Ford Cougar 1967, Fairlane 1967, Falcon 1967, Mercury Intermediate 1967, Mustang 1967 Shop Manual

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

All Rights Reserved. No part of this book may be used or reproduced in any manner

whatsoever without written permission of Forel Publishing Company, LLC. For

information write to Forel Publishing Company, LLC, 3999 Peregrine Ridge Ct.,

Woodbridge, VA 22192

1967 Cougar, Fairlane, Falcon, Mercury and Mustang Shop Manual

(Form 7760-67, First printing – March 1967)

ISBN: 0-9673211-4-X

EAN: 978-0-9673211-4-1

Forel Publishing Company, LLC

3999 Peregrine Ridge Ct.

Woodbridge, VA 22192

Email address: [email protected]

Website: http://www.ForelPublishing.com

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

of Ford Motor Company.

Disclaimer

Although every effort was made to ensure the accuracy of this book, no representations or warranties of
any kind are made concerning the accuracy, completeness or suitability of the information, either expressed
or implied. As a result, the information contained within this book should be used as general information
only. The author and Forel Publishing Company, LLC shall have neither liability n or responsibility to any
person or entity with respect to any loss or damage caused, or alleged to be caused, directly or indirectly by
the information contained in this book. Further, the publisher and author are not engaged in rendering legal
or other professional services. If legal, mechanical, electrical, or other expert assistance is required, the
services of a competent professional should be sought.





GROUP INDEX

NW-

.



FALCON

VEHICLE IDEMIIRCATION

BRAKES

SUMMON, STEERING, INNERS AND TIRES

REAR AXLE

DRIVE SHAFT AND CLUTCH

MANUAL SHIFT TRANSMISSION

AUTOMATIC TRANSMISSION

ENGINE

:

.

1GNRION SYSTEM

FUEL SYSTEM

10

1

2
3
4

5

6

7

9

COOLING SYSTEM

MERCURY-

EXHAUST SYSTEM

imam

Mir '

SMOG

VARTIHG SYSTEM

SYSTEM,

MUSTANG

SERVICE PUBLICATIONS

IPSTPF FIT NG-0ARCH_ 1907

19

19+7 FORD 1111OYpM CO PAPAW, DEAR yQR11

. 1NIC

MPIMI

nt

SPECIFICATIONS AND SPECIAL SERVICE TOOLS

.H14AN

.ATING, HEATING AND ACCESSORIES

.

BODY, DOORS AND WINDCNV5

TM % SEATS AND CONVERTIBLE TOP

5O

AT END OF EACH GROUP

HORNS

$

A

SYSTEM

AND INSTRUMENTS

5

11

12

13
14

15

16

1$

19

FOREWORD

This shop manual provides the Service Technician with information

for the proper servicing of the

1967

Cougar, Fairlane, Falcon,

Mercury Intermediate, Comet and Mustang cars.

The maintenance schedule and procedures for maintenance oper-

ations are published in the

1967

hsenger Car Maintenance and

Lubrication Manual.

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

Refer to the opposite page for important vehicle identification

data.

The descriptions and specifications in this manual were in effect at

the time this manual was

approved for printing. The Ford Motor
Company reserves the right to discontinue models at any time, or
change specifications or design, without notice and without incur­ring obligation.

1

-2

GROUP

1-Vehicle Identification

BODY SERIAL AND STYLE CODES

BODY SERIAL AND STYLE

CODES-4continu.d)

FAIRLANE

The two-digit numeral which follows the assembly plant, code identifies

the body series. This two-di it number is used in

coniunct~on with the Body

Style Code, in the Vehicle bate, which consists of a

two-d~git number with

a letter suffix. The following chart lists the Body Serial Codes, Body Style

Codes and the model.

MERCURY4OMET (INTERMEDIATE-SIZE)

w

Serial

Body

Code

Sbk
Code Body TY pe Model

02 54A 4-Door Sedan

3

Comet 202

01 62A

2.Door Sedan

61

08 54 B &Door Sedan Comet Capri
07

:63B 2-Door Hardtop

8

10 540 4-Door Sedan

3

Caliente

11

630 2-Door Hardtop

O

12 76 D 2-Door Convertible
15 63E 2-Door Hardtop

@

Cyclone

16 76C

2.Door Convertible

@

17 63H 2-Door Hardtop

3

G T

18 76H 2-Door Convertible

@)

03 7 1A 4-Door 6 Passenger Comet Voyager
08 71C 4-Door 6 Passenger Villager

Bench Seat
Bucket Seat

COUGAR

-.

MY

Body Body TY pe

Serial Style
Code Code

91 65A 2-door Hardtop (Bucket Seat)

9 1

658 2-Door Hardtop (Bucket Seat)

8

91 65D 2-Door Hardtop (Bench Seat)

2;

9 1 65C 2-Door Hardtop (Bench Seat)

@

Luxury Model

B+Y B*

Serlal

-

Style

Code Code Body Type

.

Model

3 1 54A

4.Door Sedan

@

Fairlane

30 62A 2-Door Sedan

s

34 548 &Door Sedan

2)

Fair lane 500

33

628 2-Door Sedan

8

35 638 2-Door Hardtops
36 76 B 2-Door Convertible

a

40 63C 2-Door Hardtop

~s

Fairlane 500XL

41 76C 2-Door Convertible

2

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

3

32 71D &Door Station Wagon
37 718 4-Door
38 71E

&Door

47 66A 2-Door

@

Ranchero

48

668 2.Door

3

49 66 D 2-Door

m

@

Bench Seat

@

Bucket Seat

FALCON

Body

.

