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Copyright © 2010, Forel Publishing Company, LLC, Woodbridge, Virginia
All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoeverwithout written permission of Forel Publishing Company, LLC. For information write to Forel
Publishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192
1964 Ford and Mercury Shop ManualEAN: 978-1-60371-059-6
ISBN: 1-60371-059-0
Forel Publishing Company, LLC3999 Peregrine Ridge Ct.Woodbridge, VA 22192
Email address: [email protected]: http://www.ForelPublishing.com
This publication contains material that is reproduced and distributed under a license from FordMotor Company. No further reproduction or distribution of the Ford Motor Company material is
allowed without the express written permission of Ford Motor Company.
NNoottee ffrroomm tthhee EEddiittoorr
This product was created from the original Ford Motor Company’s publication. Every effort hasbeen made to use the original scanned images, however, due to the condition of the material;some pages have been modified to remove imperfections.
Disclaimer
Although every effort was made to ensure the accuracy of this book, no representations orwarranties of any kind are made concerning the accuracy, completeness or suitability of theinformation, either expressed or implied. As a result, the information contained within this bookshould be used as general information only. The author and Forel Publishing Company, LLCshall have neither liability nor responsibility to any person or entity with respect to any loss ordamage caused, or alleged to be caused, directly or indirectly by the information contained inthis book. Further, the publisher and author are not engaged in rendering legal or otherprofessional services. If legal, mechanical, electrical, or other expert assistance is required, theservices of a competent professional should be sought.
FOREWORD
This shop manual provides the Service Technician with com-
plete information for the proper servicing of the 1964 Ford
and Mercury cars.
The information 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
are included.
Refer to the opposite page for important vehicle identifica-
tion 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 DEPARTMENT
FORD MOTOR COMPANY
FORD IDENTIFICATION
FORD IDENTIFICATION
COLOR (DYNASTY GREEN AND WIMBLEDON WHITE)
BODY STYLE(GALAXIE 500 2-DOOR SEDAN)
TURQUOISE CHAIN WEAVEFAB. AND D/L CRUSH VINYL
3.00:1 AXLE RATIO
3 SPD SINGLE RANGEAUTOMATIC TRANS.
DETROIT DISTRICT
26TH DAY AUGUST
62ADM 17 26H 33
4Z61XI00001
1964 MODEL YEAR
PRODUCED AT ST. LOUIS PLANT
CONSECUTIVE UNIT NUMBER (1ST UNIT BUILT)
ENGINE (8 CYL. 352 CID 4V CARBURETOR)
BODY SERIAL (2-DOOR SEDAN)
F IG . 1 -1964 Ford Warranty Plate
Figure 1 illustrates the 1964 Galaxie Warranty Plate. The plate is locatedon the rear (lock) face of the left front door panel.
The official Vehicle Identification Number for title and registration pur-poses is stamped on a tab attached to the top right side (weld flange) ofthe dash panel in the engine compartment (Fig. 2). Do not use the "VehicleWarranty Number" which appears on the Warranty plate for title or registra-tion purposes.
M1090-B
N1319-B
F I G . 2-Ford VehicleIdentification Number Location
VEHICLEExample (Fig. 1):
(62A DM62ADM
DATA
17 26H 33 12-Door SedanDynasty Green
6)
and Wimbledon White
17
26H3316
BODY
Ford Custom54E62E
Ford Custom 50054B62B
Galaxie 50054A57B62A63B76A
Galaxie 500XL57C63C76B
Station Wagons71A71B71C71E.
Turquoise Chain Weave Fab. andLt. Turquoise D/L Crush Vinyl
.. ..26th Day AugustDetroit District3.00:1 RatioC-4 Automatic Dual Range
4-Door Sedan2-Door Sedan
4-Door Sedan2-Door Sedan
4-Door Sedan4-Door Fastback2-Door Sedan2-Door Fastback2-Door Convertible
4-Door Fastback2-Door Fastback2-Door Convertible
4-Door 9-Pass. Country Squire4-Door 6-Pass. Country Sedan4-Door 9-Pass. Country Sedan
. . . 4-Door 6-Pass. Country Squire
FORD IDENTIFICATION
COLOR
Two-tone paint codes use the same symbols as the single colors except that
two symbols are used. The lower body color code will appear first in the
warranty plate paint color space.
If a special paint is used, the paint color space will not be stamped.
CodeABDFGJKMRTXYZ
*M-30-JNumber. .1724...1638...1625...1622..
. . .1636...1515..
. . .1621 . ..1619..
. . .1633. ..1631...1632..
. . .1623. .
. . .1630..
Color.BlackPeacock
.Med. Turquoise Met.Med. Blue MetBuffRedSilver Mink Met....WhiteYellow
.Lt. BeigeMaroon MetLt. Blue
.Med. Beige Met
Sales Name.. Raven Black..Pagoda Green.. Dynasty Green..Guardsman Blue. Prairie Tan..Rangoon Red
Silver Smoke Gray..Wimbledon White..Phoenician Yellow.. Navaho Beige. Vintage Burgundy..Skylight Blue. Chantilly Beige
*"M-32-J" Acrylic Paint Alternate with "M-30-J'
TRIMDeviation trim sets will use existing trim codes plus a suffix. A trim code witha numerical suffix is not serviced, while a trim code with an alphabeticalsuffix is serviced.
Code
03..04..
12..14..15. .16..17..
22..24..25..27..
32..34..35..
42..44..45..47..
7 1 . .72. .74..75. .76. .77..
81.82.84.85.86.87.89.
Trim SchemesRib Vinyl and Crush Vinyl
.. Med. Green and Med. Green
.. Med. Beige and Med. Beige
Chain Weave Fabric and Crush Vinyl. . . Blue and Lt. Blue D/L*. . . Beige and Beige. . . Red and Red. . . Black and Black.. Turquoise and Lt. Turquoise D/L*
Louvre Fabric and Crush Vinyl. . . Blue and Lt. Blue Met.... Beige and Beige... Red and Red.. Turquoise and Lt. Turquoise Met.
Bar Dot Fabric and Crush Vinyl. . . Blue and Lt. Blue. . . Beige and Pale Beige. . . Red and Red
Mosaic Vinyl and Crush Vinyl.. Med. Blue Met. and Lt. Blue Met....Med. Beige Met. and Beige. . . Red and Red. . . Med. Turquoise Met. and Lt. Turquoise Met.
Crush Vinyl (Bench Seat).. Med. Silver Blue D/L and Lt. Silver Blue D/L*...Med. Blue D/L and Lt. Blue D/L*. . . Lt. Beige D/L and Beige...Red...Black. . . Med. Turquoise D/L and Turquoise D/L*
Crush Vinyl (Bucket Seat). . . W h i t e.. Med. Silver Blue D/L and Silver Blue D/L*...Med. Blue D/L and Lt. Blue D/L. . . Lt. Beige D/L and Beige. . . Red...Black.. Med. Turquoise D/L and Lt. Turquoise D/L*. . . Med. Palomino (Crinkle)
*D/L—Diamond Lustre
DATEThe code letters for the month are preceded by a numeral to show the dayof the month when the car was completed. The second year code letters areto be used if 1964 model production exceeds 12 months.
MonthJanuary...February..MarchAprilMayJuneJulyAugust....September.October...November.December.
DSODomestic Special Orders, Foreign Special Orders, and Pre-Approved SpecialOrders have the complete order number recorded in this space. Also toappear in this space is the two-digit code number of the District which orderedthe unit. If the unit is regular production, only the District code numberwill appear.
FirstModelYear..A..B..C..D..E..F..G..H..J..K..L..M
SecondModelYear
NPQR
.. .STUVWXYZ
DISTRICT CODECode District
11 Boston12 Buffalo13 New York14 Pittsburgh15 Newark21 Atlanta22 Charlotte23 Philadelphia24 Jacksonville25 Richmond26 Washington31 Cincinanti32 Cleveland33 Detroit34 Indianapolis35 Lansing36 Louisville41 Chicago42 Fargo43 Rockford44 Twin Cities
Code District45 Davenport51 Denver52 DesMoines53 Kansas City54 Omaha55 St. Louis61 Dallas62 Houston63 Memphis64 New Orleans65 Oklahoma City71 Los Angeles72 San Jose73 Salt Lake City74 Seattle81 Ford of Canada83 Government84 Home Office Reserve85 American Red Cross89 Transportation Services90 Export
AXLEA number designates a conventional axle, while a letter designates an Equa-Lock differential.
Ratio3.00:13.25:1
Code1. .4 . .5 . .
Ratio.3.00:1.3.25:1.3.50:1.3.89:1.4.11:1
CodeA. .E..F.. .3.50:1H 3.89:1I. 4.11:1
TRANSMISSIONCode
12456
Type3-Speed Manual-Shift
.Overdrive
.Cruise-O-Matic4-Speed Manual-ShiftC-4 Automatic Dual Range
NUMBERVEHICLE WARRANTYExample (Fig. 1): 4Z61X100001
4 1964 Year ModelZ St. Louis Plant Assembly61 2-Door SedanX 8-Cylinder 352 Cubic Inch Engine100001 First Unit Built (Consecutive Unit Number)
M O D E L Y E A RThe numeral "4" designates 1964.
FORD-MERCURY IDENTIFICATION
A S S E M B L Y P L A N TCode Assembly Code AssemblyLetter Plant Letter Plant
A Atlanta P Twin CitiesD Dallas S Pilot PlantE Mahwah U LouisvilleG Chicago W WayneJ Los Angeles Z St. LouisN Norfolk
MODELThe model code number identifies the product line series and the particularbody style: the first of the two digits shows the product line, and the seconddigit shows a two-door style by an odd number or a four-door style by aneven number.
Ford Custom53 2-Door Sedan54 4-Door Sedan
Ford Custom 50051 2-Door Sedan52 4-Door Sedan
Galaxie 50061 2-Door Sedan62 4-Door Sedan64 4-Door Hardtop65 2-Door Convertible66 2-Door Fastback
Galaxie 500XL606869
Station Wagons72747678
ENGINECode
BCEP
QRVXz
Low Compression359
4-Door Fastback2-Door Fastback2-Door Convertible
4-Door 6-Passenger Country Sedan4-Door 9-Passenger Country Sedan
.4-Door 6-Passenger Country Squire
.4-Door 9-Passenger Country Squire
6-Cylinder 223 Cubic Inch (Police).8-Cylinder 289 Cubic Inch (2-barrel).6-Cylinder 223 Cubic Inch (Taxi).8-Cylinder 390 Cubic Inch (Police)8-Cylinder 427 Cubic Inch (4-barrel High Pert.)8-Cylinder 427 Cubic Inch (8-barrel High Perf.)
.6-Cylinder 223 Cubic Inch
.8-Cylinder 352 Cubic Inch (4-barrel)8-Cylinder 390 Cubic Inch (4-barrel)
8-Cylinder 289 Cubic Inch.6-Cylinder 223 Cubic Inch8-Cylinder 390 Cubic Inch
CONSECUTIVE UNIT NUMBEREach assembly plant, with each model year, begins with consecutive unitnumber 100001 and continues on for each car built.
MERCURY IDENTIFICATION
COLOR (GLACER BLUE AND POLAR WHITE)
TRIM (MED. BLUE CORD FABRIC
AND LT. BLUE MET. CRUSH VINYL)
BODY STYLE(MONTEREY 4-DOOR SEDAN)
CONVENTIONAL
3.50:1 RATIO AXLE
DUAL RANGE AUTO.
TRANSMISSION
4Z42Y500001
1964 MODEL YEAR
PRODUCED AT ST. LOUIS PLANT
CONSECUTIVE UNIT NUMBER
8 CYL. 390C1D 2 V CARBURETOR
BODY SERIAL CODE (4 DOOR SEDAN) N1267-B
FIG. 3-Mercury Warranty Plate
Figure 3 illustrates the 1964 Monterey Warranty plate. The plate is locatedon the rear (lock) face of the left front door panel.
The official Vehicle Identification Number for title and registration purposes
is stamped on a tab attached to the top right side (weld flange) of the dashpanel in the engine compartment (Fig. 4). Do not use the "Vehicle WarrantyNumber" which appears on the Warranty plate for title or registrationpurposes.
MERCURY IDENTIFICATION
N1268-B
F I G . 4-Mercury VehicleIdentification Number Location
CodeABDFG1JKLMRTWXYZ
*"M-32-J
*M-30-JNumber
. . . 1 7 2 4 . . .. . . . 1 6 3 8 . . .
