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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

1970 Ford Car Shop Manual

ISBN: 0-9673211-7-4
EAN: 978-0-9673211-7-2

Forel Publishing Company, LLC

3999 Peregrine Ridge Ct.
Woodbridge, VA 22192
Email address: webmaster@ForelPublishing.com
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
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of Ford Motor Company.

Disclaimer
Although every effort was made to ensure the accuracy of this book, no representations or warranties of
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services of a competent professional should be sought.

IDENTIFICATION
INDEX end lDENTlFlCATlON .

.. . . ........

20

IGUlTlON SYSTEM

STARTING SYSTEM

. .. .... ... .. ... .... 2)

. . . . .. . .
. . ... . .. . . .
... .

INDEX md IDENTIFICATION..
..
.
CHARGING SYSTEM . . .
.. . . .
EXTERIOR LIGHTS, HEADLIGHT
.
DIMMER, TURN SIGNALS, HORN
INTERIOR LIGHTS, INSTRUMENTS, INSTRU.

3
31
32

. .. . ... . . . . . .. .... 35
. . . . . .. . . 38
. . . . . . . . . 37
. 38
INDEX and lDENTlFlCATloN.. .. . . . . . . . . . 48

MIRRORS, Etr.
.
WIRING, CIRCUIT PROTECTION,
BULB CHARTS , . .. ... .
. .
VACUUM SYSTEMS . .. . . . . . . .
SPEED CONTROL, ANTI-SKID CONTROL . .

and DRIVESHAFT

.
. .. . . . . .
. . .. . .

TRANSFER, VINYL ROOFS, PAINT .. 46

INTERIOR TRIM
. . . ..
. . 47
BODY SHELL, EXTERIOR TRIM,
FRAMES, UNDERBODY . . .
. . .. 88

. . . . ..

PUBLICATloNS

..

FIRST P R I N T I N G - SEPTEMBER, 1969

@I969 FORD MOTOR COMPANY, DEARBORN. MICHIGAN

FOREWORD
This manual is divided into five volumes: I - Chassis, 2 - Engine, 3 - Electrical, 4
- Body, 5 - Maintenance and Lubrication These volumes should provide Service
Technicians with complete information covering normal service repairs on all 1970
model passenger cars built by Ford Motor Company in the US. and Canada. As
changes in the product occur, this information will be updated by Technical Service
Bulletins. When issued, TSB information always supersedes that published here.
Within each volume, information is grouped by system or component plus "General
Service" parts which contain information which is common to several similar components
The table of contents on the first page of each volume indicates the general content
of the book and provides a handy tab locater to make it easy to find the first page of
each "group. " That page will contain an index to ')arts" and the first page of each
"part" contains a detailed index which gives page location for each service operation
covered. Page numbers are consecutive in each 'Bart. "
Those who have previously used Ford Shop Manuals will find a major change this
year in the division of information into "groups" and ')arts." To make reference
easier, information has been broken down into smaller units so that essentially there
is now one "part" for each component or system. Group numbers have been
changed so that the first digit of the number indicates the volume in which thi.
group may be found.
Example:

36 - 05 - 13
Volume 3 - Group 6 - Part 5 - Page 13
We hope that this change in indexing willmake it easier and quicker to locate
desired information within these manuals
The descriptions and specifications.in this manual were in effect at the time this
manual was approved for printing. Ford Motor Company reserves the right to'discontinue models at any time, or change specifications or design, without notice and
without incurring obligation.

SERVICE P U B L I C A T I O N S

5006

July 1997

Fig. I

- Typical Vehicle

Warranty identification of the vehicle. The

first number indicates the model year. The
letter following the model year number
indicates the manufacturing assembly
plant. The next two numbers designate
the Body Serial Code followed by a letter
expressing the Engine Code. The last six
digits of the Vehicle ldentification Number indicate the Consecutive Unit Number.
The remaining information on the V.C.
Label consists of certinent vehicle identification codes. The B O D Y code is two numerals and a letter identifying the body
style. The COL (color) code is a number
or letter (or both) indicating the exterior
paint color code. The TRIM code consists of a number-letter combination designating the interior trim. The Axle code
is a number or letter indicating the rear
axle ratio and standard or rocking type
axles. The TRNS. code is a number or
letter indicating the type of transmission.
numerals for manual and letters for automatic or semi-automatic. The DSO code
consisting of two numbers designates the
district in which the car was ordered a'nd
may appear in conjunction with a Domestic Special Order or Foreign Special
Order number when applicable. Ford of
Canada DSO codes consist of a letter and
a number except for export codes which
are designated by two numbers.

ldentification N u m b e r

NUFACTURED BY
RD MOTOR COMPANY

100001

MODEL YEAR CODE

The number 0 designates 1970.
CONSECIJl IVE UN:T NO

@ OODY SERiAL CODE

MODEL YEAR CODE

ASSEMBLY DLANT CODE

@ COLOR CODE
@ BODY TYPE CODE
I(
0

D:STRlCT

SPEC EQUIP CODE

ASSEMBLY PLANT CODES

@ TRANSMlSS:ON CODE

@ ENGINE CODE

@ TRIM CODE
FIG. 2 - Vehicle

REAR A X L E CODE

1009.A
W 1009.A

Code
Letter

A ........................ Atlanta
Certification

B ........................ Oakville (Canada)

D ....................... Dallas
E ........................ Mahwah

Label

F .......................

OFFICIAL VEHICLE
IDENTIFICATION NUMBER
The official Vehicle ldentification Number (VIN) for title and registration purposes is stamped on an aluminum tab
that is riveted to the instrument panel
close to the windshield on the driver's
side of the car and is visible from outside
(Fig. I).

VEHICLE CERTIFICATION LABEL

The Vehicle Certification Label (V.C.
Label) is attached to the rear face of the
driver's door. The upper half of the label
contains the name of the manufacturer.
the month and, year of manufacture and
the certification,.statement. The V.C. label
also contains the Vehicle Identification
Number. This number is also used lor

Dearborn

G ........................ Chicago
H ....................... Lorain
J ........................ Los Angeles
K ....................... Kansas City

........................ Norfolk
R ......................... San Jose
S ......................... Allen Park
T ......................... Metuchen
N

P ......................... Twin Cities

U ........................

Louisville

W ........................ Wayne

X ......................... St. Thomas

Y ......................... Wixom

10-01-02

Index and Vehicle Identification

BODY SERlAL A N DSTYLECODES

10-0 1-02

MERCURY (Cont'd.)
Body Body

T h e two-digit numeral which follows

the assembly p l a n t code identifies the
b o d y series. T h i s t w o - d i g i t n u m b e r i s
used i n c o n j u n c t i o n w i t h the B o d y S t y l e
Code, i n the Vehicle Data, w h i c h consists
o f a t w o - d i g i t n u m b e r w i t h a letter suffix.
T h e f o l l o w i n g c h a r t lists t h e B o d y S e r i a l
Codes. B o d y S t y l e C o d e s a n d the m o d e l .

Code

Code

'>74

71G
71E

Body Type
Model
MontereyXustom
4 - Door 2 Sea.t @
4 - Door 3 Seat (Side Facing)@
Wagon
4 - Door 2 Seat 0 0
Marquis Colony Park
4 - Door 3 Seat ( S ~ d eFacing)@@
@ Bucket Seats

LINCOLN CONTINENTAL

181

Body Type
4 Door Sedan
2 . Door Hardtop

65A

MARK Ill
Body Body
Serial Style
Code Code
89
65A

Body Type
2 . Door Hardtop @
Convert ible'@
2 - Door H a r d t o p @
Convertible@
@Split Bench -

72
:::72

718
71C

Montcalm

34
65F
2 - Door Hardtop-Formal 00
57F
3 5
- 2 . Door H a r d t o o @ @
36
718
Rideau 5 0 0 6 Passenger @
37
71C
Rideau 5 0 0 4 u a l Face Rear@
. M o n t c a l m b Passenger @,
38
71E
39
71A
Montcalm4ual
DBench Seat
@ Split Bench
*Merchandised as Options

Model
Standard
XR-7 Luxury

LeMoyne
St at i o n Wagons4 Door

@Bucket Seats

MONTEGO

--

Model
Rideau
Rideau 500

MERCURY
Body Body
Serial Style
Code Code
44
54A
46
65A
48
57A
45
76A
53M.
65M
57M
54C
658
57B
53F
65F
57F
76F
53C
65C
57C
63G
63H

METEOR (CANADA)
Body Body
Serial Style
Code Code
Body Type
20
54A
4 . Door Sedan@
4 . Door S e d a n 0
22
54B
658
2 . Door Hardtop-Formal@
23
25
54C
4 - Door Sedan@@
26
65C
2 - Door H a r d t o p @ @
:'26
65E
2.DoorHardtop@@
27
57C
4 - Door Hardtop @ @
28
76C
Convertible @ @
"28.
76E
Convertible @ O
-.
.

Body Type
2 - Door Hardtop

COUGAR
Body Body
Serial Style
Code Code
91
65A
92
76A
93
658
94
768
@Bench Seat

40
41
42
54
56
158
63
66
68
65
-62
64

Body Type
4 . Door Sedan@
2 - Door H a r d t o p @
4 - Door Hardtop @
Convertible @
CANADA ONLY
4 . Door Hardtop Sedan @
2 . Door Hardtop-Formal @
4-DoorHardtopO
4 . Door Sedan@
2 - Door Hardtop@
4 - Door Hardtoo@
.
4 . Door Hardtop Sedan 00
2 . Door H a r d t o p @ @
4 - Door H a r d t o p @ @
Convertible @ @
4 . Door Hardtop Sedan @
2 . Door H a r d t o p @
4 . Door ~ a r d t o b@

Model
Monterey

2 - Door Hardtop (Tunnel Roof)

XlOO 300
4 - Door 2 Seat @
4 . Door 3 Seat (Side Facing) @

:::I5
17
16
(08

65F
65G
65H
71C

12

MontereyXustom

1-

1 ':07

658
54D
65D
570
65E

Marquis

Marquis

Brougham

2 . Door Hardtop @
4 - Door Sedan @
4 - Door Sedan @
2 . Door Hardtop@
4 . Door ~ e d a n c
2 - Door Hardtop @
4 - Door H a r d t o p @
2 . Door t i a r d t o ~@

i1- i::i::,'::z

2 Door Hardtop @
2 . Dbor Hardtop @
2 - Door Hardtop @
Montego M X @

@Bench Seat
@ S p l i t Bench
"Merchandised as Options
Monterey Wagon

Montego MX
Montego MX
Brougham
Montego MX

Cyclone

Cyclone GT
S t a t ~ o nWagon-

@ Bucket Seats

Index and Vehicle Identification

THUNDERBIRD
Body Body
Serial Style
Code Code
':83
65A
83
65C
'>84
658
84
650
':87
578
87
57C
@Benchseat
;>Merchandised as

Body Type
2 - Door ~ a r d t o p @
2 - Door Hardtop @
2 - Door Landau @
2 - Door Landau @
4 - Door Landau O
4 . Door Landau @
OSplitBench
Options

Model

@Bucket Seats
:

FALCON
Serial Style

@Bench Seat

4 . Door Sedan o
2 - Door Sedan
4 - Door Sedan @
4 - Door Standard @
4 - Door Fut ura @
O S ~ l i tBench

@Bucket Seats

MAVERICK
Body Body
Serial Style
Code Code
91
62A

Body Type
2 - Door Sedan

Model
Standard

628-

pi$-548

MUSTANG
I Body Body
Serial Style
Code Code
Body Type
65A
2.. Door Hardtop@
2 . Door Fastback @
63A
03
76A
- Convertible @
Wl
65B
2 . Door Hardtop@
"'02
638
2 - Door Fastback @
':'03
76B
Convertible @
04
65E
2 . Door Hardtop@
05
63C
2 - Door Fastback @
@Bench Seat
.@Split Bench
"Merchandised as Options

L
F

---

FORD
Body

Body

Code

Code
548

Body Type
4 - Door Sedan@
4 - Door Sedan@

FORD (Cont'd.)
Body Body
Serial Style
Code Code

Futura

58
56
60
61
64
62
66
70
71

578
63C
768
54C
65A
57F
71D
71H

72

71J

73
718
74
71C
75
71E
76
7:A
@Benchseat

Bodv Tvoe
2 - Door Hardtop Fastback @
2 - Door Hardtop Formal @
4 . Door Hardtop@
2 - Door Hardtop Fastback@@
Convertible @ @
4 - Door Sedan@@
2 - Door Hardtoo Formal @ @
4 . Door ~ a r d t h @ @
Ranchwagon4 Passenger0
Custom 500 Ranchwagon6 Passenger @
Custom 500 RanchwagonDual Face Rear @
Country Sedan4 Passenger @
Country Sedan-Dual Face Rear @
Country S q u i r e d Passenger @
Country Squire-Dual Face Rear@
OSolitBench
-

Model
Galaxie 500

Ford XL

Ford LTD

I
Station Wagon

@Bucket Seats

Station Wagon

Model
Standard

Flair

"Grande"
"Mach I"
@ Bucket Seats

Model
Custom
Custom 500

FAIRLANE
Body Boy
Serial Style
Code Code
28
548
29
658
-30
65C
31
54C
32
57C
"30
65C
33
65E
36
57E
35
63F
37
76F
---"35
63F
"37
76F
38
63H
63H
, "38
41
718
42
71C
43
71E
46
66A
47
668
"47
668
48
66C
$48
66C
49
66E
"49
66E
@Bench Seat
OMerchandised as
-

Body Type
4 . Door Sedan@
2 - Door Hardtop@
2 . Door Hardtop@
4 - Door Sedan@
4 - Door Hardtop@
2 - Door Hardtop @
2 . Door Hardtop. Formal @
4 - Door Hardtop@
2 - Door Hardtop. Fastback@
Convertible@
2 . Door Hardtop - Fastback@
Convertible @
2 - Door Hardtoo - Fastback @
2 - Door Hardtop - Fastback @
Fairlane 500@
Torino @
Torino Squire (Brougham) @
Ranchero @
Ranchero 500@
Ranchero 500 @
RancheroGTO
RancheroGTa
Ranchero Squire@
Ranchero Squire @
@Split Bench
Options

Model
Fairlane 500
Torino

Torino
Torino Brougham
Torino GT
Torino GT
Cobra
Cobra
Station Wagon
4 . Door
Ranchero
Ranchero
Ranchero

@Bucket Seats
i

Index and Vehicle Identification

:REAR AXLE RATIO CODES
l~onventional

Limited-Slip

Ratio

EXTERIOR PAINT COLOR COOES

Color

M-32.1
Number

A .....
B .....
C .....
D .....

1724.A ............
3316.A ...........
3323.A ............
3470-A ............

Color

Black
Dk.Maroon
Dk. Ivy Green Met.
Brt. Yellow-Competition
Yellow
.
E ..... 1906.A ............ Lt.Blue
F ..... 3065-A ............ Dk. Aqua Met (Brt.)-Dk.
Aqua Met.
G ..... 3075-A ............ Med. Avacado Met.-Med.
Lime Met.
-..

1 ....... 3204-A ........... ~ kOrchid

.
Met.
J ...... 3320.A ........... Brt. Blue Met. (Astra)Deep Blue Met.
K ..... 3340-A ............ Yellow M e t . d r t . Gold
Met. (Freudian GiltIMav.
erick):Deeo Gold Met.
...........

TRANSMISSION CODES
Type

Code

1.......... 3 .Speed Manual

5 ..........
6 ..........
V ..........
W .........
U .........
X ..........
Z ..........

4. S eed Manual -wide ratio

4 . %peed Manual close ratio
Semi .Automatic Stick Shift
Automatic (C4)
Automatic (C6)
Automatic (FMX)
Automatic (C6 Special)

ENGINE CODES
Code

U
T
2
L
3
V
5
B
E
F
6
D
G
H
M
Y

1P
K
N
C
Z
J
A

Type

6 Cyl.
6 Cyl.
6 Cyl. o
6 Cyl.
6 Cyl. O
6 Cyl.
6 Cyl. O
6Cyl.
6 Cyl.
8 Cyl.
8 Cyl. O
8 Cyl.
8 Cyl.
8 Cyl.
8 Cyl.
8 Cyl.
8 Cyl.
8Cyl @
8Cyl. @
8 Cyl.
8 Cyl.
8Cyl.
8Cyl.
8 Cyl.
8 Cyl.

170 Cu. In. (1V)

200 Cu. In. (1V)
200 Cu. In. (1V)
250 Cu. In. (1V)
250 Cu. In. (11)
240 Cu. In. (1V)
240 Cu. In. (1V)
240 Cu. In. (1V) Police
240 Cu. In. (1V) Taxi
302 Cu. In. (2V)
302 Cu. In. (2V)
302 Cu. In. (2V) Taxi
302.4V HO
351 Cu. In. (2V)
351 Cu. In. (4V)
390 Cu. In. 2V) Regular
428 Cu'. In. (1V) CJ
428 C u In. (4V) CJ Ram AI
428 Cu. In. (4V) Police
429 Cu. In. (2V)
429 Cu. In. (4V)
429 4V. CJ
429.4V. HO
429 4V CJ Ram Air
460 Cu. In. (4V)

O Low Compression
O Premium Fuel
O Improved Performance
O High Performance
O Ram Air Induction

CONSECUTIVE U N I T NUMBER
S t a r t i n g Serial Numbers - 1970 Passenger Cars
100,001 -Ford, Fairlane, Falcon, Mustang,
Thunder bird, Maverick
500,001 - Mercury, Meteor, Montego, Cougar
800.001 - Lincoln Continental & Mark II I

M .... 1619-A ........... White

N ..... 921.A ..;......... Platinum-Pastel Blue
0 ..... 3202.A ............ Burnt Orange Met.(Original CLnnamon/Maverici)
P ...... 3401.A ............ Med. Ivy Green Met.
Q ..... 3319.A ........... Med.BlueMet.
R ..... 3342-A ............ Dk.BrownMet.
S ..... 3199-A ............ Nug et Gold Met.-Med.
~olf~et.
T ..... 2008-A ........... Red
U ..... 1070-A ............ Med.AquaMet.
W .... 3341-A ........... Yellow
X ..... 3063-A ........... Dk. Blue
Y ...... 3347-A ............ Chestnut Met.-Chestnut
Bronze Met-Med. Bronze
Met.
Z ..... 3346-A ............ Dk. Slate Gray Met.-Dk.
Gray Met.
1 ...... 1730-A ........... Calypso Coral-Vermilion
-Competition Orange
2 ...... 3071-A ............ Lt. Ivy Yellow
,
5 ...... 3564.A ............ Ginger Met.-Med. Brown
Met.
6 ...... 3077-A ............ Med. Brt. Blue Met.Bright Blue M e t . 4 u l l a
BlueJMaverick
7 ...... 3812-A ............ Med. Peppermint Met.(Anti-Establishment Mint
/Maverick)

GLAMOUR PAINTS4pt.
19 ... 3595-A ........... Ivy Bronze Met.4reen
F i r e 4 r e e n Stardust
09 ... 3597-A ............ Olive Bronze M e t . 4 l i v e
F i r e a l i v e Stardust
89 ... 3333-A ........... Fall Bronze Met. -Bronze
F i r e d r o n z e Stardust
59 ... 3275-A ........... Med. Red Met. -Burgundy
Fire-Red Stardust
Vendor=

Grabber Paints

J ....... 0470 ............... Grabber Blue (Med.)Competition Blue

U ..... 6166 ............... Grabberoran e (Dk )
Competition [old ' Z ..... 4359 ............... Grabber Green (Med.)Competition Green

10-0 1-04
INTERIOR TRIM CODES
-Code
T r i m Schemes
1A ......... Black Vinyl
1A ......... Black Cloth & Vinyl
1A ......... Black Cloth & Black Vinyl
1A ......... Black K n i t & Vinyl
1B ........ Med./Lt. Blue Vinyl
1B ........ Dk. Blue Cloth & Vinyl
1B ........ Dk. Blue K n i t & Vinyl
1B ........ Med. Blue Vinyl
1B ........ Med. Blue Cloth & Vinyl
1D ........ Dk. Red Vinyl
1D ........Dk. Red K n i t & Vinyl
1D ........ Dk. Red Cloth and/or Dk. Red Vinyl
1F .........Med. Ginger Vinyl
1F ......... Med. Ginger Cloth & Vinyl
1G ........ Dk. Ivy Green Cloth & Vinyl
1G ....... Med. Ivy Green Vinyl
1G ....... Med. Ivy Green Cloth & Vinyl
1G ....... Med. Green Cloth & Vinyl
1G ........ Dk. Ivy Green K n i t & Vinyl
1P ........ Med. Grey Cloth & Vinyl
1Y ......... Lt. Nugget Gold Vinyl
1Y ......... Lt. Nugget .Gold Cloth & Vinyl
1Y ........ Lt. Gold Cloth & Vinyl
1Z ......... Dk. Tabacco Vinyl
1Z ......... Dk. Tabacco K n i t & Vinyl
2A ......... Black Vinyl
2A ......... Black Leather & Vinyl
2A ......... W h i t e & Black Cloth & Black Vinyl
2A ......... Black Knit & Vinyl
2 8 ....... Dk. & Lt. Blue Vinyl
2 8 ........ Dk. Blue Leather & Vinyl
2 8 ........ Med. Blue Vinyl
28 ........ Dk. Blue K n i t & Vinyl
2 8 ........ Med. Blue & Black Cloth & Med.
Blue Vinyl
2D ........ Dk. Red Vinyl
2 0 ........ Dk. Red Leather & Vinyl
2D ........ Dk. Red & Black Cloth & Dk. Red
Vinyl
2F ......... Med. Ivy Green Vinyl
2F ......... Med. Ginger Vinyl
2F .........Med. Brown Vinyl
2F ......... Med. Ginger Leather & Vinyl
2G ........ Dk. Ivy Green Vinyl
2G ........ Med. Green Vinyl
2G ........Dk. Ivy Green Knit & Vinyl
2G ........ Dk. Ivy Green Leather & Vinyl
2K ........ Lt. Aqua Leather & Vinyl
2P ......... Med. Grey Leather & Vinyl
2W ........ White Vinyl
2W ........White Leather & Vinyl
2W ........White Vinyl W i t h Black
2W ........ White K n i t & Vinyl
2Y ......... Lt. Gold Vinyl
2Y ........ Lt. Nugget Gold Vinyl
2Y .........Lt. Nugget Gold Leather & Vinyl
2Y ......... Lt. Nugget & Black Cloth & Lt.
Nugget Gold Vinyl
22 ........ Dk. Tobacco Leather & Vinyl
3A ......... Black Vinyl W i t h Red S t r i p
3A ........ Black Cloth & Vinyl
3A ........ Black Leather & Vinyl
3A ........ Med. Blue Cloth & Vinyl
3 8 ....... Med. Blue K n i t & Vinyl
3 8 ....... Med. Blue Cloth & Vinyl
38 ....... Dk. Blue Cloth & Vinyl
3B ....... Dk. Blue Leather & Vinyl
3 8 ........ Med. Blue Cloth & Lt. Blue Vinyl
3B ........ Med. Blue Vinyl
3 0 ..:..... Dk. Red Cloth & Vinyl
3D ........ Dk. Red Leather & Vinyl
3E ........ Vermilion Vinyl

Index and Vehicle Identification

INTERIOR TRlM CODES-(continued)

--

Code
Trim k h e m e s
3E ......... Vermilion K n i t & Vinyl
3F ........ Med. B r o w n Cloth & Vinyl
3F ........ Med. Ginger K n i t & Vinyl
3F ........ Med. Ginger Leather & Vinyl
3F ........ Med. Ginger Vinyl
3F ........ Med. Ginger Cloth & Vinyl
3G ....... Med. Ivy Green K n i t & Vinyl
3G ....... Med. Ivy Green Leather & Vinyl
3G ....... Med. Ivy Green Vinyl
3G ....... Med. Ivy Green Cloth & Vinyl
3G ....... Dk. Ivy Green Cloth & Vinyl
3K ....... Lt. Aqua Leather & Vinyl
3K ....... Lt. Aqua Cloth & Lt. Aqua Vinyl
3P ........ Med. Grey Leather & Vinyl
3W ....... White Leather & Vinyl
3W ....... White W i t h Black K n i t & Vinyl
3Y ........ Lt. Nugget Leather & Vinyl
3Y ........ Lt. Nugget Gold Cloth & Vinyl
3 2 ........ Dk. Tobacco Leal her & Vinyl
4A ........ Black Vinyl
4A ........ Black Cloth & Vinyl
4A ........ Dk. Black K n i t & Vinyl
4 8 ....... Dk. Blue K n i t & Vinyl
4 8 ....... Dk./Lt. Blue Vinyl
4B ....... Med. Blue Cloth & Vinyl
4 8 ....... Med. Blue Vinyl
4 0 ....... Dk. Red Vinyl
4F ........ Med. Ginger Vinyl
4F ........ Med. B r o w n Vinyl
4G ....... Dk. Ivy Green K n i t &Vinyl
4G ....... Dk. Ivy Green Vinyl
4W ....... W h i t e Vinyl
4W ....... White K n i t & Vinyl With Black
4Y ........ Lt. Gold Cloth & Vinyl
4Y ........ Lt. Nugget Gold Cloth & Vinyl
4Y ........ Lt. Nugget Gold Vinyl
5A ........ Black K n i t & Vinyl
5A ........ Black Cloth and/or Black Vinyl
5A ........ Black Vinyl
5 8 ....... Med. Blue Cloth & Vinyl
5B ....... Med. Blue K n i t & Vinyl
5 8 ....... Med. Blue Vinyl
5B ....... Dk. B l u e Cloth & Vinyl
5 0 ........ Dk. Red Cloth & Vinyl
5 0 ....... Dk. Red K n i t & Vinyl
5 0 ....... Dk. Red Vinyl
5F ........ Med. B r o w n Vinyl
5F ......... Med. Ginger K n i t & Vinyl
5F ........ Med. Ginger Vinyl
5G ........ Med. Ivy Green Cloth & Vinyl
5G ........ Dk. Green Cloth & Vinyl
5G ........ Med. Ivy Green K n i t & Vinyl
5G ........ Med. Green Vinyl & / o r Cloth
5K ........ Lt. Aqua Cloth & Vinyl
5K ........ Lt. Aqua K n i t & Vinyl
5Y ......... Lt. Nugget Gold Cloth & Vinyl
5Y ......... Lt. Gold Cloth & Vinyl
5Y ......... Lt. Nugget Gold K n i t & Vinyl
52 ......... Dk. Tobacco K n i t & Vinyl
52 ........ Dk. Tobacco Cloth & Vinyl
6A ......... Black K n i t R Vinyl
6A ........ Black Vinyl
6A ........ Black Grain Leather
6A ........ Black G r a i n Leather &/or Vinyl
6B ........ Med. Blue G r a i n Leather W i t h Vinyl
6B ........ Med. Blue G r a i n Leather
6B ....... Med. B l u e Vinyl
6 0 ........ Dk. Red Cloth & Vinyl
6 0 ....... Dk. Red Vinyl
6 0 ........ Dk. Red G r a i n Leather
6 0 .......: Dk. Red G r a i n Leather & / o r Vinyl
6F ......... Med. B r o w n Leather W i t h Vinyl
6F ......... Med. Brown Vinyl

INTERIOR TRlM CODES-(continued)

Code
T r i m Schemes
6F ......... Med. Ginger Vinyl
6F ......... Med. Ginger Grain Leather
6G ........ Med. Ivy Green Vinyl
6G ........ Med. Ivy Green G r a i n Leather
6G ........ Med. Green Vinyl
6G ........ Med. Green Cloth & Vinyl
6W ........ White Cloth & Vinyl
6W ........ White Vinyl W i t h Black
6Y ......... Lt. Nugget Gold Vinyl
6Y ......... Lt. Nugget Gold Cloth & Vinyl
62 ......... Dk. Tobacco G r a i n Leather
62 ......... Dk. Tobacco Vinyl
6Z ......... Dk. Tobacco G r a i n Lether &/or Vinyl
62 ......... Dk. B r o w n Leather & Vinyl
7A ......... Black Vinyl
7A ......... Black Cloth & Vinyl
7A ......... Black Leather & Vinyl
7 8 ........ Dk. Blue Leather & Vinyl
7B ........ Med. Blue Cloth & Vinyl
7 8 ........ Med. Blue Vinyl
7 0 ........ p k . Red Leather & Vinyl
7F ......... Med. Ginger Cloth & Vinyl
7F ......... Med. Ginger Vinyl
7F ......... Med. B r o w n Cloth & Vinyl
7G ........ Med. Ivy Green Vinyl
7G ........ Dk. Ivy Green Leather & Vinyl
7G ........ Med. Ivy Green Cloth & Vinyl
7W ........ White Leather & Vinyl
7Y ......... Lt. Nugget Gold Cloth & Vinyl
8A ......... Black Vinyl
8A ......... B l a c k K n i t & Pewter Vinyl
8A ......... Black G r a i n Leather
8A ......... Black K n i t & Vinyl
8A ......... Black G r a i n Leather & / o r Vinyl
8 8 ........ Med. Blue K n i t & Vinyl
8B ........ Med. Blue Vinyl
8 0 ........ Dk. Red Vinyl
8 0 ........ Dk. Red G r a i n Leather
8 0 ........ Dk Red K n i t & Y i @
8 0 ........ LTk. Red Grain Leather &/or Vinyl
8F ......... Med. B r o w n Vinyl
8F ......... Med. Ginger G r a i n Leather &/or Vinyl
8F ......... Med. Ginger Vinyl
8F ......... Med. Ginger G r a i n Leather
8F ......... Med. Ginger K n i t & Vinyl
8G ........ Med. Ivy Green K n i t & Vinyl
8G ........ Med. Ivy Green Vinyl
8W ........ White Vinyl W i t h Black
8W ........ White K n i t & Vinyl
8W ........ White K n i t & Vinyl W i t h Black
9A ......... Black Vinyl
9A ......... Black Cloth & Vinyl
9B ........ Med. Blue Vinyl
9 8 ........ Med. B l u e Cloth & Vinyl
9 0 ........ Dk. Red Vinyl
9 0 ........ Dk. Red Cloth & Vinyl
9F ......... Med. Ginger Vinyl
9G ........ Med. Ivy Green Cloth & Vinyl
9G ........ Med. Ivy Green Vinyl
9K ........ Lt. Aqua Cloth & Vinyl
9Y ......... Lt. Nugget Gold Cloth & Vinyl
A4 ......... White Vinyl W i t h Black Vinyl
AA ......... Black Vinyl W i t h Black Vinyl
A4 ......... Black Cloth & Vinyl
AB ........ White Vinyl W i t h Blue Vinyl
AB ........ Blue Cloth W i t h Blue Vinyl
AD ........ White Vinyl
AD ........ Dk. Red Cloth & Vinyl
AE ......... Vermilion Cloth & Vinyl
AF ......... Med. Ginger Cloth & Vinyl
AF .........White Vinyl W i t h Ginger
AG ........ White Vinyl W i t h Ivy Gold
AG ........ Med. Ivy Green Cloth & Vinyl