!$

Serial

Code Code Body Type Model

10 62A 2-Door Club Coupe

.!I

Standard

11 54A Sedan

3

20 628 2-Door Club Coupe s Futura

2

1 548 4-Door Sedan

22 62C 2-Door

@

Sport Coupe

12 71A &Door Wagon (Std.)

23 718 &Do01 Wagon (Deluxe)

o

Bench Seat

o

Bucket Seat

CONSECUTIVE UNIT NUMBER

MUSTANG

Be
Serial

Body
Sgle

Code Code Body TY pe
02 63A 2-Door Fastback

Q'

01 65A 2-Door Hardtop

Ci'

03 76A 2-Door Convertible

g!

02 638 2-Door Fastback

-'I

:z

01 658 2.Door Hardtop

.fi

:3)

03 768 2-Door Convertible

:D

@

0

1 65C 2-Door Hardtop

B)

03 76C 2.Door Convertible

(8

Bucket Seat

@

Bench Seat

o

Luxury Model

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

ENGINE CODES

Code TYP

U

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

6 Cyl.

170 Cu. In.

(lV)

T

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

6 Cyl.

200

Cu. In. (1V)

2

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

6 Cyl.

.ti

200 Cu. In. (lV)

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

C

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

:

8 Cyl. 289 Cu. In. (2V)

3

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

8 Cy I.

1:

289 Cu. In. (2V)

A

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

:

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

8 Cyl.

289 Cu. In. (4V) Prem. Fuel

K

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

8 Cyl. 289 Cu. In. (4V) Hi-Perf.

Y

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

8 Cyl.

390 Cu.

In. (2V)

H

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

8 Cy I. 390 Cu. In. (2V)

S

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

8 Cyl.

390 Cu.

In. (4V)

W

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

8 Cyl.

427 Cu.

In. (4V) HLPerf.

R

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

8 Cyl.

427 Cu. In.

(8V) Hi-Perf.

;!I

Low Compression

GROUP

I-Vehicle Identification

Code

TYP

1

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

Speed Manual

2

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

Overdrive

3

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

Sped Manual

5

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

Sped Manual

W

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

Automatic (C4)

U

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

Automatic (C6)

TRANSMISSION CODES

DISTRICT CODES (DSO)

Units built on a Domestic Special Order, Foreign Special Order, or other spe-

cial orders will have the complete order number in this space. Also to appear

in this space is the

twedigit code number of the District which ordered the

unit. If the unit is a regular production unit,

only the District code number

will appear.

FORD

REAR AXLE RATIO CODES

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

differential

DATE CODES

A

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

code letter will be used

if

the model exceeds 12 months.

Code Code

Month First Year

Second Year

January

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

A

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

N

February

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

B

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

P

March

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

C

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

Q

April

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

D

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

R

May

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

E

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

S

June

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

F

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

T

July

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

G

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

U

August

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

ti

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

V

September

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

J

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

W

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

October K

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

X

November

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

L

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

Y

December

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

M

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

Z

ASSEMBLY PLANT CODES

Code District

11

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

Boston

13

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

New York

15

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

Newark

16

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

Philadelphia

17

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

Washington

21

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

Atlanta

22

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

Charlotte

24

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

Jacksomille

25

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

Richmond

27

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

Cincinnati

28

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

Louisville

32

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

Cleveland

33

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

Detroit

34

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

Indianapolis

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

35 Lansing
37 Buffalo

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

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

38 Pittsburgh

41

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

Chicago

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

42 Fargo

43

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

Milwaukee

44

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

Twin Cities

45

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

Davenport

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

51 Denver

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

52 De Moines
53

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

Kansas City

54

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

Omaha

55

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

St Louis

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

61 Dallas

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

62 Houston

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

63 Memphis
64

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

New Orleans

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

65 Oklahoma City

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

71 Lo Angeles

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

72 an Jose

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

73

I

Lake City

74

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

Seattle

75

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

Phoenix

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

81 Ford of Canada

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

83 Government

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

84

Home Office Reserve

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

85 American Red Cross
89

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

Transportation Services

90-99

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

Export

Code

Letta

A

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

Atlanta

B

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

Oakville (Canada)

C

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

Ontario Truck

D

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

Dallas

E

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

Maw

F

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

earn

G

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

Chicago

H

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

Lorn

J

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

Los Angeles

K

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

Kansas City

MERCURY

Code

Letta
L

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

Michigan Truck

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

N Norfolk
P

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

Twin Cities

R

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

an Jose

S

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

Po Plant

T

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

Metuchen

U

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

Louisville

W

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

Wayne

Y

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

Wixom

Z

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

St Louis

Code District

11

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

Boston

16

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

Philadelphia

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

15 New York
17

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

Washington

21

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

Atbnta

22

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

Dallas

23

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

Jacksonville

26

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

Memphis

31

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

Buffalo

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

32 Cincinnati

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

33 Cleveland

1

Code District

34

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

Detroit

41

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

Chicago

42

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

St. Louis

46

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

Twin Cities

51

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

Denver

52

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

Los Angeles

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

53 Oakland
54

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

Seattle

84

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

Home Office Reserve

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

90 Export

GROUP

1-Vehicle Identification

EXTERIOR PAINT COLOR CODES

M30-J

Code

M32-J

Color

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

A 1724-A

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

Bbc k

B

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

A

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

Lt Aqua

E

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

2045

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

Me. Beige Met.