1625 . . .1622....1636 . . .1635 . . .1515 . . .1 6 2 1 . . .1637....16191633 . . .
. . . . . . 1 6 3 1 . . . .1555....1632 . . .1623....1630 . . .
" Acrylic Paint
ColorBlackPeacockMed. Turquoise MetMed. Blue MetBuffAztec GoldRedSilver Blue MetBittersweetWhiteYellowLt. BeigeLt. Pink MetMaroon MetLt. BlueMed. Beige MetAlternate with "M-30-J".
Sales Name.. Onyx.. Peacock.. Silver Turquoise... Pacific Blue.. Palomino...Aztec Gold.. Carnival Red.. Anniversary Silver... Bittersweet
Polar White...Yellow Mist... Fawn.. Pink Frost.. Burgundy. Glacier Blue.. Platinum Beige
VEHICLE DATA
Example (Fig. 3):(54A YM 22
54AYM22
26H
26H 33 5 4)4-Door Sedan
... Glacier Blue and Polar WhiteMed. Blue Cord Fabric and Lt. Blue MetCrush Vinyl26th Day of August
33 Detroit District5 3.50:1 Ratio4 Dual Range Automatic Transmission
B O D Y
Monterey54A 4-Door Sedan62A 2-Door Sedan63A 2-Door Hardtop Fastback65A 2-Door Hardtop76A 2-Door Convertible
Montclair54B57D63D65B
4-Door Sedan4-Door Hardtop Fastback2-Door Hardtop Fastback2-Door Hardtop
Parklane54F 4-Door Sedan57C 4-Door Hardtop Fastback (Bucket Seats)57F 4-Door Hardtop Fastback63C 2-Door Hardtop Fastback (Bucket Seats)65C 2-Door Hardtop (Bucket Seats)65F 2-Door Hardtop75F 4-Door Hardtop76C 2-Door Convertible (Bucket Seats)76F 2-Door Convertible
Station Wagons71A71B71C71D
4-Door 6-Pass. Commuter4-Door 6-Pass. Colony Park4-Door 9-Pass. Commuter4-Door 9-Pass. Colony Park
COLOR
Two-tone paint codes use the same symbols as the single colors except thattwo symbols are used. The lower body color code will appear first in theWarranty Plate Paint Color Space.If a special paint is used, the paint color space will not be stamped.
TRIMDeviation trim sets will use existing trim codes plus a suffix. A trim codewith a numeral suffix is not serviced, while a trim code with an alphabeticalsuffix is serviced.
Code Trim SchemesDiscus Fabric and Crush Vinyl
(Bench-Pleated)11 Med. Silver Blue and Lt. Silver Blue Met.12 Med. Blue and Lt. Blue Met.14 Med. Beige and Lt. Beige Met.16 Black and Black
Cord Fabric and Crush Vinyl(Bench-Plain)
22 Med. Blue and Lt. Blue Met.24 Med. Beige and Lt. Beige Met.26 Black and Black
Stitch Rib Vinyl and Crush Vinyl (Crinkle)(Bench-Plain)
32 Med. Blue Met. and Lt. Blue Met.35 Red and Red36 Black and Black39 Med. Palomino and Med. Palomino (*)
Ostrich Vinyl and Crush Vinyl (Crinkle)(Bucket-Biscuit)
52 Med. Blue Met. and Lt. Blue D/L*55 Red and Red56 Black and Black59 Med. Palomino and Med. Palomino82 White Pearl and White Pearl85 (W/Red) White and White Pearl86 (W/Black) White Pearl and White Pearl87 (W/Turq.) White Pearl and White Pearl)89 (W/Palomino) White Pearl and White Pearl
Caspian Fabric and Crush Vinyl(Bench-Biscuit)
61 Med. Silver Blue and Lt. Silver Blue D/L*62 Med. Blue and Lt. Blue D/L*64 Med. Beige and Lt. Beige D/L*66 Black and Black67 Med. Turquoise and Med. Turquoise Met.
Crush Vinyl (Crinkle)(Bench-Pleated)
72 Med. and Lt. Blue Met.75 Red76 Black79 Medium Palomino
Ostrich Vinyl and Crush Vinyl (*Crinkie)(Bench-Biscuit)
92 Lt. Blue Met. and Med. Blue Met.95 Red and Red96 Black and Black97 Lt. Turquoise Met. and Med. Turquoise Met.99 Med. Palomino and Med. Palomino (*)
*D/L—Diamond Lustre
MERCURY IDENTIFICATION
DATEThe code letters for the month are preceded by a numeral to show the dayof the month when the car was completed. The second year code lettersare to be used if 1964 model production exceeds 12 months.
MonthJanuary...February..MarchAprilMayJuneJulyAugust....September.October...November.December.
FirstModel Year
ABCDEFGHJKLM
SecondModel Year
NPQRSTUV
. . . WXYZ
DSODomestic Special Orders, Foreign Special Orders, and Pre-Approved SpecialOrders have the complete order number recorded in this space. Also toappear in this space is the two-digit code number of the District whichordered the unit. If the unit is regular production, only the District codenumber appears.
DISTRICTCode111213142122242531323334
CODEDistrictBoston
PhiladelphiaNew York
WashingtonAtlantaDallas
JacksonvilleMemphis
BuffaloCincinnatiCleveland
Detroit
Code4 1 . . . .4 4 . . .45. . .5 1 . . .52..53...54. . .8184... .90-99
DistrictChicago
St. LouisTwin Cities
DenverLos Angeles
OaklandSeattle
Ford of CanadaHome Office Reserve
Export
AXLEA number designates a Conventional axle, while a letter designates anEqua-Lock differential.
Code1589
TRANSMISSIONCode
1245
Ratio.3.00:1.3.50:1.3.89:1.4.11:1
CodeA. .F..H. .I...
Ratio3.00:13.50:13.89:14.11:1
Type3-Speed Manual-ShiftOverdriveAutomatic (Multi-Drive)4-Speed Manual-Shift
VEHICLE WARRANTY NUMBERExample (Fig. 3): 4W42Y 500001
4 1964 Model YearW Wayne Plant Assembly42 Monterey 4-Door SedanY 8-Cylinder 390 Cubic Inch Engine500001 First Unit Built
MODEL YEARThe numeral "4" designates 1964.
ASSEMBLYCode Letter
SZw
PLANTAssembly Plant
Pilot PlantSt. LouisWayne
MODELThe model code number identifies the product line series and the particularbody style: the first of the two digits shows the product line, and the seconddigit shows a two-door style by an odd number or a four-door style by aneven number.
Monterey4142434547
Montclair52535758
Parklane626364656768
Station Wagon72727676
ENGINECode
HP
t::::::YZ9
2-Door Sedan4-Door Sedan2-Door Hardtop2-Door Convertible2-Door Hardtop Fastback
4-Door Sedan2-Door Hardtop2-Door Hardtop Fastback4-Door Hardtop Fastback
4-Door Sedan2-Door Hardtop4-Door Hardtop
.2-Door Convertible2-Door Hardtop Fastback4-Door Fastback
4-Door 6-Pass. Commuter.4-Door 9-Pass. Commuter4-Door 6-Pass. Colony Park4-Door 9-Pass. Colony Park
. 8-Cylinder 390 Cubic Inch (2-barrel Special)8-Cylinder 390 Cubic Inch (4-barrel Police)
. 8-Cylinder 427 Cubic Inch (4-barrel High Perf.)
. 8-Cylinder 427 Cubic Inch (8-barrel High Perf.)
. 8-Cylinder 390 Cubic Inch (2-barrel)
. 8-Cylinder 390 Cubic Inch (4-barrel)
. .8-Cylinder 390 Cubic Inch (4-barrel, Low Compression)
CONSECUTIVE UNIT NUMBEREach assembly plant, with each model year, begins with consecutive unitnumber 500001 and continues on for each car built.
PART 2-1GENERAL BRAKE SERVICE
PART 2-2BRAKE SYSTEM
PAGE. .2-1
PART 2-3SPECIFICATIONS
PAGE.2-20
PAGE. 2 - 6
PART2-1
GENERAL BRAKE SERVICE
Section Page1 Diagnosis and Testing 2- 12 Common Adjustments and Repairs 2- 3
Section3 Cleaning and Inspection
Page.2- 5
DIAGNOSIS AND TESTING
PRELIMINARY TESTS
1. Check the fluid level in themaster cylinder, and add FoMoCoheavy-duty brake fluid if required.
2. With the engine running orenough vacuum in the system forpower brakes, push the brake pedaldown as far as it will go while thecar is standing still. If the pedaltravels more than halfway betweenthe released position and the floor,check the brake adjustment and theautomatic adjusters.
To check adjuster operation, checkthe shoes and the adjuster compo-nents for binding or improper instal-lation. Follow the procedure de-scribed under "Brake Shoe Adjust-ments" in Part 2-2, Section 2.
Make several reverse brake stopsto ensure uniform adjustment at allwheels.
3. On cars with power brakes,with the transmission in neutral,stop the engine and apply the park-ing brake. Depress the service brakepedal several times to exhaust all
vacuum in the system. Then, depressthe pedal and hold it in the appliedposition. Start the engine. If the vac-uum system is operating, the pedalwill tend to fall away under footpressure and less pressure will be re-quired to hold the pedal in the ap-plied position. If no action is felt,the vacuum booster system is notfunctioning. Follow the proceduresin the "Booster Diagnosis Guide".With the engine shut off, exhaust allvacuum in the system. Depress thebrake pedal and hold it in the ap-plied position. If the pedal graduallyfalls away under this pressure, thehydraulic system is leaking. Checkall tubing hoses, and connections forleaks.
If the brake pedal movement feelsspongy, bleed the hydraulic systemto remove air from the lines andcylinder. See Section 2, "HydraulicSystem Bleeding". Also, check forleaks or insufficient fluid.
4. Should one of the brakes belocked and the car must be moved,open the brake cylinder bleeder
screw long enough to let out a fewdrops of brake fluid. This bleedingoperation will release the brakes, butit will not correct the cause of thetrouble.
ROAD TEST
The car should be road testedonly if the brakes will safely stopthe car. Apply the brakes at a speedof 25-30 mph to check for the ex-istance of the trouble symptomslisted in Table 1, with the exceptionof those resolved in the preliminarytests and brake chatter. For each ofthe symptoms encountered, checkand eliminate the causes which arealso listed in Table 1. To check forbrake chatter or surge, apply thebrakes lightly at approximately 50mph.
For booster removal and installa-tion procedures, refer to Part 2-2,Section 3. For disassembly and as-sembly procedures, refer to Part 2-2,Section 4. For cleaning and inspec-tion refer to Part 2-1, Section 3.
2-2 G R O U P 2-BRAKES
TABLE 1 —Brake Trouble Symptoms and Possible Causes
Possible Causes of
Trouble Symptoms
Mechanical Resistance at Pedal or Shoes
Brake Line Restricted
Leaks or Insufficient Fluid
Improper Tire Pressure
Improperly Adjusted or Worn Wheel Bearing
Distorted or Improperly Adjusted Brake Shoe
Faulty Retracting Spring
Drum Out of Round
Linings Glazed or Worn
Oil or Grease on Lining
Loose Carrier Plate
Loose Lining
Scored Drum
Dirt on Drum-Lining Surface
Faulty Brake Cylinder
Dirty Brake Fluid
Faulty Master Cylinder
Air in Hydraulic System
Self Adjusters Not Operating
Insufficient Shoe-to-Carrier Plate Lubrication
Tire Tread Worn
Poor Lining to Drum Contact
Loose Front Suspension
"Threads" Left by Drum Turning ToolPulls Shoes Sideways
Cracked Drum
Sticking Booster Control Valve
Trouble Symptoms
One
Bra
ke D
rags
X
X
X
X
X
X
X
x
X
X
All
Bra
kes
Dra
g
x
X
X
X
X
X
Har
d Pe
dal
X
X
X
X
X
Spon
gy P
edal
X
X
Car
Pul
ls t
o O
ne S
ide
X
X
X
X
X
X
X
X
X
X
One
Whe
el L
ocks
X
X
X
X
X
X
Bra
kes
Cha
tter
X
X
X
X
X
X
X
Exce
ssiv
e Pe
dal T
rave
l
X
X
X
X
X
X
X
Peda
l G
radu
ally
Goe
sto
Flo
or
X
X
Bra
kes
Une
ven
X
X
X
X
Shoe
Clic
k A
fter
Rel
ease
X
X
X
X
Noi
sy o
r G
rabb
ing
Bra
kes
X
X
X
X
X
X
X
Bra
kes
Do
Not
App
ly
X
X
X
X
X
X
G R O U P 2-BRAKES 23
BRAKE BOOSTER TROUBLE DIAGNOSIS GUIDE
BOOSTER INOPERATIVE-HARD PEDAL
BRAKES DRAGOR GRAB
SELF APPLICATIONOF BRAKES WHENENGINE STARTS
If the preliminary tests show that lapsed condition. Repair or replacethe booster is inoperative or if a hard parts as necessary,pedal condition still exists after elimi- If the foregoing procedure does notnating the causes of "Hard Pedal" eliminate the trouble, remove thelisted in table 1, the trouble may be booster from the car. Separate thecaused by vacuum leakage. Discon- booster body from the end plate, andnect the vacuum line (two lines if check the bellows, booster body, andequipped with an automatic transmis- diaphragm assembly for damage thatsion) at the booster, remove the would cause leaks. When assembling,vacuum manifold and check valve be sure that the diaphragm assemblyassembly, and look for a sticking or is properly positioned. Improper loca-faulty check valve. Check all vacuum tion could cause leakage between theconnections for leakage or obstruction. vacuum and atmospheric sides of theCheck all hoses for a leaking or col- diaphragm.