INTERIOR TRlM CODES-(continued)

Code
T r i m Schemes
AK ........ Lt. Aqua Cloth & Vinyl
AP ......... Med. Grey Cloth & Vinyl
AY ......... Lt. Nugget Cloth & Vinyl
AZ .........White With Tobacco
BA ........ Black Vinyl
B A . ........ Black C l o t h & Vinyl
B B ........ Lt. Blue Vinyl
BB ....... Med. Blue Vinyl
B D ........Dk. Red Cloth & Vinyl
BE ........ Vermilion Vinyl
BF ........ Med. Ginger Vinyl
BG ........ Med. Ivy Green
BW..: ..... White Vinyl
BW ........ White Vinyl W i t h Black
CA ......... Black Cloth & Vinyl
CA .........Black K n i t & Vinyl
CB ........ Med. Blue K n i t & Vinyl
CB ........ Med. Blue Cloth & Vinyl
CD ........ Dk. Red Cloth & Vinyl
CD ........Dk. Red K n i t & Vinyl
CE ......... VermilionCloth & Vinyl
CF ......... Med. Ginger Cloth & Vinyl
CF ......... Med. Ginger K n i t & Vinyl
CG ........ Med. Ivy Green Cloth & Vinyl
CY .........Lt. Nugget Gold Cloth & Vinyl
DA ........Black Cloth & Vinyl
DA ........ Black Vinyl
DB ........Med. Blue Cloth & Vinyl
DB ........ Med. Blue Vinyl
DD ........ Dk. Red Cloth & Vinyl
DD ........ Dk. Red Vinyl
DE ........ Med. Ginger Cloth & Vinyl
DF ........ Med. Ginger Cloth & Vinyl
DG ........ Med. Ivy Green Cloth & Vinyl
DG ........Med. Ivy Green Vinyl
DK ........ Lt. Aqua Cloth & Vinyl
DW ........ W h i t e Y i t y l W i i h Black
BY ........ Lt. Nugget Gold Cloth & Vinyl
DY ........ L t . Nugget Gold Vinyl
EA ......... Black Cloth & Vinyl
EA .........Black K n i t & Vinyl
EA .........White & Black Vinyl
EB ........ Med. Blue K n i t & Vinyl
EB ........ Med. Blue Cloth & Vinyl
ED ........ Dk. Red Cloth & Vinyl
EF .........Med. Ginger Cloth & Vinyl
EG ........ Dk. Ivy Green K n i t & Vinyl
EG ........ Med. Ivy Green Cloth & Vinyl
EW ........White K n i t & Vinyl
EW ........White w/Black K n i t & Vinyl
EY ......... Lt. Nugget Gold Cloth & Vinyl
FA ......... Black Vinyl
FA .........White Vinyl W i t h Black
FA .........White W i t h Black Leather w/Vinyl
FB ........Med. Blue Vinyl
FB ........ White Vinyl W i t h B l u e
FD ........ Dk. Red Vinyl
FD ........ White Vinyl W i t h Red
FD ........ Dk. Red Cloth & Vinyl
FF .........White Vinyl W i t h Ginger
FF .........Med. Ginger Vinyl
FG ........ Med. Ivy Green Vinyl
FG ........ White Vinyl W i t h Dk. Ivy
FY ......... Lt. Nugget Gold Cloth & Vinyl
FZ ......... White Vinyl W i t h Tobacco
GA ........ B l a c k Vinyl
GB ........Med. Blue Vinyl
GD ........ Dk. Red Vinyl
GF ........Med. Ginger Vinyl
G F ........ Med. B r o w n Vinyl
GW ........White Vinyl W i t h Black
HA ......... Black Cloth & Vinyl
HA ......... Black K n i t & Vi'nyl

Index and Vehicle Identification

Code

INTERIOR TRIM CODES (continued)

Trim Schemes

HB ........ Med. Blue Cloth & Vinyl

HD ........Dk. Red Cloth & Vinyl
HG ........ Med. Green Cloth & Vinyl
HY ........Lt. Nugget Gold Cloth & Vinyl
HY ........ Lt. Nugget Gold Knit & Vinyl
JA ......... Black Vinyl
JA ......... Black Knit & Vinyl
JB ......... Med. Blue Cloth & Vinyl
JB .........Med. Blue Vinyl
JD ......... Dk. Red Vinyl
JF ......... Med. Ginger Vinyl
JG ......... Med. Ivy Green Vinyl
JW .........White Vinyl
JW .........White Knit & Vinyl .
JW .........White Vinyl WIBlack
JY ......... Lt. Nugget Gold Vinyl
K A ........Black Vinyl
KA ........Black Knit & Vinyl
KA ........Black Cloth & Vinyl
KA ........ Black Leather& Vinyl
KB ........ Med. Blue Cloth & Vinyl
.
KB ........Dk. Blue Leather & Vinyl
KD ........ Dk. Red Cloth & Vinyl
KD ........ Dk. Red Leather &Vinyl
KF ........ Med. Ginger Leather & Vinyl
KG ........ Med. Ivy Green Cloth & Vinyl
KG ........Dk. Ivy Green Leather & Vinyl
KK ........ Lt. Aqua Leather & Vinyl
KP ........ Med. Grey Leather & Vinyl
KW ........ White Knit & Vinyl With Black
KW ........White Leather & Vinyl
KY .........Lt. Nugget Leather & Vinyl
KY .........Lt. Nugget Gold Vinyl
KY .........Lt. Nugget Gold Knit & Vinyl
KY .........Lt. Nugget Gold Cloth & Vinyl
KY .........Lt. Gold Vinyl
KZ ........ Dk. Tobacco Cloth & Vinyl
KZ ........ Dk. Tobacco Leather & Vinyl
LE ......... Lt & Med. Beige Vinyl
MA........ Black Vinyl
MA........ Black & White Cloth & Black Vinyl
MB ....... Med. Blue Vinyl
MD ....... Dk. Red Vinyl
MD ........ Red & Black Cloth & Red Vinyl
MF ........ Med. Ginger Vinyl
NA ....... Black Vinyl
NA ....... Black Knit & Vinyl
NB ....... Med. Blue Vinyl
NF ....... Med. Ginger Knit & Vinyl
NY ....... Lt. Nugget Gold Vinyl
PA ......... Black Vinyl
PA ......... Black Cloth & Vinyl
PB ........ Lt. Blue Vinyl
PB ........ Lt. Blue Cloth & Vinyl
PD ....... Dk. Red Cloth & Vinyl
PF ......... Med. Ginger Cloth & Vinyl
PY ......... Lt. Nugget .Gold Vinyl
PY ......... Lt. Nugget Gold Cloth & Vinyl
QA ........ Black Knit & Vinyl
QB ........ Med. Blue Knit & Vinyl
Q D .......
'
Dk. Red Knit & Vinyl
QW....... White Knit & Vinyl With Black
RA ........ Black Vinyl
RA ....... Black Grain Leather Vinyl
RA ....... Black Knit & Vinyl
RA ....... Black & White Cloth & Black Vinyl
RB ....... Med. Blue Vinyl
RB ....... Med. Blue Knit & Vinyl
RD ....... Dk. Red Vinyl
RD ....... Red & Black Cloth & Red Vinyl
RD ....... Dk. Red Knit & Vinyl
RF ....... Med. Ginger Vinyl
RF ....... Med. Brown Vinyl

INTERIOR TRIM CODES (continued)

Code
Trim Schemes
RG ........ Med. Green Vinyl
RG ........ Med. Ivy Green Knit & Vinyl
RW ........White Vinyl With Black
RW ........ White'Knit & Vinyl With Black
RZ ........ Dk. Tobacco Leather & Vinyl
SA ......... Black Vinyl
SA ......... Black & White, Cloth & Black Vinyl
SB ........ Med. Blue Vinyl
SD ........ Red & Black Cloth & Red Vinyl
SD ........ Dk. Red Vinyl
SF ......... Med. Ginger Vinyl
SG ........Med. Ivy Green Vinyl
.
SW ........ White Vinyl With Black
TA ......... Black Cloth & Vinyl
TA .........Black Knit & Vinyl
TA ......... Black & White Cloth & Black Vinyl
TB ........ Med. Blue Knit & Vinyl
TD ........ Dk. Red Cloth & Vinyl
TD ........ Dk. Red & Black Cloth & Dk. Red Vinyl
TD ........ Dk. Red Knit & Vinyl
TF ......... Med. Ginger Cloth & Vinyl
TF ......... Med. Brown Cloth & Vinyl
TG ........Med.& Lt. Ivy Green Knit & Vinyl
TW ........ White Knit & Vinyl
TW ........ White With Black Knit & Vinyl
TY ......... Lt. Nugget Gold Knit & Vinyl
UA ........ Black Knit & Vinyl
UA ........ Black Vinyl
UA ........ Black Grain Leather
UB ........ Med. Blue Vinyl
UD ........ Dk. Red Grain Leather
UE ........ Vermilioncloth & Vinyl
UF ........ Med: Ginger Cloth & Ginger Vinyl
UW ........ White Knit & Vinyl With Black
UW ........ White Vinyl
UY ........ Lt. Gold Vinyl
UY ........ Lt. Nugget Gold Knit & Vinyl
UY ........ Lt. Nugget Gold Vinyl
UZ ........ Dk. Tobacco Grain Leather
VA ......... Black Knit & Vinyl
VA .........Black Vinyl
VB ........ Med. Blue Vinyl
VD ........ Dk. Red Cloth & Vinyl
VD ........ Dk. Red Vinyl
VF ......... Med. Brown Vinyl
VF ......... Med. Ginger Vinyl & Cloth
VF ......... Med. Ginger Vinyl
VF ......... Med. Ginger Knit & Vinyl
VG ........ Med. Ivy Green Vinyl
VW ........ White Vinyl
WA ........ B l a c k K n i t & Vinyl
WA ........ Black Vinyl
WA ........ Black Cloth & Vinyl
WB ........ Med. Blue Cloth & Vinyl
WD ........ Dk. Red Cloth & Vinyl
WF ........ Med. Ginger Cloth & Vinyl
WF ........Med. Brown Cloth & Vinyl
WG ........Med. Ivy Green Cloth & Vinyl
WW ....... White Knit & Vinyl With Black
WY ........ Lt. Nugget Gold Vinyl
WY ........ Lt. Nugget Gold Knit & Vinyl
YA ......... Black Knit & Vinyl
YA ......... Bla'ck Cloth & Vinyl
YB ........ Med. Blue Knit & Vinyl
YD ........ Dk. Red Knit & Vinyl
;YF ......... Med. Ginger Knit & Vinyl
YG ........ Med. Ivy Green Cloth & Vinyl
YG ........ Med. Ivy Green Knit & Vinyl
YW ........ White Knit & Vinyl With Black
W ......... Lt. Nugget Gold Cloth & Vinyl
ZA .........Black Cloth & Vinyl
ZG ........ Dk. Ivy Green Cloth & Vinyl
ZG ........ Med. Green Cloth & Vinyl

DATE CODES
A number signifying the date preceeds
the m o n t h code letter. A second-year code
letter w i l l be used i f the m o d e l exceeds I 2
months.

Month

January ..................
February ................
March ....................
Apiil ......................
May .......................
June .......................
July ........................
August ...................
September .............
October .................
November ..............
December ..............

Code
First Year

Code
Second
Year

A ....................
B ....................
C ....................
D ...................
E ....................
F ....................
G ....................
H ...................
J ....................
K ....................
L ....................
M ...................

N
P

!S
T
U
V
W
X
Y
Z

DISTRICT CODES (DSO)

U n i t s b u i l t o n a Domestic Special Order, Foreign Special Order, o r other Special orders w i l l have the completc order
number i n this space. A l s o t o appear i n
this space is the two-digit code number o f
the District which ordered the unit. I f the
u n i t i s a regular production unit, o n l y the
District code number w i l l appear.
FORD
Code

District

11 ...................... Boston
13 ...................... New York
15 ...................... Newark
16 ...................... Philadelphia
17 ...................... Washington
21 ...................... Atlanta
22 ...................... Charlotte
24 ...................... Jacksonville
25 ...................... Richmond
28 ...................... Louisville
32 ...................... Cleveland
33 ...................... Detroit
35 ...................... Lansing
37 ...................... Buffalo
38 ...................... Pittsburgh
41 ...................... Chicago
43 ...................... Milwaukee
44 ...................... Twin Cities
46 ...................... Indianapolis
47 ...................... Cincinnati
51 ...................... Denver
53 ...................... Kansas City
54 ...................... Omaha
55 ...................... St.Louls
56 ...................... Davenport
61 ...................... Dallas
62 ...................... Houston
63 ...................... Memphis
64 ...................... New Orleans
65 ...................... Oklahoma C~ty
7 1...................... Los Angeles
72 ...................... San Jose
73 ...................... Salt Lake City
74 ...................... Seattle
75 ...................... Phoenix
83 ...................... Government
84 ...................... Home Office Resewe
85 ...................... American Red Cross
89 ...................... Transportation Sewices
90-99 ................. Export

10-0 1-07

Index and Vehicle Identification

LINCOLN-MERCURY

FORD OF'CANADA

Code

District

11....................... B6ston
15 ...................... New York
16 ...................... Philadelphia
17 ...................... Washington
21 ...................... Altanta
22 ...................... Dallas
23 ...................... Jacksonville
26 ...................... Memphis
3 1 ...................... Buffalo
32 ...................... Cincinnati
33 ..................... Cleveland
34 ...................... Detroit
41 ...................... Chicago
42 ...................... St. Louis
46 ...................... Twin Cities
51 ...................... Denver
52 ...................... Los Angeles
53 ...................... Oakland
54 ...................... Seattle
84 ...................... Home Office Resene
90 ...................... Export

Code

10-0 1-07

District

B1 ..................... Central

82...................... Eastern
6 3 ....................... Atlantic
I1 thru I7.......... Export
64 ...................... Midwestern
66 ...................... Western
67 ...................... Pacific
Note: Canadian Lincoln-Mercury units use prefix
" A in place of "6"

GROUP

PART 1 1 - 0 1

PAGE PART 1 1-03

General Wheels a n d Tires

Service

Tires

...............................................11-01-01

.............................................

PAGE
1 1-03-0 1

PART 1 1 - 0 2
Wheels

...................................................1 1-02-0 1

PART 11-01 General Wheels and Tires Service

C O M P O N E N T INDEX
'This Information Applies
to All Models
FRONT WHEEL BEARING
MAINTENANCE
T I RE INSPECTION

All
Models

01-01
01-02

COMPONENT INDEX
This information Applies
to All Models
WHEEL BALANCING
WHEEL INSPECTION

All
Models

01-01
01-01

A page number indicates that the item is for the vehicle(s) listed at the head of the column.
N/A indicates that the item is not applicable to the vehicle(s) listed.

C O M M O N ADJUSTMENTS A N D REPAIRS

WHEEL BALANCING
See the instructions provided with
the Rotunda Wheel Balancer.
Make certain that the brakes are
not dragging before attempting to
spin the wheels. Push the brake shoes
into the caliper to free the rotor.

WHEEL INSPECTION
Wheel hub nuts should be inspected
and tightened to specification a t predelivery. Loose wheel hub nuts may
cause shimmy and vibration. Elongated stud holes in the wheels may also
result from loose hub nuts.
Keep the wheels and hubs clean.
Stones wedged between the wheel and

drum and lumps of mus or grease can

unbalance a wheel and tire.
Check for damage that would affect the runout of the wheels. Wobble
or shimmy caused by a damaged
wheel will eventually damage the
wheel bearings. Inspect the wheel
rims for dents that could permit air
to leak from the tires.

FRONT WHEEL BEARING

MAINTENANCE
Wheel bearings are adjustable to
correct for bearing and spindle shoulder wear. Satisfactory operation and
long life of bearings depend on proper
adjustment and correct' lubrication. If
bearings are adjusted too tightly, they
will overheat and wear rapidly. An

General Wheels And Tires Service

adjustment that is excessively loose

will cause pounding and contribute to
uneven tire wear, steering difficulties
and inefficient brakes. The bearing
adjustment should be checked at regular inspecthn intervals.
Front hhbs and bearings should be
cleaned, inspected and lubricated
whenever the hubs are removed o r at

the mileageltime periods indicated in

the maintenance schedule.
New hub grease seals should be installed when the hub is removed. An
imperfect seal may permit bearing lubricant to reach the brake linings resulting in faulty brake operation and
necessitating premature cleaning or
replacement of linings.

TIRE INSPECTION

Incorrect wheel alignment can

cause tire wear. Abnormal or excessive tire wear can also be caused by
wheelltire unbalance or incorrect tire
pressure. Typical tire wear patterns
are shown in Fig. 1.

11-01-03

General Wheels And Tires Service

STONE BRUISE

STONE BRUISE

BRUISE

NG. I-Tire

Wear Conditions

UNDERINFLATION

H E A T BRUISE

ROCK CUT

11-01-03

1 1-02-01

Wheels

,-

11-02-01

A R T 11-02 Wheels
C O M P O N E N T INDEX
Applies T o Models
As Indicated

I
1

II
I

1
1

I
I

FRONT HUB A N D D R U M
I
ASSEMBLY
Removal and Installation
02-05
FRONT H U B AND ROTOR
ASSEMBLY
Removal and Installation
02-05 02-05
FRONT WHEEL ASSEMBLY
02-0 1
Description
FRONT WHEEL BEARING
'
0242
ADJUSTMENT
F R O N T WHEEL GREASE SEAL
A N D BEARING
Removal. Ihstallation. R e ~ a c k i n e 10243 1
I
HOISTING INSTRUCTIONS
10242 1
R E A R W H E E L ASSEMBLY
Description
102-01 1
WHEEL A N D T I R E (CONVEN- 1
1

Removal and Installation

102-031
I
I
I
A page number indicates that the item is for the vehicle(s) isted at the head of the column.
N/A indicates that the item is not applicable to the ;ehicle(s) listed.

DESCRIPTION

FRONT WHEEL ASSEMBLY

Each front wheel and tire is bolted
to its respective front hub and brake
drum or rotor assembly. Two opposed tapered roller bearings are inretainer
stalled ii each hub. A
is installed a t the inner end of the hub
to prevent lubricant from leaking into
the drum or on the rotor. The entire
assembly is retained to its spihdle by
the adjusting nut, nut lock and cotter
pin (Figs. I and 2).
r .

'

REAR WHEEL ASSEMBLY

The rear wheel hub and brake
drum assembly is attached to studs on
the rear axle shaft flange by three
speed nuts. The wheel and tire
mounts on the same rear axle shaft
flange studs and is held against the
hub and drum by the wheel nuts. The
rear wheel bearing is pressed onto the
axle shaft just inside the shaft flange,
and the entire assembly is retained to
the rear axle housing by the bearing
retainer plate which is bolted to the
housing flange.

FIG. I-Front

Hub, Bearing and Grease Retainer Drum Brakes

11-02-02

11-02-02

Wheels

F1416-A

FIG. 2-Front Hub and Rotor Bearing and Grease Retainer Disc
Brakes-Typical

IN-VEHICLE ADJUSTMENTS A N D REPAIRS

HOISTING INSTRUCTIONS

Damage to steering linkage components and front suspension struts may

occur if care is not exercised when
positioning the hoist adapters of 2
post hoists prior to lifting the vehicle.
If a 2 post hoist is used to lift the
vehicle, place the adapters under the
lower arms or the No. I crossmember. Do not allow the adapters to contact steering linkage. If the adapters
are placed under the crossmember, a
piece of wood ( 2 x 4 ~ 1 6inches) should
be placed on the hoist channel between the' adapters. This will prevent
the adapters from damaging the front
suspension struts.
FRONT WHEEL BEARING
APJUSTMENT
. .
The front wheel bearings should be
adjusted 'if the wheel is loose on the
spindle or if the wheel does not rotate
freely. The following procedures will
bring the! bearing adjustment to specification.

DRUM BRAKES

1. Raise the vehicle until the wheel

and tire clear the floor.
2.- Pry off the hub cap or wheel
cover and remove the grease cap (Fig.
1) from the hub.
3. Wipe the.excess grease from the
,.

WITH WHEEL ROTATING

T(I1QUE ADJUSTING NU+,
TO 17-25 FT. LBS.

FIG. 3-Front

TIGHTEN ADJUSTING
NUT TO 1 Cb15 IN..LBS.

BACK ADJUSTING
NUT OFF 1/2 TURN

INSTAL

L~CK
AND A NEW C.OTTER PIN

Wheel Bearing Adjustment

end of the spindle, and remove the

cotter pin and nut lock.
4. While rotating the wheel, hub,
and drum assembly, torque the adjusting nut to 17-25 ft-lbs to seat the
bearings (Fig. 3).
5. Locate the nut lock on the adjusting nut so that the castellations on
the lock are aligned with the cotter
pin hole in the spindle.
6. Using a 1 t/8-inch box wrench,
back off the adjusting nut one half
turn. Retighten the adjusting nut to
10-15 in-lbs with a torque wrench or
finger tight.
7. Position the lock on the adjusting nut and install a new cotter pin.
Bend the ends of the cotter pin around the castellated flange of the nut
lock.
8. Check the front wheel rotation.

If the wheel rotates properly, install

the grease cap and the hub cap or
wheel cover. If the wheel still rotates
roughly or noisily, clean, inspect or
replace the bearings and cups as required.
DISC BRAKES
1. Raise the vehicle until the wheel
and tire clear the floor.
2. Pry off the wheel cover and
remove the grease cap (Fig. 2) from
the hub.
3. Wipe the excess grease from the
end of the spindle, and remove the
adjusting nut cotter pin and nut lock.
4. Loosen the bearing adjusting nut
three turns. Then, rock the 'wheel,
hub, and rotor assembly in and-out
several times to push' the shoe and

Wheels

linings away from the rotor.

5. While rotating the wheel, hub,
and rotor assembly, torque the adjusting nut to 17-25 ft-lbs to seat the
bearings (Fig. 3).
6. Back the adjusting nut off one
half turn. Then, -retighten the. adjusting nut to 10-15 in-lbs with a torque
wrench or finger tight.
7. Locate the nut lock on the ad-

justing nut so that the castellations on

the lock are aligned with the cotter
pin hole in the spindle.
8. Install a new cotter pin, and
bend the ends of the cotter pin around the castellated flange of the nut
lock:
9. Check. the front wheel rotation.
If the wheel rotates properly, install

the grease cap and the hub cap or

wheel cover. If the wheel still rotates
roughly or noisily, clean or replace
the bearings and cups as required.
10. Before driving the vehicle,
pump the brake pedal several times to
obtain normal brake lining to rotor
clearance and restore normal brake
. pedal travel.

REMOVAL AND INSTALLATION

HOISTING INSTRUCTIONS

vent the adapters from damaging the

front suspension struts.

Damage to steering linkage components and front suspension struts may

occur if care is not exercised when
positioning the hoist adapters of 2
post hoists prior to lifting the vehicle.
If a 2 post hoist is used to lift the
vehicle, place the adapters under the
lower arms or the No. I crossmember. Do not allow the adapters to contact the steering linkage. If the adapters are placed under the crossmember; a piece of wood ( 2 x 4 ~ 1 6inches)
should be placed on the hoist channel
between the adapters. This will pre-

WHEELS A N D TIRES
WHEEL AND T I R E
REMOVAL

1. Pry off the wheel hub -cap or

wheel cover. Loosen but do not remove the wheel hub nuts.
2. Raise the vehicle until the wheel
and tire clear the floor.
3. Remove the wheel hub nuts
from the bolts, and pull the wheel and

tire from hub and drum.

WHEEL AND TIRE
INSTALLATION

1. Clean all dirt from the hub and

drum.
2. Position the wheel and tire on
the hub and drum. Install the wheel
hub nuts and tighten them alternately
to draw the wheel evenly against the
hub and drum.
3. Lower the vehicle to the floor,
and torque the hub nuts to specification.

MAJOR REPAIR OPERATIONS

HOISTING INSTRUCTIONS
Damage to steering linkage components and front suspension struts may
occur .if care is not exercised when
positioning the hoist adapters of 2
post hoists prior to lifting the vehicle.
If a 2 post hoist is used to lift the
vehicle, place the adapters under the
lbwer arms or the No. I crossmember. Do not allow the adapters to contact the stkring linkage. If the adapters are placed under the crossmember, a piece of wood ( 2 x 4 ~ 1 6inches)
should be placed on the hoist channel
between the adapters. This will prevent the adapters from damaging the
front suspension struts.
FRONT WHEEL GREASE SEAL A N D
BEARING REMOVAL,
INSTALLATION AND/OR
REPACKING
If

bearing

adjustment

will. not

eliminate looseness or rough . and

noisy operation, the hub and bearings
should be cleaned, inspected, and repacked with specified wheel grease. If
'the bearing cups or the cone and roller assemblies are worn or damaged,
they should be repladed.
D R U M BRAKES
1. Raise the vehicle until the wheel
and tire clear the floor.
2. Remove the wheel cover or hub
cap. Remove the grease cap from the
hub. Remove the cotter pin, nut lock,
adjusting nut, and flat washer from
the spindle. Remove the outer bearing
cone and roller assembly (Fig. I).
3. Pull the wheel, hub, and drum
assembly off the wheel spindle.
4. Remove the grease retainer with
Tool 1175AB and discard: Remove
the inner bearing cone and roller, assembly from the hub.
5.. Clean the lubricant off the inner

and outer bearing cups with solvent

and inspect the cups for scratches,
pits, excessive wear, and other damage. If the cups are worn or damaged,
remove them with Tool T69L- 1102-A
(Fig. 4).
6. Thoroughly clean the inner and
outer bearing cone and roller assemblies with solvent and dry them thoroughly. Do not spin the bearings with
compressed air.
Inspect the cone and roller assemblies for wear or damage, and replace
them if necessary. The cone and roller
assemblies and the bearing cups
.should be replaced as a unit if damage to either is encountered.
7. Thoroughly clean the spindle
and the inside of the hub with solvent
to remove all old lubricant.
Cover the spindle with a clean
cloth, and brush all loose dust and
dirt from the brake assembly. T o prevent getting dirt on the spindle, carefully remove the cloth from the

Wheels

spindle.

8. If the inner and/or outer bearing cup(s) were removed, install the
replacement cup(s) in the hub with
the tool shown in Fig, 5. Be sure to
seat the cups properly in the hub.
9. Pack the inside of the hub with

specified wheel bearing grease. Add

lubricant to the hub only until the
grease is flush with the inside diameter of both bearing cups (Fig. 6).
10. All old grease should be completely cleaned from the bearings and
surrounding surfaces before repacking
t h e m with new grease ( C I A Z 19590-B). The new lithium base
grease is not compatible with sodium
base grease which may have been
present on the bearing surfaces. Pack
the bearing cone and roller assemblies

with wheel bearing grease. A bearing

packer is desirable for this operation.
If a packer is not available, work as
much lubricant as possible between
the rollers and cages. Lubricate the
cone surfaces with grease.
11. Place the inner bearing cone
and roller assembly in the inner cup.
Apply a light film of grease to the
lip(s) of the grease retainer and install
the new grease retainer with the reverse end of the tool shown in Fig. 5.
Be sure that the retainer is properly
seated.
12. Adjust the brake shoes as out-

lined in Group 12.

13. Install the wheel, hub, and
drum assembly on the wheel spindle.
Keep the hub centered on the spindle
to prevent damage to the grease retainer or the.spindle threads.
14. Install the outer bearing cone

and roller assembly and the flat washer on the spindle, then install the adjusting nut (Fig. 1).
15. Adjust the wheel bearings as
outlined in Section 2, and install a
new cotter pin. Bend the ends of the
cotter pin around the castellations of
the nut lock to prevent interference
with the radio static collector in the
grease cap. Install the grease cap.
16. Install the hub cap or wheel
cover.
D I S C BRAKES

1. Raise the vehicle until the wheel

and tire clear the floor.

2. Remove the wheel cover or hub
cap from the wheel.
3. Remove the wheel and t k e f ~ o m
the hub and rotor.
4. Remove 2 bolts and washers
that attach the caliper to the spindle.
Remove the caliper from the rotor
and wire it to the underbody to prevent damage to the brake hose.
5. Remove the grease cap from the
hub. Remove the cotter pin, nut lock,
adjusting nut, and flat washer from
the spindle. Remove the outer bearing
cone and roller assembly (Fig. 2).
6. Pull the hub and rotor assembly
off the wheel spindle.
7. Remove and discard the old
grease retainer and the inner bearing
cone and roller assembly from the
hub.
8. Clean the lubricant off the inner
and outer bearing cups with solvent
and inspect the cups for scratches,
pits, excessive wear, and other damage. If the cups are-worn or damaged,
remove them with Tool T69L- 1102-A
(Fig. 4).
9. Thoroughly clean the inner and
outer bearing cones and rollers with
cleaning solvent, and dry them thoroughly. D o not spin the bearings dry
with compressed air.
Inspect the cones and rollers for
wear or damage, and replace them i f
necessary. The cone and roller assemblies and the bearing cups should be
replaced as a set if damage to either
is encountered.
10. Thoroughly, ,-clthn the spindle

and the inside..,of"ihe hub with solvent

to remove .@old lubricant.
Cover, ,;the spindle with a clean
cloth, aid brush all loose dust and
dirt from the dust shield. To prevent
getting dirt on the spindle carefully
remove the cloth from the spindle.
11. If the inner and/or outer bear-

FIG. 4-Removing Front Wheel

Bearing Cups-Disc (Drum-Type
Similar)

ing cup(s) were removed, install the

replacement cup(s) in the hub with
the tools shown in Fig. 7. Be sure to
seat the cups properly in the hub.
12. Pack the inside of the hub with

the specified wheel bearing grease.

