- ~ -

. 1961 -- -- - - ...

- CO AR ,-lANE . CON-~~~ . eUR¥ -

- ~

-rERMEDIATE

STANQ SH9PMA

Copyright © 2006, Forel Publishing Company, LLC, Woodbridge, Virginia

All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoever without written permission of Forel Publishing Company, LLC. For information write to Forel Publishing Company, LLC, 3999 Peregrine Ridge Ct.,

Woodbridge, VA 22192

1967 Cougar, Fairlane, Falcon, Mercury and Mustang Shop Manual (Form 7760-67, First printing – March 1967)

ISBN: 0-9673211-4-X EAN: 978-0-9673211-4-1

Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192

Marketed by MustangServiceManual.com

This publication contains material that is reproduced and distributed under a license from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission

of Ford Motor Company.

Disclaimer Although every effort was made to ensure the accuracy of this book, no representations or warranties of any kind are made concerning the accuracy, completeness or suitability of the information, either expressed or implied. As a result, the information contained within this book should be used as general information only. The author and Forel Publishing Company, LLC shall have neither liability nor responsibility to any person or entity with respect to any loss or damage caused, or alleged to be caused, directly or indirectly by the information contained in this book. Further, the publisher and author are not engaged in rendering legal or other professional services. If legal, mechanical, electrical, or other expert assistance is required, the services of a competent professional should be sought.

COUGAR FAIRLANE FALCON MERCURY­INTERMEDIATE

MUSTANG

~~ SERVICE PUBLICATIONS

~'AST .... ''''T' .... _ " ..... .: ... 'M' C '"' "OItD MO TOR CQ .. .. ",,,V Oo.IIIK)RN. ""C"'O" ..

,

GROUP INDEX

VEHIa! IDENTIFICATION .. BRAKES D

SUSPEN~ON, STEERING, WHEfIS AND TIRES D REAR AKlE D

DRIVE SHAFT AND ClUTCH H MANUAL SHIFT TRANSMISSION D

AUTOMATIC TRANSMISSION B ENGINE 1m!

IGNITION SYSTEM 0 FUEL SYSTEM II!)

CooUNG SYSTEM 1m EXHAUST SYSTEM mI

CHARGING SYSTEM Ikl STARTING SYSTEM IC:I

UGHTING SYSTEM, HORNS AND INSTRUMENTS I"~

VENTILATING, HEATING AND ACCESSORIES It;· BODY, DOORS AND WINDOWS IfA

TRIM, SEATS AND CONVERTIBLE TOP II:.

SCHEMATICS IE)

SPECifiCATIONS AND SPECIAL SERVICE TOOLS AT END Of EACH GROUP

FOREWORD

This shop manual provides the Service Technician with information for the proper servicing of the 1967 Cougar, Fa irlane, Falcon, Mercury Intermediate, Comet and Mustang cars.

The maintenance schedule and procedures for maintenance oper­ations are published in the 1967 Passenger Car Maintenance and Lubrication Manual.

The information in this manual is grouped according to the type of work being performed, such as diagnosis and testing, frequent­ly performed adjustments and repairs, in-vehicle adjustments, over­haul, etc. Specifications and recommended special tools areincluded.

Refer to the opposite page for important vehicle identification data.

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

~SERVICE PUBLICATIONS

1" 1

GROUP

Vehicle Iclentification

ASSEMBLY PLANT CODE BODY SERIAL CODE

MODEL YEAR CODE ,----ENGINE CODE

,---- CONSECUTIVE UNIT NUMBER

BODY TYPE CODE DATE CODE

COLOR COD

TRANSMISSION CODE

REAR AXLE CODE

FIG. 2-Mercu ry, Comet (Intermediate- Size) Ide nt if icat ion Number Location

TRIM CODE DISTRICT or DISTRICT AND SPECIAL EQUIPMENT CODE

N 1587_A

FIG. 7- Typical Warra nty Plate-Fairlane Shown

I

FIG. 3- Couga r Identification Number locatio n

FIG. 4-Mustang Iden ti fication Num ber Location

VEHICLE WARRANTY NUMBER

The vehicle warranty number is the fi rst li ne al numbers and le tters appearing on the Warranty Plate (Fig . l). The first number indicates the model year. The letter following the model year number indicates the manufacturing assembly plant. The neIt two numbers designate the Body Serial Code followed by a letter expressing the Engine Code. The group of si x digits remai ning on the f irst line indicate the Consecutive Unit Number.