If the brakes still drag or grab after Remove and disassemble the booster,eliminating the causes listed in Table Clean, inspect, and replace parts as1, the condition is probably caused by necessary,a sticking valve plunger assembly.
Remove and disassemble the atmospheric valve. Clean, inspect, andbooster. Check the diaphragm for be- replace parts as necessary. Be sure thating out of locating radii in the hous- the diaphragm is properly locateding. Check for a sticking or unseated when assembling.
COMMON ADJUSTMENTS AND REPAIRS
PARKING BRAKE LINKAGEADJUSTMENT
Check the parking brake cableswhen the brakes are fully released.If the cables are loose, adjust themas follows.
1. Fully release the parking brakepedal by pushing down on the man-ual release lever.
2. Raise the car.3. Adjust the pedal cable to the
dimensions shown in Fig. 1.4. Depress the parking brake
pedal one notch from its normal re-leased position.
ADJUST NUTTO THIS DIMENSION
93/4
HI 297- A
F IG . 1-Pedal Cable Adjustment
5. Loosen the lock nut on theequalizer rod (Fig. 2), and then turnthe nut in front of the equalizerseveral turns forward.
6. Turn the lock nut forwardagainst the equalizer until a mod-erate drag is felt when turning therear wheels.
7. When the cables are properlyadjusted, tighten both nuts againstthe equalizer.
8. Release the parking brake, andmake sure that the brake shoes re-turn to the fully released position.
EQUALIZER ADJUSTING NUT
POWER BRAKE MASTERCYLINDER PUSH RODADJUSTMENT
The push rod is provided with anadjustment screw to maintain thecorrect relationship between thebooster control valve plunger andthe master cylinder piston. Failureto maintain this relationship willprevent the master cylinder pistonfrom completely releasing hydraulicpressure and can cause the brakesto drag.
To check the adjustment of the
EQUALIZER LEVER
REAR WHEEL CABLES LOCK NUT
F I G . 2—Parking Brake LinkagePEDAL CABLE
2-4 P A R T 2-1 -GENERAL BRAKE SERVICE
# 1 6 GAUGESHEET STEEL
ADJUSTMENTSCREW
H12O8-A
F IG . 3—Push Rod GaugeDimensions
screw, fabricate a gauge of the di-mensions shown in Fig. 3. Thenplace the gauge against the mastercylinder mounting surface of thebooster body as shown in Fig. 4.The push rod screw should be ad-justed so that the end of the screwjust touches the inner edge of theslot in the gauge. Do not set up sideforces on the push rod as it maybreak the valve plunger.
This is an approximate adjust-ment only. To verify the adjustment,look through the make-up (rear)port when installing the master cyl-inder to the booster. The mastercylinder piston should not movemore than 0.015 inch as it contactsthe push rod. No movement (exactcontact) is ideal.
HYDRAULIC SYSTEM BLEEDING
When any part of the hydraulicsystem has been disconnected forrepair or replacement, air may getinto the lines and cause spongypedal action. Bleed the hydraulicsystem after it has been properlyconnected to be sure that all air isexpelled from the brake cylindersand lines.
The hydraulic system can be bledmanually or with pressure bleedingequipment.
Push Rod Gauge
12O9-A
FIG. 4-Push Rod Adjustment
MANUAL BLEEDING
Bleed the longest lines first. Keepthe master cylinder reservoir filledwith new heavy-duty brake fluidduring the bleeding operation.
Never use brake fluid which hasbeen drained from the hydraulicsystem.
1. Position a bent %-inch boxwrench on the bleeder fitting onthe right rear brake wheel cylinder(Fig. 5). Attach a rubber drain tubeto the bleeder fitting. The end ofthe tube should fit snugly aroundthe bleeder fitting.
2. Submerge the free end of thetube in a container partially filledwith clean brake fluid, and loosenthe bleeder fitting approximately 3Aturn.
3. Push the brake pedal downslowly thru its full travel. Close thebleeder fitting, then return the pedalto the fully-released position. Repeatthis operation until air bubbles ceaseto appear at the submerged end ofthe tube.
4. When the fluid is completelyfree of air bubbles, close the bleederfitting and remove the drain tube.
5. Repeat this procedure at eachbrake wheel cylinder in order: leftrear, right front, and left front. Re-fill the master cylinder reservoirafter each brake cylinder is bled andwhen the bleeding operation is com-pleted. The fluid level should bewithin % inch of the top of thereservoir.
PRESSURE BLEEDING
Bleed the longest lines first. Neveruse brake fluid which has beendrained from the hydraulic system.
The bleeder tank should containenough new heavy-duty brake fluidto complete the bleeding operation,and it should be charged with 10-30pounds of air pressure.
1. Clean all dirt from the mastercylinder reservoir cap.
2. Remove the master cylinderreservoir cap, install an adapter capon the reservoir, and attach thebleeder tank hose to the fitting onthe adapter cap. Adapter cap 2162can be used, or an adapter cap canbe fabricated by cutting a hole inthe center of a filler cap and solder-ing a fitting at the hole.
3. Position a %-inch box wrenchon the bleeder fitting on the rightrear brake wheel cylinder (Fig. 5).Attach a rubber drain tube to thebleeder fitting. The end of the tubeshould fit snugly around the bleederfitting.
4. Open the valve on the bleedertank to admit pressurized brake fluidto the master cylinder reservoir.
5. Submerge the free end of thetube in a container partially filledwith clean brake fluid, and loosenthe bleeder fitting.
6. When air bubbles cease to ap-pear in the fluid at the submergedend of the drain tube, close thebleeder fitting and remove the tube.
7. Repeat this procedure at eachbrake wheel cylinder in order: leftrear, right front, and left front.
8. When the bleeding operation iscompleted, close the bleeder tankvalve and remove the tank hosefrom the adapter fitting.
9. Remove the adapter cap, refillthe master cylinder reservoir towithin % inch from the top of thereservoir, and install the filler cap.
APPROXIMATELY 45°
HI 300-AFIG. 5-Wrench for BleedingBrake
GROUP 2-BRAKES 25
CLEANING AND INSPECTION
BRAKE ASSEMBLY
1. Remove the wheel from thedrum, then remove the drum as out-lined in Part 2-2, Section 2. Washall the parts except the brake shoesin a cleaning fluid and dry withcompressed air.
2. Brush all dust from the carrierplates and interior of the brakedrums.
3. Inspect the brake shoes for ex-cessive lining wear or shoe damage.If the lining is worn within %2 inchof the rivet heads or if the shoes aredamaged, they must be replaced.Replace any lining that has beenoil saturated. Replace lining in axlesets. Prior to replacement of lining,the drum diameter should be check-ed to determine if oversize liningsmust be installed.
4. Check the condition of brakeshoes, retracting springs, and drum
for signs of overheating. If the shoeshave a slight blue coloring, indicat-ing overheating, replacement of theretracting and hold down springs isstrongly recommended. Overheatedsprings lose their pull and couldcause the new lining to wear pre-maturely, if they are not replaced.
5. If the car has 24,000 or moremiles of operation on the brakelinings or signs of overheating arepresent when relining brakes, thewheel cylinders should be disassem-bled and inspected for wear andentrance of dirt into the cylinder.The cylinder cups should be re-placed, thus avoiding future prob-lems.
6. Inspect all other brake partsand replace any that are worn ordamaged.
7. Inspect the brake drums and,if necessary, refinish. Refer to Part2-2, Section 4 for refinishing.
BOOSTER UNIT
A disassembled view of the brakebooster is shown in Fig. 6.
After disassembly, immerse allmetal parts in a suitable solvent. Useonly alcohol on rubber parts orparts containing rubber. After theparts have been thoroughly cleanedand rinsed in cleaning solvent, themetal parts which come in contactwith hydraulic brake fluid or rubberparts should be rewashed in cleanalcohol before assembly. Use an airhose to blow dirt and cleaning fluidfrom the recesses and internal pas-sages. When overhauling a powerbooster, use all parts furnished inthe repair kit. Discard all old rub-ber parts.
Inspect all other parts for damageor excessive wear. Replace damagedor excessively worn parts. If theinside of the booster body is rustedor corroded, polish it with steel woolor fine emery cloth. Replace thebody shell when scored.
VACUUM MANIFOLD
GROMMET
AIR FILTER
FILTER COVER HUB
PLUNGER GUIDES
BOOSTER BODY BELLOWS RETAINER P U S H , R O D CUSHION RING
BELLOWS
BELLOWS
BODY RETAINING SCREWTAPPING CHANNEL
REACTION CONE
BELLOWS RETAINER RING
FIBER GASKET CONTROL VALVE PLUNGER
DIAPHRAGM (HUB-TO-PLUNGERASSEMBLY CUSHION RING)
> /
RUBBER REACTION RING
CONTROLREACTION LOAD RING yALVE HUB
* RETURNSPRING
O-RINGRETAINER / (HUB-TO-DIAPHRAGM)
REACTION LEVER AND ATMOSPHERIC VALVE,RING ASSEMBLY " BOOT
C-RING
HUB REAR SEAL ANDADAPTER ASSEMBLY
PUSH ROD LINK
OPERATING RODPLASTIC RETAINER
END PLATE BRACKET
FIG. 6—Booster Unit—Disassembled
BOOT
LEVER
H I 203-C
2-6
PART2-2
BRAKE SYSTEM
Sectioi Page
1 Description and Operation 2- 62 In-Car Adjustments and Repairs 2- 8
Sectioi Page
3 Removal and Installation 2-134 Major Repair Operations 2-16
DESCRIPTION AND OPERATIONHYDRAULIC SELF ADJUSTINGBRAKE SYSTEM
The hydraulic brake system em-ploys single anchor, internal ex-panding and self adjusting brakeassemblies.
The master cylinder convertsphysical force from the brake pedaland booster into hydraulic pressureagainst the pistons in the wheel cyl-inders. The wheel cylinder pistons,in turn, convert hydraulic pressureback into physical force at the brakeshoes.
The self-adjusting brake mech-anism consists of a cable, cable
guide, adjusting lever, and adjusterspring (Fig. 1). The cable is hookedover the anchor pin at the top andis connected to the lever at the bot-tom. The cable is connected to thesecondary brake shoe by means ofthe cable guide. The adjuster springis hooked to the primary brake shoeand to the lever. The automatic ad-juster operates only when the brakesare applied while the car is movingrearward and only when the sec-ondary shoe is free to move towardthe drum beyond a predeterminedpoint.