Add lubricant to the hub only until
the grease is flush with the inside diameter of both bearing cups.

INNER CUP
INSTALLATION

I t is important that all old grease

be removed from the wheel bearings
and surrounding surfaces because the
new Lithium base grease C l A Z 19590-B is not compatible with Sodium base grease which ,may already be
present on the bearing surfaces.
13. Pack the bearing cone and roll-

OUTER CUP
INSTALLATION

FIG. 5-Installing Front Wheel

Bearing Cups-Drum

FIG. 6-Front
Lubrication

Wheel Hub

er assemblies with wheel bearing

grease. A bearing packer is desirable

1 1-02-05

FIG. 7-Installing

Wheels

Front Wheel

Bearing Cup-Disc
new cotter pin. Bend the ends of the
cotter pin around the castellations of
the nut lock to prevent interference
with the radio static colletor in the
grease cap. Install the grease cap.
18. Install the caliper to the spindle
and torque the attaching bolt; to specifications as detailed in Group 2.
19. Install the wheel and tire on
the .hub.
20. Install the hub cap or wheel
cover.
21. Before driving the vehicle.
pump the brake pedal several times to
obtain normal brake lining to rotor
clearance and restore normal brake
pedal travel.
F1443-A

FIG. 8-Installing

hiease

Retainer-Disc
for this operation. If a packer is not
available, work as much lubricant as
possible between the rollers and
cages. Lubricate the cone surfaces
with grease.
14. Place the inner bearing cone
and roller assembly in the inner cup.
Apply a light film of grease to the
lips of the grease retainer and install
the new grease retainer with the tool
shown in Fig. 8. Be sure the retainer
is properly seated.

15. Install the hub and rotor assembly on the wheel spindle. Keep the
hub centered on the spindle to ptevent
damage to the grease retainer or the
spindle threads.

16. Install the outer bearing cone

and roller assembly and the flat washer on the spindle, then install the adjusting nut.
17. Adjust the wheel bearings as
outlined in Section 2. and install a

FRONT HUB A N D DRUM

ASSEMBLY REMOVAL A N D
INSTALLATION
When the hub and drum assembly
is replaced, new bearings and a grease
retainer must be installed in the new
assembly. The new grease retainer
should be soaked in light engine oil at
least 30 minutes before installation.
1. Raise the vehicle until the wheel
and tire clears the floor. Pry off the
hub cap or wheel cover, and remove
the wheel and tire from the hub and
drum assembly.
2. Remove the grease cap from the
hub. Remove the cotter pin, nut lock
adjusting nut, and flat washer from
the spindle. Remove the outer bearing
cone and roller assembly (Fig. I).
3. Pull the hub and drum assembly
off the wheel spindle.
4. Remove the grease retainer and
the inner bearing cone.and roller assembly from the hub with Tool
1175AB.
5. Remove the protective coating

from the new hub and drum with carburetor degreaser.

6. Pack the inside of the hub with
specified wheel bearing grease. Add
lubricant to the hub only until the
grease is flush with the inside diameter of both bearing cups (Fig. 6).
7. All old grease should be completely cleaned from the bearings
before repacking them with new
grease. Pack the bearing cone and
roller assemblies with wheel bearing
grease. A bearing packer is desirable
for this operation. If a packer is not
available, work as much lubricant a s
possible between the rollers and
cages. Lubricate the cone surfaces
with grease.
8. Place the inner bearing cone and
roller assembly in the inner cup, and
install the new grease retainer with
the reverse end of the tool shown in
Fig. 5. Be sure that the retainer is
properly seated.

9. Adjust the brake shoes as outlined in Group 12.

10. Install the new hub and drum
assembly on the wheel spindle. Keep
the hub centered on the spindle to
prevent damage to the grease retainer.

11. Install the outer bearing cone

and roller assembly and the flat washer on the spindle; then, install the adjusting nut (Fig. I).
12. Position the wheel and tire on
the new hub and drum assembly. Install the wheel hub nuts and tighten
them alternately in order to draw the
wheel evenly against the hub and
drum.
13. Adjust the wheel bearings as
outlined in Section 2, and install a
new cotter pin. Bend the ends of the
cotter pin around the castellations of
the nut lock to prevent interference
with the radio static c o ~ ~ d c t oinr the
grease cap. Install the grease cap.
14. Install the hub cap or wheel
cover.

FRONT H U B A N D ROTOR
ASSEMBLY REMOVAL A N D
INSTALLATION
When the hub and rotor assembly
is replaced, new bearings and a grease
retainer must be installed in the new
assembly.'
1. Raise the vehicle until the wheel
and tire clear the floor. Pry off the
hub cap or wheel cover, and remove
the wheel and tire from the hub and
rotor assembly.
2. Remove 2 bolts and washers
that attach the caliper to the spindle.
Remove the caliper from the rotor
and wire it to the underbody to pre-

1 1-02-06

vent damage to the brake hose.

3. Remove the grease cap from the
hub. Remove the cotter pin, nut lock,
adjusting nut, and flat washer from
the spindle; then, remove the outer
bearing cone and roller assembly,
(Fig. 2).
4. Pull the hub and rotor off the
spindle.
5. Remove the protective coating
from the new hub and rotor with carburetor degreaser.
6. Grease and install the inner
bearing cone and roller assembly in
the inner bearing cup. Apply a light
film of grease on the grease retainer

1 1-02-06

Wheels

and install the grease retainer.

7. Install the new hub and rotor
assembly to the wheel spindle. Keep
the hub centered on the spindle to
prevent damage to the grease retainer.
8. Install the outer bearing cone

and roller assembly and the flat washer on the spindle; then, install the adjusting nut.
9. lnstall the caliper to the spindle
and tighten the attaching bolts to specifications as detailed in Group 12.
10. Position the wheel and tire on
the new hub and rotor. Install the
wheel hub nuts and tighten them alternately in order to draw the wheel

evenly against the hub and rotor.

11. Adjust the wheel bearings as
outlined in Section 2, and install a
new cotter pin. Eend the ends of the
cotter pin around the castellations of
the nut lock to prevent interference
with the radio static collector in the
grease cap. lnstall the grease cap.
12. lnstall the hub cap or wheel
cover.
13. Before driving the vehicle,
pump the brake pedal several times to
obtain normal brake lining to rotor
clearance and restore normal brake
pedal travel.

SPECIAL SERVICE TOOLS

Tool No.

Description

~ E EAB.

Grease Seal Remover (Head Only)

b-'l102-~

Front Wheel Bearing Remover

CF1540-A

1 1-03-01

_/

1 1-03-01

Tires

PART 11-03 Tires

Installation
Removal
Repairs

N/A
N/A
N/A

N/A
N/A
N/A

N/A
N/A
N/A

N/A
N/A
N/A

N / A N / A N / A N / A N / A 03-03 03-03 03-03

N / A N / A N / A N / A N / A 03-03 03-03 03-03
N / A N/A N / A N / A N / A 03-04 03-04 03-04

A page number indicates that the item is for the vehicle(s) listed at the head of the column.
N/A indicates that the item is not applicable to the vehicle(s) listed.

DESCRIPTION
LIFE GUARD TIRE

FIG. I-Life

Guord Sofety
Tire-Sectionol View

The Goodyear Power Cushion Tire

(available on Thunderbird, Lincoln
and Continental Mark I11 models)
fitted with the Life Guard Safety
Spare provides a tire within a tire
with two separate air chambers (Fig.
I). If the outer tire casing should be
punctured or otherwise damaged
causing it to go flat, the Life Guard
Safety Spare will carry the load of
the vehicle and will allow driving at.
speeds up to 40 mph with good control up to a distance of 40 miles. A
~ a f e t i - ~ i ~ nbuilt
al
into the Life
Guard tread produces a lope or vibration indicating the outer tire has lost
pressure.

IN-VEHICLE ADJUSTMENTS AND REPAIRS

HOISTING INSTRUCTIONS
Damage to steering linkage components and front suspension struts may
occur if care is not exercised when
positioning the- hoist adapters of 2
post hoists prior to lifting the vehicle.
If a 2 post hoist is used to lift the

vehicle, place the adapters under the

lower arms or the No. I crossmember. Do not allow the adapters to contact steering linkage.If the adapters
are placed under the crossmember, a
piece of wood ( 2 x 4 ~ 1 6inches) should
be placed on the hoist channel between the adapters. This will prevent

the adapters from damaging the front

suspension struts.
BALANCING LlFE
GUARD TlRE
Tires fitted with the Life Guard
Safety Spare are balanced in the

1 1-03-02

NG. 2-Breaking
Top Bead of
Tire From Wheel Rim
same manner as conventional tires. If
an excessive out of balance condition
exists the following procedure can be
used to correct the'condition:
1. Remove the core housing and

1 1-03-02

Tires

deflate both air chambers.

2. Install the core housing.
3. Unseat the beads of tire with the
bead breakers away from the valve
stem as shown in Fig. 2.
4. Rotate tire casing 90 degrees on
the wheel rim.
5. Rotate the tire casing back and
forth on the rim to center the valve.
6. Inflate both chambers of the tire
following steps 13 through 15 of the
Tire Installation procedure.
7. Balance the tire in the normal
manner.

CORRECTING VIBRATION
AND SHAKELIFE GUARD TlRE
The condition of excessive vibration
and shake is generally the result of an

incorrect pressure relationship between the inner and outer air chambers that may cause the life guard to
shift position within the tire. The following procedure should be used to
correct vibration and shake conditions:
1. Check pressure of the inner and
outer air chambers on all four tires.
2. If the inner chamber has at least
five psi more pressure than the outer
chamber the pressures should be adjusted and the tires rebalanced if
necessary.
3. If the pressures of the inner'and
outer air chambers are equal the Air
Container is leaking. To repair the
leaking air container the recommended procedures for the removal, repair
of air container, mounting, and balancing should be followed.

REMOVAL AND INSTALLATION

HOISTING INSTRUCTIONS
Damage to steering linkage components and front suspension struts may
occur if care is not exercised when
positioning the hoist adapters of 2
post hoists prior to lifting the vehicle.
If a 2 post hoist is used to lift the
vehicle, place the adapters under the
lower arms or the No. 1 crossmember. Do not allow the adapters to contact the steering linkage. If the adapters are placed under the cros'smember, a piece of wood ( 2 x 4 ~ 1 6inches)
should be placed on the hoist channel
between the adapters. This will prevent the adapters from damaging the .,
front suspension struts.

REMOVING CONVENTIONAL TlRE

FROM WHEEL
The tire can be demounted on a
mounting machine. Be sure that the
outer side of the wheel is positioned
downward. If tire irons are used,

follow the procedure given here.

1. Remove the valve cap and core,
and deflate the tire completely.
2. With a bead loosening tool,
break loose the tire side walls from
the wheel (Fig. 3).
3. Position the outer side of the
wheel downward, and insert two tire
irons about eight inches apart between the tire inner bead and the
back side of the wheel rim. Use only

tire irons with rounded edges or irons

designed for removing tubeless tires.
4. Leave one tire iron in position,

and pry the rest of the bead over the

rim with the other iron. Take small
bites with the iron around the tire in
order to avoid damaging the sealing
surface of the tire bead.
5. Stand the wheel and tire upright
with the tire outer bead in the drop
center well at the bottom of the
wheel. Insert the tire iron between the
bead and the edge of the wheel rim,
and pry the wheel out of the tire.

F1414 A

FIG. 3-Bead

Loosening Tool

MOUNTING CONVENTIONAL
TlRE TO WHEEL
1. If a used tire is being installed
remove all dirt from the tire.
If a tire is being mounted to the
original wheel, clean the rim with
emery cloth or fine steel wool. Check
the rim for dents.
If a new wheel is being installed,
coat a new valve with RUGLYDE or
similar rubber lubricant and position
the valve to the new wheel. Use a
rubber hammer or a valve replacing
tool to seat the valve firmly against
the inside of the rim.
2. Apply RUGLYDE or a similar
rubber lubricant to the sealing surface
on both tire beads. With the outer
side of the wheel down, pry the beads
over the wheel rim with two tire
irons. Do not use a hammer or mallet

FIG. 4-Tubeless

Tire Mounting

Band
to force the beads over the rim.

3. Align the balance mark on the

tire with the valve on the wheel.
4. Hold the beads against bhe tim
flanges by positioning a tire mounting
band over the tire (Fig. 4). If a
mounting band is not available, tie a
tourniquet of heavy cord around the
circumference and in the center of the
tire. Tighten the cord with a tire iron.

1 1-03-03

1 1-03-03

Tires

7. Lift the lower bead over the

wheel rim to remove the tire.
8. Remove the rubber valve housing from the wheel rim.

AIR CONTAINER

INSTALLING LlFE GUARD TlRE ON

WHEEL

CORE HOUSING RIDGE

VE GROOVES
F 1382

FIG. 5-Core

-A

Housing Disassembled

FIG. 6-Removing!
Valve Stem

Air Container

FIG. 7-Folding
Life G u a r d For
Installation in Tire

FIG. 8-Aligning

Valve with
Reference Mark on Tire

FIG. 9-Valve

Installation

Center the tire on the wheel with a

rubber mallet.
5. Give the tire a few quick bursts
of air to seat the beads properly, then
inflate the tire to 40 psi pressure.
Check to see. that the bead positioning rings (outer rings near the side
walls) are evenly visible just above the
rim flanges all the way around the
tire. If the rings are not even, deflate
the tire completely and inflate. it
again.
6. When the rings are properly positioned. deflate the tire to the recommended' pressure.
REMOVING LIFE GUARD TIRE
FROM WHEEL

I. Mark the valve stem location on

the tire sidewall.
2. Remove the core housing (Fig.
5) and deflate both air chambers.
3. Unseat the beads of the tire with
the bead breakers working away from
the valve stem (Fig. 2).
4. Starting at the valve stem, work
(he top bead of the tire over the rim
of the wheel.
5. Pull the air container valve stem
out of the rubber valve housing (Fig.
6).
6. Remove the air container before
attempting to remove the tire from
the wheel.

I. A p p l y S i l i c o n e L u b r i c a n t
(COAZ-19553-A) as the, anti-friction
treatment uniformly over the crown
and shoulder area inside the tire or
outside the life guard.
2. Fold the life guard as shown in
Fig. 7.
3. Insert life guard into tire casing.
4. Install a new rubber valve housing on the air container valve stem
and thread the core housing into
place. It is not necessary to install a
new core housing.
5. Insert air container into the life
guard with the valve grooves to the
outboard side of the tire. Place the
valve at the valve stem location
marked on the sidewall during removal as shown in Fig. 8.
6. Apply a soap solution to the
beads and the rubber valve housing.
7. Place the wheel on the mounting
machine with the valve hole away
from bead breakers. Remove all burrs
and sharp edges from valve hole in
rim.
8. Mount first tire bead exercising
care not to'pinch air container.
9. Start valve through hole in rim.
Do not pull valve housing into place
at this time.
10. Mount the second bead starting
just past the valve so the last portion
of the bead goes over the rim at the
valve.
11. Rotate the tire back and forth
to center the valve housing.
12. Pull the valve housing into
place. Make certain that the iubber
valve ridge is visible around the valve
housing (Fig. 9).
13. Tighten the core housing lightly
using pliers.
14. Thread the Inflate-Chek adapter onto the core housing.
15. Inflate the inner chamber to
seat the tire beads exercising care, not
to exceed 45 psi pressure. Adjust this
inner chamber air pressure to 15 psi
higher than the recommended tire
pressure.
16. Remove the Inflate-Chek
adapter and adjust tire (outer chamber) pressure to the recommended
pressure.
17. Recheck inner chamber pressure.
18. Install valve cap.

1 1-03-04

1 1-03-04

Tires

MAJOR REPAIR OPERATIONS

HOISTING INSTRUCTIONS

front suspension struts.

Damage to steering linkage components and front suspension struts may

occur if care is not exercised when
positioning the hoist adapters of 2
post hoists prior to lifting the vehicle.
If a 2 post hoist is used to lift the
vehicle, place the adapters under the
lower arms or the No. 1 crossmember. Do not allow the adapters to contact the steering linkage. If the adapters are placed under the crossmember, a piece of wood ( 2 x 4 ~ 1 6inches)
should be placed on the hoist channel
between the adapters. This will prevent the adapters from damaging. the

LIFE GUARD
TIRE REPAIRS

REPAIR OF OUTER TIRE

Outside Repairs
All outside repairs are made in the
same manner as on conventional
tubeless tires.
Inside Repairs
1. Remove the anti-friction treatment on the inside of the tire with

rubber solvent.
2. Buff the inside area of the tire.
3. Apply a hot cure patch only.

REPAIR OF AIR
CONTAINER
Air containers are repaired in the
same manner as conventional inner
tubes.

REPAIR OF LIFE GUARD

A damaged life guard that may
pinch the air container should be replaced. N o repairs are reqyired for
small punctures in the life guard.

PART 12-0 1

PART 12-03

PAGE

General Brake Service

........................ 12-01-01

Disc Brakes

PART 12-02
Drum Brakes

PAGE

..........................................1 2-03-0 1

PART 12-04

....................................... 12-02-0 1

Parking Brakes

.................................... 1 2-04-0 1

Part 12-01 General Brake Service

COMPONENT INDEX
Applies T o Models
As Indicated

-w

vl

>.

;L

.L
M

,-

P A R K I N GBRAKE CONTROL
Vacuum Release Test

o 1-02
01-02

A page number indicates that the item is for the vehicle(s) listed at the head of the column.
N / A indicates that the item is not applicable to the vehicle(s) listed.

12-01-02

i.

..,

BRAKE SYSTEM TESTS

Always check the fluid level in the

master cylinder before performing the
test procedures. If the fluid level is
not within t/4 inch of the top of the
master cylinder reservoirs, add Ford
Brake Fluid - Extra Heavy Duty-Part Number C6AZ-19542-A (ESAM6C25-A) or equivalent for all brake
applications. The extra heavy duty
brake fluid is colored blue for identification purposes. Do not mix low
temperature brake fluids with the
specified brake fluid.
Should one of the wheel brakes be
locked and the vehicle must be
moved, open the bleeder screw long
enough to let out a few drops of
brake fluid. This bleeding operation
will release the brakes but will not
correct the cause of trouble.
BRAKE PEDAL FREE
HEIGHT AND TRAVEL
MEASUREMENTS
With, the engine running for full
power brake operation and the .parking,brake fully released, measure the
brake b d a l free height, and check the
brake pedal travel with the use of the
Brake Pedal Pressure Gauge, Tool
WRE-500-50 as follows:
BRAKE PEDAL FREE HEIGHT
MEASUREMENT
1. Insert a slender, sharp pointed
prod through the carpet and sound
deadener to the dash panel metal and
measure the distance to the brake
pedal (Fig. 1).
2. If the position of the pedal is
not within specification, check the
brake pedal linkage for missing,
worn, or damaged bushings, or loose
attaching bolts and replace them, if
required.
3. If the-pedal free height is still
out of specification, check the brake
pedal booster or master cylinder to be
sure the correct parts are installed.
Replace the worn or damaged parts
as necessary.

BRAKE PEDAL TRAVEL

MEASUREMENT

G e n e r a l Brake Service

I. Install a Brake Pedal Effort

Gauge on the brake pedal pad (Fig.
2).
2. Hook a steel measuring tape to
the brake pedal as shown in Fig. 1 .
Measure and record the distance from

the brake pedal free height position to

the reference point, which is at the six
o'clock. position on the steering wheel
rim.
3. W i t h the steel tape still hooked
to the brake pedal depress the brake
pedal by pressing downward on the
brake pedal effort gauge. Apply a 50
pound load to the center of the pedal
by observing the pressure gauge, and
measure the distance from' the brake
pedal to the fixed reference, paint on
the steering wheel rim parallel t o the
centerline of the steering ,column.
4. T h e difference between the
brake 'pedal free height ,and the depressed. pedal measurement under a
50 pound load should' be within the
specified maximum pedal travel service specification B in Fig. I.
5. If t h e pedal travel is more than
the specified maximum shown in Fig.
I, dimension C, make. several sharp
reverse stops (equivalent'to 50 pounds
pedal pressure) with a forward stop
before each. 'Move the vehicle in reverse and forward for a distance of approximately ten feet; then, apply the
brakes sharply and hold the brake
pedal down until the vehicle is completely stopped. This will actuate the
brake self-adjusters. If these stops do
not bring the brake pedal travel within specification, make several additional forward and reverse stops as
outlined above.
6. If the second series of stops do
not bring the brake pedal travel within specification, remove the brake
drums and check the brake adjusters
to make sure they are functioning.
Check the brake linings for wear or
damage. Repair or replace all worn
or damaged parts and non-functioning
adjusters. Adjust the brake lining outside diameter to the approximate inside diameter of the' brake drum with
Rotunda Tool HRE-8650 described in
Part 12-02.
7. If all the brake adjusters, brake
drums and. linings are functional and
the brake travel is not within specifications, check the pedal linkage for
missing or worn bushings, or loose attachments. Bleed the brakes and centralize the differential valve.
POWER BRAKE
FUNCTIONAL TEST
1. Check the hydraulic brake
system for leaks or insufficient fluid.
2. With the transmission in neutral,

.
.
stop the eng& a:nd apply the parkirig
brake. .Depress:the brake peaai several times .to exhaust all vacuum in the
system.
3. With the engine sh:ut off sind'all
vacuum in the. system exhausted, depress the, pedal, 'and hold, it irirthe applied position. Stari the engine.,If,,the
vacuum 'system is oper&ting,the p d a l
will tend to fall away under foot piessure arid less. pressure will be required
to hold the pedal in the applied position. I f .no action is fglf,.;the'vacuum
booster system is not functioning.
If' the. brake pedal:-movement feels
spongy, bleed the hydraulic system to
remove air from the-syste@- Refer to
Hydraulic System Bleeding;, in this
Part.

VACUUM TEST S-VACUUM

RELEASE PARKING BRAKES
V'isually check the operation, of the
brake lin'kage as the brake; pedal. is
depressed. Then, check,;$e:;operation
of.the brake linkage when the manual
release lever is activated. These
checks should indicate whether the
manual' parking brake control,linkage
is operating properly or requires, repair or adjustment due to..inability-of
the parking brake to titiold against
moderate vehicle- movenient. Perform
tests of the parking brake system and
controls after -making certain the, linkage, and manual controls operate
properly.
When testing .a parking br.&kevacuum, releasesystem, a minimum of 10
inches of vacuum (Hg.). should be
available at all points where vacuum
is applied. This can be checked ,with a
Rotunda Fuel Pump Tester Gauge
(ARE345) and two Distr.itiutor Tester
hose adapters (Marked, Q) connected
together. with a coupling. This ,allows
the Fuel Pump Tester Gauge hose to
be adapted to any other vacuum hose
or rubber connector in the vacuum
systems.
Failure to maintain 1 0 ,inches of
vacuum (Hg.) during vacuum system
tests could be caused by a loose hose
connection, resulting in a vacuum
leak. When checking for vacuum between two points, trace the hose along
the entire routing to be sure it is not
crossed with another hose and connected to the wrong connection.
All of the vacuum parking brake
control checks are to be performed
with the engine running a t idle speed.
,

,,

General Brake Service

LINCOLN. MARK 111 T'BIRD

MEASURED FROM CENTER
LINE OF CURVED PEDAL

& \;n

SURFACE

STEEL MEASURING TAPE

FORD. MERCURY METEOR

MAVERICK

VEHICLE

E E R C U R Y ANDMETEOR

MONTEGO FAIRLANE FALCON

TYPE

N O N ~ DRR W

8.09.7.17

FORD, MERCURY AND METEOR

NOH-POWER DISC

8.65 7.82

FORD,MERCURYANDMETEOR

POLICE POWER DISC

7.58-6.72

FAIRLANE AND MONTEGO

NON-POWER D R W

8 . 3 2 7.02

FAIRLANE AND MONTEGO

POWER DISC

7.67- 6.52

MUSTANG AND COUGAR

NON-POWER D R W

7.49.6.43

MUSTANGANDCOUGAR

POWER DISC

6.55-5.88

THUNDERBIRD

POWER DISC

CONTINENTAL
LINCOLN

MARK Ill

POWER DISC

CONTINENTAL

POWER DISC

PEDALFG
1
HEIGHT- B

PEDAL FREE
HEIGHT-A

TRAVEL-C

7.39

- 6.62

3.10

3.27

STD. DRUM

7.42

6.45

POLICE DRUM

7.67

6.52

2.20

MONTEGO

POLICE DISC

8.40

7.25

2.80

FALCON

STO. DRUM

8.13

6.91

2.90

MAVERICK
MDNTEGO

2.90

NOTE: A 8 B DIMENSION TO BE MEASURED TOSHEET METAL

C DIMENSION TO BE MEASURED PARALLEL TO THE VERTICAL CENTERLINE OF THE
STEERING COLUMN WlTH A 50 POUND LOAD APPLIED TO THE CENTERLINE OF THE
BRAKE PEDAL PAD. (CHECKS ON POWER BRAKE VEHICLES MADE WlTH ENGINE RUNNING)

MUSTANG COUGAR

FIG. I-Brake

Pedal Height and Travel

Measurements

12-0 1-04

General Brake Service

the vacuum gauge. Connect two distributor tester vacuum hose adapters
together with a coupling a s a connector to attach the gauge. A minimum
of ten inches of vacuum is required t o
actuate the parking brake vacuum
motor. If a minimum reading is not
present when checking each of the
aforementioned components, they
must be replaced.
P A R K I N G BRAKE
OPERATION

FIG. 2-Brake

P e d a l Effort G a u g e Installed

Leaks in the parking brake hoses

or a disconnected or improperly connected hose can usually. be\fourtd. by
listening for a hissing sound along the
hose routines. U n d e r no circumstances should air pressure be -applied t o
the yacuum system a s th6.actuator diaphragm in the parking brake vacuum motor may be damaged.
1. Start the engine and. run it a t
idle speed. With the transmission shift
control in neutral, depress the parking
brake pedal to apply the parking
brake. Move the transmission shift
control to D range and observe the

parking brake pedal to see that the

pedal moves upward and the parking
brake releases. I f the parking brake
releases. the parking brake vacuum
control is working properly.
2. I f the parking brake does not release, test for vacuum at the back-up
light switch mounted on the steering
column and the vacuum lines to the
parking brake release vacuum motor.
Use the Rotunda Vacuum and Fuel
Pump Tester 345. This can be accomplished by removing the hose from
each component and: attaching it to

Check the operation of the parking

brake. With the vehicle on a hoist and
the parking brake fully released, the
cables should not have any slack.
Also, the rear brakes should not drag
when the wheels are turned. I f either
of the above'conditions exist, adjust
as required.
ROAD TEST
A road test should be conducted
only when the operator is sure the
brakes will stop the vehicle.
I f the road test reveals one o r more
problem conditions, correct all malfunctions of the vacuum system,
brake booster and hydraulic system
prior t o removing brake drums, brake
calipers, brake shoes and linings o r
backing plates.

.
2

C O M M O N ADJUSTMENTS A N D REPAIRS

POWER BRAKE MASTER

CYLINDER PUSH ROD
ADJUSTMENT

The push rod is provided with an

adjustment screw to maintain the correct relationship between the booster
control valve plunger and the master
cylinder. I f the plunger is t o o long it
will prevent the master cylinder piston
from completely releasing hydraulic
pressure and can cause the brakes to
drag. I f the plunger is too short it will
result in excess pedal travel and an
undesirable clunk in the booster area.
The adjustment-screw is set t o the
correct height a t the time of original
assembly of the power' unit. Under
normal service the adjustment screw
does not require any further attention
providing the original push rod assembly remains in the original unit.
I f a check of the push rod adjust-

ment is necessary, the push rod length

may be verified with a push rod
length gauge and measured with the
engine running to apply vacuum to
the booster (Fig. 3).
The push rod length verification
and adjustment of Midland-Ross
power brake booster assemblieb must
be done according to the following
procedure:
I. Disconnect the master cylinder
from the booster assembly and secure
it away from the booster without disconnecting the brake tubes.
2. Reinstall. the air filter assembly
on the booster i f it was removed with
the master cylinder (Fig. 4).
3. Install and tighten the master
cylinder retaining nuts to retain the
air filter assembly securely against the
booster body and t o seal the booster
bellows against air leaks.
4. Place the gauge against the

#I6 U.S.S. GAUGE SHEET STEEL

b-2-7.'6"-4

q+

H1087-E

FIG. 3-Push

Rod G a u g e Dimen-

sions
master cylinder mounting surface of
the air filter assembly.
5. Adjust the push rod screw to
provide a slight tension against the
inner edge of the adjustment gauge
slot. (Approximately 5 pounds of ten-

General Brake Service

MANIFOLD CHECK VALVE-2365 19.25

IN. LB.

