off easi
ly, insert
in
remove
chor pin.
Remove the three Tinnerman
and
shoe-to-an
the tool shown
and unhook the cable eye
wheel.
1390- A
Removal
2. Remove the primary
(SLUG KNOCKED
REMOVAL
tire
12.
the
brake
parking brake
assemble the
brake lever to the
secondary
ad
parking
shoe and
2-14
GROUP 2
secure
2.
the
with
retaining
washer
spring
and
clip.
Apply
of high-
light coating
a
grease
brake
the
at
points
shoes contact the car
rier plate.
(Fig.
plate
the
shoes on
secure the
and
assembly
with
the hold-down springs. Install
the parking brake link and spring.
Connect the parking brake cable to
The
the adjusting
of
end
by
the
the
nut.
dicate
a
dicates
a
nuts
number of
the
grooves machined around
L
or
pivot
adjusting
be distinguished
R
an
with
stamped
14).
prevent
the wrong side of the
on
socket
is
screw
can
3. Position the brake
carrier
the
car,
To
operated.
mechanism
installation
temperature
where the
ing
-BRAKES
body
of
4. Install
the
anchor
the anti-rattle
pin
plate
the lever
3/16 inch (plus
inch)
above
this centerline, the lever will
right
thread,
in
on
left thread.
ADJUSTING LEVER
determine
To
guide
the
the
Check the
between the
and
guide
anchor
be
IDENTIFICATION LINES
the
the
and
Screw
-Adjusting
Lever
Identification
10. Place
not
shoe web.
secondary
spring (Fig.
this
to
shoe
13)
the
the
or extend
and the cable
ing
on
the adjust
shoe ends with
the
nearest
wheel
left brake assembly (Fig. 14).
12. Position the hooked
adjuster
end of the
completely
spring
the
should
(plus
or
should
assembly
1/64
The
length.
cable
1/8 inches
11
measure
minus
the cable
inch) from
the
into the
large hole in the primary shoe web.
The last coil of the spring should be at
the edge of the hole. Connect the loop
end of the spring to the adjuster lever
hook.
Check the
c.
for dam
cable guide
age.
The
allel
to the shoe web, and the
the
shoe.
11. Hook the cable hook into the
hole in the adjusting lever. The adjust
ing levers are stamped with an R or L
to indicate their installation on a right
or
this
meet
damage is in
end of the cable anchor to the end of
socket
adjusting
toothed
screw
section of
replaced.
cable
install this assembly
and
screw
secondary
H1391-A
fittings. The
H1143-B
be
cable
cable end
possible
b. Check
FIG. 14
between the
7. Install
dicated
ADJUSTING SCREW
and
It is imperative that the
in this groove
the
of
cause
completely fill
slightly beyond the crimped
the fittings. If it does not
cable guide groove
(Fig. 4).
positioned
the
cable should
the
on
Thread
web.
be
by
actuated
anchor
specification,
shoe
is
screw
not
condition:
cable eye over the an
cable
will
screw
turned as the lever
and
secondary shoe web with the flanged
hole properly fitted into the hole in
around
the
and
the
is below
not lock
in the adjusting
teeth
the
wheel,
1/32
of
point
contact
in
one groove
the carrier plate.
cable
the
top),
or minus
centerline
grooves on the nut
chor pin with the crimped side toward
the secondary
If
screw.
the
at the
the adjusting
should contact
wheel
a.
6. Install the
(anchor
position
vertical
pin.
5. Place the
the adjusting screw
With the brake in a
on
wheel.
cable.
clip
the
on
toothed
Two
parking brake lever (Fig. 4).
the
lever
the
of
cable groove should
guide
Replace the
web.
lie flat
should
be
par
body
guide
if it
pivot
hook
of
the
against
da
shows
mage.
d. Check
the
hook
The
lever.
the
square
with
proper
pivoting.
the
hook
e.
et
shows
body
the
on
be
should
surfaces
lever for
of the
Replace the lever if
damage.
See that the adjusting screw sock
seated in the notch in
is properly
the shoe web.
hole.
FIG. 13
Spring
-Retracting
13. Pull
automatic
and
Installation
with
chor
spring
Fig. 4.
Be
shown
cable eye
on
All
installed.
when
flat
that the
binding
or
tool
the
should
parts
ing
screw
screw.
back
into
limit
the
to
the
off
car
brake
Turn the
adjust
threads and
the
then
1/2 turn.
screw
pand
grease
from
assemblies
to the other
shoes
each
to
retract
time the
ing
shoe adjust
one side of
would
rather
cause
the
than ex
automatic
adjust
lever
screw
by pulling the sec
between the cable
past a
The
release
lever
should
behind the
position
next
of the cable should
cause
the adjuster spring to return the
lever
to
its
action
original
of the
screw one
If pulling the
duce the
lever
disassemble, inspect,
the
remove
carrier plate
or
hone
and
when
Removal is necessary only
the
cylinder
is damaged or
scored
beyond
overhaul.
repair.
action
action
positive and
is
DISASSEMBLY
tooth on the adjust
wheel.
snap into
tooth, and
adjusting
necessary to
from the
not
cylinder
the adjusting lever toward
and
the
return
the brake
cable
check the ac
the secondary shoe web far enough to
lift
the adjusting pivot nut
of
Interchanging
ing
be
threads and the socket end of
adjusting
the
of
guide
brake
(Fig. 4).
installation,
not
tion
It is
sec
to
anchor pin
9. Apply high-temperature
the
shoe web
ondary
REAR WHEEL CYLINDER
REPAIR
the
to engage
rear
tion of the adjuster
is
on the anchor pin.
the
to
in
spring down
adjuster
to an
14. After
certain
cocked
the
cable
hook in the large hole in the
pivot
shoe
lever,
adjuster
the
toward
and
8. Install the primary
the
position.
lever
will
This
turn the
tooth.
cable
sluggish
from
cylinder.
and
ends
and the rubber
of
brake
the
Remove the pistons, cups,
return
bore (Fig.
the
spring from the
15).
2. Remove the bleeder
cylinder
screw
from
the cylinder.
does
described,
1. Remove the links
boots
not pro
or
if the
instead
of
sharp, check the position
INSPECTION
1. Wash
natured
all
alcohol.
parts
If
in
clean
alcohol
is
de
not
PART 2-2
2-15
SYSTEM
-BRAKE
BOOT
BOOT
flange.
Insert the
housing
so that the splines en
housing
into
the
the differential side gear with the
gage
bearing
retainer
taching bolts
RETURN SPRING
SCREW
CYLINDER
2. Install
H1385-A
connect
this
available,
Dry
Rear Brake Wheel Cylinder
use
brake fluid.
specified
with compressed air.
2. Check
internal
all
from
parts
for
cessive wear or
damage. If any
internal
require
parts
be
should
the
marks
or
honed.
the
all
replacing,
If
taching bolts
lock
and
drum
brake
the
cylinder
for
bore
the
more
cylinder
than 0.003
2),
INSTALLATION
Wipe
line to
the
into
ASSEMBLY
the hydraulic
foreign matter
any
the
rear
Enter
into the threads
2. Secure the
all
2. Thread
internal
3. Insert
the
in
positions
into
screw
cylinder
tubing into
ihe
lock
or
fitting
and
system
a
spring,
their
cups,
respective
its
fitting
Milbar
with
nut
to
1112-
tool
the
at
rear
connector
the
at the
or
line
boot
as
4. Bleed the brake hydraulic
detailed in Section 2.
system
lined in this
If
a
wheel
in
a raised posi
wheel and
the drum.
brake
the
shoe
procedures
as
out
there is no vacuum in
the booster system before disconnect
the hydraulic
Unscrew
the
entire system after
be
the
cylinder.
tube
juster
inder
al
tube
assemblies
as
and
the entire section
replaced with
fitting
that con
Do
not
tube away from the
Pulling the tube out of the
and
make
The tube
tubing
of
the
type, size, shape, and length.
Copper tubing should not be used in a
tube.
section.
disconnect
3. Rotate the
hole in the
the wheel cyl
the carrier
and
remove
the parking
will
Clean
plate
the
by flushing
that the
flange lines up
attaching nuts
nuts.
Pull the
axle
assembly out of the housing with
tool 4235C and a slide hammer (Part
4-2),
and
then
will
bend the
remove
the
carrier
plate.
INSTALLATION
met
1. Position
installation diffi
separate
from the
on
the
a new rear carrier plate
attaching
good
be flared
leak-proof
brake tubing
the
denatured
cohol, before installation.
with
clean
a tube to a
tube connector, disc caliper,
cylinder, tighten the tube
the
specified
1 1 12-144
torque
with
al
hose,
or
brake
fitting
nut to
Milbar
tool
or equivalent.
cable.
axle shaft so
axle shaft
with
On
should
provide
When connecting
shoe and ad
in this
outlined
the rear wheel,
and
metal
cylinder connection
cult.
brake tubing
the
of
BRAKE HOSE REPLACEMENT
A flexible brake hose should
be
placed
if it
cracking,
shows signs of
or other
shaft
nects the tube to the cylinder.
pull
brake
brake line from
wheel
2. Remove the brake
3. Disconnect the brake line from
ing
the
brake lever from the
section.
stopped and
tube
replacement.
section
connections.
the brake cylinder. Be sure the engine
is
brake
16).
becomes damaged,
properly to
drum. Disconnect the
the brake cylinder.
following
semblies,
the
wheels and
BRAKE TUBE REPLACEMENT
or crack the
REMOVAL
REMOVAL
2. Remove
front
hydraulic
system.
When
bending
brake tubing to fit underbody or rear
axle contours, be careful not to kink
over each end
1. Remove
tion,
exception of
housing
axle
(Fig.
Always bleed the
should
equivalent.
REAR BRAKE CARRIER
PLATE REPLACEMENT
the
as
washers.
bore
cylinder
REAR WHEEL CYLINDER
REPLACEMENT
remove
(Section
throughout the
used
with
All brake tubing
1. With the
shoes
bleed the brake system
in Part 2-1, Section 2.
to the carrier
attaching bolts
the
brake
any hose
of the cylinder.
cylinder
by installing
specification
144
the cylinder.
of
parking brake
Install the brake
and wheel.
flexible hoses
wheel
3. Tighten the tube
securely.
return
the
15). Place
(Fig.
in this
same
into
pistons
and
parts.
bleeder
the
the cylinder and tighten
and
heavy-duty
of
coating
ad
and
the
lever.
the
Steel tubing is
of
connections.
position.
plate
brake fluid to
to
shoe
outlined
HYDRAULIC LINES
end(s)
remove
1. Place
sure
nut
a
as
4. Adjust the brake
washers and re
the cylinder, and start the tube
Apply
brake
the
at
move the cylinder.
before making
4. Check the bleed hole to be
that it is open.
1.
in
as outlined
must
diameter.
original
and
cylinder
wheel
Connect
section.
cable
either condi
cylinder
be honed
inch beyond its
bore
cylinder
rust.
However,
should not
the
assemblies
outlined
tion is present, the
be
4. Remove
ex
removed
replaced.
3. Inspect
score
of
is
the carrier plate.
axle
section.
juster
cylinder when the cylinder
nuts
attaching
hole in the
brake line
the
3. Install
15-
FIG.
the
access
at
the carrier
against
flange.
shaft
PISTON
the
the
onto
sliding
and
Install
plate.
through
PISTON
shaft
axle
bolts
in
the
axle
When
hose,
damage.
installing
position the
tact
with
new
copper
re
softening.
a
new
hose
front brake
to aNoid con
other chassis part;..
Place a
hose fit
ting and screw the hose
assembly into
the front disc brake
caliper. Place the
opposite
end
of
the
hose at the
bracket on the frame.
Install the
gasket
over the
2-16
GROUP 2
-BRAKES
BRACKET-2073
TO LEFT WHEEL
2268 ASSY.
2814
S
REAR TUBE CONNECTOR
FRONT END OF HOSE
/
2A448ASSY.
USE EXISTING NUT
(REF.)
IMPORTANT
MUST LOOP DOWNWARD
-HOSE
374674 -S3
31497-S8
TO MASTER CYLINDER
\
41183- S2 4
REQD
RETAINING
CLIP
2814 2 REQD.
\*
354538-S8
FRONT HOSE ASSY.
16-
FIG.
VALVE ASSY.
-2078
Service Brake System
horseshoe-type retaining clip,
nect
tube
A
fitting
nut
the
that
so
hose
and con
with
it does
muffler outlet pipe or shock absorber.
the
(Fig. 16).
brake hose
rear
stalled
to
tube
the
H1364-A
-2B091
Place
hose
be in
should
not touch the
a
new
fitting
gasket
and
the
over
hose
the
screw
rear
as
sembly into the rear brake tube con
nector. Place the front end of the hose
bracket on the frame. Install
horseshoe-type retaining clip, and
connect the tube to the hose with the
the
at
the
tube
fitting
nut.
REMOVAL AND INSTALLATION
4. Remove the
MASTER CYLINDER
power
ing
unit.
Do
push
not
rod
from
disturb the
the
adjust
screw.
outer
REMOVAL
2. Remove
washers
the
unit
that
cylinder
two nuts and lock
sure
not
unit.
master
Separate
from the booster
cylinder
make
does
the
secure
to the booster
master
and
the
that
rest
the master
on
the
push
rod.
seal
of
from the
the master
and
discard the
outer groove
cylinder.
rubber
at the end
rod
push
mounting
of the vacuum
1.
a light coating of lub
COAZ-19584-A to the piston
of the hydraulic
push rod and
Apply
ricant
end
guide
the piston end
into the
center
bore
of
of
the push rod
the booster pis
ton.
push rod to make cer
against
no
the
reaction
air pocket
push rod and
disc
is bottomed
and
between the
the reaction
there
is
end of the
disc.
at
cylinder, (Part
should
be from 0.990 to 0.995 inch measured
metal to metal. If the push rod dimen
sion
is
not
correct,
see
Master
Cylinder Push Rod Adjustment, Part
2-1, Section 2.