With the car moving rearwardand the brakes applied, the "wrap-
around" action of the shoes follow-ing the drum forces the upper endof the primary shoe against the an-chor pin. The action of the wheelcylinder moves the upper end of thesecondary shoe away from the an-chor pin. The movement of the sec-ondary shoe causes the cable to pullthe adjusting lever upward andagainst the end of a tooth on theadjusting screw star-wheel. The up-ward travel of the lever increases aslining wear increases. When thelever can move upward far enough,it passes over the end of the toothand engages the tooth. When thebrakes are released, the adjusting
PARKING BRAKE LEVERRETAINING CLIP
PARKING BRAKELINK
• ANCHOR PIN PLATE
•ANCHOR PIN
PRIMARY SHOE-TO-ANCHORSPRING
CABLE ANCHORFITTING
SECONDARYSHOE-TO-ANCHOR
SPRING SHOEHOLD-DOWN
SPRINGS
SECONDARYSHOE
SHOEHOLD-DOWN
SPRINGS
BRAKEPARKING
LEVER PARKING BRAKECABLE HOUSING
RETAINERPARKING
BRAKE CABLEAND HOUSING
AUTOMATIC ADJUSTERSPRING
PRIMARYSHOE
ADJUSTINGLEVER /
/SOCKET
' //
ADJUSTINGSCREW
FRONTBRAKE
PIVOT \NUT \
\AUTOMATIC ADJUSTER
SPRINGH1145-A
F I G . 1-Self-Adjusting Brake Assemblies
G R O U P 2-BRAKES 2-7
spring pulls the lever downwardcausing the starwheel to turn andexpand the shoes. The star-wheel isturned one tooth at a time as thelinings progressively wear.
With the car moving forward andthe brakes applied, the secondaryshoe is against the anchor pin andthe primary shoe is moved towardthe drum. Therefore, the adjusterdoes not operate.
The rear brake assembly is basic-ally the same as the front brake.The conventional parking brakelever, link, and spring are used inthe rear brake.
The anchor pins on all brakes arefixed and non-adjustable.
BOOSTER SYSTEM
The optional power brake boosteris installed on the engine side of thedash panel and is connected to thebrake pedal through a lever assem-bly and push rod link.
The booster consists of a vacuumchamber, atmospheric valve, controlvalve plunger assembly, diaphragm,and an atmospheric chamber (Figs.2, 3, and 4).
Atmospheric pressure is presentat all times in the atmosphericchamber at the front side of theatmospheric valve. The air intaketo the atmospheric chamber is pro-tected by an air filter. The atmos-pheric chamber is separated fromthe vacuum chamber by the bellowsassembly within the vacuum cham-ber.
Vacuum is present at all times inthat area of the vacuum chamberforward of the diaphragm. Vacuum
VACUUM SOURCE-
ATMOSPHERIC •SOURCE
VACUUMPORT OPEN
ATMOSPHERICSOURCE ^ j * * * ^ * * * ^
MASTERCYLINDER
wyLI
3_V_ 'un
I I I VACUUM
Wil ATMOSPHERIC PRESSURE
FIG. 3-Booster in Holding Position
is supplied through a hose from theintake manifold to the vacuum man-ifold and check valve on the boosterbody. With this integral check valveand vacuum chamber, it is possibleto obtain several power assistedbrake applications with the engineshut off. This arrangement makes avacuum reservoir unnecessary.
Either vacuum from the forwardside of the diaphragm or air fromthe bellows (atmospheric chamber)can be connected to the rear side ofthe diaphragm through porting inthe control valve hub and theplunger assembly.
APPLYING POSITION
As the brake pedal is depressed,the valve operating rod and valve
VACUUM PORTCLOSED
BRAKEPEDAL
BRAKE PEDAL
ATMOSPHERICPORT OPEN
VACUUM
ATMOSPHERIC PRESSURE
'7 v v
ATMOSPHERICPRESSURE
H1205-A
FIG. 2-Booster in Applied Position
H12O6-A
plunger assembly move forwardcompressing the plunger returnspring (Fig. 2). The initial move-ment of the plunger closes the port-ing from the vacuum chamberpreventing further evacuation of thearea back of the diaphragm. Furthermovement of the plunger forces theatmospheric valve off its seat so thatatmospheric pressure from the bel-lows can enter the hub porting thatleads to the rear side of the dia-phragm.
With vacuum on the front side ofthe diaphragm and atmosphericpressure on the back side of thediaphragm, a force is developed tomove the diaphragm, push rod andmaster cylinder piston forward toclose the compensating port andforce hydraulic fluid under pressurethrough the residual pressure checkvalve and brake tubes to the wheelbrakes. As hydraulic pressure isdeveloped in the hydraulic system,a reaction counter-force acts againstthe reaction lever and ring assem-bly. This reaction lever and ring as-sembly is designed to transmit thereaction forces back through theactuating control valve assembly tothe brake pedal and provide thedriver with a resistance that is inproportion to the brake hydraulicapply forces. This is the means ofproviding the proper "driver feel"to the power brake unit.
HOLDING POSITION
When the forward motion of thebrake pedal is stopped and held, thevalve operating rod ceases to move
2-8 P A R T 2 -2-BRAKE SYSTEM
VACUUM SOURCEBELLOWS
ATMOSPHERIC
SOURCE
MASTERCYLINDER
DIAPHRAGM
ATMOSPHERIC VALVE
VACUUM PORT OPEN
BRAKEPEDAL
£ ] VACUUM
[g] ATMOSPHERIC PRESSURE
F I G . 4—Booster in Released Position
the control valve plunger forward.However, the unbalanced forces ofatmospheric pressure and vacuum oneach side of the diaphragm will con-tinue to move the outer sleeve ofthe control valve plunger forwardkeeping the vacuum porting closed.At the same time, the reaction forceacting through the reaction ring andlever assembly will tend to move theatmospheric valve to the closed po-sition (Fig. 3). When these com-bined forces balance, the porting tothe vacuum supply will remainclosed and the atmospheric valvewill cut off any further passage ofatmospheric pressure to the area be-hind the diaphragm. Therefore, thepower assist force acting on the
VALVE HUB
H1207-A
master cylinder piston will stabilizeand the hydraulic force applying thebrakes will be maintained at a con-stant level.
RELEASED POSITIONWhen the pedal pressure is re-
leased from the valve operating rodand plunger assembly, the plungerreturn spring moves the plungeraway from the atmospheric valveallowing the valve to seat againstthe hub (Fig. 4). This seating of thevalve closes off the bellows chamberfrom the hub porting that connectsto the rear side of the diaphragm.At the same time, the rearwardmovement of the plunger opens theporting from the vacuum chamber
and draws out the air from the realside of the power diaphragm. Withvacuum on both sides of the dia-phragm, the assist force against themaster cylinder push rod is elimin-ated. The brake shoe retractingsprings will, therefore, cause the hy-draulic fluid to return the mastercylinder piston, push rod, controlvalve plunger assembly and the dia-phragm to the released position.
With the piston and push rod inthe released position, the hydrauliccompensating port in the mastercylinder is open. The open port per-mits fluid either to return from thebrake system to the fluid reservoir,or enter the brake system from thereservoir.
PARKING BRAKE
An independent foot-operatedparking brake control actuates therear wheel brake shoes through acable linkage. The operating cableis routed from the parking brakecontrol assembly to the equalizerlever which is attached to the equal-izer assembly. The rear brake cablesconnect the equalizer assembly tothe parking brake lever at each rearsecondary shoe (Fig. 1).
When the pedal is depressed thesecondary brake shoes are forcedagainst the rear brake drums. Thepedal is held in the applied positionby the engagement of a springloaded pawl with a ratchet. Pushingdown on the release handle disen-gages the pawl from the ratchet torelease the brakes.
IN-CAR ADJUSTMENTS AND REPAIRSBRAKE SHOE ADJUSTMENTS
The car should be raised with thewheels off the floor. If the car israised on a frame-contact hoist, dis-connect the parking brake cables toprevent the rear brakes from beingpartially applied due to rear axle andspring sag on the hoist.
The hydraulic service brakes areself-adjusting and require a manualadjustment only after the brakeshoes have been relined, replaced, orwhen the length of the adjustingscrew has been changed while per-forming some other service opera-tion.
The brake drums should be atnormal room temperature when ad-justing the brake shoes. If the shoesare adjusted when the drums arehot and expanded, the shoes may
drag when the drums are cool andcontracted.
1. After the shoes have been in-stalled or the adjusting screw hasbeen turned, install the drum. Besure that all excess grease, oil, andother foreign material are wiped offthe carrier plate and drum.
Before installing the brake drumon the front wheel spindle, wipe thespindle completely free of grease.Install the drum carefully so thatthe grease seal retainers within thehub will not be damaged.
2. Remove the adjusting holecover from the carrier plate and,from the carrier plate side, turn theadjusting screw upward to expandthe shoes (Fig. 5). Expand the shoesuntil a drag is felt when the drumis rotated.
3. Remove the drum. Mark thetooth on the star wheel where thelever contacts the adjusting screw.While holding the adjusting lever
Brake Shoe Adjusting Tool H I 1 22-A
FIG. 5-Expanding Brake Shoes
G R O U P 2-BRAKES 2-9
out of engagement with the adjust-ing screw, back off the adjustingscrew 3A of a turn with the fingers.If finger movement will not turn thescrew, free it up; otherwise, the self-adjusting lever will not turn thescrew. Lubricate the screw with athin uniform coating of Stanolube—HD Moly Grease-Grade 2.
Any other adjustment proceduremay cause damage to the adjustingscrew with consequent self adjusterproblems.
4. Apply a small quantity of high-temperature grease to the pointswhere the shoes contact the carrierplate, being careful not to get thelubricant on the linings. Install thedrum.
On a front wheel, install the wheelouter bearing, washer, and adjustingnut, then adjust the wheel bearingsas outlined in Part 3-4, Section 2.
On rear wheels, install the threeTinnerman nuts and tighten securely.
5. Install the wheel on the drumand tighten the mounting nuts tospecification.
6. Install the adjusting hole coveron the brake carrier plate.
7. When adjusting the rear brakeshoes, check the parking brakecables for proper adjustment. Makesure that the equalizer lever oper-ates freely.
8. After the brake shoes havebeen properly adjusted, check theoperation of the brakes.
FRONT BRAKE DRUMREMOVAL
1. Raise the car until the wheeland tire clear the floor. Remove thewheel cover or hub cap, and removethe wheel and tire assembly fromthe drum.
MOVE HANDLEUPWARDS
H1144-A
FIG. 6-Backing Off BrakeAdjustment
2. Insert a narrow screwdriverthrough the brake adjusting hole atthe inner side of the brake carrierplate, and disengage the adjustinglever from the adjusting screw.While holding the adjusting leveraway from the screw, back off theadjusting screw with the brake ad-justing tool (Fig. 6). Be very carefulnot to burr, chip, or damage thenotches in the adjusting screw;otherwise the self-adjusting mech-anism will not function properly.
3. Remove the grease cap fromthe hub. Remove the cotter pin, nutlock, adjusting nut, and flat washerfrom the spindle. Remove the outerbearing cone and roller assembly.
4. Pull the hub and drum as-sembly of the wheel spindle.
INSTALLATION1. If the drum is being replaced,
remove the protective coating fromthe new drum with carburetor de-greaser. Install new bearings andgrease retainer. Soak the new greaseretainer in light engine oil at least30 minutes before installation. Packthe wheel bearings, install the innerbearing cone and roller assembly inthe inner cup, and install the newgrease retainer. See Part 3-4, Sec-tion 4.
If the original drum is being in-stalled, make sure that the greasein the hub is clean and adequate.
2. Install the drum assembly andadjust the brakes as outlined under"Brake Shoe Adjustments" in thissection.
3. Install the outer wheel bearing,washer and adjusting nut.
4. Adjust the wheel bearing asoutlined Part 3-4, Section 2, theninstall the grease cap. Install thewheel and hub cap.
REAR BRAKE DRUMREMOVAL
1. Raise the car so that the wheelis clear of the floor.
2. Remove the hub cap andwheel. Remove the three Tinnermannuts and remove the brake drum.Insert a narrow screwdriver throughthe brake adjusting hole in the car-rier plate, and disengage the adjust-ing lever from the adjusting screw.While holding the adjusting leveraway from the adjusting screw, backoff the adjusting screw with thebrake adjusting tool (Fig 6). Be verycareful not to burr, chip, or damagethe notches in the adjusting screw;otherwise, the self-adjusting mech-anism will not function properly.
INSTALLATION1. Remove the protective coating
from a new drum with carburetordegreaser.
2. Place the drum over the brakeassembly and into position. Adjustthe brakes as outlined under "BrakeShoe Adjustments" in this section.
3. Install the three Tinnermannuts and tighten securely. Install thewheel on the axle shaft flange studsagainst the drum, and tighten theretaining nuts to specifications.
