r - Money back Guarantee · INTERIOR TRIM CODES INTERIOR CODESHContinued) Code 1A IB ID 1G IK 1U 1Y...

Demo

Demo Only

This DEMO contains only a few pages of the entire manual/product. Not all Bookmarks work on the Demo but they do on the full version. Features: - Searchable text - Printable pages - Bookmarked for easy navigation - High Resolution images - Zoom to see exact details - Save to USB feature - Money back Guarantee

http://www.forelaffiliates.com/go.php?offer=napstek&pid=67&tid=fordmanual67pdf


Copyright © 2011, 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

1968 Ford and Mercury Shop Manual EAN: 978-1-60371-092-3

ISBN: 1-60371-092-2

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.

NNoottee ffrroomm tthhee PPuubblliisshheerr 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 shall have neither liability nor responsibility to any person or entity with respect to any loss or damage caused, or alleged to be caused, directly or indirectly by the information contained in this book. Further, the publisher and author are not engaged in rendering legal or other professional services. If legal, mechanical, electrical, or other expert assistance is required, the services of a competent professional should be sought.



FOREWORD

This shop manual provides the Service Technician with information forthe proper servicing of the 1968 Ford and Mercury Cars.

The maintenance schedule and procedures for maintenance operations arepublished in the 1968 Passenger Car Maintenance and LubricationManual.

The information in this manual is grouped according to the type of workbeing performed, such as diagnosis and testing, frequently performed ad-justments and repairs, in-vehicle adjustments, overhaul, etc. Specificationsand recommended special tools are included.

Refer to the opposite page for important vehicle identification data.

The descriptions and specifications in this manual were in effect at thetime this manual was approved for printing. Ford Motor Company re-serves the right to discontinue models at any time, or change specifica-tions or design, without notice and without incurring obligation.

SERVICE PUBLICATIONS


Vehicle IdentificationGROUP

l I

54C M 3B I4H 3454E M IB I4H 33

© © © <0>

1 MODEL YEAR CODE

2 ASSEMBLY PLANT CODE

3 BODY SERIAL CODE

4 ENGINE CODE

5 CONSECUTIVE UNIT NO.

6 BODY TYPE CODE

FIG. 1 — Warranty Plates — Ford and Mercury

(2) © ©

7 COLOR CODE

8 TRIM CODE

9 DATE CODE

10 DISTRICT OR DISTRICT AND SPEC. EQUIP. CODE

11 REAR AXLE CODE

12 TRANSMISSION CODE

N 1669-A

FORD

MERCURY

N 1670- A

FIG. 2—Ford and Mercury VehicleIdentification Number (VIN) Tabs


1-2 Group 1 — Vehicle Identification

VEHICLE WARRANTY NUMBERThe vehicle warranty number is the first line of numbers and letters

appearing on the Warranty Plates (Fig. D.The Warranty Plate is rivetedto the left front door lock face panel. The first number indicatesthe model year. The letter following the model year number indicatesthe manufacturing assembly plant. The next two numbers designate theBody Serial Code followed by a letter expressing the Engine Code. Thegroup of six digits remaining on the first line indicate the ConsecutiveUnit Number.VEHICLE DATA

The vehicle data appears on the second or lower line on the WarrantyPlate. The first two numbers and a letter identify the Body Style. Aletter or a number appears next indicating the Exterior Paint Color fol-lowed by a number-letter combination designating the Interior Trim. Tothe right of this code appears the Date Code indicating the date thecar was manufactured. A two digit number next designates the districtin which the car was ordered and may appear in conjunction with aDomestic Special Order or Foreign Special Order number when applicable.The final two spaces indicate the Rear Axle Ratio(numbers for regularaxles, letters for locking-types) and the Transmission type (numbersfor manual, letters for automatic).

OFFICIAL VEHICLE IDENTIFICATION NUMBERThe official Vehicle Identification Number (VIN) for title and registra-

tion purposes will be stamped on an aluminum tab that will be rivetedto the instrument panel close to the windshield on the passenger side ofthe car and will be visible from outside (Fig. 2).

MODEL YEAR CODEThe number 8 designates 1968.

ASSEMBLY PLANT CODES

FORD

CodeLetter

ABcDEFGHJK

Atlanta LOakville (Canada) N

Ontario Truck PDallas R

Mahwah SDearborn T

Chicago ULorain W

Los Angeles XKansas City Y

CodeLetter

Michigan TruckNorfolk

Twin CitiesSan Jose

Pilot PlantMetuchenLouisville

WayneSt Thomas

WixomSt Louis

BODY SERIAL AND STYLE CODESThe two-digit numeral which follows the assembly plant code identi-

fies the body series. This two-digit number is used in conjunction withthe Body Style Code, in the Vehicle Data, which consists of a two-digitnumber with a letter suffix. The following chart lists the Body SerialCodes, Body Style Codes and the model.

CONSECUTIVE UNIT NUMBEREach model year, each assembly plant begins production with num-

ber 100001 (Ford) or 500001 (Mercury) and continues on for each unitbuilt.

ENGINE CODESCode

V5EBF6YXZQ8PW

®

6Cyl.6 Cyl.6 Cyl.6 Cyl.8 Cyl.8 Cyl.8 Cyl.8 Cyl.8 Cyl.8 Cyl.8 Cyl.8 Cyl.8 Cyl.

Low Compression

Type

240 Cu. In. (IV)240 Cu. In. (IV) ®240 Cu. In. ( IV) Taxi240 Cu. In. ( IV) Police302 Cu. In. (2V)302 Cu. In. (2V) ®390 Cu. In. (2V)390 Cu. In. (2V) (Prem. Fuel)390 Cu. In. (4V)428 Cu. In. (4V)428 Cu. In. (4V) ®428 Cu. In. (4V) Police427 Cu. In. (4V) Hi-Perf.

BodySeriaCode

5150

5352

5456555758

6061

666264

70

7172

7374

7576

®(D®

Body1 Style

Code

54E62E

54B62B

54A57B63B76A65C

63C76B

57F65A54C

71D

71H71J

71B71C

71E71A

Bench SeatBucket SeatFormal Roof

Body Type

4-Door Sedan ®2-Door Sedan ®

4-DoorSedan ®2-Door Sedan ®

4-Door Sedan ®4-Door Hardtop ®2-Door Hardtop ®2-Door Convertible ®2-Door Hardtop ®

2-Door Hardtop ®2-Door Convertible ®

4-Door Hardtop ®2-Door Hardtop ®@>4-DoorSedan

4-Door 6 Passenger

4-Door 6 Passenger4-Door 10 Passenger

4-Door6 Passenger4-Door 10 Passenger

4-Door6 Passenger4-Door 10 Passenger

Model

Custom

Custom 500

Galaxie 500

Ford XL

LTD

Ranch Wagon

Custom Ranch WagonCustom Ranch Wagon

Country Sedan

Country Squire

MERCURYBodySeriaCode

4444484745

54545857

64686765

64686972727676®®®®

BodyStyleCode

54A54B57A63A76A

54C54D57B63B

54E57F63F76F

54J57C

63D

71B71C

71E71A

Bench SeatSplit BenchFixed BackliteDrop Backlite

Body Type

4-Door Sedan ® ®4-Door Sedan ® ®4-Door Hardtop $2-Door Hardtop ®2-Door Convertible ®

4-Door Sedan ® ®4-Door Sedan ® - ®4-Door Hardtop ®2-Door Hardtop ®

4-Door Sedan ® ® ®4-Door Hardtop ® ®2-Door Hardtop ® ®2-Door Convertible ®

4-Door Sedan ® ®4-Door Hardtop ®

2-Door Hardtop ®

4-Door 6 Passenger ®4-Door 10 Passenger ®

4-Door6 Passenger ®4-Door 10 Passenger ®

Model

Monterey

Montclair

Parklane

Parklane Brougham

Marquis

Commuter

Colony Park

TRANSMISSION CODESCode Type

1 3-Speed Manual5 4-Speed ManualW Automatic (XP3)U Automatic (XPL)Y Automatic (MX)X Automatic (FMX)Z Automatic (XPL Special)


Group 1 — Vehicle Identification 1-3

REAR AXLE RATIO CODESA number designates a convential axle, while a letter designates a

locking differential.

FORD

Code

135978

Ratio

2.75:12.80:13.00:13.10:13.25:13.50:1

Code

ACE_G

Ratio

2.75:12.80:13.00:1_

3.25:1

EXTERIOR

Code

ABF|MN0PQRTuWXY26

PAINT COLORM-30-JM-32-J

1724-A3059-A..3065-A2041-A1619-A921-A

2040-A2065-A1624-A .3067-A2008-A1070-A3120-A3061-A3073-A..2050-A1631-A

CODES

ColorBlackMaroonDark Aqua Met.Lime Green MetWhiteDiamond BlueLight GreenPewter MetMedium Blue MetDark Green MetRedMed Aqua MetYellowDark Blue Met.Med Gold MetRose MetLight Beige

DISTRICT CODES (DSO)Units built on a Domestic Special Order, Foreign Special Order, or

other special orders will have the complete order number in thisspace. Also to appear in this space is the two-digit code number ofthe District which ordered the unit. If the unit is a regular produc-tion unit, only the District code number will appear.

MERCURY

Code

1116151721222326313233

District

Boston.. Philadelphia

New YorkWashingtonAtlanta

.. DallasJacksonvilleMemphis

.. Buffalo

.. Cincinnati

.. Cleveland

Code

344142465152535484

90

District

DetroitChicagoSt. LouisTwin CitiesDenverLos AngelesOaklandSeattleHome Office Reserve

Export

Code District Code District

11 Boston 52 ..13 New York S3 ..15 Newark 54 ..16 Philadelphia 55 ..17 Washington 61 ..21 Atlanta 62 ..22 Charlotte 63 ..24 Jacksonville 64 ..25 Richmond 65 ..27 Cincinnati 71 ..28 Louisville 72 ..32 Cleveland 73 ..33 Detroit 74 ..34 Indianapolis 75 ..35 Lansing 81 ..37 Buffalo 83 ..38 Pittsburgh 84 ..41 Chicago 85 ..42 Fargo 89 ..43 Milwaukee 90-9944 Twin Cities45 Davenport51 Denver

Des MoinesKansas CityOmahaSt. LouisDallasHoustonMemphisNew OrleansOklahoma CityLos AngelesSan JoseSalt Lake CitySeattlePhoenixFord of CanadaGovernmentHome Office ReserveAmerican Red CrossTransportation ServiceExport

FORD OF CANADA

BlB2B311 thru 17

CentralEasternAtlanticExport

B4B6...B7...

MidwesternWestern

.. . Pacific

Note: Lincoln-Mercury units will use suffix "A" in place of "B" .

DATE CODESA number signifying the date precedes the month code letter. A

second-year code letter will be used if the model exceeds 12 months.

Month

JanuaryFebruaryMarchAprilMayJuneJulyAugustSeptemberOctoberNovemberDecember

CodeFirst Year

ABcD

. . . . E

. . . . FGH

. . . . JKL

. . . . M

CodeSecond Year

NpQRsTUVWX

. . . . YZ


1-4 Group 1 —Vehicle Identification

INTERIOR TRIM CODES INTERIOR CODESHContinued)

Code

1AIBID1GIK1U1Y

2A2B2B2D2G2U2U2Y

3A3B3B3D3G3G3K3K3Y

4A4B4D4K4K4U4Y5A5B5B5G5G5K5K5Y

6A6B6B6D6G6G6K6U6Y7A7B7D7G7U9A9B9D9G9K9YBABBBD

Trim Schemes

Black Cloth and Black VinylMed. Blue Cloth and Lt. Blue VinylDk. Red Cloth and Dk. Red VinylMed. Ivy Gold Cloth and Lt. Ivy Gold VinylMed. Aqua Cloth and Lt. Aqua VinylLt. Parchment Cloth and Pastel Parchment VinylLt. Nugget Gold Cloth and Lt. Nugget Gold Vinyl

Black VinylDk. Blue Vinyl (Mercury)Med. Blue Cloth and Lt. Blue Vinyl (Ford)Dk. Red VinylMed. Ivy Gold Cloth and Lt. Ivy Gold VinylPastel Parchment Vinyl (Mercury)Lt. Parchment Cloth and Pastel Parchment Vinyl (Ford)Lt. Nugget Gold Vinyl

Black Cloth and Black VinylMed. Blue Cloth and Lt. Blue Vinyl (Mercury)Dk. Blue Cloth and Dk. Blue Vinyl (Ford)Dk. Red Cloth and Dk. Red VinylMed. Ivy Gold Cloth and Lt. Ivy Gold Vinyl (Mercury)Dk. Ivy Gold Cloth and Dk. Ivy Gold Vinyl (Ford)Med. Aqua Cloth and Lt. Aqua Vinyl (Mercury)Lt. Aqua Cloth and Lt. Aqua Vinyl (Ford)Lt. Nugget Gold Cloth and Lt. Nugget Gold Vinyl

Black VinylLt. Blue VinylDark Red VinylLt. Aqua VinylLt. Nugget Gold and Black VinylPastel Parchment VinylLt. Nugget Gold VinylBlack Cloth and Black VinylDk. Blue Cloth and Dk. Blue Vinyl (Mercury)Med. Blue Cloth and Lt. Blue Vinyl (Ford)Dk. Ivy Gold Cloth and Dk. Ivy Gold Vinyl (Mercury)Med. Ivy Gold Cloth and Lt. Ivy Gold Vinyl (Ford)Lt. Aqua Cloth and Lt. Aqua Vinyl (Mercury)Med. Aqua Cloth and Lt. Aqua Vinyl (Ford)Lt. Nugget Gold Cloth and Lt. Nugget Gold Vinyl

Black VinylDk. Blue Vinyl (Mercury)Lt. Blue Vinyl (Ford)Dk. Red VinylDk. Ivy Gold Vinyl (Mercury)Lt. Ivy Gold Vinyl (Ford)Lt. Aqua VinylPastel Parchment VinylLt. Nugget Gold VinylBlack VinylDk. and Lt. Blue VinylDk. Red VinylMed.and Lt. Ivy Gold VinylPastel Parchment VinylBlack Cloth and Black VinylDk. Blue Cloth and Dk. Blue VinylDk. Red Cloth and Dk. Red VinylDk. Ivy Gold Cloth and Dk. Ivy Gold VinylLt. Aqua Cloth and Lt. Aqua VinylLt. Nugget Gold Cloth and Lt. Nugget Gold Vinyl

Black Cloth and Black VinylDk. Blue Cloth and Dk. Blue VinylDk. Red Cloth and Dk. Red Vinyl

Code

BGBYCACBCDCUCYDADBDDDUEAEBEDEGEKEYFAFBFDFGFGFYFUHAHBHDHGHUKAKBKDKGKYLENANBNBNDNUPAPBPDPGPURARBRDRGRKRYRUSASBSGSKSYZAZBZY

Trim Schemes

Dk. Ivy Gold Cloth and Dk. Ivy Gold VinylLt. Nugget Gold Cloth and Lt. Nugget Gold VinylBlack VinylDk. Blue VinylDk. Red VinylPastel Parchment and Black VinylLt. Nugget Gold VinylBlack VinylDk. and Lt. Blue VinylDk. Red VinylPastel Parchment Vinyl

Black Cloth and Black VinylDk. Blue Cloth and Dk. Blue VinylDk. Red Cloth and Dk. Red VinylDk. Ivy Gold Cloth and Dk. Ivy Gold VinylLt. Aqua Cloth and Lt. Aqua VinylLt. Nugget Gold Cloth and Lt. Nugget Gold VinylBlack VinylDk. Blue VinylDk. Red VinylLt. Ivy Gold Vinyl (Mercury)Dk. Ivy Gold Vinyl (Ford)Lt. Nugget Gold VinylPastel Parchment VinylBlack VinylDk. and Lt. Blue VinylDk. Red VinylMed. and Lt. Ivy Gold VinylPastel Parchment VinylBlack Cloth and Black VinylDk. Blue Cloth and Dk. Blue VinylDk. Red Cloth and Dk. Red VinylDk. Ivy Gold Cloth and Dk. Ivy Gold VinylLt. Nugget Gold Cloth and Lt. Nugget Gold Vinyl

Lt. and Med. Beige VinylBlack VinylDk. and Lt. Blue Vinyl (Mercury)Lt. Blue Vinyl (Ford)Dk. Red VinylPastel Parchment VinylBlack VinylDk. and Lt. Blue VinylDk. Red VinylMed. and Lt. Ivy Gold VinylPastel Parchment VinylBlack VinylLt. Blue VinylDk. Red VinylLt. Ivy Gold VinylLt. Aqua VinylLt. Nugget Gold VinylPastel Parchment VinylBlack Cloth and Black VinylMed. Blue Cloth and Lt. Blue VinylMed. Ivy Gold Cloth and Lt. Ivy Gold VinylMed. Aqua Cloth and Lt. Aqua VinylLt. Nugget Gold Cloth and Lt. Nugget Gold VinylBlack Cloth and Black VinylDk. Blue Cloth and Dk. Blue VinylLt. Nugget Gold Cloth and Lt. Nugget Gold Vinyl


2-

PART 2-1 PAGEGeneral Brake Service 2-1

PART 2-2Brake System 2-9

PART 2-3Specifications

PAGE2-31

PART 2 - 1 - Genera/ Brake ServiceSection Page

1 Diagnosis and Testing 2-1Brake System Tests 2-1Road Test 2-3

2 Common Adjustments and Repairs 2-3Parking Brake Linkage Adjustment 2-3Power Brake Master Cylinder

Push Rod Adjustment 2-4Hydraulic System Bleeding and

Centralizing of the DifferentialValve 2-4

Section Page3 Cleaning and Inspection 2-6

Disc Brakes 2-6Drum Brakes 2-6Booster Unit 2-6Disc Brake Trouble Symptoms

and Possible Causes 2-7Drum Brake (and General System)

Trouble Symptoms and PossibleCauses 2-8

1 DIAGNOSIS AND TESTING

REFER TO Figs. 9 and 10 for thebrake trouble symptoms and possiblecauses.