FIG. 5-Wrench
f o r Bleeding
Brake Hydraulic System
down slowly through its full travel.
Close the bleeder fitting and return
the pedal to the fully released position. Repeat this operation until fluid
is free of air bubbles, then tighten the
bleeder screw. D o not use the second-

PUS+^ mD ADJUSTMENT-BENMX

PUSH ROD ADJUSTMENTMIDLAND- ROSS

FIG. 4-Brake

Booster Push Rod Measurement

sion against the push rod is required

to assure that the push rod is firmly
seated in the booster assembly).
6. Remove the retaining nuts from
the booster master cylinder mounting
studs.
7. Install the master cylinder on
the brake booster and tighten the retaining nuts to the specified torque.
The push rod length verification of
the Bendix power brake booster
assemblies is accomplished as follows:
1. Disconnect the master cylinder
from the booster assembly and secure
away from the booster without disconnecting the brake tubes.
2. Adjust the push rod screw to
provide a slight tension against the
inner edge of the adjustment gauge
slot. (Approximately 5 pounds of tension against the push rod is required
to assure that the push rod is firmly
seated in the booster assembly). See
Figure 4.
3. Install the master cylinder on
the brake booster and tighten the retaining nuts to the specified torque.
D o not set up side forces on the
push rod as it may break the valve
plunger.
This is an approximate adjustment
only. T o verify the adjustment, look

through the make-up (rear) port of

the master cylinder when installing
the master cylinder to the booster.
The master cylinder piston should not
move more than 0.015 inch as it contacts the push rod. No movement
(exact contact) is ideal.

HYDRAULIC SYSTEM BLEEDING

When any part of the hydraulic

system has been disconnected for repair or replacement, air may enter the
system and cause spongy pedal action. Bleed the hydraulic system after
it has been properly connected, to be
sure that all air is expelled.
M A N U A L BLEEDING
The Ford, Mercury, Meteor, Continental M a r k 111, Lincoln Continental,
Thunderbird models equipped with
disc brakes must be bled with pressure bleeding equipment.

The primary and secondary (front

and rear) hydraulic brake systems are
individual systems and are bled separately. Bleed the longest line first on
the individual system being serviced.
During the complete bleeding operation. D O N O T allow the reservoir to
run dry. Keep the master cylinder res-

ervoirs filled with Ford Fluid-Extra

Heavy Duty-Part
Number C6AZ19542-A (ESA-M6C 25-A). The extra
heavy duty brake fluid is colored blue
for identification purposes. D o not
mix low temperature brake fluids
with the specified fluid during the
bleeding operations. Never re-use
brake fluid which has been drained
from the hydraulic systems.
1. If the m a s t e r cylinder is

equipped with a bleed screw, loosen

the bleed screw. Push the brake pedal

ary piston stop screw, located on the

bottom of the master cylinder to
bleed the brake system. Loosening or
removing this screw could result in
damage to the secondary piston or
stop screw.

2. T o bleed the secondary (rear)

brake system, position a suitable 318
inch box wrench (Fig. 5) on the
bleeder fitting on the brake wheel cylinder. Attach a rubber drain tube to
the bleeder fitting. The end of the
tube should fit snugly around the
bleeder fitting.
3. Submerge the free end of the

tube in a container partially filled

with clean brake fluid, and loosen the
bleeder fitting approximately 314
turn.
4. Push the brake pedal down
slowly through its full travel. Close
the bleeder fitting, then return the
pedal to the full-released position.
Repeat this operation until a i r
bubbles cease to appear at the submerged end of the bleeder tube.
5. When the fluid is completely
free of air bubbles, close the bleeder
fitting and remove the bleeder tube.
6. Repeat this procedure at the
brake wheel cylinder on the opposite
side. Refill the master cylinder reservoir after each wheel cylinder is bled
and install the master cylinder cover
and gasket. Be sure the diaphragm
type gasket is properly positioned i n
the master cylinder cover. When the
bleeding operation is completed, the
fluid level should be filled to within
114 inch of the top of the reservoirs.

7. If the primary (front brake)

system is to be bled. Repeat steps 2
through 6 at the right front brake caliper or cylinder and ending at the left
front brake caliper or cylinder.
8. On disc brake equipped models
be sure that the front brake pistons
are returned to their normal positions
and that the shoe and lining assemblies are properly seated by depress-

1 2-0 1-06

G e n e r a l Brake Service

ing the brake pedal several times until

normal pedal travel is established.
9. Centralize the pressure differential valve. Refer to centralizing the
Pressure Differential Valve procedures.
P R E S S U R E BLEEDING ALL
MODELS
Bleed the longest lines first. The
bleeder tank should contain enough
new Ford Brake Fluid to complete
the bleeding operation. Use Ford
Brake Fluid - Extra Heavy Duty Part Number C6AZ-19542-A (ESAM6C25-A) or equivalent for all brake
applications. The brake fluid is colored blue for identification purposes.
Do not mix low temperature brake
fluid with the specified brake fluid
during the bleeding operations. Never
re-use brake fluid that has been
drained from the hydraulic system.
The tank should be charged with approximately 10 to 30 pounds of air
pressure. Never exceed 50 pounds
pressure.
1. Clean all dirt from the master
cylinder reservoir cover.
2. Remove the master cylinder reservoir cover and rubber gasket, and
fill the master cylinder reservoir with

the specified brake fluid. Install the

pressure bleeder adapter tool to the
master cylinder, and attach the bleeder tank hose, to the fitting on the
adapter.
Master cylinder pressure bleeder
adapter tools can be obtained from
the various manufacturers of pressure
bleeding equipment. Follow the instructions of the manufacturer when
installing the adapter.
3. I f the m a s t e r cylinder is
equipped with a bleed screw, loosen
the bleed screw and bleed the master
cylinder until the fluid is free of air
bubbles; then, tighte'n the bleed ,screw.
D o not use the secondary piston stop
screw, located on the bottom of the
master cylinder, to bleed the master
cylinder.
4. I f the rear wheel cylinders, the
secondary brake system, are to be
bled, position a 318 inch box wrench
(Fig. 5) on the bleeder fitting on the
right rear brake wheel cylinder. Attach a bleeder tube to the bleeder fitting. The end of the tube should fit
snugly around the bleeder fitting.
5. Open the valve on the bleeder
tank to admit pressurized brake fluid
to the master cylinder reservoir.
6. Submerge the free end of the
tube in a container partially filled

FORD-MERCURY-METEOR
THUNDERBIRD A N D MARK I l l

CENTRALIZIN G T H E
P R E S S U R E DIFFEREN'I-I AL
AND/OR P R E S S U R E
CONTROL VALVE

COMPRESS
TOOL A N D
POSITION
ONTO VALVE.
RELEASE TO
ALLOW
SPRING
ACTION TO
FORCE
ROD OUT

R E L E A S E ROD

FIG. 6-Disc

with clean brake fluid, and loosen the

bleeder fitting.
7. When air bubbles cease to appear in the fluid a t the submerged end
of the bleeder tube, close the bleeder
fitting and remove the tube.
8. Repeat steps 3 through 7 a t the
left rear wheel cylinder.
9. If the vehicle is equipped with
disc brakes, repeat steps 4 through 7,
starting at the right front disc caliper
and ending a t the left front disc caliper.
On Ford? Mercury, Meteor, Continental Mark Ill, Lincoln Continental
and Thunderbird models the metering
valve release rod must be pulled outward and held a minimum of 1/16
inch (Fig. 6) while bleeding the priniayy brake system.
10. I f the vehicle contains drumtype front brakes and the primary
(front) brake system is to be bled, repeat steps 4 through 7, starting at the
right front wheel cylinder ending a t
the left front wheel cylinder.
11. When the bleeding operation is
completed, close the bleeder tank
valve and remove the tank hose from
the adapter fitting.
12. On disc brake equipped vehicles, be sure that the front brake
pistons are returned to their normal
positions and that the shoe and lining
assemblies are properly seated by
depressing the brake pedal several
times until normal pedal travel is established.
13. Remove the Piessure ' Bleeder
Adapter Tool. Fill the master cylinder
reservoirs to within 114 inch of the
top. Install the master cylinder cover
and gasket. Be sure the Diaphragm
type gasket is properly positioned in
the master cylinder cover.
14. Centralize the pressure differential valve. Refer to Centralizing the
Pressure Differential Valve procedures.

H164.4-8

Brake Metering Valve-Ford,

Mercury, Meteor, Lincoln
Continental, Continental M a r k I l l a n d Thunderbird

After any repair or bleeding of the

primary (front brake) or secondary
(rear brake) system, the dual-brake
warning light will usually continue to
be illuminated due to.the pressure differential valve remaining in the offcenter position.
To centralize the pressure differential valve and turn off the warning
light after a repair operation:
1. Turn the ignition switch to the
ACC or O N position.

G e n e r a l Brake Service

2. Check the fluid level in the

master cylinder reservoirs and fill
them to within 114 inch of the top
with the specified brake fluid, if necessary.
3. Depress the brake pedal and the
piston will center itself causing the
brake warning light to go out.
4. Turn the ignition switch to the
O F F position.
5. Before driving the vehicle. check

repaired or bled last.

1. Turn the ignition switch to the
ACC or O N position. Loosen the differential valve assembly brake tube
nut at the outlet port on the opposite
side of the brake system that was
wheel balanced, repaired and/or bled
last. Depress the brake pedal slowly
to build line pressure until the pressure differential valve is moved to a
centralized position and the brake

warning light goes out; then, immediately tighten the outlet port tube nut.
2. Check the fluid level in the master cylinder reservoirs and fill them t o
within 1.14 inch of the top with the
specified brake fluid, if necessary.
3. Turn the ignition switch to the
O F F position.
4. Before driving the vehicle, check
the operation of the brakes and be
sure that a firm pedal is obtained.

CLEANING AND INSPECTION

DlSC BRAKES
1. Remove the wheel and tire and
the shoe and lining assemblies as outlined in Part 12-03.
2. On all models make the thickness measurements with a micrometer
across the thinnest section of the shoe
and lining. If the assembly has worn
to a thickness of 0.230-inch (shoe and
lining together) or 0.030-inch (lining
material only) at any one of three
measuring locations or i f there is
more than 0.125 taper from end to
end or i f lining shows evidence of
brake fluid contamination, replace all
(4) shoe and lining assemblies on both
front wheels.
3. Check the caliper to spindle attaching bolts torque. Torque them to
specification, if required.
4. To check rotor runout, first
eliminate the wheel bearing end play
by tightening the adjusting nut. After
tightening the nut, check to see that
the rotor can still be rotated.
5. Clamp a dial indicator to the
caliper housing so that the pointer
contact the rotor at a point approximately I inch from the outer edge.
Rotate the rotor and take an indicator reading. If the reading exceeds
0.003 inch on custom vehicles and
0.002 inch on light vehicles total lateral runout on the indicator, replace
or resurface the disc brake rotor. The
following requirement must be met
when resurfacing disc brake rotors:

Rotunda Disc Brake Attachment

FRE-2249-2 is the only approved tool
to be used to refinish the disc brake
rotors. The step-by-step resurfacing
procedure provided with the tool must
be adhered to.
The finished braking surface of the
rotor must be flat and parallel within
0.0007 inch: lateral runout must not
exceed 0.003 inch on custom vehicles

and 0.002 inch on light vehicles total

indicator reading, braking surface are
to be 80115 micro inches.
On all models the minimum limiting dimension from the inboard bearing cup to the inboard rotor face and
the minimum rotor thickness dimension, must be observed when removing material from the rotor braking
surfaces. A ball and gage bar (Rotunda Kit FRE-70160) is to be used
when checking minimum dimensions
(Fig. 7).
When the runout check is finished
be sure to adjust the bearings as outlined in Croup 11-02 in order to prevent bearing failure.
6. Check the rotor for scoring.

Minor scores can be removed with a

fine emery cloth. If the rotor is cxcessively scored, refinish it as outlined
in step 5 or replace the rotor, if required.
7. Visually check the caliper. If the
caliper housing is leaking it should be
replaced. If a seal is leaking the caliper must be disassembled and new
seals installed. If a piston is seized in
the bore a new caliper housing is required.
Check the brake hoses for signs of
cracking, leaks or abrasion. Replace
them if necessary.
DlSC BRAKE SERVICE
PRECAUTIONS
1. Grease or any other foreign material must be kept off the caliper assembly, surfaces of the rotor and external surfaces of the hub during service operations. Handling of the rotor
and caliper assemblies should be done
in a way to avoid deformation of the
brake rotor and nicking or scratching
of brake linings.
2. If a caliper piston is removed for

FAIRLANE
MUSTANGCOUGAR
MONTECO

4k

THUNDERBIRD-CONTINENTAL
MARK Ill-LINCOLN
CONTINENTAL
1 1 ) YIN.4

FIG. 7-Disc
Limits-All

'875 M I N '

~16w-~

Brake Rotor Service

Models

any reason, the piston seal must be

replaced.
3. During removal and installation
of a wheel assembly, exercise care not
to interfere with and damage the caliper splash shield or the bleeder screw
fitting.
4. Front wheel bearing end play is
critical and must be within specifications.
5. Be sure the vehicle is centered
on the hoist before servicing any front
end components, to avoid bending or
damaging the rotor splash shield on
full right or left wheel turns.
6. Riding of the brake pedal (common on left foot applications) should
be avoided during vehicle operation.
7. The wheel and tire must be
removed separately from the brake
rotor, unlike drum brakes where the
wheel, tire and drum are removed a s
a unit.
8. On floating caliper type disc
brakes whenever the caliper is removed the caliper locating pins should

General Brake Service

be inspected for wear or damage.

9. On floating caliper type disc
brakes. the caliper assembly must be
removed from the spindle prior to removal of the shoe and lining assemblies.
10. On floating caliper type disc
brakes the calipers must not be interchanged from one side to the other.
When the caliper is installed on its
proper anchor plate and spindle, the
bleeder screw will point to the rear of
the vehicle. I f a caliper is installed on
the wrong side of the vehicle. it is not
possible to bleed the system properly.
11. Do not attempt to clean or
restore oil or grease soaked brake linings. When contaminated linings are
found. brake linings must be replaced
in complete axle sets.
D R U M BRAKES

1. Remove the wheel from the

drum, and remove the drum as outlined in Part 12-02.
2. Brush all dust from the backing
plates and interior of the brake
drums.
3. Inspect the brake shoes for excessive lining wear or shoe damage. If
the lining is worn within 1/32 inch of
the rivet heads or i f the shoes are
damaged, they must be replaced. Replace any lining that had been contaminated with oil, grease or brake
fluid. Replace lining in axle sets.
Prior to replacement of lining, the
drum diameter should be checked to
determine if oversize linings must be
installed.
4. Check the condition of brake
shoes, retracting springs, hold-down
springs, and drum for signs of overheating. If the shoes have a slight
blue coloring, indicating overheating,

replacement of the retracting and

hold-down springs is strongly recommended. Overheated springs lose their
pull and could cause the new lining to
wear prematurely, if they are not replaced. I f the brake drums are heat
spotted, indicating a overheated condition, they should be replaced.
5. If the vehicle has 30,000 or more

miles of operation on the brake linings or signs of overheating are present when relining brakes, the wheel
cylinders should be disassembled a n d
inspected for wear and entrance of
dirt into the cylinder. The cylinder
cups should be replaced, thus avoiding
future problems.
6. Inspect all other brake parts and
replace any that are worn or damaged.
7. Inspect the brake drum and, if
necessary, refinish. Refer to Part
12-02 for refinishing.
BRAKE BOOSTER

Check the booster operation as

noted in Part 12-01. Power Brake
Functional Test. If the brake booster
is damaged or inoperative replace it
with a new booster. The brake booster is serviced only as an assembly.
HYDRAULIC LINES

Steel tubing is used throughout the

brake system with the exception of
the flexible.hoses at the front wheels
and at the rear axle housing brake
tube connection.
Always bleed the applicable primary or secondary brake system after
primary or secondary brake system
hose or line replacement. Centralize

the pressure differential valve after

bleeding the.system.

BRAKE TUBING

If a section of the brake tubing becomes damaged, the entire section

should be replaced with tubing of the
same type, size, shape and length.
Copper tubing should not be used in a
hydraulic system. When bending

brake tubing to fit underbody or rea;

axle contours, be careful not to kink
or crack the tube.
All brake tubing should be double
flared properly t o provide good leakproof connections. Clean the brake
tubing by flushing with clean brake
fluid before installation.
When connecting a tube to a hose,
tube connector, or brake cylinder,
tighten the tube fitting nut to specified torque with Milbar Tool 1 1 12144 or equivalent.
BRAKE HOSE

A flexible brake hose should be replaced if it shows signs of softening,

cracking, or other damage.
When installing a new front brake
hose, position the hose to avoid contact with other chassis parts. Place a
new copper gasket over the hose fitting and thread the hose assembly
into the front wheel cylinder. Engage
the opposite end of the hose to the
bracket on the frame. Install the horseshoe-type retaining clip, and connect the tube to the hose with the
tube fitting nut.
A rear brake hose should be installed so that it does not touch the
muffler outlet pipe or shock absorber.
Thread the hose into the rear brake
tube connector. Engage the front end
of the hose to the bracket on the
frame. Install the horseshoe-type retaining clip, and connect the tube to
the hose with the tube fitting nut.

12-0 1-09

General Brake Service

12 - 0 1-09

SPECIAL TOOLS
SPEC1AL TOOLS
*

Ford Tool No.

Description

Rotunda WRE-500.50

Brake Pedal E f f o r t Gauge

Rotunda ARE-345

Vacuum and Fuel Pump Tester Gauge

Rotunda 1436

Diaphragm Type Bleeder

Tool 4201-C

Universal Dial Indicator and Bracket

Rotunda FRE.70160

B a l l and Bar Gauge

Rotunda-FRE-1432

Brake Drum Micrometer

Rot unda-2249-2

Disc Brake ~ t t a c h m e n t

Milbar 1112.144

Inch Pound Torque Wrench

1 2-02-0 1

Drum Brakes

PART 12-02 Drum Brake

COMPONENT I N D E X

1 2-02-0 1

12-02-02

12-02-02

Drum Brakes

DESCRIPTION

The drum brake system employs

single anchor, internal expanding and
self adjusting brake assemblies.
The self-adjusting brake mechanism
consists of a cable, cable guide, adjusting lever, adjusting screw assembly, and adjuster spring (Fig. I). The
cable is hooked over the anchor pin at
the top and is connected to the lever
at the bottom. The cable is routed
along the webb of the secondary
brake shoe by means of the cable
guide. The adjuster spring is hooked
to the primary brake shoe and to the
lever. The automatic adjuster operates
only when the brakes are applied
while the vehicle is moving rearward
and only when the secondary shoe is
free to move toward the drum beyond
a predetermined point.
A vacuum booster is used with the
power drum brake system.
DUAL MASTER CYLINDER
BRAKE SYSTEM

The dual-master cylinder brake

system has been incorporated in all

models to provide increased safety.
The system consists of a dual-master
cylinder (Fig. 2). pressure differential
valve assembly and a switch (Fig. 3).
The switch on the differential valve
activates a dual-brake warning light,
located on the instrument panel.
BRAKE BOOSTER SYSTEM

This diaphragm-type brake booster

is a self-contained vacuum-hydraulic
braking unit mounted on the engine
side of the dash panel.
The brake booster is of the vacuum
suspended-type which utilizes engine
intake manifold vacuum and armospheric pressure for its power.
Adjustment of the push rod and replacement of the check valve and
grommet are the only services permitted on the brake booster. The booster
unit i s t o be exchanged when it i s inspected, checked and found t o be inoperative.

FIG. 7-Self-Adjusting

Brake Assemblies

A self centering pressure differential valve assenibly is used on all vehicles having power or non-power
drum type brakes.
The valve body is step bored to accommodate a sleeve and seal installed
over the piston and into the larger
valve body bore in the front brake
system area. The brake warning light
switch is mounted at the center of the
valve body and the spring loaded
switch plunger fits into a tapered
shoulder groove in the center of the
piston. In this position the electrical
continuity through the switch is interrupted and the brake warning lamp
on the instrument panel is out. (Fig.
3)

SHOE W I D E (ANCHOR PIN) PLATE

SHOF GUIDE (ANCHOR PIN) P L A T E

AND HOUSING

PRESSURE DIFFERENTIAL VALVE

SPRING

A U J U b I INb

SCREW

PRIMARY SHOE.TO.ANCHOR

12-02-03

1 2-02-03

Drum Brakes

PRIMARY SYSTEM BRAKE

FLUID RESERVOIR

RETURN SPRING (PRIMARY)

ASSEMBLY

9G.2-Dual

Master
Cylinder-Typical
BRAKE WARNING LAMPSWITCH

FRONT BRAKE

INLET
FRONT BRAKE

REAR BRAKE

RIGHT FRONT

INLET FROM

RAKE OUTLET

NORMAL POSITION
REAR BRAKES

(CENTERED)

OUTLET TO
RIGHT FRONT BRAKE

LIGHT CAR

FIG. 3-Pressure

(CENTERED)

CUSTOmCAR

H1698-8

Differential Valve and Brake Warning Light Switch

IN-VEHICLE ADJUSTMENTS AND REPAIRS

After any brake service work,

obtain a firm brake pedal before
moving the vehicle. Riding the brake
pedal (common on left foot application) should be avoided when driving
the vehicle.

BRAKE SHOE ADJUSTMENTS

The hydraulic drum brakes are
self-adjusting and require a manual
adjustment only after the brake shoes

have been -relined, replaced, or when

the length of the adjusting screw has
been changed while performing some
other service operation. The manual
adjustment is performed with the
drums removed, using the tool and

12-02-04

Drum B r a k e s

6. Install the wheels on the drums

and tighten the nuts to specification.
7. Complete the adjustment by
applying the brakes several times with
a minimum of 50 Ibs pressure on the
pedal while backing the vehicle. After
each stop the vehicle must be moved
forward.
8. After the brake shoes have been
properly adjusted, check the operation
of the brakes by making several stops
while operating in a forward direction.

WHEEL CYLINDER REPAIR

Wheel cylinders should not be disassembled unless they are leaking or
unless new cups and boots are to be
installed. It is not necessary to remove the brake cylinder from the
backing plate t o disassemble, inspect,
or hone and overhaul the cylinder.
Removal is necessary only when the
cylinder is damaged or scored beyond
repair.
DISASSEMBLY

FIND CORRECT -BRAKE

SHOE DIAMETER HERE

FIG. 4-Adjusting

BOOT

Brake Shoes Using Tool HRE-8650

CUP
1

1. Remove the links and the rubber

boots from the ends of the brake cylinder. Remove the pistons, cups, and
return spring from the cylinder bore
(Fig. 5).
2. Remove the bleeder screw from
the cylinder.

CUP

INSPECTION

PISYON

CYLINDER

H1385-B

FIG. 5-Brake

Wheel ~ ~ l i n d e r - ~ ~ ~ i c a l

the procedure detailed below.

When adjusting the rear brake

shoes, check the parking brake cables
for proper adjustment. Make sure
that the equalizer operates freely.
To adjust the brake shoes:
1. Use Rotunda Tool HRE 8650,
(Fig. 4) to determine the inside diameter of the drum braking surface.
2. Reverse the tool as shown in
Fig. 4 and adjust the brake shoe diameter to fit the gauge. Hold the automatic adjusting lever out of engagement while rotating the adjusting
screw, to prevent burring the screw

slots. Make sure the adjusting screw

rotates freely. If necessary, lubricate
the adjusting screw threads with a
thin, uniform coating of C I A Z
19590-B Moly Dysulfide.
3. Rotate Tool HRE 8650 around
the brake shoes to be sure of the setting.
4. Apply a small quantity of high
temperature grease to the points
where the shoes contact the backing
plate, being careful not to get the lubricant on the linings.
5. Install the drums. Install Tinnerman nuts and tighten securely.

1. Wash all parts in clean brake

fluid. Dry with compressed air.
2. Replace scored pistons. Always
replace the rubber cups and dust
boots.
3. Inspect the cylinder bore for
score marks or rust. If either condition is present the cylinder bore must
be honed. However, the cylinder
should not be honed more than 0.003
inch beyond its original diameter.
4. Check the bleeder hole to be

sure that it is open.

ASSEMBLY
1. Apply a light coating of heavyduty brake fluid to all internal parts.
2. Thread the bleeder screw into
the cylinder and tighten securely.
3. Insert the return spring, cups,
and pistons into their respective positions in the cylinder bore (Fig. 12).
Place a boot over each end of the cylinder. Bleed the brake system.

12-02-05

Drum Brakes

12-02-05

REMOVAL AND INSTALLATION

FRONT BRAKE D R U M

REMOVAL
1. Raise the vehicle until the wheel
and tire clear the floor. Remove the
wheel cover or hub cap, and remove
the wheel and tire from the drum.
2. Remove the grease cap from the
hub. Remove the cotter pin, nut lock,
adjusting nut, and flat washer from
the spindle. Remove the outerbearing
cone and roller assembly.
3. Pull the drum off the wheel
spindle.
4. If the drum will not come off,
pry the rubber cover from the brake
backing plate. Insert a narrow screw;
driver through the slot and disengage
the adjusting lever from the adjusting
screw. While holding the adjusting
lever away from the screw, back, off
the adjusting screw with the brake adjusting tool (Fig. 6). Be very careful
not to burr, chip, or damage the
notchesin the adjusting screw; otherwise the self-adjusting mechanism will
not function properly.
H1590-A 2 1 1 1 6 ~2 112
INSTALLATION
1. If the drum is being replaced,
remove the protective coating from
the new drum with carburetor degreaser. Then, use sandpaper to insure that no residue remains. Wipe
the drum with a cloth coaked with
denatured alcohol. Install new bearings and grease seal. Pack the wheel
bearings, install the inner bearing
cone and roller assembly in the inner
cup, and install the new grease seal
see Part 11-02.
If the original drum is being installed, make sure that the grease in
the hub is clean and adequate.
2. Adjust the brakes and install the
drum assembly as outlined under
Brake Shoe Adjustments in this section.
3. Install the outer wheel bearing,
washer and adjusting nut.
4. Adjust the wheel bearing as outlined in Part 11-02, then install the
grease cap. Install the wheel and hub
cap.

REAR BRAKE D R U M

REMOVAL
1. Raise the vehicle so that the tire

is clear of the floor.

2. Remove the hub cap and wheel.
Remove the three Tinnerman nuts
and remove the brake drum. If the
drum will not come off, pry the rubber cover from the backing plate. Insert a narrow screwdriver through the
hole in the backing plate, and disengage the adjusting lever from the adjusting screw. While holding the adjusting lever away from the adjusting
screw, back off the adjusting screw
with the brake adjusting tool (Fig. 6).
Be very careful not to burr, chip, or
damage the notches in the adjusting
screw; otherwise, the self-adj,usting
mechanism will not function properly.
INSTALLATION
1. Remove the protective coating
from a new drum with carburetor degreaser; then sand lightly and wipe
with a cloth soaked with denatured
alcohol.
2. Adjust the brakes as outlined
under Brake Shoe Adjustments in this
section. Place the drum over the
brake assembly and into position.
3. Install the three Tinnerman nuts
and tighten securely. Install the wheel
on the axle shaft flange studs against
the drum, and tighten the attaching
nuts to specifications.
BRAKE SHOESAND ADJUSTING
SCREW
REMOVAL
1. With the wheel and drum removed install a clamp over the ends
of the brake cylinder as shown in Fig.
7.
2. Remove the secondary shoe to
anchor spring with the tool shown in
Fig. 7. With the same tool remove the
primary shoe to anchor spring and
unhook the cable eye from the anchor
pin.
3. On Ford, Mercury, Meteor.
Thunderbird, Continental Mark I11
and Lincoln Continental models, remove the shoe . guide (anchor pin)
plate (Fig. I).
4. Remove the shoe hold-down
springs, shoes, adjusting screw, pivot
nut, socket and automatic adjustment
parts.
5. On rear brakes, remove the
parking brake link and spring. Disconnect the parking brake cable from
the parking brake lever.

RUBBER PLUG

OVE HANDLE UPWARD

RETRACT BRAKESHOES

'/
FIG. 6-Backing
Adiustment

FIG. 7-Retracting
Removal

H1590-A

Off Brake

Spring

6. After removing the rear brake

secondary shoe, disassemble the parking brake lever from the shoe by removing the retaining clip and spring
washer (Fig. I).

1. Before installing the rear brake

shoes, assemble the parking brake
lever to the secondary shoe and secure
with the spring washer and retaining
clip.
2. Apply a light coating of hightemperature grease a t the points
where the brake shoes contact the
backing plate.
3. Position the brake shoes on the
backing plate and secure the assembly
with the hold down springs. On the
rear brake, install the parking brake
link and spring, back off the parking
brake adjustment then connect the

Drum Brakes

parking brake cable to the parking

brake lever (Fig. 1).
4. Install the shoe guide (anchor
pin) plate on the anchar pin when so
equipped.
5. Place the cable eye over the anchor pin with the crimped side toward
the backing plate.
6. Install the primary shoe to anchor spring (Fig. 8).
7. Install the cable guide on the
secondary shoe web with the flanged
hole fitted into the hole in the secondary shoe web. Thread the cable
around the cable guide groove (Fig.
1).
I t is imperative that the cable be
positioned in this groove and not between the guide and the shoe .web.

8. Install the secondary shoe to anchor spring with the tool shown in
Fig. 8.
Be certain that the cable eye is not
cocked or binding on the anchor pin
when installed. All parts should be
flat on the anchor pin. Remove the

brake cylinder clamp.

9. Apply high-temperature grease
C I A 2 19590-B Moly Dysulfide to the
threads and the socket end of the adjusting screw. Turn the adjusting
screw into the adjusting pivot nut to
the limit of the threads and then back

FIG. 8-Retracting
Installation

Spring

ADJUSTING SCREW
IDENTlFlCATlON LINES
HllU-C

FIG. 9-Ad'usting
Serew a n d
Lever ldenti ication

off t 2 turn.
I n erchanging the brake sboe adjusting screw assemblies from one
side of the vehicle to the other would
cause the brake shoes to retract ratHer than ekpPnd each time the automatic adjusting mechanism operated.