VEHICLE DATA

The veh icle data appears on the second or lower line on the Warranty Plate. The first two numbers and a letter iden ti fy the Body Style. A letter or anum· ber appea rs next ind ica ting the Exterior Paint Color followed by a number· letter combination designating the Interior Trim. To the right of this code aj} pears the Da te Code ind ica ting the date the car was manufactured. A two-digit number ne xt designates the distr ict in which the car was ordered and may appear in conjunction with a Domestic Spec ia l Order or Foreign Special Order number wh en applica ble . The f ina l two spaces indicate the Rear Axle Ratio (numbers for regu lar ax les, leUers fo r lock ing·types) and the Transmission type (numbers for manual, letters for automatic ).

OFFICIAL VEHICLE IDENTIFICATION NUMBERS

Th e officia l Vehicle identification Numbers for tit les and reg istration purposes are stamped in the following locations:

Mercury, Comet (Intermediate-size), Fairlane, Falcon - On the top surface of the radiatur and front fender apron support (near the radia tor fill cap) Fig. 2.

Cougar - On the top upper flange of the left front fender apron (Fig. 3).

MUSTANG - On the top upper ftange of the teft hont fendel 'plOn ( f ig. 4).

MODEL YEAR CODE

The number 7 designates 1967 .

1-2 GROUP 1-Vehicle Identification

BODY SERIAL AND STYLE CODES

The two·digit numeral which follows the assembly plant code identifies the body series. This two·digit number is used in conjunction with the Body Style Code, in the Vehicle Date, which consists of a two-digit number with a letter suffix. The following chart lists the Body Serial Codes, Body Style Codes and the model.

MERCURY -COMET (I NTERMEDIA TE-S IZE)

Body Body Serial Style Code Code Body Type Model

02 54A 4·Door Sedan j Comet 202 01 62A 2·Door Sedan (1

OS 54B 4.Door Sedan 1 Comet Capri 07 63B 2·Door Hardtop 1

10 54D 4·Door Sedan :1' Caliente 11 63D 2·Door Hardtop j)

12 76D 2·Door Convertible

15 63E 2·Door Hardtop .2 Cyclone 16 76C 2·Door Convertible .2

17 63H 2·Door Hardtop 2 GT IS 76H 2·Door Convertible 2

03 71A 4·Door 6 Passenger Comet Voyager

OS 7lC 4·Door 6 Passenger Villager

Bench Seat Bucket Seat

COUGAR

Body Serial Code

Body Body Type Style-------------------I

91 91 91 91

Code

65A 65B 65D 65C

1 Luxury Model

MUSTANG

Body Body Serial Style Code Code

02 63A 01 65A 03 76A 02 63B 01 65B 03 76B 01 65C 03 76C

'I, Bucket Seat ·2) Bench Seat 3, Luxury Model

2·door Hardtop (Bucket Seat) 2·Door Hardtop (Bucket Seat) 'I,'

2·Door Hardtop (Bench Seat) 1:

2·Door Hardtop (Bench Seat)

Body Type

2.Door Fastback 1

2·Door Hardtop 1

2.Door Convertible I

2.Door Fastback I 3

2.Door Hardtop I 3

2.Door Convertible I ~

2·Door Hardtop 2

2·Door Convertible 2

BODY SERIAL AND STYLE CODES-(continued)

FAIRLANE

Body Body Serial Style Code Code Body Type Model

31 54A 4·Door Sedan I Fairlane 30 62A 2·Door Sedan I

34 54B 4·Door Sedan I Fairlane 500 33 62B 2·Door Sedan .1

35 63B 2·Door Hardtop I'

36 76B 2·Door Convertible I

40 63C 2·Door Hardtop 2 Fairlane 500XL 41 76C 2·Door Convertible 2

42 63D 2·Door Hardtop 2' Fairlane 500GT 43 76D 2·Door Convertible'

32 7tD 4·Door Station Wagon 37 7lB 4·Door 3S 7IE 4·Door

47 66A 2·Door 1) Ranchero 48 66B 2.Door I

49 66D 2·Door ,

I Bench Seat 2 Bucket Seat

FALCON

Body Body Serial Style Code Code Body Type Model

10 62A 2·Door Club Coupe I Standard 11 54A 4·Door Sedan 1

20 62B 2·Door Club Coupe I F utura 21 54B 4·Door Sedan 1

22 62C 2.Door 2' Sport Coupe

12 71A 4·Door Wagon (Std.)

23 7lB 4·Door Wagon (Deluxe)

I' Bench Seat 'l Bucket Seat

CONSECUTIVE UNIT NUMBER

Each model year, each assembly plant begins production with number 500001 (Mercury, Comet or Cougar) or 100001 (Fairlane, Falcon, Mustang) and continues on for each unit built.