BRAKE SYSTEM TESTS

Always check the fluid level in themaster cylinder before performing thetest procedures. If the fluid level isnot within 1/4 inch of the mastercylinder reservoirs, add RotundaBrake Fluid—Extra Heavy D u t y -Part Number C6AZ-19542-A (ESA-M6C25-A) or equivalent for all brakeapplications.

The disc brake extra heavy dutybrake fluid is colored blue for identi-fication purposes. Do not mix lowtemperature brake fluids with thespecified disc brake fluid.

1. Turn the ignition switch to theACC or ON position. If the light onthe brake warning lamp remains on,the condition may be caused by a de-fective switch, grounded switch wiresor the differential pressure valve isnot centered. Centralize the differ-ential pressure valve as outlined underBleeding the Brake System in thissection of the manual. If the warning

light remains on, check the switchconnector and wire for a groundedcondition and repair or replace thewire assembly. If the condition of thewire is good, replace the brake warn-ing lamp switch.

2. Turn the ignition switch to thestart position. If the brake warninglamp does not light, check the lightand wiring for defects and replace orrepair wiring.

3. If the. brake warning lamp doesnot light when a pressure differentialcondition exists in the brake system,the warning lamp may be burned out,the warning lamp switch is inopera-tive or the switch to lamp wiring hasan open circuit. Check the bulb andreplace it, if required. Check theswitch to lamp wires for an open cir-cuit and repair or replace them, ifrequired. If the warning lamp stilldoes not light, replace the switch.

BRAKE PEDAL FREEHEIGHT AND TRAVELMEASUREMENTS

With the engine running for fullpower brake operation, measure thebrake pedal free height, and check

the brake pedal travel with the use ofthe Brake Pedal Pressure Gauge,Tool WRE-5OO-5O as follows:

Brake Pedal Free HeightMeasurement

1. Insert a slender, sharp pointedprod through the carpet and sounddeadener to the dash panel metal andmeasure the distance to the brakepedal (Fig. 1).

2. If the position of the pedal is notwithin specification, check the brakepedal linkage for missing, worn, ordamaged bushings, or loose attachingbolts and replace them, if required.

3. If the pedal free height is stillout of specification, check the brakepedal booster or master cylinder tobe sure the correct parts are installed.Replace the defective parts as neces-sary.

Brake Pedal TravelMeasurement

1. Install a Brake Pedal EffortGauge on the brake pedal pad (Fig.2).

2. Hook a steel measuring tape tothe brake pedal as shown in Fig. 1.


2-2 GROUP 2 - Brakes

CENTERLINE OFSTEERING COLUMN

VEHICLE

FORD-MERCURY

FORD-MERCURY

FORD

TYPE

N 0B*ffE R

POWERDISC

NON-POWERDISC

AMAX.7.91

6.40

8.70

MIN.6.92

5.14

7.65

•MAX.2.90

3.10

2.28

TOEBOARDOR DASH METAL

"A" DIMENSION TO BE MEASURED TO SHEET METAL.

" B " DIMENSION TO BE MEASURED PARALLEL TO THE VERTICAL CENTERLINEOF THE STEERING COLUMN WITH A 50 POUND LOAD APPLIED TO THECENTERLINE OF THE BRAKE PEDAL PAD. (CHECKS ON POWER BRAKEVEHICLES MADE WITH ENGINE RUNNING)

H 1544-B

FIG. 7—Brake Pedal Height andTravel Measurements

Tool -WRE-500-SO

FIG. 2—Brake Pedal EffortGauge Installed

Measure and record the distance fromthe brake pedal free height position tothe reference point, which is at the sixo'clock position on the steering wheelrim.

3. With the steel tape still hookedto the brake pedal depress the brakepedal by pressing downward on thebrake pedal effort gauge. Apply a 50pound load to the center of the pedal

by observing the pressure gauge, andmeasure the distance from the brakepedal to the fixed reference point onthe steering wheel rim parallel to thecenterline of the steering column.

4. The difference between thebrake pedal free height and the de-pressed pedal measurement under a50 pound load should be within thespecified maximum pedal travel serv-ice specification B in Fig. 1.

5. If the pedal travel is more thanthe specified maximum shown in Fig.1, dimension B, make several sharpreverse stops (equivalent to 50 poundspedal pressure) with a forward stopbefore each. Move the vehicle inreverse and forward for a distance ofapproximately ten feet; then applythe brakes sharply and hold the brakepedal down until the vehicle is com-pletely stopped. This will actuate thei>nke self-adjusters. If these stops donot bring the brake pedal travel with-in specification, make several addi-tional forward and reverse stops asoutlined above.

6. If the second series of stops donot bring the brake pedal travel with-in specification, remove the brakedrums and check the brake adjustersto make sure they are functioning.Check the brake linings for wear ordamage. Repair or replace all wornor damaged parts and non-function-ing adjusters. Adjust the brake lining

outside diameter to the approximateinside diameter of the brake drumwith Rotunda Tool HRE-8650 (Figs.12 and 13, Part 2-2).

7. If all the brake adjusters, brakedrums and linings are functional andthe brake travel is not within speci-fications, check the pedal linkage formissing or worn bushings, or looseattachments, Bleed the brakes andcentralize the differential valve.

POWER BRAKEFUNCTIONAL TEST

1. With the transmission in neutral,stop the engine and apply the parkingbrake. Depress the brake pedal sev-eral times to exhaust all vacuum inthe system.

2. With the engine shut off, de-press the brake pedal and hold it inthe applied position. If the pedalgradually falls away under this pres-sure, the hydraulic system is leaking.Check all tubing, hoses, calipers (ifso equipped), wheel cylinders andconnections for leaks.

3. With the engine shut off and allvacuum in the system exhausted, de-press the pedal, and hold it in theapplied position. Start the engine. Ifthe vacuum system is operating, thepedal will tend to fall away under footpressure and less pressure will berequired to hold the pedal in the ap-plied position. If no action is felt,the vacuum booster system is notfunctioning.

If the brake pedal movement feelsspongy, bleed the hydraulic systemto remove air from the system. Referto Hydraulic System Bleeding, Part1, Section 2, Also, check for leaks orinsufficient fluid.

LOCKED WHEEL BRAKE

Should one of the wheel brakes belocked and the vehicle must be moved,open the bleeder screw long enoughto let out a few drops of brake fluid.This bleeding operation will releasethe brakes but will not correct thecause of trouble.

VACUUM TESTS—VACUUMRELEASE PARKING BRAKES

Visually check the operation of thebrake linkage as the brake pedal isdepressed. Then, check the operationof the brake linkage when the manualrelease lever is activated. Thesechecks should indicate whether themanual parking brake control linkageis operating properly or requires re-


PART 2-1 - General Brake Service 2-3

pair or adjustment due to inability ofthe parking brake to hold againstmoderate vehicle movement. Performtests of the parking brake system andcontrols after making certain the link-age and manual controls operateproperly.

Diagnosis of vacuum release sys-tems is basically similar to electricaldiagnosis. That is, the vacuum sys-tem must be complete from thesource to the vacuum components.Any leaks, like a bad connection willmake the system inoperative. If a leakdevelops in one of the vacuum sys-tems, one or all of the vacuum com-ponents may become inoperative. Thiswould be dependent on the location ofthe vacuum leak. If the leak is in thevacuum supply, all systems will be-come inoperative. If the leaks is inthe component side of the vacuumcontrol for the specific system, allother systems will operate when theleaking system is off.

When testing a parking brakevacuum release system, a minimum of10 inches of vacuum (Hg.) should beavailable at all points where vacuumis applied. This can be checked witha Rotunda Fuel Pump TesterGauge (ARE345) and two DistributorTester hose adapters (Marked Q)connected together with a coupling.This allows the Fuel Pump TesterGauge hose to be adapted to anyother vacuum hose or rubber connec-tor in the vacuum systems.

Failure to maintain 10 inches of

vacuum (Hg) during vacuum systemtests could be caused by a loose hoseconnection, resulting in a vacuumleak. When checking for vacuum be-tween two points, trace the hose alongthe entire routing to be sure it is notcrossed with another hose and con-nected to the wrong connection.

All of the vacuum parking brakecontrol checks are to be performedwith the engine running at idle speed.

Leaks in the parking brake hosesor a disconnected or improperly con-nected hose can usually be found bylistening for a hissing sound alongthe hose routings. Under no circum-stances should air pressure be appliedto the vacuum system as the actuatordiaphragm in the parking brake vac-uum motor may be damaged.

1. Start the engine and run it atidle speed. With the transmissionshift control in neutral, depress theparking brake pedal to apply theparking brake. Move the transmissionshift control to D range and ob-serve the parking brake pedal to seethat the pedal moves upward and theparking brake releases. If the parkingbrake releases, the parking brakevacuum control is working properly.

2. If the parking brake does notrelease, test for vacuum at the steeringcolumn neutral switch port in thejunction block, vacuum lines and theparking brake release vacuum motor.Use the Rotunda Vacuum and FuelPump Tester 345. This can beaccomplished by removing the hose

from each component and attachingit to the vacuum gauge. Connect twodistributor tester vacuum hose adapterstogether with a coupling as a con-nector to attach the gauge. A mini-mum of ten inches of vacuum is re-quired to actuate the parking brakevacuum motor. Do not remove anyof the vacuum hoses from the junctionblock unless the junction block isbeing replaced, as the plastic nipplesare thin and very brittle and damagemay result. If a minimum readingis not present when checking eachof the aforementioned components,they must be replaced.

ROAD TESTA road test should be conducted

only when the operator is sure thebrakes will stop the vehicle.

During a road test, apply thevehicle brakes at a road speed of20 mph for all problem conditionslisted in Figs. 9 and 10 with the ex-ception of those resolved in the brakesystem tests and brake chatter. Tocheck for brake chatter or surge, ap-ply the brakes lightly at 50 mph. Foreach of the symptoms encounteredcheck and eliminate the caused whichare listed in Figs. 9 and 10.

If the road test reveals one ormore problem conditions listed Figs.9 and 10, correct all malfunctions ofthe vacuum system, brake boosterand hydraulic system prior to remov-ing brake drums, brake calipers,brake shoes and linings or backingplates.

COMMON ADJUSTMENTS AND REPAIRS

PARKING BRAKE LINKAGEADJUSTMENT

Check the parking brake cableswhen the brakes are fully released.If the cables are loose, adjust them asfollows:

1. Fully release the parking brakepedal by pulling the release lever, oron a vacuum release pedal by pushingdown the manual release lever.

2. Depress the parking brake pedaluntil it is engaged in the first notch ofthe control,

3. Raise the vehicle. With thetransmission in neutral, turn theadjusting nut forward against theequalizer (Fig. 3) until a moderatedrag is felt when turning the rearwheels (approximately 100 lbs offorce at the outside diameter of thetire is required to turn the

REAR WHEEL CABLE-2A809

EQUALIZER-TO-CONTROL CABLE-2A815

RiARWHiiUCAIUi=2A63i

ADJUSTING NUT

HI 537- A

rear FIG. 3—Parking Brake Adjustment



wheels).4. Release the parking brake, and

check to make sure that the brakeshoes return to the fully released po-sition.

5. Depress the parking brake pedalto the third notch. Under normal con-ditions, this will hold the vehiclesatisfactorily.

6. Release the parking brake again,and check as in step 4.

7. If the rear brakes do not fullyrelease, check the cables for kinksor binds. Free the cables as required.

# 1 6 GAUGESHEET STEEL

2%'

MIDLAND-ROSS0.980-0.995 __,MUSTANG

COUGAR, FALCON,0.970-0.980

BENDIX*~ 0.980-0.995 l

H1208-D

FIG. 4—Push Rod GaugeDimensions

POWER BRAKE MASTERCYLINDER PUSH RODADJUSTMENT

The push rod is provided with anadjustment screw to maintain the cor-rect relationship between the boostercontrol valve plunger and the mastercylinder. Failure to maintain thisrelationship will prevent the mastercylinder piston from completely re-leasing hydraulic pressure and cancause the brakes to drag.

The adjustment screw is set to thecorrect height at the time of originalassembly of the power unit. Undernormal service the adjustment screwdoes not require any further attentionproviding the original push rod assem-bly remains in the original unit.

To check the adjustment of the

screw, fabricate a gauge of the di-mensions shown in Fig. 4. On theMidland-Ross booster, remove themaster cylinder and air filter assem-bly and push the bellows back intothe booster body. Re-install the airfilter directly against the boosterbody, and then place the gaugeagainst the master cylinder mountingsurface of the air filter assembly asshown in Fig. 5 or 6. The push rodscrew should be adjusted so that theend of the screw just touches the in-ner edge of the slot in the gauge.

AIR FILTER

action. Bleed the hydraulic systemafter it has been properly connected,to be sure that all air is expelled.

H1349-A

FIG. 5—Push Rod Adjustment—Midland-Ross

Do not set up side forces on thepush rod as it may break the valveplunger.

To check the Bendix-type booster,remove the master cylinder and fitthe gauge against the master cylindermounting surface as shown in Fig. 6.

This is an approximate adjustmentonly. To verify the adjustment, lookthrough the make-up (rear) port ofthe master cylinder when installingthe master cylinder to the booster.The master cylinder piston should notmove more than 0.015 inch as itcontacts the push rod. No movement(exact contact) is ideal.

HYDRAULIC SYSTEM BLEEDINGAND CENTRALIZING OF THEDIFFERENTIAL VALVE

When any part of the hydraulicsystem has been disconnected for re-pair or replacement, air may enterthe system and cause spongy pedal

H 1330-B

FIG. 6—Push Rod Adjustment—Bendix

MANUAL BLEEDING

The primary and secondary (frontand rear) hydraulic brake systemsare individual systems and are bledseparately. Bleed the longest line firston the individual system being serv-iced. During the complete bleedingoperation, DO NOT allow the reser-vior to run dry. Keep the master cyl-inder reservoirs filled with RotundaFluid—Extra Heavy Duty—PartNumber C6AZ-19542-A (ESA-M6C-25-A). The disc brake extra heavyduty brake fluid is colored blue foridentification purposes. Do not mixlow temperature brake fluids with thespecified fluid during the bleedingoperations. Never re-use brake fluidwhich has been drained from the hy-draulic systems.

1. Loosen the bleed screw locatedon the side of the master cylinder.Do not use the secondary piston stopscrew, located on the bottom of themaster cylinder to bleed the brakesystem. Loosening or removing thisscrew could result in damage to thesecondary piston or stop screw.

2. To bleed the secondary (rear)brake system, position a suitable 3/8inch box wrench (Fig. 7) on thebleeder fitting on the brake wheel


PART 2-1 - General Brake Service 2-5

APPROXIMATELY 45°

HI 300-A

FIG. 7—Wrench for BleedingBrake Hydraulic System

cylinder. Attach a rubber drain tubeto the bleeder fitting. The end of thetube should fit snugly around thebleeder fitting.

3. Submerge the free end of thetube in a container partially filledwith clean brake fluid, and loosen thebleeder fitting approximately 3/4turn.

4. Push the brake pedal down slow-ly through its full travel. Close thebleeder fitting, then return the pedalto the fully-released position. Repeatthis operation until air bubbles ceaseto appear at the submerged end of thebleeder tube.

5. When the fluid is completely freeof air bubbles, close the bleeder fit-ting and remove the bleeder tube.

6. Repeat this procedure at thebrake wheel cylinder on the oppositeside. Refill the master cylinder reser-voir after each wheel cylinder is bledand install the master cylinder coverand gasket. Be sure the diaphragmtype gasket is properly positioned inthe master cylinder cover. When thebleeding operation is completed, thefluid level should be filled to within1/4 to 1/2 inch from the top of thereservoirs.

7. If the primary (front brake) sys-tem is to be bled. Repeat steps 2through 6 at the right front brakecaliper or cylinder and ending at theleft front brake caliper or cylinder.