To prevent installation on the wrong

side of the vehicle, the socket end of
the adjusting screw is stamped with
an R or L (Fig. 9). The adjusting
pivot nuts can be distinguished by thC
number of grooves machined around
the body of the nut. Two grooves on
the nut indicate a right thread; one
groove indicates a left thread.
10. Place the adjusting socket ofi
the screw and install this assembly
between the shoe ends with the adjusting screw toothed wheel nearest
the secondary shoe.
11. Hook the cable hook into the
hole in the adjusting lever. The adjusting levers are stamped with an R
or L to indicate their installation on
right or left brake assembly (Fig. 9),
12. Position the hooked end of the
adjuster spring completely ,into the
large hole in the primary shoe web.
The last coil of the spring should be
at the edge of the hole. Connect the
loop end of the spring to the adjuster
lever
13. h"$
Pu the adjuster lever, cable
and automatic adjuster spring down
and toward the rear to engage the
pivot hook in the large hole in the
secondary shoe web (Fig. 1).
14. After installation, check the ac'tion of the adjuster by pulling the section of the cable between the cable
guide and the anchor pin toward the
secondary shoe web far enough to lift
the lever past a tooth on the adjusting
screw wheel. The lever should snap
into position behind the next tooth,
and release of the cable should cause
the adjuster spring to return the lever
to its original position. This return
action of the lever will turn the adjusting screw one tooth.
If pulling the cable does not produce the action described, or if the
lever action is sluggish instead of positive and sharp, check the position of
the lever on the adjusting screw
toothed wheel. With the brake in a
vertical position (anchor at the top),
the lever should contact the adjusting
wheel 3/16 inch (plus or minus 1/32
inch) above the centerline of the
screw. If the contact point is below
this centerline, the lever will not lock
on the teeth in the adjusting screw
wheel, and the screw will not be
turned as the lever is actuated by the
cable.

To determine the cause of this condition:

a. check the cable end fittings.
The cable should completely fill or
extend slightly beyond the crimped
section of the fittings. If it does not
meet this specification, possible damage is indicated and the cable assembly should be replaced.
b. Check the cable length. On
Ford, Mercury, Meteor, Thunderbird,
Continental Mark 111, and Lincoln
Continental models, the cable should
measure 11 t/8 inches (plus or minus
f/64 inch) from the end of the cable
anchor to the end of the cable hook.
On Fairlane, Montego, Falcod,
Mustaw, and Cougar models the
cable should measure 8 13/32 inches
on 9 inch brakes or 9 314 inches on
10 inch brakes from the end of the
cable anchor to the end of the cable
hook.
C. Check the cable guide for damage. The cable groove should be parallel to the shoe web, and the body of
the guide should lie flat against the
web. Replace the guide if it shows
damage.
d. Check the pivot hook on the
lever. The hook surfaces should be
square with the body of the lever for
proper pivoting. Replace the lever if
the hook shows damage.
e. See that the adjusting screw
socket is properly seated in the notch
in the shoe web.
WHEEL CYLINDER

REMOVAL
1. Remove the wheel and the
drtim.
2. Remove the brake shoe assemblies, following procedures outlined in
this section.
3. Disconnect the brake line from
the brake cylinder. O n a vehicle with
a vacuum brake booster, be sure the
engine is stopped and there is no vacuum i n the booster system before disconnecting the, hydraulic lines.

To disconnect the hose at a front

cylinder, loosen the tube fitting that
connects the opposite end of the hose
to the brake tube at a bracket on the
frame. Remove the horseshoe-type retaining clip from the hose and bracket, disengage the hose from the
bracket, then unscrew the entire hose
assembly from the front wheel cylinder.
At a rear cylinder, unscrew the
tube fitting that connects the tube to
the cylinder. D o not pull the metal
tube away from the cylinder. Pulling

1 2-02-07

Drum Brakes

the tube out of the cylinder connection will bend the metal tube and
make installation difficult. The tube
will separate from the cylinder when
the cylinder is removed from the
backing plate.
4. On all except the front wheels
on Ford, Mercury, and Meteor models, remove the wheel cylinder attaching bolts and lock washers and remove the cylinder. On the front wheel
of Ford, Mercury and Meteor models, remove the nut and washer that
attaches the cylinder to the anchor
pin. Remove the cylinder from the
anchor pin.
1NSTALLATION

Wipe the end(s) of the hydraulic

line to remove any foreign matter before making connections.
1. On all models except Ford,
Mercury and Meteor, to install a
front wheel cylinder, position the cylinder to the backing plate. Install the
two lock washers and attaching bolts.
Torque them to specifications.
On Ford, Mercury and Meteor
models, to install a front -wheel cylinder, position the cylinder on the anchor pin against the backing plate.
Install the washer and cylinder attaching nut on the anchor pin, and
torque it to specification. Lock the
washer retainer securely.
2. Install a new copper gasket over
the hose fitting. Thread the hose into
the cylinder and tighten it to specified
torque.
3. 'Engage the opposite end of the
hose to the bracket on the frame. Install the horseshoe-type retaining clip,
and connect the brake tube to the
hose with the tube fitting nut. Tighten
the nut to specification with tool
11 12-144.
4. To install a rear wheel cylinder,
place the rear wheel cylinder into
position. Enter the tubing into the
cylinder, and start the tube fitting nut
into the threads of the cylinder.
5. Secure the cylinder to the backing plate by installing the attaching
bolts and lock washers.
6. Tighten the tube fitting nut to
specification with tool 1 1 12-144.
7. Install the links in the ends of
the wheel cylinder, install the shoes
and adjuster assemblies, and adjust
the shoes as outlined in this section.
8. Adjust the brakes as described
in this part. Install the brake drum
and wheel. Bleed the brakes and centralize the differential valve as outlined in Part 12-01.

BRAKE BACKING PLATE

REMOVAL
I. Remove the wheel and brake
drum. Disconnect the brake line from
the brake Fylinder.
2. Remove the brake shoe and
adjuster assemblies and the wheel cylinder as outlined in this section. On
the rear wheels, disconnect the parking brake lever from the cable.
3. If the rear backing plate is being
replaced, remove the axle shaft from
the applicable rear axle as outlined in
Group 15, Part 2 or 3, Rear, Axle,
Section 2, disengage parking brake
cable retainer from backing plate.
Remove the backing plate and gasket.
If the front backing plate is being
replaced, remove the bolts and nuts
that secure the backing plate to the
front wheel spindle and remove the
plate and gasket.

is to be replaced, position a new front

backing plate and gasket to the wheel
spindle and install the attaching bolts
and nuts.
2. Install the wheel cylinder and
connect the brake line as outlined in
this section.
3. Install the brake shoe and adjuster assemblies as outlined in this
section. On a rear brake, connect the
parking brake cable to the lever.
4. Adjust the brake shoes as outlined in this section, and install the
brake drums and wheels. Bleed the
brake system and centralize the differential valve as outlined in Part 120 1.
DUAL MASTER CYLINDERNON POWER BRAKES
FORD, MERCURY
AND METEOR
Removal

If a rear backing plate,is to be replaced, position a new rear backing

plate and gasket on the attaching
bolts in the axle housing flange. Insert parking brake cable into backing
plate and secure retaining fingers. Install the rear axle shaft tor applicable
rear axle. Refer to Group 15 Part 2
or' 3 Rear Axle, Section 2 for the
proper installation procedure.
1. If the front brake backing plate

Refer to Fig. 10.

I. Disconnect -the stoplight switch
wires at the connector. Remove the
spring retainer. Slide the stop light
switch off the brake pedal pin just far
enough to clear the end of the pin,
then lift the switch straight upward
from the pin. Use care to avoid
switch damage during removal.
2. Slide the master cylinder push
rod and the nylon washers and bushings off the brake pedal pin.
BUSHING

STOPLIGHT SWITCH
13480

FIG. 10-Dual

Master cyIinde; Installation-Non

Mercury, a n d Meteor

H1637-A

Power Brbkes-Ford,

'

12-02-08

12-02-08

Drum Brakes

Installation

SHAFT ( A U T W T I C

UPPER STUD

' I

STOP L I T E
SWITCH
13180
MASTER CYLINDER
PUSH ROD

BUSHING
LOWER STUD

FIG. 7 1-Dual

Master Cylinder Installation-Non

B r a k e i F a i r l a n e , Montego, a n d Falcon

BRA;(
PEDAL

Power

CLUTCH

1. Position the boot on the push

rod and secure the boot to the master
cylinder. Carefully insert the master
cylinder push rod and boot through
the dash panel opening and position
the master cylinder on the panel.
2. Install the cap screws at the
dash panel and torque them to specification.
3. Coat the nylon bushings with
SAE 10W oil. Install the nylon washer and bushing on the brake pedal
pin.
4. Position the stop light switch on
the brake pedal pin, install the nylon
bushing and washer and secure them
in position with the spring retainer.
5. Connect the wires at the stop
light switch connector.
6. Connect the brake lines to the
master cylinder leaving the brake line
fittings loose.
7. Fill the master cylinder with the
specified brake fluid to within k/4
inch of the top of the dual reservoirs.
Use Ford Brake Fluid-Extra Heavy
Duty-Part
Number C6AZ- 19542-A
(ESA-M6C25-A) or equivalent..for all
drum brake applications. The extra
heavy duty brake system fluid is colored blue for identification. Do not
mix low temperature brake fluids
with the specified fluid for the power
disc brake system.
8. Bleed the dual-master cylinder
and the primary and secondary brake
systems. Centralize the pressure differential valve. Refer to Hydraulic
System Bleeding and Centralizing of
the Differential Valve, Part 12-01, for
proper procedure.
9. Operate the brakes several
times, then check for external hydraulic leaks.

FAIRLANE, MONTEGO,
MAVERICK, FALCON,
MUSTANG.AND COUGAR
Removal

AUTOMATIC
TRANSMISSION

2140
STOP LIGHT
SWITCH 13480

FIG. 12-Dual
Brake-Mustang

Master cylinder Installation-Non

and Cougar

3. Remove the brake tube from the

primary and secondary outlet ports of
the master cylinder.
4. Remove the cap screws and

CLUTCHPEDAL
BUMPER STOP

H163BA

Power

lockwashers that secure the master

cylinder to the dash panel and lift the
cylinder forward and upward from
the vehicle.

Refer to Figs. I l land 12.

1. Working from inside the vehicle
below the instrument panel, disconnect the master cylinder push rod
from the brake pedal assembly. The
push rod cannot be removed from the
master cylinder.
2. Disconnect the stoplight switch
wires a t the connector. Remove the
hairpin retainer. Slide the stop light
switch off the brake pedal pin just far
enough to clear the end of the pin,
then lift the switch straight upward.

12-02-09

D r u m Brakes

from the pin. Use care to avoid

switch damage during removal.

3. Slide the master cylinder push

rod and the nylon washers and bushings off the brake pedal pin.
4. Remove the brake tubes from
the primary and secondary outlet
ports of the master cylinder.
5. Remove the lock nuts or cap
screw and lockwashers that secure the
master cylinder to the dash panel and
lift the cylinder forward and upward
from the car.
Installation

Refer to Figs. l 1 and 12.

1. Position the boot on the push
rod and secure the boot to the master
cylinder. Carefully insert the master
cylinder push rod and boot through
the dash panel opening.
2. On Fairlane, Falcon or Montego
models, position the gasket and
master cylinder on the mounting
studs on the dash panel. Install the
lock nuts on the studs at the dash
panel and torque them to specification.
3. On Mustang or Cougar models,
position the gasket and master cylinder on the dash panel. Install the retaining screws and torque them to
specification. Coat the nylon bushings
with S A E 10W oil. Install the nylon
washer and bushing on the brake
pedal pin.
4. Position the stop light switch on
the brake pedal pin, install the nylon
bushing and washer and secure them
in position with the spring retainer.
5. Connect the wires a t the stop
light switch connector.
6. Connect the brake lines to the
master cylinder and tighten to specified torque.
7. Fill the master cylinder with the
specified brake fluid to within t/4
inch of the top of the dual reservoirs.
Use Ford Brake Fluid-Extra Heavy
Duty-Part
Number C6AZ-19542-A
for all brake applications. The brake

DUAL MASTER CYLINDERPOWER BRAKES

REMOVAL
1. Remove the brake tubes from
the primary and secondary outlet
ports of the master cylinder (Figs. 13
thiu 15).
2. Remove the two nuts and two
lock washers attaching the master
cylinder to the brake booster assembly.
3. Slide the master cylinder forward and upward from the vehicle.

INSTALLATION
1. Before

installing the master

cylinder, check the distance from the
outer end of the booster assembly
push rod to the master cylinder
mounting surface. Turn the push rod
adjusting screw in or out as required
to obtain the specified length. Refer
to Part 12-01. Power Brake Master
Cylinder Push Rod Adjustment for
the proper procedure.
2. Position the master cylinder
assembly over the booster push rod
and onto the two studs on the booster
assembly (Figs. 13 thru 15).
3. Install the attaching nuts and

lock washers and torque them to

specifications.
4. Install the front and rear brake
tubes to the master cylinder outlet fit;
tings.
5. Fill the master'cylinder with the
specified brake fluid to, within 1/4
inch of the top of the dual reservoirs.
Use Ford Brake Fluid-Extra Heavy
Duty-Part
Number C6AZ-19542-A
(ESA-M6C25-A) for all brake applications. The extra heavy duty brake
fluid is coloredblue for identification.
D o not mix low temperature brake
fluids with the specified fluids for the
disc brake, system.
6. Bleed the dual-master cylinder

and the primary and secondary brake

systems. Centralize the pressure differential valve. Refer t o Hydraulic
System Bleeding and Centralizing of
the rdfferential Valve, Part 12-01, for
the proper procedure.
7. O p e r a t e the brakes several
times, then check for external hydraulic leaks.
PRESSURE DIFFERENTIAL VALVE
ASSEMBLY
REMOVAL
The pressure differential ' valve

W.10 AIR CONDITIONING

BUSHING

VbCUUM BOOSTER

MASTER CYLINDER

fluid is colored blue for identification.

D o not mix low temperature brake
fluids with the specified fluid for the
brake system.

8. Bleed the dual-master cylinder

and the primary and secondary brake
systems. Centralize the pressure differential valve. Refer to Hydraulic
System Bleeding and Centralizing of
the Differential Valve, Part 2-1, Section 2 for the proper procedure.
9. O p e r a t e the brakes several
times, then check for external hydraulic leaks.

LIGHT \

STOP
SWITCH 13480

SPACER

H 1642A

FIG. 13-Master
a n d Meteor

Cylinder Installation-Power

Brake-Ford,

Mercury

1 2-02- 10

Drum Brakes

BRAKE VACUUM BOOSTER -2005

sembly (Fig. 3).

3. Remove the two attaching nuts
and bolts from the valve bracket on
the underside of the fender apron and
remove the valve assembly and bracket from the vehicle.
INSTALLATION

I. Position the valve assembly and

bracket to the fender apron. Install
the attaching nuts and bolts: torque
them to specifications.
2. Install the front inlet and rear
outlet tubes to the valve assembly.
Torque them to specifications.
3. Connect the brake warning light
connector to the warning light switch.
4. Bleed the system and centralize
the pressure differential valve following the procedures in Centralizing
the Pressure Differential Valve.
BRAKE BOOSTER
REMOVAL
H 1557-C

NG. 14-Master Cylinder Installation-Power

M o n t e g o a n d Falcon

Brake-Fairlane,

ASSIST
SPRING BRACKET

BUSHING
I

--.*

-- \

CLUTCH ASSIST
SPRING
BRA,KJnLFDAL

CLUTCH
PEDAL

VACUUM
HOSE

HAIRPIN
BUSHING
UG

I
MASTER CYLINDER

STOPLIGHT
SWITCH 17460

CLUTCH PEDAL
TO EQUALIZER ROD

BOOSTER
2005

2140

FIG. 15-Master
Cougar

Cylinder Installation-Power

assembly is serviced as an assembly

only. D o not attempt to repair this
unit.

1. Disconnect the brake warning

Brake-Mustang

and

light connector from the warning light

switch.
2. Disconnect the front inlet and
rear outlet tubes from the valve as-

1. Working from inside the vehicle

below the instrument panel, disconnect the booster push rod from the
brake pedal assembly. To do this,
proceed as follows:
Disconnect the stop light switch
wires at the connector. Remove the
hairpin retainer. Slide the stop light
switch off from the brake pedal pin
just far enough for the switch outer
hole to clear the pin, and then remove

the switch, from the pin and booster

push rod. Be careful not to damage
the switch during removal. Slide the
booster push rod and the nylon washers and bushing off the brake pedal
pin (Figs 13 thru 15).
2. Open the hood and remove the
master cylinder from the booster. Secure it to one side without disturbing
the hydraulic lines. I t is not necessary
to disconnect the brake lines, but care
should be taken that the brake lines
are not deformed. Permanent deformation of brake lines can lead to tube
failure.
3. Disconnect the manifold vacuum

hose or hoses from the booster unit.

4. Remove the booster-to-dash
panel attaching nuts or bolts (Figs. 13
thru 15). Remove the booster and
bracket assembly from the dash
panel, sliding the push rod link out
from the engine side of the dash
panel.
5. On Fairlane, Montego, and Falcon models, remove the push rod link
boot from the dash panel.

Drum Brakes

INSTALLATION
1. On Fairlane, Montego and Falcon models, install the push rod link
boot in the hole in the dash panel as
shown in Fig. 14. Install the four
spacers on the mounting studs.
2. Mount the booster and bracket
assembly to the dash panel by inserting the push rod or push rod link in
through the hole and boot in the dash
panel. Install the bracket-to-dash
panel attaching lock nuts or bolts
(Figs. 13 thru 15).
3. Connect the manifold vacuum
hose or hoses to the booster.
4. Before installing the master
cylinder, check the d i s t ~ n c efrom the
outer end of the booster assembly
push rod t o master cylinder surface.
Turn the screw in or out to obtain the
specified length. Refer to Part 12-01,
Power Brake Master Cylinder Push
Rod Adjustment. Install the master
cylinder and torque the attaching nuts
to specifications.
5. Working from inside the vehicle
befow the instrument panel, connect
the booster push rod link to the brake
pedal assembly. To do this, proceed
as follows:
Install the inner nylon washer, the
booster push rod, and the bushing on
the brake pedal pin. Position the
switch so that it straddles the push
rod with the switch slot on the pedal
pin and the switch outer hole just
clearing the pin. Slide the switch
completely onto the pin, and install
the nylon washer as shown in Figs. 13
thru 15. Be careful not t o bend or deform the switch. Secure these parts to
the pin with the hairpin retainer.
Connect the stop light switch wires to
the connector, and install the wires in
the retaining clip.
BRAKE PEDAL

FORD, MERCURY
AND METEOR
Removal

I. Disconnect the stop light switch

wires at the connector.
2. Remove the hairpin retainer.
Slide the stop light switch off the
brake pedal pin just far enough for
the switch outer hole t o clear the pin,
and then lift the switch straight upward from the pin. Be careful not t o
damage the switch during removal.
Slide the master cylinder or booster
push rod and the nylon washers and
bushing off the brake pedal pin (Figs.
10 and 15).

3. Remove the hairpin-type retainer and washer from the brake pedal
shaft, then remove the shaft, the
brake pedal and the bushings from
the pedal support bracket.

pedal assembly, and the bushings from the pedal support bracket (Figs.
I l and 14).
Installation

Installation

I. Apply
coating of SAE 10
Engine oil to the bushings and locate
bushings in their proper places on the
pedal assembly and pedal support
bracket (Figs. 10 and 15).
2. Position the brake pedal assembly to the support bracket, then install the pedal shaft through' the suppori bracket and brake pedal assembly. Install the retainer.
3. Install the inner nylon washer,
the master cylinder or booster push
rod, and the bushing on the brake
pedal pin. Position the switch so that
it straddles the push rod with the
switch slot on the pedal pin and the
switch outer hole just clearing the pin.
Slide the switch completely onto the
pin, and install the nylon washer as
shown in Figs. 10 and 13. Be careful
not t o bend or deform the switch. Secure these parts to the pin with the
hairpin retainer.
4. Connect the stop light, switch
wires to the connector, and install the
wires in the retaining clip.
5. Check the Brake Pedal Free
Height and Travel Measurements,
Part 12-01.
FA[ RLANE, MONTECO,
MAVERICK AND
FALCON-MAN UAL-SHIFT
TRANSMISSION
Removal

1. Remove the clutch pedal assist

spring.
2. Disconnect the clutch pedalto-equalizer rod at the clutch pedal by
removing the retainer and bushing.
3. Disconnect the stop light switch
wires at the connector.
4. Remove the switch retainer, and
slide the stop light switch off the
brake pedal pin just far enough for
the switch outer hole t o clear the pin.
Then lower the switch away from the
pin. .
5. Slide the master cylinder or
booster push rod and the nylon washers and bushing off from the brake
pedal pin (Figs. I l and 14).
6. Remove the self-locking ,pin and
washer from the clutch and brake
pedal shaft, then remove the clutch
pedal and shaft assembly, the brake

I. Apply a co.ating of SAE 10

engine oil to the bushings and locate
all bushings in their proper places on
the clutch and brake pedal assemblies.
'2. Position the brake pedal to the
support bracket, then install the
clutch pedal and shaft assembly
through the support bracket and
brake pedal assembly. Install the
spring clip (Figs. I I and 14).
3. Install the clutch pedal assist
spring.
4. C o n n e c t the clutch pedalto-equalizer rod to the clutch pedal
assembly with the bushing and the
spring clip retainer. Apply SAE 10
engine oil to the bushing.
5. Install the inner nylon washer,
the master cylinder or booster push
rod, and the bushing on the brake
pedal pin. Position the switch so that
it straddles the push rod with the
switch slot on the pedal pin and the
switch outer hole just clearing the pin.
Slide the switch completely onto the
pin, and install the outer nylon washer as shown in Figs. I I and 14. Se- cure these parts to the pin with the
self-locking pin.
6. Connect the stop light switch ,
wires to the connector, and install the
wires to the retaining clip.
7. Adjust the clutch pedal free play
(Group 16-02) to specification, if required.
8. Check the Brake Pedal Free
Height and Travel Measurements
(Part 12-01, Section I).
MUSTANG AND COUCARMANUAL-SHIFT
TRANSMISSION
Removal

I. Disconnect the battery ground

cable from the battery.
2. Remove the steering column.
Refer to Part 13-02 for procedure.
3. On non-power brakes, remove
the two cap screws retaining the master cylinder to the dash panel and
remove the two cap screws retaining
the brake pedal support bracket to
the, dash panel. On power brakes remove the two cap screws retaining the
booster to the dash panel.
4. Working inside the vehicle, se-

Drum Brakes

cure the clutch pedal against the

bumper stop with a small C-clamp as
shown in Figs. 12 and IS.
5. D sconnect the clutch peda!
to-equalizer rod at the clutch pedal by
removing the retainer and bushing.
6. Disconnect the stop light switch
wires at the connector.
7. Remove the switch retainer and
slide the stop light switch off the
brake pedal pin just far enough for
the switch outer hole to clear the pin.
Then lower the switch away from the
pin. Remove the master cylinder or
booster push rod, bushing and nylon
washer from the brake pedal pin.
8. Remove the screw retaining the
pedal support bracket to the top inner
cowl bracket (Figs. I2 and 15).
9. Remove the two sheet metal
screws retaining the pedal support
bracket to the dash panel. On power
brakes remove the nuts from the
brake booster studs.
10. Remove the two screws retaining the pedal support bracket to the
upper cowl brace and lower the pedal
support bracket away from the steering column studs.
11. Remove the pedal support
bracket assembly from the vehicle.
12. Position the pedal and support
bracket assembly in a vise.
13. Remove the C-clamp to release
the clutch pedal from its bumper stop
and pivot the pedal away from the
bumper.
14. Remove the clutch pedal assist
spring.
15. On non-power brakes, remove
the retainer clip from the clutch and
brake pedal shaft, then remove the
clutch pedal and shaft assembly,; the
brake pedal assembly, and the bushings from the pedal support bracket.
On power brakes, remove the retainer
nut from the brake pedal shaft then
remove the pedal shaft, the brake
pedal assembly and the bushings from
the pedal support bracket.
Installation
1. Apply a coating of SAE 10
engine oil to the bushings and locate
all bushings in their proper places on
the clutch and brake pedal assemblies.
2. On non-power brakes, position
the brake pedal to the pedal support
bracket, then install the clutch pedal
and shaft assembly through the support bracket and brake pedal assem-

bly. On power brakes position the

brake pedal to the pedal support
bracket, then install the pedal shaft
and nut.
3. Install the clutch pedal assist
spring and pivot the clutch pedal
against its bumper stop. Secure the
pedal to the stop with a small Cclamp as shown in Figs. 12 and 15.
4. Position the pedal support
bracket assembly to 'the dash panel,
and to the steering column retainer
studs.
5. Align the pedal support bracket
holes with the holes in the dash panel
and install the two attaching sheet
metal screws. On power brakes install
the nuts on the brake booster studs.
6. Install the two cap screws attaching the pedal support bracket to
the upper cowl bracket.
7. Install the cap screw attaching
the pedal support bracket to the top
inner cowl bracket (Figs. 12 and 15).
8. Install the inner nylon washer,
the master cylinder push rod, and the
bushing on the brake pedal pin. Position the stop light switch so that it
straddles the push rod with the switch
slot on the pedal pin and the switch
outer hole just clearing the pin. Slide
the switch completely onto the pin,
and install the outer nylon washer as
shown in Figs. 12 and 15. Secure
these parts to the pin with the selflocking retainer.
9. Connect the stop light switch
wires to the connector.
10. Connect the clutch pedalto-equalizer rod to the clutch pedal
assembly with the bushing and the
spring clip retainer. Apply SAE 10
engine oil to the bushing. Remove the
C-clamp from the clutch pedal.
11. Working from the engine side
of the dash panel, on non-power
brakes, install the two cap screws attaching the pedal support bracket to
the dash panel. Then install the two
screws attaching the master cylinder
to the dash panel. On power brakes
install the cap screws retaining the
brake booster to the dash panel.
12. Install the steering column.
Refer to Part 13-02 for procedure.
13. Adjust the clutch pedal free
play (Group 16-02) to specification, if
required.
14. Check the Brake Pedal Free
Height and Travel Measurements
Part 12-01.
15. Connect the ground cable to
the battery.

FAIRLANE, MONTEGO,
FALCON, MAVERICK,
MUSTANG AND
COUGAR-AUTOMATIC
TRANSMISSION
Removal
1. Disconnect the stop light switch
wires a t the connector.
2. Remove the self-locking pin and
slide the stop light switch off the
brake pedal pin just far enough for
the switch outer hole to clear the pin.
Then lower the switch away from the
pin. Slide the master cylinder or
booster push rod and the nylon washers and bushing off from the brake
pedal pin (Figs. 1 1, 12, 14 and 15).
3. On all vehicles except Mustang
and Cougar with power brakes, remove the self-locking pin and washer
from the brake pedal shaft, then remove the shaft, the brake pedal
assembly and the bushings from the
pedal support bracket. On Mustang
and Cougar vehicles with power
brakes, remove the locknut and bolt
from the pedal. Remove the pedal assembly from the support bracket (Fig.
15).

Installation
1. Apply a coating of SAE 10
engine oil to the bushings and locate
all the bushings in their proper places
on the pedal assembly and pedal support bracket (Figs. 11, 12, 14 and 15).
2. Position the brake pedal assembly to the support bracket, then install the pedal shaft or bolt through
the support bracket and brake pedal
assembly. Install the retainer or locknut.
3. Install the inner nylon washer,
the master cylinder or booster push
rod, and the bushing on the brake
pedal pin. Position the switch so that
it straddles the push rod with the
switch slot on the pedal pin, and the
switch outer hole just clearing the pin.
Slide the switch completely onto the
pin, and install the outer nylon washer as shown in Figs. 11, 12, 14 and
IS. Secure these parts to the pin with
the self-locking pin.
4. Connect the stop light switch
wires to the connector, and install the
wires in-the retaining clip.
Check the Brake Pedal Free Height
and Travel Measurements, Part 1201.

1 2-02- 1 3

. 12-02- 1 3

Drum Brakes

MAJOR REPAIR OPERATIONS

BRAKE D R U M REFINISHING

Minor scores on a brake drum can

be removed with sandpaper. A drum
that is excessively scored or shows a
total indicator runout of over 0.007
inch should be turned down. Remove
only enough stock to eliminate the
scores and true up the drum. The refinished diameter must not exceed
0.060 inch oversize.
Check the inside diameter of the
brake drum with a brake drum micrometer (Tool FRE- 143 l).
If the drum diameter is less than
0.030 inch oversize after refinishing,
standard lining may be installed. If
the drum diameter is 0.030-0.060
inch oversize after refinishing, oversize lining must be installed.
After a drum is turned down, wipe
the refinished surface with a cloth
soaked in clean denatured alcohol. If
one drum is turned down, the opposite drum on the same axle should
also be cut down to the same size.

RETAINER

GASKET
SECONDARY SYSTEM
BRAKE O U T L E T

SNAP RING

- 2155
- 7821
PUSH ROD

RETAINER

* SECONDARY PISTON
ASSEMRLY

t TUBE SEAT -

- 2A502

NOT USED ON POWER BRAKE E W l P P E D VEHICLES

28220

t N O T SERVICED
*REPLACE AS AN ASSEMBLY ONLY

Brake linings that are worn to

within 1./32 inch of the rivet head or
are less than 0.030 inch thick (bonded
lining) or have been contaminated
with brake fluid, grease or oil must
be replaced. Failure to replace worn
linings will result in a scored drum.
When it is necessary to replace linings, they must also be replaced on
the wheel on the opposite side of the
vehicle.

Inspect brake shoes for distortion,

cracks, or looseness. .If this condition
exists, the shoe must be discarded. DO
to repair

- 2167

MASTER CYLINDER

BRAKE S H O E RELINING

not attempt
brake shoe.

- 28245

a defective

1. Wash the brake shoes thoroughly in a clean solvent. Remove all

burrs or rough spots from the shoes.
2. Check the inside diameter of the
brake drum with a brake drum micrometer (tool FRE-1431). If the
diameter is less than 0.030 inches
oversize, standard lining may be ins t a l l e d . If t h e d i a m e t e r i s
0.030-0.060 inches oversize, oversize
lining should be installed.
3. Position the new lining on the
shoe. Starting in the center, insert
and secure the rivets, working alternately towards each end. Replacement linings are ground and no further grinding is required.