ENGINE CODES

Code Type

J ::::::::::::::::::::::::::::::::::::::::::::::::::::i ~: l:, ~ ~~: l:: 11 ~l C ........................................................... s Cyl. 289 Cu. In. (2V) 3 ........................................................... 8 Cyl. 1· 289 Cu. In. (2V) A ........................................................... 8 Cyl. 289 Cu. In. (4V) Premo Fuel K ........................................................... S Cyl. 289 Cu. In. (4V) Hi·Perf. y ........................................................... 8 Cyl. 390 Cu. In. (2V) H ........................................................... S Cyl. 390 Cu. In. (2V) S ........................................................... S Cyl. 390 Cu. In. (4V) W ........................................................... SCyl. 427 Cu. In.(4V) Hi·Perf. R ........................................................... S Cyl. 427 Cu. In. (8V) Hi·Perf.

Low Compression

GROUP 1-Vehicle Identification 1-3

TRANSMISSION CODES

Code Type

1 ............................................................................................. 3·Speed Manual 2 ............................................................................................. Overdrive 3 ............................................................................................. 3·Speed Manual 5 ............................................................................................. 4·Speed Manual W ........................................................................................... .Automatic (C4) U ............................................................................................. Automatic (C6)

REAR AXLE RATIO CODES

A number designates a conventional axle, while a letter designates a locking differential

Code Ratio Code Ratio

1 ............................................ .3.00: 1 A ........................................... 3.00:1 2 ............................................ 2.83:1 3 ............................................. 3.20:1 C ........................................... 3.20: 1 4 ............................................. 3.25:1 D ........................................... 3.25: 1 5 ............................................. 3.50: 1 E ........................................... 3.50: 1 6 ............................................. 2.80: 1

DATE CODES

A number signifying the date precedes the month code letter. A second·year code letter will be used ~ the model exceeds 12 months.

Month Code

First Year Code

Second Year

January .............................................. .A ............................................... N February ............................................. B ............................................... P March .................................................. C ............................................... Q April .................................................... D ............................................... R May ..................................................... E ............................................... S June ................................................... ,F ............................................... T July ..................................................... G ............................................... U August ................................................. H ............................................... v September ......................................... J ................................................ w October ............................................... K ............................................... X November ........................................... L ............................................... Y December ........................................... M ............................................... z

ASSEMBLY PLANT CODES

Code Lettl!f'

Code Letter

A ........................................... Atlanta L ................................... Michigan Truck B ........................... Oakville (Canada) N ............................................... Norfolk C ................................. Ontario Truck P .......................................... Twin Cities o ............................................. Oallas R ............................................. San Jose E .......................................... Mahwah S ........................................... Pilot Plant F ......................................... Oearborn T ............................................ Metuchen G ........................................... Chicago U ............................................ Louisville H ............................................. Lorain W ................................................ Wayne J ..................................... Los Angeles Y ................................................. Wixom K ..................................... Kansas City Z ............................................. St. Louis

DISTRICT CODES (DSO)

Units built on a Domestic Special Order, Foreign Special Order, or other spe· cial orders will have the complete order number in this space. Also to appear in this space is the two-digit code number of the ~istrict which ordered the unit. If the unit is a regular production unit, only the District code number will appear.

FORD

Code District

11 .................................................................................. Boston 13 .................................................................................. New York 15 .................................................................................. Newark 16 .................................................................................. Philadelphia 17 .................................................................................. Washington 21 ................................................................................. .Atla nta 22 .................................................................................. Charlotte 24 ................................................................................. Jacksonville 25 .................................................................................. Richmond 27 .................................................................................. Cincinnati 28 .................................................................................. Louisville 32 .................................................................................. Cleveland 33 .................................................................................. Oetroit 34 .................................................................................. lndianapolis 35 .................................................................................. Lansing 37 .................................................................................. Buffalo 38 .................................................................................. Pittsburgh 41 .................................................................................. Chicago 42 .................................................................................. Fargo 43 .................................................................................. Milwaukee 44 .................................................................................. Twin Cities 45 .................................................................................. Oavenport 51 .................................................................................. Oenver 52 .................................................................................. 0es Moines 53 ................................................................................. Kansas City 54 .................................................................................. 0maha 55 .................................................................................. St. Louis 61 ....................... , .......................................................... Oa lIa s 62 .................................................................................. Houston 63 .................................................................................. Memp his 64 .................................................................................. New Orleans 65 .................................................................................. Oklahoma City 71 .................................................................................. Los Angeles 72 .................................................................................. San Jose 73 .................................................................................. Salt Lake City 74 .................................................................................. Seattle 75 .................................................................................. Phoenix 81 .................................................................................. F ord of Canada 83 .................................................................................. Government 84 .................................................................................. Home Office Reserve 85 ................................................................................. .American Red Cross 89 .................................................................................. Transportation Services 90·99 ............................................................................. Export