I

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

21

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

Lime Met.

K

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

1-A

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

Dk. Blue Met.

M

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

1619

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

White

Q

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

16244

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

Med. Blue Met.

T

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

A

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

Red

.

V

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

2066

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

Bronze Met.

W

.......................................... A ......................................

Me. Aqua Met.

X

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

1632-

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

Maroon Met.

Y

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

203

Dk Green Met.

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

Z

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

11-

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

Me. Gold Met.

2

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

A

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

Yellow

4

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

A

Me. Gray Met.

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

6

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

163-A

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

Lt Beige

8

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

1955-

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

Yellow

INTERIOR

TRIM

CODES

Code Trim Schema

10

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

Be Cloth and Blue Vinyl

1D

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

Red Cloth and Red Vinyl

1K

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

Aqua Cloth and Aqua Vinyl

1U

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

Parchment Cloth and Parchment Vinyl WBlack

2A

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

Black Vinyl

28

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

Be Vinyl

20

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

Red Vinyl

2F

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

Sad Vinyl

2G

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

I

Gold Vinyl

2K

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

Aqua Vlnyl

2U

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

Parchment Vinyl WIBbck

38

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

Be Cloth and Blue Vinyl

36

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

I

Gold Cloth and Ivy Gold Vinyl

3K

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

Aqua Cloth and Aqua Vtnyl

3U

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

Parchment Cloth and Parchment Vinyl WBlack

4A

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

Black Vinyl

48

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

Be Vinyl

4D

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

RVi 1

4G

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

~oly~in~l

4K

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

Aqua Vlnyl

4U

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

Parchment Vinyl

SA

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

Black Cloth and Black Viny!

SB

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

Dark Blue Cloth and BlueVtnyl

SK

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

Aqua Cloth and Aqua Vinyl

SU

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

Parchme Cloth and Parchment Vinyl W/Saddle

6A

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

Black Vinyl

60

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

Dark Bluevinyl

60

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

Red Vinyl

6F

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

Sad Vinyl

6G

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

Dk Ivy Gold Vinyl

6K

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

Aqua Vinyl

6U

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

Parchment Vinyl

7A

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

Black Vinyl

IB

......

:

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

Be Vinyl

7U

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

Parchment Cloth and Parchment Vinyl

8A

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

Bck Vinyl

88

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

Be Vinyl

80

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

R Vinyl

8F

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

Sad Vinyl

INTERIOR TRIM CODES-(continued)

Code Trim Schemes

8G

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

I Gold Vinyl

8K

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

Aqua Vinyl

8U

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

Parchment Vinyl W/Black

9A

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

Black Cloth and Black Vinyl

90

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

Dk. Blue Cloth and Dk. Blue Vinyl

90

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

Dk. Red Cloth and Dk. Red Vinyl

9K

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

Aqua Cloth and Aqua Vinyl

9U

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

Parchment Cloth and Parchment Vinyl WIBlack

FA

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

Parchment Vinyl WIBlack

FB

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

.!

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

Parchment Vinyl WIBlue

FD

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

Parchment Vinyl WiRed

FG

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

P

Vinyl Wllvy Gold

FK

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

Parchment Vinyl WIAqua

GA

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

Back Vinyl WParchment

GB

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

Be Vinyl WParchment

GD

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

Red Vinyl WParchment

GG

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

I

Gold Vinyl WIParchment

GF

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

Sad Vinyl WParchment

GK

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

A Vinyl WParchment

LB

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

Red Vinyl

LD

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

Be Vinyl

LU

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

Parchment Cloth and Parchment Vinyl WIBlack

OU

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

Parchment Vinyl

UA

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

Parchme Vinyl WIBbck

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

UB Parchment Vinyl WBlue

UD

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

Parchment Vinyl WIRed

UF

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

Parchment Vinyl W/Saddle

UG

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

Parchment Vinyl Wllvy Gold

UK

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

Parchment Vinyl WIAqua

2-2

GROUP

2-Brakes

STEERING WHEEL RIM

NOTE: A DIMENSION TO

i3E MEASURED TO SHEET METAL

B DIMENSION TO BE MEASURED PARALLEL

70

THE VERTICAL CENTERLINE

OF

THE

STEERING COLUMN

WlTH A

50

POUND LOAD APPLIED TO THE CENTERLINE OF THE

BRAKE PEDAL PAD. (CHECKS ON POWER BRAKE VEHICLESMADE

WlTH ENGINE RUNNIP4C-l

H1551-~

FIG. I-Brake Pedal Height and Travel Measurements

FIG. 2-Brake Pedal

Effort

Gauge Installed - Typical

Brake Pedal Travel

Measurement

1.

Install a Brake Pedal Pressure

Gauge on the brake pedal pad (Fig.

2).

2.

Hook a steel measuring tape

to the brake pedal as shown in Fig.

I. Measure and record the distance
from the brake pedal free height po­sition to the reference point, which is
at the six o'clock position on the steer-

ing wheel rim.

3.