4. When the
2. Twist the
to the
surface
2-1, Fig. 2). This dimension
tain the end of the piston
3. Remove
the
of
cylinder
the end
INSTALLATION
proceeding with the in
distance from the
check the
end
master
1. Disconnect the brake lines from
the outlet fittings (Fig. 16)
cylinder
3. Before
stallation,
correct,
the
install
groove
at
push rod adjustment
a
new
the end
rubber
seal
is
in
of the master
cylinder.
5. Position the
the
master cylinder over
push rod onto the two studs
that
PART 2-2
are
integral
6. Install
lock
the
with
the
nuts
attaching
and
washers and torque the nuts to
Working inside
4.
booster body.
below the
instrument panel, disconnect the boostpush rod link from the brake pedal
To
assembly.
specifications.
the car
do
this,
proceed
as
follows:
7. Connect the brake lines to the
outlet fittings (Fig. 16).
8. Bleed the brake
3/8-inch from the
master cylinder to
top
the filler opening. Use Rotunda
of
Extra
Fill the
Brake
Heavy Duty
Fluid,
R103-
A, Ford Part No. C6AZ-19542-A. Be
that the gasket is properly seated
in the filler cap, and install the cap.
at
hairpin
to
the
light
stop
switch
Remove the
the connector.
Slide the stop light
from the brake pedal just
retainer.
off
switch
far
enough
clear
straight
for the
the pin,
upward
switch outer
and
then lift
from the
hole
switch
pin.
Slide
sure
the
master cylinder push rod and
nylon
the dash
2.
washer
and
bushing
the brake pedal pin (Fig.
off
the
BRAKE BOOSTER
dash
the
and washers.
panel
til
6. Remove the booster
and
from
the
the
booster.
2. Remove three bolts
one
hose
vacuum
and
loosen
to allow the brace between the
cowl
and
positioned
spring
inboard
for
be
to
tower
side of the
dash
bracket
the dash panel, sliding
the push rod link out
1. Disconnect
and
panel
from the
engine
(Fig. 17).
lines.
the brake
on
to
disconnect
the
not
brake
BUSHING-2A188
the
and
pin
pedal
just clearing
the hairpin
light
nector,
and
retaining
INSTALLATION
attaching
1. Mount the booster
and
bracket
assembly to the dash panel by sliding
the bracket mounting studs and the
in
to the
pin
Connect the
the
to
wires
wires
con
in the
clip.
and
torque the booster
nuts to specification.
master
booster, install
and
shown
parts
install the
5. Position the
the
as
retainer.
switch
Install the
pin.
washer
nylon
stop
panel
the
hole
outer
switch
the
onto
completely
straddles
the pin. Slide the switch
with
dash
it
the switch slot on the
with
rod
Posi
pin.
pedal
the
and
rod,
tion the switch so that
for
the
as
fol
as
washer, the
nylon
17. Secure these
in
pedal
proceed
push
cylinder
Fig.
in the slot
installation.
the booster
lows:
4. Tighten
from the booster. It is
necessary
To do this,
sembly.
7. Remove the dust seal from the
booster push rod link and position it
clearance.
cylinder
the car below the
connect
link to the brake
rod
outer
obtaining
3. Remove the attaching nuts and
lock washers, and remove the master
pedal
instrument panel,
push
bushing
nuts
un
assembly has been
Working inside
3.
push
assembly from
the
after
loose
nuts
connected.
bracket-to-
attaching
below the
retaining nuts
panel
Leave the
Install the inner
17).
four
car
instrument panel, install the mounting
from
washers.
REMOVAL
inside the
Working
master
5. Remove
1 7).
(Fig.
panel
holes in
through the
link in
rod
push
bracket-to-dash
Disconnect
wires
system.
2-17
SYSTEM
-BRAKE
the
to
washers
torque
and
nuts,
attaching
cylinder
lock
to
specification.
BUSHING-2461 2 REQD.
6. Position the
brace, install
PEDAL ASSY.-2455 (REF.)
cowl
to spring tower
the bolts and nuts, and
torque to specification.
WASHER
7. Connect the
vacuum
hoses to the
booster.
BOOSTER ASSY.
PUSH ROD LINK
BRAKE PEDAL
REMOVAL
1. Loosen
the
booster
mounting
nuts.
2. Disconnect the stop light
switch
wires at the connector.
3. Remove the hairpin retainer.
Slide the stop light switch off from the
brake pedal pin just far enough for
the switch outer hole to clear the
pin,
and then lift the switch straight
374759-S
up
ward
from the
cylinder
washers
brake
push
and
pin.
Slide the
master
rod
and
the
nylon
bushing
pedal pin
(Fig.
off
from
4. Remove the
H1382-A
FIG. 17
Broke Booster
and
Pedal Installation
pivot bolt and nut
holds the pedal to the pedal
sup
port bracket. Remove the
brake pedal
assembly from the pedal support
that
34367-S8
the
17).
bracket,
and remove the
bushings.
2-18
GROUP 2 -BRAKES
INSTALLATION
1.
Apply
PARKING BRAKE CONTROL
ASSEMBLY
SAE 10 en
gine oil to the bushings and locate all
the bushings in their proper places
on
the pedal
assembly (Fig. 17).
a
coating
of
2. Install the brake pedal
assembly
and bushings to the support
bracket,
and then install the pivot bolt through
the
REMOVAL
by removing the adjust
the support
ing
(Fig. 1. Part 2-1). Remove
assembly.
the
nut
U-clip and disengage
housing from the bracket.
2. Lower the
washer,
car.
In the
switch
on
outer
the
hole
just clearing the pin. Slide the switch
completely onto the pin, install the
outer
nylon
washer
as
shown
in
Fig. 17. Secure these parts to the pin
with the hairpin retainer.
4. Connect
wires to the
wires
the
connector,
in the retaining
5. Torque
the
light
stop
and
switch
the cable
passenger
end of
the cable and connect the clevis
pin
the
inner
move the air
the
brake
cowl
retaining
Remove
the air duct
obtain access to
Remove
duct.
control assembly.
the control cable from the air
3. Disconnect
the
hose
from the
4. Remove the
control
brake
the U-clip.
3. Position
control
pin
retainer.
cable
housing
control
the
to the
housing
parking
to
assembly
and
the clevis
clevis
with
brake
the
mounting
install the three attaching
assembly-to-
4. Connect the
mounting
U-clip that retains
housing to the parking brake
control housing (Fig. 18).
vacuum
hose to the
vacuum power unit.
5. Remove the
the cable
Secure the
2. Secure the
parking
bracket
bolts.
vacuum power unit.
hairpin
with the
panel, and then re
duct to
(Fig. 18).
5. Position the
cowl
panel,
retaining
air
and
screws.
duct to the inner
secure
Connect
with
the air
four
duct
EQUALIZER-TO-REAR
WHEEL CABLES
PART OF VENTILATION
SYSTEM INSTALLATION
HI 309- A
FIG.
18"
Parking
Brake
System
as
cable
1. Position the cable through the
hole in the parking brake control
housing. Install the clevis on the ball
pad.
install the
nuts to specification.
the
INSTALLATION
left kick
mounting bracket bolts.
clip.
booster
and
screws and the
to
the switch slot
the
cable
compartment,
push
and
the
to the actuating arm with
the four screws that retain
with
from
of
control
the
tion the switch so that it straddles the
pin
the
remove
remove
the master cylinder push rod, and the
bushing on the brake pedal pin. Posi
rod
then
end
hoist and dis
cable from
the
pedal
pedal
Disengage
from the ball
car on a
the
nylon
retainer and
clevis.
housing.
1. Raise the
lever
3. Install the inner
from the
clevis
sembly
connect
and torque to specification.
pin
cable,
equalizer
bracket and brake pedal
Install the pivot bolt nut
6. Remove the hairpin
clevis
PART 2-2
duct. Position
control cable to the air
left kick
the
pad to the side panel and
secure with two
6. Raise the
car on a
housing to the
U-clip (Fig. 1,
the cable
with
stall
a
frame bracket
the
lever
install the half-moon type
nut on
adjusting
to the equalizer
cable
REMOVAL
1. Raise the
the
connect
ing
pedal
lever
equalizer
by
cable
dis
and
from
cable
removing the
the
adjust
1, Part 2-1). Remove
(Fig.
nut
hoist
car on a
spring, and spring
washer,
seat.
Remove the
gage
the
U-clip
housing
cable
and
disen
from
the
bracket.
2. Lower the
brake.
the
left kick
pad.
four
screws
that
duct to the inner
cowl
unit
out
that
from
the
car
in
Removal
air
control
as
from
the control cable
Re
the air
retain
control
connects
release
the
two
the
vacuum
power
control as
grind
or
the
off
the rivet
vacuum piston
lever,
and
remove
link
the
5. Remove the
that
control
clevis
housing to the parking brake
housing (Fig. 18).
the
from the
pin
1. Position the
Remove the
Disengage
clevis.
end
the
of
vacuum
power
it from
1. From the
piston
a
link
floor
install the half-moon type
to
cable
equalizer
the end of the cable.
nut on
9. Adjust the parking brake linkage
as outlined in Part 2-1, Section 2, and
then check the operation of the park
ing
brake.
PARKING BRAKE EQUALIZER TO
REAR WHEEL CABLE
wave
to be positioned on the
bolt between the vacuum pis
ton link and the release lever. The link
and release lever must pivot freely.
is
3. Install the parking brake control
assembly in the car as described under
in
the
foregoing
proce
dure.
the
lock
operations
control
and
of
assembly
automatic
the
with
parking
the
en
running in all the transmission
selector lever positions. With the en
the
gine
running,
parking brake
gine
remain
engaged
should
REMOVAL
1. Raise
release
in
the
remove
and
car
Remove the
cover.
the
wheel and
from the drum.
2. Remove
Tinnerman
three
the
brake drum, then
the brake drum.
nuts that secure the
remove
assembly
housing.
under
3. Loosen the adjusting nut on the
rod and disengage the ball
equalizer
the car.
the
of
from the
cable
equalizer
1, Part 2-1).
(Fig.
4. Remove the
the
U-clip that retains
housing to the frame
Disengage the housing from
cable
bracket.
bracket
hook (Fig.
neutral or
in any drive
of
underside
upper
end
of
the
re
into the hole in the
cable
5.
the car,
and
the retainer
off
slip
18).
plate
prongs
on
they
pan.
Working
carrier
2. From
cable and
in
the
the inside, pull the
housing up through the
floor
in
the
cable
through
brake
the
parking
housing. Install the clevis
end of
to
the
control
on the
the
cable
plate.
out of the
the
compress
so that
retainer
the
Draw the
hole in the
cable retainer
hole.
hole
pan.
3. Position
hole
new
the wheel side of the
on
(Fig. 4),
can pass through
carrier
shoulder
The
and wave washer.
and
the
guide
shoulder
park
the
the
and
unit
placement
2. Connect the vacuum
to the release lever with
should
and
Assemble
the
and nuts.
brake
spring
of the cable.
lever
end
control
cable and cable
pan and remove
the parking brake control assembly
and secure with two round head bolts
release
cable
rear end
retainer and
from the ball
clevis
cable.
on
4. Test
the
on
retains
INSTALLATION
Installation
hoist. Engage
a
car on
the spring seat,
washer
tire
U-clip
the cable
from the
INSTALLATION
washer
screws.
housing to the frame bracket
U-clip (Fig. 1, Part 2-1). In
a
with
stall
wheel
7. Push the cable and housing
down through the hole in the floor
nut
8. Raise the
assembly-to-
6. Remove the hairpin
out
from the
hose
the
4. Remove the
the
power unit.
bolt
to the side panel and
two attaching
obtain access
assembly.
mounting bracket bolts.
off
grind
or
to the parking brake
the
to
to the air duct. Position
pad
vacuum power unit.
sembly.
3. Drill
the
panel, and then
duct to
air
brake
the
3. Disconnect
brake
parking
procedure.
that
rivets
the
under
2. Drill
the
remove
secure
at
duct
duct.
assembly
foregoing
attaching
Remove
remove
move
1. Remove
described
passenger
screws and the
to
control
In the
compartment,
the
REMOVAL
car.
air
the cable
adjusting
then check the operation of the park
PARKING BRAKE VACUUM
POWER UNIT
left kick
the
four
with
Connect the
screws.
secure with
the
the end of the cable.
7. Adjust the parking brake linkage
as outlined in Part 2-1, Section 2, and
ing
panel,
duct to the inner
air
secure
and
control cable
Part 2-1). In
Assemble
and
cowl
taching
rear end of the cable.
the
on
TO-CONTROL ASSEMBLY CABLE
hoist. Engage
the spring seat, cable spring and
washer
7. Position the
EQUALIZER-
PARKING BRAKE
screws.
attaching
2-19
SYSTEM
-BRAKE
6. With the spring tension off the
parking brake lever, lift the cable out
the
of
slot
in the lever
through the carrier plate
ball
and
remove
hole.
the cable and connect the clevis
pin
the
actuating arm with the clevis
(Fig. 18). Secure the clevis pin
with
the hairpin retainer.
4. Secure the
parking brake
the U-clip.