MERCURY

Code District Code District

11 ................... Boston 34 ................... 0etroit 16 ................... Philadelphia 41 ................... Chicago 15 ................... New York 42 ................... St. Louis 17 ................... Washington 46 .................. .T win Cities 21 .................. .Atlanta 51 ................... 0enver 22 ................... 0allas 52 ................... Los Angeles 23 ................... Jacksonville 53 ................... 0akland 26 ................... Memphis 54 ................... Seattle 31 ................... Buffalo 84 ................... H ome Office Reserve 32 ................... Cincinnati 33 ................... Cleveland 90 ................... Export

1-4 GROUP 1-Vehicle Identification

EXTERIOR PAINT COLOR CODES

Code M-3O.J M-32·J Color

A ........................................... 1724·A ...................................... Black B .......................................... .1734·A ...................................... Lt. Aqua

f.:::::::::::::::::::::::::::::::::::::::::::~~:t~ ::::::::::::::::::::::::::::::::::::::~i~e ~~r.e Met. K ........................................... 1903·A ...................................... Ok. Blue Met. M .......................................... 1619-A ...................................... White Q ........................................... 1624·A ...................................... Med. Blue Met. T .......................................... .2008·A ...................................... R ed V .......................................... 2066·A ...................................... Bronze Met.

~.::::::::::::::::::::::::::::::::::::::::::l~~t~ ::::::::::::::::::::::::::::::::::::::~:~o~~e~et. y ........................................... 2039·A ...................................... Ok. Green Met. Z .......................................... .1 915·A ...................................... Med. Gold Met. 2 ........................................... 1633·A ...................................... Yellow

i :::::::::::::::::::::::::::::::::::::::::::!~H ::::::::::::::::::::::::::::::::::::::r~:~:Y Met.

INTERIOR TRIM CODES

Code Trim Schemes

IB ....................................... Blue Cloth and Blue Vinyl 10 ....................................... Red Cloth and Red Vi~1 1 K ....................................... AQua Cloth and Aqua inyl 1U ....................................... Parchment Cloth and Parchment Vinyl W/Black 2A ....................................... Black Vinyl 2B ....................................... Blue Vinyl 20 ....................................... Red Vinyl 2F ....................................... Saddle Vinyl 2G ....................................... Ivy Gold Vinyl 2K ...................................... AQua Vinyl 2U ....................................... Parchment Vinyl W /Black 3B ....................................... Blue Cloth and Blue Vinyl 3G ..................................... ..Ivy Gold Cloth and Ivy Gold Vinyl 3K ....................................... AQua Cloth and Aqua Vinyl 3U ....................................... Parchment Cloth and Parchment Vinyl W/Black 4A ....................................... Black Vinyl 4B ....................................... Blue Vinyl 40 ....................................... Red Vinyl 4G ...................................... .lvy Gold Vinyl 4K ...................................... .AQua Vinyl 4U ....................................... Parchment Vinyl 5A ....................................... Black Cloth and Black Vinyl 5B ....................................... Oark Blue Cloth and Blue Vinyl 5K ...................................... .AQua Cloth and Aqua Vinyl 5U ....................................... Parchment Cloth and Parchment Vinyl W/Saddle 6A ....................................... Black Vinyl 6B ....................................... Oark Blue Vinyl 60 ....................................... Red Vinyl 6F ....................................... Saddle Vinyl 6G ....................................... Ok. Ivy Gold Vinyl 6K ...................................... .AQua Vinyl 6U ....................................... Parchment Vinyl 7A ....................................... Black Vinyl 7B ....................................... Blue Vinyl 7U ....................................... Parchment Cloth and Parchment Vinyl 8A ....................................... Black Vinyl 8B ....................................... Blue Vinyl 80 ....................................... Red Vinyl 8F ....................................... Saddle Vinyl

INTERIOR TRIM CODES~continu.d)

Code Trim Schemes

8G ...................................... .Ivy Gold Vinyl 8K ...................................... .AQua Vinyl 8U ....................................... Parchment Vinyl W/Black 9A ....................................... Black Cloth and Black Vinyl 9B ....................................... Ok. Blue Cloth and Ok. Blue Vinyl 90 ...................................... Ok. Red Cloth and Ok. Red Vinyl 9K ...................................... .AQua Cloth and Aqua Vinyl 9U ....................................... Parchment Cloth and Parchment Vinyl W/Black FA ....................................... Parchment Vinyl W /Black FB ....................................... Parchment Vinyl W/Blue FO ....................................... Parchment Vinyl WIRed FG ....................................... Parchment Vinyl W/lvy Gold F K ....................................... Parchment Vinyl W/Aqua GA ....................................... Black Vinyl W /Parchment GB ....................................... Blue Vinyl W/Parchment GO ....................................... Red Vinyl W/Parchment GG ....................................... Ivy Gold Vinyl W/Parchment GF ....................................... Saddle Vinyl W/Parchment GK ...................................... .AQua Vinyl W/Parchment LB ....................................... Red Vinyl LO ....................................... Blue Vinyl LU ....................................... Parchment Cloth and Parchment Vinyl W/Black OU ....................................... Parchment Vinyl UA ....................................... Parchment Vinyl W/Black U B ....................................... Parchment Vinyl W /Blue UO ....................................... Parchment Vinyl WIRed U F ....................................... Parchment Vinyl W /Saddle UG ....................................... Parchment Vinyl W/lvy Gold UK ....................................... Parchment Vinyl W/AQua

2- 1 -

GROUP

Brakes 2 PART 2-1

Genera I Brake Serv ice .. . PART 2-2

Brake System ... .. ......... .. . .

i·

PAGE . 2-1

.. 2-9

PART 2-3 Specif ications .....