With the steel tape still hooked
to the brake pedal depress the brake
by pressing downward on the

brake
pedal effort gauge. Apply a 50
pound load to the center of the pedal
by observing the pressure gauge,
agd measure the distance ffom the

brake pedal to the fixed reference
point on the steering wheel rim,
parallel to the ccnterline of the steer-.

ing column.

4.

The difference between the brake

pedal free height and the depressed

pedal measurement under a 50
pound load should be within the speci­fied maximum pedal travel service
specification B in Fig.

1.

5.

If

the pedal travel is more than

the specified maximum shown in Fig.

I,

dimemion B, make several sharp
reverse stops (equivalent to 50 pounds
pedal pressure) with a forward stop
before each. Move the, car in reverse

and forward for a distance of ap­proximately ten feet; then apply the

brakes sharply

and hold the brake

pedal down until the car is completely
stopped. This will actuate the brake
self-adjusters.

If

these stops do not

bring the brake pedal travel with-

in specification, make several addi­tional forward and reverse stops as
outlined above.

6.

If

the second series of stops do

not bring the brake pedal travel
within specification, remove the brake
drums and check the brake adjusters
to make sure they are functioning.
Check the brake linings for wear or
damage. Repair or replace all worn

or damaged parts and

non-function­ing adjusters. Adjust the brake lin­ing outside diameter to The approxi­mate inside diameter of the brake

drlrm wi!h Rotunda Too! HRE 8650
(Figs.

I I and 12, Part 2-2).

7.

If all the brake adjusters.
brake drums and linings are func­tional and the brake pedal travel is
not within specifications, check the
pedal linkage for missing bushings.
or loose attachments. Bleed the brake
and centralize the differential valve.

POWER BRAKE
FUNCTIONAL TEST

I.

With the transmission in neutral.

stop the engine and apply the parking

brake. Depress the brake pedal sev-

eral times to exhaust all vacuum in

the system.

2.

With the engine shut off. de­press the brake pedal and hold it in
the applied position.

If

the pedal

gradually falls away under this

pressure, the hydraulic

system is

leaking. Check all tubing, hoses.

calipers (if so equipped), wheel cyl-

inders and connections for leaks.

If

the brake pedal movement f&ls
spongy, bleed the hydfaulic system
to remove air

from the system. Refer

to Hydraulic Systern Bleeding, Part

1, Section 2. Also, check for leaks or
insufficient fluid.

3.

With the engine shut off and
all vacuum in the system exhausted,
depress the pedal arid hold it in the ap­plied position. Start the engine.

If

the

vacuum system is operating, the

pedal will tend to fall .away under
foot pressure and less pressure will

PART

2-1-General Brake Service 2-3

be required to hold the pedal in the

applied position.

If

no action is felt,
the vacuum booster system is not
functioning.

LOCKED WHEEL BRAKE
Should one of the wheel brakes be

locked and the car must

be

moved,
open the bleeder screw long enough
to let out a few drops of brake fluid.

This bleeding operation

will

release
the brakes but will not correct the
cause of trouble.

PARKING BRAKE

Visually check the operation of the
parking brake linkage as the park­ing brake controls are moved to the

applied position. Then, check the opera­tion of the brake linkage when the
parking brake controls are moved to
the released position. These checks

should indicate whether the manual

parking brake control linkage is op­erating properly or requires repair
or adjustment due to inability of the
parking brake to hold against mod­erate vehicle movement.

ROAD TEST

A

road test should

only

be con-

ducted when the operator is sure the

brakes

will

stop the vehicle.

During a road test, apply the ve-

hicles brakes at a road speed of 20

mph for all problem conditions listed

in Figs.

I I

and I2 with the excep-

tion of those resolved in the Brake Sys­tem Tests and brake chatter. To check
for brake chatter or surge, apply the
brakes lightly at 50 mph. For each
of the symptoms encountered, check
and eliminate the causes which are
listed in Figs.

l

l

and 12.

If the road test reveals one or more

problem conditions listed in Figs.

11

and

12,

correct all malfunctions of
the vacuum system, brake booster
and hydraulic system prior to re­moving brake drums, brake calipers

(if so equipped), brake shoes and
linings or backing plates.

COMMON ADJUSTMENTS AND REPAIRS

PARKING BRAKE
LINKAGE ADJUSTMENT

MUSTANG- COUGAR

Check the parking brake cables
when the parking brakes are fully
released.

If

the cables are loose, ad-

just them as follows:

I.

Fully release the parking
brake by turning the handle coun­terclockwise and pushing

it

inward.

2.

Pull the parking brake handle
outward to the third notch from its
normal released position.

3.

Raise the vehicle. Remove the

wheel cover. Install Tool

T66L-

4204-L on the rear wheel (Fig. 3).

4.

Turn the locking adjustment

nut forward against the cable guide

on the equalizer (Fig. 4) until there

is 100 ft-lbs break-away torque at

the rear wheel when turning the rear
wheels in the direction of forward ro­tation with a torque wrench (Fig. 3).

The torque measurement must be

made relative to the centerline of the

wheel.

5.

Release the parking brake and

make sure the brake shoes return to
the fully released position and no
drag is felt when turning the rear
wheels.

6.

Remove Tool T66L-4204-L. In­stall the wheel attaching bolts and
torque them to specification. Install
the wheel cover. Lower the vehicle.

