1969 Ford Car Shop Manual Volume One Chassis

7/24/2019 1969 Ford Car Shop Manual Volume One Chassis

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FOREWORD

The five volumes of

this

shop manual provide the Service Technician

with complete information for the proper servicing of all the 1969 line

of Ford Passenger Cars.

The information is grouped according to the type of work b eing per-

formed

such as frequently performed adjustmen ts and repairs, in-

vehicle adjustments, major repair, etc. Specifications, maintenance

information and recommended special tools are

included.

The descriptions and specifications in this manual were in effect at the

time this manual was approved for printing. Ford Motor Company

reserves the right to discontinue models at any time, or change specifi-

c tions

or design, without notice and without incurring obligation.

S E R V IC E P U B L IC A T IO N S


4/412

GENERAL INFORMATION

Individual carline shop manuals have been combined in one Car

Shop M anual divided into five volumes for 1969.

The 1969 Car Shop Manual has been organized into general

Groups as in previous shop manuals. All G roups are listed in the Group

index on the first page of each Volume. Groups not contained in a

given Volum e are listed with a solid gray background.

To locate the beginning page of any particular Group, first select

the Volume containing that Group. Bend the manual until the black

mark on the first page of the Group can be seen in line with the Group

title on the first page of the V olume.

The first page of each Group lists the material contained in the

Group under Part headings and also lists the beginning page of each

Part.

On the beginning page of each Part, there is a Part index which

lists in detail all information appearing in the Part, the page where

the information is given, and the vehicles to which the information

applies.

All pages carry a six-digit number which indicates the Group,

Part and Page nu mber.

For Exam ple: Page 03-02-01 indicates

Group 3, Part 2, Page 1

Part Indexes will use only the Part and Page reference numbers.

For Example: Page 03-02-01 will appear in the Part Index as

02-01.

Each Part will start with Page 01.


5/412

01-01-01 01-01-01

1

I 9Y82A848000|

Y 8 9 A 8 4 8 0 0 0 r

MMUNTrNUMBW

I 5 3 A

A IA I8H 34 4

^J MODEL YEAR CODE

2) ASSEMBLY PLAN T CODE

5)

BODY SER IAL CODE

T) ENGINE CODE

T) CONSECUTIVE UNIT N O .

T) BODY TYP E CODE

(7)

COLOR CODE

0 TRIM CODE

DATE CODE

(JO) DIST RICT-S PEC . EQU IP. CODE

(lT ) REAR AXLE CODE

(12) TRANSMISSION CODE

W1001-A

Fig.

1Warranty

P latesPas senger Cars

9Y83NI0000I

Fig.

2Typical Vehicle Identif icat ion Number (VIN) Tab

W 1002-A


6/412

01-01 -02 Vehicle Identification

01-01-02

VEHICLE WARRANTY NUMBER

The vehicle warranty number is the first l ine of numbers and

letters appearing on the Warranty Plates (Fig. 1). The Warranty

Plate is riveted to the left front door lock face panel. The first

number indicates the model year. The letter fol lowing the model

year number indicates the manufacturing assembly plant. The next

two numbers designate the Body Serial Code fol lowed by a letter

expressing the Engine Code. The group of six digits remaining on

the first l ine indicate the Consecutive Unit Number.

VEHICLE DATA

The vehicle data appears on the second or lower l ine on the

Warranty Plate. The first two numbers and a letter identify the

Body Style. A letter or a number appears next indicating the

Exterior Paint Color fol lowed by a number-letter combination

designating the Interior Trim. To the right of this code appears the

Date Code indicating the date the car was m anufactured. A two-

digit number next designates the district in which the car was

ordered and may appear in conjunction with a Domestic Special

Order or Foreign Special Order number when applicable. The final

two spaces indicate the Rear Axle Ratio (numbe rs for regular axles,

letters for locking-types) and the Transmission type (numbers for

manual,

letters for automatic).

OFFICIAL VEHICLE IDENTIFICATION NUMBER

The official Vehicle Iden tification N umber (VI N ) for ti t le and

registration purposes is stamped on an aluminum tab that is riveted

to the instrument panel close to the windshield on the driver's side

of the car and is visible from outside (Fig. 2).

MODEL YEAR CODE

The number 9 designates 1969.

ASSEMBLY PLANT CODES

COUGAR

Code

Letter

Code

Letter

A

B

C

D

E

F

G

H

J

K

Atlanta L

Oakville (Canada) N

Ontario Truck P

Dallas

R

. , Mahwah S

Dearborn T

Chicago U

Lorain W

Los Angeles X

Kansas City Y

Z

Michigan Truck

Norfolk

Twin Cities

San Jose

. ( P i lot ) . . . .A l len Park

Metuchen

Louisville

Wayne

St. Thomas

Wixom

St. Louis

BODY SERIAL AND STYLE CODES

The two-digit numeral which fol lows the assembly plant code

identifies the body series. This two-digit number is used in con-

junction with the Body Style Code, in the Vehicle Data, which

consists of a two-digit number with a letter suffix. The fol lowing

chart l ists the Body Serial Codes, Body Style Codes and the model.

LINCOLN CONTINENTAL

B o d y B o d y

S e r i a l S t y l e

C o d e C o d e B o d y T y p e

82 53A 4-Door Sedan

80 65A 2-Door Hardtop

CONTINENTAL MARK I II

B o d y B o d y

S e r i a l S t y l e

C o d e C o d e B o d y T y p e

89 65A

2-Door

Hardtop

Body

Serial

Code

91

92

93

94

91

Body

Style

Code

65A

76A

65B

76B

65C

Bench Seat

MERCURY

Body

Serial

Code

44

46

48

45

40

4 1

42

54

56

58

63

66

68

65

63

66

68

60

61

72

72

74

74

76

76

Body

Style

Code

54A

65A

57A

76A

53M

65M

57M

54C

65B

57B

53F

65F

57

F

76F

53C

65C

57C

63G

63H

71 B

71C

71 F

71G

71E

71A

Bench Seat

BodyType

2-Door Hardtop

Convertible

2-Door

Hardtop

Convertible

2-Door Hardtop

Model

Standard

XR-7 Luxury

Standard

S plit Bench Bu cket Seats

Body Type

4-Door Sedan

2-Door Hardtop-Formal

4-Door Hardtop

Convertible

CANADA ONLY

4-Door Hardtop Sedan


4-Door Hardtop

4-Door Sedan

2-Door

Hardtop-Formal

4-Door Hardtop



4-Door Hardtop

Convert ible



4-Door Hardtop

Model

Monterey

Marquis

Monterey-Custom

Marquis

Brougham (Option)

2-Door

Hardtop (Tunnel Roof) Marauder

2-Door

Hardtop (Tunnel Roof)

4-Door 2 Seat

4-Door 3 Seat (Side Facing)

4-Door2 Seat


4-Door 2 Seat


Monterey Wagoi

Monterey-Custom Wagon

Marquis Colony Park

Sp lit Bench Bu cket Seats

METEOR (CANADA)

Body

Serial

Code

20

21

23

Body

Style

Code

54A

54B

65B

Body Type

4-Door Sedan

4-Door Sedan

2-Door

Hardtop-Formal

Model

Rideau

Rideau 500

30 54C 4-Door Sedan

35 65C

2-Door

Hardtop-Formal

35 65E 2-Door H ardtop-Formal{ 5-33)

33 57C 4-Door H ardtop

34 76C Convertible

34 7 6E Convertible (S -33)

Montcalm

24 65F 2-Door H ardtop-Formal

27 57 F 4-Door H ardtop

LeMoyne

28 7 1B Rideau 50 0- 6 Passenger

29 71C Rideau 500 -Du al Face Rear

38 7 1E Mo ntca lm-6 Passenger

39 71A Mont calm-D ual Face Rear

Sta tion Wagons.

Bench Seat Sp lite Bench Bucke t Seats


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01-01 -03

Vehicle Identification

01-01-03

BODY SERIAL AND STYLE CODES-(continued)

MONTEGO

Body

Serial

Code

01

02

06

07

10

11

12

11

12

10

11

Body

Style

Code

65A

54A

54B

65B

54D

65D

76D

65 E

76B

54C

65C

Body Type

2-Door Hardtop-formal

(Sports Coupe)

4-Door Sedan (Sports)

4-Door Sedan


4-Door Sedan


Convertible


Convertible

4-Door Sedan


Model

Comet

Montego

Montego MX

Montego MX

Montego MX Brougham

MUSTANG

15 63A 2-Door Hardtop Fastback

(GT Appearance Opt.) Cyclone

15 63C 2-Door Hardtop Fastback

16

63 H

2-Door Hardtop Fastback

(Sports Appearance Opt. ) Cyclone CJ

03

7 1B

Montego

08 71C Montego MX

08 7 1A Montego MX (Woodg rain)