PAGE ...... 3-34

PART 2-1- General Brake Service Sec tio n

1 Di agnos is and Tes ting Brake System T ests. Road Test. .. ......... .

2 Common Adjust ments a nd Repai rs Park ing Brake Linkage Adjustme nt P ower Brake Master Cvlinder Pu sh

Pl.l~(,

..... 2-1 ...... 2-1

. ...... 2-3 ........ 2-3

....... 2-3

Section Page Hydraul ic System Bleeding and

C entra liz ing of the Differential Valve ....... 2~4 3 Clea ning a nd In spection ......... . . ... . .. ...... . ...... 2-6

Di sc (Front) Brakes.......... . .............. 2-6 Rear Brakes ................... . .. ... ..•....... 2-6

Rod Adjustm ent ............... .... . . . .. . . 2-4

D DIAGNOSIS AND TESTING

BRAKE SYSTEM TESTS

BRAKE FLU ID LEVEL AND HYDRA U LI C S YSTEM

I. Always check the flu id level In

the brake master cy linde r rese rvoirs befo re pcr ro rming the les t procedures. If the fluid level is not within 1/ 4 to 1/2 inch of the top of the master cy l­inder reservoirs. add the spec ified brake fl uid. Add Rotunda Brake Ftuid -Ext ra Hea vy Duty - Pa rt Numbe r C6A Z -19542-A (ESA-M 6C25- A) o r eq ui va lent for all di sc brake appli ca­tions and Rotunda Brake Fluid -I-!cavy Duty - Part Numbe r B7AZ-19542-A, R- I03-A o r equi va lent for power drum or s ta ndard drum appli c<lli ons. T he di sc bra ke ext ra heavy duty brake fluid is co lored blue for identification purposes. Do not mix low te mpe ratu re brake flu ids with t he specified di sc bra ke fluid .

D U AL MASTER CY LI NDE R IIRAKE S YSTEM

I. Turn the ignition switc h to the ACe or ON position. If the ligh t on the brake warning lamp remains on,

the condition may be caused by a defect ive s witc h. grounded switc h wires o r the dirrerential pressure va lve is not ce nte red . Cent rali ze the differential press ure va lve as outlined under Hy­d rau lic Sys te m Bleeding a nd Cen­tra liz ing of the Diffe rentia l Va lve in this sect ion of the manual. If the warning light remains on. chec k the swi tch connector and wi re fo r a grounded condition and repair o r repl ace the wire assembly. If the condition o f the wi re is good, rep lace the brake warning lamp sw itch.

2. Turn the ignition swi tc h to the start pos ition. If the brake warn ing lamp docs not light , c heck the light a nd wiring fo r defects and replace o r repai r wiring.

3 . If the..: brake warning lam p docs not li ght when a press ure differe nt­ial condition ex is ts in the bra ke sys­tem . the warning lamp may be burned o ut . the warning lam p switch is inoperative or the switc h to la mp wiring has an open ci rc ui t. C hec k the bulb and rep lace it , if re ­quired . C hec k the switch to lamp wi res fo r an o pen c irc uit and repair or re· place the m, if requ ired . If the warn­ing lamp s titl docs not light , rep lace the switc h.

BRAKE P EDAL FREE HEIGHT AND TRAVEL

MEASU REME NTS

W ith the e ngi ne running for full power brake opera t ion, measure the brake peda t free he ight , and check the bra ke peda l travel with the use of the Brake Pedal Pressure Gauge, Tool WRE-500-50 as follows:

Brake Pedal Free Height Me asuremen t

I. Inse rt a s lende r, sharp po inted prod through the ca rpel a nd sound deadncr to the dash panel meta l a nd measure the di s tance to the brake peda l (F ig. I).

2. If the pos iti on of the pedal is nll t within speci ficat ion. check the brake pedal lin kage for miss ing bushings o r loose attaching bolts and rep la ce them . if requi red .

3. If the peda l free height is still o ut of spec ific;Hion, c heck the brake pedal booster push rod (if so equipped) o r master cy li nder to be sure the co r­rec t pa rts are ins ta ll ed. Replace the defective parts as necessary.