8. Be sure that the front brakepistons are returned to their normalpositions and that the shoe and liningassemblies are properly seated bydepressing the brake pedal severaltimes until normal pedal travel isestablished.

9. Centralize the pressure differen-tial valve. Refer to the Centralizingthe Pressure Differential Valve pro-cedures which follow.

PRESSURE BLEEDING

Bleed the longest lines first. Thebleeder tank should contain enoughnew Rotunda Brake Fluid to com-plete the bleeding operation. UseRotunda Brake Fluid—Extra Heavy

Duty Part Number C6AZ-19542-A(ESA-M6C25-A) or equivalent for allbrake applications. The brake fluid iscolored blue for identification pur-poses. Do not mix low temperaturebrake fluid with the specified brakefluid during the bleeding operations.Never re-use brake fluid that has beendrained from the hydraulic system.The tank should be charged with ap-proximately 10 to 30 pounds of airpressure. Never exceed 50 poundspressure.

1. Clean all dirt from the mastercylinder reservoir cover.

2. Remove the master cylinderreservoir cover and rubber gasket,and fill the master cylinder reservoirwith the specified brake fluid. Installthe pressure bleeder adapter tool tothe master cylinder, and attach thebleeder tank hose to the fitting on theadapter.

Master cylinder pressure bleederadapter tools can be obtained fromthe various manufacturers of pressurebleeding equipment. Follow the in-structions of the manufacturer wheninstalling the adapter.

3. If the master cylinder isequipped with a bleed screw, loosenthe bleed screw and bleed the mastercylinder until the fluid is free of airbubbles; then, tighten the bleedscrew. Do not use the secondary pis-ton stop screw, located on the bottomof the master cylinder, to bleed themaster cylinder.

Loosen the primary and secondarytube nuts at the master cylinder ofthose master cylinders without bleedscrews and bleed the master cylinderuntil the fluid flow is free of airbubbles, then tighten the tube nuts tothe specified torque. Do not over-tighten.

4. If the rear wheel cylindersthe, secondary brake system, are to bebled, position a 3/8 inch box wrench(Fig.7) on the bleeder fitting on theright rear brake wheel cylinder. At-tach a bleeder tube to the bleederfitting. The end of the tube shouldfit snugly around the bleeder fitting.

5. Open the valve on the bleedertank to admit pressurized brake fluidto the master cylinder reservoir.

6. Submerge the free end of thetube in a container partially filledwith clean brake fluid, and loosen thebleeder fitting.

7. When air bubbles cease to ap-pear in the fluid at the submereged endof the bleeder tube, close the bleeder

fitting and remove the tube.8. Repeat steps 3 through 7 at the

left rear wheel cylinder.9. If the vehicle is equipped with

disc brakes, repeat steps 4 through7, starting at the right front disccaliper and ending at the left frontdisc caliper.

10. If the vehicle contains drum-type front brakes and the primary(front) brake system is to be bled,repeat steps 4 through 7, starting atthe right front wheel cylinder endingat the left wheel cylinder.

11. When the bleeding operation iscompleted, close the bleeder tankvalve and remove the tank hose fromthe adapter fitting.

12. On disc brake equipped vehi-cles, be sure that the front brakepistons are returned to their normalpositions and that the shoe and lin-ing assemblies are properly seated bydepressing the brake pedal severaltimes until normal pedal travel isestablished.

13. Remove the Pressure BleederAdapter Tool. Fill the master cylinderreservoirs to within 1/4 inch fromthe top. Install the master cylindercover and gasket. Be sure the Dia-phragm type gasket is properly posi-tioned in the master cylinder cover.

14. Centralize the pressure differ-ential valve as follows.

CENTRALIZING THEPRESSURE DIFFERENTIALVALVE

After a failure of the primary(front brake) or secondary (rearbrake) system has been repaired andbled, the dual-brake warning lightwill usually continue to be illumi-nated due to the pressure differentialvalve remaining in the off-center ps-sition. Front wheel balancing opera-tions on disc brake equipped vehiclescan also cause a pressure differentialin the primary (front) brake system,illuminating the brake warning light.

To centralize the pressure differen-tial valve and turn off the warninglight after a repair operation, a pres-sure differential or unbalance condi-tion must be created in the oppositebrake system from the one that wasrepaired or bled last.

1. Turn the ignition switch to theACC or ON position. Loosen the dif-ferential valve assembly brake tubenut at the outlet port on the oppositeside of the brake system that waswheel balanced, repaired and/or bled



last. Depress the brake pedal slowlyto build line pressure until the pres-sure differential valve is moved to acentralized position and the brakewarning light goes out; then, immedi-

ately tighten the outlet port tube nut.2. Check the fluid level in the mas-

ter cylinder reservoirs and fill them towithin 1/4 to 1/2 inch of the top withthe specified brake fluid, if necessary.

3. Turn the ignition switch to theOFF position.

4. Before driving the vehicle, checkthe operation of the brakes and be surethat a firm pedal is obtained.

CLEANING AND INSPECTION

DISC BRAKES

1. Remove the wheel and tireand the shoe and lining assembliesas outlined in Part 2-2, Section 2.

2. Make thickness measurementswith a micrometer across the thinnestsection of the shoe and lining. If theassembly has worn to a thickness of0.230-inch (shoe and lining together)or 0.030-inch (lining material only)at any one of three meauring locationsor if lining shows evidence of brakefluid contamination, replace all (4)shoe and lining assemblies on bothfront wheels.

3. Check the caliper to spindle at-taching bolts torque. Torque them tospecification, if required.

4. To check rotor runout, firsteliminate the wheel bearing end playby tightening the adjusting nut. Aftertightening the nut, check to see thatthe rotor can still be rotated.

5. Clamp a dial indicator to thecaliper housing so that the styluscontact the rotor at a point approxi-mately 1 inch from the outer edge.Rotate the rotor and take an indica-tor reading. If the reading exceeds0.002 inch total lateral runout on theindicator, replace or resurface the discbrake rotor. The following require-ment must be met when resurfacingdisc brake rotors:

Rotunda Disc Brake AttachmentFRE-2249-2 is the only approved toolto be used to refinish the disc brakerotors. The step-by-step resurfacingprocedure provided with the toolmust be adhered to.

The finished braking surface of therotor must be flat and parallel within0.0007 inch; lateral runout must notexceed 0.002 inch total indicatorreading, and the surface finish of thebraking surface are to be 85/15micro inches. The minimum limitingdimension (Fig. 8) from the inboardbearing cup to the inboard rotor face(dimension B) and the outboard rotorsurface and the inboard bearing cup(dimension A), must be observedwhen removing material from therotor braking surfaces.

When the runout check is finished

HI 532-A

FIG. 8—Disc Brake Rotor ServiceLimits.

be sure to adjust the bearings as out-lined in Group 3, in order to preventbearing failure.

6. Check the rotor for scoring.Minor scores can be removed with afine emery cloth. If the rotor is ex-cessively scored, refinish it as outlinedin step 5 or replace the rotor, if re-quired.

7. Visually check the caliper ifexcess leakage is evident, it should bereplaced. Slight leakage around thepiston or a seized piston indicatesthe need for removal and disas-sembly.

8. If upon disassembly the caliperif found to be distorted or damaged,or if the cylinder bores is scored orexcessively worn, replace the assem-bly.

9. Check the brake hoses for signsof cracking, leaks or abrasion. Re-place them if necessary.

DRUM BRAKES

1. Remove the wheel from thedrum, and remove the drum as out-lined in Part 2-2, Section 2.

2. Brush all dust from the backingplates and interior of the brakedrums.

3. Inspect the brake shoes for ex-cessive lining wear or show damage.If the lining is worn within 1/32 inchof the rivet heads or if the shoes aredamaged, they must be replaced. Re-place any lining that had been con-taminated with oil, grease or brakefluid. Replace lining in axle sets.Prior to replacement of lining, thedrum diameter should be checked todetermine if oversize linings must beinstalled.

4. Check the condition of brakeshoes, retacting springs, hold-downsprings, and drum for signs of over-heating. If the shoes have a slightblue coloring, indicating overheating,replacement of the retracting andhold-down springs is strongly recom-mended. Overheated springs lose theirpull and could cause the new liningto wear prematurely, if they are notreplaced.

5. If the vehicle has 30,000 or moremiles of operation on the brake lin-ings or signs of overheating are pres-ent when relining brakes, the wheelcylinders should be disassembled andinspected for wear and entrance ofdirt into the cylinder. The cylindercups should be replaced., thus avoid-ing future problems.

6. Inspect all other brake parts andreplace any that are worn or dam-aged.

7. Inspect the brake drum and, ifnecessary, refinish. Refer to Part 2-2,Section 4 for refinishing.

BOOSTER UNIT

Check the booster operation asnoted in Part 2-1, Section 1, PowerBrake Functional Test. If the brakebooster is damaged or defective, re-place it with a new booster. Thebrake booster is serviced only as anassembly.


PART 2-1 — General Brake Service 2-7

POSSIBLE CAUSES OF TROUBLE

Shoe and Lining Knock-back after Violent Cornering or Rough RoadTravel

Shoe and Lining Assembly not Properly Seated or Positioned

Leak or Insufficient Fluid in System or Caliper

Loose Wheel Bearing Adjustment

Damaged or Worn Caliper Piston Seal

Improper Master Cylinder Push Rod Adjustment

Excessive Rotor Runout or Out of Parallel

Incorrect Tire Pressure

Frozen or Seized Pistons

Brake Fluid, Oil or Grease on Linings

Shoe and Lining Worn Below Specifications

Proportioning Valve Malfunction

Booster Inoperative

Caliper Out of Alignment with Rotor

Loose Caliper Attachment

Metering Valve Seal Leaks

Excessive Clearance Between Shoe and Caliper or Between Shoeand Splash Shield

Shoe Hold Down Clips Missing or Improperly Positioned

Operator Riding Brake Pedal

Scores in the Cylinder Bore

Corrosion Build-Up in the Cylinder Bore or on the Piston Surface

Bleeder Screw Still Open

Caliper Out of Parallel with Rotor

One Section Dual Brake System Is Inoperative

Differential Pressure Valve Is not Centered

Wiring to Warning Lamp Switch Is Grounded

Warning Lamp Switch Is Grounded

Warning Lamp Is Burned Out

Warning Lamp Switch Has an Open Circuit

Warning Lamp Switch Is Inoperative

Wiring to Warning Lamp Has Open Circuit

TROUBLE SYMPTOMS

Exc

essi

ve P

edal

Tra

vel

X

X

X

X

X

X

X

Bra

ke R

ough

ness

or

Cha

tter

(Ped

al P

umpi

ng)

X

X

X

Exc

essi

ve P

edal

Effo

rt

X

X

X

X

X

X

X

Pul

l

X

X

X

X

X

X

X

X

Rat

tle

X

X

X

Bra

kes

Hea

t U

p D

urin

g D

rivin

g a

nd F

ail

toR

elea

se

X

X

X

Leak

y W

heel

Cyl

inde

r

X

X

X

Gra

bbin

g or

Une

ven

Bra

king

Act

ion

X

X

X

X

X

X

X

No B

raki

ng E

ffect

Whe

n P

edal

Is

Dep

ress

ed

X

X

X

X

Bra

kes

for

the

Res

pect

ive

Sys

tem

Do N

ot A

pply

X

Ped

al G

radu

ally

Mov

es T

owar

d F

loor

or

Das

hP

anel

X

X

War

ning

Lam

p S

tays

Li

t.

X

X

X

X

War

ning

Lam

p D

oes

Not

Lig

ht

X

X

X

X

. 9—Disc Brake Trouble Symptoms and Possible Causes



POSSIBLE CAUSES OF TROUBLE

Mechanical Resistance at Pedal or Shoes

Brake Line Restricted

Leaks or Insufficient Fluid

Improper Tire Pressure

Distorted or Improperly Adjusted Brake Shoe

Faulty Retracting Spring

Drum Out of Round

Lining Glazed or Worn

Oil or Grease on Lining

Loose Carrier Plate

Loose Lining

Dirt on Drum-Lining Surface

Faulty Brake Cylinder

Dirty Brake Fluid

Faulty Master Cylinder

Air in Hydraulic System

Self Adjusters Not Operating

Insufficient Shoe-to-Carrier Plate Lubrication

Tire Tread Worn

Poor Lining to Drum Contact

Loose Front Suspension

Threads Left by Drum Turning Tool Pulls Shoes Sideways

Cracked Drum

One Section Dual Brake System Is Inoperative

Differential Pressure Valve Not Centered

Wiring to Warning Lamp Switch Is Grounded

Warning Lamp Switch Is Grounded

Warning Lamp Is Burned Out

Warning Lamp Switch Has an Open Circuit

Wiring to Warning Lamp Has Open Circuit

TROUBLE SYMPTOMS

One

Brak

e Dr

ags

X

X

X

X

X

X

X

X

X

All B

rake

s Dr

agX

X

X

X

X

Hard

Ped

al

X

X

X

X

Spon

gy P

edal

X

X

Car

Pulls

to O

ne S

ide

X

X

X

X

X

X

X

X

X

One

Whe

el L

ocks

X

X

X

X

X

X

Brak

es C

hatte

rX

X

X

X

X

X

X

Exce

ssive

Ped

al T

rave

l

X

X

X

X

X

X

X

Peda

l Gra

dual

ly G

oes

to F

loor

X

X

Brak

es U

neve

n

X

X

X

Shoe

Clic

k Af

ter

Rele

ase

X

X

Noisy

or

Grab

bing

Bra

kes

X

X

X

X

X

X

Brak

es D

o No

t App

ly

X

X

X

X

X

XBr

akes

for

the

Resp

ectiv

e Sy

stem

Do

Not

Appl

y

X

War

ning

Lam

p St

ays

Lit.

X

X

X

X

Peda

l Gr

adua

lly M

oves

Tow

ard

Floo

r or D

ash

Pane

l

X

X

War

ning

Lam

p Do

es N

ot L

ight

X

X

X

FIG. 10—Drum Brake (and General System) Trouble Symptoms and Possible Causes


2-9

PART 2 - 2 - Brake SystemSection Page

1 Description and Operation 2-9Dual-Master Cylinder Brake System 2-9Disc Brakes 2-10Hydraulic Self-Adjusting

Brake System 2-12Booster System 2-14Parking Brake 2-14

2 In-Vehicle Adjustments and Repairs 2-15Brake Shoe Adjustments 2-15Front Brake Drum 2-16Rear Brake Drum 2-16Brake Shoes and Adjusting Screw 2-16Disc Brake Shoe and Lining

Replacement 2-17Disc Brake Caliper Assembly 2-20Front Wheel Hub and Rotor Assembly-

Disc Brakes 2-20Disc Brake Rotor Splash Shield 2-20Proportioning Valve 2-20Standard or Rear Wheel Cylinder

Repair 2-21Wheel Cylinder Replacement 2-21

Section PageBacking Plate Replacement 2-21Hydraulic Lines 2-23

3 Removal and Installation 2-23Dual-Master Cylinder-

Standard Brakes 2-23Dual-Master Cylinder-

Power Brakes 2-24Pressure Differential Valve 2-24Booster Unit 2-25Brake Pedal—Manual Shift

Transmission 2-25Brake Pedal—Automatic Transmission 2-26Parking Brake Control Assembly 2-26Parking Brake to Equalizer Cable 2-26Parking Brake Equalizer to

Rear Wheel Cable 2-264 Major Repair Operations 2-28

Brake Drum Refinishing 2-28Rotor Refinishing 2-28Brake Shoe Relining 2-28Dual-Master Cylinder 2-28Disc Brake Caliper 2-29

1 DESCRIPTION AND OPERATION

Disc brakes are available as op-tional equipment for the front wheels.The dual-master cylinder equippedhydraulic brake system employs sin-gle anchor, internal expanding andself-adjusting drum brake assemblieson the rear wheels of vehicles with discbrakes, and on the front and rearwheels of all others.

A vacuum booster is available asoptional equipment.

DUAL MASTER CYLINDERBRAKE SYSTEM

The dual-master cylinder brakesystem has been incorporated in allmodels to provide increased safety.The system consists of a dual-mastercylinder, pressure differential valveassembly and a switch. The switchon the differential valve activates adual-brake warning light, located onthe instrument panel.

The dual-master cylinder brakesystem is similar to a conventional(single) system, two master cylindersare combined in a singal cast ironcasting (Fig. 1). One portion actuatesthe primary (front) brake system andthe other actuates the secondary(rear) brake system (Figs. 20 and 22).Hydraulic fluid leakage or failure ofone of the systems does not impairthe operation of the other portion ofthe dual-brake system. A dual-brake

warning light signals a failure ofeither the front (primary) or rear(secondary) brake system.

On power disc equipped vehicles,the dual-master cylinder has the mas-ter cylinder outlet port for the rear(secondary) brake system located onthe bottom of the master cylinderbody. A master cylinder hydraulicsystem bleed screw is located in theoutboard side of the master cylindercasting. The front (primary) brakesystem outlet port is located on theoutboard side of the master cylinder.