Station Wagons-4 Door

B ench Seat Spl it Bench B ucket Seats

THUNDERBIRD

Body Body

Serial Style

Code Code

Body Type Model

83

65A

2-Door H ardtop

83 65C 2-Door H ardtop

84 65 B 2-Door Landau

84

65D

2-Door Landau

87 57 B 4-Door Landau

87 57 C 4-Door Landau

Be nch Seat S plit Bench Buc ket Seats Bl ind Quarter Roof

FALCON

Body

Serial

Code

10

11

20

22

21

12

23

Body

Style

Code

62A

54A

62B

62C

54B

71A

71B

Bench Seat

Body Type

2-Door Sedan

4-Door Sedan

2-Door Sedan

2-Door Sports Coupe

4-Door Sedan

Standard

Futura

Spl it Bench

Model

Standard

Futura

Station Wagons

- 4 Door

Bucket Seat

Body

Serial

Code

01

02

03

01

02

03

01

01

01

02

Body

Style

Code

65A

63A

76A

65B

63B

76B

65C

65D

65E

63C

Bench Seat

Body Type

2-Door Hardtop

2-Door Fastback

Convert ible

2-Door Hardtop

2-Door Fastback

Convert ible

2-Door Hardtop

2-Door Hardtop

2-Door Hardtop

2-Door Fastback

Model

Standard

Luxury

Standard

Luxury

Grand

Mach l

Sp lit Bench Bucke t Seats H i-Back Bucket

FORD

Body

Serial

Code

50

51

52

53

Body

Style

Code

62E

54

E

62B

54B

Body Type

2-Door Sedan

4-Door Sedan

2-Door Sedan

4-Door Sedan

Model

Custom

Custom 500

54 54 A 4-Door Se dan

55

63 B

2-Door Ha rdtop-Fastback

58

65C

2-Door H ardtop-Forma l

Galaxie 500

56

57

60

61

64

62

66

57B

76A

63C

76B

54C

65A

57F

4-Door Hardtop

Convertible

2-Door Hardtop-Fastback

Convertible

4-Door Sedan


4-Door Hardtop

Ford XL

Ford LTD

70 7 1D Ranchwagon-6 Passenger

7 1

7 1H

Custom 500 Ran chwagon -

6 Passenger

72 7 1J Custom 500 Ranchwa gon-

Dual Face Rear

73 7 1B Country Se dan-6 Passenger

74 7 1C Country Seda n-Dual Face Rear

75

7 1E

Country Squire6 Passenger

76

7 1A

Country Sq uire-D ual Face Rear


B ench Seat Sp lit Bench Buck et Seats


8/412

01-01-04


01-01-04

BODY SERIAL AND STYLE CODES-(continued)

FAIRLANE

Body

Serial

Code

30

31

34

35

33

36

35

33

36

40

4 1

42

44

43

42

44

43

46

46

45

45

32

37

38

47

48

48

49

49

Body

Style

Code

65A

54A

54B

63B

65B

76B

63E

65E

76E

65C

54C

63F

65F

76F

63D

65D

76D

63B

63E

65A

65E

71 D

71 B

71E

66A

66B

66B

(Opt.)

66C

66D

B ench Seat

Body Type

2-Door

Hard top- fo rmal

4-Door

Sedan

4-Door

Sedan

2-Door

HardtopFastback

2-Door

Hard top- fo rmal

Convertible

2-Door

HardtopFastback

2-Door

Hardtop-Formal

Convertible


4-Door

Sedan

r t

2-DoorHardtopFastbackCD

2-Door

Hardtop-Formal

Convertible

2-Door HardtopFastback

2-Door

Hardtop-Formal

Convertible

2-Door

Hardtop-Fastback

2-Door Hardtop-Fastback

2-Door

Hardtop-Formal

2-Door

Hard top- fo rmal

Fairlane

Fairlane 500

Fairlane Torino Squire

Ranchero

Ranchero 500

Ranchero 500

Ranchero

Ranchero

Model

Fairlane

Fairlane 500

Fairlane 500

Torino

Torino GT

Torino GT

Cobra


Ranchero

Ranchero

Ranchero GT

Split Bench Bucket Seats

REAR AXLE RATIO CODES

Conventional

Limited-Slip

Ratio

1 J 2.50:1

2 K 2.75:1

3 L 2.79:1

4

M 2 . 8 0 1

5 N 2 .83 :1

6

0 3.00:1

7

P 3.10:1

8

Q

3.20:1

9 R 3.25:1

A

S 3.50:1

B T 3.07:1

C U 3.08:1

D

V

3.91:1

E

W

4.30:1

TRANSMISSION CODES

Code Type

1

3-Speed

Manual

5 4-Speed Manual -wide ratio (2.7 8 1st Gear)

6 4-Speed Manua l-close ratio (2.32 1st Gear)

W Automatic (C4) (XP-3)

U Automatic (C6) (XPL)

Y Automatic (MX )

X Automatic (FMX )

Z Automatic (C6 Special) (XP L, Spe cial)

For Police & trailer towing

-

Not available with bucket seats

ENGINE CODES

Code

U 6 C y l .

T 6 C y l .

2 6 Cyl .

L 6 Cyl.

3

6

Cyl

CD

V

6

Cyl.

5 . 6Cyl CD

B 6

C y l .

E

6

C y l .

F

8

C y l .

6 8 Cyl.

D 8 C y l .

H 8 Cyl.

M 8 Cyl.

Y 8 C y l .

X 8 Cyl.

S 8 Cyl.

P 8 Cyl.

8 Cyl.

8 Cyl.

K 8

C y l .

N 8 Cyl.

A 8 C y l .

Lo w Compression

H igh Performance

Type

170 C u . In . ( I V )

200 C u .

I n .

( I V )

200 C u .

In .

( I V )

250

C u . I n .

( I V )

250 C u . In . ( I V )

24 0 C u . I n . ( I V )

24 0 C u .

I n .

( I V )

240 Cu. In. (I V ) Police

240 Cu. In. (IV) Taxi

302

C u . I n .

(2V)

302 C u . I n . (2V)

302 Cu. In. (2V) Police & Taxi

351 C u .

I n .

(2V)

351 C u .

I n .

(4V )

390 C u .

I n .

(2V)

390Cu. ln . (2V)

390

C u . I n .

(4V )

428 Cu. In. (4V) Police Interceptor

42 8 C u . In . (4V ) CJ

42 8 C u .

In .

(4V )

CJ

42 9 C u .

I n .

(2V)

42 9 C u .

In .

(4V )

460 C u .

I n .

(4V )

Pre mium Fuel Improved Performance

Ram Air Induction

CONSECUTIVE UNIT NUMBER

Starting Serial Numbers1969 Passenger Cars

100,001Ford, Fairlane, Falcon, Mustang, Thunderbird

500,001 -Mercury, Montego,

Cougar,

Meteor

848,000Lincoln

Continental & Continental Mark

I I I

EXTERIOR PAINT COLOR CODES

Code

Reference

Number Color

A

B

c

D

E

F

G

H

|

J

K

L

. .

M

N

p

Q

R

S .

.. .

T

u

v

W

X

Y

z

2 .

..

3

4

6 . . .

7

8

.. 1724-A 1

3059-A

3197-A

3303-A

3191-A

3065-A . .

3203-A

. .

, .2067-A

2041-A

3080-A

3204-A

3060-A

1619-A ..

921-A

3064-A

1624-A

3198-A . .

3199-A

2008-A

1070-A

3201-A

3120-A

3061-A . . .

3202-A

2044-A

3071-A

. .

1730-A

3230-A

. 3077-A

3193-A

3190-A

..M6J-49B..

....M6J-50B.

Black

Maroon

Dk. Ivy Green Met.

Pastel Gray

Lt. Aqua

Dk. Aqua Met. (Brt.)

M e d .Orchid Met.

Lt. Green

M e d .

Lime Met.

Dk. Aqua Met.

Dk. Orchid Met.

Lt. Gray M et.

White

Platinum

M e d . Blue Met.

M e d . Blue Met.

Lt.Gold

M e d .

Gold Met.

Red

M e d .

Aqua Met.

Lt. Aurora Copper IVIet.

Yellow

Dk. Blue Met.

Burnt Orange Met.

Dk. Grey Met.

Lt. Ivy Yellow

Calypso Coral

M e d .

Emerald Met.

M e d . B lue Met. (B rt)

Lt. Emerald Green Met.

Lt. Blue

Red Primer

Grey Primer


9/412

01-01-05 Vehicle Identification

01-01-05

INTERIOR TRIM CODES

Code Trim Schemes

1A Black Vinyl (Cougar, Falcon)

1A Black Cloth & Vinyl

IB Med. Blue Cloth/Lt. Blue Vinyl

IB Med. or Lt. Blue Vinyl

IB Dk. Blue Cloth & Vinyl

(Lincoln, T-Bird, Mark III, Mercury)

IB Lt. Blue Cloth & Vinyl

(Ford,

Montego, Meteor)

ID Dk. Red Cloth and Vinyl

IF Me d. Saddle Vinyl (Cougar)

1G Dk. Ivy Gold Cloth & Vinyl

1G Lt. Ivy Gold Vinyl (Cougar)

IK Lt. Aqua Cloth and/or Vinyl

I P

Med.

Grey Cloth & V inyl (Mark III)

1Y Lt. Nugget Gold Vinyl (Cougar-Falcon)

1Y Lt. Nugget Gold Cloth & Vinyl

2A Black Vinyl

2A Black Leather & Vinyl (Lincoln)

2A Black Leather (Mark III)

2B Dk. or Lt. Blue Vinyl

2B Dk. Blue Leather & Vinyl (Lincoln)

2B Dk. Blue Leather (Mark III)

2D Dk. Red Vinyl

2D Dk. Red Leather & Vinyl (Lincoln)

2D Dk. Red Leather (Mark III)

2F Med. Saddle Vinyl (Cougar)

2F Med.Saddle Leather & Vinyl (Lincoln)

2F Med. Saddle Leather (Mark III)

2G Lt. or Dk. Ivy Gold Vinyl

2G Dk. Ivy Gold Leather & Vinyl (Linco ln)

2G Dk. Ivy Gold Leather (Mark III)

2K Lt. Aqua Vinyl

2K Lt. Aqua Leather & Vinyl (Lincoln)

2K Lt. Aqua Leather (Mark III)

2P

Med.