COMET-FALCON­FAIRLANE

Check the parking brake cables

when the brakes are fully released.

FIG. 3-Checking Parking Brake Break-Away Torque

If

the cables are loose, adjust them

as follows:

1.

Fully release the parking brake

pedal.

2.

Raise the vehicle. Loosen the

equalizer lock nut (Fig.

5)

and turn
the nut forward against the cable
guide on the equalizer until there is
22 to 27 pounds tension on the

left
rear cable or there is 100 ft-lbs
break-away torque when turning the

rear wheels in the direction of forward

rotation with

a

toraue wrench and

ADJUSTMENT NUT-37993062

EQUALIZER-2A602

EQUALIZER ROD-2628

H1552-A

Tool T66L-4204-L as shown in

FIG. 4-Parking Brake Linkage

Fig. 3.

The torque measurement

must be made relative

to

the center-

Adjustment - Mustang and Cougar

line of the wheel.

Tighten the lock nut.

torque wrench and Tool

T66L-4204-L,

3.

Make sure there is no drag

if

required, Install the wheel attach-

when turning the rear wheels.

inn nuts and torque them to specifi-

4.

Lower the vehicle. Remove the

cation. Install the wheel cover.

\

CONVERTIBLE

NU'L

PARKING

ERAKE

CA:

AND

CONDUIT

,

ASSEMBLY-2853

\

,

SPRING-2A651

CAaLE

ASSEMSLY

,

A/

2A604

eRAKE

Y

RETAINER-74277.5

AND

CONDUIT

,

7-10

LB.FT.

\LR~'~AINER-~A~I~

CONVERTIBLE ONLY

H1553-A

FIG.

5-Parking Brake Linkage

Adjustment

-

Comet, Fairlane and

Falcon

r

#16

GAUGE

SHEET STEEL

HIX)8-0

FIG.

6-Push Rod Gauge Dimensions

POWER BRAKE MASTER
CYLINDER PUSH ROD
ADJUSTMENT

The push rod is provided with an
adjustment screw to maintain the cor­rect relationship between the booster.
control valve plunger and the master
cylinder pistons. Failure to maintain
this relationship will prevent the master
cylinder piston from completely re­leasing hydraulic pressure and can

cause the brakes to drag, or cause
excessive brake pedal travel.

GROUP

2-Brakes

FIG.

7-Push Rod Adjustment

-

Midland-Ross

To check the adjustment of the
screw, fabricate a gauge of the
dimension shown in Fig. 6. Then place
the gauge against the master cyl­inder mounting surface of the booster
body as shown in Figs.

7

or

8.

The
push rod screw should be adjusted
so that the end of the screw just touch­es the inner edge of the slot in the
gauge. Do not set up side forces on
the push rod. Side forces may break
the valve plunger.

This is an approximate adjust-

ment only.

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

HYDRAULIC SYSTEM BLEEDING
AND CENTRALIZING OF THE
DIFFERENTIAL VALVE

When any part of the hydraulic
system has been disconnected for re­pair or replacement, air may enter
the system and cause spongy pedal
action. Bleed the hydraulic system
after it has been properly connected,
to be sure that all air is expelled.

MAN

UAL

BLEEDING

The primary and secondary (front
and rear) hydraulic brake systems
are individual systems and are bled
separately. Bleed the longest line
first on

:he individual system being

serviced.

During the complete bleeding
operation, DO NOT allow the reser­voir to run dry.

Keep the master cyl­inder reservoirs filled with Rotunda
Fluid

-

Extra Heavy Duty - Part

Number

C6AZ- 19542-A (ESA-

M6C25-A).

The

disc brake extra

FIG.

8-Push-Rod Adjustment

-

Bendix

heavy duty brake fluid is colored
blue for identification purposes.

Do

not mix low temperature brake fluids
with the specified fluid during the

bleeding operations. Never re-use
brake fluid which has been drained
from the hydraulic system.

I.

Loosen the bleed screw located

on the side of the master cylinder.

Do

not use the secondary piston stop

screw, located on the bottom of the

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

2.

To bleed the secondary (rear)

brake system, position a suitable

318

inch box wrench (Fig. 9) on
the bleeder fitting on the brake wheel
cylinder. Attach a rubber drain
tube to the bleeder fitting.

The end of
the tube should fit snugly around
the bleeder fitting.

3.

Submerge the free end of the
tube in a container, partially filled
with clean brake fluid, and loosen
the bleeder fitting approximately

314

turn.

4.

Push the brake pedal down
slowly through its full travel. Close
the bleeder fitting, then return the

pedal to the fully-released position.

Repeat this operation until air bub-

bles cease to appear at the sub­merged end of the bleeder tube.

5.

When the fluid is completely
free of air bubbles, close the bleeder
fitting and remove the bleeder tube.

6.

Repeat this procedure at the

brake wheel cylinder on the opposite
side. Ref

ill

the master cylinder reser-

voir after each wheel cylinder is bled

PART

2-1-General Brake Service 2-5

APPROXIMATELY

45"

H1300-A

FIG.

9-

Wrench for Bleeding Brake

Hydraulic System

and install the master cylinder cover
and gasket. Be sure the diaphragm
type gasket is properly positioned in
the master cylinder cover. When the
bleeding operation is completed, the
fluid level should be filled to within

114 to 112 inch from the top of

the reservoirs.