4. Check the clearance between the

FIG. 16-Dual

Master Cylinder Disassembled

shoe ,and lining. The lining must seat

tightly against 'the shoe with not more
than -0.608 inch clearance between
any two rivets.

S.rop Ring P l i e r s

DUAL MASTER CYLINDER

When a repair i s necessary on the
master cylinder, i t is required practice
during the warranty period to replace
the cylinder as a unit instead of overhauling the cylinder with a service repair kit.
DISASSEMBLY

1. Clean the outside of the master

cylinder and remove the filler cover
and diaphragm. Pour out any brake
fluid that remains in the cylinder.
Discard the old brake fluid.
2. Remove the secondary piston
stop bolt from the bottom of the cylinder (Fig. 16).
3. Remove the bleed screw, if required.
4. Depress the primary piston and
remove the snap ring from the retaining groove at the rear of the master

FIG. 17-Removing
Ring-Typical

Snap

cylinder bore (Fig. 17). Remove the

push rod and the primary piston assembly from the master cylinder bore.
D o not remove the screw that retains
the primary return spring retainer, return spring, primary cup and protector on the primary piston. This assemhly is factory pre-adjusted and

Drum Brakes

should not be disassembled.

5. Remove the secondary piston

assembly. DO not remove the outlet
tube seats, outlet check valves and
outlet check valve springs from the
master cylinder body.

for signs of etching, pitting, scoring

or rust. If it is necessary to hone the
master cylinder bore to repair damage, do not exceed allowable hone
specifications.
ASSEMBLY

INSPECTION AND REPAIR

1. Clean all parts in clean isopropyl alcohol, and inspect the parts for
chipping, excessive wear or damage.
When using a master cylinder repair
kit, install all the parts supplied.

2. Check all recesses, openings and

internal passages to be sure they are
open and free of foreign matter. Use
an air hose to blow out dirt and
cleaning solvent. Place all parts on a
clean pan or paper.
3. Inspect the master cylinder bore

1. Dip all parts except the master

cylinder body in clean Rotunda Extra
Heavy Duty Brake Fluid.
2. Carefully insert the complete
secondary piston and return spring
assembly in the master cylinder bore.
3. Install the primary piston assembly in the master cylinder bore.
4. Depress the primary piston and
install the snap ring in the cylinder
bore groove.
5. Install the push rod, boot and
retainer on the push rod, if so

equipped. Install the push rod assembly into the primary piston. M a k e
sure the retainer is properly seated
and holding the push rod securely.
6. Position the inner end of the

push rod boot (if so equipped) in the

master cylinder body retaining
groove.
7. Install the secondary piston stop
bolt and O-ring in the bottom of the
master cylinder.
8. Install the bleed screw (if so
equipped). Install the gasket (diaphragm) in the master cylinder filler
cover. Position the gasket as shown in
Fig. 16. M a k e sure the gasket is securely seated.

9. Install the cover and gasket on

the master cylinder and secure the
cover into position with the retainer.

12-02- 15

5
1

12-02- 15

Drum Brakes

SPECIFICATIONS
LINING DIMENSIONS -DRUM BRAKES -INCHES
Vehicle
..... ...
FORD, MERCURY, METEOR
Ford, Meteor Passenger (Riveted
Lining) Except 390, 429 ClD
Galaxie 500XL, Ford LTD, LeMoyne.

Ford, Mercury, Meteor w i t h Disc

Brakes.
Mercury Passenger, Sta. Wag. andp
Conv. Ford Meteor Station Wagon
and Convertible. 390, 429 ClD
Galaxie 500 XL, Ford LTD, LeMoyne.
Ford, Meteor 240, 302 CID Taxi
Only (Bonded Lining) Max Wear
Resistance.
MONTEGO, FAIRLANE
Passenger 250, 302 CID E xcept
Convertible
Station Wagon, Ranchero and
Convertible 250. 302 CID.
Passenger and convertible
351, 390, 428 Cl D.

'

Front

Rear

Primary

2.50 x 9.34

2.25 x 9.34

Secondary
Primary
Secondary

2.50 x 12.12
N/A
N /A

2.25 x 12.12
2,25 x 9.34
2.25 x 12.12

Primary

3.00 x 9.34

2.25 x 9.34

Secondarv

3.00 x 12.12

2.25 x 12.12

Primary
Secondary

2.25x8.43
2.25 x 10.82

2.00x8.43
2.00 x 10.82

Primary

2.50 13.43

2.061 8.43

'

Station Wagon and Ranchero 351,

390,428 CI D.
FALCON MAVERICK
Sedan 6-Cylinder.

Primary

Station Wagon 6-Cylinder.

Position

Sedan 8.Cyli nder.

Station Wagon 8-Cylinder.
MUSTANG, COUGAR
200 CI D Engine.

250, 302 CI DSngines.

351, 390, 4 28 Cl D Engines.
I

Secondary
Primary
Secondary

2.25 x 10.82
2.50 x 8.43
2.50 x 10.82

2.00 x 10.82
2.00 x 8.43
2.00 x 10.75

Primary
Secondary
Primary
Secondary
Primary
Secondarv

2.25 x 7.62
2.25 x 9.77
2.25 x 8.43
2.25 x 10.82
2.50 x. 8.43
2 . 5 0 ~10.82

1.50
1.50
1.75
1.75
2.00
2.00

'

x 7.62
x 9.77
x 8.43
x 10.82
x 8.43
x 10.82

THUNDERBIRD, CONTINENTAL MARK Ill

Primarv
Secondjy

2.25 x 9.34
2.25 x 12.12

N/A
N /A

LINCOLN CONTINENTAL
Primary

1 Secondarv
Wear Limits Riveted: 1/32 i n c h f r o m top of rivets.
Bonded: 0.030 inch t o t a l lining thickness.

N/A
N /A

2.50 x 9.34
2.50 x 12.12

12-02-16

12-02- 16

Drum Brakes

BORE DIAMETERS-BRAKE DRUM, WHEEL CYUNDER AND MASTER CYUNDER

Models
Ford,
Mercury
and
Meteor

MOmetO
and

Taxi and Station Wagon

Muter Cylinder Bore

Dia.
With Power Less Power
Brake@
Brake@
1.000
1.000

Wheel Cylinder Bore

Dia.

Brake D~~~
Inside BoringLirnit
Diameter
(Max.)$)
11.030
11.090

FrontO Rear@
1.094
0.938

Other
Pass. except Conv. 250, 302 ClD Engines
Pass. and Conv. 351, 390, 428 Cl D Eng.
Convertible 250, 302 CID Engines

11.030
10.000

1 10.000 1
10.000

11.090
10.060
10.060
10.060

1.125
1.125

0.938
0.906

1.000
0.9375

1.000
1.000

1.125

0.906

0.9375

1.000

1.125

0.906

0.9375

1.000

Fair lane
Maverick
Falcon
Mustang
and Cougar

Station and Ranchero

9 Inch Brake - Passenger Car
10 Inch Brake - Station Wanon
"
10 Inch Brake - Passenger Car
200 CI D Engine
351, 390, 428 ClD Engine
250, 302, CID Engine

Thunderbird
Continental Mark I l l
Lincoln Continental
@Max. Runout 0.007
@Max. Allowable Hone 0.003

1.000
0.9375
10.060
10.000
1.125
0.968
9.060
9.000
1.0620
1.000
0.8440 0.9375
1.000
0.9375
10.060
10.000
1.125
0.968
0.9375
1.125
10.060
10.000
0.875
1.000
1.0620
0.8440 1.000
9.060
1.000
9.000
10.000
1.000
0.906
10.060
1.125
1.000
0.875
10.060
10.000
1.000
1.125
1.000
11.030
0.938
11.090
NIA
NIA
N/ A
0.938
11.090
11.030
NIA
NIA
N/A
0.938
11.130
11.090
NIA
NIA
N/ A
@Front Wheel Cylinder cannot be honed on Falcon or Mustang with 9 inch
Brakes

12-02- 17

1 2-02- 1 7

Drum Brakes

TORQUE LIMITSGENERAL4T-LBS
FairlaneMontego
Falcon Maverick

Ford-Mercur y
Meteor
Master Cylinder t o Dash Panel Screw
Master Cylinder t o Booster
Booster t o Dash Panel

13-25
13.25
13-25

Wheel Cylinder t o Backing Plate Screws

10-20

13.25
13-25
13-25
10 in. Brake
10-20
9 in. Brake
5-7

13-25
13-25
13-25
' l o i n . Brake

Wheel Cylinder & Backing Plate

Anchor Pin Nut
Rear Brake Backing Plate t o Axle
Housing:
Removable Carrier
Integral Type
Front Brake Backing Plate t o Spindle
Pressure Differential
Valve Bracket Bolts and Nuts
Wheel Cylinder Bleeder Screw
Brake Hose Connection t o f r o n t
Wheel Cylinder
Brake Line Connection t o Rear Axle
Housing:
Removable Carrier
Integral Type
Hydraulic Tube Connections@

318 x 24
7/18 x 24
112 x 20
9/16 x 18

Thunderbird
Continental
Mark Ill

MustangCougar

10-20
9 in. Brake
5-7

13-25
13i25

Lincoln
Continental

13-25
13-25

10.20

10.20

50-70

30-35

7-11

7.11

.6.15

6-15

20-30
50-70
20-40
25-40
7-11

20-40
20-35
7-11

20-40
20-35
7.11

32-650

32-650

Inch-lb.

Inch-lb.

12-20

12-20

12.20

30-40
25-35

12.19
12-19

12-19
12-19

30-40

10-15
10-15
10.17
10-17

10-15
10-15
10-17
10-17
4 lug
55-85
5 lug
70-115

10-15
10-15
10-17
10-17
4 lug
55-85
5 lug
70-115

10.15
10-15
10-17
10-17

10-15
10-15
10-17
10-17

70-115

70-115

6.15

Wheel t o Hub and Drum

70-115

@All hydraulic lines must be tightened t o the specified torque value and be free of f l u i d leakage.

SPECIAL TOOLS
Ford Tool No.
Rotunda HRE 8650
~

~-

Description
Brake Adjusting Gage
Brake Cylinder Retaining Clamp

Former No.
LM 119

2162
2035N
Tool 7000-00
Tool 33621

33621

1
Tool 4235-C

I Rotunda FRE 1431

Adapter Cap
Brake Shoe R & R Spring
Rubber Tipped Air Nozzle
Internal Snap Ring Pliers

1
I

1112-144
4235-C

Inch Pound Torque Wrench

Axle Shaft Remover

Brake Drum Micrometer

Disc Brake

BART 12-03 Disc Brake

COMPONENT INDEX.
Applies T o Models As Indicated

12-03-02

12-03-02

Disc Brake

DESCRIPTION
cylinder equipped hydraulic brake
DUAL MASTER CYLINDER
BRAKE SYSTEM
system employs single anchor, internal expanding and self-adjusting drum
brake assemblies on the rear wheels
The dual-master cylinder brake
of vehicles with disc brakes.
system has been incorporated in all
The disc brake consists of a ventimodels to provide increased safety.
The system consists of a dual-master
lated rotor and caliper assembly. The
caliper used is a single piston floating
cylinder (Fig. 2), pressure differential
caliper (Fig. I).
valve assembly and' a switch (Fig. 3).
A pressure control valve provides
The switch on the differential valve
balanced braking action between front
activates a dual-brake warning light,
located on the instrument panel.
and rear brakes.
On Ford, Mercury, ~ e t e o r , " ~ o n t i nental Mark 111, Lincoln Continental
FLOATING CALIPER
and Thunderbird models a metering
valve, in the hydraulic line between
the differential valve and the front
The caliper assembly -is made up of
wheel disc brakes, prevents the front
a floating caliper housing assembly
brakes from applying until approxiand an anchor plate. The anchor platemately 125 psi is obtained in the sysis bolted to the wheel spindle arm by
tem (Fig. I). This delaying action is
two bolts. The floating caliper is atrequired to prevent the front brakes
tached to the anchor plate by steel
from performing all the braking acstabilizers on Ford, Mercury, Meteor,
Lincoln Continental, Thunderbird and
tion on low speed stops and thereby
increasing the rate of lining wear, and
Continental Mark I11 models and by
from- locking on ice and slippery
one stabilizer on Fairlane, Montego,
pavement.
Mustang and Cougar models. The
A vacuum booster is used with the
floating caliper slides on two locating
pins which also attach to the stabilizpower disc brake system.
ers. The floating caliper contains the

Disc brakes are available as optional equipment for the front wheels on
Ford, Mercury, Meteor, Fairlane,
Montego, Mustang and Cougar models and are standard on Thunderbird,
Continental Mark 111, and Lincoln
Continental models. The dual-master
I N N E R B R A K E SHOE
HOLD DOWN CLIPS
20164

O U T E R B R A K E SHOE
R E T A I N I N G CLIPS
2066

2 ~ 1 1 R.H.
8
201 1 9 L.H.
H 1690.~

FIG. 7-Disc Brake AssemblyFloating Caliper

SECONDARY B R A K E
FLUID RESERVOIR
PRIMARY SYSTEM B R A K E
FLUID RESERVOIR

R E T U R N SPRING ( P R I M A R Y )

B R A K E OUTLET
PORT

FIG. 2-Dual

SECONDARY PISTON
ASSEMBLY

B R A K E OUTLET
PORT

Master Cylinder-Typical

P R I M A R Y PISTON
ASSEMBLY

H 1545-A

12-03-03

12-03-03

Disc Brake

NORMAL POSITION
CENTERED

T OUTLET

LIGHT CAR

CUSTOM CAR

niro7.e
FIG. 3-Pressure
Differential a n d Pressure Control Valve a n d Brake
Warning Light Switch

single cylinder and piston assembly.

The cylinder bore contains a piston
with 'a molded rubber dust boot. to
seal the cylinder bore from contamination (Fig. 4). A'square section rubber piston seal is positioned in a
groove in the cylinder bore and is
used to provide sealing between the
cylinder and piston (Fig. 5).
The outer brake shoe and lining
assembly islonger than the inner assembly, and the shoe and lining
assemblies are not interchangable.
The outboard shoe and lining is fixed
to the floating caliper and is retained
by two pins and spring clips. The
shoe and lining assembly consists of
friction material bonded t o a metal
plate called the shoe. It is replaced as
a unit.

The cast iron disc is of the ventilated rotor-type incorporating forty fins
and is attached to, and rotates with
the wheel hub. A splash shield bolted
to the spindle is used primarily to
prevent road contaminants from contacting the inboard rotor and lining
surfaces. The wheel provides protection for the outboard surface of the
rotor.

CALIPER HOUSING

BRAKE BOOSTER SYSTEM

PISTON-

SHOE

This diaphragm-type brake booster

is a self-contained vacuum-hydraulic
braking unit mounted on the engine
side of the dash panel.
The brake booster is of the vacuum
suspended-type which utilizes engine
intake manifold vacuum and atmospheric pressure for its power.

LINING-

PISTON-SEAL

ANCHOR PLATE

H 1568-8

FIG. 4-Floating

Caliper Assembly-Sectional

View

Adjustment of the push rod and replacement of the check valve and
grommet are the only services permitted on the brake booster. The booster
unit is to be exchanged when i t is inspected, checked and found to be inoperative.

12-03-04

12-03-04

Disc Brake

PISTON SEAL
DISTORTED

PISTON SEA,L RELAXED

CALIPER HOUSING
BRAKES APPLIED

FIG. 5-Function

BRAKES RELEASED

H1569-8

o f Piston Seal

REMOVAL A N D INSTALLATION

DlSC BRAKE CALIPER ASSEMBLY

'REMOVAL
I. Remove the wheel and tire
assembly from the hub. Use care to
avoid damage or interference with the
bleeder screw fitting during removal.
2. Disconnect the brake hose from
the caliper. Cap the hose fitting to
prevent brake system contamination
and loss of brake fluid from the master cylinder. Mark the left and right
caliper assemblies with chalk prior to
removal from the vehicle.
3. Remove the caliper locating pins
and lower stabilizer attaching bolts
and discard the stabilizer (Figs. 3 and
6).
4. L i f t the caliper from the anchor
plate.
INSTALLATION
I. Install the caliper assembly over
the rotor with the outer brake shoe
against the rotor braking surface during installation in the anchor plate to
prevent pinching the piston boot between the inner brake shoe and the
piston. Check that the correct caliper
is installed on the correct anchor
plate as marked during disassembly.
2. Position the new stabilizer (supplied in the brake kit). Apply water
to the locating pins and attach the
stabilizer to the caliper. Be sure the
locating pins are free of oil, grease or

dirt. Torque the caliper, locating pins

to specifications.
3. Install the stabilizer to anchor
plate attaching screws and torque to
specifications.
4. Remove the cap from the brake
hose fitting. Install a new copper
yasher on each side of the hose fitting a d install' the brake hose to the
caliper. Torque the attaching bolt to
specifications.
5. Bleed the brake system and
centralize the brake pressure differential valve as outlined in Part 12-01.
6. Fill the master cylinder as required to within t/4 inch of the top
of the reservoir.
7. Install the wheel and tire assembly and torque the wheel nuts to specifications.
8. Apply the brake pedal prior to
moving the vehicle to position the
brake linings.
9. Road test vehicle.
DlSC BRAKE SHOE A N D LINING
FORD, MERCURY, METEOR,
THUNDERBIRD,
C O N T I N E N T A L M A R K Ill,
LINCOLN CONTINENTAL
Removal
I. Remove the master cylinder cap
and check the fluid level in the prim a r y (large) reservoir. Remove
enough fluid until the reservoir is half

BLEEDER SCREW FACING THIS D ~ R E C ~ O N ~

FROHT

ROTOR SPLASH SHIELD

Hl64LB

FIG. 6-Floating
Installed-Rear

Caliper
View

full. Discard this fluid.

2. Remove the wheel and tire
assembly from the hub. Be careful t o
avoid damage or interference with the
caliper splash shield or bleeder screw
fitting.
3. Remove the inner shoe hold
down clips (Fig. 3).
4. Place a small screwdriver under
the outer shoe retaining clip tang and
l i f t away from the pin groove and
slide the clip from the shoe retaining
pin. Remove the other brake shoe retaining clip. See Fig. 3 and remove
the outer brake shoe.
5. Remove the caliper locating pins

Disc Brake

(Fig. 6).
6. Remove the upper stabilizer to
anchor plate attaching bolt and remove the upper stabilizer to avoid interference with the brake hose during
caliper removal (Fig. 6).
7. Lift the caliper assembly from
the anchor plate and remove the outer
shoe and retaining pins from the caliper assembly.
8. Suspend the caliper from the
vehicle upper control arm with a wire
hooked through the upper caliper locating pin hole.
9. Remove the caliper locating pin
insulators (Fig. 3).
10. Remove the inner shoe and lining assembly and inspect both rotor
braking surfaces.
Installation
1. Install the inner shoe and lining
assembly in the anchor plate, then install new locating pin insulators (supplied in the shoe and lining kit). Use
a cloth to protect the insulators during installation (Fig. 3). Check that
both insulator flanges straddle the ancho'r plate.
2. Install the inner brake shoe hold
down clips and torque the retaining
bolts to specifications.
3. Install the piston retracting tool

in the caliper with the brake shoe lances positioned in the slots in the caliper outer legs and retract the piston
(Fig. 7).
The piston retracting tool can be
fabricated from a discarded outer
brake shoe and a threaded rod. Refer
to Fig. 8 for tool fabricating details.
When using the piston retracting
tool, turn the threaded rod one half
turn at a time and pause to permit
the piston to move in the seal. Reduce
the time interval as the piston nears
the bottom of the cylinder bore to ensure bottoming of the piston. If the
piston is not fully bottomed, the spacing between the linings will be insufficient to position the brake shoe and
caliper assembly over the rotor.
Inspect the piston dust boot for
cracks due to overheating and replace
as required (Part 12-03, Section 4).
4. Turn the tool handle clockwise
with one hand and guide the ram into
the piston cavity with the other until
the piston is bottomed in the cylinder
bore. Remove the tool.
5. Install the outer brake shoe and
lining assembly, then install the retaining pins and retainer clips (Fig.
3).
6. Remove the caliper assembly
from the upper control arm and insert
the caliper assembly in the anchor

plate.
7. Position the upper stabilizer and
install the stabilizer to Anchor plate
attaching bolt. Be careful to, properly
position the tab at the tower bolt
location. Torque the attaching bolt to
specifications.
8. Install the caliper locating pins
and torque to specifications (Fig. 6).
9. Add fluid in the master cylinder
as required until the fluid level is
within t/4 inch of the top of the reservoir.
10. Install the wheel and tire assembly and torque the wheel nuts to
specifications.
11. Pump the brake pedal prior to
moving the vehicle 'to position the
brake linings.
12. Road test the vehicle.
FAIRLANE. MONTEGO,
MUSTANG, COUGAR
Removal
1. Remove the wheel and tire
assembly from the hub. Be careful to
avoid damage or interference with the
caliper splash shield or bleeder screw
fitting.
2. Remove the caliper from the
vehicle following the procedures outlined under Disc Brake Caliper Assembly.
3. Remove the inner brake shoe
hold down clips from the anchor
plate, remove the locating pin insulators from the anchor plate and remove the inboard brake shoe and lining assembly.
4. To remove the outer brake shoe.
place a small screwdriver under the
outer brake shoe retaining clip tang
WELD SECURELY
TO T H R E A D E D RO
1/2-13 THREADED

TO BRAKE SHOE

n l693.A

FIG. 8-Piston
FIG. 7-Installing

Piston Retracting Tool

Dimensions

Retracting Tool

12-03-06

12-03-06

Disc Brake

4. Install the new outer brake shoe

and lining assembly on the caliper
and install the outer brake shoe retaining clips. Hold the retaining pins
in position with an allen wrench or
bolt while installing the retaining
clips.
5. Install the caliper on the vehile
following the procedures outlined
under Disc Brake Caliper Assembly.

and lift away 'from the pin groove and

slide the clip from the brake shoe retaining pin. Remove the other brake
shoe retai-ning clip. See Fig. 3 and remove the outer brake shoe.
Installation

1. To install a new inner brake

shoe in the anchor plate, install new
caliper locating pin insulators (supplied in the brake shoe and lining
kit). Use a cloth to protect the insulators during assembly. Check that both
insulator flanges straddle the anchor
plate (See Fig. 3).
2. Install the inner brake shoe hold
down clips and torque the retaining
screws to specifications.
3. Install the piston retracting tool
in the caliper with the brake shoe lances positioned in the slots in the caliper outer legs and retract the piston.
The piston retracting tool can be fabricated from a discarded outer brake
shoe and a threaded rod. Refer to
Fig. 8 for tool fabricating details.
When using the piston retracting tool,
turn the threaded rod one half turn at
a time and pause to permit the piston
to move in the seal. Reduce the time
interval to ensure bottoming of the
piston. If the piston is not fully bottomed, the spacLng between the' linings is insufficient - to assemble the
brake shoe and caliper assembly over
the .rotor. Use a cloth to catch brake
fluid from the caliper bore (See Fig.
7).

FRONT WHEEL H U B A N D ROTOR

ASSEMBLY
'
REMOVAL
I . Remove the wheel and tire from
the hub. Be careful to avoid damage
or interference with the bleeder screw
fitting.
2. Remove the caliper assembly
from the spindle and the rotor. If the
caliper does not require servicing, it is
not necessary to disconnect the brake
hose or remove the caliper from the
vehicle. Position the .caliper out of the
way, and support it with a wire to
avoid damaging the caliper or stretching the hose. Insert a clean cardboard
spacer between the linings to prevent
the piston from coming out of the
cylinder, bore while the caliper is
removed.
Handle the rotor and caliper
assemblies in such a way a s to avoid
deformation of the rotor and nicking,
scratching or contamination of the
brake linings.
'3. Remove the grease cap from the

hub. Remove the cotter pin, nut lock,

adjusting nut, and flat washer from
the spindle. Remove the outer bearing
cone and roller assembly.
4. Remove the hub . and rotor
assembly from the spindle.
INSTALLATION
1. If the rotor is being replaced,
remove the protective coating from
the new rotor with carburetor degreaser. Pack a new set of bearings
with specified grease (M- IC75B), and
install the inner bearing cone and
roller assembly in the inner cup. Pack
grease lightly between the lips of a
new grease seal and install the seal
(Fig. 9).
If the original rotor is being installed, make sure that the grease in
the hub is clean and adequate, that
the inner bearing and grease seal are
lubricated and in good condition, and
that the rotor braking surfaces are
clean.
2. Install the hub and rotor assembly on the spindle.
3. Lubricate and install the outer
wheel bearing, washer and adjusting
nut.
4. Adjust the wheel bearings to
specification, and then install the nut
lock, cotter pin, and grease cap. The
wheel bearing adjustment is especially
important with disc brakes.
5. Mount the caliper assembly on
the spindle following the Disc Brake
Caliper Assembly Installation proceC A L I P E R PARTS

34806.5

ff K?>R.*

28118 R H
281 I 9 L H

FAIRLANE, MONTEGO, FALCON,

MUSTANG A N D COUGAR

...a.

\CONE

b..

W
"
.,.

AND ROLLER

m?$$7

:LATE*

CONE AND ROLLER

3105'~.~.
3106-L.H.

28160

ROTOR SPLASH SHIELD

2KWd-R.H.
2KOO5-L.H.

FIG. 9-Disc

Brake

is assembled

.I .Inl

GREASE S I:AL

I I

T t

h<

SHOE
2019

PIN

SHOE
20 18

12-03-07

12-03-07

Disc B r a k e

dure in this section.

DISC BRAKE ROTOR

SPLASH SHIELD

CLIP

W '0 A I R CONDITIONING
I

BUSHING

REMOVAL
I. Remove the caliper and the hub
and rotor assembly as outlined under
Removal in the foregoing procedure
(it is not necessary to disconnect hydraulic connections).
2. Remove the three bolts that attach the splash shield to the spindle,
and remove the shield (Fig. 9).
3. Remove and discard the splash
shield to spindle gasket.
INSTALLATION

LIGHT

STOP
SWITCH 13480

FIG. 10-Master
Meteor

\
SPACER

Cylinder Installation-Power Brake-Ford,

BRAKE VACUUM BOOSTER

Mercury a n d

DUAL MASTER CYLINDERPOWER BRAKES

-2OAj

REMOVAL

JOOT-2A02 1

MASTER
CYLINDER
ASSEMBLY

ASSEMBLY

TRANSMISSION
BRAKE

PEDAL ASSEMBLY
H 1557-C

Montego

1. Remove the brake tubes from

the primary and secondary outlet
ports of the master cylinder (Figs. 29
thru 33).
2. Remove the two nuts and two
lock washers attaching the master
cylinder to the brake booster assembly.
3. Slide the master cylinder forward and upward from the vehicle.

INSTALLATION

STOP LIGHT SWITCH-134

FIG. 1 ]-Master

1. Install a new splash 'shield to

spindle gasket.
2. If the shield is bent, straighten it
out before installation. Position the
shield to the mounting bracket, install
the attaching bolts, nuts and torque
them to specification.
3. Install the hub and rotor assembly and the caliper as outlined under
Installation in the foregoing procedure.

Cylinder Installation-Power

Brake-Fairlane,

1. Before installing the master

cylinder, check the distance from the
outer end of the booster assembly
push rod to the master cylinder
mounting surface. Turn the push rod
adjusting screw in or out as required
to obtain the specified length. Refer
to Part 12-01, Section 2, Power
Brake Master Cylinder Push Rod
Adjustment for the proper procedure.
2. Position the master cylinder
assembly over the booster push rod
and onto the two studs on the booster
assembly (Figs. 10 thru 14).
3. Install the attaching nuts and
lock washers and torque them to
specifications.

12-03-08

12-03-08

Disc Brake

( E S A - ~ 6 ~ 2 5 - Afor
) all biake applications. The extra heavy duty brake
fluid i s colored blue for identification.
Do not mix low temperature brake
fluids with the specified fluids,for the
disc brake system.
6. Bleed the dual-master cylinder

and the primary and secondary brake

systems. Centralize the pressure differential valve. Refer to Hydraulic
System Bleeding and ,Centralizing o f
the Differential Valve, Part 2-1, Section 2 for the proper procedure.
7. Operate the brakes several
times, then check for external hydraulic leaks.
PRESSURE DIFFERENTIAL A N D
PRESSURE CONTROL VALVE
SWITCH l74EO

TO EQUALIZER ROD

2005

Refer to Fig. 2.

MASTER CYLINDER
2140

FIG. 12-Master

REMOVAL

Cylinder Installation-Power

Brake-Mustang

and

Cougar

The Brake and/or Pressure Differential and Pressure Control Valve assembly is serviced as an assembly
only. D o not attempt to repair this
unit.
1. Disconnect the brake warning

light connector from the warning light

switch.
2. Disconnect the front inlet and
rear outlet tubes from the valve assembly (Fig. 2).
3. Remove the two attaching nuts
and bolts from the valve bracket on
the underside of the fender apron and
remove the valve assembly and bracket from the vehicle.

SOOSTER ASSEMBLY- 2005

/

INSTALLATION

BUSHING

MASTER CYLINDER
2140

FIG. 13-Master
Mark Ill

BRAKE LIGHT SWITCH-I3480

Cylinder Instollation-Thunderbird

a n d Continental

1. ~os.ition the valve assembly and

bracket to the fender apron. Install
the attaching nuts and bolts. Torque
them to specifications.
2. Install the front inlet and rear
outlet tubes to the valve assembly.
Torque them to specifications.
3. Connect the brake warning light
connector to the warning light switch.
4. Bleed the system and centralize
the pressure differential valve following the procedures in Centraliz~ng
the Pressure Differential Valve..
PRESSURE METERING
VALVE-FORD, MERCURY,
METEOR, CONTINENTAL M A R K
Ill, THUNDERBIRD, LINCOLN
CONTINENTAL
REMOVAL

4. Install the front and rear brake

tubes to the master cylinder outlet fittings.
5. Fill the fnaster cylinder with the

specified brake fluid to within 114

inch of the top of the dual reservoirs.
Use Ford Brake Fluid-Extra Heavy
Duty-Part
Number C6AZ-19542-A

Refer to Fig. 15.