Grey Leather (Mark III)

2U Pastel Parchment w/Black Leather (Mark III)

2W Whitew/Black Vinyl

2W White w/Black Leather & Vinyl (Lincoln )

2W Whitew/Black Leather (Mark I I I )

2Y Lt. Nugget Gold Vinyl

2Y Lt. Nugget Gold Leather & Vinyl (Lincoln)

2Y Lt. Nugget Gold Leather (Mark III)

3A Black w/Red K nit and/or Vinyl (Mustan g,

Montego)

3A Black K nit and/or Vinyl


3A Black Leather & Vinyl (Linco ln)

3B Lt. Blue Kn it and/or Vinyl

3B Lt. or Dk. Blue Cloth & Lt. Blue Vinyl

3B Lt. Blue Cloth & Vinyl

(Fairlane,

Ford,

Montego, Meteor)

3B Med. Blue Cloth & Lt. Blue Vinyl

3B Dk. Blue Cloth & Vinyl (T-B ird, Me rcury)


3D Dk.Red Cloth & Vinyl

3D Dk. Red K nit and/or Vinyl


3G Dk. Ivy Gold Leather & Vinyl (Linc oln)

3K Lt. Aqua Cloth & Vinyl

3W White w/Black K nit and/or Vinyl

3W Whitew/Black Leather & Vinyl (Lincoln)


3Y Lt. Nugget Gold K nit and/or Vinyl (T-B ird)



4B Dk. Blue Vinyl


4D Dk.Red Vinyl


4G Dk. Ivy Gold Vinyl

4K Lt. Aqua Vinyl

4W White w/Black Vinyl

4Y Lt. Nugget Gold K nit and/or Vinyl




5B Lt. Blue Cloth and/or Vinyl

5B Lt. Blue Knit and/or Vinyl


5B Dk. Blue Cloth & Vinyl (Mercury)

5D Dk.Red Cloth & Vinyl (Montego)

INTERIOR TRIM

CODES-(cont inued)

Code Trim Schemes


5D Dk. Red Leather & Vinyl (Lincoln )

5F Med. Saddle Leather & Vinyl (Lin coln)

5G Dk. Ivy Gold K nit and/or Vinyl


5G Dk. Ivy Gold Leather & Vinyl (Linco ln)

5K Lt. Aqua Cloth & Vinyl (Montego)

5K Lt. Aqua Vinyl

5K Lt. Aqua Leather & Vinyl (Lincoln)

5W White w/Black K nit and/or Vinyl

5W White w/Black Leather & Vinyl (Lincoln )


5Y Lt. Nugget Gold Kn it and/or Vinyl (Mustang,

Fairlane)

5Y Lt. Nugget Gold Leather & Vinyl (Lincoln)


6A Black Cloth & Vinyl (Lincoln)

6A Black Lea the; & Vinyl (Cougar)


6B Dk. Blue Leather & Vinyl (Cougar)


6D Dk.Red Leather & Vinyl (Cougar)

6F

Med.

Saddle Leather

I

Vinyl

6G Dk. Ivy Gold Vinyl

6G Dk. Ivy Gold Leather & Vinyl (Cougar)

6K Lt. Aqua Vinyl

6K Lt. Aqua Leather & Vinyl (Cougar)



6Y Lt. Nugget Gold Leather & Vinyl (Cougar)

7A Black Vinyl

7A Black Cloth & Vinyl (Fairlane)


7B Lt. Blue Vinyl (Cougar, Montego, Ford)

7B Dk. Blue Cloth & Vinyl

7B Dk. Blue Leathe; & Vinyl (Lincoln)

7D Dk. Red Vinyl (Mustang)

7D Dk. Red Cloth & Vinyl

7G Dk. Ivy Gold Cloth and/or Vinyl

7G Dk. Ivy Gold Leather & Vinyl (Lincoln )



7W White Leather & Vinyl (Lincoln)



(Ford, Meteor, Mustang)


8A Black Leather & Vinyl (T-Bird)

8B Dk. or Lt. Blue K nit and/or Vinyl


8F Med. Saddle K nit and/or Vinyl

8G Dk. Ivy Gold K nit and/or Vinyl

8K Lt. Aqua K nit and/or Vinyl

8W White w/Black and/or Vinyl

8W White w/Black Leather & Vinyl (T-Bird)

8Y Lt. Nugget Gold K nit and/or Vinyl


9A Black Cloth & Vinyl (Ford, Me teor)

9B Lt. Blue Knit and/or Vinyl

9B Dk. Blue Cloth & Vinyl (Ford, Meteor)


9D Dk. Red Cloth & Vinyl (Ford-Meteor)



9Y Lt. Nugget Gold Cloth and/or Vinyl

9Y Lt. Nugget Gold Kn it and/or Vinyl

AA(1W)

White Vinyl

With B lack (Cougar)

AA Black Cloth & Vinyl (Lincoln)

AB(1W ) White Vinyl With Blue (Cougar)

AB Lt. Blue Cloth & Vinyl (Lincoln)

AD(1W) White Vinyl With Red (Cougar)

AG(1W) White Vinyl With Ivy Gold (Cougar)

AG Lt. Ivy Gold Cloth & Vinyl (Lincoln )

AK (1W) White Vinyl With Aqua (Cougar)

AK Lt. Aqua Cloth & Vinyl (Lincoln)

AL Lt. Si lver Cloth & Vinyl (Lincoln)

AY Lt. Nugget Gold Cloth & Vinyl (Lincoln)

AY(1W) White Vinyl With Nugget Gold (Cougar)

BA(2W) White Vinyl With Black (Cougar)

BA Black Vinyl (Fairlane)

BB (2W) White Vinyl With Blue (Cougar)


10/412

01-01 -06


01 -01 -06

INTERIOR TRIM CODES-(continued)

Code Trim Schemes

BB Lt. Blue Vinyl (Fairlane)

BB Lt. Blue Leather & Vinyl (Lincoln)

BD(2W) ..White Vinyl With Red (Cougar)

BG(2W) White

Vinyl

With Ivy Gold (Cougar)

BG Lt. Ivy Gold Leather & Vinyl (Li ncol n)

BK (2W) White Vinyl With Aqua (Cougar)

BY(2W) White Vinyl With Lt. Nugget Gold (Cougar)

BY Lt. Nugget Gold Vinyl (Fairlane )

CA Black Cloth & Vinyl

CA Black Vinyl (Monte go)

CB Dk. Blue Cloth & Vinyl

CB Lt. Blue Vinyl (Montego)

CD Dk. Red Cloth & Vinyl

CD Dk. Red Vinyl

CG Dk. Ivy Gold Cloth & Vinyl

CG Lt. Ivy Gold Leather & Vinyl (Li ncoln )

CK Lt. Aqua Cloth & Vinyl

CY Lt. Nugget Gold Cloth & Vinyl

CY Lt. Nugget Gold Vinyl (Mon tego)

DA Black Cloth & Vinyl

DA(4W) White

Vinyl

With Black (Cougar)

DA Black K nit and/or Vinyl

DB Dk. Blue Cloth & Vinyl

DB Dk. Blue Vinyl (Me rcury)

DB(4 W) White Vinyl With Blue (Cougar)

DD(4W) White Vinyl With Red (Cougar)

DD Dk. Red Kn it and/or Vinyl

DD Dk. Red Cloth & Vinyl

DG Dk. Ivy Gold Vinyl

DG Dk. Ivy Gold Cloth & Vinyl

DK Lt. Aqua Cloth & Vinyl

DW White w/Black Knit and/or Vinyl

DY Lt. Nugget Gold Cloth & Vinyl

DY Lt. Nugget Gold Vinyl (Me rcury)

EA Black Kn it and/or Vinyl

EA Black Cloth & Vinyl

EB Dk. Blue Cloth & Vinyl

ED Dk. Red Cloth & Vinyl

EG Dk. Ivy Gold Cloth & Vinyl

EK Lt. Aqua Cloth & Vinyl

EW White w/Black Kn it and/or Vinyl

EY Lt. Nugget Gold Cloth & Vinyl

FA Black Knit and/or Vinyl

FA(6W) White

Vinyl

With Black (Cougar)

FB Lt. or Dk. Blue Vinyl

FB(6W) White Vinyl With Blue (Cougar)

FD Dk. Red K nit and/or Vinyl

FD(6W) White Vinyl With Red (Cougar)

FG Dk. Ivy Gold Vin yl

FG(6W) White

Vinyl

With Ivy Gold (Cougar)

FK(6W) White Vinyl With Lt. Aqua (Cougar)

FW White w/Black Kn it and/or Vinyl

FY Lt. Nugget Gold Vinyl

FY(6W) White Vinyl With Nugget Gold (Cougar)

GA Black Vinyl

GB Lt. Blue Vinyl

GD Dk. Red Vinyl

GG Dk. Ivy Gold Vinyl

GY Lt. Nugget Gold Vinyl

HA Black Kn it and/or Vinyl

HA (8W) White Vinyl With Black (Cougar)

HA Black Leather & Vinyl (Me rcury)

HB Lt. Blue Vinyl

HB (8W) White Vinyl With Blue (Cougar)

HD Dk. Red Vinyl

HD Dk. Red Leathe; & Vinyl (Mercury)

HD(8 W) White Vinyl With Dk. Red (Cougar)

HG Dk. Ivy Gold Vinyl

HG (8W) White Vinyl With Ivy Gold (Cougar)

HK Lt. Aqua Vinyl

HK (8W) White Vinyl With Lt. Aqua (Cougar)

HW White w/Black Leather & Vinyl (Me rcury)

HW White w/Black Vinyl (Fairlane)

INTERIOR TRIM CODES-(contlnuad)

Code Trim

Schemes

HY(8 W) White Vinyl With Nugget Gold (Cougar)

HY Lt. Nugget Gold K nit and/or Vinyl

JA Black Knit and/or Vinyl

JB Lt. Blue Cloth & Vinyl (Lincoln)

JG Lt. Ivy Gold Cloth & Vinyl

JW .....White w/Black K nit and/or Vinyl

JY Lt. Nugget Gold Knit and/or Vinyl

JY Lt. Nugget Gold Cloth & Vinyl (Lin coln)

KA Black Knit and/or Vinyl

KA Black Cloth & Vinyl (Ford-Mercury-M eteor)

KA Black Leather & Vinyl (Lin coln)

KB Dk. Blue Cloth & Vinyl

KB .....Med. Blue Cloth & Lt. Blue Vinyl (Ford-Monte go)