7.

If the primary (front brake)
system is to be bled, remove the front
wheel covers, and the front wheel and

tire assemblies to gain access to the

bleeder fittings on the disc brake cal­ipers. Repeat steps 2 through 6 at

the right front disc brake caliper and
ending at the left front disc brake
caliper.

8.

Be

sure that the front brake
pistons are returned to their normal
positions and that the shoe and lining
assemblies are properly seated by
depressing the brake pedal several
times until normal pedal height exists.
Install the front wheel and tire assem­blies on the front wheels, and torque

the mounting bolts to specification.

Install the wheel covers.

9.

Centralize the pressure dif­ferential valve. Refer to the Centraliz­ing the Pressure Differential Valve

Procedures which follow.

PRESSURE

BLEEDlNG

Bleed the longest lines first. The
bleeder tank should contain enough
new Rotunda Brake Fluid to complete
the bleeding operation. Use Rotunda
Brake Fluid

-

Extra Heavy Duty

-

Part Number C6AZ- 19542-A

(ESA-M6C25-A) or equivalent for all

disc brake applications and Rotunda

Brake Fluid

-

Heavy Duty - Part

Number

B7AZ- 19542-A, R103-A
or equivalent for power drum or
standard drum applications. The
brake fluid is colored blue for identi-

fication purposes. Do not mix low
temperature brake fluid with the
specified disc brake fluid during the

bleeding operations. Never re-use
brake fluid that has been drained

from the hydraulic system. The tank
should be charged with approxi-

mately 10 to 30 pounds of air

pressure. Never exceed 50 pounds
pressure.

1. Clean all dirt from the master

cylinder reservoir cover.

2. Remove the master cylinder res­ervoir cover and rubber gasket, and
fill

the master cylinder reservoir with
the specified brake fluid. Install the
pressure bleeder adapter tool to the

master cylinder, and attach the
bleeder tank hose to the fitting on the
adapter.

Master cylinder pressure bleeder
adapter tools can be obtained from
the various manufacturers of pres­sure bleeding equipment. Follow the
instructions of the manufacturer
when installing the adapter.

3. Loosen the primary and sec­ondary tube nuts at the master cyl­inder and bleed the master cylinder
until the fluid flow is free of air
bubbles, then tighten the tube nuts

to the specified torque. Refer to Figs.

20 and 21, Part 2-2. Do not over-

tighten the nuts.

4. If the rear wheel cylinders and

the secondary brake system is to be
bled, position a

318 inch box
wrench (Fig. 9) on the bleeder fitting
on the right rear brake wheel cylinder.
Attach a bleeder tube to the bleeder

fitting. The end of the tube should

fit snugly around the bleeder fitting.

5. Open the valve on the bleeder

tank to admit pressurized brake fluid

to the master cylinder reservoir.

6.

Submerge the free end of the

tube in a container partially filled

with clean brake fluid, and -loosen

the bleeder fitting.

7.

When air bubbles cease to ap-

pear in the fluid at the submerged
end of the bleeder tube, close the
bleeder fitting and remove the tube.

8.

Repeat steps 3 through 7 at the
left wheel cylinder of the secondary sys­tem being bled.

9.

If the primary (front brake)

system is to be bled, remove the front

wheel covers, and the front wheel and

tire assemblies to gain access to the
bleeder fittings on the disc brake
calipers. Repeat steps 4 through 7,
starting at the right front disc cali­per and ending at the left front disc
caliper.

10.

If

the vehicle contains drum­type front brakes and the primary
(front) brake system is to be bled,

repeat steps 4 through 7, starting
at the right front wheel cylinder and

ending at the left wheel cylinder.

11. When the bleeding operation

is completed, close the bleeder tank

valve and remove the tank hose from

the adapter fitting.

12. On disc brake equipped ve­hicles, be sure that the front brake
pistons are returned to their normal

positions and that the shoe and lining
assemblies are properly seated by
depressing the brake pedal several
times until normal pedal height is
obtained. Install the front wheel and
tire assemblies on the front wheels, and
torque the mounting bolts to specifi-

cation.

1

nstall the wheel covers.

13. Remove the Pressure Bleeder

Adapter Tool. Fill the master cylinder

reservoirs to within

114 to 112 inch

from the top.

lnstall the master cyl­inder cover and gasket. Be sure the
diaphragm-type gasket is properly
positioned in the master cylinder cover.

14. Centralize the pressure dif-

ferential valve as follows:

CENTRALlZlNG THE
PRESSURE DIFFERENTIAL
VALVE

After a failure of the primary
(front brake) or secondary (rear
brake) system has been repaired
and bled, the dual-brake warning

light will usually continue to be

il-

luminated due to the pressure dif-

ferential valve remaining in an

off-

center position.

To centralize the pressure differ-

ential valve and turn off the warning

light after a repair operation, a pres-

sure differential or unbalance con­dition must

be

created in the opposite

brake system from the one that was

repaired and bled last.

1. Turn the ignition switch to the
ACC or ON position. Loosen the dif­ferential valve assembly brake tube
nut at the outlet port on the opposite
side of the brake system that was
repaired and/or bled last. Depress
the brake pedal slowly to build line
pressure until the pressure differential
valve is moved to a centralized posi­tion and the brake warning light
goes out; then, immediately tighten

the outlet port tube nut to the speci­fied torque. Refer to Fig. 20 and 2

I.