BRAKE SHOES ANDADJUSTING SCREW
REMOVAL1. With the wheel and drum re-
moved, install a clamp over theends of the brake cylinder as shownin Fig. 7.
2. Contract the shoes as follows:a. Disengage the adjusting lever
from the adjusting screw by pullingbackward on the adjusting lever(Fig. 1).
b. Move the outboard side of theadjusting screw upward and backoff the pivot nut as far as it will go.
3. Pull the adjusting lever, cableand automatic adjuster spring downand toward the rear to unhook thepivot hook from the large hole inthe secondary shoe web. Do not at-tempt to pry the pivot hook out ofthe hole.
4. Remove the automatic adjusterspring and adjusting lever (Fig. 1).
5. Remove the primary shoe toanchor spring with the tool shownin Fig. 7. With the same tool, re-move the secondary shoe to anchorspring and unhook the cable eyefrom the anchor pin.
6. Remove the anchor pin plate.7. Remove the cable guide from
the secondary shoe (Fig. 1).8. Remove the shoe hold-down
springs, shoes, adjusting screw, pivotnut, and socket.
Tool-2035-N or 2086-L
Tool-LM-119 H1146-B
FIG. 7—Retracting SpringRemoval
2-10 PART 2-2-BRAKE SYSTEM
Tool-2035-N or 2086-1
Tool-LM-119 H1147-B
F IG . 8—Retracting SpringInstallation
9. On rear brakes, remove theparking brake link and spring. Dis-connect the parking brake cablefrom the parking brake lever.
10. After removing the rear brakesecondary shoe, disassemble theparking brake lever from the shoeby removing the retaining clip andspring washer (Fig. 1).
INSTALLATION
1. Before installing the rear brakeshoes, assemble the parking brakelever to the secondary shoe andsecure with the spring washer andretaining clip.
2. Apply a light coating of high-temperature grease at the pointswhere the brake shoes contact thecarrier plate.
3. Position the brake shoes on thecarrier plate and secure the assem-bly with the hold down springs. Onthe rear brake, install the parkingbrake link and spring. Connect theparking brake cable to the parkingbrake lever (Fig. 1).
4. Install the anchor pin plate onthe anchor pin.
5. Place the cable eye over theanchor pin with the crimped sidetoward the carrier plate.
6. Install the secondary shoe toanchor spring (Fig. 8).
7. Install the cable guide on thesecondary shoe web with the flangedhole fitted into the hole in the sec-ondary shoe web. Thread the cablearound the cable guide groove(Fig. 1).
It is imperative that the cable bepositioned in this groove and notbetween the guide and the shoe web.
8. Install the primary shoe to an-chor spring with the tool shown inFig. 8.
Be certain that the cable eye isnot cocked or binding on the an-chor pin when installed. All partsshould be flat on the anchor phi.
Remove the brake cylinder clamp.9. Apply high-temperature grease
to the threads and the socket end ofthe adjusting screw. Turn the ad-justing screw into the adjusting pivotnut to the limit of the threads andthen back off Vi turn.
Interchanging the brake shoe ad-justing screw assemblies from oneside of the car to the other wouldcause the brake shoes to retractrather than expand each time theautomatic adjusting mechanism op-erated. To prevent installation on thewrong side of the car, the socket endof the adjusting screw is stampedwith an R or L (Fig. 9). The adjust-ing pivot nuts can be distinguished bythe number of grooves machinedaround the body of the nut. Twogrooves indicate a right hand nut;one groove indicates a left hand nut.
10. Place the adjusting socket onthe screw and install this assemblybetween the shoe ends with the ad-justing screw toothed wheel nearestthe secondary shoe.
11. Hook the cable hook into thehole in the adjusting lever. The ad-justing levers are stamped with anR or L to indicate their installationon a right or left hand brake as-sembly (Fig. 9).
12. Position the hooked end ofthe adjuster spring completely intothe large hole in the primary shoeweb. The last coil of the springshould be at the edge of the hole.Connect the loop end of the springto the adjuster lever hole.
13. Pull the adjuster lever, cableand automatic adjuster spring downand toward the rear to engage thepivot hook in the large hole in thesecondary shoe web (Fig. 1).
14. After installation, check theaction of the adjuster by pulling thesection of the cable between thecable guide and the adjusting levertoward the secondary shoe web farenough to lift the lever past a toothon the adjusting screw wheel. Thelever should snap into position be-hind the next tooth, and release ofthe cable should cause the adjusterspring to return the lever to its orig-inal position. This return action ofthe lever will turn the adjustingscrew one tooth.
If pulling the cable does not pro-duce the action described, or if thelever action is sluggish instead ofpositive and sharp, check the posi-tion of the lever on the adjustingscrew toothed wheel. With the brakein a vertical position (anchor at thetop), the lever should contact the
adjusting wheel %6 inch plus orminus %2 inch) above the centerlineof the screw. If the contact point isbelow this centerline, the lever willnot lock on the teeth in the adjust-ing screw wheel, and the screw willnot be turned as the lever is actu-ated by the cable.
To determine the cause of thiscondition:
a. Check the cable end fittings.The cable should completely fill orextend slightly beyond the crimpedsection of the fittings. If it does notmeet this specification, possible dam-age is indicated and the cable as-sembly should be replaced.
b. Check the cable length. Thecable should measure 11V& inches(plus or minus %4 inch) from theend of the cable anchor to the endof the cable hook.
c. Check the cable guide for dam-age. The cable groove should beparallel to the shoe web, and thebody of the guide should lie flatagainst the web. Replace the guideif it shows damage.
d. Check the pivot hook on thelever. The hook surfaces should besquare with the body of the leverfor proper pivoting. Replace thelever if the hook shows damage.
e. See that the adjusting screwsocket is properly seated in thenotch in the shoe web.
WHEEL CYLINDER REPAIRIt is not necessary to remove the
brake cylinder from the carrier plateto disassemble, inspect, or hone andoverhaul the cylinder. Removal isnecessary only when the cylinder isdamaged or scored beyond repair.
DISASSEMBLY1. Remove the links and the rub-
ber boots from the ends of the brakecylinder. Remove the pistons, cups,and return spring from the cylinderbore (Fig. 10).
ADJUSTING LEVER
ADJUSTING SCREW
IDENTIFICATION LINES H 1 1 4 3 - A
F I G . 9—Adjusting Screw andLever Identification
GROUP 2 - BRAKES 2-11
BOOT B O O T
CUP FRONT BRAKE CYLINDER CUP
BOOT BOOT
CUPREAR BRAKE CYLINDER CUP
HHOO-A
F IG . 10-Front and Rear Wheel Cylinders
2. Remove the bleeder screwfrom the cylinder.
INSPECTION1. Wash all parts in clean de-
natured alcohol. If alcohol is notavailable, use specified brake fluid.Dry with compressed air.
2. Check all internal parts forexcessive wear or damage. If any ofthe internal parts require replacing,all should be replaced.
3. Inspect the cylinder bore forscore marks or rust. If either con-dition is present, the cylinder boremust be honed. However, the cylin-der should not be honed more than0.003 inch beyond its original di-ameter.
4. Check the bleeder hole to besure that it is open.
ASSEMBLY1. Apply a coating of heavy-duty
brake fluid to all internal parts.2. Thread the bleeder screw into
the cylinder and tighten securely.3. Insert the return spring, cups,
and pistons into their respective po-sitions in the cylinder bore (Fig.10). Place a boot over each end ofthe cylinder. Bleed the brake system.
WHEEL CYLINDERREPLACEMENTREMOVAL
1. With the wheel in a raised po-sition, remove the wheel and thedrum.
2. Place a clamp over the endsof the brake cylinder as shown inFig. 7.
3. Remove the brake shoe assem-blies, following procedures outlinedin this section.
4. Disconnect the brake line fromthe brake cylinder. On a car witha vacuum brake booster, be surethe engine is stopped and there isno vacuum in the booster system be-fore disconnecting the hydrauliclines.
To disconnect the hose at a frontcylinder, loosen the tube fitting thatconnects the opposite end of thehose to the brake tube at a bracketon the frame. Remove the horse-shoe-type retaining clip from thehose and bracket, disengage thehose from the bracket, then un-screw the entire hose assembly fromthe front wheel cylinder.
At a rear cylinder, unscrew thetube fitting that connects the tubeto the cylinder. Do not pull the metaltube away from the cylinder. Pull-ing the tube out of the cylinder con-nection will bend the metal tube andmake installation difficult. The tubewill separate from the cylinder whenthe cylinder is removed from thecarrier plate.
5. On the rear wheel, remove thewheel cylinder retaining bolts andlock washers and remove the cylin-der. On the front wheel, remove thenut and washer that retains the cyl-inder to the anchor pin. Removethe cylinder from the anchor pin,and remove the clamp from the cyl-inder.
INSTALLATIONWipe the end(s) of the hydraulic
line to remove any foreign matterbefore making connections.
1. To install a front cylinder:a. Position the cylinder on the
anchor pin against the carrier plate.Install the washer and cylinder retain-ing nut on the anchor pin, and torqueto specification.
b. Install a new copper gasket overthe hose fitting. Screw the hose as-sembly into the cylinder.
c. Engage the opposite end of thehose to the bracket on the frame, in-stall the horseshoe-type retaining clip,and connect the brake tube to thehose with the tube fitting nut. Tightenthe nut to specification with tool1112-144.
2. To install a rear cylinder:a. Place the rear wheel cylinder
into position. Enter the tubing intothe cylinder, and start the tube fittingnut into the threads of the cylinder.
b. Secure the cylinder to the car-rier plate by installing the retainingbolts and lockwashers.
c. Tighten the tube fitting nut tospecification with tool 1112-144.
3. Install the links in the ends ofthe wheel cylinder, install the shoeand adjuster assemblies, and adjustthe shoes as outlined in this section.
4. Install the brake drum andwheel, adjust the brakes (Part 2-2,Section 2), and bleed the brakes asoutlined in Part 2-1, Section 2.
BRAKE CARRIER PLATEREPLACEMENT
REMOVAL1. Remove the wheel and brake
drum. Disconnect the brake linefrom the brake cylinder.
2. Remove the brake shoe andadjuster assemblies and the wheelcylinder as outlined in this section.On the rear wheels, disconnect theparking brake lever from the cable.
3. If the rear carrier plate is be-ing replaced, rotate the axle shaftso that the hole in the axle shaftflange lines up with the carrier plateretaining nuts and remove the nuts.Pull the axle shaft assembly out ofthe housing with tool-4235C and aslide hammer (Part 4-2), then re-move the carrier plate.
If the front carrier plate is beingreplaced, remove the bolts and nutsthat secure the plate to the frontwheel spindle and remove the plate.
2-12 PART 2-2-BRAKE SYSTEM
INSTALLATION1. Position a new rear carrier
plate on the retaining bolts in theaxle housing flange. Insert the axleshaft into the housing so that thesplines engage the differential sidegear with the bearing retainer slid-ing onto the retaining bolts andagainst the carrier plate. Install theretaining nuts through the accesshole in the axle shaft flange.
Position a new front carrier plateto the wheel spindle and install theretaining bolts and nuts.
2. Install the wheel cylinder andconnect the brake line as outlined inthis section.
3. Install the brake shoe and ad-juster assemblies as outlined in thissection. On a rear brake, connectthe parking brake cable to the lever.Install the brake drum and wheel.
4. Adjust the brake shoes (Sec-tion 2), and bleed the brake systemas outlined in Part 2-1, Section 2.
HYDRAULIC LINESSteel tubing is used throughout
the brake system with the exceptionof the flexible hoses at the frontwheels and at the rear axle housingbrake tube connector (Fig. 11).
Always bleed the entire systemafter any hose or line replacement.
BRAKE TUBE REPLACEMENT
If a section of the brake tubingbecomes damaged, the entire sectionshould be replaced with tubing ofthe same type, size, shape, andlength. Copper tubing should not beused in a hydraulic system. Whenbending brake tubing to fit under-body or rear axle contours, be care-ful not to kink or crack the tube.
All brake tubing should be flaredproperly to provide good leak-proofconnections. Clean the brake tubingby flushing with clean denaturedalcohol, before installation.
When connecting a tube to ahose, tube connector, or brake cyl-inder, tighten the tube fitting nut tospecified torque with Milbar tool1112-144 or equivalent.
BRAKE HOSE REPLACEMENT
A flexible brake hose should bereplaced if it shows signs of soften-ing, cracking, or other damage.