5. Position
INSTALLATION
1. Pull
housing to the
control housing with
cable
the
parking
brake
housing
cable
rier
the
side
enough
so
of
plate
access
cable, insert the
vacuum
position.
vacuum power unit.
hose to
the
Pulling
carrier
plate
the
of
car
hole from the inner
bolts.
6. Connect the
end
and engaged with the slot
parking brake lever.
2.
the
may be inserted through the
assembly to the mounting
bracket and install the three attaching
control
the cable through
that
from
the
housing into
the
the excess slack
cable
access
in the
hole
retainer prongs expand
.
so
that the
2-20
GROUP 2
3. Thread the front end of the cable
the frame bracket, and en
through
gage the cable
Install
housing
U-clip and
the
bracket.
hook
to the
retainer
(Fig. 18).
-BRAKES
4. Insert the ball end of the cable
into the equalizer and tighten the ad
justing nut
install the
and
wheel and
wheel cover.
slightly.
5. Install
the
6. Adjust the parking brake linkage
in Part 2-1, Section 2.
drum. Tighten
rear
Tinnerman
the three
drum,
the
nuts that secure
as outlined
MAJOR REPAIR OPERATIONS
REAR BRAKE DRUM
REFINISHING
Minor
be
removed with a
drum
brake drum can
fine emery cloth. A
scores on a
is excessively scored or
indicator runout or over
0.007 inch should be turned down.
Remove
enough
stock
to
only
that
shows a total
the
eliminate
drum. The
scores
diameter
0.060 inch
not exceed
each
supplied
in the kit. Ford
Install
end.
linings are ground
grinding is required.
4. Check the
shoe
than
and
parts
further
no
between the
lining
clearance
must
between any
two rivets.
after
(11.120
refinishing, standard
inches)
lining may
in
the
moving
against
the piston
snap ring retainer,
re
and
then remove the piston assembly, cup,
11.120-11.150 inches,
be installed.
(Fig. 19).
linings
oversize
After
the
drum is turned
a
refinished
soaked
down,
with
a
wipe
cloth
denatured alcohol. If
is turned down, the op
drum on the same axle should
clean
drum
one
posite
also
in
surface
be
cut
down to the
spring,
residual
linings
1/32 inch
2. Remove secondary cup from the
Remove the cover by releasing
the spring clips on the sides, and re
move the
hermetic diaphragm.
within
been
of
saturated
semble
grease
or
be replaced. Failure to
linings will result in a
drum. When it is necessary to
should
the
must also
wheel on
be
oil
check
the
Dip the hydraulic
in brake fluid and as
check
valve, and
in the bore of the
shown in Fie. 19.
valve
the
exists,
Do
cylinder
spring
in the
shoes
shoe
replace
COVER
scored
1. Wash the brake
a clean solvent.
or rough spots
shoes
from the
with the
spring
(only if
in the cover,
defective)
to the cylinder
cover
clips.
DISC BRAKE CALIPER
DISASSEMBLY
not remove
the
the bridge bolts that
halves
two
the caliper
of
together. The two caliper housings are
shown
separated
lustration
in
Fig. 21
for il
purposes only.
1. Remove
from the car as
the
caliper
outlined
assembly
in Section 2.
lining
DIAPHRAGM
4. Remove the flexible brake hose
from the caliper.
MASTER CYLINDER
tube.
5. Remove
VALVE
thorough
the
external
transfer
6. Remove the four dust boots
from the caliper housings and piston
shoe.
all
shoe and
assemblies.
condition
Remove
the
attach
3. Remove the two
replace
be discarded.
should
and
diaphragm
2. Remove the two attaching bolts
(Fig. 21).
(Fig. 21).
for distortion,
defective brake
to
order
replaced on
looseness. If this
not repair a
ly in
seal, residual
piston return
the opposite side of the
Inspect brake
or
cylinder
vise.
parts
the
master
car.
cracks,
piston
and the caliper splash shield
worn
linings, they
to
worn
the rivet or have
with
is
hold
cylinder
are
a new
the old one
Do
ASSEMBLY
Clamp
housing in a
that
the
against
the spring while seating the
ring in the groove in the cylinder
piston.
1.
Brake
in
bore.
check valve and seat
same size.
REAR BRAKE SHOE
RELINING
the end
on
assembly, and guide it
the cylinder
5. Install
1. Press
be installed. If the drum diameter is
must
into
snap
bore.
If the drum diameter is less than
oversize
the piston
4. Press
DISASSEMBLY
0.030 inch
3. Place the primary cup
of
lip of
shown.
compress
MASTER CYLINDER
(11.150
oversize
inches).
the cup as
must seat
against the shoe with not more
0.005 inch
2. If the secondary piston cup was
from the piston, dip the cup
in brake fluid and assemble the cup in
removed
the groove of the piston with the
clearance
lining. The
and
tightly
all
replacement
true up the
and
refinished
towards
grooves.
burrs
my.
7.
PRIMARY CUP
shoes.
Clamp the caliper in a vise and
it by the mounting flanges on
inboard housing (Fig. 20).
secure
2. Check the inside diameter
that
11.120
inches,
11.120-11.150
should
y/%1
inches,
the
Starting in
the
;
lining
the center,
insert
the
FIG. 19
-Master
and
rivets, working alternately
Disassembled
the
four
pistons
from
the cylinder bores with the special tool
SNAP RING
lining
on
the
SECONDARY CUP
shown
H 1387
new
,
8. Remove
linings
diameter is
oversize
P
SPRING
be installed.
3. Position
shoe.
the
standard
may be installed. If the
secure
of
drum. If the diameter is less
brake
-
Cylinder
in Fig. 20. To
with consequent
A
-
prevent cocking
damage to the piston
or bore,
rotate the piston with the
tool while pulling it outward at the
same
time.
Be
careful
to avoid
scratching
or
damaging
the outside
PART 2-2
diameter
surface
groove
retaining
damage causes
dust
or
of
Check the
boot
the piston. Such
Replace
poor sealing.
the
Check
off.
for
retainer
if
chrome
the
is
it
pis
and
excessive
or
piston
the
or
scored,
bores
cylinder
for damage
tons
wear.
pitted,
plating is worn
dust boot
caliper
wear or
2-21
SYSTEM
-BRAKE
squarely in the bore
steady
easily
Clamp
secure it by
2. If
housing
in
seats
retainer
and
the piston seal and the
will
of
Installing
Removing
to
Pistons
the
is
completely seized in
bore that it can not be re
piston
cylinder
moved
tool, force the
cylinder out of the
bore
two
in the
screwdrivers
boot retaining
To
ward.
the
of
prevent
prying
force
to
boot
lightly
film
in the
the
the
installed,
use
Fig. 20.
Rotate
tool
while
same
time.
5.
seal
one
in
area
around.
be
not
install
cylinder
positioned at
groove
Do
the
tons.
Be
Do
the
the
at
new
housings
dust
and pis
fully
its
respective
and piston
(Fig. 21).
groove of
housing
not use
in
with
that each boot is
sure
in the
shown
it inward
install four
on the caliper
good
properly
piston
pushing
Carefully
caliper
tool
the
piston
the original dust boots.
transfer tube.
external
brake fluid
the
of
should
the
piston seal
boots
seated
If the
bore in
housing.
of clean
grooves
and
use
gently
the orig
seals.
7. Install the flexible brake hose to
the caliper.
8. Install
the
spindle,
lining
the
assembly on
install the shoe and
caliper
and
assemblies and the splash shield
as outlined
dust
in Section 2.
tap
hammer,
pistons
outside
them in the cylinder
open
end
of
diameter
brake fluid
with
bores
and
of
the
install
so that the
the piston and the boot
9. Check the
under
not
move
pedal
caliper
maximum
is
the
for fluid leaks
pedal
car
until
pressures.
a
Do
firm brake
obtained.
out
prying
around
4. Coat the
the end
the
cir
while
CALIPER ABUTMENTS
the
being applied. Be
damaging the dust
in the caliper housing
method of removal
be
pistons must
outboard caliper housing
is
retaining
groove
pry the
housing
PISTON SEAL (4)
is
DUST BOOT RETAINING GROOVE
replaced.
dust boot
caliper
scratched,
caliper
caliper
a
is
(Fig. 21). If this
If the
in the
Install
with
avoid
retainer
used, the
positioning
piston
cocking,
cumference with a
careful
by
groove and
piston
housing.
seal.
in
so
the special
with
the retainer surface that
the
bore. The
inal
a
the caliper
Loctite Sealant,
new caliper piston seals and
worked
If
to
Apply
them
or
area on
apply
the
not go
6. Install the
3.
20
on
boot
dust
caliper
contact
and
Grade H
FIG.
a vise and
mounting flange
the
new
a
the
clean
A
in
is to be installed, thoroughly
retainer
-
caliper
inboard housing.
the
H 1372
the
not
will
bore,
it
condition and
1.
a slow
apply
piston
way into the bore, re
thoroughly inspect the
installation
still
and
a
piston
go all the
cylinder
ASSEMBLY
If
pressure.
bore.
out of the
locate the
cocking,
avoid
move
damage.
face
groove
retaining
To
o
retainer or
damaged
EXTERNAL TRANSFER TUBE
^>
or
retainer out of
the
DUST BOOT (4)
with screwdrivers.
^
SPLASH SHIELD
9. Remove the
from
by
knife
the
the
and
SHOE AND LINING ASSEMBLIES
INBOARD CALIPER HOUSING
of a
point
in
pointed
seal
up far enough
fingers.
seal
out with
seals
bores
other
or
under
strument
the
inserting
carefully
small
piston
cylinder
rubber
in the
the grooves
raising
to be pulled
the
CLEANING AND INSPECTION
Clean
or
clean,
out
free
dry,
and
ways.
and
all
metal
Be
dry
with
alcohol
(Fig. 21).
compressed
air
to
Use
clean
the grooves and passage
sure
component
of
parts
solvent
suitable
a
that
the
parts
any foreign
caliper
are
material.
FLEXIBLE HOSE
H1367-B
bore
completely
FIG.
21
Caliper
Assembly
Exploded View
2-22
PART
2-3
SPECIFICATIONS
DRUM BRAKE DIMENSION-IN INCHES
Drum
Maximum
Drum
Inside
Diameter
Lining
Boring
11.030
Cylinder
Bore
Master
Cylinder
Bore
Wheel
Lining Width
Length
Limit
Primary
Secondary
Primary
Secondary
Diameter
Diameter
11.090
9.39
12.21
2.50
2.50
15/16
15/16
i
BRAKE CHECKS AND ADJUSTMENTS
Type
of
Check or Adjustment
Specification
Brake Lining Required
Oversize
Drum Diameter
11.060-11.090
Brake Shoe Repair
Brake
Lining Clearance (Midway between Rivets) Maximum 0.008
Lining Wear Limit (From Top
of
inch
Rivets) Maximum 1/32 inch
Hydraulic Master Cylinder Bore, Honed Diameter. Maximum 0.9405 inch
Master Cylinder
Push Rod Adjustment 0.480-0.995 inch
Power Unit
Refinish if Total Indicator Runout Exceeds 0.007 inch
Drum Out-of-Round
Rotor Runout
Replace if Runout Exceeds 0.002 inch
DISC BRAKE SHOE AND LINING DIMENSIONSINCHES
TORQUE LIMITS
Lining Material
Ft-
Description
Front Brake Hose Bracket to Chasis Bolt
Rear Brake Drum to Rear Axle Shaft Flange
to Axle
Bearing
Lining Size
5.36x1.90
10-15
Lining Area
10.03 Sq. In./segment
Shoe and Lining Thickness
0.600
nominal
Lining Thickness
0.436
nominal
Shoeand Lining Maximum
Wear Limit
0.231
Hand Push Fit
75-110
Rear Wheel to Axle Shaft to Drum
Rear Brake Carrier Plate and
Lbs
Retainer
Housing
50-70
Master Cylinder to Booster
1218
Master Cylinder Tube
6-12
Fitting
Brake Booster to Dash Panel
Support Bracket
and
(from
surface of
shoe)
15-25
15-19
0.066
Lining to Rotor Clearance
(brakes released)
Pedal
Parking Brake Control to Mounting Bracket
Lining Maximum Wear Limit
Proportioning Valve
0.002-0.010
450 PSI
cut
(43%%
in
reduction in rear
pressure over
450 psi)
line
2-23
PART2-3-SPECIFICATI0NS
DISC BRAKE TORQUE SPECIFICATIONS
Caliper Assembly to Spindle
90-115 Ft-Lbs
Caliper Bleeder Screw
10-Ft-Lbs (120
SERVICE TOOLS
tn-lbs)
Maximum-must be leakproof
Caliper Splash Shield
Rotunda HRE-8650
-
10-20 Ft-Lbs
Brake Tube
70 In-Lbs-Maximum-must
be leakproof
Fitting Nuts to
Proportioning Valve
Rotor Assembly to
Front Wheel Spindle
17-25
and
Wheel
Hub
Ft-Lbs-
while
Rotate
Brake Adjusting Tool
2162
Adapter
2035-N
Brake Shoe R& R
33621
TOOL-33621
rotor
Milbar
1112-144
torqueing 0
Bendix 73800
to Front Wheel
Rotor Assembly
Cap
Spring
2086-L
Assembly
and
Retaining Clamp
2018-A
65-75 Ft-Lbs
Rotor Splash Shield to Spindle
Adjusting Gauge
Brake Cylinder
-
-
Hub
Brake
_
-
7-9 Ft-Lbs
Caliper Bridge Bolts
Description
Former No.
Ford Tool No.