On power drum and standard drumequipped vehicles, the rear (secon-dary) and front (primary) brake sys-tem outlet ports are located on theoutboard side of the master cylindercasting. A bleed screw is not used onthe master cylinder for power drumand standard drum equipped vehicles.

A code letter is stamped on theend of the master cylinder body cast-ing for easy service identification.Code letter A or P identifies thepower disc brake master cylinder,code letter T identifies the standarddrum brake master cylinder.

A brake pressure differential valveassembly (Fig. 2) incorporating ahydraulically operated mechanicalswitch is utilized to operate a dual-brake warning light, located on theinstrument panel.

Brake tubes are connected from the

dual-master cylinder front (primary)and rear (secondary) brake systemsto the pressure differential valve (Fig.2).

The pressure differential valve ismounted vertically on the frame siderail within the engine compartment.The primary (front) brake systemoutlet tubes are connected to theports located in the upper side of thedifferential vavle assembly and thesecondary (rear) brake system outlettubes are connected to the ports lo-cated in the lower side of the dif-ferential valve assembly.

Hydraulic pressure for both rearwheel brakes is provided from thesingle secondary (rear) brake outletline, located opposite the secondarysystem inlet port of the differentialvalve. On disc brake equipped vehi-cles, a proportioning valve is includedin the system and is connected tothe differential valve through inletand outlet tubes. The brake hosebracket serves as a junction point forthe individual brake lines that leadto the wheel cylinders of right andleft rear brake components.

When the brake pedal is depressed,both the primary (front brake) andsecondary (rear brake) master cylin-der pistons are moved simultaneouslyto exert hydraulic fluid pressure ontheir independent hydraulic system.The fluid displacement of the dual-


2-10 GROUP 2-Brakes

DISC BRAKES

RETURN SPRING(SECONDARY)

RETAINER

PRIMARY SYSTEM BRAKEFLUID RESERVOIR

RETURN SPRING (PRIMARY)

BOOT

PUSH ROD

(SECONDARY)BRAKE OUTLETPORT

SECONDARY PISTONASSEMBLY

(PRIMARY)BRAKE OUTLETPORT

PRIMARY PISTONASSEMBLY

FIG. 1 — Dual-Master Cylinder-Typical

master cylinders is porportioned tofulfill the requirements of each of thetwo independent hydraulic brake sys-tems (Fig. 1).

If a failure of the rear (secondary)brake system should occur, initialbrake pedal movement causes the un-restricted secondary piston to bottomin the master cylinder bore. Primarypiston movement displaces hydraulicfluid in the primary section of thedual-master cylinder to actuate thefront brake system.

Should the front (primary) brakesystem fail, initial brake pedal move-ment causes the unrestriced primarypiston to bottom out against the sec-ondary piston. Continued downwardmovement of the brake pedal movesthe secondary piston to displace hy-draulic fluid in the rear brake system,actuating the rear brakes. On discbrake equipped vehicles, the pressuredifferential valve will move to the lowpressure area of the front system. Thismovement uncovers the rear brakesystem outlet passage and provides adirect passage from the rear inlet pas-sage to the outlet passage, bypassingthe proportioning valve. This providesfull hydraulic pressure to the rearbrake system.

The increased pedal travel and theincreased pedal effort required to

compensate for the loss of the failedportion of the brake system providesa warning that a partial brake systemfailure has occurred. When the igni-tion switch is turned to the start posi-tion, a dual-brake warning light pro-vides a visual indication the warninglamp is functional. When the ignitionswitch is turned to the ON or ACCposition, a dual-brake warning lighton the instrument panel also providesa visual indication if one portion ofthe dual-brake system has becomeinoperative.

Should a failure of either the frontor rear brake hydraulic system occur,the hydraulic fluid pressure differen-tial resulting from the pressure lossof the failed brake system forces thevalve toward the low pressure area toilluminate the brake warning light(Fig. 2).

A mechanically operated electricalswitch is located on the side of thepressure differential valve assemblybetween the front and rear brake sys-tem inlet ports. The inner-end of thespring loaded switch plunger con-tacts the bottom of a tappered shoul-der groove in the center of the valve(Fig. 2). O-ring seals are retained inseal ring lands near each end of thevalve.

Should a failure of the rear brake

H 1545-A

system occur, hydraulic fluid pres-sure in the rear brake system woulddrop. During brake pedal operationthe fluid pressure build-up of the frontbrake system forces the valve to movetoward the low pressure area, or to-ward the rear brake system outletport (Fig. 2). Movement of the dif-ferential valve forces the switch plun-ger upward over the tapered shoulderof the valve to close the switch electri-cal contacts and light the dual brakewarning lamp, signalling a brake sys-tem failure.

In the event a front brake systemfailure should occur, greater pressurefrom the rear brake system duringbrake pedal operation forces the valveforward, moving the switch plungerupward onto the valve ramp to lightthe brake system warning lamp. How-ever, failure of either the front orrear system does not impair opera-tion of the other brake system.

DISC BRAKES

Disc brakes are available as op-tional equipment for the front wheels.The hydraulic brake system employssingle anchor, internal expanding andself-adjusting drum brake assemblieson the rear wheels of vehicles withdisc brakes, and on front and rearwheels of all others.


PART 2-2 -Brake System 2-11

BRAKE WARNING LAMP SWITCH

PISTON

BRAKE WARNING LAMP SWITCHPLUNGER IN THE ON POSITION

CONNECTOR

BRAKE WARNING LAMP SWITCH

E\VALVE PISTON HAS MOVEDTO LOW PRESSURE AREA.WARNING LAMP SWITCH

PLUNGER IS DEPRESSED,LIGHTING THE BRAKE

WARNING LAMP

LOW PRESSURE SIDE •

BRAKE WARNING LAMP SWITCHPLUNGER IN OFF POSITION

HIGH PRESSURE SIDE

VALVE PISTON ISCENTRALIZED. PRIMARYAND SECONDARY SYSTEM

PRESSURES ARE EQUALIZED

CONNECTOR

BRAKE WARNINGLIGHT SWITCH

TOPROPORTIONINGVALVE

sLEFT FRONT OUTLET

\PROPORTIONING VALVE REAR BRAKE INLET

DISC BRAKES

BRAKE FLUID

H-1577- A

FIG. 2—Pressure Differential Valve and Brake Warning Light Switch Operation

A vacuum booster is available asoptional equipment.

The master cylinder converts phys-ical force from the brake pedal (andbooster if so equipped) into hydraulicpressure against the piston in eachcaliper (disc brakes) or in the wheelcylinders (drum brakes). The pistonsin turn convert hydraulic pressureback into physical force at the brakeshoes,

RELATION AND FUNCTIONOF COMPONENT PARTS

The disc brake is a floating cali-per, single piston, ventilated disc-type, actuated by a hydraulic system.

The caliper assembly is made upof a floating caliper assembly and

an anchor plate. The anchor plateis bolted to the wheel spindle armby two bolts. The floating caliperis attached to the anchor platethrough two spring steel stabilizers.The floating caliper slides on twoguide pins which also attach to thestabilizers. The floating caliper con-tains the single cylinder and piston as-sembly, The cylinder bore contains apiston with a molded rubber dustboot to seal the cylinder bore fromcontamination and also to return thepiston to the released position whenhydraculic pressure is released. Alsoa rubber piston seal is used to providesealing between the cylinder andpiston. (Fig. 4).

The shoe and lining assemblies aremounted in two different ways. The

outboard shoe and lining is fixed tothe floating caliper and is retainedby two pins and spring clips. Theinboard shoe and lining attaches tothe end of the cylinder piston andis retained by two spring clips (Fig.18). The shoe and lining assemblyconsists of friction material bondedto a metal plate called the shoe. Itis replaced as a unit (Fig. 6).

The cast iron disc is of the venti-lated rotor type incorporating fortyfins and is attached to, and rotateswith the wheel hub. The outside dia-meter of the rotor is 11 7/8 inchesand the inside diameter is 7 7/8 in-ches. This type of design increasescooling area and permits circulationof air through the rotor resulting inmore rapid cooling of the brake. A


2-12 GROUP 2-Brakes

FIG. 3—Disc Brake Assembly

splash shield bolted to the spindleis used primarily to prevent road con-taminants from contacting the inboardrotor and lining surfaces. The wheelprovides protection for the outboardsurface of the rotor.

As the brake pedal is depressed,hydraulic pressure from the mastercylinder forces the piston out of thebore. The inboard shoe and lining,being attached to the piston, isforced against the rotor. When theinboard shoe is against the rotor hy-draulic pressure equalizes and movesthe entire floating caliper assemblyinward. The outboard shoe and liningassembly attached to the floatingcaliper assembly is thereby forcedagainst the rotor. Hydraulic pressureforcing the piston-mounted shoe andlining outward and the caliper-mount-ed shoe and lining inward creates asqueezing action against the rotor,effecting braking action.

During braking action the rubberboot stretches as the piston movesoutward (Fig. 5). When hydraulic pres-sure is released the boot relaxes andpulls the inboard shoe and lining awayfrom the rotor. When brakes are ap-plied, hydraulic pressure moves thefloatirg caliper, overcoming thetension of the stabilizers. Whenhydraulic pressure is released, thestabilizers move the caliper back toits normal position. Since the outboardshoe and lining is attached to thecaliper it is moved away from therotor. In addition, inherent rotor

CALIPER HOUSING

PISTON

SHOE

LINING

PISTON SEAL

FIG. 4—Caliper Assembly—SectionalView

H 1568-A

PISTON SEALDISTORTED PISTON

CALIPER HOUSING

BRAKES APPLIED

FIG. 5—Function of Piston Seal

runout will aid in maintaining run-ning clearance between the rotor andthe shoe and lining assemblies.Automatic adjustment is accom-plished by the piston sliding in theseal outward from the cylinderbores. The piston gradually changesits position relative to the seal as thelining wears and, thus, maintains thecorrect adjustment location at alltimes.

When the brakes are in the unap-plied position, there is no hydraulicpressure to the calipers because thefluid source at the master cylinder by-passes the residual check valve.

A proportioning valve located be-tween the pressure differential valve

PISTON SEAL RELAXED

BRAKES RELEASED H 1569-A

and the rear brake wheel cylindersprovides balanced braking action be-tween the front and the rear brakesunder a wide range of braking condi-tions (Fig. 7). By regulating thehydraulic pressure applied to the rearwheel cylinders, the valve limits rearbraking action when high pressuresare required at the front brakes. Inthis manner, premature rear wheelskid is prevented. The proportioningvalve is serviced as an assembly andis never adjusted or overhauled.

HYDRAULIC SELF-ADJUSTINGBRAKE SYSTEM

The standard hydraulic brake sys-tem employs single anchor, internal


PART 2-2 - Brake System 2-13

PROPORTIONINGVALVE 2B091

H 1570-A

FIG. 7—Proportioning Valve\

1578-A

FIG. 6— Inner Brake Shoe

SHOE GUIDE (ANCHOR PIN) PLATEWASHER

PARKINGBRAKE LEVER

RETAININGCLIP

SHOE GUIDE (ANCHOR PIN) PLATE PRIMARY SHOE-TO-ANCHORSPRING

PRIMARYSHOE

BRAKEPARKING

LEVER

CABLE HOOKPARKING

BRAKE CABLEAND HOUSING

AUTOMATICADJUSTER

PIVOT SPRINGNUT

FIG. 8—Self-Adjusting Brake AssembliesH 1394 -B

expanding and self adjusting brakeassemblies.

The master cylinder converts phys-ical force from the brake pedal and

booster into hydraulic pressureagainst the pistons in the wheel cyl-



inders. The wheel cylinder pistons, inturn, convert hydraulic pressure backinto physical force at the brake shoes.

The self-adjusting brake mecha-nism consists of a cable, cable guide,adjusting lever, and adjuster spring(Fig. 8). The cable is hooked overthe anchor pin at the top and is con-nected to the lever at the bottom. Thecable is routed along the webb of thesecondary brake shoe by means of thecable guide. The adjuster spring ishooked to the primary brake shoe andto the lever. The automatic adjusteroperates only when the the brakes areapplied while the vehicle is movingrearward and only when the secondaryshoe is free to move toward the drumbeyond a predetermined point.

With the vehcile moving rearwardand the brakes applied the wrap-around action of the shoes followingthe drum forces the upper end of theprimary shoe against the anchor pin.The action of the wheel cylindermoves the upper end of the secondaryshow away from the anchor pin. Themovement of the secondary shoecauses the cable to pull the adjustinglever upward and against the end ofa toothe on the adjusting screw star-wheel. The upward travel of the leverincreased as lining wear increases.When the lever can move upward farenough, it passes over the end of thetooth and engages the tooth. Whenthe brakes are released, the adjustingspring pulls the lever downwardcausing the star-wheel to turn andexpand the shoes. The star-wheel isturned one tooth at a time as the lin-ings progressively wear.

With the vehicle moving forwardand the brakes applied, the secondaryshoe is against the anchor pin and theprimary shoe is moved toward thedrum. "Therefore, the adjuster doesnot operate.

The rear brake assembly is basical-ly the same as the front brake. Theconventional parking brake lever,link, and spring are used in the rearbrake.

The anchor pins on all brakes arefixed and non-adjustable.

BRAKE BOOSTER SYSTEM

This diaphragm type brake boosteris a self contained vacuum-hydraulicbraking unit mounted on the engineside of the dash panel.

The brake booster is of the vacuumsuspended type which utilizes engineintake manifold vacuum and atmos-pheric pressure for its power.

Adjustment of the push rod is theonly service permitted on the brake

booster. The booster unit is to be ex-changed when it is inspected, checkedand found to be defective.

PARKING BRAKEAn independent foot-operated park-

ing brake control actuates the rearwheel brake shoes through a cablelinkage. The operating cable is routedfrom the parking brake control as-sembly to the equalizer. The rearbrake cables connect the equalizerassembly to the parking brake leverat each rear secondary shoe (Fig. 8).

Two types of brake pedal controlare used. The automatic (vacuum)release type (Fig. 9) is used on theMercury Parklane. All other modelsuse the manual release type (Fig. 10).

When the pedal is depressed (eithermanual or automatic release type) thesecondary brake shoes are forcedagainst the rear brake drums. Thepedal is held in the applied positionby the engagement of a spring-loadedpawl with a ratchet in the control as-sembly (Figs. 9 and 10).

Either type of parking brake con-

trol assembly is mounted to the dashpanel and the instrument panel. Thepedal, pivots on a stationary pedalmount. A spring-loaded pawl and arelease lever are assembled to thepedal. A ratchet is assembled to theupper end of the pedal. The pawl con-tacts the ratchet at such an angle thatthe ratchet teeth will slide over thepawl as the pedal is depressed; how-ever, when the applying motion stopsand the pedal starts to release, thepawl engages the ratchet and thuslocks the brakes in the applied posi-tion.

When the lever is pulled back onthe manual release type (Fig. 10), thecam action of the lever on the pawlcam pin will disengage the pawl fromthe ratchet to release the brakes.

On the automatic type, the vacuumpower unit will release the parkingbrakes automatically when the trans-mission selector lever is moved intoany drive position with the enginerunning. The brakes will not releaseautomatically, however, when theselector lever is in the neutral or

-VACUUM POWER UNIT

PAWL (UPPER END)

PISTON ROD

REVERSE LEVER PEDAL MOUNT

CABLE CLEVIS

H1350-A

FIG. 9—Parking Brake Control Assembly with Automatic Release



TO VACUUMPOWER UNIT

FIG. 10—Parking Brake Control Assembly—Manual Release

park position with the engine running,or in any position with the engine off.

The power unit piston rod is at-tached to the release lever. Since the

release lever pivots against the pawl,a slight movement of the release leverwill disengage the pawl from the rat-chet allowing the brakes to release.

NEUTRALSAFETY SWITCH

(VACUUM RELEASE VALVE)

TO ENGINEMANIFOLDVACUUM

H1286-A

VACUUMJUNCTION BLOCK

FIG. 11— Connections forAutomatic Parking Brake Release

The release lever pivots on a rivet pinin the pedal mount (Fig. 9).

The vacuum power unit withmounting bracket is riveted to thecontrol assembly. The vacuum actu-ated piston within the unit is con-nected by a rod to the upper end ofthe release lever to move the pawl outof engagement with the ratchet (Fig9). The lower end of the release leverextends out for alternate manual re-lease in the event of vacuum powerfailure or for optional manual releaseat any time.

Hoses connect the power unit andthe engine manifold to a vacuum re-lease valve in the transmission neu-tral safety switch (Fig. 9 and 10).Moving the transmission selector le-ver into any drive position with theengine running will open the releasevalve to connect engine manifold vac-uum to one side of the actuating pis-ton on the power unit (Fig. 12). Thepressure differential thus created willcause the piston and link to pull therelease lever.