When installing a new front brakehose, position the hose to avoid con-tact with other chassis parts. Placea new copper gasket over the hosefitting and screw the hose assemblyinto the front brake cylinder. En-gage the opposite end of the hose tothe bracket on the frame. Install thehorseshoe-type retaining clip, andconnect the tube to the hose withthe tube fitting nut. (Fig. 11).
A rear brake hose should be in-stalled so that it does not touch themuffler outlet pipe or shock ab-sorber.
Place a new gasket over the rearhose fitting and screw the hose as-sembly into the rear brake tube con-nector. Engage the front end of thehose to the bracket on the frame.Install the horseshoe-type retainingclip, and connect the tube to thehose with the tube fitting nut.
REAR TUBE TO LEFT ̂ CYLINDERCONNECTOR
FRONT HOSE
H 1 2 9 8 - A
F I G . 11 -Service Brake System
G R O U P 2-BRAKES 2-13
REMOVAL AND INSTALLATIONMASTER CYLINDER-STANDARD BRAKESREMOVAL
1. Disconnect the rubber bootfrom the rear end of the master cyl-inder in the passenger compartment.
2. Disconnect the brake line fromthe master cylinder. Disconnect thestop light switch wires from theswitch (Fig. 12).
3. Remove the bolts that securethe master cylinder to the dashpanel and lift the cylinder out andaway from the push rod. Removethe rubber boot from the push rod.
INSTALLATION1. With the rubber boot on the
push rod, guide the master cylinderover the end of the push rod, andposition the cylinder against thedash panel.
2. Install and torque the mount-ing bolts to specification.
3. Connect the brake line to themaster cylinder fitting, but leave thebrake line fitting loose.
4. Fill the master cylinder reser-voir with heavy-duty brake fluid towithin VA inch of the top. Installand tighten the filler cap.
5. Bleed the master cylinder to letair escape from the cylinder at thebrake line fitting. Then tighten thefitting.
6. Remove the filler cap and fillthe reservoir to the level specified.Install the cap and wipe off any fluidfrom the cylinder.
BRAKE MASTER CYLINDER
STOPLIGHT SWITCH H 1 1 1 6 - A
F I G . 1 2-Brake Master CylinderInstalled
7. Connect the wires to the stoplight switch and the rubber boot tothe master cylinder.
MASTER CYLINDER-POWER BRAKESREMOVAL
1. Remove the hydraulic line out-let fitting from the master cylinder.
2. Disconnect the stop lightswitch wires. It is not necessary toremove the stop light switch.
3. Remove the retaining nuts,lockwashers, and the master cylin-der from the booster unit (Fig. 14).
4. Remove the rubber seal fromthe outer groove at the end of themaster cylinder.
INSTALLATION1. Before installing the master
cylinder, check the distance fromthe outer end of the push rod to themaster cylinder mounting surface atthe end of the vacuum cylinder (Fig.4, Part 2-1). If the push rod dimen-sion is not correct, see "Master Cyl-inder Push Rod Adjustment," Part2-1, Section 2.
2. When the push rod adjustmentis correct, replace the rubber seal inthe groove at the end of the mastercylinder.
3. Position the master cylinderover the push rod onto the two studsthat are integral with the boosterbody.
4. Install the attaching nuts andlockwashers and torque the nuts tospecifications.
5. Replace the stop light switchwires.
6. Install the master cylinder hy-draulic line outlet fitting.
7. Bleed the brake system. Fillthe master cylinder within lA inchfrom the top of the filler opening.Install the filler cap and gasket.
BOOSTER UNITREMOVAL
1. Working inside the car belowthe instrument panel, disconnect thebooster push rod link from thebrake pedal assembly. To do this,remove the C-washer (retaining clip)and slide the push rod link andbushings off the pin that is integralwith the pedal (Fig. 13). Removethe push rod link boot.
2. Open the hood and disconnectthe wires and retaining clip fromthe stop light switch at the brakemaster cylinder (Fig. 14).
3. Disconnect the brake line at
BOOSTER PUSHROD LINK
C-WASHER
BUSHINGSH1305-A
F IG . 13-Booster-to-PedalConnections
the master cylinder outlet fitting.4. Disconnect the manifold vac-
uum hose from the booster unit.Disconnect the transmission vacuumthrottle valve hose, if the car is soequipped.
5. Remove the four bracket-to-dash panel retaining nuts and wash-ers (Fig. 14). Remove the boosterand bracket assembly from the dashpanel, sliding the push rod link outfrom the engine side of the dashpanel.
INSTALLATION1. Mount the booster and bracket
assembly to the dash panel by slid-ing the bracket holes on the mount-ing studs and the push rod link inthrough the hole in the dash panel.Install the bracket-to-dash panel re-taining nuts and washers (Fig. 14).
2. Connect the manifold vacuumhose to the booster. Connect thetransmission vacuum throttle valvehose, if so equipped.
3. Connect the brake line to themaster cylinder outlet fitting andconnect the wires and retaining clipto the stop light switch and brakebooster.
4. Working inside the car belowthe instrument panel, install push rod
OUTLET BRACKET-TO-DASHFITTING VACUUAA HOSE PANEL NUTS
BOOSTER-TO-BRACKET NUTS
HI 304-A
FIG. 14-Master Cylinder andBooster Installation
2-14 PART 2 - 2 - BRAKE SYSTEM
link boot, and connect the boosterpush rod link to the brake pedalassembly. To do this, lubricate thebushings with specified lubricant andinstall the bushings and the push rodlink onto the pin that is integral withthe pedal (Fig. 13). Secure the linkto the pin with a C-washer.
5. Bleed the brake system.
BRAKE PEDAL—MANUALSHIFT TRANSMISSIONREMOVAL
1. Back off the clutch pedal assistspring adjusting nut to the last fewthreads (Fig. 15).
2. Disconnect the clutch pedal-to-equalizer rod at the clutch pedalby removing the hairpin type retain-er and bushing.
3. Remove the clutch pedalbumper bracket from the pedal sup-port bracket. Remove the assistspring adjusting nut, and disconnectthe retainer and spring from thepedal support bracket.
4. Remove the C-washer and ny-lon bushings (Fig. 16), and discon-nect the master cylinder push rodfrom the brake pedal assembly.
5. Remove the hairpin type re-tainer and spring washer from theclutch and brake pedal shaft, thenremove the clutch pedal and shaftassembly, the brake pedal assembly,and the bushings from the pedal sup-port bracket (Fig. 16).
INSTALLATION1. Apply a coating of Lubriplate
to the bushings and locate all bush-ings in their proper places on theclutch and brake pedal assemblies.
2. Position the brake pedal to thesupport bracket, then install theclutch pedal and shaft assemblythrough the support bracket andbrake pedal assembly. Install thespring washer and retainer (Fig. 16).
3. Hook the clutch assist springto its retainer, and connect the re-tainer to the pedal support bracketwith the adjusting nut (Fig. 15).
4. Mount the clutch pedal bump-er bracket to the pedal supportbracket (Fig. 15). Adjust the bump-er for clutch total travel.
5. Connect the clutch pedal-to-equalizer rod to the clutch pedal as-sembly with the bushing and hairpinretainer. Apply Lubriplate to thebushing. Adjust clutch pedal freeplay to specification by lengtheningor shortening the rod at the equal-izer.
6. Adjust the clutch lever assistspring to the dimension shown in
SPRING ADJUSTING NUT
CLUTCH PEDAL-TO-EQUALIZER ROD
'EQUALIZER
FIG. 1 5-Clutch and Brake Pedal Assembly
BUMPER BRACKET
ROD-TO- PEDALRETAINER
CLUTCH PEDAL ANDSHAFT ASSEMBLY
HI 302-A
Fig. 15 by loosening or tighteningthe adjusting nut on the retainer atthe pedal support bracket.
7. Connect the master cylinderpush rod to the brake pedal assem-bly with a C-washer and nylonbushings (Fig. 16). Apply Lubriplateto the bushings.
BRAKE PEDAL—AUTOMATICTRANSMISSION
REMOVAL1. Remove the C-washer and ny-
lon bushings, and disconnect themaster cylinder push rod from thebrake pedal assembly (Fig. 16).
2. Remove the hairpin type re-tainer and spring washer from thebrake pedal shaft, then remove theshaft, the brake pedal assembly andthe bushings from the pedal supportbracket.
PEDAL SHAFT RETAINER
INSTALLATION1. Apply a coating of Lubriplate
to the bushings and locate all thebushings in their proper places onthe pedal assembly and pedal sup-port bracket (Fig. 16).
2. Position the brake pedal as-sembly to the support bracket, theninstall the pedal shaft through thesupport bracket and brake pedal as-sembly. Install the spring washerand retainer.
3. Connect the master cylinderpush rod to the brake pedal assem-bly with a C-washer and nylon bush-ings (Fig. 16).
PARKING BRAKEPEDAL ASSEMBLYREMOVAL
1. Remove the bolts that retainthe parking brake control assemblyto the dash side panel.
SPRING WASHER
BRAKE PEDAL SHAFT(AUTOMATIC
TRANSMISSION)
CLUTCH PEDALAND SHAFT
ASSEMBLY(MANUAL SHIFTTRANSMISSION)
C-WASHER
MASTER CYLINDER PUSH ROD
BRAKE PEDAL ASSEMBLY'
FIG. 16—Brake Pedal Removal and Installation
H1303-A
G R O U P 2-BRAKES 2-15
CABLE HOUSINGTRANSMISSION SUPPORT CROSS-MEMBER
EQUALIZER-TO-REARWHEEL CABLES
CABLE HOUSINGRETAINING CLIP
F IG . 17—Parking Brake System
2. Remove the U-clip that re-tains the cable housing to the park-ing brake control housing (Fig. 17).
3. Remove the hairpin retainerand clevis pin from the clevis. Dis-engage the clevis from the ball endof the cable, then remove the con-trol assembly from the cable andhousing.
INSTALLATION1. Insert the parking brake cable
and housing through the hole in thecontrol housing and install the U-clip (Fig. 17).
2. Install the clevis over the ballon the end of the cable, and attachthe clevis to the actuating arm byinserting the clevis pin. The head ofthe clevis pin must be assembled onthe slotted side of the clevis asshown in Fig. 17. Secure the clevisby installing the hair pin retainer.
3. Position the parking brakecontrol assembly to the dash sidepanel and secure with retainingbolts.
4. Check the adjustment and op-eration of the parking brake system.
TAPE MARKERX HAIRPIN RETAINER
I CLEVIS
U-CLIP
CABLE HOUSING END
CLEVIS PIN
CONTROL HOUSING
H I 3 0 6 - A
PARKING BRAKE EQUALIZERTO CONTROL CABLE
REMOVAL1. Raise the car on a hoist. Move
the parking brake equalizer leverforward far enough to permit re-moval of the half moon-type adjust-ing nut, then remove the adjustingnut from the end of the cable (Fig.2, Part 2-1).
2. Remove the hairpin retainerfrom the cable housing at the trans-mission rear support crossmember.Remove the cable spring and seat(Fig. 17).
3. Remove the attaching screwsand the two cable housing retainingclips at the underside of the floorpan (one retaining clip at each sideof the frame side rail).
4. Pull the cable through thecross member and over the frameside rail, then lower the car.
5. Working inside the car, pullback the upper left hand corner ofthe floor mat. Remove the retainingbolts and the parking brake controlassembly from the dash side panel.
6. Remove the U-clip that retainsthe cable housing to the parkingbrake control housing (Fig. 17).
7. Remove the hairpin retainerand clevis pin from the clevis. Ro-tate and remove the clevis, then re-move the cable and housing fromthe control assembly.
8. Push the parking brake cableand grommet down through thefloor pan.
INSTALLATION1. Guide the lower end of the
replacement cable and grommetdown through the floor pan.
2. Position the upper end of thecable into the control housing as-sembly, and secure the cable hous-ing with the U-clip (Fig. 17).
3. Install the clevis over the ballon the end of the cable, and attachthe clevis to the actuating arm byinserting the clevis pin. The headof the clevis pin must be assembledon the slotted side of the clevis asshown. Secure the clevis by install-ing the hair pin retainer.
4. Position the parking brake
2-16 PART 2-2-BRAKE SYSTEM
control assembly to the dash sidepanel and secure with the retainingbolts.
5. Raise the car on a hoist. Routethe cable over the frame side railand through the cross member.
6. Secure the cable housing to theframe side rail by installing two re-taining clips, one on each side of theside rail. Position the cable assem-bly so that the tape marker is lo-cated at the in-board clip.