Internal
Snap Ring Pliers
In-lb Torque Wrench
Booster
Disassembly and Assembly
tool
70-115 Ft-Lbs
A/C Tool
to
of
maximum
bearing
end
play
with
torque
specification
T00L-4235C
17-25 Ft-Lbs
4235C
HYDRAULIC FLUID AND LUBRICANT
Description
Hydraulic Fluid
Lubricant
and
Brake Shoe Adjusting Screw Lubricant
Brake Fluid
General Chassis Grease
C1AZ-19590-B
C6AZ-19542-A
Disc brakes function best with a fluid having a higher boiling point than pre
viously available fluids. If C6AZ-19542-A fluid is not available, small quantities
of a reputable
be added to
brand
of
"heavy duty fluid
maintain required
fluid level.
meeting SAE
specification
70R3 may
Axle Shaft Remover
3-1
SUSPENSION,
STEERING, WHEALS
AND
GROUP
3
TIRES
PART 3-1
PAGE
PAGE PART 3-4
SUSPENSION, STEERING,
3-35
WHEELS AND TIRES
WHEELS AND
TIRES-GENERAL SERVICE
3-1
PART 3-2
PART 3-5
SUSPENSION
3-9
SPECIFICATIONS
3-40
.
PART 3-3
STEERING
3-18
PART
3-1
SUSPENSION, STEERING, WHEELS AND
TIRES-GENERAL SERVICE
3-1
Belt
Camber
3-1
Caster
3-1
Toe-In
3-3
Turning Effort
Pump Fluid Pressure Test
3-3
3-5
Angle
and
3-5
3-5
3-6
3-6
Repairs
Wheel Alignment Adjustments
3-1
Fluid Leaks
Front Wheel Alignment Checks
Turning
2 Common Adjustments
3-1
Checks
Fluid Level
Pump
Front Wheel
3-1
Diagnosis and Testing
Steering
Power Steering Preliminary
Air Bleeding
Page
Section
Page
Section
and
Wheel Alignment
Steering
Adjustments
3 Cleaning and Inspection
3-6
3-7
3-3
Front End General Inspection
3-4
Wheel I nspection
Equipment Installation
3-4
Upper Ball Joint Inspection
Caster
3-5
Lower Ball Joint I nspection
Camber
3-5
Flushing
Toe-I n
3-5
the
Power
3-7
3-7
3-7
3-7
System
Steering
3-8
DIAGNOSIS AND TESTING
POWER STEERING
STEERING
Fluid Level.
PRELIMINARY CHECKS
Table
lists
1
in
table
should
the
to
Table
the
be
trouble
causes.
in
order
checked.
fourth
1,
tire
are
causes
possible
listed in the
sible
Turning
proceeding
dicated.
item
with
2
in
pos
gear
trouble
symptoms and possible causes.
Steering
and
to
Table
3,
for
Movable
Column Trouble Symptoms
Possible Causes.
following
always
be
forming
any
operations.
Also,
Air
preliminary checks
made before per
diagnosis
trouble
see
Tables 1
and
steering
making
to
power
bubbles in
After
reservoir
is filled
(the fluid
must
temperature
operating
be
at
when
is made), turn the steering
through its full travel three or
check
wheel
four times
in
by
with
operation.
against
level.
their
Do
at
stops.
hold the
left
and right
and shut off the engine.
wheels
Recheck the fluid
reservoir.
The level
the full mark on the
level
is low,
add
power
be
dipstick. If the
enough
must
automatic
fluid (C1AZ-19582-A) to
raise the level to the F mark on the
dip stick. Do not overfill the reser
transmission
voir.
PUMP BELT
If the pump belt is
the windshield wiper
not
the way to the
times,
Check the fluid level in the
bled.
be
that the
specification
normal
(shown
should
sure
several
steering
system
fluid)
the
wheel all
2.
Bleeding
Air Bleeding. Air in the
the
Table 2 lists steering
Refer
The
should
pres
size) before
the other items in
(tire
Fluid Level. Run the engine un
fluid is at normal operating
temperature. Then turn the steering
the
til
When
When checking the
causes, check item 1 (tire
and
refer
symptom
Stationary.
sure)
they
which
For example,
trouble
Hard
suspension,
possible
and
their
and
symptoms
The
wheel
and
steering,
various
or
Us
worn,
replace
it
broken, glazed,
with
a
new
belt.
only the specified type of belt.
Refer to Part 3-3 for belt adjustment.
3-2
3
GROUP
TABLE
1
Steering
SUSPENSION, STEERING,
System Trouble Symptoms
and
WHEELS AND TIRES
Possible Causes
op
I/)
n
t/>
(/)
ca
<
Ua
H
mm
It
00
ft,
cn
>->
u
o
"o
ca
</>
c
(/)
(/)
o
'5
u.
Cn
H
o
c
a
c
w
Ua
ml
CO
cu
OO
c
'mm
<u
u
Cn
Cn
00
Ua
u
cu
Cn
o
o
OS
H
>
B
H
'u
Glazed, Loose
or
7.
Rear
Spring
Rear
Spring
cn
i
O
Spring
<u
c
o
S
o
-o
fc
o
o
cu
Oi
i
O
o
PL
<U
u
mm
cr
oo
o
00
o
in
O
CQ
H
ft.
<
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
10. Bent Spindle Arm
X
11. Bent Spindle
X
X
X
X
13.
Air in Power
14.
Steering System
Obstruction in Power
%
Steering
X
Lines
X
X
X
15. Loose
or
Weak Shock Absorber
X
X
16.
Loose
or
Worn Suspension Arm Bushings
X
X
17.
Binding Front Suspension
Steering Linkage
18.
Worn, or Damaged Steering
Loose^
Connections
Ball Joints
Loose
Steering
20. Insufficient
Steering Gear
22.
Incorrect Brake Adjustment
23.
Incorrect Front Wheel
Wheel Out
of
Bearing
27.
Frame
of
X
X
X
X
Adjustment
X
X
X
X
X
or
X
X
of
30.
Steering Gear Valve
of
X
X
X
Spool
or
Steering
Gear
.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Out
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Internal Parts
Binding
X
X
X
Adjustment
31. Obstruction Within
X
Alignment
Steering Pump
Excessive Wear
X
X
28. Bent Rear Axle Housing
29.
X
Brake Drum
Underbody Out
X
X
X
X
X
25. Incorrect Front Wheel Alignment
Out-of-Round Wheel
X
X
Balance
26.
X
X
Adjustment
Incorrect
X
Linkage
Pressure
21.
24.
X
X
Gear Mountings
Steering Pump
X
or
or
19.
X
X
X
X
X
X
X
X
Front Hanger Mislocated
X
CU
X
X
X
3
00
ca
ca
OO
X
X
Lubrication
ca
X
X
of
u
OO
X
X
X
Lack
c
a.
ft.
X
12.
C
o
Sfi
'JO
o
c
c
x>
X
o
Cm.
o
"c5
2
JC
00
3
Ua
5
c
X
o
JC
o
u
X
OJ
-o
3
00
>^
T3
CU
X
Tie Bolts
Ua
J2
"c5
u
3
o
X
X
>.
oo
X
X
o
a.
o
oo
X
X
ca
u.
i
Tie Bolt Off Center
8. Broken Rear
9.
Steering Pump
3
55
X
Broken Power
-a
c
ca
Spring
Belt
c
I
X
X
Fluid Level Low-Leak
Broken
u
o
Loaded Vehicle
Unevenly
6.
or
j:
Ua
<L>
ca
X
Sagging
i_
X
X
5.
ca
u
u
2. Tire Sizes Not Uniform
Steering
00
c
u*
X
4. Power
T3
C
T3
X
or
C/3
ca
3
1. Incorrect Tire Pressure
3. Overloaded
E
</i
u
O
u
>
o
O.
00
c
l
u
c
u
ca
00
c
v.
POSSIBLE CAUSES OF TROUBLE
o
i/>
i>
>
Cu
>.
a.
c
o
a
'.
o
s
0
u
CC
o
of
X
X
X
X
X
X
PART 3-1
Fluid Leaks.
With the
ing
wheel
Turning
engine
idling,
times.
Check
all
points.
Tighten
all
replace
any damaged lines
leakage
possible
loose
several
fittings,
or
and
With
ligned
Steering
correct,
times to
several
check
3. Attach
the
car on
dry concrete,
set
brakes.
the parking
engine warmed
up
and
warm
left and
the fluid.
wheel.
Measure the
to turn the
pull
wheel one com
direction. The
plete revolution
in
each
effort
to
rotate
required
right
to the rim of
a pull scale
steering
the
turn
speed,
the
to
wheel
required
2. With the
2 Power
a-
properly
wheel.
1. With the
defective
wheels
the effort required to turn the steering
seats.
TABLE
front
the
and tire pressures
idle
at
running
Effort
steering
turn the steer
from stop to stop
3-3
WHEELS AND TIRES -GENERAL SERVICE
STEERING,
-SUSPENSION,
wheel should not exceed
the steering
3.5
pounds.
Gear Diagnosis Guide
Low fluid level
JERKY STEERING
Obstruction in
or within
.
.
Air
steering lines
power
gear mountings.
Incorrect steering
gear adjustment.
the steering gear.
Low fluid level
HARD STEERING AND/OR
LOSS OF POWER
ASSIST
Loose steering
fluid leakage.
or
Insufficient
fluid leakage.
or
power
steering
pump
pressure.
.
in power
steering
system.
,.
_,
Obstruction
or within
in power
steering lines
the steering gear.
Incorrect steering
Steering
gear adjustment.
binding
gear valve spool
or
out of adjustment.
HARD TURNING WHEN
Low fluid level
STATIONARY
Obstruction in
or within the
Air in
power
or
the
or within
fluid leakage.
power
Loose steering
Insufficient
system.
steering lines
power
steering
Insufficient
steering
pump
pressure.
gear.
steering
Obstruction in
steering lines
power
steering
Low fluid level
STEERING GEAR
DIAGNOSIS GUIDE
POWER
fluid leakage.
or
gear mountings.
power
Incorrect steering
gear.
steering
pump
Pressure-
gear adjustment.
LOOSE STEERING
SHIMMY OR WHEEL TRAMP
Loose steering
gear mountings.
Incorrect steering gear adjustment.
SIDE-TO-SIDE WANDER
T
BINDING OR POOR RECOVERY
.
ef-
Insufficient
,
power
.
steering
pump
Steering
gear valve spool
binding
or
out of adjustment.
pressure.
T
BODY SWAY OR ROLL
POWER STEERING GEAR
.
gear adjustment.
Incorrect steering
gear adjustment.
Steering
DIAGNOSIS GUIDE
Obstruction
..
.
Incorrect steering
gear valve spool
within
the
steering
8
__
binding or
out of adjustment.
ABNORMAL OR IRREGULAR
Incorrect steering
TIRE WEAR
A
Pump-Fluid Pressure Test.
fluid
the
pressure
pump
or
test will show whether
some
other
unit
in the
power
trouble
below
gear adjustment.
system
is
steering
in the system. Steps
should
causing
outlined
be followed to deter
mine
the cause of the trouble.
1. Measure the pump belt tension.
3 4
GROUP 3
When adjusting the belt tension on
power steering pump, do not pry
against the pump to obtain the proper
belt load.
-SUSPENSION,
the shut off
the
valve
3. Connect
corporated
pump
on
boss has been in
cast
the front face of the
cover plate onto which a
the pump and obtain
tension.
2. Disconnect
the
line
pressure
hose from the pump outlet, and install
a
0-2000 psi pressure gauge (Tool
T56L-33610-D)
between the
pump
and
end
shut
off
hose
the
of
idle
to
sure
all
valve,
TABLE
engine and operate
for
least two
fluid.
the
up
speed
5. Cycle
the
connections
3 Movable
is
the shut off
are
at
1075 to 1150
Do
tight,
and
Remove
reservoir filler cap and
fluid level in the reservoir.
If
add
lubricant
necessary,
(CI AZ-19582-A) to the proper level.
the
the
engine
normal
rpm and
steering
the
temperature,
operating
at
of
less than 50
If the
psi.
to
and
pressure
(maximum 5
sec
abnormally in
would
the lubricant temperature and
cause
undue
gear
wear.
If
fast idle
If
is
more
is
pressure
not
test.
less than
or
as
pump
as specified and
heavy,
are
and/or control valve could
is
steering
should
the
replace
efforts
steering
rpm
during this
pressure
specification,
sembly.
and/or
pump
Engine
the gear
be
at
fault.
8. Remove the tachometer.
Possible Causes
bracket
column
this
as
the valve for more
seconds
crease
ap
pressure gauge should show a pressure
Track
BINDING, ROUGH, OR
no
at
lubricant
the
and
applied,
running
to
engine
psi.
close
few
a
exceed
Column Trouble Symptoms
Steering
not
onds),
6. With the
speed
the
from
than
check
and
the pump pressure should be
closed,
valve
pressure gauge
and
it
hoses for kinks
1000 rpm, then slowly close the gauge
With the valve fully
shut-off valve.
minutes
wheel
steering
proximately 500
that the
(2)
at
the
obstructions.
en
stop-to-stop several times to expel any
air from the system; stop the engine.
effort
Be
higher, inspect
open.
7. Increase
warm
and the
outlet.
between the pump
fully
gine.
9/16"
be fitted to pry
the proper belt
open end wrench can
is
WHEELS AND TIRES
tachometer to the
a
4. Start the
A half inch
STEERING,
mis-
Locking
plate
of
adjustment
with
instrument
out
rubs pawl.
alignment.
RASPING COLUMN
Shroud interference
panel.
Slide tension out of adjustment.
Track
to
column
bracket
HARD COLUMN
MOVEMENT
Locking
mis-
plate
out
adjustment-
of
rubs pawl.
alignment.
POSSIBLE SHIFT INTO
Locking
plate out of adjustment.