KB Dk. Blue Leather & Vinyl (Lincoln)

KD Dk. Red Cloth & Vinyl

KG Dk. Ivy Gold Leather & Vinyl (Li ncoln )

KG Dk. Ivy Gold Cloth & Vinyl

KL Lt. Silver Leather & Vinyl (Lincoln)

KW White W/Black Leather & Vinyl (Lin coln)

KY Lt. Nugget Gold Kn it and/or Vinyl

KY Lt. Nugget Gold Cloth & Vinyl

LA Black Knit and/or Vinyl

LA Black Leather & Vinyl (Lincoln)

LB Lt. Blue Knit and/or Vinyl

LB Dk. Blue Leather & Vinyl (Lincoln)

LD Dk. Red Kn it and/or Vinyl

LE Lt. & Med.Beige Vinyl

LG Dk. Ivy Gold Leather & Vinyl (Lin coln)

LW White w/Black K nit and/or Vinyl

LW White w/Black Leather & Vinyl (Lin coln)

LY Lt. Nugget Gold K nit and/or Vinyl

MA Black Vinyl

MB Lt. Blue Vinyl

MD

Dk

Red Vinyl

MW White w/Black Vinyl

NA Black Kn it and/or Vinyl

N B L t . B l u e V i n y l

NY Lt. Nugget Gold K nit and/or Vinyl

PA Black Vinyl

PB Lt. Blue Vinyl

PY Lt. Nugget Gold Vinyl

QA Black Kn it and/or Vinyl

)B

. L t

Blue Vinyl

JW White Kn it and/or Vinyl

Lt. Nugget Gold Vinyl

Black Knit and/or Vinyl

RA Black Leather & Vinyl

RB Lt. Blue Knit and/or Vinyl

RD Dk. Red Kn it and/or Vinyl

RD Dk. Red Leather & Vinyl

RW White w/Black Leather & Vinyl

RW White W/Black Kn it and/or Vinyl

RY Lt. Nugget Gold K nit and/or Vinyl

SB Lt. Blue Leather & Vinyl (Lincoln )

SG Lt. Ivy Gold Leather & Vinyl (Lin coln)

TG Lt. Ivy Gold Leather & Vinyl (Lin coln)

VA Black K nit and/or Vinyl

VB

Dk

Blue Vinyl

VG Dk. Ivy Gold Vinyl

VW White w/Black K nit and or Vinyl

VY Lt. Nugget Gold Vinyl

WA Black K nit and/or Vinyl

WW White w/Black K nit and/or Vinyl

WY Lt. Nugget Gold Knit and/or Vinyl

YA Black Cloth & Vinyl

YB Dk. Blue Cloth & Vinyl

YD Dk. Red Cloth & Vinyl

YG Dk. Ivy Gold Cloth

&

Vinyl

YK Lt. Aqua Cloth & Vinyl

YY Lt. Nugget Gold Cloth & Vinyl

ZA Black Cloth & Vinyl

ZB Dk. Blue Cloth & Vinyl

ZG Dk. Ivy Gold Cloth & Vinyl


11/412

01-01-07

Vehic le Ident i f icat ion

01-01-07

DATE CODES

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

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

Month

Code

First Year

Code

Second Year

January

February

March

Apr i l

Ma y

June

July

August

September

October

November

December

. . . . A . .

. . . B . .

. . . C .

. . . D . .

. . . E . .

. . .

F..

. . .

G.

. . . H .

. . . J . .

. .

K.

. . . . L .

. . . M .

DISTRICT CODES (DSO)

Units built on a Domestic Special Order, Foreign Special Order,

or other special orders wil l have the complete order number in

this space. Also to appear in this space is the two-digit code number

of the District which ordered the unit. If the unit is a regular

production unit, only the District code number will appear.

FORD

Code

Dis tr ic t Code

Distr ict

1 1 . . .

13

.. .

1 5 . . .

1 6 . . .

1 7 . . .

2 1 . . .

22

. . .

2 4 . . .

2 5 . . .

2 8 . . .

3 2 . . . .

3 3 . . .

3 5 . . .

3 7 . . .

3 8 . . . .

4 1 . . .

4 3 . . .

4 4 . . .

4 6 . . . .

4 7 . . .

Boston

. . . N e w Y o rk

Newark

. . . P h i l a d e l p h i a

Washington

Atlanta

Charlotte

. . . J ac k s o nv i l l e

Richmond

. . . . Louisv i l le

. . . .C leve land

. . . . De t ro it

Lansing

. . . B u f f a l o

. . . .P i t tsburgh

Chicago

Milwaukee

Twin Cit ies

. . . I n d i a n a p o l i s

Cincinnati

51

53

54

55

56

61

62

63

64

65

7 1

72

73

74

75

83

84

85

89

90's

..

. . . Denver

. . .Kansas City

.. Omaha

. . . S t . Lo u is

. . Davenport

.. Dallas

. . . Houston

. . Memphis

. . New Orleans

. . .Oklahoma C ity

. . . Los Angeles

. . .S an Jose

. . .S al t Lake City

. . . S ea t t l e

. . .Phoenix

. . Government

... Home Office Reserve

. . Ame rican Red Cross

. . .Transportation Services

. . . E x p o r t

LINCOLN-MERCURY

Code Dis tric t

Code

Distr ict

11

15

16

17

21

22

23

26

31

32

33

Boston

New York

Philadelphia

Washington

Altanta

Dallas

Jacksonville

Memphis

Buffalo

Cincinnati

Cleveland

34

4 1

42

46

51

52

53

54

84

9 0 ' s . . .

. . . Detroit

.. Chicago

..

St.

Louis

. . . T win Cit ies

Denver

Los Angeles

Oakland

Seatt le

Home O ffice R eserve

Export

FORD OFCANADA

Code

District Code District

B l

B 2

B 3

I I thru

17..

Central

Eastern

Atlantic

Export

B 4 .

B 6.

B 7 .

Midwestern

Western

. Pa cific

Note: Canadian Lincoln-Mercury units use pref ix

A in

place of"B".


12/412

02-01-01

02-01-01

GROUP

2

PART

2-1

PAGE

General Brake Service 02 -01 -01

PART 2-2

Brake System 02 -0 2- 01

PART 2-3

Specifications

PAGE

02-03 -01

Part2-1 General Brake Service

COMPONENT INDEX

A N T I SK I D C O N T R O L S Y S T E M

Tests

B R A K E B O O S T E R

Adjus tments

C l ean ing

and

Inspection

Tests

B R A K E P E D A L

Free Height Test

Tota l Trave l Tes t

D I S C B R A K E S

C lean ingandInspection

Service Precautions

D R U M B R A K ES

C lean ingand Inspection

H Y D R A U L I C SY S T EM B L E ED I N G

P A R K I N G B R A K E C O N T R O L

Vacuum Release Test

P A R K I N G B R A K E L I N K A G E

Adjus tment

P R E S S U R E D I F F E R E N T I A L V A LV E

Adjus tment (C entra l ize)

MODEL APPLIC ATION

A

l

M

s

01-04

01-07

01 -02

01-01

01 -01

01 -07

01 -07

0 1 - 0 8

01 -05

01 -07

F

d

N / A

01-03

01 -03

M

c

y

N / A

01-03

01 -03

M

e

N / A

01-03

01 -03

C

o

N / A

N / A

01-03

F

r

a

N / A

N / A

01-03

a

c

N / A

N / A

01-03

M

e

N / A

N / A

01-03

M

a

N / A

N / A

01-03

L

n

n

C

n

a

N / A

01-03

01 -04

T

b

r

d

01-03

01 -03

01 -04

C

n

a

M

a

k

01-03

01 -03

01 -04

A page number indicates that the itemis for thevehicle listedatthe headof theco lumn .

N /A indica tes tha t the i temis notappl icabletothe vehicle l isted.

1 BRAKE SYSTEM TESTS

Always check the fluid level in the

master cylinder before performing the

test procedures.

If the fluid levelis not

within 1/4 inch of the top of the mas-

ter cylinder reservoirs, add Ford

B rake Fluid E x t ra Heavy D u t y

P a r t N u m b e r C 6 A Z - 1 9 5 4 2 - A (ESA-

M 6 C 2 5 - A ) or equivalent for all brake

appl ica t ions .

The extra

heavy

duty

brake fluid is colored bluefor identifi-

cation purposes.Do not mix low tem-

perature brake fluids with the speci-

fied brake fluid.

Should one of the wheel brakes be

locked and thevehicle must be moved,

open the bleeder screw long enough to

l et out a few d rops 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, measure the

brake pedal free height, and check the

brake pedal travel with the use of the

B rake Peda l Pressure Gauge, Tool

WRE-5OO-5O as fol lows:

BRAK E PEDAL F R E E H EIG H T

MEASUREMENT

1.

Insert a s lender, sharp pointed

prod through the carpet and sound

deadener to the dash panel m etaland

measure the distance to the brake

pedal (Fig. 1).

2 . If the position of the pedal is not

within specification, check

the

brake

pedal l inkage for missing, worn, o

damaged bushings, or loose attachin

bol ts

and

replace them,

if

required.

3 .

If the pedal free height is sti

out of specification, check the brak

pedal booster or master cylinder to b

sure the correct parts are instal led

Replace theworn or damaged partsa

necessary.

B R A K E P E D A L T R A V E L

M E A S U R E M E N T

1 .

Instal l a B rake Pedal Effo

Gauge on the brake pedalpad(Fig . 2

2 . Hook a steel measuring tape t

the brake pedal as shown in Fig. 1.