7. Secure the cable housing to therear side of the transmission rearsupport cross member by installingthe hairpin retainer (Fig. 17). Installthe spring seat and cable spring onthe cable.
8. Assemble the rear end of thecable to the equalizer lever, and in-stall the half moon-type adjustingnut on the end of the cable.
9. Adjust the parking brake link-age as outlined in Part 2-1, Section2, and check the operation.
PARKING BRAKE EQUALIZERTO REAR WHEEL CABLEREMOVAL
1. Raise the car and remove thehub cap and wheel.
2. Remove the three Tinnermannuts that hold the brake drum inplace, back off the brake shoes, andremove the drum.
3. Loosen the lock nut on theequalizer rod, and disconnect thecable from the equalizer (Fig. 2,Part 2-1).
4. Remove the hair pin retainerthat holds the cable housing to theframe bracket and pull the cable andhousing out of the bracket (Fig. 17).
5. Working on the wheel side(Fig. 1), compress the prongs on thecable retainer so that they can passthrough the hole in the carrier plate.Draw the cable retainer out of thehole.
6. With the spring tension off theparking brake lever, lift the cableout of the slot in the lever and re-move through the carrier plate hole.
INSTALLATION1. Pull enough of the cable
through the housing so that the endof the cable may be inserted overthe slot in the parking brake lever(Fig. 1).
2. Pulling the excess slack fromthe cable, insert the cable housinginto the carrier plate access hole sothat the retainer prongs expand.
3. Thread the front end of thecable housing through the framebracket and install the hair pin re-tainer (Fig. 17).
4. Insert the ball end of the cableinto the equalizer and tighten thelock nut on the equalizer end slight-ly (Fig. 2, Part 2-1).
5. Install the rear drum. Tightenthe three Tinnerman nuts that retainthe drum, and install the wheel andhub cap.
6. Adjust the rear brake shoes asoutlined in Section 2. Adjust theparking brake linkage as outlined inPart 2-1, Section 2.
MAJOR REPAIR OPERATIONSBRAKE DRUM REFINISHING
Minor scores on a brake drumcan be removed with a fine emerycloth. A drum that is excessivelyscored or shows a total indicatorrunout of over 0.007 inch should beturned down. Remove only enoughstock to eliminate the scores andtrue up the drum. The refinisheddiameter must not exceed 0.060inch oversize (11.090 inches).
If the drum diameter is less than0.030 inch oversize (11.060 inches)after refinishing, standard liningmay be installed. If the drum diame-ter is 11.060-11.090 inches, oversizelinings must be installed.
After a drum is turned down,wipe the refinished surface with acloth soaked in clean denatured al-cohol. If one drum is turned down,the opposite drum on the same axleshould also be cut down to the samesize.
BRAKE SHOE RELINING
Brake linings that are worn towithin %2 inch of the rivet or havebeen saturated with grease or oilshould be replaced. Failure to re-place worn linings will result in ascored drum. When it is necessaryto replace linings, they must also bereplaced on the wheel on the oppo-side of the car.
Inspect brake shoes for distortion,
cracks, or looseness. If this condi-tion exists, the shoe should be dis-carded. Do not repair a defectivebrake shoe.
1. Wash the brake shoes thor-oughly in a clean solvent. Removeall burrs or rough spots from theshoes.
2. Check the inside diameter ofthe brake drum. If the diameter isless than 11.060 inches, standard lin-ing may be installed. If the diameteris 11.060-11.090 inches, oversizelining should be installed.
3. Position the new lining on theshoe. Starting in the center, insertand secure the rivets, working alter-nately towards each end. Install allparts supplied in the kit. Replace-ment linings are ground and nofurther grinding is required.
4. Check the clearance betweenthe shoe and lining. The lining mustseat tightly against the shoe with notmore than 0.005-inch clearance be-tween any two rivets.
MASTER CYLINDERDISASSEMBLY
1. Clean the outside of the cylin-der, and remove the filler cap andgasket. Pour out any brake fluid thatmay remain in the cylinder or res-ervoir.
2. Remove the stop light switchand the brake line fitting from the
forward end of the cylinder (Figs.18 and 19).
3. Remove the snap ring fromthe bore at the rear of the cylinderwith tool 33621 (Fig. 20).
4. When disassembling a mastercylinder used with the standardbrake system, remove the piston as-sembly, cup, spring, check valve,and valve seat from the cylinderbore (Fig. 18).
When disassembling a master cyl-inder used with a booster, removethe piston assembly, cup, and thespring and check valve assemblyfrom the cylinder bore. Remove theO-ring from the piston (Fig. 19).
CLEANING, INSPECTION,AND REPAIR
1. Clean all master cylinder partsin clean denatured alcohol, and in-spect the parts for wear or damage,replacing them as required. Whenusing a master cylinder repair kit,install all of the parts supplied.
2. Check the ports and vents inthe master cylinder to make surethat all are open and free of foreignmatter.
3. A leaf-type valve is riveted tothe front end of the piston in amaster cylinder used with the stand-ard brake system (Fig. 18). If thisvalve is loose or has moved so thatthe piston ports are open, replacethe piston.
G R O U P 2-BRAKES 2-17
PUSH ROD
STOP LIGHTSWITCH
SNAP RING
SNAP RING PLIERS
SECONDARYCUP
PISTON
BOLTOUTLET CHECK
VALVE H1233-A
F I G . 1 8-Master Cylinder with Standard Brake System
When inspecting a master cylin-der used with a booster, check theports in the piston to make surethat they are open and free of for-eign material (Fig. 19).
4. Inspect the cylinder walls forscores or rust, and recondition themif necessary. Hone the cylinder wallsno more than necessary (0.003 inchmaximum). Oversize pistons andcups are not available for excessivelyhoned cylinders.
5. Remove any burrs or loosemetal that may have resulted fromthe honing operation, and clean thecylinder with denatured alcohol.
ASSEMBLY1. Dip all parts except the master
cylinder body in clean FoMoCoheavy-duty brake fluid.
2. Install the brake line fittingand the stop light switch on the cyl-
FILLER CAP
inder and tighten them securely.3. When assembling a master cyl-
inder used with the standard brakesystem, install the valve seat, checkvalve, spring, cup, and piston assem-bly in the cylinder bore (Fig. 18).
When assembling a master cylin-der used with a booster, install theO-ring on the piston. Install thespring and check valve assembly,cup, and piston in the cylinder bore(Fig. 19).
4. Install the snap ring in theback of the bore (Fig. 20).
DISASSEMBLY OF BOOSTERREMOVAL OF EXTERNALPARTS
1. Remove the two attaching nutsand lockwashers, and separate themaster cylinder from the boosterbody.
2. Remove the filter cover and
O-RING
WASHER
NUT•STOP LIGHT SWITCH
FIG. 19-Master Cylinder with Booster
HI 2 79-A
H1291-A
FIG. 20—Removing Snap Ringfrom Master Cylinder
hub and the air filter from the boost-er body (Fig. 6, Part 2-1).
3. Remove the vacuum manifoldand check valve assembly and therubber grommet from the boosterbody (Fig. 6, Part 2-1).
4. Disconnect the valve operatingrod from the lever assembly by re-moving the retainer clip and con-necting pin (Fig. 6, Part 2-1).
5. Disconnect the lever assemblyfrom the end plate brackets by re-moving the retainer clip and pivotpin.
6. Remove the retaining nuts, anddisassemble the brackets from theend plate.
7. Remove the rubber boot fromthe valve operating rod.
SEPARATION OFMAJOR COMPONENTS
1. Remove the large C-ring thatretains the rear seal adapter assem-bly to the booster end plate (Fig. 6,Part 2-1).
2. Scribe a line across the boosterbody and end plate to facilitateproper alignment at reassembly. Re-move the booster body-to-end plateretaining screws, tap the outside ofthe end plate with a fibre hammer,and separate the end plate from thebooster body, leaving the rear sealand adapter assembly on the controlvalve hub.
3. Push the bellows assembly intothe vacuum chamber (Fig. 21), andseparate the bellows, control valve,and diaphragm assembly from thebooster body.
4. Remove the outer O-ring fromthe rear seal adapter assembly (Fig.6, Part 2-1).
DISASSEMBLY OF BELLOWS,PUSH ROD AND VALVEASSEMBLY FROM DIAPHRAGM
1. Remove the large bellows re-taining ring, bellows, bellows retain-er and support ring from the dia-phragm and valve assembly (Fig. 22).
2. Remove the retainer and sup-port ring from the bellows (Fig. 6,Part 2-1).
2-18 PART 2-2-BRAKE SYSTEM
PLUNGER GUIDES
H1199-A
F IG . 21-Separation of Bellows,Control Valve, and DiaphragmAssembly from Booster Body
3. Remove the push rod assem-bly, the reaction lever and ring fromthe control valve hub (Fig. 23).
4. Remove the retainer, the cush-ion ring and the reaction cone fromthe push rod assembly, and disassem-ble the reaction levers from the rings(Fig. 23). Also see Fig. 6, Part 2-1.
5. Remove the 2 plastic plungerguides from the control valve plung-er, then remove the retainer thatholds the reaction load ring, returnspring, and atmospheric valve to thecontrol valve hub (Fig. 23).
6. Slide the reaction load ring,the return spring and the atmos-pheric valve from the control valvehub (Figs. 23 and 24).
7. Separate the control valve huband the control valve plunger assem-bly from the diaphragm by slidingthe valve plunger and rear sealadapter from the rear of the valvehub (Fig. 24). Remove the hub outerO-ring from the front side of thediaphragm.
BELLOWS
CONTROL VALVE HUB
RUBBER REACTION RING
REACTION LEVERAND RING ASSEMBLY
DIAPHRAGM ASSEMBLYPUSH ROD ASSEMBLY f "***» -X̂ |
{ RETAINER
1 ; H1201-A
FIG. 23-Assembly of Reaction Components and Push Rod to Valve Hub
DISASSEMBLY OF CONTROLVALVE PLUNGER
1. Remove the hub rear sealadapter from the valve plunger as-sembly, and remove the seal fromthe adapter.
2. Remove the O-rings, the seal,and the fibre gasket from the valveplunger (Fig. 25).
3. Do not remove the valve oper-ating rod from the control valveplunger unless the plunger assemblyor the rod is to be replaced. To re-move, hold the rod firmly and forcethe plunger off the rod, breaking the
REAR SEAL ADAPTER
CONTROL VALVE PLUNGERASSEMBLY
CONTROL VALVE HUB
plastic retainer. Remove all thebroken pieces of the plastic retainerfrom the groove in the plunger, ifthe plunger is to be used again witha replacement rod.
ASSEMBLY OF BOOSTER
ASSEMBLY OF CONTROLVALVE PLUNGER
1. If the valve operating rod wasremoved from the plunger, assemblea new plastic retainer to the end ofthe rod (Fig. 6, Part 2-1). Insert therod into the plunger so that the re-tainer engages the groove in the
!̂f RETAINING RING HI200-A
F I G . 2 2 -Be I lows Removal orInstallation
H1202-BFIG. 24—Disassembly of Control Valve Components from Diaphragm
G R O U P 2-BRAKES 2-19
FIBER GASKET
ROD
'O-RINGS
PLUNGER
PLUNGER SEAL
H1234-A
F I G . 25—Valve Operating Rodand Plunger Assembly
plunger.2. Install the fibre gasket, the
plunger seal, and the O-rings to thevalve plunger assembly (Fig. 25).
ASSEMBLY OF VALVEASSEMBLY, PUSH ROD, ANDBELLOWS TO DIAPHRAGM
1. Insert the control valve plung-er into the control valve hub fromthe rear of the hub (Fig. 26).
2. Assemble the atmosphericvalve, the return spring and the re-action load ring to the valve plungerand hub.
3. Push the control valve plung-er assembly forward and the reac-tion load ring backward against thereturn spring in order to install theretainer in the groove of theplunger.
4. Install the O-ring in the grooveon the outer circumference of thevalve hub. Assemble the valveplunger and hub assembly to thediaphragm so that the operating rodand the small-diameter end of thehub enter the front side of the dia-phragm and protrude from the rearside.