2. Check the fluid level in the

master cylinder reservoirs and

fill

them to within 114 to 112 inch of

the top with the specified brake fluid,

if

necessary.

3.

Turn the ignition switch to the

OFF position.

4. Before driving the vehicle, check

the operation of the brakes and

be

sure that a firm pedal is obtained.

GROUP

2-Bra

kes

CLEANING AND INSPECTION

DISC (FRONT) BRAKES

1.

Remove the wheel and tire, cali­per splash shield, and the shoe and lin­ing assemblies as outlined in Part

2-2, Section 2.

2.

Make three thickness measure­ments with a micrometer across the
middle section of the shoe and lining.
Take one reading at each side and
one in the center. If the assembly has
worn to

'a thickness of 0.231 inch
(shoe and lining together) or 0.066
inch (lining material only) at any
one of the three measuring locations
or

if

the brake lining shows evidence
of brake fluid contamination, re­place all four shoe and lining as-

semblies on both front wheels.

3.

Check the caliper to spindle

attaching bolt and caliper bridge

bolt torque. Tighten them to the
specified torque,

if

required.

4.

To check rotor runout, first
eliminate the wheel bearing end play
by tightening the adjusting nut.
After tightening the nut check to see
that the rotor can still be rotated.

5.

Clamp a dial indicator to the
caliper housing so that the stylus

contacts the rotor at a point approxi­mately

I

inch from the outer edge.

Rotate the rotor and take an indica-

tor reading.

If

the reading exceeds

0.002 inch total lateral

runout on

the indicator, replace or resurface

the disc brake rotor.

The following

requirements must be met when re-

surfacing disc brake rotors:

Rotunda Disc Brake Attachment

FRE-2249-2 is the

only approved

tool

to

be

used to refinish the disc
brake rotors. The step-by-step resur­facing procedure provided with the
tool must be adhered to.

The finished braking surfaces of
the rotor must be flat and parallel
within 0.0007 inch; lateral

runout
must not exued 0.002 inch total
indicator reading, and the surface
finish of the braking surfaces are

to

be

85/15 micro inches.

The min-

imum limiting dimensions (Fig.

10)

from the inboard bearing cup to
the outboard rotor face (dimension

A)

and from the inboard bearing

cup to the inboard rotor face (di-

mension

B)

must be observed when

removing material from the rotor

braking surfaces.

When the runout check is finished,

be sure to adjust the bearings as

outlined in Group

3,

in order to pre-

vent bearing failure.

6.

Check the rotor for scoring.
Minor scores can be removed with a
fine emery cloth. If the rotor is exces-

sively scored, refinish it as outlined
in step 5 or replace the rotor,

if

re-

quired.

7.

Visually check the caliper. If

excess leakage is evident, it should

be replaced. Slight leakage around
the pistons or seized pistons indicate

removal and disassembly:

.

8.

If upon disassembly the cali-

per is found to be distorted or dam­aged, or

if

the cylinder bores are
scored or excessively worn, replace
the assembly

.

The two halves of the caliper as­sembly should never be separated.
Damage or failure of one requires
replacement of both as a unit.

REAR BRAKES

1.

Remove the wheel from the drum,

then remove the drum as outlined in

Part 2-2, Section 2. Wash all the

parts except the brake shoes in a

cleaning solvent and dry with com-

pressed air.

2.

Brush all dust from the back-

ing plates and interior of the brake

drums.

3.

Inspect the brake shoes for ex-

cessive lining

:wear or shoe damage.

If

the lining is worn to within 1/32

inch of the rivet heads or

if

the shoes

are damaged, they must

be

re­placed. Replace any lining that has
been contaminated with oil, grease
or brake fluid. Replace lining, in
axle sets. Prior to replacement of
lining, the drum diameter should

be

checked to determine

if

oversize linings

must be installed.

4.

Check the condition of the brake
shoes, retracting springs, and drum
for signs of overheating. If the springs
show any loss of load or change in
free length indicating overheating,

LATERIAL RUNOUT

0.002

MAXIMUM TOTAL

INDICATOR READING

BEARING CUP

DIMENSION

"B"

1.117

MINIMUM

DIMENSION "A"

0.402

MAXIMUM

SURFACE

FINISH-

/IS

MICRO INCHES

H1%3-A

FIG.

10-Disc Brake Rotor Service

Limits

-

Typical

replacement of the retracting and
hold down springs and the parking
brake cable is necessary.

Overheated
springs lose their pull and could
cause the new lining to wear pre-

maturely if they are not replaced.

5.

If the car has 30,000 or more

miles of operation, or signs of ex-

treme overheating are present when

relining brakes, the wheel cylinders

should be disassembled and inspected

for wear and dirt in the cylinder. The
cylinder cups and other parts con­tained in the overhaul kit should be

replaced thus avoiding future prob­lems.

6.

Inspect all other brake parts
and replace any that are worn or
damaged.

7.

Inspect the brake drums and,

if

necessary, refinish. Refer to Part

2-2,

Section 4 for refinishing.

BOOSTER UNIT

Check the booster operation as

noted in Part 2-1, Section

1, Power

Brake Functional Test.

If

the brake
booster is damaged or defective, re­place it with a new booster.

The

booster is serviced only

as

an assem­bly.