Measure and record thedistanc e from

the brake pedal free height position t

the reference point, which is at the si


13/412

02-01-02

Brakes

02*01-02

STE E R I NG

WHE EL RIW

TO E BO A R D O R

D AS H M E T A L

C H E C K I N G P O I N T S

STE E R I NG

C O L U M N -

S T E E L

M E A S U R IN G T A P E

V E H I C L E

F ORD,ME R C UR Y A ND ME TE O R

F ORD,

ME R C UR Y A ND ME TE O R

F ORD,

ME R C UR Y A ND ME TE O R

F ORD,ME R C UR Y A ND ME TE O R

F A I R L A N E ,

MO NTE GO A ND FA L C O N

F A I R L A N E ,

MO NT E GO A ND FA LC O N

MUSTANG

A ND C O UGA R

MUSTANG

A ND C O UGA R

T H U N D E R B I R D

C O NT I NE NTA L MA R K I I I

L I NC O L N

C O N T I N E N T A L

T Y P E

NON-POWER DRUM

POWER DRUM & DISC

NON-POWER

DISC

POLICE POWER DISC

NON-POWER DRUM

POWER D ISC

NON-POWER DRUM

POWER

DISC

POWER DISC

POWER DISC

POWER

DISC

P E D A L

FREE

H E I G H T - A

8 .0 9 -7 .1 7

6.18-5.99

8 .65-7 .82

7 .58 -6 .72

8.13-6.91

7 .2 5 -5 .71

7 .49 -6 .43

6.25-5.56

PEDAL FREE

H E I G H T - B "

5.96-5.04

5.96-5.04

6.50-5.50

P E D A L

T R A V E L - C

3.10

3.27

2.18

3.27

2.90

2.35

2.58

1.75

3.00

3.00

2.25

N O T E : A g B D IM E N S IO N T O B E M E A S U RE D T O S H E E T M E T A L

C D I ME N S IO N T O BE M E A S U R E D P A R A L L E L T O T H E V E R T I C A L C E N T E R L I N E O F T H E

S T E E R IN G C O L U M N W IT H A 5 0 P O U N D L O A D A P P L I E D T O T H E C E N T E R L I N E O F T H E

B R A K E

P E D A L P A D . (C H E C K S O N P O WE R B R A K E V E H I C L E S M A D E W IT H E N G I N E R U N N I N G

H1630-A

FIG. 1 Brake Pedal H eight and Travel Measurements

Tool-WRE-l

HI525-A

FIG. 2Brake Pedal Effort Gauge Installed

o'clock position on the steering wheel

rim.

3 . With the steel tape still hooked

to the brake pedal depress the brake

pedal by pressing downward on the

brake pedal effort gauge. Apply a 50

pound load to the center of the pedal

by observing the pressure gauge, and

measure the distance from the brake

pedal to the fixed reference point on

the steering wheel rim parallel to the

centerline of the steering column.

4. The difference between the brake

pedal free height and the depressed

pedal measurement under a 50 pound

load should be within the specified

maximum pedal travel service specifi-

cation B in Fig. I.

5 . If the pedal travel is more than

the specified maximum shown in Fig.

1,

dimension C , make several sharp

reverse stops (equivalent to 50 pounds

pedal pressure) with a forward stop

before each. Move the vehicle in rev-

erse and forward for a distance of ap-

proximately ten feet; then, apply the

brakes sharply and hold the brake

pedal down until the vehicle is com-

pletely stopped. This wil l 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. C heck the

brake linings for wear or damage. Re-

pair or replace all worn or damaged

parts and non-functioning adjusters.

Adjust the brake lining outside diame-

ter to the approximate inside diameter

of the brake drum with Rotunda Tool

HRE-8650 (Fig . 12 , Par t 2 -2 ) .

7 .

If all the brake adjusters, brake

drums and linings are functional and

the brake travel is not within specifi-

cations, check the pedal linkage for

missing or worn bushings, or loose at-

tachments. Bleed the brakes and cen-

tralize the differential valve.

POWER BRAKE

FUNCTIONAL TEST

1 . C heck the hy draulic brake sys-

tem for leaks or insufficient fluid.

2 . With the transmission in neutral,

stop the engine and apply the parking

brake. D epress the brake pedal several

times to exhaust all vacuum in the

sys tem.

3 . With the engine shut off and all

vacuum in the system exhausted, dep-

ress the pedal, and hold it in the ap-

plied position. Start the engine If the


14/412

02-01-03

Brakes

02-01-03

vacuum system is operating, the pedal

will tend to fall away under foot pres-

sure and less pressure will be required

to hold the pedal in the applied posi-

tion. If no action is felt, the vacuum

booster system is not functioning.

If the brake pedal movement feels

spongy, bleed the hydraulic system to

remove air from the system. Refer to

Hy draulic System B leeding, Part 1 ,

Section 2 .

VACUUM TESTSVACUUM

RELEASE P ARK ING BRAKES

Visually check the operation of the

brake linkage as the brake pedal is

depressed. Then, check the operation

of the brake linkage when the manual

r e l e a s e l e v e r i s a c t i v i a t e d . T h e s e

checks should indicate whether the

manual parking brake control l inkage

is operating properly or requires re-

pair or adjustment due to inability of

the parking brake to hold against

moderate vehicle movement. Perform

tests of the parking brake system and

controls after making certain the link-

age and manual controls operate

proper ly .

When testing a parking brake vacu-

um release system, a minimum of 10

inches of vacuum (Hg.) should be

available at all points where vacuum is

applied. This can be checked with a

Rotunda Fuel Pump Tester Gauge

(ARE3 45 ) and two D is tributor Tester

hose adapters (Marked Q) connected

together with a coupling. This al lows

the Fuel Pump Tester Gauge hose to

be adapted to any other vacuum hose

or rubber connector in the vacuum

systems.

Failure to maintain 10 inches of

vacuum (Hg.) during vacuum system

tests could be caused by a loose hose

connection, resulting in a vacuum

leak. When checking for vacuum be-

tween two points, trace the hose along

the entire routing to be sure it is not

crossed with another hose and con-

nected to the wrong connection.

All of the vacuum parking brake

control checks are to be performed

with the engine running at idle speed.

Leaks in the parking brake hoses or

a d i sco n n e c ted o r imp ro p er l y co n -

nected hose can usually be found by

listening for a hissing sound along the

hose routings.

Under no circumstances

should air pressure be applied to the

vacuum system as the actuator dia-

phragm in the parking brake vacuum

motor may be damaged.

1. Sta rt th e engine and run it at

idle speed. With the transmission shift

control in neutral, depress the parking

brake pedal to apply the parking

brake. Move the transmission shift

contro l to D range and observe the

parking brake pedal to see that the

pedal moves upward and the parking

brake releases. If the parking brake

releases, the parking brake vacuum

control is working properly .

2 . If the parking brake does not re-

lease, test for vacuum at the steering

column neutral switch port in the

junction block, vacuum lines and the

parking brake release vacuum motor.

Use the Rotunda Vacuum and Fuel

Pump Tester 345. This can be accom-

plished by removing the hose from

each component and attaching it to

the vacuum gauge. C onnect two dis-

tributor tester vacuum hose adapters

together with a coupling as a connec-

tor to attach the gauge. A minimum

of ten inches of vacuum is required to

actuate the parking brake vacuum

motor . Do not remove any of the vac

uum hoses from the junction block

unless the junction block is being re

placed, as the plastic nipples are thin

and very brittle and damage may re

sult.

If a minimum reading is no

present when checking each of the

a f o r e m e n t i o n e d c o m p o n e n t s , t h e y

must be replaced.

ROAD TEST

A road test should be conducted

only when the operator is sure th

brakes will stop the vehicle.

If the road test reveals one or more

problem conditions, correct al l mal

functions of the vacuum system, brake

booster and hydraulic system prior to

removing brake drums, brake calipers

brake shoes and linings or backing

plates.

ANTI-SK ID CONTROL

SYSTEM TESTS

No adjustments or repairs are to b

performed on the skid control system

D amaged or worn parts are to be re

placed.

Refer to Ford Ca r and Truck D iag

nosis Manual for Testing procedures

COMMON ADJUSTMENTS AND REPAIRS

PARKING BRAKE LINKAGE

ADJUSTMENT

F O R D , M E R C U R Y , M E T E O R ,

F A I R L A N E , M O N T E G O ,

F A L C O N , M U S T A N G

A N D C O U G A R

C heck the parking brake cables

when the brakes are fully released. If

1

the cables are loose, adjust them as

follows:

1 . Fully release the parking brake

pedal by pulling the release lever.

2 .

D epress the parking brake pedal

until it is engaged in the first notch of

the control . On a vacuum release

brake, the first notch will be approxi-

mately two inches of pedal travel .

3 . R a i s e t h e v e h i c l e . W i t h t h e

transmission in neutral, turn the ad-

justing nut forward against the equal-

izer (Figs. 3 and 4) until there is 100

L . H . R E AR W H E E L C A B L E - 2 A 8 0 9 > 2 A7 91 (2 R E Q U IR E D )

E Q U A L I Z E R -T O - A C T U A T O R C A B L E - 2 A 8 1 5

R . H . R E A R W H E E L C A B L E - 2 A 6 3 5

A D J U S T I N G N U T - 2 A 8 1 2

H 1537-C

FIG. 3Parking Brake AdjustmentFord, Mercury, Meteor,

Thunderbird and Continental Mark I I I


15/412

02-01-04

Brakes

02-01-04

ft-lb breakaway torque.

The

breaka-

way torque is the torque required to

turn

the

rear wheels

the

direction

of

forward rotation with

a

torque wrench

and tool shown

in Fig. 5.The

torque

measurement must

be

made relative

to

the center line

of the

wheel.

4. Release

the

parking brake,

and

check

to

make sure that

the

brake

shoes return

to the

fully released posi-

tion.

5 .

D epress

the

parking brake pedal

to

the

third notch. U nder norm al

con-

ditions, this will hold

the

vehicle satis-

factorily .

6 . Re lease theparking brake again,

and check

as in

step

4.

7 .