REVERSE WITH COLUMN
AT EXTREME RIGHT
POOR SHIFTING INTO OR
OUT OF PARK
LATERAL LOOSENESS IN
COLUMN WHEN LOCKED
pawl
not attempt
wheel
to
check and adjust
alignment
without
first
all
the factors of front
except
the
turning
pivot
braces.
at
arm
binding
in
pivot
caster,
camber
been
adjusted
The front
cations
given
to
be
The
only
toe-in have
specifications.
wheel
alignment specifi
in Part 3-5
are correct
only when the car is at Curb Height.
or
Before
checking
adjusting the
wheel
alignment
angle
alignment
factors,
factors,
out of adjustment.
out of ad
checked
and
gear.
gear.
adjustments.
angle should
after
Pivot bracket loose at steering
Left stop out of adjustment.
slide tension
steering
Right stop bolt (on track)
justment.
turning
3.
Check
or
before making any
inspection of
making a preliminary
the front-end parts. Refer to Section
alignment
loose in
arm
Pivot bracket loose
ALIGNMENT CHECKS
front
Locking
bushing.
Loose track
FRONT WHEEL
pawl
bushing.
VERTICAL LOOSENESS IN
RIGHT SHROUD HITS AIR
Lock
out of adjustment.
COLUMN WHEN LOCKED
CONDITIONING UNIT
Do
Left stop
the
suspension
the
suspension
be installed to
alignment spacers must
obtain
the curb height.
EQUIPMENT INSTALLATION
Equipment
alignment
for
Alignment
curate.
(Figs.
used
inspection
1
and
2)
are
front
must
height
used
wheel
be
ac
spacers
to check
caster and camber.
The
when
spacers
should
checking toe-in.
be
omitted
PART 3-1
WHEELS AND TIRES
STEERING,
-SUSPENSION,
35
GENERAL SERVICE
POSITIVE
ALIGNMENT MARKS
CAMBER
POSITIVE
CASTER
CASTER
CL OF TIRE
JjLl
FR0NTr
CAR
CAMBER
ANGLE
F1216-A
FIG. 4-Caster
Tool
T65P
-
3000
-
-
B
F
1268-
A
1213-A
Angles
top (Fig. 4). If
the
FIG.
FIG. 3 Typical Straight Ahead
1 Alignment Spacer
Installation-Front
in Fig. 1. The lower
et as shown
the
of
alignment
over
placed
spacers
head
of
should
the ball
Position the
nut.
retaining
spacers
the
for the
is
camber
inward,
rear of
end
be
joint
alignment
is
a wheel tilts out
If
positive.
camber
correct camber
the edge of the frame spring pock
and
ward,
tilts
Position Marks
Camber
and
is
wheel
camber angles should not exceed
However,
than
difference
a
1/4
is
tilt,
maximum
between both front
difference
The
or outward
angle,
in Part 3-5. The
specified
a wheel
negative.
of
not
1/2.
more
preferred.
the car between
the rear axle and the frame side rail as
in Fig. 2. Lower the
shown
the car so that the weight
hold
will
the
alignment
rear of
the
of
TOE-IN
body
spacers
in
height
Alignment
used
to check and
spacers
are
not
adjust toe-in.
place.
Toe-in
3. Install
the car. Whichever type
is used, follow the in
inspection instructions
and
stallation
and
establish
then
the
column
collar
steering
(Fig. 3). Do not adjust the steering
wheel spoke position at this time. If
the
front
time
wheels
turned
are
at
any
during the inspection, align
to bring the wheels back to
marks
the
end
in
install
adjustment,
alignment
car
spacers
tablish the curb
for the
inspection
the
as
Caster is the forward
wheel.
tilt
ward
spindle
and
suspension
follows to
front
caster angle at each
at
the
top
the
of
(Fig. 4). If the
or rear
wheel
rear, caster is positive. If the
tilts to the front, caster is neg
ative. The "correct caster angle, or tilt
spindle
is
specified
in Part 3-5.
Correct toe-in, or inward pointing
both front wheels at the front, is
specified in Part 3-5.
maximum
not
exceed
ference
ferred.
difference between
wheel caster angles should
1/2
However, a dif
.
of not more
FRONT WHEEL
TURNING ANGLE
than
1/4
is
pre
20,
between
the
suspension
spacers
upper
arm
the
the
combination
toe-in
therefore,
front
the
wheel.
amount
the
The
front
angle
at
camber angle
wheels are
each
is the
tilted at
of
turning
of
the outside
caster, camber,
adjustments
be
angle
specifications,
and
should,
only after
have been made. If
does not measure to
measured
these adjustments
camber
is turned
wheel
angle
should be as specified in Part
3-5. The turning angle cannot be ad
justed directly, because it is a result of
and
Check
inside
the
turning
wheel
the
alignment
ex
and also
of
When
es
of the car and posi
suspension
front
the
CAMBER
tion the
front
spindle tilts to
height.
Lift the front
the
with
is the toe-in.
The
position
alignment
toe-in
straight-ahead position.
CASTER
both front
2. With the
the
in the
between the ex
treme rear of both front wheels. The
difference between these two distances
the
straight-ahead position.
front
adjusted to specifications.
Measure the distance between the
Check the
front wheels,
the steering wheel hub
mark
checked and
caster and camber
straight-
the
and
wheels
the
turer.
line
straight
the
of
position
ahead
a
after
Check
treme
in
car
to
enough
the equipment manufac
-Rear
1. Drive the
far
by
provided
adjusted
has been
only be
should
alignment
equipment
F 1269
Installation
wheel
equipment on
of
FIG. 2 Alignment Spacer
the
check
other suspension parts
the
for
spindle
a
bent
or
con
dition.
COMMON ADJUSTMENTS AND REPAIRS
WHEEL ALIGNMENT
ADJUSTMENTS
After front wheel
have been checked,
alignment
make
the
factors
neces-
sary adjustments. Do
adjust
front
wheel
not attempt
alignment
to
by
3-6
GROUP 3
bending
the
suspension
or
steering
parts.
STEERING, WHEELS AND TIRES
-SUSPENSION,
SHIM RETAINING NUT
\
PIVOT BRACKET
PIVOT BRACKET
SrilM RETAINING NUT
|
BRACKET RETAINING NUT.
LOWER ARM
I
SHIMS
CAMBER
Adjust the
by removing or
between the pivot
the front suspension lower
installing
bracket
camber
shims
of
the mounting bracket on the
underbody in the engine compartment
(Fig. 5).
arm and
The
between the
brackets will
move
the lower ball joints inward.
The installation of shims between the
mounting and pivot brackets will
move
the lower ball joint outward.
Camber adjusting shims are available
in several standard shim thicknesses.
removal
A 1/16-inch
will
pivot
change of shim thickness
the
change
The total
of shims
and
mounting
camber
not exceed
1/3.
angle
thickness should
shim stack
11/16-inch.
CASTER
The
caster
adjustment
is
by
made
repositioning the strut on the lower
arm as shown in Fig. 5. Adjust the
loosening
by
caster
the
rearward
washers, nuts and bolts. Lift the
strut
be free
from the serrations on the lower arm.
Lengthen the distance between the
so that the strut serrations will
forward
strut
the
lower
mount
(Fig.
arm
the side
and
STRUT RETAINING BOLTS AND NUTS
FIG. 5 Caster
and
STRUT
Camber Adjustments
SPINDLE
CONNECTING ROD
2. Adjust
and the side of the
5, dimension A)
(Fig.
Tighten
angle.
caster
to
are
lower
the
nuts that retain the strut to the
Check the caster, camber,
toe-in alignment for the correct
listed in the
tings
the
move
the
rearward
arm.
not
necessary
spoke alignment
3. Recheck
alignment
SPINDLE ARM
TOE-IN AND STEERING WHEEL
position
the
the
when
front
spokes
tion,
are
they
not
can
is
in
being
toe-in
toe-in
specification
spoke
If
is
specified
spoke
spindle
connecting
rod
are
normal
rods
toe-in
spokes
position, make
steering
(Fig. 8).
wheel
ward
of
in
toe-in
and
alignment.
steering
If toe-in is
and the
still
not
steering wheel spokes
in their normal position,
both connecting rod sleeves up
or downward the same number
turns to
spokes
TURN DOWNWARD TO
INCREASE ROD LENGTH
TURN UPWARD
TO DECREASE
ROD LENGTH
The
in Part
1. Loosen the two clamp bolts
(Fig. 6).
Connecting
Rod Sleeve
move
the
steering
wheel
(Fig. 8).
TURN
TURN UPWARD TO
DOWNWARD
TO DECREASE
INCREASE ROD LENGTH
ROD LENGTH
jJI^D O^jfl
3-5.
each
6 Spindle
adjusted
adjusted.
both
the
their normal posi
be properly
while
FIG.
wheels are
position.
straight-ahead
F1117-A
turn
ALIGNMENT ADJUSTMENTS
wheel
shorten
rod adjustments to ob
set
correct
steering
steering
correct toe-in and
tain
wheel
the
in their
and
spacers.
Check
the
normal posi
Re
specifications.
suspension
or
If
in their
to
obtain
correct
equally
(Fig. 7). If the steering wheel
arm
increase
the
lengthen
tion,
forward
lower
toe-in.
wheel spokes are
to decrease the caster angle. Decrease
mount
F1116-C
of
5, dimension A)
the distance between the strut
CASTER ADJUSTMENT SLOTS
on
sleeve
LEFT-HAND
FIG.
7 Spindle
Rod Adjustments
SLEEVE
Connecting
RIGHT-HAND SLEEVE
F1037-B
3-7
PART 3-1 -SUSPENSION, STEERING, WHEELS AND TIRES GENERAL SERVICE
WHEN TOE-IN IS CORRECT
TURN BOTH CONNECTING ROD
TURN BOTH CONNECT
PC
.NG
4. When
toe-in
and
SLEEVES DOWNWARD TO
SLEEVES UPWARD TO ADJUST
DJUST SPOKE POSITION
SPOKE POSITION.
WHEN TOE-I
in
are
tie
the
sure
make
ends
are
alignment
spoke
the
steering wheel
both correct,
clamp bolts
tie
rod
position
and
and
rods
neutral
on
both
con
torque
the
necting
rod sleeves to specifications.
SHORTEN LEFT ROD
NOT CORRECT
TO DECREASE TOE
IN
LENGTHEN LEFT ROD TO
LENGHTEN RIGHT ROD
INCREASE TOE-IN
TO INCREASE TOE-IN
SHORTEN RIGHT ROD
TO DECREASE TOE-IN
ADJUST BOTH RODS EQUALLY TO MAINTAIN NORMAL SPOKE POSITION
FIG. 8
and
Toe-In
F1254-A
Wheel Spoke Alingment Adjustments
Steering
CLEANING AND INSPECTION
MAXIMUM TOLERANCE
FRONT END GENERAL
WHEEL INSPECTION
INSPECTION
Wheel hub
Do
wheel
the
check
not
first making
inspection for front-end
following
damage,
1. Check for
all
Shake
grasping the
each
upper and
the tire. Check the
ball joints
brake
wheel
surfaces
front
suspension
3. Check
and
bolts to
all
the
worn
specifi
parts
as
mountings
to
linkage is
If any of
bent, it must be
specifications.
worn or
4. Check the front wheel bearings.
If any in-and-out free play is noticed,
the bearings to specification.
adjust
damaged bearings
Replace
worn
outlined
in Part 3-4.
or
front
with
wheel
spinner, and check and
wheel
runout
absorbers.
the
If
as
in
not
settle
in
and
front
wheel
fected
.
good
lumps
and
of mud
would affect
wheels.
by
a
Wobble
damaged
wheel
eventually damage the wheel
bearings. Inspect the wheel rims for
that
could
permit
to leak
air
balance
action
from the tires.
the
shock
condition,
the
car
may
level position,
alignment may be af
a normal,
FIG. 9
cator
so
5.
1. Raise the
or
car on a
by floor jacks
frame
contact
beneath
placed
the underbody until the wheel
falls to
full down position as shown in
Fig. 9. This will unload the upper
ball joint.
the
2. Adjust
the
wheel
bearings
dial indicator to the up
a
Position the indicator
so that
the plunger rests against the underside
of
the
spindle
at the upper
ball joint
stud.
4. With the dial indicator
to
the
upper
arm,
position
the wheel rim ad
the
ball joint.
tire at
the
top
and
and
slowly move the tire in
and
out (Fig. 9). Note the
reading
(radial play) on the dial indicator. If
the
exceeds
reading
(Part
3-5),
replace
specifications
the
upper
ball
joint.
INSPECTION
To determine if the lower ball joint
is excessively worn or loose, perform
the
following procedure.
1. Raise the car on a frame
contact
hoist or by floor jacks placed
beneath
attached
the
indi-
the
the
of
upper arm
LOWER BALL JOINT
as
described in Part 3-4.
per arm.
side
Grasp
bottom,
Play
that the plunger rests against
inner
jacent to the
UPPER BALL JOINT
Upper
Measuring
Ball Joint Radial
the
INSPECTION
3. Attach
of
F1235-A
or
will
a
the shock absorbers are
not
the
of
caused
shimmy
each wheel as required.
6. Check
clean.
wheel and
can unbalance a wheel and
Check for damage that
the
hoist
each
between the
drum
wheels
nuts.
hubs
and
wheels
rear
grease
in the
tire.
replaced.