1. Loosen the tube nuts connecting
the inlet and outlet tubes at the me-

Disc Brake

tering valve, and remove the tubes.

2. Remove the two screws retaining
the metering valve to the frame
crossmember, and remove the metering valve. The metering valve is
serviced as an assembly only.

INSTALLATION
NUT (4 REQUIRED) -557685
WASHER (4 REQUIRED) - 4 4 7 2 6 5 8

I. Position the metering valve to

the frame crossmember, and install
the retaining screws.
2. Connect the inlet and outlet
tubes to the metering valve, and tighten the tube nuts to specification.
3. Pressure Bleed the system.

3EFORE ASSE

BRAKE BOOSTER

REMOVAL

MASTER CYLINDER
IDENTIFICATION

Him-0

FIG. 14-Master

Cylinder Installation-Lincoln

1. Working from inside the vehicle

below the instrument panel, disconnect the booster push rod from the
brake pedal assembly. To do this,
proceed as follows:
Disconnect the stop light switch
wires at the connector. Remove the
hairpin retainer. Slide the stop light
switch off from the brake pedal pin
just far enough for the switch outer
hole to clear the pin, and then remove

Continental

the switch from the pin and booster

push rod. Be careful not to damage
the switch during removal. Slide the
booster push rod and the nylon washers and bushing off the brake pedal
pin (Figs. 10 thru 14).
2. Open the hood and remove the
master cylinder from the booster. Secure it to one side without disturbing
the hydraulic lines. It is not necessary
to disconnect the brake lines, but care
should be taken that the brake lines
are not deformed. Permanent deformation of brake lines can lead to tube
failure.

FORDMERCURY-METEOR
THUNDERBIRD AND MARK Ill
METERING VALVE
BLEEDER RETAINER

RELEASE ROD

FIG. 15-Metering

Valve Location

3. Disconnect the manifold vacuum

hose or hoses from the booster unit.
4. Remove the booster-to-dash
panel attaching nuts or bolts (Figs. 10
thru 14). Remove the booster and
bracket assembly from the dash
panel, sliding the push rod link out
from the engine side of the dash
panel.
5. On Fairlane, Montego, and Falcon models, remove the push rod link
boot from the dash panel.

COMPRESS
TOOL AND
POSITION
ONTO VALVF.
RELEASE TO
ALLOW
SPRING
ACTION TO
FORCE
R W OUT

INSTALLATION
HIUB

I. On Fairlane, Montego and Falcon models, install the push rod link
boot in the hole in the dash panel as
shown in Fig. 11. Install the four
spacers on the mounting studs.

12-03-1 0

2. Mount the booster and bracket

assembly to the dash panel by inserting the push rod o r push rod link in
through the hole and boot in the dash
panel. lnstall the bracket-to-dash
panel attaching lock nuts or bolts
(Figs. 10 thru 14).
3. Connect the manifold vacuum
hose or hoses to the booster.
4. Before installing the master
cylinder, check the distance from the
outer end of the booster assembly
push rod to master cylinder surface.
Turn the screw in or out to obtain the
specified length. Refer to Part 12-01,
Section 2, Power Brake Master Cylinder Push Rod Adjustment. Install
the master cylinder and torque the attaching nuts to specifications.
5. Working from inside the vehicle
below the instrument panel, connect
the booster push rod link to the brake
pedal assembly. To do this, proceed
as follows:
lnstall the inner nylon washer, the
booster push' rod, and the bushing on
the brake pedal pin. Position the
switch so that it straddles the push
rod with the switch slot on the pedal
pin and the switch outer hole just
clearing the- pin. Slide the switch
completely onto the pin, and install
the nylon washer as shown in Figs. 10
thru 14. Be careful not to bend or deform the switch. Secure these parts to
the pin with the hairpin retainer.
Connect the stop light switch wires to
the connector, and install the wires in
the retaining clip.

BRAKE PEDAL
FORD, MERCURY
AND METEOR
Removal
1. Disconnect the stop light switch
wires a t the connector.
2. Remove the hairpin retainer.
Slide the, stop light switch off the
brake pedal pin just far enough for
the switch outer hole to clear the pin,
and then lift the switch straight upward from the pin. Be careful not to
damage the switch during removal.
Slide the master cylinder or booster
push rod and the nylon washers and
bushing off the brake pedal pin (Fig.
10).
3. Remove the hairpin-type retainer and washer from the brake. pedal
shaft, then remove the shaft, the
brake pedal and the bushings from
the pedal support bracket.

12-03- 10

Disc B r a k e

Installation
1. Apply a coating of SAE 10
Engine oil to the bushings and locate
bushings in their proper places on the
pedal assembly and pedal support
bracket (Fig. 10).
2. Position the brake pedal assembly to the support bracket, then install the pedal sh-aft through the support bracket and brake pedal assembly. Install the retainer.
3. Install the inner nylon washer,
the master cylinder or booster push
rod, and the bushing on the brake
pedal pin. Position the switch so that
it straddles the push iod with the
switch slot on the pedal pin and the
switch outer hole just clearing the pin.
Slide the switch completely onto the
pin, and install the nylon washer as
shown in Fig. 10. Be careful not to
bend or deform the switch. Secure
these parts to the pin with the hairpin
retainer.
4. Connect the stop light switch
wires to the connector, and install the
wires in the retaining clip.
5. Check the Brake Pedal Free
Height. and Travel Measurements,
Part 12-01, Section I.

FAIRLANE,
MONTEGO-MANUALSHIFT-TRANSMISSION
Removal
1. Remove the clutch pedal assist
spring.
2. Disconnect the clutch pedalto-equalizer rod at the clutch pedal.by
removing the retainer and bushing. '
3. Disconnect the stop light switch
wires at the connector.
4. Remove the switch retainer, and
slide the stop light switch off the
brake pedal pin just far enough for
the switch outer hole to clear the pin.
Then lower the switch away from the
pin.
5. Slide the master cylinder or
booster push rod and the nylon washers and bushing off from the brake
pedal pin (Fig. I I).
6. Remove the self-locking pin and
washer from the clutch and brake
pedal shaft, then remove the clutch
pedal and shaft assembly, the brake
pedal assembly, and the bushings
from the pedal support bracket (Fig.
I I).

Installation
1. Apply a coating of SAE 10
engine oil to the bushings and locate

all bushings in their proper places on

the clutch and brake pedal assemblies. .
2. Position the brake pedal to the
support bracket, then install the
clutch pedal a n d shaft assembly
through the support bracket and
brake pedal assembly. Install the
spring clip (Figs. 27 and 30).
3. Install the clutch pedal assist
spring.
4. C o n n e c t the clutch pedalto-equalizer rod to the clutch pedal
assembly with the bushing and the
spring clip retyiner. Apply SAE 10
engine oil to the bushing.
5. Install the inner nylon washer,
the master cylinder or booster push
rod,, and the bushing on the. brake
pedal pin. Position the switch so that
it sstraddles the push rod with the
switch slot on the pedal pin and the
switch outer hole just clearing the pin.
Slide, the switch completely onto the
pin, and install the outer nylon washer as shown in Fig. I I . Secure these
parts to the pin with the self-locking
pin.
6. connect the stop light switch
wires to the connector, and install the
wires to the retaining clip.
7. Adjust thg clutch pedal free play
(Group 16-02) to specification, if required.
8. Check the Brake Pedal Free
Height and Travel Measurements
(Part 12-01, Section I).
MUSTANG AND COUGARMANUAL-SHIFT
TRANSMISSION
Removal
1. Disconnect the battery ground
cable .from the battery.
2. Remove the steering column.
Refer to Part 13-02 for procedure..
2. Remove the two cap screws retaining the booster to the dash panel.
4. Working inside the vehicle, secure. the clutch pedal against the
bumper stop with a small C-clamp as
shown in Fig. 12.
5. Disconnect the clutch pedalto-equalizer rod at the clutch pedal by
removing the retainer and bushing.
6. Disconnect the stop light switch
wires a t the connector.
7. Remove the switch retainer and
slide the stop light switch off the
brake pedal pin just f a r enough for
the switch outer hole to clear the pin.
Then lower the switch away from the
pin. -Remove the master, cylinder or
booster push rod, bushing and nylon
washer from the brake pedal pin.

Disc Brake

8. Remove the screw retaining the

pedal support bracket to the top inner
cowl bracket (Fig. 12).
9. Remove the two sheet metal
screws retaining the pedal support
bracket to the dash panel. On power
brakes remove the nuts from the
brake booster studs.
10. Remove the two screws retaining the pedal support bracket to the
upper cowl brace and lower the pedal
support bracket away from the steering column studs.
11. Remove the pedal support
bracket assembly from the vehicle.
12. Position the pedal and support
bracket assembly in a vise.
13. Remove the C-clamp to release
the clutch pedal from its bumper stop
and pivot the pedal away from the
bumper.
14. Remove the clutch pedal assist
spring.
15. Remove the clutch pedal and
shaft assembly, the brake pedal assembly, and the bushings from the
pedal support bracket. Remove the
retainer nut from the brake pedal
shaft then remove the pedal shaft, the
brake pedal assembly and the bushings from the pedal support bracket.

bushing on the brake pedal pin. Position the stop light switch so that it
straddles the push rod with the switch
slot on the pedal pin and the switch
outer hole just clearing the pin. Slide
the switch completely onto the pin,
and install the outer nylon washer as
shown in Fig. 12. Secure these parts
to the pin with the self-locking retainer.
9. Connect the stop light switch
wires to the connector.
10. Connect the clutch pedalto-equalizer rod to the clutch pedal
assembly with the bushing and the
spring clip retainer. Apply S A E 10
engine oil to the bushing. Remove the
C-clamp from the clutch pedal.
11. Working from the engine side
of the dash panel. Install the cap
screws retaining the brake booster to
the dash panel.
12. Install the steering column.
Refer to Part 13-02 for procedure.
13. Adjust the clutch pedal free
play (Part 16-02) to specifications, i f
required.
14. Check the Brake Pedal Free
Height and Travel Measurements
(Part 12-01, Section I).
15. Connect the ground cable to
the battery.

Installation

1. Apply a coating of SAE 10

engine oil to the bushings and locate
all bushings in their proper places on
the clutch and brake pedal assemblies.
2. Install the clutch pedal and shaft
assembly through the support bracket
and brake pedal assembly. On power
brakes position the brake pedal to the
pedal support bracket, then install the
pedal shaft and nut.
3. Install the clutch pedal assist
spring and pivot the clutch pedal
against its bumper stop. Secure the
pedal to the stop with a small Cclamp as shown in Fig. 12.
4. Position the pedal support
bracket assembly to the dash panel,
and to the steering column retainer
studs.
5. Align the pedal support bracket
holes with the holes in the dash panel
and install the two attaching sheet
metal screws. Install the nuts on the
brake booster studs.
6. Install the two cap screws attaching the pedal suRport bracket to
the upper cowl bracket.
7. Install the cap screw attaching
the pedal support bracket to the top
inner cowl bracket (Fig. 12).
8. lnstall the inner nylon washer,
the master cylinder push rod, and the

FAIRLANE, MONTEGO,
MUSTANG AND
COUGAR-AUTOMATIC
TRANSM ISSlON

Removal

1. Disconnect the stop light switch

wires at the connector.
2. Remove the self-locking pin and
slide the stop light switch off the
brake pedal pin just far enough for
the switch outer hole to clear the pin.

Then lower the switch away from the

pin. Slide the master cylinder or
booster push rod and the nylon washers and bushing off from the brake
pedal pin (Fig. 12).
3. On all vehicles except Mustang
and Cougar, remove the self-locking
pin and washer from the brake pedal
shaft, then remove the shaft, the
brake pedal assembly and the bushings from the pedal support bracket.
On Mustang and Cougar vehicles, remove the locknut and bolt from the
pedal. Remove the pedal assembly
from the support bracket (Fig. 12).
Installation

1. Apply a coating of SAE 10

engine oil to the bushings and locate
all the bushings in their proper places

on the pedal assembly and pedal support bracket (Fig. 12).

2. Position the brake pedal assembly to the support bracket, then install the pedal shaft or bolt through
the support bracket and brake pedal
assembly. Install the retainer or locknut.
3. Install the inner nylon washer,
the master cylinder or booster push
rod, and the bushing on the brake
pedal pin. Position the switch so that
it straddles the push rod with the
switch slot on the pedal pin, and the
switch outer hole just clearing the pin.
Slide the switch completely onto the
pin, and install the outer nylon washer as shown in Fig. 12. Secure these
parts to the pin with the self-locking
pin.
4. Connect the stop light switch
wires to the connector, and install the
wires in the retaining clip.
Check the Brake Pedal Free Height
and Travel Measurements, Part 120 1, Section I .
THUNDERBIRD AND
CONTINENTAL MARK 111
Removal

I. Loosen the booster mounting

nuts.
2. Disconnect the stop light switch
wires a t the connector.
3. Remove the hairpin retainer.
Slide the stop light switch off from
the brake pedal pin just far enough
for the switch outer hole to clear the
pin, and then lift the switch straight
upward from the pin. Slide the master

cylinder push rod and the nylon washers and bushing off from the brake
pedal pin (Fig. 13).
4. Remove the pivot bolt and nut
that holds the pedal to the pedal support bracket. Remove the brake pedal
assembly from the pedal support
bracket, and remove the bushings.
Installation

1. Apply a coating of S A E 10
engine oil to the bushings and locate
all the bushings in their proper places
on the pedal assembly (Fig. 13).
2. Install the brake pedal assembly
and bushings to the support bracket,
and then install the pivot bolt through
the support bracket and brake pedal
assembly. lnstall the pivot bolt nut
and torque to specifications.
3. Install the inner nylon washer,
the master cylinder push rod, and the
bushing on the brake pedal pin. Position the switch so that it straddles the

Disc B r a k e

push rod with the switch slot on the

pedal pin and the switch outer hole
just clearing the pin. Slide the switch
completely onto the pin, install the
outer nylon washer as shown in Fig.
13. Secure these parts to the pin with
the hairpin retainer.
4. Connect the stop light switch
wires to the connector, and install the
wires in the retaining clip.
5. Torque the booster mounting
nuts to specifications.
LINCOLN CONTINENTAL
Removal
1. Disconnect the battery ground
cable from the battery.
2. It is necessary to obtain clearance to remove vacuum hoses and the
electrical connector to the temperature heat control box. Remove the
two screws retaining the relay to the
fender and push the relay aside. Disconnect the vacuum hoses and connector a t the heat control box.
3. Working under the instrument
panel, disconnect the vacuum hoses.
wires and retaining clip from the temperature heat control box. Remove
the two screws securing -the temperature control box to the dash panel.
4. Remove the lower control housing retaining screws (6). Disconnect
the wire harnesses a t the lower control panel and place the panel aside.
Remove the wire harness shield. Remove the wire harness clip. Position

the wire harness aside. Remove the

temperature control box and position
it aside.
5. Remove the hair-pin type retainer. Slide the stop light switch off the
brake pedal pin just far enough for
the switch outer hole to clear the pin.
Lift the switch upward from the pin.
Slide the master cylinder push rod,
nylon washers and bushing off the
brake pedal pin.
6. Remove the pivot bolt and nut
that holds the pedal to the pedal support bracket. Remove the brake pedd
assembly from the support bracket
and remove the bushings.
7. If required, remove the brake
pedal pad retaining nuts and remove
the brake pedal pad.
Installation
I. If the brake pedal pad was
removed, position the pad on the
pedal. lnstall the pad retaining nuts
and torque them to specification.
2. Apply SAE 10 engine oil to the
bushings and locate all the bushings
in their proper places on the pedal assembly.
3. lnstall the brake pedal assembly
and bushings to the support bracket.
and then install the pivot bolt through
the support bracket and pedal assembly. Install the pivot bolt nut and torque it to specification.
4. Install the inner nylon washer,the
master cylinder push rod link, and the

12-03-1 2

bushing on the brake pedal pin. Position the switch so that it straddles the
push rod link with the switch slot on
the pedal and the switch outer hole
just clearing the pin. Install the outer
nylon washer as shown in Fig. 14. Install the hair-pin type retainer on the
brake pedal pin.
5. Connect the stop light switch
wires to the connector, and install the
wires in the retaining clip.
6. Position the wire harness and
clip on the temperature control box
and install the retaining screw. Position the temperature control box to
the dash panel and install the two retaining bolts.
7. Connect the vacuum lines and
the electrical connector to the control
box. Position the wire harness to the
control box and install the retaining
clip.
8. Position the wire harness shield
and install two retaining bolts.
9. Connect the wire harnesses to
the lower control panel and install the
retaining screws.
10. Working within the engine
compartment, connect the wire connector to the temperature heat control
box.
11. Position the relay to the fender
apron and install the retaining bolts.
12. Connect the ground cable to
the battery.
13. Check the brakes and light
switch for proper operation. Close the
hood.

MAJOR REPAIR OPERATIONS

After any service work, obtain a

firm brake pedal before moving the
vehicle. Riding the brake pedal (common on left foot application) should
be avoided when driving the vehicle.
ROTOR REFINISHING
Rotunda Disc Brake Attachment,
FRE-2249-2, is the only recommended tool to refinish the disc brake rotors. The step-by-step resurfacing procedure provided with the tool must be
adhered to.
The finished braking surfaces of the
rotor must be flat and parallel within
0.0007 inch; lateral runout must not
exceed 0.003 inch on Custom Vehicles
and 0.002 irich on Light Vehicles total
indicator reading, and the surface fin,

ish of the braking surfaces are to be

80/15 micro inches. The minimum
limiting dimensions (Fig. 16) from the
inboard bearing cup to the outboard
rotor face and from the inboard bearing cup to the inboard rotor face
must be observed when removing material from the rotor braking surfaces.
On ail models the limiting dimensions
are to be measured with the ball and
gage bar (Rotunda Kit FRE-70160).
DISC BRAKE ROTOR CHECK
Refer to Fig. 16.
A ball and gauge bar are required
to measure wear on the rotor inner
braking surface and to determine the
maximum stock removal limit when

brake rotors require refinishing.

Gauging of the rotor is accomplished
on the bench prior to mounting in a
rotor lathe. A controlled dimension
notch machined in one edge of the
gauge bar identified custom car
(Ford, Mercury, Meteor and Thunderbird, Continental Mark I11 and
Lincoln Continental). The opposite
raised center of the gauge bar is identified light car (Montego, Fairlane.
Mustang and Cougar). Refer to
Fig. 16.
Gauging of the rotor is accomplished accordi'ng to the following
procedure:
1. Remove the inner bearing assembly and grease retainer and thoroughly clean the inner bearing cup
and hub bore.

--.

12-03-13

Disc Brake

FAIRIANE
MUSTANGCOUGAR

4k
.

'875 'IN'

RETAINER

- 28245

GASKET -2167

THUNDERBIRD-CONTINENTAL
MARK Ill-LINCOLN
1 .I2 M l N . 4
CONTINENTAL

FIG. 16-Disc

1-

Brake Rotor

Service Limits

2. Carefully place the gauge ball in

the inner bearing cup ( D o not drop).
3. Position the gauge bar across
the rotor inner braking surface and
over the gauge ball (Fig, 16). Measure
the distance between the gauge bar
and ball. This clearance is equal to
the maximum allowable stock removal. If the gauge bar touches the ball,
no additional stock removal is allowed. If the gauge bar is below the
top of the ball, the rotor must be replaced.
4. The rotor thickness dimensions
after refinishing are limited to the
minimum
measurements
shown
below.
Ford, Mercury, Meteor,
Thunderbird, Continental
Mark 111 and Lincoln Continental
1.120-inch minimum.
Fairlane, Montego,
Mustang and Cougar
0.875-inch minimum.
Rotors having a thickness less than
above specifications must be replaced
regardless of the ball and gauge bar
measurement.

5. The finished braking surface

must be flat and parallel within
0.0007 inch; lateral runout must not
exceed 0.003 inch on Custom Vehicles
and 0.002 inch on Light Vehicles total
indicator reading, and the surface finish of the braking area is to be 80115
micro inches.
The ball and gauge bar kit is available through Rotunda Equipment
(Part No. FRE-70160).

DUAL MASTER CYLINDER

When a repair is necessary on the
master cylinder, i t is required practice
during the warranty period to replace

ASSEMBLY

FIG. 17-Dual

- 2A502

Master Cylinder Disassembled

the cylinder as a unit instead of overhauling the cylinder with,a service repair kit.

Snop Ring P l i e r s

SNAP RING

DISASSEMBLY

1. Clean the outside of the master

cylinder and remove the filler cover
and diaphragm. Pour out any brake
fluid that remains .in the cylinder.
Discard the old brake fluid.
2. Remove the secondary piston
stop bolt from the bottom of the cylinder (Fig. 17). ,
3. Remove the bleed screw, if required.
4. Depress the primary piston and
remove the snap ring from the retaining groove at the rear of the master
cylinder bore (Fig. 18). Remove the
push rod and the primary piston assembly from the master cylinder bore.
D o not remove the screw that retains
the primary return spring retainer, return spring, primary cup and protector on the primary piston. This assembly is factory pre-adjusted and
should not be disassembled.

n1m-c

FIG. 18-Removing

Snap

Ring-Typical
INSPECTION A N D REPAIR

1. Clean all parts in clean isopropyl alcohol, and inspect the parts for
chipping, excessive wear or damage.

5. Remove the secondary piston

assembly. DO not remove the outlet

When using a master cylinder repair

kit, install a l l the parts supplied.
2. Check all recesses, openings and

tube seats, outlet check valves and

outlet check valve springs f r o m the
master cylinder body.

internal passages to be sure they are

open and free of foreign matter. Use
an air hose to blow out dirt and

Disc Brake

cleaning solvent. Place all parts on a

clean pan or paper.
3. Inspect the master cylinder bore
for signs of etching. pitting. scoring
or rust. If it .is necessary to hone the
master cylinder bore to repair damage. do not exceed allowable hone
specifications.

INNER BRAKE

SHOE &NO LINING

ASSEMB,LY-2019

OUTER SHOE
RETAINING CLIPS
2066

ASSEMBLY
1. Dip all parts except the master
cylinder body in clean Rotunda Extra
Heavy Duty Brake Fluid.
2. Carefully insert the complete
secondary piston and return spring
assembly iri the master cylinder bore.
3. Install the primary piston assembly in the master cylinder bore.
4. Depress the primary piston and
install the snap ring in the cylinder
bore groove.
5. Install the push cod. boot and
retainer on the push rod, if so
equipped. Install the push rod assembly into the primary piston. Make
sure the retainer is properly seated
and holding the push rod securely.
6. Position the inner end of the
push rod boot (if so equipped) in the
master cylinder body retaining
groove.
7. Install the secondary piston stop
bolt and O-ring in the bottom of the
master cylinder.
8. Install the bleed screw (if so
equipped). Install the gasket (diaphragm) in the master cylinder fillercover. Position the gasket as shown in
Fig. 17. Make sure the gasket is securely seated.
9. Install the cover and gasket on
the master cylinder and secure the
cover into position with the retainer.

DISC BRAKE CALIPER

Disassembly
>
1. Remove the caliper assembly
from the vehicle ,as outlined in Section 2.
2. Remove the caliper locating pins
from the caliper assembly and lift the
anchor plate from the caliper.
3. Slide the two outer shoe retaining clips ,off the retaining' pins (Fig.
19).
4. Remove the two retaining pins,
then remove the outer brake shoe
from the caliper.
5. Slide the inner brake shoe outward uniil it is free of,the hold-down
springs, then remove the brake shoe.
6. Apply air pressure to the fluid
port in the caliper with a rubber
tipped nozzle (Tool 7000-DD) as
shown in Fig. 20 to remove the pis-

LOCATING PIN

C F Q

CLIP
20164

FIG. 19-Caliper

Assembly-Disassembled

ton. Place a cloth over the piston before applying air pressure to prevent
damage to the piston. If the piston is
seized and cannot be forced from the
caliper, tap lightly around the piston
while applying air pressure. Care
should be taken because the piston
can develop considerable force due to
pressure build-up.
7. Remove the dust boot-from the
caliper assembly.
8. Remove the rubber piston seal
from the cylinder and discard it.
Cleaning a n d Inspection
Clean all metal parts with isopropyl
alcohol or a suitable solvent. 'Use
clean, dry, compressed air to clean
out and dry the grooves and passage
ways. Be sure that the caliper bore
and component parts are completely
free of any foreign material.
Check the cylinder bore and piston
for damage or excessive wear. Replace the piston if it is pitted, scored,
or the chrome plating is worn off.

1. Apply a film of clean brake

fluid to the new caliper piston seal
and install it in the cylinder bore. Be
sure the seal does not become twisted

FIG. PO-Removing
Caliper

Piston From

and that it is seated fully in the

groove.
2. Install a new dust boot by setting the flange squarely in the outer
groove of the caliper bore.
3. Coat the piston with the specified fluid and install the piston in the
cylinder bore. Spread the dust boot
over the piston as it is installed. Seat
the dust boot in the piston groove.
4. Position the inner brake shoe so
that the ear's of the shoe rests on the

12-03-15

top of the anchor plate bosses and beneath the hold-down springs.
5. Install new caliper locating pin
insulators i n the anchor plate.
6. Position the caliper on the an-

1 2-03- 1 5

. Disc Brake

chor plate.
7. Apply water or isopropyl alcohol to the caliper locating pins and
install them loosely i n the anchor
plate. Be sure the guide pins are free

of oil, grease or dirt.

8. Install the caliper on the spindle
as outlined under Disc Brake Caliper
Assembly.

SPECIFICATIONS

BORE DIAMETERS MASTER CYLINDER

I

Models
Ford, Mercury
and Meteor

Taxi and Station Wagon

Other
Pass. except Conv. 250, 302 CID Engines
Pass. and Conv. 351, 390, 428 CID Eng.
Convertible 250, 302 Cl0 Engines
Station and Ranchero
9 Inch' Brake Passenger Car
10lnch Brake Station Wagon
10 Inch Brake Passenaer Car
200 CID Enaine
351, 390, 428 Cl D Engine
250, 302, CID Engine

Montego
and
Fair lane
Falcon
Mustang
and Cougar

Thunderbird
Continental Mark I l l
I
Lincoln Continental
@Max.-Allowable Hone 0.003
02.755 for Ford, Mercury, Meteor with Disc Brakes
2.381for Fairlane, Montego, Mustang, Cougar with Disc Brakes

Master Cylinder
Bore Dia.
With Power
Brake@
1.000
1.000
0.9375
0.9375
0.9375
0.9375
N/A
N/A
N /A
1.000
1.000
1.000

1.000

CH1724-A

12-03- 16

12-03- 16

Disc Brake-

SHOEAND UNlNG DIMENSIONSDl% BRAKES -INCHES

Fair lane, Montego
Ford, Mercury,
Mustang, Cougar
Meteor, Thunder.
bird, Continental
Mark Ill, Lincoln
Continental
Bonded
Lining Material
Bonded
Lining Size
7.38 x 2.27 Outer 6.82 x 1.80 Outer
5.36 x 2.03 lnner 4.90 x 1.84 lnner
Lining Area - Square Inches
12.25 Outer
11.30 Outer
per Segment
8.44 l nner
8.80 Inner
Lining Thickness Nominal
0.394
0.333 Outer
0.362 lnner
Lining Wear Limit (Front
Surface of Shoe) Max.
0.030
0.030
Lining- Taper
-Max.
0.125
0.125
.
I
I
Lining t o Rotor Clearance
(Brakes Released)
0.000-0.010
0.000-0.010

CALIPER CYLINDER
BORE DIAMETER -INCHES
Meteor. Thunderbird. Continental Mark Ill
Lincoln Continental
Mustang, Cougar, Fairlane and Montego

IFord, Mercury,

2.755

2.381

CH1725.A
TORQUE LIMITS -HUB TO SPINDLE
Description
Ft Lbs
Hub and Drum or Rotor Pissembly Rotate hub while torquing t o 17t o Front Wheel Spindle
25 ft-lbs. Back off the adjust.
ing nut 112 t u r n and retighten
t o 10-15 inch pounds while rot a t i n g wheel Selectively posit i o n nut retainer on adjusting
nut .so that a set of slots are
i n line with cotter pin hole. Adjusting nut should not be rotated
i n t h i s operation. Lock adjusting
nut and nut retainer with cotter
pin so that the cotter pin end
does not interfere w i t h seating
of wheel static collector i n spindle hole.

ROTOR DIMENSIONS
Car Line
Ford, Mercury, Meteor,
Lincoln Continental
Thunder bird, Continental
Mark Ill
Fairlane, Montego;Mustang
and Cougar

Nom.
Thickness

Diameter
Outside Inside

1.180

11.72

7.785

1.180

11.72

7.785

0.935

11.29

7.355

ROTOR REFINISH

The following requirements must be met when resurfacing disc

brake rotors:
Rotunda Disc Brake Attachment FRE-2249-2 i s the only approved tool t o be used t o refinish the disc brake rotors. The step-bystep resurfacing procedure provided w i t h the tool must be adhered
to.
The finished braking surfaces .d the rotor must be f l a t and
parallel within 0.0007 inch; lateral runout must not exceed 0.003

on Custom vehicles and 0.002 inch on light vehicles t o t a l

indicator reading, and the surface finish of the braking. surfaces
are t o be 80-15 micro inches.
On a l l models the limiting dimension f r o m the inner bearing
,cup t o the inner rotor face must be measured with a ball and
gage bar (Rotunda FRE-70160).