IN-VEHICLE ADJUSTMENTS AND REPAIRS

After any brake service work, ob-tain a firm brake pedal before mov-ing the vehicle. Riding the brakepedal (common on left foot applica-tion) should be avoided when drivingthe vehicle.

BRAKE SHOE ADJUSTMENTS

The hydraulic service brakes areself-adjusting and require a manualadjustment only after the brake shoeshave been relined, replaced, or whenthe length of the adjusting screw hasbeen changed while performing someother service operation. The manual

adjustment is performed with thedrums removed, using the tool andthe procedure detailed below.

When adjusting the rear brakeshoes, check the parking brake cablesfor proper adjustment. Make surethat the equalizer operates freely.

To adjust the brake shoes:1. Use Rotunda Tool HRE 8650,

(Fig. 12) to determine the inside di-ameter of the drum braking surface.

2. Reverse the tool as shown inFig. 13 and adjust the brake shoediameter to fit the gauge. Hold theautomatic adjusting lever out of en-gagement while rotating the adjust-

ing screw, to prevent burring thescrew slots. Make sure the adjustingscrew rotates freely. If necessary, lu-ricate the adjusting screw threadswith a thin, uniform coating of MIC-100-A.

3. Rotate Tool HRE 8650 aroundthe brake shoes to be sure of the set-ting.

4. Apply a small quantity of hightemperature grease to the pointswhere the shoes contact the backingplate, being careful not to get the lu-bricant on the linings.

5. Install the drums. Install Tinner-man nuts and tighten securely.



H 1411-B

FIG. 12—Measuring Drum

6. Install the wheels on the durmsand tighten the nuts to specification.

7. Complete the adjustment by ap-plying the brakes several times witha minimum of 50 lbs pressure on thepedal while backing the vehicle. Aftereach stop the vehicle must be movedforward.

8. After the brake shoes have beenproperly adjusted, check the opera-tion of the brakes by making severalstops while operating in a forwarddirection.

FRONT BRAKE DRUM

REMOVAL

1. Raise the vehicle until the wheeland tire clear the floor. Remove thewheel cover or hub cap, and removethe wheel and tire from the drum.

2. Remove the grease cap fromthe hub. Remove the cotter pin, nutlock, adjusting nut, and flat washerfrom the spindle. Remove the outerbearing cone and roller assembly.

3. Pull the drum off the wheelspindle.

4. If the drum will not come off,pry the rubber cover from the brakebacking plate. Insert a narrow screw-driver through the slot and disengagethe adjusting lever from the adjustingscrew. While holding the adjustinglever away from the screw, back offthe adjusting screw with the brakeadjusting tool (Fig. 14). Be very care-ful not to burr, chip, or damagethe notches in the adjusting screw;otherwise the self-adjusting mechanismwill not function properly.

INSTALLATION

1. If the drum is being replaced,remove the protective coating fromthe new drum with carburetor de-greaser. Then, use sandpaper to in-sure that no residue remains. Wipethe drum with a cloth soaked with de-natured alcohol. Install new bearings

H 1412- B

FIG. 13—Measuring Shoes

and grease seal. Pack the wheelbearings, install the inner bearingcone and roller assembly in the innercup, and install the new grease sealsee Part 3-5, Section 4.

If the original drum is being in-stalled, make sure that the grease inthe hub is clean and adequate.

2. Adjust the brakes and installthe drum assembly as outlined underBrake Shoe Adjustments in this sec-tion.

3. Install the outer wheel bearing,washer and adjusting nut.

4. Adjust the wheel bearing as out-lined in Part 3-7, Section 2, then in-stall the grease cap. Install the wheeland hub cap.

REAR BRAKE DRUM

REMOVAL

1. Raise the vehicle so that thetire is clear of the floor.

2. Remove the hub cap and wheel.Remove the three Tinnerman nutsand remove the brake drum. If thedrum will not come off, pry the rubbercover from the backing plate. In-sert a narrow screwdriver through thehole in the backing plate, and disen-gage the adjusting lever from theadjusting screw. While holding the ad-justing lever away from the adjust-ing screw, back off the adjustingscrew with the brake adjusting tool(Fig. 14). Be very careful not to burr,chip, or damage the notches in the ad-justing screw; otherwise, the self- ad-justing mechanism will not functionproperly.

INSTALLATION

1. Remove the protective coatingfrom a new drum with carburetordegreaser; then sand lightly and wipewith a cloth soaked with denaturedalcohol.

2. Adjust the brakes as outlinedunder Brake Shoe Adjustments in this

MOVE HANDLEUPWARDS

HI 144-B

FIG. 14— Backing Off BrakeAdjustment

section. Place the drum over thebrake assembly and into position.

3. Install the three Tinnerman nutsand tighten securely. Install the wheelon the axle shaft flange studs againstthe drum, and tighten the attachingnuts to specifications.

BRAKE SHOES ANDADJUSTING SCREW

REMOVAL

1. With the wheel and drum re-moved install a clamp over the endsof the brake cylinder as shown in Fig.15.

2. Remove the secondary shoe toanchor spring with the tool shown inFig. 15. With the same tool removethe primary shoe to anchor spring andunhook the cable eye from the anchorpin.

3. Remove the shoe guide (anchorpin) plate (Fig. 8).

4. Remove the shoe hold-downsprings, shoes, adjusting screw, pivotnut, socket and automatic adjust-ment parts.

5. On rear brakes, remove theparking brake link and spring. Dis-connect the parking brake cable fromthe parking brake lever.

6. After removing the rear brakesecondary shoe, disassemble theparking brake lever from the shoe byremoving the retaining clip andspring washer (Fig. 8).

INSTALLATION

1. Before installing the rear brakeshoes, assemble the parking brakelever to the secondary shoe and securewith the spring washer and retainingclip.

2. Apply a light coating of high-



temperature grease at the pointswhere the brake shoes contact thebacking plate.

3. Position the brake shoes on thebacking plate and secure the assemblywith the hold down springs. On therear brake, install the parking brakelink and spring. Connect the parkingbrake cable to the parking brake lever(Fig.8).

4. Install the shoe guide (anchorpin) plate on the anchor pin.

5. Place the cable eye over theanchor pin with the crimped side to-ward the backing plate.

6. Install the primary shoe to an-chor spring (Fig. 16).

7. Install the cable guide on thesecondary shoe web with the flangedhole fitted into the hole in the second-ary shoe web. Thread the cable aroundthe cable guide groove (Fig. 8).

It is imperative that the cable bepositioned in this groove and not be-tween the guide and the shoe web.

8. Install the secondary shoe toanchor spring with the tool shown inFig. 16.

Be certain that the cable eye is notcocked or binding on the anchor pinwhen installed. All parts should beflat on the anchor pin. Remove thebrake cylinder clamp.

9. Apply high-temperature grease(MIC-100-A) to the threads and thesocket end of the adjusting screw.Turn the adjusting screw into the ad-justing pivot nut to the limit of thethreads and then back off 1/2 turn.

Interchanging the brake shoe ad-justing screw assemblies from oneside of the vehicle to the other wouldcause the brake shoes to retract ratherthan expand each time the automaticadjusting mechanism operated. Toprevent installation on the wrong sideof the vehicle, the socket end of theadjusting screw is stamped with anR or L (Fig. 17). The adjusting pivotnuts can be distinguished by the num-ber of grooves machined around thebody of the nut. Two grooves on thenut indicate a right thread; one grooveindicates a left thread.

10. Place the adjusting socket onthe screw and install this assemblybetween the shoe ends with the ad-justing screw toothed wheel nearestthe secondary shoe.

11. Hook the cable hook into thehole in the adjusting lever. The ad-justing levers are stamped with an Ror L to indicate their installation onright or left brake assembly (Fig.17).

12. Position the hooked end of theadjuster spring completely into thelarge hole in the primary shoe web.

The last coil of the spring should beat the edge of the hole. Connect theloop end of the spring to the adjusterlever hole.

Tool-2035-N or 2086-1

Tool-LM-119 H1146-B

FIG. 15—Retracting SpringRemoval

Tool-2035-N or

Tool-LM-1 19 H1147-B

FIG. 16—Retracting SpringInstallation

ADJUSTING LEVER

ADJUSTING SCREW

IDENTIFICATION LINES H 114 3 -B

FIG. 17—Adjusting Screw andLever Identification

13. Pull the adjuster lever, cableand automatic adjuster spring downand toward the rear to engage thepivot hook in the large hole in thesecondary shoe web (Fig. 8).

14. After installation, check theaction of the adjuster by pulling thesection of the cable between the cableguide and the anchor pin toward thesecondary shoe web far enough to liftthe lever past a tooth on the adjust-ing screw wheel. The lever shouldsnap into position behind the nexttooth, and release of the cable shouldcause the adjuster spring to returnthe lever to its original position. This

return action of the lever will turn theadjusting screw one tooth.

If pulling the cable does not pro-duce the action described, or if thelever action is sluggish instead of pos-itive and sharp, check the position ofthe lever on the adjusting screwtoothed wheel. With the brake in avertical position (anchor at the top),the lever should contact the adjustingwheel 3/16 inch (plus or minus 1/32inch) above the centerline of thescrew. If the contact point is belowthis centerline, the lever will not lockon the teeth in the adjusting screwwheel, and the screw will not beturned as the lever is actuated by thecable.

To determine the cause of this con-dition.

a. Check the cable end fittings. Thecable should completely fill or extendslightly beyond the crimped section ofthe fittings. If it does not meet thisspecification, possible damage is in-dicated and the cable assembly shouldbe replaced.

b. Check the cable length. The ca-ble should measure 11 1/8 inches(plus or minus 1/64 inch) from theend of the cable anchor to the end ofthe cable hook.

c. Check the cable guide for dam-age. The cable groove should be par-allel to the shoe web, and the body ofthe guide should lie flat against theweb. Replace the guide if it showsdamage.

d. Check the pivot hook on thelever. The hook surfaces should besquare with the body of the lever forproper pivoting. Replace the lever ifthe hook shows damage.

e. See that the adjusting screwsocket is properly seated in the notchin the shoe web.

DISC BRAKE SHOE ANDLINING REPLACEMENT

DISC BRAKE SERVICEPRECAUTIONS

1. Grease or any other foreign ma-terial must be kept off the caliperassembly, surfaces of the rotor and ex-ternal surfaces of the hub during serv-ice operations. Handling of the rotorand caliper assemblies should be donein a way to avoid deformation of thebrake rotor and nicking or scratchingof brake linings.

2. If the piston is removed forany reason, the piston seal must bereplaced.

3. During removal and installationof a wheel assembly, exercise carenot to interfere with and damage thecaliper splash shield or the bleeder



screw fitting.4. Front wheel bearing end play is

critical and must be within specifica-tions.

5. Be sure the vehicle is centeredon the hoist before servicing any frontend components, to avoid bending ordamaging the rotor splash shield onfull right or left wheel turns.

6. The proportioning valve shouldnot be disassembled or adjustmentsattempted on it.

7. Riding of the brake pedal (com-mon on left foot applications) shouldbe avoided during vehicle operation.

8. The wheel and tire must be re-moved separately from the brake ro-tor, unlike drum brakes where thewheel, tire and drum are removed asa unit.

9. The caliper assembly must beremoved from the spindle prior to re-moval of the shoe and lining assemb-lies.

10. Do not attempt to clean orrestore oil or grease soaked brakelinings. When contaminated liningsare found, brake linings must be re-placed in complete axle sets.

REMOVAL

1. Remove the wheel and tire fromthe hub. Be careful to avoid damageor interference with the bleeder screw

fitting.2. Remove the two bolts that at-

tach the caliper to the spindle.3. To facilitate removal and in-

stallation of the shoe and lining as-semblies, the piston must be pushedinto its bore. Apply a steady in-ward pressure against the inner shoeand lining assembly. Maintain the pres-sure for at least a minute.

4. Slide the two outer shoe re-taining clips off the retaining pins(Fig. 18).

5. Remove the two retaining pinsfrom the outer shoe, then remove theshoe from the stationary caliper.

6. Slide the inner brake shoeoutward until it is free of the hold-down springs, then remove the brakeshoe.

7. Remove the caliper guide pinsand stabilizer attaching bolts, thenremove the stabilizers.

8. Remove the guide pin insulatorsfrom the anchor plate.

INSTALLATION

When new shoe and lining assem-blies are being installed to replaceworn linings it will be necessary topush the piston all the way into thecaliper bore. This will displace fluidfrom the caliper into the master cyl-inder reservoir. Check the primary

(front) brake system reservoir leveland remove fluid to approximatelyhalf full before replacing brake shoes.This will prevent overflow. Do notreuse the removed fluid.

1. Install new caliper guide pininsulators in the anchor plate.

2. Position the caliper assemblyin the anchor plate.

3. Apply the specified fluid tothe caliper guide pins and installthem loosely in the anchor plate.Be sure the guide pins are free ofoil, grease or dirt.

4. Position the outer brake onthe caliper and install the two re-taining pins and clips.

5. Install the inner brake shoeso that the ears of shoe are on topof the anchor plate bosses and underthe shoe hold-down springs.

6. Position the shoe and liningassemblies so that the caliper assem-bly can be placed over the rotor.Rotate a hammer handle between thelinings to provide the proper clear-ance.

7. Install the caliper assemblyover the rotor and on the spindle.Install the two caliper attachingbolts, and torque them to specifica-tions. The upper bolt must be tighten-ed first. Install the safety wire andtwist the ends at least five turns.

8. With moderate pressure applied

SPINDLE

CALIPER PARTS2B120 R.H.2B121 L.H.

2B296

20310-S

34806-S

CALIPER ASS'Y.2B118 R.H.2B119 L.H.

INSULATOR

CL.P 2 B 2 "2B164

INNER BEARINGCONE AND ROLLER

1201

ANCHOR PLATE2B293 L.H.2B292 R.H.

HUBCUP

CONE AND ROLLER

1216

ROTOR SPLASH SHIE2K004'R.H.2K005.LH,

ADJUSTING NUT374504>S GREASE CAP

1131 COVER-1130

H 1571-A

FIG. 78—Disc Brake Disassemblied


CLAMP-376428-S8•2REQ'D.

TIGHTEN ALL HYDRAULIC TUBE CONNECTIONSWITH TORQUE WRENCH AS FOLLOWS.

15 LB. FT.10-18 LB. FT.12-20 LB. FT.15-25 LB. FT.

HOSE - 2A047

VIEW IN CIRCLE Y240 & 302 ENG.

WITH AUTO. TRANS.

EXISTING BOLT &WASHER ASSY. PARTOF REAR AXLE25-35 LB. FT..

VIEW R

CEMENT NIPPLETO CHECK VALVE

VIEW IN CIRCLE T

390, 410 & 428 ENG. CLIP -

fEXISTING NUT PARTOF REAR AXLE30-40 LB. FT.

BEND CLIPS TORETAIN TUBE

, AT ASSYVIEW R

TUBE - 2268(L.H.

EXISTING WASHER••VIEW S

BRACKET -2A448

INSTALLATION - FOR 240 & 302 ENGINESSAME AS MAIN VIEW & VIEW EXCEPT AS SHOWN

SAME AS VIEW IN CIRCLE Y EXCEPTAS SHOWN. ALL STD, TRANS. & 390,

& 428 ENG. WITH AUTO. TRANS.

TUBE -2263

BRACKET -2082 R.H.2A056 L.H.

CLIP -28142REQ'D.

HOSE - 2B218(L.H.)

VIEW IN CIRCLE UTYPICAL 4 PLACES

CLIP -381661-S2

BOLT -381877- S 2 - * -

CLIP -376236-S2

TUBE - 2265

VIEW IN CIRCLE N

BOLT -381877-S23 REQ'D.

VIEW IN CIRCLE XTYPICAL 3 PLACES

VIEW WTYPICAL 2 PLACES

TUBE - 2265

VIEW IN CIRCLE K USED FORSTEEL FUEL LINES ONLY

C L I P -37623frS2 -

4B O L T -381877 S2

V /pj|5 -i^iw

TJBE - '2265 ASSY.

VIEW IN CIRCLE

H

//

/

1/V

L

1572-A

FIG. 19—Service Brake System— Disc Brakes



to the brake pedal, torque the sta-bilizer attaching screws and caliperguide pins to specification.

DISC BRAKE CALIPERASSEMBLY

REMOVAL

1. Remove the front wheel cover.Remove the wheel and tire assemblyfrom the hub and rotor assembly.Be careful to avoid damage or inter-ference with the caliper splash shieldor bleeder screw fitting.

2. Disconnect the brake line fromthe caliper.

3. Remove the safety wire and thetwo bolts that attach the caliper as-sembly to the spindle.

4. Lift the caliper assembly offthe rotor and place it on the bench.

INSTALLATION

1. Position the caliper assembly onthe rotor, and mate the mounting boltholes in the caliper with those in thespindle. It may be necessary to pushthe caliper piston into the cylinderbore to obtain clearance between theshoe and lining assembly and the ro-tor.