5. Spin
the
at
nuts
vibration.
and
from loose hub
wedged
rotor or
or
dents
gear
steering
steering linkage
for looseness. Torque all
connections
Stones
hub
wheel
all
and
mountings
also result
may
for loose
in Part 3-2.
outlined
the
front
lower
attaching bolts. Torque
nuts
Replace
cations.
the
damage. Check the
and
caliper
loose
car off
mountings
and
wear
ness,
the
specification
may cause shimmy
Elongated stud holes
Keep
of
to
Loose
predelivery.
be inspected
nuts should
tightened
and
four tires.
floor.
all
or wear.
specified air pressures
2. Raise the front
of
front
adjust
alignment without
maladjustment,
in
and
underbody until the
full down position.
wheel
falls
to
3-8
GROUP 3
2. Ask
lower
an
edge
wheel
in
to
wheel
is
being
out, observe the lower
spindle and the
4.
Any
lower
grasp the
the tire and move the
and out.
3. As the
and
assistant
of
lower
moved
in
end of the
between
the
indicates ball joint
During
per
may
6. While
checked
If the pump
ternal components and
the need for
the steering system, when in
the
ball joint
move.
movement
foregoing
will
be
wear and
the
at
wheel
check, the up
unloaded
Disregard
the
all
and
such
ball joint.
Also, do not mistake loose wheel
bearings for a worn ball joint.
of
upper
7. As
1. Remove
and
2. Install
a
the
nect
only
pump (Part 3-3).
3. Place
suitable
Should a power
become inoperative,
steering
the
pulley
power
as outlined
steering
in Part
pump and con
pressure hose to the
the
oil
return
line in
plug the
raise
time cycle
the
steering
stop.
lubricant
the engine
the
coil
the front wheels
off
to
wire
from starting
and
the ground.
as all of the
soon
in,
poured
lubricant
turn off the
igni
and attach the coil wire.
8. Remove the plug from the
return
pipe,
hose to the
and
attach
res
the
reservoir.
reservoir fluid level;
fluid (C1AZ-19582-A) to
level. Do not overfill.
9. Check the
if low
add
the proper
reservoir with
5. Disconnect
the shaft and pul
key,
ervoir
a
reser
voir return pipe.
prevent
tion
return
(C1AZ-19582-A).
pump
has been
new
container and
4. Fill the
FLUSHING THE POWER
STEERING SYSTEM
same
from stop to
a new pump.
stalling
pump
3-3.
two
approximately
steering gear lubricant are
into the reservoir, turn
poured
being
the engine over using the ignition key,
of
quarts
end of the spindle and the
lower
loss
of preload. If
any such movement is
observed, replace the lower are.
arm
be
WHEELS AND TIRE
for freedom of
shaft does not
turn freely (binding), it is an indica
tion that there is wear on the
pump in
should
rotation.
flushing
arm.
movement
ley
STEERING,
-SUSPENSION,
10. Lower the
car.
11. Start
engine
steering
pel
the
wheel
any trapped
and
cycle the
from stop to stop to
air
from the
system.
ex
3-9
PART
3-2
SUSPENSION
Section
1 Description
and Operation
Front Suspension
Rear Suspension
2 In-Car Adjustments and Repairs
Upper Ball Joint Replacement
Arm In Car
Stabilizer Repair
3 Removal and Installation
Front Wheel Spindle
Front Shock Absorber
Front Spring
Upper Arm
Lower Arm
Page
Section
Page
3-9
3-9
3-10
3-10
3-10
Rear Shock Absorber
3-15
Rear
3-15
Spring
3-16
Major Repair Operations
Arm Removed
Upper Arm Overhaul
Bushing
and
3-16
3-16
Inner Shaft Replacement
3-16
Ball Joint Replacement
3-11
3-11
3-11
3-12
3-12
3-13
3-14
3-16
Arm Removed
Lower Arm Overhaul
3-17
Ball Joint Replacement
Rear
Spring
Rear Shackle
Spring
3-17
Spring Removed
Assembly
and Hangar Assembly
Overhaul
Front Hangar
Leaves
and
3-17
3-17
3-17
Tie Bolt
DESCRIPTION AND OPERATION
FRONT SUSPENSION
is bolted to the underbody (Fig. 1). A
spring seats between the upper
coil
Each
spindle.
front wheel rotates on
The upper and lower ends
a
of
the spindle are attached to upper and
lower ball joints
to an
upper and
ly. The
which
lower
are mounted
which
assembly
bushing
is bolted to
the underbody. The
on a
bolt
mounted
the
and
top
of
the
spring
housing. A double-acting shock
sorber is bolted to the upper arm
the top of the spring housing.
ab
and
lower arm
in a bracket
The
joints
swiveling
allow
pivots
semblies
which
changes
the
action
of
the
in
ball
wheel and spindle as
to move up and down
road surface.
wheels
also permit the spindles and
to be turned to the left or right
by the steering gear and linkage.
The pivoting
action of
the suspen
and
down
for the spindles and wheels
as required by bumps or depressions
in the road surface. The coil springs,
sion
arms
provides
up
movement
arm respective
upper arm pivots on a
and shaft
arm
ball joints
with
The swiveling
shock
absorbers,
control
down
the
front
and
stabilizer
suspension
up
bar
and
movements.
SHOCK ABSORBER UPPER RETAINING NUT
CALIPER ASSEMBLY
ROTOR AND HUB ASSEMBLY
DUST SHIELD
WHEEL BEARING
ADJUSTMENT NUT ^
FIG. 1
Front
Suspension
NUT LOCK
F1203-B
3-10
GROUP 3
The struts, which are connected
between the suspension lower arms
the underbody,
and
pension
and
prevent the sus
from moving forward
arms
backward.
flange. The
axle shaft
shaft
assembly
housing. Two
the axle
with
by spring
hub and brake
drum assembly is bolted to the reai
rear
rotates
upper
in the
mounted
wheel,
body;
the lower end
is
spring
pad at the axle
housing.
axle
from the under
hanger
and shackle
by
the front and rear. The
suspended
at
to the
housing is
The
of
body
mounted
is
under
the springs
of
assembly is
assemblies
the
integral
plates, and nuts (Fig. 2). Each spring
rail
bracket in
two leaf
provide
side
shock absorber
each
a
pads,
(U-bolts), spring clip
clips
to
rest on
spring
housing,
rear axle
of
end
wheel and axle
spring assemblies. The
fastened to the center
REAR SUSPENSION
Each
STEERING, WHEELS AND TIRES
-SUSPENSION,
SHOCK ABSORBER
by
springs
for up
/
shock
and
down
the rear axle and
changes
in the
absorbers
movement
wheels as required
road surface.
They
also cushion road shocks.
REAR HANGER
HOUSING
and
HUB AND BRAKE DRUM
SHACKLE ASSEMBLY
WHEEL
/
GASKET
SPRING CLIP
NUT
REAR SPRING
WHEEL BEARING
FRONT HANGER
FIG. 2
F1204-B
Suspension
Rear
IN-CAR ADJUSTMENTS AND REPAIRS
UPPER
T57P-3006-A
end
T57P-30O6-A,
tool
of
Damage
to
suspension
if
cur
post
If
hoists
a
2
adapters
NO.
the
is
care
1
not
prior
post
to
may
exercised
hoist
the
positioning
and/or
components
when
adapters
lifting the
oc
of
2
hoist is used, place the
the lower arms or the
Do
crossmember.
to contact
linkage. If the
steering
adapters are placed un
der the crossmember, a piece of wood
(2 x 4 x 16 inches) should be placed
on
the
hoist channel between the
This
adapters.
ers
from
the adapt
will prevent
damaging
the
front
remove the cotter pin
prevents
lower
the
are
1. Raise the front
stud
the
wrench
tension,
from the
hammer. Do
safety
the chas
3. Loosen
joint-to-arm)
the
Place
a
the
upper
box
upper
tire.
stud
(ball
nut.
4. Remove
loosen the
wheel and
cotter
ball joint
wrench
over
pin
joint
that
upper
bore.
retaining nut,
and
stud out of
Remove the
drive the ball
out of the suspension arm.
the
front
stud with
Remove the ball
stud nut.
spindle
of
the
recess
replacement
in the
ball joint
the car
ball
upper arm so
notch
faces the
(Fig. 4). Install the
upper stud and
into
place
by
tightening the nut.
9. Position the ball joint stud in
the spindle bore, install the stud nut,
and
stud nut.
new
lower
both
loosen
by tapping
loosen the
alone.
6. Slide the ball joint
and
the
on the
until
then
spindle
retaining nut on the
draw the ball joint
sis.
2. Remove the
not
tool pressure
8. Position
of the car and
stands under
from seating
under
joint in its
position
from the
cotter pin
the spindle near the upper stud with a
upper
CAR
if the
stud
the tool
5. Turn
joint
UPPER BALL JOINT
the
stud.
studs
the
REPLACEMENT-ARM IN
against
of
sary to
suspen
sion struts.
firmly
seat
posi
both studs, and not against
the lower stud nut. It may be neces
allow
not
the
should
ends
lower ball joint
car.
under
adapters
tool
and
in Fig. 3. The
tion the tool as shown
steering linkage
ARM
UPPER BALL JOINT
HOISTING INSTRUCTIONS
torque to specifications. Install a
cotter
pin.
Tighten the nut, if
hole.
necessary, to align the cotter pin
\
LOWER BALL JOINT
LOWER ARM
T62F-3006-A
FIG. 3
Loosening
Stud
F1205-B
Ball Joint
PART 3*2
3-11
-SUSPENSION
10. Install
SHOCK UPPER
RETAINING NUT
the
tire as
and
wheel
sembly.
11. Remove
lower
the
caster and
car,
the
safety
and
check
stands,
camber,
toe-in.
STABILIZER REPAIR
HELIX
INSULATOR
LOWER
GUIDE PLATE
To
each
the
replace
end
link,
stabilizer
use
bushings
the
on
following
procedure.
1
Raise the
.
car on a
hoist.
2. Remove the link-to-stabilizer bar
SHOCK ABSORBER
retaining nut, washers,
(Fig.
SHIM
and
insulators,
disconnect the link from the bar
and
1).
3. Remove
link-to-lower
the
arm
retaining nut, washers, and insulators,
and remove the link from the arm.
FLAT INSULATOR
UPPER ARM
the
link and new
insulators to the lower
4. Assemble
and
washers
arm, then
HELIX
INSULATOR UPPER
attaching
INSTALL BETWEEN
FIRST AND SECOND
install the link-to-lower
arm
nut.
5. Connect the link to the bar with
insulators and secure
new washers and
COILS OF SPRING
with
the attaching nut.
6. Lower the
car.
0f^p?
YELLOW COLOR DESIGNATES
LEFT HAND SIDE-
GREEN COLOR RIGHT
IAND SIDE
F1206-B
FIG. 4
Arm, Shock Absorber
Upper
and
Spring Connections
REMOVAL AND INSTALLATION
HOISTING INSTRUCTIONS
from
ers
damaging
the front suspen
sion struts.
Damage
to
cur
if
positioning
post
If
hoists
a
2
1
the
prior
post
hoist
to
lifting
on
x
4
of
2
x
the
adapters.
16
hoist
This
hub
the
and
rotor
spindle.
5. Remove 3 bolts
shield
and
and remove the
gasket
from
the
pin
and
spindle.
Do
not
the
allow
steering
a piece of wood
should
channel
will
FRONT WHEEL SPINDLE
the car.
adapters are placed un
inches)
from the
splash
hoist is used, place the
the lower arms or the
der the crossmember,
4. Remove
oc
when
adapters
to contact
linkage. If the
(2
may
exercised
not
crossmember.
adapters
the
components
under
adapters
NO.
is
care
and/or
suspension
steering linkage
it to the underbody to
damage to the brake hose.
rotor and wire
prevent
be
placed
between
the
prevent the adapt
1. Raise the front
position
safety
of
the car and
stands under the chas
sis.
6. Remove
spindle
2. Remove the
move
the
wheel and
3. Remove
that
(Fig.
attach
2
wheel cover and re
spindle
the
cotter
disconnect
connecting rod end from
arm with Tool 3290-C.
retaining
then
nut,
the
the
tire from the hub.
bolts
and
washers
7. Remove the cotter pins
loosen the ball joint stud nuts.
and
the caliper to the spindle
1). Remove the
caliper
from the
8. Position
a
box
wrench over the
3-12
GROUP 3
lower
end
and
the Tool
of
the
position
T57P-30O6-A
as shown in
tool
Fig. 3.
The tool
against
the ends of both studs,
firmly
seat
not
the stud nuts.
against
9. Turn the
studs
loosen the
studs
ping the
until
in the
the tool
spindle
loosen the
not
move
the
guide
plate
Remove
by tap
from both
spindle
studs.
of
nuts
to
new
to the
spindle
tighten
nuts, and
the
Continue
specifications.
both
tighten
to
nuts until the cotter pin
holes line up
spindle
nut.
retaining
Tighten the
nut to
and
install
align
slot
cotter pin.
shield
the
the
on
splash
and
gasket
Tighten
spindle.
retaining bolts to
the
specifications.
4. Install the hub
bearings.
5. Position the caliper over the
rotor and install the attaching bolts.
for
Check
bolts
the
the
then
plate,
attaching
nut
shock absorber shaft.
the
outlined under
as
absorber
shock
Installation.
holes
FRONT SPRING
Install
arm.
nuts on the studs.
2. Install the two bolts that
attach
dash
panel
the
to
plate
guide
brace.
Install
bracket
and the three
the
the
upper
mounting
attaching
to
sion
and
the car, posi
of
safety stands under the suspen
lower arms; then, lower the car
slightly.
2. Remove the wheel and tire
Remove the front shock
sembly.