5. Install the two plastic plungerguides in their grooves on the valveplunger assembly (Fig. 23).
6. Install the rubber reaction ringin the valve hub so that the ringlocating knob indexes in the notch
REACTION LOAD RING
ATMOSPHERICVALVE
\ ^RETURN SPRING^RETAINER
CONTROL VALVE HUB
H1235-B
F I G . 26—Assembly of ControlValve Components to Valve Hub
in the hub (Fig. 26), with the ringtips toward the front (Fig. 23).
7. Assemble the reaction leverand ring assembly, then install theassembly in the valve hub (Fig. 23).
8. Assemble the reaction coneand cushion ring to the push rod,and secure to the rod with the re-tainer (Fig. 6, Part 2-1). Install thepush rod assembly to the valve hubso that the valve plunger indexes inthe push rod (Fig. 23).
9. Assemble the bellows, retainer,and support ring (Fig. 6, Part 2-1).The support ring is positioned onthe middle fold of the bellows.
10. Position the bellows assemblyand secure it to the diaphragm byinstalling the retaining ring (Fig.22). Make sure that the retainingring is fully seated.
ASSEMBLY OF MAJORCOMPONENTS
1. With a screw driver, slightlymove the booster body retainingscrew tapping channel in order toprovide a new surface for the self-tapping attaching screws (Fig. 6,Part 2-1).
2. Install the diaphragm, the con-trol valve components, and the bel-lows as an assembly to the boosterbody. Make sure that the lip of thediaphragm is evenly positioned onthe retaining radius of the boosterbody.
3. Install the O-ring in the frontside of the end plate.
4. Install the valve hub rear sealin the adapter assembly with thesealing lip toward the rear, then in-stall the adapter assembly into thefront side of the end plate with thesmall diameter end of the adapterprotruding from the rear side of theend plate (Fig. 27).
5. Install the large C-ring to therear seal adapter at the rear side ofthe end plate (Fig. 27).
6. Position the end plate to thebooster body. Align the scribe lines,compress the two assemblies to-gether with a clamp, then install theattaching screws.
7. Pull the front lip of the bel-lows through the booster body, andposition it around the outer grooveof the booster body (Fig. 27).
8. Adjust the push rod as out-lined in Part 2-1, Section 2.
INSTALLATION OFEXTERNAL PARTS
1. Install the rubber boot to thevalve operating rod (Fig. 6, Part2-1).
2. Position the mounting bracketsto the end plate, and install the re-taining nuts.
3. Connect the lever assembly tothe lower end of the mountingbrackets with the pivot pin. Installthe retainer clip.
4. Connect the valve operatingrod to the upper end of the leverwith the connecting pin and clip.
5. Install the rubber grommet inthe vacuum port in the boosterbody. The large diameter side of thegrommet should be to the outside ofthe booster. Force the vacuum man-ifold and check valve assemblythrough the grommet. Do not pushthe grommet into the vacuum cham-ber.
6. Install the following parts tothe booster body in the order indi-cated: first the air filter; then the fil-ter cover and hub; and finally thebrake master cylinder. Torque themaster cylinder mounting nuts tospecification.
HUB REAR SEAL
END PLATE-FRONT SIDE
C-RING
END PLATE-REAR SIDE
H1236-A
F IG . 27-lnstallation of HubRear Seal and Adapter Assembly
2-20
PART2-3 SPECIFICATIONS
DIMENSIONS—INCHES
Model
Sedan
Station Wagon,Police Interceptor,and Taxi
Front
Rear
Front
Rear
DrumInsideDiam-eter
11.030
DrumMaximum
BoringLimit
11.090
Lining Length
Primary
9.34
Second-ary
12.12
Lining Width
Primary
2V2
3
IVi
Second-ary
2V2
3
IVi
WheelCylinder
BoreDiameter
P/32
%*
P/32
15/l6 %*
Master CylinderBore Diameter
Standard 1.000
Power 0.875
*For Taxi, (Max. Wear) only
BRAKE CHECKS AND ADJUSTMENTS
Type of Check or Adjustment
Brake Shoe Repair
Master Cylinder
Power Unit
Drum Out of Round
Self Adjustment Cable Length
Specification
Drum Diameter Brake Lining Required
11.030-11.060 inch Standard
11.060-11.090 inch Oversize
Maximum Brake Lining Clearance (Midway between Rivets)—0.005 inch
Maximum Lining Wear Limit (From Top of Rivets)—Vk inch
Hydraulic Master Cylinder Bore Maximum Honed Diameter (1.003 inch stand.) (0.878 Power)
Push-Rod Adjustment—0.995-1.005 inch
Refinish if Total Indicator Run-Out Exceeds 0.007 inch
End of Cable Anchor to End of Cable H o o k - l i f t inch ± Vu
TORQUE LIMITS
Description
Master Cylinder-To-Pedal Support Bracket
Pedal Pad to Brake Pedal Nut
Control Assembly-Parking Brake to Cowl Side Bolt
Master Cylinder Fitting
Left Hand Brake Hose—Front to Connector Bolt
Wheel Cylinder Bleeder Screw
Master Cylinder Stop Light Switch
Vacuum Connector at Engine Manifold
Foot-Pounds
20-25
12-16
15-19
6-12
12-18
120 in-lbsMaximum
6-12
20-28
FRONT BRAKES
Carrier Plate and Cylinder Assembly Brake Shoe AnchorPin Nut
Anchor Pin to Spindle Bolt
Wheel Assembly to Hub and Drum Assembly Nuts
Front Brake Carrier Plate to Spindle Nut
20-30
80-106
75-110
25-45
TORQUE LIMITS (Cont.)
REAR BRAKES
Description
Drum Assembly to Axle Shaft Assembly Speednut
Wheel Assembly to Axle Shaft to Drum Assembly Nuts
Brake Cylinder to Brake Carrier Plate Bolt
Brake Carrier Plate to Axle Housing
Foot-Pounds
HandPush Fit
75-110
10-20
30-40*
POWER BRAKES
Master Cylinder to Booster Body
Brake Booster to Pedal Support Bracket
10-13
15-25
"Models 59, 71 RPO Heavy Duty—55-65 Foot Pounds
3-1
SUSPENSION, STEERINGWHEELS AND TIRES
GROUP3
PART 3-1 PageSUSPENSION, STEERING, WHEELS
AND TIRES GENERAL SERVICE 3-1
PART 3-2SUSPENSION 3 -8
PART 3-3MANUAL STEERING 3-16
PART 3-4 PagePOWER STEERING 3-26
PART 3-5WHEELS AND TIRES 3-35
PART 3-6SPECIFICATIONS 3-39
PART3-1
SUSPENSION, STEERING, WHEELSAND TIRES GENERAL SERVICE
Section Page1 Diagnosis and Testing 3-12 Common Adjustments and Repairs 3-4
Section3 Cleaning and Inspection
Page. .3-7
DIAGNOSIS AND TESTING
MANUAL STEERING
Table 1 lists various steering trou-ble symptoms and possible causes.Several of these symptoms are alsocommon to suspension, frame, andwheel and tire troubles. For this rea-son, be sure that the cause of thetrouble is in the steering gear or link-age before adjusting, repairing, or re-placing any of the steering parts.
POWER STEERING
PRELIMINARY TESTSThe following preliminary checks
should always be made before per-forming any trouble-shooting opera-tions.
Check Pump Belt. If the pump beltis broken, glazed, or worn, replace itwith a new belt. Use only the specifiedtype of belt.
Check the belt tension. If the belt istoo loose or too tight, it should beadjusted to the proper tension. Thefollowing procedure is for necessaryadjustment.
Do not try to increase belt ten-sion pulling on the reservoir.
In the following procedure, a "usedbelt" is one that has run ten min-utes or longer.
1. Check the power steering belttension, using tool T62L-8620-A. SeePart 3-6 for specified tension on newand on used belts.
2. If necessary, loosen the powersteering pump bracket adjusting boltand the pivot bolt.
3. Increase or decrease tension asrequired by adjusting the pump posi-tion.
4. Torque the adjusting bolt andthe pivot bolt to specification, andcheck the power steering belt tension.
Check Fluid Level. Start the en-gine, turn the steering wheel all theway to the left and right several times,and shut off the engine.
Check the fluid level in the reser-voir. If the level is low, add enoughfluid (Part 3-4) to raise the level to apoint VA inch from the top or to theF mark on the dip stick. Do notoverfill the reservoir.
Check for Fluid Leaks1. If the power steering fluid does
not already include yellowish greendye, pre-mix one teaspoonful of oil-soluble aniline dye with 2 pints ofautomatic transmission fluid. Then re-fill the reservoir with the dye solution.
2. With the engine running at idle
speed, turn the steering wheel fromstop to stop several times to distributethe dye solution throughout the hy-draulic system. Do not hold the wheelagainst each wheel stop more than 3seconds. "
3. Shut off the engine, and checkfor leaks.
FITTING AND TUBE SEATLEAK INSPECTION. Since mostfluid leaks occur at the fittings andconnections in a power steering hy-draulic system, these parts should bechecked before any other part is re-placed.
1. With the engine running at idlespeed, raise the car on a hoist.
2. Clean the outside of the controlvalve and the power cylinder, the bot-tom surfaces of the pump, and alllines and fittings. Dirt, oil, and greaseshould be removed from all areaswhere leaks may exist.
3. Tighten all fittings, using a spe-cial 5-flat tube wrench. Do not tightenthe fittings with a standard open endwrench. If a properly tightened fittingleaks, replace the seat.
PUMP, CONTROL VALVE,AND POWER CYLINDER LEAKINSPECTION. If the fittings and
Page Page
SUSPENSION
Common Adjustments and Repairs 3-4Caster, Camber, Toe-in 3-5Equipment Installation 3-5Front Wheel Alignment Checks 3-5Front Wheel Turning Angle 3-6Toe-In and Steering Wheel Spoke Positions
Adjustments 3-6Description and Operation 3-8Diagnosis and Testing 3-1In-Car Adjustments and Repairs 3-10Inspection 3-7Major Repair Operations 3-13Removal and Installation 3-11Specifications 3-39
— T —
TAILGATE
Diagnosis and Testing 17-1In-Car Adjustments 17-31Removal and Installation 17-38
TAPPET REPLACEMENT
Mileage Maker Six 8-37289 V-8 8-65352, 390, and 427 V-8 8-86
THERMOSTAT 11-11
Diagnosis and Testing 11-1
TIMING CHAIN AND SPROCKETS
Chain Deflection 8-11Cleaning and Inspection 8-20Removal and Installation
Mileage Maker Six 8-36289 V-8 8-62352, 390, and 427 V-8 8-89
TIRES 3-1
Rotation 3-36Specifications 3-40
TOOLS—SPECIAL 22-1
TRANSMISSIONS
See Automatic TransmissionSee Manual-Shift TransmissionSee Overdrive
TURN INDICATOR 15-17Diagnosis and Testing 15-2Replace 15-20
VALVES
Cleaning and Inspection 8-19Reconditioning
Refacing Valves 8-16Select Fitting Valves 8-16
Valve Face Runout 8-19Valve Stem Clearance 8-20
Specifications 8-113
VALVE CLEARANCE—HYDRAULIC VALVE LIFTERS. . 8-13
VALVE LASH
Cold 8-12Hot 8-12
VALVE ROCKER ARM SHAFT ASSEMBLY
Cleaning and Inspection 8-18Disassembly and Assembly
Mileage Maker Six 8-31289 V-8 8-59352, 390, and 427 V-8 8-86
Removal and InstallationMileage Maker Six 8-31289 V-8 8-59352, 390, and 427 V-8 8-86
Specifications 8-115VALVE SPRING
Pressure 8-115Specifications 8-115Squareness 8-115
VALVE STEM SEAL REPLACEMENT
Mileage Maker Six 8-34289 V-8 8-61352, 390, and 427 V-8 8-93
VENTILATING SYSTEM 16-6
Duct Replace 17-17
_ W —
WATER PUMP 11-15General Cooling System Service 11-1
WHEELS
Diagnosis and Testing 3-1Common Adjustments and Repairs 3-4Description and Operations 3-35In-Car Adjustments and Repairs 3-35Inspection 3-7Major Repair Operations 3-37Removal and Installation 3-36Specifications 3-39
WINDOWSDiagnosis and Testing 17-1In-Car Adjustments 17-31Removal and Installation 17-38
WINDSHIELD WIPER 15-17Blade Adjustment 15-18Electric Motor Assembly and Adjustment . . 15-22Electric Motor Disassembly 15-21Motor Replacement 15-21Pivot Shaft and Link Replacement 15-21