12-03-17

Disc Brake Caliper t o Spindle Bolts

Disc Brake

12-03- 17

12-03- 1 8

SPEb A1 TOOLS
Ford Tool No.
Tool 7000.00
Rotunda 70160
Tool 33621

Rotunda FR E 22492

Disc Brake

Former No.
2162

,33621
Milbar
1112-144
1 22742 (Kent Moore)

12-03- 1 8

Description
Adapter Cap
Rubber llpped Air Nozzle
Ball and Gage Bar
Internal Snap Rinn Pliers
Inch Pound Torque Wrench
Bleeder Valve Clip Spring
Disc Brake Rotor Attachment
CH1728-A

1 2-04-0 1

12-04-0 1

Parking Brakes

BART 12-04Barking Brake

-=

VI

COMPONENT INDEX
Applies T o Models As Indicated

PARKING BRAKE

u
0

E7

;
2

'

8.;

S = zI

2=
'

g:

;
C

04-0I

the head of the column.

N/A indicates that the item is not applicable to the vehicle(s) listed.

DESCRIPTION

An independent foot-operated
(hand-operated on Maverick) parking
brake control actuates the rear wheel
brake shoes through a cable linkage.
On all models except Ford, Mercury,
Meteor, Thunderbird, Coptinental
Mark 1 1 1 and Lincoln Continental.
The operating cable is routed from
the parking brake control assembly to
the equalizer. On Ford, Mercury.
Meteor. Thunderbird, Continental
Mark 111 and Lincoln Continental the
operating cable is routed from the
parking brake control assembly to the
actuator assembly. On Maverick, the
operating cable is routed from the
parking brake control assembly ,to the
equalizer pivot lever which is attached
to the equalizer assembly. An intermediate cable connects t h e actuator

to the equalizer except on the Lincoln

Continental. The rear brake cables
connect the equalizer assembly to the
parking brake lever at each rear secondary shoe. Refer to Part 12-02.
On all vehicles except Maverick,
there are two types of foot-operated
parking brake controls used. The automatic (vacuum) release type (Fig. I )
is used on the Mercury, Ford LTD,
Meteor LeMoyne. Thunderbird, Continental Mark 111 and Lincoln Continental models. All other models use
the manual release-type (Fig. 2).
On the automatic-type, the vacuum
power unit with mounting bracket is
riveted to the control assembly. The
vacuum actuated piston within the
unit is connected by a rod to the
upper end of the release lever (Fig. 9).

The lower end of the release lever extends out for alternate manual release
in the event of vacuum power failure
or for optional manual release at any
time.
Hoses connect the power unit and
the engine manifold to a vacuum release valve on the back-up light
switch.
On a Maverick, the parking brake
control is hand-operated. When the
handle is pulled the primary and secondary brake shoes are forced against
the rear brake drums. The handle is
held in the applied position by the engagement of a spring loaded pawl
'with a ratchet. Turning the handle
counterclockwise disengages the pawl
from the ratchet to release the brakes.

12-04-02

FIG. ]--Parking
Release-Typical

12-04-02

Parking B r a k e s

Brake Control Assembly w i t h Automatic

RELEASE PAWL CAM PIN

L CAM LEVER

H16SA

FIG. 2-Parking

Brake Control Assembly w i t h M a : i u a l Release-Typical

IN-VEHICLE ADJUSTMENTS A N D REPAIRS

PARKING BRAKE LINKAGE

ADJUSTMENT
I.Make sure that the parking
brake is fully released.

2. Place the transmission :in neutral. Raise the vehicle.

3. Tighten the adjusting nut against
the cable equalizer (Fig. 3. 4. 5, 6. 7.
8) to cause rear wheel brake drag.

Then. loosen the adjusting nut until

the rear brakes are fully released.
There should be no brake drag.
4. Lower the vehicle and check the
operation of the parking brake.

Parking Brakes

REMOVAL A N D INSTALLATION

PARNING BRAKE CONTROL

ASSEMBLY

FORD, M E R C U R Y
A N D METEOR
Removal

Refer to Fig. 3.
1. Make sure the parking brake is
fully released.
2.- Remove all tension from the
rear cables by backing off the adjusting nut from the equalizer.
3. Remove the roll pin that secures
the release knob to the cable and remove the knob.
4. Remove the nut that secures the
release cable to the instrument panel
and remove the cable from the rear of
the instrument panel.
5. Remove the two nuts attaching
the control assembly to the dash
panel.
6. Remove the cap screw attaching
the control assembly to the cowl side
bracket.
7. Disconnect the hose to the parking brake vacuum unit, if so
equipped.
8. Remove the front cable assembly retainer clip from the cable assembly and disconnect the cable ball
from the control clevis.
9. Remove the control assembly
from the vehicle.
Installation
1. Position the control assembly in
the vehicle.
2. Fit the cable assembly through
its mounting hole and install the retaining clip. Connect the cable ball to
the control clevis.
3. Connect the vacuum hose to the
parking brake unit, if so equipped.
4. Install the attaching cap screw
to the cowl side bracket. Do not
tighten.
5. Install the two control assembly-to-dash panel nuts. Tighten the
nuts and the cap screw to specifications.
6. Insert the release cable into the
instrument panel and install the retaining nut.
7. Install the release knob on the
a b l e with the roll pin.
8. Check the operation of the parking brake. Adjust the parking brake
as required.

FAIRLANE, MONTEGO
A N D FALCON
Removal

Refer to Fig. 4.
I. Make sure the parking brake is
completely released.
2. Remove all tension from, the
rear cables by backing off the jam nut
and adjustirig nut from the equalizer.
3. Working inside the vehicle,
remove the four bolts and one nut retaining the left air vent and cable
assembly to the dash and instrument
panels. Remove the vent assembly.
4. Remove the parking brake front
cable ball retaining clip from the clevis.
5. Disconnect the cable ball from
the notch in the brake clevis.
6. Remove the three screws that attach the control assembly to the left
cowl inner side panel.
7. Disconnect the wire lead at the
parking brake warning light switch
and remove the control assembly.
Installation
1. Connect the wire. lead to the
parking brake warning light switch.
2. Position the control assembly to
the cowl inner side panel and install
the three attaching screws.
3. Connect the ball-end of the
parking brake front cable assembly to
the control assembly, and install the
hairpin retainer.
4. Position the cable ball in the
notch in the brake clevis.
5. Position the left air.vent assembly to the dash and instrument panels.
Install the four bolts and one nut retaining the air vent to the panels.
6. Check the operation of the parking brake. Adjust the parking brake.

M U S T A N G A N D COUGAR
Removal

Refer to Fig. 5.
I. Make sure the parking brake is
completely released.
2. Remove all tension from the
rear cables by backing off the jam nut
and adjusting nut from the equalizer.
3. Disconnect the wire lead at the
parking brake warning light switch (if
so equipped).
4. Remove the parking brake front
cable ball retaining clip from the clevis.

5. Remove the parking brake

warning light switch and attaching
screw (if so equipped).
6. Disconnect the cable ball from
the notch.in the brake clevis.
7. Remove the three screws that attach the control assembly to the left
cowl inner side panel.
8. Pull the control away from the
cowl panel. Remove the hair-pin retainer securing the front cable assembly to the control assembly. Remove
the control assembly.

Installation
1. Connect the ball-end of the
parking brake front cable assembly to
the control assembly, and install the
hair-pin retainer.
2. Position the control asseinbly to
the cowl inner side panel and install
the three attaching screws.
3. Position the parking brake
warning light switch and install the
attaching screw; Connect the parking
brake warning light switch wire lead
(if vehicle is so equipped).
4. Position the cable ball in the
notch in the brake clevis.
5. Check the operation of the parking brake. Adjust the parking brake.

MAVERICK
Removal

Refer to Fig. 6.
1. Remove the two screws that
hold the control bracket on the instrument panel.
2. Remove the two nuts that secure
the control to the dash panel.
3. Remove the hairpin clip and
clevis pin that secures the pulley to
the control handle assembly.
4. Disengage the locking pawl.
Slide the rod forward and remove the
ball on the cable from the slot on the
control assembly.
5. Remove the control from the
vehicle.
Installation

Refer to Fig. 6.
1. Disengage the locking pawl.
Slide the rod forward and connect the
ball end of the cable to the slot in the
control assembly and pull. the rod
rearward, engaging the pawl in the
ratchet.

FIG. 3-Parking

CONTROL

INSTRUMENT PANEL

VlEW Z
VACUUM RELEASE

Br,ake System-Ford,

VlEW Z
MANUAL RELEASE

BRAKE PEDAL BRACKET

Mercury a n d Meteor

INTERMEDIATE CABLE

ADJUSTING NUT

CROSSMEMBER

CABLE AND HOUSING L.H.

CABLE AND HOUSING R.H.

CLIP

VIEWY

VlEW X

LOCKED I N PLACE WITHIN

BRAKE DRUM
L . K SHOW R.H. TYPICAL

SUSPENSION ARM

CABLE MUST BE TIGHT

ON -4 CROSSMEMBER

12-04-05

Parking Brakes

12-04-05

Parking Brakes'

12-04-06

Parking Brakes

CABLE ASSEMBLY
2853

WEW Y

PRONGS MUST BE SECURELY

CABLE ASSEMBLY 2A635

WASHER 381629-S

WASHER?^^^

EQUALIZER LEVER 2Am5

EQUALIZER R
CABLE 2A635

L.H. INSTALLATION SHOYN

R.H. T Y P I C A L

CABLE ASSEMBLY 2A635

CABLE 2A635

.-&

VIEW U

CABLE ASSEMBLY 2853

CLEVIS PIN

PRONGSM U ~ TBE SECURELY

LOCKED IN PLACE
VlEW T
INSTALLATION O F CABLE
WITHIN BRAKE DRUM
L.H..6 R.H. T Y P I C A L

I
SIDE RAIL REF
VlEW I N CIRCLE B

RETAINER

CABLE ASSEMBLY 2853

VIE-W Z

FIG. 6-Maverick

Parking Brake System

FIG. 7-Parking

Brake System-Thunderbird

a n d Continental M a r k Ill

Parking Brakes

2. Assemble the pulley to the control handle and the clevis pin. lnstall
the clevis retainer.
3. Position the assembly against
the dash panel and instrumentpanel.
Secure the assembly to the instrument
panel with the two screws.
4. Working under the hood, install
the two parking brake control-to-dash
panel attaching nuts.
5. Check the parking brake for
proper operation. Adjust the parking
brake.
T H U N D E R B I R D .AND
CONTINENTAL M A R K 111
Removal

Refer to Fig. 7.
I. Remove the two nuts retaining
the control to the dash panel.
2. Remove two screws from the left
scuff plate.
3. Remove one screw retaining the
left cowl trim panel and remove the
panel.
4. Remove the two screws retaining
the left air duct and remove the air
duct.
5. Remove the two screws retaining
the dimmer switch and position the
switch out of the way.
6. Remove the clip retaining the
cable assembly to the control.
7. Disconnect the cable ball from
the control clevis.
8. Disconnect the vacuum hose at
the brake release.
9. Remove the bolt retaining the
control to the cowl side bracket and
remove the control.
Installation

1. Position the parking brake control in the vehicle.

2. lnstall the cable assembly in the
control and connect the cable ball to
the control clevis.
3. lnstall the clip retaining the
cable to the control.
4. lnstall the bolt retaining the
control to the cowlside bracket.
5. Connect the vacuum hose to the
parking brake release vacuum motor.
6. Position the, dimmer switch and
install the retainhg screws.
7. Position the air duct and install
the retaining screws.
8. Position the cowl trim panel and
install the retaining screw.
9. Install the two scuff plate
screws.
10. Install the two nuts retaining
the control to the dash panel.
11. Adjust the parking brake.

LINCOLN CONTINENTAL
Removal

Refer to Fig. 8.
1. Make sure that the parking
brake is fully released.
2. Remove the two nuts from the
control assembly mounting studs on
the engine compartment side of the
dash panel.
3. Working under the instrument
panel, remove the control assembly to
mounting bracket retaining screw.
4. Disconnect the vacuum tube
from the automatic release vacuum
servo motor.
5. Remove the retaining clip from
the cable housing at the control assembly.
6. Disconnect the control cable ball
end from' the control assembly cable
clevis.
7. Remove the control assembly
from the vehicle.
Installation

1. Connect the vacuum tube to the

automatic release vacuum servo
motor.
2. lnstall the control assembly
mounting studs through the holes in
the dash panel and against the body
mounting bracket.
3. Assemble the control cable ball
end 10 the control assembly cable
clevis.
4. lnstall the cable retaining clip at
the control assembly.
5. lnstall the control assemblyto-mounting bracket retaining bolt
and torque them to specifications.
Torque them to 12-25 ft-lbs.
6. Install the nuts on the control
assembly mounting studs on the engine side of the dash panel and torque
them to 10-20 fblbs.
7. Verify correct operation of the
parking brake system.
PARKING BRAKE ACTUATORTO CONTROL CABLE

FORD, MERCURY
A N D METEOR
Removal

1. Raise the vehicle on a hoist.

2. Loosen the actuator lever to
equalizer cable adjusting nut at the
equalizer (Fig. 3).
3. Disconnect the cable ball from
the clevis on the actuator lever.
4. Remove spring clip that retains

the cable to the frame.

5. From inside of passenger compartment, remove spring clip that retains the cable to the parking brake
control. Disconnect the cable ball
from the control assembly.
6. Remove the cable assembly
from the vehicle.
Installation

1. Position the cable through the

provided openings and in the approximate final installation position.
2. Install the hairpin retainer on
the cable at the frame crossmember.
3. Connect the ball end of the
cable to the parking brake control.
lnstall the cable-to-control hairpin retaining clip.
4. Position the .cable seal at the
dash panel, and slide the retaining
clip upward to seal the cable at the
dash opening.
5. Connect the ball end of the
cable to the clevis on the actuator
lever.
6. Adjust the parking brake.
7. Lower vehicle on hoist.
THUNDERBIRD AND
CONTINENTAL MARK Ill
Removal

Refer to Fig. 7.
1. Partially raise the vehicle.
2. Back off the adjusting nut at the
equalizer to relieve the tension on the
cable.
3. Remove the spring at the actuator lever and disconnect the control
cable from the clevis on the lever.
4. Remove the clip retaining the
control cable assembly to the frame
bracket.
5. Attach a length of wire to the
control cable.
6 . Working inside the vehicle
remove two screws retaining the left
scuff plate.
7. Remove one screw and remove
the left cowl side trim panel.
8. Remove the two screws retaining
the left air duct to the inner panel
and remove the air duct.
9. Remove the two screws retaining
the dimmer switch and position the
dimmer switch back out of the way.
10. Remove the clip retaining the
cable assembly to the :control and remove the cable ball from the control
clevis.
11. Pull the cable up through the
opening in the dash panel and remove
the cable'from the length of wire.

FIG. 8-Parking

2 REQUIRED

10-20 LB. FT.

BOLT
381,877- S2
2 REQD.

Brake System-Lincoln

nw T

BOLT
37403262

Continental

VlEW IN CIRCLES U

VlEW V

EQUALIZER ROD

PRONGS MUST BE
SECURELY LOCKED IN PLACE
L.H. SHOW (R.H. TYPICAL)

VIEW W

PARKING BRAKE

ADJUSTMENT NUT
2A812

CLl P

Parking Brakes

lnstallation

1. Attach the cable to the length of

wire and pull the cable down through
the opening in the dash panel.
2. Position the upper end of the
control cable to the control. Connect
the cable ball to the control clevis and
install the clip retaining the cable
housing to,the control.
3. Remove the length of wire from
the cable assembly and position the
cable in the frame bracket. Install the
retainer.
4. Connect the cable ball to the
clevis on the actuator lever and install
the actuator lever spring.
5. Adjust the parking brake.
6. Reposition the dimmer switch
and install the retaining screws.
7. Position the air duct to the inner
panel and'install the retaining screws.
8. Position the cowl side trim panel
and install the retaining screw.
9. Install the two screws in the
scuff plate.
PARKING BRAKE
EQUALIZER TO CONTROL
CABLE

FAIRLANE, MONTEGO
AND FALCON
Removal

Refer to Fig. 4.
1. Make certain the parking brake
is fully released.
2. Raise the vehicle on a hoist. Remove the two nuts that attach the
cable to the equalizer. Remove. the
equalizer, spring seat and spring.
3. Remove the hairpin retainer
holding the cable assembly to the
body bracket and remove the cable
from the slot in the bracket.
4. Lower the vehicle partially.
5. Remove the hairpin retainer
which retains the cable assembly to
the control.
6. Remove the cable bolt retaining
clip from the control clevis and disconnect the cable ball from the clevis.
7. Pull the cable down through the
opening in the floor pan and frame
side rail.
lnstallation

1. Route the new cable through

frame side rail and up through
opening in the floor pan. Pull
cable up into position.
2. Connect the ca.ble ball in
control clevis.
3. Insert the cable housing into

the
the
the
the
the

control and install the hairpin retainer.

4. Raise the vehicle.
5. Position the cable in the body
bracket and install the hairpin retainer.
6. Position the spring, spring retainer and equalizer on the cable and
install the two nuts.
7. Adjust the parking brake.

MAVERICK
Removal

Refer to Fig. 6.
1. Remove the hairpin clip and
clevis pin that secures the cable pulley
to the control handle assembly and
remove the pulley.
2. Disengage the locking pawl and
slide the control rod forward. Remove
the cable ball from the slot in the
control rod.
3. Remove the hairpin retainer
from the dash panel bracket and disengage the cable from the bracket.
4. Pull the cable and insulator tube
down through the hole in the dash
panel. Remove the insulator tube
from the cable.
5. Raise the vehicle on a hoist.
6. Remove the retaining screw and
clip from the cable on the chassis side
rail.
7. Disengage the cable stepped-rod
from the equalizer lever.
8. Remove the hairpin retainer
from the cable housing at the
crossmember.
9. Pull the cable forward through
the crossmember and remove the
cable from the vehicle.
Installation

Refer to Fig. 6.
1. Pass the stepped-rod rearward
through the crossmember and connect
it into the equalizer lever.
2. Install the hairpin retainer on
the cable housing at the crossmember.
3. Install the cable housing retaining clip on the cable and install the
retaining screw on the chassis side
rail.
4. Install the insulator tube onto
the upper end of the cable and push
the cable and insulator up through the
hole in the dash panel.
5. Engage the upper end of the
cable housing in the dash panel
bracket and install the hairpin retainer.
6. Connect the cable ball to the
control rod.
7. Assemble the pulley to the con-

trol assembly and install the clevis pin

and hairpin retainer.
8. Check the parking brake for
proper operation. Adjust the parking
brake.

MUSTANG AND COUGAR

Removal

Refer to Fig. 5.
1. Make certain the parking brake
is fully released.
2. Raise the vehicle on a hoist. Remove the two nuts that attach the
cable to the equalizer. Remove the
equalizer spring seat and spring.
3. Remove the hairpin retainer
holding the cable assembly to the
body bracket and pull the cable out
of the side rail access holes.
4. Attach a wire to the end of the
cable to assist in routing new cable.
5. Lower the vehicle.
6. Remove the parking brake front
cable ball retaining clip from the clevis.
7. Disconnect the cable ball from
the notch in the brake clevis.
8. Remove the hairpin retainer and
remove the cable assembly from the
brake control assembly.
9. Pull the cable assembly up
through the opening in the floor and
remove the wire from the end of the
cable.
lnstallation

Refer to Fig. 5.
1. Connect the wire to the end of
the cable assembly and pull the cable
down through the opening in the
floor. Remove the wire.
2. Connect the cable assembly to
the brake control assembly and install
the hairpin retainer.
3. Position the ball end of the
cable in the notch of the brake clevis.
4. Raise the vehicle on a hoist.
5. Pull the cable grommet into position and route the cable through the
access holes in the side rail and under
the fuel line.
6. Insert the cable into the body
bracket and install the hairpin retainer.
7. Position the spring, spring seat.
and equalizer on the cable and install
the two nuts.
8. Adjust the parking brake.

LINCOLN CONTlNENTAL
Removal

Refer to Fig. 8.

Parking Brakes

1. Make sure that the parking

brake is fully released.
2. Raise the vehicle.
3. Loosen the parking brake cable
adjusting nut at the equalizer lever.
4. Lower the vehicle.
5. Remove the cable housing retaining clip and then disconnect the
control cable ball end from the control assembly clevis.
6. Raise the vehicle.
7. Pull the cable and housing
downward through the .dash panel
opening.
8. Remove the retainer clip from
the cable housing at the number 3
crossmember.
9. Disconnect the cable ball end
from the parking brake cable clevis at
the actuator lever.
1 0 , Pull the parking brake cable
forward through. the holes in the
number 3 crossmember and remove
the cable and housing assembly from
the vehicle.

Installation
1. Push the rear end of the parking
brake cable rearward through the
holes in the number 3 crossmember.
2. Connect the cable ball end to
the parking brake cable clevis at the
actuator lever.
3. Install the retaining clip on the
cable housing at the number 3
crossmember.
4. Push the forward end of the
cable and housing upward through the
dash panel opening.
5. Lower the vehicle.
6. Connect the cable ball end to
the control assembly clevis and install
the retaining clip.
7. Raise the vehicle.
8. Adjust the parking brake. Refer
to the Parking Brake Adjustment,
Procedures in this manual.
9. Lower the vehicle.
10. Verify correct operation of the
parking brake.

PARKING BRAKE
ACTUATOR-TO-EQUALIZER
CABLE

--

FORD, MERCURY,
METEOR, THUNDERBI RD
AND CONTINENTAL
MARK I I I

equalizer.
3. Remove the cable end from the
equalizer.
4. Unhook the cable from the actuator, and remove from the vehicle.
lnstallation
1. Insert new cable end into actuator.
2. Insert cable end into equalizer
and tighten the adjusting nut snug.
Install the lock nut.
3. Adjust the parking brake.
4. Lower the vehicle.

PARKING BRAKE EQUALIZER

TO REAR WHEEL CABLE
FORD, MERCURY,
METEOR, THUNDERBI RD
AND CONTINENTAL
MARK Ill
Removal
1. Raise the vehicle and loosen the
parking brake equalizer rod adjusting
nut. Disconnect the equalizer from
the rear cables (Figs. 3 and 7).
2. Compress the prongs on the left
cable-to-frame side member retainer
so the prong can pass through the
side-member. Remove the clip that
attaches the left cable to the left
lower arm. Pull the cable thru the
frame left side member.
3. Compress the prongs. on the
right cable-to-frame side member retainer bracket so the prong can pass
through the bracket. Remove the clips
retaining the right cable to the frame
crossmember.
4. Remove the rear wheel cover
and wheel. Remove the three Tinnerman nuts that hold the brake drum in
place and remove the drum.
5. Working on the wheel side of
the rear brake, remove the automatic
brake adjuster spring. Compress the
prongs on the parking brake cable retainer so that they can pass through
the hole in the brake backing plate.
Draw the cablt retainer through the
hole.
6. With the spring tension off- the
parking brake lever, lift the cable out
of the slot in the lever,and remove the
cable through the backing plate hole.

Removal
Refer to Figs. 3 and 7.
1. Raise the vehicle on a hoist.
2. Remove the lock and adjusting
nut which retains the cable to the

1. Pull .enough of the parking

brake cable through the housing so
that the end of the cable may be inserted over the slot .in the parking
brake lever on the rear brake shoe.

2. Pull the excess slack from the

cable, and insert the cable housing
into the brake backing plate access
hole so that the retainer prongs expand. The prongs must be securely
locked in place. lnstall the automatic
brake adjuster spring.
3. Position the right hand cable
and the two retaining clips and screws
on the rear crossmember. Compress
the prongs on the right cable and position the cable in the retaining bracket on the frame side member. Be sure
the lo.cating stripe on the cable is
midway between the retaining clips
and tighten all retaining clip screws.
4. Position the left cable, retaining
clip and screw on the left lower suspension arm. Compress the prongs on
the left cable and position the cable
through the frame side-member. The
prongs must be securely locked in
place.
5. Insert the ball ends of the cables
into the equalizer assembly.
6. Install the rear drum(s) and
tighten the three Tinnerman nuts and
secure the drum. Install the wheel and
tire and the wheel cover.
7. Adjust the parking brake linkage.

MAVERICK
Removal
Refer to Fig. 6.
1. Completely release the parking
brake.
2. Raise the vehicle on a hoist.
3. Loosen the adjusting nut and
remove rear parking brake cable ball
end from the connector.
4. Remove the adjusting nut from
the equalizer rod and remove the
cable from the equalizer.
5. Compress the pronged retainer
at the rear spring front h.anger bracke t and pull the cable rearward
through the bracket.
6. Remove the wheel cover, wheel
and, tire, and rear brake drum.
7. Remove the self-adjuster springs
to allow clearance to remove the
cable retainer from the backing plate.
Disconnect the rear end of the cable
from the parking brake lever on the
secondary brake shoe.
8. Compress the pronged retainer
at the brake backing plate and pull
the cable from the backing plate.
9. Remove the screw from the retainer on the rear spring. Remove the
parking brake cable from the retainer
and remove the cable from the vehicle.

Parking Brakes

Installation

Refer to Fig. 6.
I . Insert the forward end of the
new parking brake cable through the
hole in the rear spring front hanger
bracket. Pull the cable through until
the cable retainer prongs are firmly
seated in the bracket hole.
2. Push the cable rear end through
the hole in the brake backing plate
and pull into backing plate hole until
cable retainer prongs are securely positioned in the backing plate cable
hole.
3. Connect the cable end to the
parking brake lever on the rear brake
secondary shoe and install the brake
self-adjuster spring.
4. lnstall the brake drum, wheel
and tire assembly and wheel cover.
5. Position the parking brake cable
in the rear spring cable retainer, and
install and tighten the nut on the retainer stud.
6. Install the ball end of the cable
in the connector.
7. Position the cable in the equalizer and install the equalizer rod adjusting nut.
8. Verify proper operation of the
parking brake.
9. Adjust the parking brake. Refer
to "Parking Brake Adjustment".
FAIRLANE, MONTEGO,
MUSTANG AND COUGAREXCEPT STATION WAGON
Removal

1. Remove the equalizer lock, ,nut

and adjusting nut, equalizer, spring
and spring seat.
2. With the cables slack, disconnect the ballends from the connector
(Figs. 4 and 5).
3. Remove the cable from the retainer hooks (station wagon models)
and the underbody guide (convertible
models) if required.
4. Remove the hairpin lock retaining the cable housing to the side rail
bracket.
5. Remove the wheel cover, wheel
and tire and the rear brake drum as
outlined in Part 12-02.
6. Remove self-adjuster springs to
allow clearance to remove cable retainer from the backing plate. Disconnect the rear end of the cable
from the parking brake lever on the

brake shoe. Disengage the cable housing retaining grommet or steelpronged Hi-Hat from the backing
plate and withdraw the cable and
housing from the inboard side of the
backing plate.
7. Slide the cable and housing out
of the side rail bracket.
Installation

I. Insert the rear end of the cable

through the side rail bracket and pull
the cable and housing into position.
2. lnsert the rear end of the cable
and housing through the hole in the
backing plate from the inboard side.
3. Connect the cable to the parking
brake lever on the brake shoe and install the cable housing retaining
grommet or steel-pronged Hi-Hat in
the backing plate.
4. Install the self-adjuster springs.
Position the cable housing in the side
rail bracket and install the hairpin
type retainer.
5. Install rear hub and drum assembly, wheel and tire assemblies and
wheel cover as outlined in Section 2.
6. Position the cable retainer hooks
(station wagon models) in the underbody guide (convertible models) and
install the connector, thus hooking
the two cables together.
7. Insert the cable into the equalizer and install the equalizer, spring
seat, spring, adjusting nut and lock
nut to the front, parking brake control cable.
8. Adjust the parking brake.

FA1 RLANE AND MONTEGO

STATION WAGONS AND
FALCON PASSENGER
MODELS
Removal and lnstallation

Refer to Fig. 4.
Generally follow the procedure
given above, omitting separation of
the cables, since the parking brake
rear cable assemblies supplied for
these models is in one piece. Removal
and installation of both rear wheels,
tires and drums will also be required.
LINCOLN CONTINENTAL
Removal

Refer to Fig. 8.

I. Raise the vehicle.

2. Loosen the parking brake adjustment nut and disconnect the rear
brake cables from the equalizer.
3. Remove the rear cable retaining
clips and pull the cables through the
left frame side member.
4. Remove the retaining clip that
attaches the left rear cable to the
lower left arm.
5. Remove the clips that retain the
right rear cable to the number 4
crossmember and at the right frame
side rail.
6. Remove the rear wheel covers,
and the tire and wheel assemblies.
Remove the Tinnerman retaining nuts
and remove the rear drums.
7. Remove the automatic brake
adjuster spring.
8. Compress the parking brake
cable housing retainer prongs and pull
the retainer through the backing plate
hole.
9. Relieve the spring tension and
lift the cable end from the parking
brake lever.
10. Remove the parking brake
cable from the backing plate.
lnstallation

I. Position the parking brake cable

through the hole in the backing plate.
2. Relieve the spring tension and
install the cable ball end in the parking brake lever slot. Securely seat the
retainer prongs in the hole in the
backing plate.
3. Install the automatic brake
adjuster spring.
4. Install the brake drum and the
Tinnerman retaining nuts. Install the
wheel and tire assembly and wheel
cover.
5. Install the clips that attach the
right rear cable to the number 4
crossmember and the clip that retains
the cable at the right frame side rail.
6. Install the cable clip that attaches the left rear cable to the left lower
arm.
7. Position the cables through the
left frame side member and install the
retaining clips.
8. Install the cable ends in the
equalizer lever.
9. Adjust the parking brakes. Refer
to the Parking Brake Adjustment
procedures in this manual.
10. Lower the vehicle.

12-04- 14

12-04- 14

Parking Brakes

SPECIFICATIONS

TORQUE UMlrSGENERAL-fT4BS.

Parking Brake Control Assembly

Mounting Nuts and Bolts

Ford-Mercury
Meteor
Cap Screw
12-19
Nuts 7-11

FairlaneMontego
Falcon
12-25

Maverick
Cap Screw
8-12
Nuts 8-12

Mustang.
Cougar
12-25

Thunderbird
Continental
Mark Ill
12-18

Lincoln
Continental
Dash Panel
12-25
Inst. Panel
10-20
CH1730-A

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