1. Remove
front
the
2. Remove the
attaching
separate
nut and
ab
procedure.
up
to
3. Raise the
shock absorber
insulator,
the shock absorber
guide plate
bolt,
shock
Removal.
then
from the
(Fig. 4).
the
nut
and
lower mounting
bracket to the replacement shock ab
sorber
the tool
Pry loose
the insulator retaining
and
3
slightly in
order
upper
arm.
suspension
bearing
shaft
upper
so
screw
and
upper plate over
against
opening in
that
top
upper
4.
2
foregoing
the shaft nut.
Insert the tool assembly through the
the
(Fig. 5).
car
steps
the
as
ab
Install spring tool T63P-5310-A. Slide
the
attaching
and transfer the
lower the
in
in
Removal
under
sorber as outlined under
described
as
sorber
specifications.
correct
1. Raise the front
tion
nuts.
3. Remove the safety stands,
lower the car.
3. Remove
and rotor on the
spindle and adjust the wheel
Tighten
upper
suspension
lower attaching
per
3. Install
and
so that the three
studs enter the
connecting
to the spindle arm, and install
specifications,
housing
REPLACEMENT
2. Connect the
rod end
shock absorber and
guide
insulator
outer
to the
slots, then install
with
new cotter pins.
the
crimping the
by
retaining tabs.
assembly through the top
plate
the spring
lower mounting
lower ball joint studs, in
stud
as
insulator in the
new
a
and secure
REMOVAL
1. Position the
the
an
as
5. Install
guide plate
7. Install
1. Position the
the
stall
bracket
INSTALLATION
INSTALLATION
and
lower
guide
absorber,
4).
6. Assemble the
in the
upper
shock
insulator from
the
remove
and
the guide plate (Fig.
to the dash panel brace.
the
and
guide
nuts and the
stud
tabs
the
in
studs
AND TIRES
sembly.
tool pressure alone.
spindle with
10. Remove the
mounting bracket. Re
two bolts that attach the
upper
tension, then
under
spindle near the studs with a
hammer. Do
absorber
plate,
wrench
the
places
the
should
STEERING, WHEELS
-SUSPENSION,
the
the spring
shaft screw
housing
goes through
spring with the tool
holes going over the studs
in Fig. 6.
the coil
of
plate
as shown
Too/-T63P-53I0-A
Shaft Nuf D-2
flexible hose
routing (Part 2-2).
6. Install the
wheel and
tire on the
hub.
7. Lubricate
the
the
lower
the
arm and
steering stop
the mating flat
spindle with specified
on
on
lubricant.
8. Remove the safety stands, lower
the
and
and
car,
check
camber, caster,
toe-in.
FRONT SHOCK ABSORBER
SHOCK
ABSORBER
REMOVAL
1. Raise the front
a
position
lower
safety
suspension
of
the car and
stand
under
"/TaiuMifl n^^ii ^j
the
arm; then, lower the
car slightly.
2. Disconnect
the
absorber
shock
per
arm
retaining
by
removing
nuts and washers
3. Open
the
LOWER
MOUNTING-
lower mounting bracket from the up
the
BRACKET
three
F1175-B
(Fig. 4).
hood; then,
remove
the three retaining nuts and the shock
FIG. 5
and
Front
Shock Absorber
Mounting Bracket
SQUARE
DRIVE HOLE
FIG. 6
Upper
Plate D-5
D-7
F1186-A
Compressing
Releasing
Bearing
or
Spring-Upper View
3-13
PART 3-2-SUSPENSION
4. From
lower
tool
the car, place the
under
plate
the fourth
under
from the bottom. Secure the
the
coil
in
the
by installing
in
groove
coil
plate
shaft
spring tool, then
the
the spring from the car.
wrench
screw
1. Insert
between
helix-type insulator
one
the
two
top
coils
and attach the other
Tool-T63P-53IO-A
tom
Retainer D-4
in
both
on
8.
9.
install the
Partially
tool
As
6).
(Fig.
the
seat
spring is
the
in the
the square drive
10. Tighten
the
UP COIL.
then
pletely,
during
from
plate
drive
square
Hold
turning
Use
release.
to
com
the tool.
remove
spring
1/2-inch
inner
arm
upper
nuts
lower
tool
the
with
plate
attaching
Release the spring
specifications.
it
upper
wrench.
shaft-to-chassis
INSERT FLUSH WITH END
OF SPRING BY PRYING
re
that
the
of
groove
being
so
coil
Hold the tool lower
arm.
of
nut
shaft
counterclockwise
the lower
leased, pry
will
the spring ten
release
T63P-5310-A
posi
shaft-to-
not tighten.
Do
nuts.
attaching
inner
arm
by turning
sion
into
the upper arm
Swing
chassis
WITH RAISED CENTER SECTION
DOWNWARD.
1).
(Fig.
and nuts
on
install the
and
bolt.
tion and
INSERT INSULATOR AS SHOWN
bar
stabilizer
links
7. Position the brake line and clip
the chassis and install the attaching
tape.
sulators with
the
and right
bushings
rubber
the
of
to the bot
Secure
(Fig. 8).
coil
left
the
drive flex-handle
square
.
6. Position
INSTALLATION
(Fig. 7).
Lower Plate D-3
1/2-inch
the
to
the tool retainer
the
10. Remove
remove
the
flex-handle
wrench.
11. With
Shaft Screw Dl
lower the
F1187-A
FIG. 7
spring
ATTACH INSULATOR TO
BOTTOM OF SPRING.
or
Compressing
5. Insert
flex-handle
with
spring
turning (Fig. 7).
on
lock
nuts and
that attach the upper arm
washers
The
the way.
of
out
arm pivots
the ball joint.
7. Remove
the
clip
then
and
move
bolt that
the
retains
brake line to the chassis,
the brake line out of the
link
hand
at
the
suspension
bar
stabilizer
both left
lower
and
right
by
arms
re
moving the bar-to-link attaching nuts
1). Position
and upper bushings (Fig.
the
bar
9.
out of
Fully
by turning
terclockwise
the
lower
wrench
or
snap
7).
(Fig.
release
shaft
(Fig. 6). Be
of
square
so
nut
sure
coun
to hold
the tool with the
drive
top
it
and secure
during
spring
release
rubber
insulator
spring (Fig. 4),
tape in three places.
the
of
with
top
absorber
plate
assembly
the spring
of
housing
lower mounting studs
holes in the suspension up
Install the lower attaching
the studs.
13. Install the two bolts that
attach
dash
panel
the mounting plate to the
brace. Install the three mounting
plate
attaching nuts.
3. Assemble
of
ponents
shaft nut.
seated
bearing
com
by
and the upper
the
screw against
Position the spring from
its
so
that
upper
the
wheel
Remove
Check caster,
the
tire as
and
stands.
safety
camber and
toe-in.
end
UPPER ARM
tool assembly through the upper
the
shaft
the
screw
coil
spring
with
holes going
shown in Fig. 6.
tool
lower
housing
under
the
studs
as
the car, place the
plate under
the
fourth
coil
plate
to
the tool retainer
to the groove in the tool shaft screw.
5. Compress the spring
by turning
tool shaft nut clockwise
Hold the tool lower
spring
1. Remove the
coil
plate
(Fig. 6).
from turn
compression.
Use
shock absorber and
spring assemblies,
the arm
by installing
ing during
REMOVAL
top
the tool upper
over
from the bottom. Secure the
the coil
so that
goes through the
plate
the
14. Install
sembly.
un
is
in the spring housing. Insert
car
opening in the spring
of
upper
T63P-5310A
the shaft
over
der the
the
Tool
sliding the tool
flex-handle
that the tool will not turn
loose
the
4. From
the spring tension
tool
plate
1/2-inch
2. Place the flat
the way.
the
the
arm.
nuts on
the
8. Disconnect
from
per
plate
way (Fig. 7).
the
enter
in
to the chassis, and swing the
shaft
FIG. 8 Front Spring Insulator
over
shock
that the three
Installation
nut
the
mounting
through the
so
arms,
slightly.
the
(Fig. 6).
6. Remove the two
arm
tool
holding the tool, compress
by turning the tool shaft
clockwise
ner
the
prevent
from
spring
While
to
plate
F1145-A
drive
square
in the drive hole in
wrench
lower
the
1/2-inch
a
placed
lower
to compress the
car enough
upper
and
stands
suspension
12. Position
BOTTOM
OF SPRING
Releasing Spring-Lower View
the safety
the
under
outlined
dure
under
2. Remove
Place
a
Fig. 3.
disconnect
Removal.
loosen the
Tool
and
inner shaft from the chassis as
in the Front Spring proce
box
the
upper
cotter
as
and
stud nut.
lower
wrench over
T57P-3006-A
The tool
pin
ball joint
end of
shown
should
seat
in
firmly
against
the
against
the lower stud nut. It
may be
ends of
both
studs and not
3-14
GROUP 3 -SUSPENSION,
necessary to remove the
from the lower ball joint
stud
if the
cotter
tool
from
pin
lower
3. Turn the
are
under
per
stud
the
prevents
the
on
seating
cotter
pin
STEERING,
WHEELS AND TIRES
PIVOT
SHIM
RETAINING
BRACKET
RETAINING
BRACKET
NUT
NUT
BRACKET RETAINING NUT
SHIM RETAINING NUT
PIVOT BRACKET
LOWER ARM
m
stud.
both studs
loosen the up
wrench until
tension,
from the
then
by tapping
spindle
the spindle near the upper stud with a
hammer. Do
tool
per stud
loosen the
not
pressure
nut, and
ball joint
and
Remove the
stud with
Remove the up
disengage the upper
alone.
from the spindle.
from the car.
stud
upper arm
INSTALLATION
1. Position the
inserting
the
the
spindle
bore.
upper
stud
cotter
pin
holes
in
Install the
nut to specifi
cations, then continue to tighten
the
by
the car
on
ball joint
Tighten the
nut.
stud
arm
upper
until
are aligned with
the slots. Install a new cotter pin.
2. Install
the
coil
connect
spring,
the upper arm inner shaft to the chas
install the
and
sis,
Follow
the
shock
absorber.
in the Front
steps
Spring
Installation.
procedure under
LOWER ARM
REMOVAL
1. Raise the front
install safety
of the
FIG. 9
the
wheel
2
3. Remove
the
bolts
and
washers
prevent
to
4. Remove
from
hub
the
and
from seating
tool
9. Turn
rotor
the
shield
tool
pressure
link
nut
under
(Fig. 9), and dis
link from the
washers
the
attaching
and
plates,
the strut
from
nuts,
and
lower
the
dis
arm
10.
8. Remove
the
cotter
box
wrench
T57P-3006-A,
180
from
Fig. 3 (wrench
should
seat
both studs,
alone.
joint
Remove
and
and
over
and
and
nut.
nut
the
and
pivot
the
bracket
F1102-A
shim
lower
the
nut
from the
pivot
the
at
the top).
in
against the ends of
Assembly
and
the
pivot
bracket from the
the
nut
the
lower
pivot
bolt,
arm.
the assembly in a vise and install
bolt
snug.
nut
(Fig.
Do
not torque
10). Tighten
it
until
assembly is installed in
arm
the car.
2. Slide
INSTALLATION
The tool
not against the upper stud
Arm
place
the
shown
10 Lower Suspension
FIG.
bolt
10). Remove the
the
a vise and
pivot
the end of
position
position
firmly
pin
stud
stud with
Disengage the
stud from the
11. Place the assembly in
separate
loosen the lower ball joint
a
stud with a
retaining
(Fig. 9), then remove the bracket
lower arm assembly from the car.
(Fig.
Place
by tapping
lower
spindle.
remove
(Fig. 9).
both
spindle
stablizer
7. Remove
tool
ball
until
loosen the
not
and
nut
connect
wrench
tension, then loosen
from the
stud
retaining
bolts,
under
hammer. Do
splash
the
arm
the
Lower Arm Installed
on the upper stud.
the
the spindle near the
arm.
Tool
are
lower
the
Suspension
cotter
studs
the spindle.
6. Remove
connect
F1101-C
It may be necessary to remove
pin
from the upper ball
joint stud if the cotter pin prevents the
the
to
spindle.
5. Remove the
neath
rotor
the
underbody
damage to the brake hose.
from the
gasket
from the
caliper
it
wire
STRUT
nut.
that attach the caliper to the spindle.
Remove
BAR
tire
and
from the hub.
and
STABILIZER
AND NUTS
car, and
stands.
2. Remove
RETAINING BOLTS
retaining
1. Assemble the
the new
lower
pivot
bracket
arm with the pivot
to
bolt,
bracket
lower
the
bolts
(Fig.
arm and
shims
against
10),
pivot
then
the
over
the
pivot
mount
the
bracket assembly
3-15
PART 3-2-SUSPENSION
to
the
chassis
mounting bracket
(Fig. 9). Install the pivot bracket and
shim
install the
the
of
wheel
stud
until
the cotter pin
4. Connect
aligned
with
the slots.
with
and
and connect the
to the lower
Remove
lower
the
bolts
the
suspension arm
to
2. Remove
bar link
lower suspension arm, and in
the washers, bushings and link
Tighten
nut.
retaining
the
nut
shock
to
at
the
lower
bolt
arm
pivot
and nut
bracket to
and
the spindle. Refer to
on
the
the
remove
on
able
move
gasket
spindle and adjust
tighten
from
splash
Tighten
the
the nut,
outer
washer
that secure the shock ab
bracket,
shock absorber
is
and
service
new
requires
the
the
shock
absorber
1. Raise
ports
and place
rear
sup
underbody.
2. Remove the spring clip (U-bolt)
(Fig. 1 1), then lower the jack
enough
to remove the spring clips.
3. Remove the spring front hangerto-underbody mounting bolts and
lock
washers
(Fig.