2. Install the caliper to spindle at-taching bolts and torque them to spec-ification. The upper bolt must betightened first. Install the safety wireon the bolts and twist the wire endsat least five turns. Check to insurethat the rotor runs squarely and cen-trally between the two brake shoes.

3. Position the brake hose fittingwith a new copper washer on eachside of the fitting on the caliperassembly. Install the bolts and torqueto specification.

4. Bleed the brake system and cen-tralize the differential valve as out-lined in Part 2-1. Check the mastercylinder fluid level and add the speci-fied fluid, as required. Pump the brakepedal several times to actuate thepiston seals and to position the shoeand lining assemblies.

6. Install the wheel and tire assem-bly and the wheel cover.

7. Road test the vehicle.

FRONT WHEEL HUB ANDROTOR ASSEMBLY—DISCBRAKES

REMOVAL

1. Remove the wheel and tire from

the hub. (Fig. 18). Be careful to avoiddamage or interference with the bleed-er screw fitting.

2. Remove the caliper assemblyfrom the spindle and the rotor. If thecaliper does not require servicing, itis not necessary to disconnect thebrake hose or remove the caliper fromthe vehicle. Position the caliper out ofthe way, and support it with a wire toavoid damaging the caliper orstretching the hose. Insert a cleancardboard spacer between the liningsto prevent the piston from comingout of the cylinder bore while thecaliper is removed.

Handle the rotor and caliper as-semblies in such a way as to avoiddeformation of the rotor and nickingscratching or contamination of thebrake linings.

3. Remove the grease cap from thehub. Remove the cotter pin, nut lock,adjusting nut, and flat washer fromthe spindle. Remove the outer bearingcone and roller assembly.

4. Remove the hub and rotor as-sembly from the spindle.

INSTALLATION

1. If the rotor is being replaced,remove the protective coating fromthe new rotor with carburetor de-greaser. Pack a new set of bearingswith specified grease (M-1C75A), andinstall the inner bearing cone and rol-ler assembly in the inner cup. Packgrease lightly between the lips of anew grease seal and install the seal(Fig. 18).

If the original rotor is being in-stalled, make sure that the grease inthe hub is clean and adequate, thatthe inner bearing and grease sealare lubricated and in good condition,and that the rotor braking surfacesare clean.

2. Install the hub and rotor assem-bly on the spindle.

3. Lubricate and install the outerwheel bearing, washer and adjustingnut.

4. Adjust the wheel bearings tospecification, and then install the nutlock, cotter pin, and grease cap. Thewheel bearing adjustment is especial-ly important with disc brakes.

5. Mount the caliper assembly onthe spindle and torque the two at-taching bolts to specification. Theupper bolt must be installed first. Ifnecessary, push the caliper piston intothe cylinder bore to obtain clear-ance between the shoe and lining as-semblies and the rotor. Be sure thatthe shoe and lining assemblies are

seated on the bridges. Check the flex-ible hose for correct routing.

6. Install the wheel and tire on thehub.

7. Pump the brake pedal as re-quired to establish the proper pedalheight.

8. Fill the master cylinder to theproper level with the specified fluid.

DISC BRAKE ROTOR SPLASHSHIELD

REMOVAL

1. Remove the caliper and the huband rotor assembly as outlined underRemoval in the foregoing procedure(it is not necessary to disconnect hy-draulic connections).

2. Remove the three bolts that at-tach the splash shield to the spindle(Fig. 18).

INSTALLATION

1. If the shield is bent, straighten itout before installation. Position theshield to the mounting bracket, installthe attaching bolts nuts, and torquethem to specification (Fig. 18).

2. Install the hub and rotor assem-bly and the caliper as outlined underInstallation in the foregoing proce-dure.

PROPORTIONING VALVE

The proportioning valve is servicedas an assembly and is never adjustedor overhauled.

REMOVAL

1. Disconnect and remove the dif-ferential pressure valve to proportion-ing valve brake tube. (Fig. 19).

2. Disconnect the outlet braketube at the proportioning valve.

3. Remove the bolt attaching theproportioning valve to the bracket andremove the valve.

INSTALLATION

1. Position the proportioning valveto the bracket and install the attachingbolt.

2. Connect the outlet brake tubeto the valve.

3. Position and connect the differ-ential pressure valve to proportioningvalve brake tube.

4. Bleed the brake system and cen-tralize the diffential valve. (Refer toPart 2-1, Section 2 for the correctprocedure.)



STANDARD OR REARWHEEL CYLINDER REPAIR

Wheel cylinders should not be disas-sembled unless they are leaking orunless new cups and boots are to beinstalled. It is not necessary to removethe brake cylinder from the backingplate to disassemble, inspect, or honeand overhaul the cylinder. Removalis necessary only when the cylinderis damaged or scored beyond repair.

DISASSEMBLY

1. Remove the links and the rubberboots from the ends of the brake cyl-inder. Remove the pistons, cups, andreturn spring from the cylinder bore(Fig. 20).

2. Remove the bleeder screw fromthe cylinder.

INSPECTION

1. Wash all parts in clean brakefluid. Dry with compressed air.

2. Replace scored pistons. Alwaysreplace the rubber cups and dustboots.

3. Inspect the cylinder bore forscore marks or rust. If either condi-tion is present the cylinder bore mustbe honed. However, the cylindershould not be honed more than 0.003inch beyond its original diameter.

4. Check the bleeder hole to be surethat it is open.

ASSEMBLY

1. Apply a light coating of heavy-duty brake fluid to all internal parts.

2. Thread the bleeder screw intothe cylinder and tighten securely.

3. Insert the return spring, cups,and pistons into their respective po-sitions in the cylinder bore (Fig. 20).Place a boot over each end of the cyl-inder. Bleed the brake system.

WHEEL CYLINDERREPLACEMENT

REMOVAL

1. Remove the wheel and the drum.2. Remove the brake shoe assem-

blies, following procedures outlinedin this section.

3. Disconnect the brake line fromthe brake cylinder Figs. 19 and 21. Ona vehicle with a vacuum brake boost-er, be sure the engine is stopped andthere is no vacuum in the booster sys-tem before disconnecting the hydrau-lic lines.

To disconnect the hose at a frontcylinder, loosen the tube fitting that

BOOT BOOT

CUPFRONT BRAKE CYLINDER CUP

BOOT BOOT

RETURNSPRING PISTON

CUPREAR BRAKE CYLINDER

FIG. 20— Front and Rear Wheel Cylinders

CUP

H 1100-B

connects the opposite end of the hoseto the brake tube at a bracket on theframe. Remove the horseshoe-typeretaining clip from the hose and brac-ket, disengage the hose from the brac-ket, then unscrew the entire hose as-sembly from the front wheel cylin-der.

At a rear cylinder, unscrew thetube fitting that connects the tube tothe cylinder. Do not pull the metaltube away from the cylinder. Pullingthe tube out of the cylinder connec-tion will bend the metal tube andmake installation difficult. The tubewill separate from the cylinder whenthe cylinder is removed from the back-ing plate.

4. On the rear wheel, remove thewheel cylinder attaching bolts andlock washers and remove the cylin-der. On the front wheel, remove thenut and washer that attaches the cyl-inder to the anchor pin. Remove thecylinder from the anchor pin.

INSTALLATION

Wipe the end(s) of the hydraulicline to remove any foreign matter be-fore making connections.

1. To install a front wheel cylinder,position the cylinder on the anchorpin against the backing plate. In-stall the washer and cylinder attachingnut on the anchor pin, and torque it tospecification. Lock the washer retain-er securely.

2. Install a new copper gasket overthe hose fitting. Thread the hose intothe cylinder.

3. Engage the opposite end of thehose to the bracket on the frame. In-stall the horseshoe-type retainingclip, and connect the brake tube tothe hose with the tube fitting nut.Tighten the nut to specification withtool 1112-144.

4. To install a rear wheel cylinder,place the rear wheel cylinder intoposition. Enter the tubing into thecylinder, and start the tube fittingnut into the threads of the cylinder.

5. Secure the cylinder to the backingplate by installing the attaching boltsand lock washers.

6. Tighten the tube fitting nut tospecification with tool 11 12-144.

7. Install the links in the ends ofthe wheel cylinder, install the shoesand adjuster assemblies, and adjustthe shoes as oulined in this section.

8. Adjust the brakes (Part 2-2,Section 2). Install the brake drum andwheel. Bleed the brakes and central-ize the differential valve as outlinedin Part 2-1, Section 2.

BRAKE BACKING PLATEREPLACEMENT

REMOVAL

1. Remove the wheel and brakedrum. Disconnect the brake line fromthe brake cylinder.

2. Remove the brake shoe and ad-juster assemblies and the wheel cyl-inder as outlined in this section. Onthe rear wheels, disconnect the park-ing brake lever from the cable.

3. If the rear backing plate is


NUT - 55734-S2

CLIP - 370431-S2INSTALLATION - FOR 240 & 302 ENGINES

EXCEPT STATION WAGONSSAME AS MAIN VIEW EXCEPT AS SHOWN.

TUBE-2267

EXISTING BOLT & WASHERASSY. PART OF REARAXLE 25-35 LB. FT.

EXISTING NUT PARTOF REAR AXLE30-40 LB. FT.

BOLT - 55405-S24-6 LB. FT.

BEND CLIPS TO RETAINTUBES AT ASSY.TUBE - 2267

VIEW U

CLIP-381799-S2FOR POWER BRAKES

DUAL MASTERCYLINDER-2140 BRACKET ASSY.-:

2A448

VIEW IN CIRCLE SBRAKES CLIP - 381799-S2

- . FOR STD. BRAKESVIEW ZTYPICAL 2 PLACES

PRESSURE DIFFERENTIAL. VALVE ASSEMBLY - 2B257

HOSE - 20782REQ'D. GASKET-2149

2REQ'D.

TUBE ASSEMBLY -2A040

PRESSURE DIFFERENTIALVALVE ASSY. - 2B257

2B264 REF.

TUBE - 2265

VIEW IN CIRCLE XTYPICAL 4 PLACES

VIEW IN CIRCLE YTYPICAL 3 PLACES

TUBE - 2264

TUBE - 2B253

TIGHTEN ALL HYDRAULIC TUBE CONNECTIONSWITH TORQUE WRENCH AS FOLLOWS.

3/8-24 THD. 8-15 LB. FT.7/16-24 THD. 10-18 LB. FT.1/2-20 THD. 12-20 LB. FT.9/16-18 THD. 15-25 LB. FT.

VIEW IN CIRCLE M

H 1548-B

. 21—Service Brake System—Standard Brakes



being replaced, remove the axle shaftfrom the applicable rear axle as out-lined in Group 4, Part 4-2—RearAxle, Section 2. Remove the backingplate and gasket.

If the front backing plate is beingreplaced, remove the bolts and nutsthat secure the backing plate to thefront wheel spindle and remove theplate and gasket.

INSTALLATION

If a rear backing plate is to be re-placed, position a new rear backingplate and gasket on the attachingbolts in the axle housing flange. In-stall the rear axle shaft for the appli-cable rear axle. Refer to Group 4,Part 4-2—Rear Axle, Section 2 for theproper installation procedure.

1. If the front brake backing plateis to be replaced, position a new frontbacking plate and gasket to the wheelspindle and install the attaching boltsand nuts.

2. Install the wheel cylinder andconnect the brake line as outlined inthis section.

3. Install the brake shoe and ad-juster assemblies as outlined in thissection. On a rear brake, connect theparking brake cable to the lever.

4. Adjust the brake shoes (Section2), and install the brake drums andwheels. Bleed the brake drums andwheels. Bleed the brake system andcentralize the differential valve asoutlined in Part 2-1, Section 2.

HYDRAULIC LINES

Steel tubing is used throughout thebrake system with the exception ofthe flexible hoses at the front wheelsand at the rear axle housing braketube connection (Figs. 19 and 21).

Always bleed the applicable pri-mary or secondary brake system afterprimary or secondary brake systemhose or line replacement. Centralizethe brake system after bleeding thesystem.

BRAKE TUBEREPLACEMENT

If a section of the brake tubing be-comes damaged, the entire section

DISC BRAKE

OUTLET TUBEREAR BRAKES

BUSHING

\ SHAFT (AUTOMATICV TRANSMISSION)I

BLFEDER SCREW

SPACER STUD

CLUTCHPEDAL

ASSEMBLY

BUSHING

NUT

LOCK WASHER/

MASTER CYLINDER PUSH ROD

STOP LITE BRAKE PEDALSWITCH ASSEMBLY

H 1491-C

FIG. 22— Master Cylinder Installation— Standard Brakes

should be replaced with tubing of thesame type, size, shape, and length.Copper tubing should not be used ina hydraulic system. When bendingbrake tubing to fit underbody or rearaxle contours, be careful not to kinkor crack the tube.

All brake tubing should be doubleflared properly to provide good leak-proof connections. Clean the braketubing by flushing with clean brakefluid before installation.

When connecting a tube to a hose,tube connector, or brake cylinder,tighten the tube fitting nut to speci-fied torque with Milbar tool 1112-144or equivalent.

BRAKE HOSEREPLACEMENT

A flexible brake hose should be re-placed if it shows signs of softening,

cracking, or other damage.When installing a new front brake

hose, position the hose to avoid con-tact with other chassis parts. Place anew copper gasket over the hose fit-ting and thread the hose assembly in-to the front wheel cylinder. Engagethe opposite end of the hose to thebracket on the frame. Install thehorseshoe-type retaining clip, andconnect the tube to the hose with thetube fitting nut (Figs. 19 and 21).

A rear brake hose should be in-stalled so that it does not touch themuffler outlet pipe or shock absorber.

Place a new gasket over the rearhose fitting and thread the hose intothe rear brake tube connector. En-gage the front end of the hose to thebracket on the frame. Install thehorseshoe-type retaining clip, andconnect the tube to the hose with thetube fitting nut.

REMOVAL AND INSTALLATIONDUAL MASTER CYLINDER-STANDARD BRAKES

REMOVAL

1. Working from inside the vehicle

below the instrument panel, disconnectthe master cylinder push rod from thebrake pedal (Fig. 22).

2. Disconnect the stoplight switchwires at the connector. Remove the

spring retainer. Slide the stop lightswitch off the brake pedal pin justfar enought to clear the end of the pin,then lift the switch straight upwardfrom the pin. Use care to avoid switch



damage during removal.3. Slide the master cylinder push

rod and the nylon washers and bush-ings off the brake pedal pin.

4. Remove the brake tube fromthe primary and secondary outletports of the master cylinder.

5. Remove the lock nuts that se-cure the master cylinder to the dashpanel and lift the cylinder forwardand upward from the vehicle.

INSTALLATION

1. Position the boot on the pushrod and secure the boot to the mastercylinder. Carefully insert the mastercylinder push rod and boot throughthe dash panel opening and positionthe master cylinder on the mountingstuds on the dash panel (Fig. 22).

2. Install the lock nuts on the studsat the dash panel and torque them tospecification.

3. Coat the nylon bushings withSAE 10W oil. Install the nylon washerand bushing on the brake pedal pin.

4. Position the stop light switch onthe brake pedal pin, install the nylonbushing and washer and secure themin position with the spring retainer.

5. Connect the wires at the stoplight switch connector.

6. Connect the brake lines to themaster cylinder leaving the brake linefittings loose.

7. Fill the master cylinder withthe specified brake fluid to within 1/4inch of the top of the dual reservoirs.Use Rotunda Brake Fluid—ExtraHeavy Duty—Part Number C6AZ-19542-A (ESA-M6C25-A) for discbrake applications, and RotundaBrake Fluid—Part Number B7AZ-19542-A, R103-A or equivalent fordrum brake applications. The discbrake system fluid is colored blue foridentification. Do not mix low tem-perature brake fluids with the speci-fied fluid for the power disc brakesystem.

8. Bleed the dual-master cylinderand the primary and secondary brakesystems. Centralize the pressure dif-ferential valve. Refer to HydraulicSystem Bleeding and Centralizing ofthe Differential Valve, Part 2-1, Sec-tion 2 for proper procedure.

9. Operate the brakes severaltimes, then check for external hy-draulic leaks.

DUAL MASTER CYLINDER-POWER BRAKES

REMOVAL

1. Remove the brake tubes from

DISC BRAKE SHAFT CLUTCH(AUTOMATIC PEDAL

TRANSMISSION) ASSEMBLY

OUTLET TUBEREAR BRAKES

ALL STANDARD TRANSMISSIONSAND 390, AND 428

ENGINES WITH AUTOMATICTRANSMISSION

FORD MODELS ONLY240 AND 302

ENGINES-AUTOMATICTRANSMISSION

H 1495-C

FIG. 23—Master Cylinder Installation— Power Brakes

the primary and secondary outletports of the master cylinder (Fig.23).

2. Remove the two nuts and twolock washers attaching the master cyl-inder to the brake booster assembly.

3. Slide the master cylinder for-ward and upward from the vehicle.

INSTALLATION

1. Before installing the master cyl-inder, check the distance from theouter end of the booster assemblypush rod to the master cylindermounting surface. Turn the push rodadjusting screw in or out as requiredto obtain the specified length. Referto Part 2-1, Section 2, Power BrakeMaster Cylinder Push Rod Adjust-ment for the proper procedure.