If the

rear brakes

do not

fully

release, check

the

cables

for

kinks

or

binds. Free thecables as required.

8 . Lower

the

vehicle . R emove

the

torque wrench

and

tool . Instal l

the

wheel attaching nuts

and

torque them

to specification. Install the wheel

cover.

R E T A I N E R - * ^ RE AR W HE EL

(CAB LE AS S EMB LY

E Q U A L I Z E R

N U T

P ARKING

B R A K E C A B L E

A N D C O N D U I T

AS S EMB LY-28 5 3

S P RING-2A6 5 1

S P RING S EAT -2A6 16

JAM NUT

H1631-A

FIG. 4Parking Brake Linkage

AdjustmentFair lane, Montego,

Falcon,

Mustang

and

Cougar

T H U N D E R B I R D ,

C O N T I N E N T A L M A R K III,

AND LINCO LN

C O N T I N E N T A L

Check

the

parking brake cables

when

the

brakes

are

ful ly released.

If

the cables are loose, adjust them as

fol lows:

1 . Ful ly release

the

parking brake

pedal

by

pushing down

the

manua l

re-

lease lever.

2 .

D epress

the

parking brake pedal

1 1/4 inch from its norm al released

position.

3 .

Raise

the

vehicle with

the

t rans-

mission

in

neutra l .

4. Loosen thelock nut andturnthe

adjusting nut forward against the

equalizer (Figs .

3 and 6)

unti l there

is

100 ft-lbs breakaway torque.

The

breakaway torque

is the

torque

re-

quired to turn the rear wheels the di-

rection

of

forward ro tation w ith

a tor-

que wrench

and

tool shown

in Fig. 5.

The torque measurement must

be

made relative

to the

centerline

of the

wheel.

Tighten

the

lock

nut.

5 .

Release

the

parking brake ,

and

check

to

make sure tha t

the

brake

shoes return to thefully released posi-

tion.

6 . D epress

the

parking brake pedal

until

it is

ful ly engaged.

7 . Release

the

parking brake again,

and check as in step5.

8 . D epre ss

the

pedal

1/2

inch.

The

brakes should

not

drag .

9 .

If the

rear brakes

do not

fully

release, check

the

cables

for

kinks

or

binds.

Free

the

cables

as

required.

1 0.

Lower

the

vehicle . Remove

the

torque wrench

and

tool . Instal l

the

wheel attaching nuts and torque them

to specification. Install

the

wheel

cover.

Tool-T59L

4204-A,

T65K 4204-A,

T66L-4204-A,

OR

Tool-4421UA

E1897-A

POWER BRAKE MASTER

CYLINDER PUSHROD

ADJUSTMENT

The push

rod is

provided with

an

adjustment screw to maintain the cor-

rect relationship between

the

booster

control valve plunger

and the

master

cy l inder .

If the

plunger

is too

long

it

will prevent themaster cylinder piston

from completely releasing hydraulic

pressure

and can

cause

the

brakes

to

drag .

If the

plunger

is too

short

it

will

result in excess pedal travel and an

undesirable clunk

in the

booster area.

The adjustment screw

is set to the

correct height

at the

time

of

original

assembly

of the

power unit. Under

normal service

the

adjustment screw

does

not

require

any

further attention

providing the original pushrodassem-

bly remains

in the

original unit.

If

a

check

of the

push

rod

adjust-

ment

is

necessary,

the

push

rod

length

may be verified with a push rodlength

gauge

and

measured with

the

engine

running

to

apply vacuum

to the

boost-

er (Fig.

7).

The push rod length verificationand

adjustment

of

Midland-Ross power

brake booster assemblies must

be

done according

to the

following proce-

dure :

REAR W HEEL ADJUS T ING NUT

CAB LES

E Q U A L I Z E R

SPRING

CAB LE AS S EMB LY

H1632-A

FIG. 6Parking Brake Linkage

AdjustmentLincoln Continental

FIG. 5Checking Parking Brake Breakaway Torque

# 1 6

UJ

\

0.980"

0.995"

FIG. 7 P u s h

Dimensions

>.S. GAUGE SHEET

i

1

STEEL

H1087-E

Rod Gauge


16/412

02-01-05

Brakes

02-01-05

1. D isconnect the master cy linder

from the booster assembly and secure

away from the booster without discon-

necting the brake tubes.

2 .

Reinstall the air filter assembly

on the booster if it was removed with

the master cylinder (Fig. 8).

3 .

Instal l and tighten the m aster

cylinder retaining nuts to retain the

air fi l ter assembly securely against the

booster body and to seal the booster

bel lows against air leaks.

4. Place the gaug e against the

master cylinder mounting surface of

the air filter assembly.

5 .

Adjust the push rod screw to

provide a slight tension against the

inner edge of the adjustment gauge

slot . (Approximately 5 pounds of ten-

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 . Instal l the master cylinder on the

brake booster and tighten the retain-

ing nuts to the specified torque.

The push rod length verification of

t h e B e n d i x p o w e r b r a k e b o o s te r

assemblies is accomplished as fol lows:

1. D isconnect the master cy linder

from the booster assembly and secure

away from the booster without discon-

necting the brake tubes.

2 .

Adjust the push rod screw to

provide a slight tension against the

inner edge of the adjustment gauge

s lot . (Approximate ly 5 pounds of ten-

sion against the push rod is required

to assure that the push rod is firmly

seated in the booster assembly.) See

Figure 8.

3 .

Instal l the master cylinder on the

brake booster and tighten the retain-

ing nuts to the specified torque.

Do not set up side forces on the

push rod as it may break the valve

plunger.

This is an approximate adjustment

only. To verify the adjustment, look

through the make-up (rear) port of the

master cylinder when instal l ing the

master cylinder to the booster. The

master cylinder piston should not

move more than 0.015 inch as it con-

tacts the push rod. No movement

(exact contact) is ideal .

HYDRAULIC SYSTEM BLEEDING

AND CENTRALIZING OF THE

DIFFERENTIAL VALVE

When any part of the hydraulic sys-

tem has been disconnected for repair

or replacement, air may enter the sys-

tem and cause spongy pedal action.

B leed the hydrau lic system after it has

been properly connected, to be sure

that al l air is expel led.

M A N U A L B L E E D I N G

The Lincoln Continental hydraulic

brake system is to be bled only with

pressure bleeding equipment.

The primary and secondary (front

MANIF OLD CHECK V ALV E-23 6 5 19 -25 IN . LB .

T I G H T E N R E T A I N I N G N U T S

T O S ECURE A IR F ILT E R

AGAINS T B OOS T ER B ODY

AND B ELLOW S

ADJUST PUSH ROD SCREW TO

P ROV IDE A S L IGHT T ENS ION

(AP P ROXIM AT ELY 5 LB S . )

AGAINS T T HE GAUGE

P US H ROD GAUGE

and rear) hydraulic brake systems are

individual systems and are bled separ-

ately . B leed the longest line first on

the individual system being serviced.

During the complete bleeding opera-

tion,

DO NOT allow the reservoir to

run dry. Keep the master cylinder res-

ervoirs filled with Ford FluidExtra

Heavy D u ty Pa r t Number C 6 AZ -

1 9 5 4 2 - A ( E S A - M 6 C 2 5 - A ) .

The extra

heavy duty brake fluid is colored blue

for identification purposes. Do not

mix low temperature brake fluids with

the specified fluid during the bleeding

operations. Never re-use brake fluid

which has been drained from the hy-

draulic

sys tems .

1.

If t h e m a s t e r c y l i n d e r is

equipped with a bleed screw, loosen

the bleed screw. Push the brake pedal

down slowly through its full travel.

C lose the bleeder fitting and return

the pedal to the fully released posi-

tion. Repeat this operation until fluid

is free of air bubbles, then tighten the

bleeder screw.

Do not use the second-

ary piston stop screw, located on the

bottom of the master cylinder to bleed

the brake system. Loosening or re-

moving this screw could result in dam-

age to the secondary piston or stop

screw.

2.

To bleed the secondary (rear)

brake sy stem, position a suitable 3 /8

inch box wrench (Fig. 9) on the bleed-

er fitting on the brake wheel cylinder.

Attach a rubber drain tube to the

bleeder fitting. The end of the tube

should fit snugly around the bleeder

fitting.

APPROXIMATELY 45

PUSH ROD ADJUSTMENT-MIDLAND-ROSS

FIG. 8B rake Booster Push Rod M eas ureme nt

PUSH ROD ADJUSTMENT-BENDIX

H1589-A

H1300-B

. 9 W r e n c h f o r B l e e di ng

Brake H ydra ul ic System

3 .

Sub mer ge the free end of the

tube in a container partially filled with

clean brake fluid, and loosen the

bleeder fitting approximately 3/4 turn.

4. Push the brake pedal down slow-

ly through its ful l travel . C lose the

bleeder fitting, then return the pedal

to the full-released position. Repeat

this operation until air bubbles cease

to appear at the submerged end of the

bleeder tube.

5 .

When the fluid is com pletel y 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


17/412

0 2 - 0 1 - 0 6

Brakes

0 2 - 0 1 - 0 6

side. Refill the master cylinder reser-

voir after each wheel cylinder is bled

and install the master cylinder cover

and gasket. Be sure the diaphragm

type gasket is properly positioned in

the master cylinder cover. W hen the

bleeding operation is completed, the

fluid level should be filled to within

1/4 inch of the top of the reservoirs.

7.

If the primary (front brake) sys-

tem is to be bled. Repeat steps 2

through 6 at the right front brake cal-

iper 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 assem-

blies are properly seated by depressing

the brake pedal several times until

normal pedal travel is established.

9 . C entralize the pressure differen-

tial valve. Refer to the C entralizing

the Pressure D ifferential Valve proce-

dures which follow.

PRES S URE BLEEDING

The Lincoln Continental hydraulic

brake system is to be bled only with

pressure bleeding equipment.