4. Remove
and
and
1. Place
and
inner
the
mounting
and
stud.
shackle
12).
the
rear
bar,
shackle
then
nuts
remove
assembly from the
spring (Fig. 13).
rear
until
the
hanger
the spring
front hanger assembly is free
mounting
bushing,
bracket,
washer,
Torque the
6. Lift the
sulator
the
2. Connect the
stands,
washer
on the shock absorber upper
bushing
tire on the
safety
beneath the
the
until
of
the car.
hub.
the
floor,
5. Lower the jack
to the spindle
wheel and
car
the
nuts
stud.
INSTALLATION
the wheel bearings.
caliper
the
wheels clear
upper
and rotor on the
flexible hose routing (Part 2-2).
12. Remove
remove
bushings, re
inner bushing and washer
and
mounting
attaching bolts to
Check for the correct
11. Install the
and
REMOVAL
shackle
the
specifications.
i. Com
.,.
REAR SPRING
specifications.
9. Install the hub
10. Install the
and
the
to the mounting
the bracket.
4. If the
19 for the
Group
spindle.
retaining bolts to
and
on
lubricant.
8. Install
shield
bushing
sorber
7. Lubricate the steering stop
the lower arm and the mating flat
from
specifications.
and
shock absorber
car.
3. Remove
specifications.
specified
absorber
it from the
pivot
nut
attaching
the shock absorber
press
specifications.
6. Tighten the
the
from the
to
and
nut.
the
lower mounting stud at the spring pad
on the axle housing. Disconnect the
the
stall
retain
absorber
outer washer
stabilizer
that
nut
inner
attaching
stud
the car.
of
end
mounting bracket to
the underbody (Fig. 11).
shock
retaining plates, bolts, washers,
nuts (Fig. 9). Torque the nuts.
5. Connect the
rear
and
the
of
eye
with
pad
spring
Torque the
1. Raise
specifi
to the mounting
washers
outer
cotter pin.
to the underbody
lower
the
absorber
the
on
REMOVAL
holes are
Install a new
mounting bracket
the
absorber
11). Torque the bolts to
shock
to specifications, then continue to
arm strut
shock
cations.
REAR SHOCK ABSORBER
spindle,
Tighten the
stud nut.
tighten
4. Position
3. Connect
and
(Fig.
3. Insert the lower ball-joint
nut
and check the camber,
caster, and toe-in.
nuts.
retaining
in the lower bore
and
lower the car,
upper
and
stud
to the
install
and nut on
the
the stud.
nut to specifications.
top
of
the
7. Remove
hanger
and
the
shim
retainer,
as an
(if used), upper in
insulator from
and
spring.
the spring and front
assembly from the jack,
separate the spring
clip plate and
lower insulator from the spring.
SPRING CLIP (U-BOLT)
BRACKET
RETAINING
BOLT
INSULATOR RETAINER
INNER
BUSHING
INSULATORS
SPRING CLIP PLATE
MOUNTING WASHERS
SPRING CLIP NUT
F1207-B
FIG. 1 1
Rear
Shock Absorber
and
Spring Center Mounting
3-16
GROUP 3 -SUSPENSION, STEERING, WHEELS AND TIRES
HANGER MOUNTING BOLTS
retaining nuts. Do
this time.
and
FRONT HANGER
tighten the
not
nuts at
3. Position the spring and front
hanger assembly on the underbody,
and install the hanger mounting bolts
(Fig.
12). Do
not tighten
bolts
the
at
this time.
4. Install
SPRING FRONT
the
if
the axle shim
stall
5. Raise the jack
the spring, the
the
and
BUSHING
perly
FIG. 12
Spring
-Rear
and
Front Hanger
the
spring
(Fig. 11).
Mounting
the axle
INSTALLATION
the spring clip
1. Position the lower insulator
plate
spring clip
block
wood
jack
entire
assembly
jack,
then
and
the
13 Rear
FIG.
Spring
Rear Hanger Mounting
the
rear
rear
hanger
eye
the
of
center
13). The
(Fig.
rear
is
eye
at
the spring from the
tie bolt. Install the shackle bar
long
the
of
end
is
the weight
rear axle so
the rear suspension.
8. Torque the
rear shackle nuts and
hanger
front
bolts to
mounting
specification.
install
and
the shackle assembly to the spring and
hanger
and
the
tighten at this
on
the car
of
the
on
spring
F 1209- A
BUSHING
7. Raise the
on a
raise
position.
2. Position
not
time.
is in mounting
the spring
until
the
the holes in
the center of the
on
Place the
spring.
and
housing
Install the spring
plate.
but do
nuts,
clip
against
over
clips
and through
housing
axle
used.
are all pro
positioned
6. Install the spring
SIDE RAIL
was
the retainer,
plate
on
pad
and
11). In
the center of
insulators,
and
aligned
one
until
spring clip
F1208-B
insulator
upper
spring (Fig.
the
on
retainer
MOUNTING BOLT
ly
9. Torque the spring clip nuts even
to specification (Part 3-5). Make
sure
that the lower
the
jack
insulator
retainer
Remove
the upper retainer.
contacts
block.
and wood
MAJOR REPAIR OPERATIONS
UPPER ARM OVERHAUL-
2. Position the shaft in the arm, ap
ply grease to the new bushings, and
install the bushings loose on the shaft
ARM REMOVED
arm.
and
INSPECTION
the
Inspect the
age.
upper arm and
the inner
for cracks, bends or other dam
Replace the parts as required.
Replacement
arms
come
with
the
inner shaft, and ball joint
installed. If the original arm is to be
bushings,
used, these components should be re
placed on
the bench.
is
shaft
The
arm.
shaft
Turn the bushings
tered
exactly
in the
be properly cen
located at the dimension
in Fig. 14.
3. Fabricate
from
centered
a
pipe or
section
metal
1. Remove the
retaining
nut
joint from
ball joint-to-arm
and
the
the
ball
(Fig.
14).
remove
upper
arm
will
shaft
when
shown
that
so
BALLJOINT REPLACEMENT
a
9 1/4-inch
of
3/4-inch diameter
spacer
of comparable size and
2. Install the
replacement
ball joint
in its recess in the upper arm so that
the ball joint notch faces the front of
the car (Fig. 4).
3. Install
the
attaching
torque to specifications (Fig.
nut
and
14).
strength.
4. Position the
assembly in
arm and
a vise.
BUSHING AND INNER
parallel with
SHAFT REPLACEMENT
the spacer
inner
Position the
shaft
spacer
the inner shaft, and force
between the flanges
LOWER ARM OVERHAULARM REMOVED
of the
upper arm.
Always
replace
bushings, if
damaged.
when
either
only
replacing the inner
in
a
the
vise,
bushings from the
move
the assembly
separate
new
worn or
bushings
arm
inner
unscrew
shaft and arm.
from
the inner shaft
the
Re
the vise, and
from the
If
the
spacer
between the
sive
arm
distrotion,
can
not
be
flanges due to
replace
the
forced
exces
upper arm
assembly.
shaft.
upper
then
arm
upper
bushing is
Install
1. Position
shaft
both
arm.
5. With the
spacer positioned
in the
arm, torque the bushings to specifica
tion.
sure
Pivot the
that
no
arm on the shaft to
binding
move the spacer.
exists, then
be
re
INSPECTION
Inspect
lower
the
arm,
the
inner
bushings, and the pivot bolt for cracks,
bends, wear or other damage, and
replace the arm
Replacement
if
necessary.
arms
come
ball joint installed. If the
is to be used,
the
replaced on the
ball joint
bench.
with
the
original arm
should
be
3-17
PART 3-2-SUSPENSION
from the spring front mounting bolt
1-7/8"
(Fig. 12).
2.
INNER
SPRING LOWER SEAT
SHAFT
the
Tap
spring
mounting
bolt
hanger,
then
the bushings and
out of
the
separate
from the
nager
spring.
Remove the bushings.
3. Position the bushings in the front
the spring. Assemble the front
eye of
the spring eye and install
hanger to
the spring mounting bolt through the
hanger, bushings,
shown
and
spring
eye
as
in Fig. 12.
4. Install the lock washer and nut
the mounting bolt and tighten to
on
the specified torque.
REAR SHACKLE AND
BALL JOINT-TO-ARM STUD
AND RETAINING NUT
SHOCK MOUNTING
BRACKET BOLT HOLES
HANGER ASSEMBLY
BALL JOINT-TO-SPINDLE STUD
Inspect the
studs for
and
place parts
VIEW PARTIALLY
TOP
BOTTOM
VIEW
If the
ASSEMBLED
DISASSEMBLED
F1210-A
FIG.
que
Suspension Arm
BALL JOINT REPLACEMENT
The lower ball joint cannot be re
must be replaced if it is
and
damaged.
worn or
1. Remove
lined in
under
the
Lower Arm
procedure
Removal.
through
drill
off
pilot
hole
the
each
rivet, and then
head through the
3/8-inch drill. Drive
rivet
with a
all rivets out of
4. Install
holes,
and
cracked.
Use
nuts, and
rivet the
a
new
only
washers.
new
ball joint
the
on
cracks
rear
hanger
attaching bolts to
Do
the
bolts,
specified
not attempt
ball joint to the
to
arm.
nuts and
bolts to
SPRINGS LEAVES AND
TIE BOLT
specifications.
6. Install the lower arm as outlined
in the Lower Arm procedure under
Installation.
in the
replace
the
metal
arm
at the
if it is
REAR SPRING OVERHAULSPRING REMOVED
If the front hanger
replaced,
1. Remove the
inserts between
them if they
are worn. The spring leaves must be
dry and free of oil and dirt before new
inserts are installed.
or
bushings
as
nut and
lock
and
replace
spring clip plate and insulator
for distortion.
retain
ers
are
follows:
proceed
anti-squeak
leaves,
Inspect the spring clips for worn or
damaged threads (Fig. 11). Check the
FRONT HANGER ASSEMBLY
to be
Check for broken spring leaves. In
spect the
the
the holes.
3. Clean the end of the arm, and
remove all burrs from the hole edges.
Check for
bushings are to
be necessary to re
hanger assembly. Tor
will
5. Torque the ball joint attaching
the lower arm as out
2. Remove the ball joint from the
arm. If the ball joint is riveted to the
arm, drill a 1/8-inch pilot hole com
pletely
where
bushings,
damage. Re
necessary (Fig. 13).
or
specification when reinstalled.
arm.
paired
the
the
shackle
wear
rear shackle
be replaced, it
move
14 Upper
rear
washer
If the spring center tie bolt requires
clamp the spring in a
vise to keep the spring compressed
during bolt removal and installation.
replacement,
3-18
PART
?_V
STEERING
Section
Page
1 Description
and
Operation
3-18
Gear
Steering
Description
Left Turn
Power
Steering Pump
Movable Steering Column
2 In-Car Ajustments and Repairs
Valve Spool Centering Check
Steering Gear Adjustments
Adjustments in Car
Power
Adjustments
3-22
3-22
3-23
3-23
Lock Mechanism
3-23
Wheel Replacement
Steering
Steering
Shaft Upper
Bearing
Replacement
Movable Column
Stop
Steering Pump Pulley
Steering Column Shift Tube and
3-25
3-28
Lever Replacement
4 Major Repair Operations
Steering
3-28
3-28
Gear
Shim Replacement
Valve
Centering
Steering Gear Disassembly
Parts Repair
Valve
3-22
Adjustment
3-24
3-25
3-25
Power
Belt Tension
Steering Pump
3-23
3-24
Slide Friction
3 Removal and Installation
Steering Gear
Power Steering Pump
3-18
3-18
3-19
3-19
3-19
3-19
3-19
3-21
3-21
3-21
3-21
3-21
Operation
Straight Ahead Position
Right Turn
Page
Section
or
3-29
3-30
3-30
3-31
3-31
3-31
3-32
Replacement
Housing
Worm
and
Valve
Piston
and
Ball Nut
Steering Gear Housing
Steering Gear Assembly
Power Steering Pump Reservoir
Replacement
3-33
DESCRIPTION AND OPERATION
STEERING GEAR
OUTLET PORT
INPUT SHAFT
INLET PORT
DESCRIPTION
The
power
bar type
This
hydraulic
of
power
torsion-
SECTOR SHAFT COVER
to reduce
effort required
turning
It
wheel.
the steering
at
a
assisted system.
furnishes
system
the amount of
is
unit
steering
also reduces
road shock and vibrations.
The torsion bar
includes
is
CONTROL VALVE HOUSING
steering
one
and
worm
a
which
piston,
power
meshed
piece
also
includes
actuator,
valve
sembly
and
the end
of the worm shaft and operated
action
is designed
gear
rack-piston,
piece
shaft
in
spool
in
This
makes
and
the
and
one
sector
attaching
between the
hoses,
internal
possible
thus eliminating
return
with
worm
housing and the valve
housing (Fig. 1).
one
an
passages
der,
bar.
torsion-bar type of power steer
The
ing
by the
torsion
the
of
The
hydraulic valve,
torsion bar as
a
which are mounted on
twisting
rack
to the gear
teeth on the steering sector shaft.
unit
unit
except
hoses
MOUNTING PADS
fluid
valve and cylin
all external
the
pressure
SECTOR SHAFT
G1276.A
lines
and
FIG. 1
between the pump and
Steering
Gear
gear assembly.
part of the gear
is an integral
housing. The piston is
double
in that fluid
The
power
acting,
cylinder
pressure
may be
applied
to either side
of
the
piston.
A
selective
the valve
housing
purpose of
metal
shim, located in
forts. If
of
the gear
is for the
tailoring steering
efforts are not within
gear ef
specifi-
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