2. Position the master cylinder as-sembly over the booster push rod andonto the two studs on the booster as-sembly (Fig. 23).

3. Install the attaching nuts andlock washers and torque them to spec-ifications.

4. Install the front and rear braketubes to the master cylinder outletfittings.

5. Fill the master cylinder with thespicified brake fluid to within 1/4

inch of the top of the dual reser-voirs. Use Rotunda Brake FluidExtra Heavy Duty Part NumberC6AZ-19542-A (ESA-M6C25-A) forall brake applications. The brakesystem fluid is colored blue for identi-fication. Do not mix low temperaturebrake fluids with the specified fluisfor the disc brake system.

6. Bleed the dual-master cylinderand the primary and secondary brakesystems. Centralize the pressure dif-ferentical valve. Refer to HydraulicSystem Bleeding and Centralizing ofthe Differential Valve, Part 2-1, Sec-tion 2 for the proper procedure.

7. Operate the brakes severaltimes, then check for external hydrau-lic leaks.

PRESSURE DIFFERENTIALVALVE ASSEMBLY

REMOVAL

1. Disconnect the brake warninglight wire from the pressure differen-tial valve assembly switch (Figs. 19and 21). To prevent damage to thebrake warning switch wire connector,expand the plastic lugs to allow re-moval of the shellwire connector



from the switch body.2. Loosen the tube nut connecting

the primary (front brake) system in-let tube at the top of the pressure dif-ferential valve assembly and discon-nect the tube.

3. Disconnect the primary systemleft front brake outlet tube from thetop side of the pressure differentialvalve assembly.

4. Disconnect the primary systemright front brake outlet tube from thetop side of the differential valve as-sembly.

5. Disconnect the secondary (rearbrake) system inlet tube at the lowerside of the pressure differential valveassembly.

6. Disconnect the secondary sys-tem rear brake outlet tube from thelower side pressure differential valveassembly.

7. Remove the screw retaining thepressure differential valve assemblyto the frame side rail and remove thevalve assembly.

8. On disc brake equipped vehicles,place the pressure differential valveassembly and mounting bracket in avise. Loosen the proportioning valvetube nuts at the differential valveand at the proportioning valve. Re-move the proportioning valve from themounting bracket.

9. If the differential valve is to bereplaced, remove the brake warninglamp switch and install the switch inthe new differential valve. The pre-sure differential valve assembly andthe brake warning lamp switch areseparate units and each is servicedas a separate assembly only.

INSTALLATION

1. On disc brake equipped vehicles,connect the proportioning valve inletand outlet tubes to the proportioningvalve and differential valve bodies.Tighten the tube nuts to specification.

2. Mount the pressure differentialvalve assembly on the frame side railand tighten the attaching screw.

3. Connect the rear brake systeminlet tube to the pressure differentialvalve assembly and tighten the tubenut to the specified torque (Refer toPart 2-3).

4. Connect the rear brake systemoutlet tube to the pressure differen-tial valve assembly. Tighten the tubenut to the specified torque.

5. Connect the front brake systeminlet tube to the pressure differentialvalve assembly and tighten the tubenut to the specified torque.

6. Connect the right front brake

outlet tube to the pressure differentialvalve asssmbly. Tighten the tube nutto the specified torque.

7. Connect the left front brake out-let tube to the pressure differentialvalve assembly. Tighten the tube nutto the specified torque.

8. Connect the shell-wire connectorto the brake warning lamp switch.Make sure the plastic lugs on the con-nector hold the connector securely tothe switch.

9. Bleed the brakes and centralizethe pressure differential valve.

BOOSTER NUT

REMOVAL

1. Working from inside the vehiclebelow the instrument panel, discon-nect the booster push rod link fromthe brake pedal assembly. To do this,proceed as follows:

Disconnect the stop light switchwires at the connector. Remove thehairpin retainer. Slide the stop lightswitch off from the brake pedal pinjust far enough for the switch outerhole to clear the pin, and then lift theswitch straight upward from the pin.Be careful not to damage the switchduring removal. Slide the boosterpushrod and the nylon washers and bush-ing off the brake pedal pin (Fig.23).

2. Open the hood and remove themaster cylinder from the booster. Se-cure it to one side without disturbingthe hydraulic lines. It is not necessaryto disconnect the brake lines, but careshould be taken that the brake linesare not deformed. Permanent defor-mation of brake lines can lead to tubefailure.

3. Disconnect the manifold vac-uum hose from the booster unit. Ifthe vehicle is equipped with an auto-matic transmission disconnect thetransmission vacuum unit hose.

4. Remove the four bracket-to-dashpanel attaching nuts (Fig. 23). Re-move the booster and bracket assem-bly from the dash panel, sliding thepush rod link out from the engine sideof the dash panel. Remove the fourspacers.

5. Remove the push rod link bootfrom the dash panel.

INSTALLATION

1. Install the push rod link boot inthe hole in the dash panel as shownin Fig. 23. Install the four spacers onthe mounting studs.

2. Mount the booster and bracketassembly to the dash panel by sliding

the bracket onto the mounting studsand the push rod link in through thehole and boot in the dash panel. In-stall the bracket-to-dash panel attach-ing locknuts(Fig. 23).

3. Connect the manifold vacuumhose to the booster. If the vehicle isequipped with an automatic trans-mission connect the transmissionvacuum unit hose.

4. Before installing the master cyl-inder, check the distance from theouter end of the booster assemblypush rod to master cylinder surface.Turn the screw in or out to obtain thespecified length. Refer to Part 2-1,Section 2, Power Brake Master Cyl-inder Push Rod Adjustment. Installthe master cylinder and torque theattaching nuts to specifications.

5. Working from inside the vehiclebelow the instrument panel, connectthe booster push rod link to the brakepedal assembly. To do this, proceedas follows:

Install the inner nylon washer, thebooster pushrod, and the bushing onthe brake pedal pin. Position theswitch so that it straddles the pushrod with the switch slot on the pedalpin and the switch outer hole justclearing the pin. Slide the switch com-pletely onto the pin, and install thenylon washer as shown in Fig. 23.Be careful not to bend or deform theswitch. Secure these parts to the pinwith the hairpin retainer. Connectthe stop light switch wires to the con-nector, and install the wires in theretaining clip.

BRAKE PEDAL—MANUALSHIFT TRANSMISSION

REMOVAL

1. Disconnect the clutch pedal-to-equalizer rod at the clutch pedal byremoving the hairpin type retainerand bushing (Figs. 22 and 23).

2. Disconnect the stop light switchwires at the connector.

3. Remove the spring retainer.Slide the stop light switch off the brakepedal pin just far enough for theswitch outer hole to clear the pin, andthen lift the switch straight upwardfrom the pin. Be careful not to dam-age the switch during removal. Slidethe master cylinder or booster pushrod and the nylon washers and bush-ing off the brake pedal pin (Figs.22 and 23).

4. Remove the hairpin type retain-er and washer from the clutch andbrake pedal shaft. Remove the clutchpedal and shaft, the brake pedal, and



the bushings from the pedal supportbracket (Figs. 22 and 23).

INSTALLATION

1. Apply a coating of SAE 10 en-gine oil to the bushings and locate allbushings in their proper places on theclutch and brake pedal assemblies.

2. Position the brake pedal to thesupport bracket, then install theclutch pedal and shaft through thesupport bracket and brake pedal. In-stall the retainer (Figs.22 and 23).

3. Install the inner nylon washer,the master cylinder or booster pushrod, and the bushing on the brakepedal pin. Position the switch so thatit straddles the push rod with theswitch slot on the pedal pin and theswitch outer hole just clearing thepin. Slide the switch completely ontothe pin, and install the nylon washeras shown in Figs. 22 and 23. Becareful not to bend or deform theswitch. Secure these parts to the pinwith the hairpin retainer.

4. Connect the stop light switchwires to the connector, and installthe wires in the retaining clip.

5. Connect the clutch pedal-to-equalizer rod to the clutch pedal as-sembly with the bushing and hairpinretainer. Apply SAE 10 engine oil tothe bushing. Adjust the clutch pedalfree play (Group 5) to specificationif required. Check the Brake PedalFree Height and Travel Measure-ments (Part 2-1, Section 1).

BRAKE PEDAL—AUTOMATICTRANSMISSION

REMOVAL

1. Disconnect the stop light switchwires at the connector.

2. Remove the hairpin retainer.Slide the stop light switch off thebrake pedal pin just far enough forthe switch outer hole to clear the pin,and then lift the switch straight up-ward from the pin. Be careful not todamage the switch during removal.Slide the master cylinder or boosterpush rod and the nylon washersand bushing off the brake pedal pin(Figs. 22 and 23).

3. Remove the hairpin type retain-er and washer from the brake pedalshaft, then remove the shaft, thebrake pedal and the bushings from thepedal support bracket.

INSTALLATION

1. Apply a coating of SAE 10 En-

gine oil to the bushings and locatebushings in their proper places onthe pedal assembly and pedal sup-port bracket (Figs. 22 and 23).

2. Position the brake pedal assem-bly to the support bracket, then installthe pedal shaft through the supportbracket and brake pedal assembly.Install the retainer.

3. Install the inner nylon washer,the master cylinder or booster pushrod, and the bushing on the brakepedal pin. Position the switch so thatit straddles the push rod with the switchslot on the pedal pin and the switchouter hole just clearing the pin. Slidethe switch completely onto the pin,and install the nylon washer as shownin Figs. 22 and 23. Be careful not tobend or deform the switch. Securethese parts to the pin with the hairpinretainer.

4. Connect the stop light switchwires to the connector, and installthe wires in the retaining clip.

5. Check the Brake Pedal FreeHeight and Travel Measurements,Part 2, Section 1.

PARKING BRAKECONTROL ASSEMBLY

REMOVAL

1. Remove the two nuts attachingthe control assembly to the dash pan-el (Fig. 24).

2. Remove the bolt attaching thecontrol assembly to the instrumentpanel.

3. Disconnect the hose to the park-ing brake vacuum unit, when soequipped.

4. Remove the cable retainer clipfrom the cable end and disconnect thecable from the control.

5. Remove the control assemblyfrom the car.

INSTALLATION

1. Position the control in the ap-proximate final position.

2. Fit the cable through its mount-ing hole and install the retaining clip.

3. Connect the vacuum hose to theparking brake unit, when soequipped.

4. Install the attaching bolt to theinstrument panel. Do not tighten.

5. Install the two attaching nuts onthe control assembly bracket on theengine side of the dash panel.

6. Torque all nuts and bolts tospecifications.

7. Adjust parking brake cable ten-sion, and check operation, as out-

lined in Part 2-1, Section 2.

PARKING BRAKE TOEQUALIZER CABLE

REMOVAL

1. Raise the vehicle on a hoist.2. Loosen the parking brake cable

adjusting nut at the equalizer (Fig. 24).3. Remove the cable from the fold-

over tab on the underbody. Removespring retainer clip.

4. Remove spring clip that retainsthe cable to the frame.

5. From inside of passenger com-partment, remove spring clip that re-tains the cable to the parking brakecontrol. Disconnect the cable ballfrom the control assembly.

6. Remove the cable assemblyfrom the vehicle.

INSTALLATION

1. Position the cable through theprovided openings and in the approxi-mate final installation position.

2. Install the hairpin retainer onthe cable at the frame crossmember.

3. Connect the ball end of the cableto the parking brake control. Installthe cable-to-control hairpin retainingclip.

4. Position the cable seal at thedash panel, and slide the retainingclip upward to seal the cable at thedash opening.

5. Install the spring retainer clip.Position cable in the foldover tab onthe underbody.

6. Position the cable thru the equal-izer and install the cable adjustingnut.

7. Adjust the parking brake (Part2-1, Section 2).

8. Lower vehicle on hoist.

PARKING BRAKE EQUALIZERTO REAR WHEEL CABLE

REMOVAL

1. Raise the vehicle and loosen theparking brake equalizer rod adjust-ing nut. Disconnect the equalizerfrom the rear cables (Fig. 26).

2. Compress the prongs on theleft cable-to-frame side memberretainer so the prong can pass throughthe side-member. Remove the clipthat attaches the left cable to theleft lower arm. Pull the cable thruthe frame left side member.

3. Compress the prongs on theright cable-to-frame side member re-tainer bracket so the prong can pass


NO. 4 CROSSMEMBER REF.

• TUBE - 2A635

HOSE - 2A596

TO INTERMITTENT WIPERS

PARKING BRAKE REARCABLE - 2A809 (L.H

TRANSMISSION GEAR SHIFTSWITCH -7A247

HOSE - 2A804

INST. PANEL

NUT - 379930-S72 REQ'D.5-9 LB. FT

RETAINER -74277-S

CABLE ANDCONDUIT ASSY. - :2853

NUT - 55736-S2

INST. PANEL

PARKING BRAKEREAR CABLE -2A635 (R.H.

2A791 - 2 REQ'D.

EQUALIZER -2A602

2A635 ASSY. R.H. TO BE POSI-TIONED WITH RUBBER LOCATORSCENTERED IN BRACKETS

VIEW X

LOWER ARM L.H.

BRAKE PEDAL PADCOVER - 2A798

\ - - " ~

VIEW IN CIRCLE S

CABLE ANDCONDUIT - 2853

PARKING BRAKEREAR CABLE - ROLT -2A809 ASSY. 41OO6.S2

2 REQ'D.

TUBE -2A635

PARKING BRAKE CONTROLASSEMBLY - 2780

VIEW Z MERCURY VACUUM RELEASESAME AS MAIN VIEWEXCEPT AS SHOWN

VIEW 7.

/ -'''.->::::"^N\ .---.:--rr*rrr::'."-*.*- " 2A635 ASSY.X

/ U'/s •""! \ lJv ^ ^ Y ^ f e ^ " V * t ^ CABLE AND V l

CLIP -2A7202 REQ'D.

VIEW IN CIRCLE V2 PLACES

FLOOR PAN REF.

PARKING BRAKEREAR CABLE -2A809 (L.H.)

FOLD TAB OVERAT ASSY.

30 REF.EXISTING HOLE IN

, v TUBE .185 DIA.

'•̂ A\^

PARKING BRAKEREAR CABLE -2A809 (L.H.)

2A596 HOSE\ \ TO TEE

\2A804HOSETO PARKING BRAKEPARKING BRAKE CONTROL ASSY.-

2780

INSTALLATION FOR AUTO. TRANS.CONSOLE SHIFT ONLY SAME AS

VIEW X MERCURY EXCEPT AS SHOWN

tf -.-:«•••*'' PRONGS MUST BE SECURELYLOCKED IN PLACE

CABLE ANDCONDUIT - 2853

CABLE WITHIN BRAKE DRUML.H. SHOWN R.H. TYPICAL

VIEW WGROUND WIRE REF.

BOLT -42353-S242353-S8 ~ U K I

2 REQ'D.

^

VIEW IN CIRCLE TMERCURY ONLY

TRANSMISSION GEAR SHIFT

+ .005.110- .002 DIA. HOLE INTUBE LOCATED FROMEXISTING HOLE IN LEVERAT ASSY.

H 1549-B

FIG. 24 — Parking Brake System



through the bracket. Remove the clipsretaining the right cable to the framecrossmember.

4. Remove the rear wheel coverand wheel. Remove the three Tinner-man nuts that hold the brake drumin place and remove the drum.

5. Working on the wheel side ofthe rear brake, remove the automaticbrake adjuster spring. Compress theprongs on the parking brake ca-ble retainer so that they can passthrough the hole in the brake back-ing plate. Draw the cable retainerthrough the hole.

6. With the spring tension off theparking brake lever, lift the cableout of the slot in the lever and removethe cable through the backing platehole.

INSTALLATION

1. Pull enought of the parkingbrake cable through the housing sothat the end of the cable may be in-serted over the slot in the parkingbrake lever on the rear brake shoe.

2. Pull the excess slack from thecable, and insert the cable housinginto the brake backing plate accesshole so that the retainer prongs ex-pand. The prongs must be securelylocked in place. Install the automat-ic brake adjuster spring.

3. Position the right hand cable andthe two retaining clips and screws onthe rear crossmember. Compress theprongs on the right cable and positionthe cable in the retaining bracket on

the frame side member. Tighten allretaining clip screws.

4. Position the left cable, retainingclip and screw on the left lower sus-pension arm. Compress the prongs onthe left cable and position the cablethrough the frame side-member. Theprongs must be securely locked inplace.

5. Insert the ball ends of the cablesinto the equalizer assembly.

6. Install the rear drum(s) andtighten the three Tinnerman nuts thatsecure the drum. Install the wheel andtire and the wheel cover.

7. Adjust the parking brake link-age as outlined in Part 2-1, Section 2.Adjust the rear brakes, as required(Part 2-1, Section 2).