2-2 GROUP 2-Brakes

STEERING WHEel R~~\

\ \ -\

STEERING COLUMN

A

9<) ' STEE RING COLUMN

TDEBDA PiJ OR DASH METAL

STEEL MEASURING TIIPE

VEHICLE TYPE PEDAL FREE PEDAL TRAVEL Il HEIGHT A

F:'LCON-CO:.~ET -FAIRUNE NON.PQI,'ER DRUM 803 !l 81 2.74

FALCON-COI/.e T -FAIRLANE PO .... E P. QRur,\ SO~ ) 14 '" FALCON eOtAET FAIR LANE PQNER DI.~C 639.!9Q 2.08

F AlCON-COt.IET -FAIRUNE No.".PO"'ER DISC aOJ 681 2.0B

!.lUST ANG-COUGAR NOi~·POWER DRUM 6.98 603 2.68

~'\USTA NG-COUGAR POWER DRUM HI 4 60 La2

MUSTANG COUGAR POWER DISC HI J 60 1.B1

NOTE: A DIMENSION T0 ~E "IEASURED TO SHEET ME T Al

B DIMENSI ON TO BE MEASURED PARAL LEL 1 0 THE VER TICAL CENTERLI NE OF TH( STE ERING COLUMN WI TH ,\ 50 POUND LOAD APPLIED TO THE CE NTERLINE OF TH E i3R AKE PEDAL PAD. ((ti EC KS ON POWER BRAKE VE HICLES MADE WITH ENGIN E RUNNlt!(;' \ H1551-A

FIG . 7-Brake Pedal He ight a nd Travel Measu reme nts

FIG. 2- Bra ke Pedal Effort G ouge Insta lled - Typical

Brake Pedal Tra vel M ea sure ment

l. I nstal1 a Brake Pedal Press ure Gauge on the brake pedal pad (Fig. 2).

2. Hoo k a steel measu ring tape to the brake pedal as shown in fig. \. Measure and record the distanct: from the brake peda l free heigh t po· s it ion to the re ference point. which is at the s ix o'cloc k position on the steer­ing whee l rim .

3. With the steel tape st ill hookt:d to the brakt: pedal depress the brake by pressi ng downward on the brake pedal effo rt gauge . Apply a 50 pound load to the cente r of the pedal by observing the press ure gauge, :t!1d meas ure the d is tance from the brake pedal to tht: fixed rcfert:nce po int on the stee ring wheel rim. parallel to the cente rl ine of the steer· ing col umn.

4. The Llifference between the brake pedal free height and the depressed

pedal measurement under a 50 pound load should be within the speci­fied ma xi mum pedal travel service spec ifica tion B in Fig. I.

5. If the pedal travel is more than the spec ified maximum shown in Fig. I. dimert" ion B, make several sharp revt:rsc stops (equivalent to 50 pounds pedal pressure) with a forward stop befo re each. Move the car in rcvt:rst: a nd forward for a distance of ap­proxi mately ten feel ; then apply the brakes sha rply and hold the bra ke pedal down until the car is completely stopped. This will actuate the brake self-adjuste rs. Jr these stops do not bring the brake peda l travel with­in specification. make st:vt:ral addi­ti onal fo rvo'ard and reverst: stops as outlined above.

6. If the second ser ies of stops do not bring the brakc pedal travel within spec ification. remove the bra ke drums and check the brake adjusters to make sure thc ), arc fun ction ing. Check the brake linings for wear or damage . Repair or rep lacc all worn or damaged parts and non· fun ct ion­in g adjusters. Adjust the brakl.! lin­in g outs ide diameter to the appro:.;,i­matt: ins ide diameter of the brake drum with Rotunda Too! I-IR E g650 (Figs. II and 12, Part 2-2).

7_ If all the brake adjustt:rs. brake drums and lin ings arc func ­ti onal and the brake pedal travel is not within spt:cificati ons. chl.!ck tht: pedal linkage for miss ing bushings. o r loose altach ments. Bleed the brake and centralizc tht: differentia l va lve.

POW ER BR A K E FUNCTIONA LTEST

I. With the transmiss ion in neutral. stop the engine and apply the parking brake. lXpress thl.! bra kt: pcdal sev­eral timt:s to t:xha ust all vacuum in the syste m.

2. With the eng ine shut off. de­prt:ss the brake pedal and hold il in the applied position . If the Ix;dal gradually falls away undl.!r this pressu re, the hydraulic s)'s tl.!l11 is 1c ~lking. Check all tubing. hoses. ca lipe rs (if so equipped). wheel cyl­inders and connections fur leaks.

If the br"lk t: pedal move ment feels spongy, bleed tht: hydraulic sys tem to remove air from the sys tem . Refer to Hydraulic System Bleeding. Part I. &:ct ion 2. J\lso. check for leaks or insuffic.:ien t fluid .