B leed the longest lines first. The

bleeder tank should contain enough

new Ford B rake Fluid to compl ete the

bleeding operation. Use Ford B rake

Fluid Extra Heavy D uty Part

N u m b e r C 6 A Z - 1 9 5 4 2 - A ( E S A -

M6 C 2 5 -A) or equiva lent for al l brake

applications.

The brake fluid is col-

ored 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 ap-

proxim ately 10 to 30 pounds of air

pressure.

Never exceed 50 pounds

pressure.

1. Cl ean al l dirt from the master

cylinder reservoir cover.

2 .

Remove the master cylinder res-

ervoir 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 bleed-

er tank hose to the fittng on the

adapter .

Master cylinder pressure bleeder

adapter tools can be obtained from

the various manufacturers of pressure

bleeding equipment.

Follow the in-

structions of the manufacturer when

instal l ing the adapter.

3 .

If t h e m a s t e r c y l i n d e r is

equipped with a bleed screw, loosen

the bleed screw and bleed the master

cylinder until the fluid is free of air

bubbles; then, tighten the bleed screw.

Do not use the secondary piston stop

screw, located on the bottom of the

master cylinder, to bleed the master

cylinder.

4. If the rear wheel cylinders, the

secondary brake system, are to be

bled, position a 3 /8 inch box wrench

(Fig. 9) on the bleeder fitting on the

right rear brake wheel cylinder. At-

tach a bleeder tube to the bleeder fit-

ting. 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 . Sub me rge the free end of the

tube in a container partially filled with

clean brake fluid, and loosen the

bleeder fitting.

7.

When air bubbles cease to ap-

pear in the fluid at the submerged end

of the bleeder tube, close the bleeder

fitting and remove the tube.

8. Repeat steps 3 through 7 at the

left rear wheel cylinder.

9. If the vehicle is equipped with

disc brakes,

repeat steps 4 through 7,

starting at the right front disc caliper

and ending at the left front disc cali-

per.

On Lincoln C ontinental m odels the

front wheel and tire assemblies must

be removed to gain access to the

bleeder fittings on the calipers. Also

on Lincoln C ontinental m odels the

metering valve release rod must be

pul led outward and held a minimum

of 1/1 6 inch (Fig. 10) while bleeding

the primary brake sys tem.

10.

If the vehicle contains drum-

type front brakes and the primary

(front) brake system is to be bled, re-

peat steps 4 through 7, starting at the

right front wheel cylinder ending at

the left front wheel cylinder.

1 1 .

When the bleeding operation is

completed, close the bleeder tank

valve and remove the tank hose from

the adapter fitting.

1 2 .

On d i s c b ra ke equ ipp ed ve -

hicles, be sure that the front brake

pistons are returned to their normal

positions and that the shoe and lining

assemblies are properly seated by dep-

ressing the brake pedal several times

until normal pedal travel is esta-

blished.

13 .

Remove the Pressure B leeder

Adapter Tool . Fil l the master cylinder

reservoirs to within 1/4 inch of the

top. Instal l the master cylinder cover

and gasket.

Be sure the Diaphragm

type gasket is properly positioned in

the master cylinder cover.

14. C entralize the pressure differen-

tial valve as follows.

METERING VALVE

BLEEDER RETAINER

SE E

VIEW A

RELEASE ROD

FIG. 10Disc Brake Meter ing ValveLincoln Continental

HI 644-A


18/412

02-01-07

B rakes

02-01-07

C E N T R A L I Z I N G T H E

P R E S S U R E D I F F E R E N T I A L

VALVE

After a failure of the primary (front

brake) or secondary (rear brake) sys-

tem has been repaired and bled, the

dual-brake warning l ight wil l usual ly

continue to be i l luminated due to the

pressure differential valve remaining in

the off-center position.

To centralize the pressure differen-

tial valve and turn off the warning

light after a repair operation, a pres-

sure differential or unbalance condi-

tion must be created in the opposite

brake system from the one that was

repaired or bled last.

1.

Tur n the ignition sw itch to the

AC C or ON position. Loosen the dif-

ferential 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 . D epress the brake pedal slowly to

build l ine pressure unti l the pressure

differential valve is moved to a cen-

tralized position and the brake warn-

ing light goes out; then, immediately

tighten the outlet port tube nut.

2 .

C heck the fluid level in the mas-

ter cylinder reservoirs and fill them to

within 1/4 inch of the top with the

specified brake fluid, if necessary.

3 .

Turn the ignition switch to the

OFF pos i t ion .

4.

B efore driving the vehicle, check

the operation of the brakes and be

sure that a firm pedal is obtained.

CLEANING AND INSPECTION

DISC BRAKES

1. Remove the wheel and tire and

the shoe and l ining assemblies as out-

l ined in Part 2-2, Section 2.

2 . On al l m odels except Lincoln

C ontinenta l , make thickness measure-

ments with a micrometer across the

thinnest section of the shoe and lining.

If the assembly has worn to a thick-

ness of 0.230-inch (shoe and l ining to-

gether) or 0.030-inch (l ining material

only) at any one of three measuring

locations or if there is more than

0.125 taper from end to end or if l in-

ing shows evidence of brake fluid con-

tamination, replace al l (4) shoe and

lining assemblies on both front wheels.

O n L i n c o l n C o n t i n e n ta l b r a k e s

make three thickness measurements

with a micrometer across the middle

section of the shoe and lining. Take

one reading at each side and one in

the center. If the assembly has worn

to a thickness of 0.231 inch (shoe and

lining together) or 0.066 inch (l ining

material only) at any one of the three

measuring locations, replace al l (4)

shoe and l ining assemblies on both

front wheels .

3 .

C heck the caliper to spindle at-

taching bolts torque. Torque them to

specification, if required.

4 .

To check ro tor runout, first

el iminate the wheel bearing end play

by tightening the adjusting nut. After

tightening the nut, check to see that

the rotor can sti l l be rotated.

5 .

C lam p a dia l indica tor to the

caliper housing so that the stylus con-

tact the rotor at a point approximate-

ly 1 inch from the outer edge. Rota te

the rotor and take an indicator read-

ing. If the reading exceeds 0.003 inch

total lateral runout on the indicator,

replace or resurface the disc brake

rotor .

The following requirement must

be met when resurfacing disc brake

rotors:

Rotunda D isc B rake Attachment

FRE -2249 -2 i s 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 paral le l within

0.0007 inch; lateral runout must not

exceed 0.003 inch total indicator

reading, braking surface are to be 80/15

micro inches.

On al l models except Lincoln C on-

tinental the minimum limiting dimen-

sion from the inboard bearing cup to

the inboard rotor face and the mini-

mum rotor thickness dimension, must

be observed when removing material

from the rotor braking surfaces . A

bal l and gage bar (Rotunda Kit FRE

70160) is to be used when checking

minimum dimens ions (Fig . 11) .

FALCON-FAIRLANE

MUSTANG-COUGAR

MONTEGO

.046 MAX-**

.119 M A X .

FORD-MERCURY

METEOR - THUNDERBIRD

875 M IN

H1633-A

.12 M I N . - ^

?? Di sc B r a ke R o to r

S e r v i c e L i m i t s A l l M o d e l s E x c e p t

L i n c o l n C o n t i n e n t a l

On L inco ln Cont inenta l m ode ls the

minimum l imi t ing d imens ion (F ig . 12)

f rom the inboard bear ing cup to the

inboard rotor face (d imens ion B)

and the outboard rotor surface and

the inboard bear ing cup (d imens ion

A ) , must be observed when remov-

ing mater ia l f rom the rotor brak ing

surfaces.

Whe n the runout check is f in ished

be sure to adjust the bear ings as out-

l ined in Group 3, in order to prevent

bear ing fa i lure .

6 . C heck the rotor for scoring. Mi-

nor scores can be removed with a

fine emery clo th. If the roto r is ex-

cessively scored, refinish it as out-

lined in step 5 or replace the ro tor,

if required.

7 .

Visually check the caliper. If the

caliper housing is leaking it should be

replaced. If a seal is leaking the cali-

per must be disassembled and new

.seals installed. If a piston is seazed

in the bore a new caliper housing is

required.

On Lincoln C ont inental mode ls the

two halves of the caliper assembly

should never be separated. D amage or

failure of one requires replacement of

both as a unit.

C heck the brake hoses for signs of

cracking, leaks or abrasion. Replace

them if necessary.

DISC BRAKE SERVICE

PR EC A U TION S

1. Grease or any other foreign ma

terial must be kept off the caliper as

sembly, surfaces of the rotor and ex-

ternal surfaces of the hub during serv-

ice 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 l inings.

2 .

If a caliper piston is removed fo

any reason, the piston seal must be re

placed.

3 .

D uring removal and instal lation

of a wheel assembly, exercise care no

to interfere with and damage the cali


19/412

02-01-08

Brakes

02-01-08

B E A R I N G C U P

D IM E N S IO N " B "

0.755 MINIMUM

D IM E N S IO N " A '

0.395 MINIMU M

H1532-B

FIG. 12 Disc Brake Rotor Service

L imi t sLinco ln Cont inenta l

per splash shield or the bleeder screw

fitting.

4.

Front wheel bearing end play is

critical and must be within specifica-

tions.

5 . Be sure the vehicle is centered on

the hoist before servicing any front

end components, to avoid bending or

damaging the rotor splash shield on

full right or left wheel turns.

6 . The proportioning valve should

not be disassembled or adjustments

attempted on it .

7 .

Riding of the brake pedal (com-

mon on left foot applications) should

be avoided during vehicle operation.

8. The wheel and tire must be re-

moved ' separatel y from the brake

rotor, unlike drum brakes where the

wheel, tire and drum are removed as a

unit.

9 . On f loating caliper ty pe disc

brakes whenever the caliper is re-

moved the caliper locating pins should

be inspected for wear or damage.