MAJOR REPAIR OPERATIONS

BRAKE DRUM REFINISHING

Minor scores on a brake drum canbe removed with sandpaper. A drumthat is excessively scored or shows atotal indicator runout of over 0.007inch should be turned down. Removeonly enough stock to eliminate thescores and true up the drum. The re-finished diameter must not exceed0.060 inch oversize (11.090 inches).

If the drum diameter is less than0.030 inch oversize (11.060 inches)after refinishing, standard lining maybe installed. If the drum diameter is11.060-11.090 inches, oversize liningsmust be installed.

After a drum is turned down, wipethe refinished surface with a clothsoaked in clean denatured alcohol. Ifone drum is turned down, the oppo-site drum on the same axle shouldalso be cut down to the same size.

ROTOR REFINISHING

Rotunda Disc Brake Attachment,FRE-2249-2, is the only recommendedtool to refinish the disc brake rotors.The step-by-step resurfacing procedureprovided with the tool must be adheredto.

The finished braking surfaces of therotor must be flat and parallel within0.0007 inch; lateral runout must notexceed 0.002 inch total indicator read-ing, and the surface finish of thebraking surfaces are to be 85/15micro inches. The minimum limitingdimensions (Fig. 8, Part 2-1) from theinboard bearing cup to the outboardrotor face (dimension A) and from

the inboard bearing cup to the in-board rotor face (dimension B)must be observed when removingmaterial from the rotor braking sur-faces.

BRAKE SHOE RELINING

Brake linings that are worn towithin 1/32 inch of the rivet head orare less than 0.030 inch thick (bondedlining) or have been contaminatedwith brake fluid, grease or oil mustbe replaced. Failure to replace wornlinings will result in a scored drum.When it is necessary to replace linings,they must also be replaced on the wheelon the opposite side of the vehicle.

Inspect brake shoes for distortion,cracks, or looseness. If this conditionexists, the shoe must be discarded.Do not attempt to repair a defectivebrake shoe.

1. Wash the brake shoes thoroughlyin a clean solvent. Remove all burrsor rough spots from the shoes.

2. Check the inside diameter of thebrake drum with a brake (jrum mi-crometer (tool FRE-1431). If thediameter is less than 11.030 inches,standard lining may be installed. Ifthe diameter is 11.060-11.090 inches,oversize lining should be installed.

3. Position the new lining on theshoe. Starting in the center, insertand secure the rivets, working alter-nately towards each end. Replacementlinings are ground and no furthergrinding is required.

4. Check the clearance betweenthe shoe and lining. The lining mustseat tightly against the shoe with not

more than 0.008 inch clearance be-tween any two rivets.

DUAL MASTER CYLINDER

DISASSEMBLY

1. Clean the outside of the mastercylinder and remove the filler coverand diaphragm. Pour out any brakefluid that remains in the cylinder.

2. Remove the secondary pistonstop bolt from the bottom of the cyl-inder (Figs. 25 and 26).

3. Remove the bleed screw, if re-quired.

4. Remove the snap ring from theretaining groove at the rear of themaster cylinder bore (Fig. 27). Re-move the push rod and the primarypiston assembly from the master cyl-inder bore. Do not remove the screwthat retains the primary return springretainer, return spring, primary cupand protector on the primary piston.This assembly is factory pre-adjustedand should not be disassembled.

5. Remove the secondary pistonassembly. Do not remove the outlettube seats, outlet check valves and out-let check valve springs from themaster cylinder body.

INSPECTION ANDREPAIR

1. Clean all parts in clean dena-tured alcohol, and inspect the partsfor chipping, excessive wear or dam-age. Replace them as required. Whenusing a master cylinder repair kit,install all the parts supplied.



RETAINER - 2B245

SECONDARY SYSTEMBRAKE OUTLET

COVER - 2166

GASKET - 2167

MASTER CYLINDER -2155

SNAP RING -7821

• BOOT

PUSH ROD

a

PRIMARY PISTONASSEMBLY - 2169

fTUBE SEAT -2B220

* SECONDARY PISTONASSEMBLY - 2A502

NOT USED ON POWER BRAKE EQUIPPED VEHICLES

fNOT SERVICED* REPLACE AS AN ASSEMBLY ONLY

H 1499-B

FIG. 25 — Dual Master Cylinder Disassembled— Except Disc Brakes

RETAINER - 2B245

* PRIMARY PISTONASSEMBLY-2169

*SECONDARY PISTONASSEMBLY-2A502

RETURN SPRING

RETAINER x fNOT SERVICEDCUP \ * REPLACE AS

PROTECTOR .ASSEMBLY ONLY

, \PUMPING CUP

tVALVE2175

SECONDARYBRAKE SYSTEM

OUTLETH 1550-A

FIG. 26 — Dual Master Cylinder Disassembled—Disc Brakes

2. Check all recesses, openings andinternal passages to be sure they areopen and free of foreign matter. Usean air hose to blow out dirt and clean-ing solvent. Place all parts on a cleanpan or paper.

3. Inspect the master cylinder borefor signs of etching, pitting, scoringor rust. If it is necessary to hone themaster cylinder bore to repair dam-age, do not exceed allowable honespecifications.

ASSEMBLY

1. Dip all parts except the mastercylinder body in clean Rotunda ExtraHeavy Duty Brake Fluid.

2. Carefully insert the completesecondary piston and return springassembly in the master cylinder bore.

3. Install the primary piston andreturn spring assembly in the mastercylinder bore.

4. Install the push rod retainer onthe push rod, if so equipped. Installthe push rod assembly in the cylinderbore. Make sure the retainer is prop-erly seated and holding the push rodsecurely.

5. Depress the primary piston andinstall the snap ring in the cylinderbore groove.

6. Position the inner end of thepush rod boot (if so equipped) inthe master cylinder body retaininggroove.

7. Install the secondary pistonstop bolt and gasket in the bottom ofthe master cylinder.

8. Install the bleed screw (if soequipped). Install the gasket (dia-phragm) in the master cylinder fillercover. Position the gasket as shown inFigs. 27 and 28. Make sure the gasketis securely seated.

9. Install the cover and gasket onthe master cylinder and secure thecover into position with the retainer.

DISC BRAKE CALIPER

DISASSEMBLY

1. Remove the caliper assemblyfrom the vehicle as outlined in Section2.

2. Remove the caliper guide pinsfrom the caliper assembly and liftthe anchor plate from the caliper.

3. Slide the two outer shoe re-taining clips off the retaining pins(Fig. 28).

4. Remove the two retaining pins,then remove the outer brake shoe fromthe caliper.

5. Slide the inner brake shoe out-ward until it is free of the hold-down



Snap Ring Pliers

PUSH ROD (NOTUSED WITHBRAKE BOOSTERS)

1477-B

FIG. 27 — Removing Snap Ring—Typical

FIBERBLOCK

CAI IDLR

PISTON

H1574-A

FIG. 29 — Removing PistonFrom Caliper

OUTER SHOERETAINING CLIPS

2066

INNER BRAKESHOE 2019 OUTER BRAKE

SHOE 2018

STABILIZERS2B295

H 1573-A

FIG. 28 — Caliper Assembly—Disassembled

springs, then remove the brake shoe.6. Apply air pressure to the fluid

port in the caliper as shown in Fig.29 to remove the piston. Place a cloth

over the piston before applying airpressure to prevent damage to thepiston. If the piston is seized andcannot be forced from the caliper,

tap lightly around the piston whileapplying air pressure. Care shouldbe taken because the piston can developconsiderable force due to pressurebuild-up.

7. Remove the dust boot from thecaliper assembly.

8. Remove the rubber piston sealfrom the cylinder and discard it.

CLEANING AND INSPECTION

Clean all metal parts with alcoholor a suitable solvent. Use clean, dry,compressed air to clean out and drythe grooves and passage ways. Besure that the caliper bore and com-ponent parts are completely free ofany foreign material.

Check the cylinder bore and pis-ton for damage or excessive wear.Replace the piston if it is pitted,scored, or the chrome plating is wornoff.

ASSEMBLY

1. Apply a film of clean brakefluid to the new caliper piston sealand install it in the cylinder bore.Be sure the seal does not become twist-ed and that it is seated fully in thegroove.

2. Install a new dust boot bysetting the flange squarely in theouter groove of the caliper bore.

3. Coat the piston with the speci-fied fluid and install the piston inthe cylinder bore. Spread the dustboot over the piston as it is instal-led. Seat the dust boot in the pistongroove.

4. Position the inner brake shoeso that the ears of the shoe restson the top of the anchor plate bossesand beneath the hold-down springs.

5. Install new caliper guide pininsulators in the anchor plate.

6. Position the caliper on theanchor plate.

7. Apply the specified fluid tothe caliper guide pins and installthem loosely in the anchor plate.Be sure the guide pins are free ofoil, grease or dirt.

8. Install the caliper on thespindle as outlined under Disc BrakeCaliper Assembly.


2-31

PART 2-3-Specifications

CHECKS AND ADJUSTMENTS—INCHES

Description

Pedal Total Travel-Standard

Pedal Total Travel-Power

Power Brake Push Rod Adjustment -InchBendixMidland Ross

Lining Maximum Wear Limit(From Top of Rivets)

Lining Maximum Wear Limit(Bonded)

Drum Diameter

Self Adjustment Cable Length-End Cable Anchor to End of Cable Hook

Ford, Mercury

6.67 0

3.70 ®

0.980-0.9950.980-0.995

1/32

0.030 TotalLining Thickness

11.030

11.140-11.100

0 3 1/4—On Ford and Mercury Vehicles with Front Wheel Disc Brakes® 2 1/4-On Ford and Mercury Vehicles with Front Wheel Disc Brakes

SHOE AND LINING DIMENSION!DISC BRAKES—INCHES

Lining Material

Lining Size

Lining Area—Square inches per Segment

Lining Thickness—Nominal

Lining Wear Limit (Front Surface of Shoe)—Max

Lining to Rotor Clearance (Brakes Released)

FordMercury

5.36 x 1.90

10.030

0.436

0.030

0.000-0.010

BORE DIAMETERS—BRAKE DRUM, WHEEL CYLINDER AND MASTER CYLINDER

Ford andMercury

Models

Taxi

Other

® Max. Runout 0.007® 0.969 for 240 & 302 CID

Brake Drum

InsideDiameter

11.030

11.030

Boring Limit® (Max.)

11.090

11.090

Wheel Cylinder Bore Dia.

®Front

1.094

1.094 ®

® Max. Allowable Hone 0.003Ford Passenger ® 2.750 for Ford and Mercury with Disc Brakes

®Rear

0.938

0.938 ®

Master Cylinder

With PowerBrake ®

1.000

1.000

Bore Dia.

Less PowerBrake ®

1.000

1.000

LINING DIMENSIONS—DRUM BRAKES—INCHES

Ford and Mercury

Ford Passenger (Riveted Lining)

Ford and Mercury—All 427 CIDEngine and All Police—Max.Fade Resistance

Ford and Mercury Station Wagons

Ford and Mercury Passenger Cars—240 & 302 CID Engines—Taxi Only—(Bonded Lining)Max. Wear Resistance

Mercury Passenger Cars

Position

Primary

Secondary

Primary

Secondary

Primary

Secondary

Primary

Secondary

Primary

Secondary

Front

2.50 x 9.34

2.50 x 12.12

3.00 x 9.34

3.00 x 12.12

3.00 x 9.34

3.00 x 12.12

3.00 x 9.34

3.00x12.12

2.50 x 9.34

2.50 x 12.12

Rear

2.25 x 9.34

2.25 x 12.12

2.25 x 9.34

2.25 x 12.12

2.25 x 9.34

2.25 x 12.12

2.50 x 9.34

2.50 x 12.12

2.25 x 9.34

2.25 x 12.12

Color Code

Yellow-Black

Blue-Black

Yellow-Black

Blue-Blue

Yellow-Black

Blue-Black

Pink

Red-Red

Yellow-Black

Blue-Black



TORQUE LIMITS (FT-LBS)

ROTOR

Car Line

Ford, Mercury

Thickness

1.250

Diameter

Outside

11.96

Rotor Runout-Maximum Allowable—0.0025 inch.

Inside

7.785

Description

Parking Brake Control Assembly Mounting Bolt

Master Cylinder to Dash Panel Bolts

Brake Hose Bolt

Wheel Cylinder Bleeder Screw

Brake Pedal Support Bracket to InstrumentPanel

Wheel to Hub and Drum Nuts—5-Lug

FordMeriury

15-19

18-25

Leak Proof

9-13

70-115

TORQUE LIMITS—DISC BRAKES (FT-LBS)

Description

Caliper Assembly to Spindle

Caliper Bleeder Screw

Caliper Guide Pins

Rotor Splash Shield to Spindle

Wheel Assembly to Front WheelHub and Rotor Assembly

Brake Tube Fitting Nuts toProportioning Valve

Stabilizer to Anchor Plate

FTLBS

Upper 110-120Lower 90-120

6-15 (Must be leakproof)

25-35

9-14

75-110

70 in-lbs(Max. Must beleakproof)

8-11

DescriptionHub and Rotor Assembly to

Front Wheel Spindle

FTLBSRotate rotor while torquing to17-25 ft-lbs. Back off the ad-justing nut 1/2 turn and re-tighten to 10-15 inch poundswhile rotating wheel. Selec-tively position nut retainer onadjusting nut so that a setof slots are in line with cotterpin hole. Adjusting nut shouldnot be rotated in this opera-tion. Lock adjusting nut andnut retainer with cotter pinso that the cotter pin enddoes not interfere with seat-ing of wheel static collectorin spindle hole.

TORQUE LIMITS (FT-LBS) (Continued)

DescriptionFRONT BRAKES—DRUM TYPE

Backing Plate to Spindle Nut

MercuryFord

25-45

Wheel, Hub and Drum Assembly to Wheel Spindle Nut Rotate wheel and drum while torquing the wheel bearing adjustingnut to 17-25 ft-lbs torque. Back off the adjusting nut 1/2 turn andre-tighten to 10-15 inch pounds while rotating the drum and wheelSelectively position nut retainer on adjusting nut so that a set ofslots are in line with cotter pin hole. Adjusting nut should not berotated in this operation. Lock the adjusting nut and retainer withcotter pin so that cotter pin end does not interfere with seating ofwheel static collector in spindle hole.

REAR BRAKES—DRUM TYPEDrum to Axle Shaft Speed Nut

Brake Cylinder to Brake Backing Plate Bolt

Brake Backing 1'late to Axle Housing: All

Brake Line Connection to Axle Housing Bolt

POWER BRAKES: Master Cylinder to Booster Body

Brake Booster to Pedal Support Bracket or Dash

Hand Push Fit

50-20in-lbs

50-70

12-18

18-25

18-25


PART 2-3 — Specifications 2-33

SERVICE TOOLS

Ford Tool No.

Rotunda HRE 8650

—

—

—

—

7000-00

Former No.

—

LM-119

2018-A

2162

2035-N

—

Description

Brake Adjusting Gauge

Brake Cylinder Retaining Clamp

Brake Adjusting Tool

Adapter Cap

Brake Shoe R & R Spring

Rubber Tipped Air Nozzle

Ford Tool No.

TOOL 33621

TOOL-4235-C

Former No.

33621

Milbar1112-144

4235-C

Description

Internal Snap Ring Pliers

Inch-lb torque wrench

Axle Shaft Remover


•140 (18)-

297(12)

EU8V

I8A900-BASSY.

I9H(20)

CONNECTIONWHEN FRONT SPEAKERSPECIFIED ONLY

R.H.REAR SEATSPEAKER

D-39y j-D-39

I (o\ f»)-b U- G ( l 8 )

19 (18)-

CONTROLASSY.FADER-MERCURY

D(18)

W I R I N G C O L O R C O D E

F I9H

I9A017-A ASSY.MODELS - A L LEXCEPT 71 & 76

19 A 1921

G 137140

BLUE-RED STRIPEYELLOWYELLOW-BLACK STRIPEBLACK-RED STRIPE

NOTE:

©

297A 297 BLACK-GREEN STRIPEA BROWNB BROWN-GREEN STRIPEC BROWN-RED STRIPED BUCK• SPLICE-= GROUND

DETAIL & ITEM REFERENCE SiHOWNON PRODUCT DRAWING

ALL NUMBERS IN PARENTHESIS ( )INDICATE WIRE GAUGES

ALL LETTERS CIRCLED AS SHOWNINDICATE CONNECTORS

UNLESS OTHERWISE SPECIFIEDALL CONNECTORS fiRE BLACK

E (18)

UGHTING SWITCH I9A0I7-B ASSY. MODELS 71 & 76 ONLY

K2225-C

. 33— Mercury Radio—AM & Rear Seat Speakers & Fader


Date post:	03-Jun-2020
Category:	Documents
Upload:	others
View:	2 times
Download:	0 times

r - Money back Guarantee · INTERIOR TRIM CODES INTERIOR CODESHContinued) Code 1A IB ID 1G IK 1U 1Y...

Documents