.1. With the cngi ne shut off and all vacuum in tht: system ex haustt:d . dt:press the pedal and hold il in the ap­plied pos ition. Start tht: engine. If the vac uum sys tem is ope rating. I hI.! peda l will tend to fall away under foot pressu re and less press ure will

be required to hold the pedal in the applied position. If no action is fell , the vacuum booster system is not lunctioning.

LO CKED WHEEL BRAKE

Should one of the wheel brakes be locked and the car must be moved , open the bleeder sc rew long enough to let out a few drops of brake fluid. This bleeding operation will release the brakes bur will not correct the ca use of trouble.

PARKING BRAKE

Visuall y check the operation of the parking brake link age as the park­ing brake controls arc moved to the

PART 2-1-General Brake Service

applied position . Then, check the opera­tion of the brake link age when the parking brake con trols are moved to the released position. These checks shou ld indicate whether the manual parking brake control linkage is op­erating properly or requires repair o r adjustment due to in abi lity of the parking brake to hold agai nst mod­erate veh icle move ment.

ROAD TEST

A road tesl should only be con­ducled when ttN.' operator is sure Ihe brakes will stol) the vehicle.

During a road tesl, apply the ve­hicles brakes at a road speed of 20 mph for all problem co nd itions listed in Figs. II and 12 with the excep-

2-3

tion of those resolved in the Brake Sys­tem Tests and brake chatter. To check for brake chatte r o r surge, app ly the bra kes li ghtly at 50 mph . For each of the symptoms encountered, check and eliminate the ca uses which are listed in Figs . II and 12.

If the road test revea ls one or morc problem cond itions li sted in Figs. II and 12, cor rect all malfunctions of the vacuum system, bra ke booster and hyd r<lu lic sys tem prior to re­moving br<lke drums. brake c<l lipcrs (if so equipped), brake shoes and linings or backing plates.

EJ COMMON ADJUSTMENTS AND REPAIRS

PARKING BRAKE LINKAGE ADJUSTMENT

MUSTANG - COUGAR

Check the parking brake cables when the parking brakes are fully released. If the cables arc loose, ad­just them as follows:

I. Fully release the parking brake by turning the handle coun­terclockwise and pushing it inward.

2. Pull the park ing brake handle outward to the third notch from its normal released position .

3. Raise the vehicle. Remove the wheel cover. Insta ll Tool T66L-4204-L on [he rea r whee l (Fig. 3).

4. Turn the lOCking adjustment nut forward against the cable guide on the equalizer (Fig. 4) unt il there is 100 ft-lbs break-away torque at the rear wheel when turning the rear wheels in the direction of forw urd ro­tation with a torque wrench (Fig. 3). The torque measurement must be made relative to the centerline of the wheel.

5. Release the parking brake and make sure the brake shoes return to the full y released position und no drag is felt when turning the rear wheels.

6. Remove Tool T66L-4204- L. In­sta ll the wheel attac hing bolts and torque them to spec ification. Install the wheel cover. Lower the vehicle.

COMET- FALCON­FAIRLANE

Check the parking brake cClbles when the brakes arc fully rcleClsed.

Tool- T66L·,J10d· A

FIG. 3- Checking Parking Brake Break-Away Torque

If the cables arc loose, adj ust them as fo ll ows:

I. Fully release the pa rking brake pedal.

2. Raise the ve hicle. Loosen tht! equalizer lock nut (Fig. 5) and turn the nut forw a rd aga inst the cable gu ide on the equa li ~er until there is 22 to 27 pounds tension on the left rea r cab le o r there is 100 fI -!bs break-away lOrquc when turning the rear wheels in the d irection of forward rotation with ~I torque wrench and Tool T66L-4204-L as shown III

Fi g. 3. The lorque I11l'3s ureml'nt must bl' madl' relative 10 the cen(er­linl' of the wheel. Tighten thl: lock nu l.

3. Make sure then' is no drag whl'n turning Ihl' rear wheels.

4. Lowc. r thc vehicle. Remove thc

ADJUSTME NT NUT -3799JO .S2~

'21

EQUALIZER RDO -262S

EQUALIZER LEVER 2A60S

H 1552·A

FIG. 4-Parking Broke linkage

Adjustment - Mustang and Cougar

torque wrcnch and Tool T66L-4204-L. if rcquircd . Install the whed attac h­ing nuts and turljuc them to speci fi­cation. InslaJlthc whcc l cove r.