1 0. On floating caliper ty pe disc

brakes, the caliper assembly must be

removed from the spindle prior to re-

moval of the shoe and lining assem-

blies.

1 1 .

On floating cal iper ty pe disc

brakes the calipers must not be inter-

changed from one side to the other.

When the caliper is installed on its

proper anchor plate and spindle, the

bleeder screw will point to the rear of

the vehicle (Fig. 22). If a caliper is in-

stalled on the wrong side of the vehi-

cle,

it is not possible to bleed the sys-

tem properly .

1 2 . D o not attem pt to clean or re-

store oil or grease soaked brake lin-

ings.

When contaminated linings are

found, brake linings must be replaced

in complete axle sets.

D R U M B R A K E S

1 . Remove the w heel from the

drum, and remove the drum as out-

lined in Part 2 -2, Section 2 .

2 . B rush all dust from the backing

plates and interior of the brake

drums.

3 . Inspect the brake shoes for ex-

cessive lining wear or shoe damage. If

the lining is worn within 1/32 inch of

the rivet heads or if the shoes are

damaged, they must be replaced. Re-

place any lining that had been con-

taminated with oil, grease or brake

fluid. Replace lining in axle sets. Prior

to replacement of lining, the drum di-

ameter should be checked to deter-

mine if oversize linings must be in-

stal led.

4. C heck the condition of b rake

shoes,

retracting springs, hold-down

springs, and drum for signs of over-

heating. If the shoes have a slight blue

coloring, indicating overheating, re-

placement of the retracting and hold- .

down springs is strongly recommen ded.

Overheated springs lose their pull and

could cause the new lining i:o wear

prematurely, if they are not replaced.

5. If

the vehicle has 30,000 or more

miles of operation on the brake linings

or signs of overheating are present

when relining brakes, the wheel cylin-

ders should be disassembled and in-

spected for wear and entrance of dirt

into the cylinder. The cylinder cups

should be replaced, thus avoiding fu-

ture problems.

6. Inspect all other brake parts and

replace any that are worn or dam-

aged.

7 . Inspect the brake drum and, if

necessary, refinish. Refer to Part 2-2,

Section 4 for refinishing.

BRAKE BOOSTER

C heck the booster operation as

noted in Part 2 -1 , Section 1, Power

B rake Functional Test. If the brake

booster is damaged or defective, re-

place it with a new booster.

The brake

booster is serviced only as an assem-

bly.


20/412

02-02-01

B rake Sys tem

02-02-01

Part 2-2 Brak e System

C O M P O N E N T I N D E X

ANTI SKID C ONTROL SYSTEM

D escription

ANTI SKID C ONTROL AC TUATOR

Removal and Installation

ANTI SKID C ONTROL MODULE


ANTI SKID C ONTROL SENSOR


B RAKE BAC KING PLATE (D RUM)


BRAKE BOOSTER

C leaning and Inspection-See Part 2-1

D escription


B RAKE D RUM

C leaning and Inspection-See Part 2-1

Refinishing

Removal and Installation (Front)

Removal and Installation (Rear)

BRAKE PEDAL


B RAKE SHOES (D RUM)

Adjustments

Relining


D IS C B RA KE

D escription

D ISC B RAKE CALIPER

C leaning and Inspection

D isassembly and Overhaul


D ISC B RAKE ROTOR AND HUB

C leaning and InspectionSee Part 2 -1

Refinishing


D ISC B RAKE ROTOR SPLASH SHIELD


D ISC B RAKE SERVIC E PRECAUTIONS

See P art 2 -1

MOD EL APPLIC ATION

A

l

M

o

s

0 2 - 1 6

02 -06

0 2 - 2 4

0 2 - 3 9

02 -09

02 -09

02 -07

0 2 - 3 9

02 -09

02 -03

0 2 - 3 9

0 2 - 1 9

0 2 - 1 9

F

d

N / A

N / A

N / A

N / A

02-09

0 2 - 2 5

02 -41

02 -41

0 2 - 1 6

M

e

c

u

y

N / A

N / A

N / A

N / A

02-09

0 2 - 2 5

02 -41

02 -41

0 2 - 1 6

M

e

N / A

N / A

N / A

N / A

02-09

0 2 - 2 5

02 -41

02 -41

0 2 - 1 6

C

o

N / A

N / A

N / A

N / A

02-09

0 2 - 2 5

02 -41

02 -41

0 2 - 1 6

F

r

a

N / A

N / A

N / A

N / A

02-09

0 2 - 2 5

02 -41

02 -41

0 2 - 1 6

F

c

N / A

N / A

N / A

N / A

02-09

0 2 - 2 5

02 -41

02 -41

0 2 - 1 6

M

e

N / A

N / A

N / A

N / A

02-09

0 2 - 2 5

02 -41

02 -41

0 2 - 1 6

M

a

N / A

N / A

N / A

N / A

02-09

0 2 - 2 5

02-41

02-41

0 2 - 1 6

L

n

n

C

n

a

N / A

N / A

N / A

N / A

N / A

0 2 - 2 7

02 -42

02 -41

0 2 - 1 7

T

b

r

d

02-07

0 2 - 3 6

0 2 - 3 8

0 2 - 3 8

N / A

0 2 - 2 6

04-41

02 -41

0 2 - 1 6

C

n

a

M

a

k

02-07

0 2 - 3 6

0 2 - 3 8

0 2 - 3 8

N / A

0 2 - 2 6

02 -41

02 -41

0 2 - 1 6

A page number indicates that the item is for the vehicle listed at the head of the column.

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


21/412

02-02-02

Brake System

02-02-02

COMPONENT INDEX

D ISC BRAKE SHOE AND LINING

C leaning and Inspection-SeePart 2 -1


DRUM BRAKE

D escription

D UAL B RAKE SYSTEM

D escription

HYD RAULIC LINES

RemovalandInstallation (Hose)

Removaland Installation (Tube)

MASTER C YLIND ER

C leaningand Inspection

D isassembly andOverhaul

RemovalandInstallation - Non-Power

RemovalandInstallation - Power

PARKING B RAKE

D escription

PARKING B RAKE AC TUATORTO

CONTROL CABLE

RemovalandInstallation

PARKING B RAKE AC TUATORTO

EQUALIZER CABLE


PARKING BRAKE CONTROL


PARKING BRAKE EQUALIZER

TO

CONTROL CABLE


PARKING BRAKE EQUALIZERTO

REAR WHEEL CAB LE


PRESSURE D IFFERENTIAL VALVE


PRESSURE METERING VALVE


PROPORTIONING VALVE


WH EELCY LIN DER

C leaningand Inspection

D isassembly andOverhaul

Removal

and

Installation

MODEL APPLICATION

A

l

M

s

02-05

02-03

02-08

02-08

02-40

02-39

02-21

02-06

02-22

02-08

02-07

02-10

F

d

02-18

02-19

02-34

02-35

02-27

N /A

02-35

N /A

02-23

M

c

y

02-18

02-19

02-34

02-35

02-27

N /A

02-35

N /A

02-23

M

e

02-18

02-19

02-34

02-35

02-27

N /A

02-35

N /A

02-23

C

02-18

02-20

N /A

N / A

02-30

02-34

02-36

N /A

02-23

F

r

a

02-18

02-20

N /A

N /A

02-27

02-34

02-36

N /A

02-23

F

c

02-18

02-20

N /A

N /A

02-27

02-34

02-36

N /A

02-23

M

e

02-18

02-20

N /A

N /A

02-27

02-34

02-36

N /A

02-23

M

a

02-18

02-20

N /A

N /A

02-30

02-34

02-36

N /A

02-23

L

n

n

C

n

a

02-18

N /A

N /A

N /A

02-30

02-35

02-36

02-24

02-24

T

b

r

d

02-18

N /A

02-34

02-35

02-30

N /A

02-35

N /A

02-24

C

n

a

M

k

02-18

N /A

02-34

02-35

02-30

N /A

02-35

N /A

02-24

A page number indicates that the itemis forthe vehicle listedatthe headofthe column.

N/ A indicates that the item isnotapplicabletothe vehicle listed.


22/412

02-02-03

B rake Sys tem

02-02-03

DESCRIPTION

D isc brakes are available as option-

al equipment for the front wheels on

Ford, Mercury, Meteor, Fair lane,

Montego, Falcon, Mustang and C ou-

gar models and are standard on Thun-

derbird, C ontinenta l Mark III , and

L i n c o l n C o n t i n e n t a l m o d e l s . T h e

dual-master cylinder equipped hydrau-

lic brake system employs single an-

c h o r , i n t e r n a l e x p a n d i n g a n d

self-

adjusting drum brake assemblies on

the rear wheels of vehicles with disc

brakes, and on the front and rear

wheels of all others.

A vacuum booster is used with the

power disc brake system.

DUAL MASTER CYLINDER

B R A K E S Y S T E M

The dual-master cylinder brake sys-

tem has been incorporated in all mod-

els to provide increased safety. The

system consists of a dual-master cylin-

der (Fig. 1), pressure differential valve

assembly and a switch (Fig. 2) . The

switch on the differential valve acti-

vates a dual-brake warning light, lo-

cated on the instrument panel .

DISC BRAKE

The disc brake consists of a venti-

lated rotor and caliper assembly . The

caliper used on all models except Lin-

coln C ontinental is a single piston

floating cal iper (Fig. 3 ) . The caliper

used on Lincoln C ontinental models is

a four piston fixed caliper (Fig. 4).

A proportioning valve in the rear

hydraulic circuit provides balanced

braking action between front and rear

brakes .

On al l models except Lincoln a

pressure impulse valve located at the

primary inlet of the pressure differen-

tial valve prevents brake fluid surge

back to the master cylinder reservoir.

On Lincoln C ontinental m odels a

mete ring valve, in the hy draul ic line

between the differential valve and the

front wheel disc brakes, prevents the

front

Documents

1969 Ford Car Shop Manual Volume One Chassis