2-4

RETAINER - (j. RETAINER-2A6t6 NUT 74'l77·5 ,(;.alE ASSEMBLY 33798-58

2A6G.l 7- 10 La.FT. EQUALIZER _iA602 L

-- "j» ,p:;

~'''''--,---:I)(ir:~~\ ~. ~- . .. J' SPRING-2A651 I

ALL MODELS EXCEPT CONVER T! BlE NUT -33923·58

PARKING

eRA KE CA3LE i __ RETAINER-7~2ns MlO CONDUIT *'

ASSE M(3l Y -2853 \

\SPR ING_2M5 1 ; CABlE ASSE MBLY

-........... ' 2A604

............ \ NUT - 33Q23 58

"\\ 1 '~.- :b~ l,-==--:.:: :-:,- .. I \! ....... " NUT -3 3798-58

~ " \' 7- 10LB.FT.

• ~ '-': EQUAllZER - 2A602

~~RETAINER_2A616 CONvERTIBLE ONLY HI553-A

FIG. 5-Parking Brake Linkage Adjustme nt - Comet, Fairlane and Fa lcon

2

HI :xis-a

FIG. 6-Push Ro d Gau ge Dime nsions

POWER BRAKE MASTER CYLINDER PUSH ROD ADJUSTMENT

The push rod is provided wi th an adjustment sc rew to mainta in the cor­rect relat ionshi p between the booste r co ntrol v<.llve plunger and the master cylinde r pistons. Fai lure to maintain this relationship will p reve nt the maste r cy l inder piston fro m complete ly re­leasi ng hydrau lic p ressure a nd can cause the brakes to drag , or ca use excessive bra ke pedal trave l.

GROUP 2-Brakes

FIG . 7-Push Rod Ad justme nt -Midland ·Ross

To check the adjustment of the sc rew, fabri cate a gauge of the dimens ion shown in Fig. 6. Then place the gauge against the mas te r cy l­inder mounting s urface of the booster body as shown in Figs. 7 or 8. The push rod sc rew should be adjus ted so that the end of the screw j ust to uch­es the inne r edge of the s lot in the ga uge. Do not se t up s ide forces o n the push rod. S ide fo rces may break the valve p lunge r.

This is a n approx imate adjust­me nt onl y. The push rod shou ld not move mo re tha n 0 .015 inch as it contacts the master cy linder pis ton . No movement (exact con tact) is idea l.

HYDRAULIC SYSTEM BLEEDING AND CENTRALIZING OF THE DIFFERENTIAL VALVE

When any parl of the hydrau li c sys tem has been di scon nected for re­pair or replacement, <ii r may en ter the syste m and ca use spongy pedal act ion. Bleed the hyd rau lic sys tem a fter it has been properly connected, to be sure that a ll a ir is e xpe lled.

MAN UAL IlLEE DING

T he pr imary and secondary ( front and rca r) hydra ul ic b ra ke sys tems are ind ividua l systems a nd a re b led sepa rate ly. Bleed the lo ngest li ne first on ', he ind ividual sys tem be ing servired . During the co mplete blee ding o pera tion, 00 NOT a llow the rese r­voir to run d ry . Keep the mas ter cy l­inder reservoirs fi ll ed wi th Rotunda Fluid - Extra Heavy Duty - Pa rl Numbe r C6AZ- 19542-A (ESA­M6C25· A). T he d isc bra ke ex tra

t ,

H 1330· B

FIG. 8-Push-Rod Ad justment -Bend ix

hea vy duly bra ke fluid is colored blue fo r ide ntificati on purposes. Do not mix low te mpera ture bra ke fluids with the specified fluid during the bleed ing ope rations. Ne ve r re-usc bra ke fI uid whic h has bee n dra ined fro m the hydra uli c system.

I. Loosen the bleed sc rew located on the s ide of the maste r cy linde r. Do not use the secondary pis lon stop sc rew, located on the botto m of the maste r cy linde r to bleed the brake syste m. Loosening o r re moving this sc re w could result in da mage t o the secondary pis ton o r st o p screw.

2. To bleed the secondary (rear) b ra ke sys te m, position a s uitab le 3/8 inch box wrench (Fig. 9) on the bleede r fitt ing on the brake wheel cylinder. Attach a rubber drain tube to the bleede r filling . T he e nd of the tube s hould fit s nugly a round the bleeder Iitling.

3. Submerge the free end of the tube in a container pa rti ally filled with clean bmke fluid , and loosen the bleeder filling approximately 3/4 turn .

4. Pus h the brake pedal dow n slowly through its full t ravel. Close the b leeder fitt ing, the n ret urn the pedal to the fully- re leased pos it ion. Re pea t th is operatio n unt il a ir bub­bles cease to appea r at the sub­merged end of the bleeder tube .

S. Whe n the fl uid is completely free of a ir bubbles, cl ose the bleede r fitting and remove the bleeder tube .

6. Repeat this procedu re at the brake wheel cyli nder on the o pposite s ide. Refi ll the master cy linder rese r­voir after each whee l cy li ndl! r is bled