-

PART

2-1-General Brake Service

FIG.

I

I-Front Wheel Disc Brake Trouble Symptoms and Possible Causes

Trouble Symptoms

m

3

C

c

.-

t

>

C

.-

C

ii

0

-=

+

m

LO

r

II),m

m

Possible Causes

Of

Trouble

Shoe and Lining Knock-back after Violent Cornering or
Rough Road Travel

Shoe and Lining Assembly not Properly Seated or Positioned
Leak or Insufficient Fluid in System or Caliper
Loose Wheel Bearing Adjustment
Damaged or Worn Caliper Piston Seal
Improper Master Cylinder Push Rod Adjustment
Excessive Rotor

Runout or Out of Parallel
Incorrect Tire Pressure
Frozen or Seized Pistons
Brake Fluid, Oil or Grease on Linings
Shoe and Lining Worn Below Specifications
Proportioning Valve Malfunction
Booster Inoperative
Caliper Out of Alignment with Rotor
Loose Caliper Attachment
Metering Valve Seal Leaks

Excessive Clearance Between Shoe and Caliper or Between

Shoe and Splash Shield

Shoe Hold Down Clips Missing or Improperly Positioned
Operator Riding Brake Pedal
Scores in the Cylinder Bore
Corrosion Build-Up in the Cylinder Bore or on the Piston

X
X
X
X

X

X

X

Differential Pressure Valve Is Not Centered

X

X

X

Wiring To Warning Lamp or Switch Is Grounded

Warning Lamp Switch Is Grounded

Warning Lamp Is Burned Out
Warning Lamp or Switch Has An Open Circuit

Warning Lamp Switch Is Inoperative

Wiring To Warning Lamp Has Open Circuit

X

X

X

X

X
X

.Y

S

X

X

X

X
X

?(

X

X X X

X

X

X

?(

X

X

X

X

X

X

X'

.Y

>i

X
X

X

.-

--

-

-

-

X

--

2-8

GROUP

2-Bra

kes

Trouble Symptoms

t

C

z

0

-

P

Y

.-

4)

4

al

2

-

r

r

-

'Possible Causes

Of

Trouble

Mechanical Resistance at Pedal or Shoes

X

X

I

IIIII

I

I

Warning Lamp Switch Is Inoperative

1

IIIII

111

111

I

X

FIG.

12-Drum Brake and General System Trouble Symptoms and Possible Causes

I

Section Page

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

1

Description and Operation 2-9

...........

Dual-Master Cylinder Brake System 2-9

Disc Brakes

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

2-1

1

Hydraulic Self-Adjusting Brake System

........

2-13

Booster System

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

.2-13

Parking Brakes

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

2-14

2

In-Vehicle Adjustments and Repairs

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

2-14

Front (Disc) Brake Shoe and Lining

Replacement

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

2-17

Disc Brake Caliper Assembly

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

2-18

.......

Front Wheel Hub and Rotor Assembly

2-18

Disc Brake Rotor Splash Shield

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

2-19

Proportioning Valve..

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

2-19

........

Brake Shoe Adjustments-Rear Wheels 2-16
Rear Brake Drum.

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

2-20

Rear Brake Shoe Replacement

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

.2-20

Rear Wheel Cylinder Repair

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

2-19

Rear Wheel Cylinder Replacement

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

2-19

Rear Brake Backing Plate Replacement

.......

2-20

Hydraulic Lines

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

2-20

Section Page

Brake Tube Replacement

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

2-20

Brake Hose Replacement

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

2-20

3

Removal and Installation

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

2-23

Dual Master Cylinder

-

Standard Brakes

......

2-23

Dual-Master

Cylinder-Power Brakes

.........

2-24

Pressure Differential Valve Assembly

..........

2-24

Brake Booster

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

2-25

Brake Pedal

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

2-25

Parking Brake Control Assembly

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

2-26

Parking Brake Equalizer to Control

Cable

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

.2-26

Parking Brake Equalizer to Rear Wheel

Cable

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

2-27

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

4

Major Repair Operations 2-28

Brake Drum Refinishing

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

2-28

Rotor Refinishing

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

2-28

Brake Shoe Relining

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

2-29

Dual-Master Cylinder

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

2-29

Disc Brake Caliper

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

.2-30

DESCRIPTION AND

Disc brakes are available as op-

tional equipment for the front wheels
on the various vehicle models listed

in (Fig. I).

The dual-master cylinder equipped

hydraulic brake system employes

sin­gle-anchor, internal expanding and
self-adjusting drum brake assemblies
on the rear wheels of vehicles with
disc brakes, and on the front and rear
wheels of all others (Fig.

1).

DUAL-MASTER CYLINDER
BRAKE SYSTEM

The dual-master cylinder brake sys-

tem has been incorporated in all car

models to provide increased vehicle

safety. The system consists of a dual­master cylinder, pressure differential
valve assembly and a switch. The
switch on the differential valve acti­vates a dual-brake system warning
light, located on the instrument panel.

The dual-master cylinder brake sys-

tem is similar to a conventional
(single) brake master cylinder sys­tem. In the dual-system, two master
cylinders are combined in a single
cast iron casting (Fig. 2). One por­tion actuates the front brake system
and the other actuates the rear brake
system (Figs. 20 and 21). Hydraulic
fluid leakage or failure of one of
the systems does not impair the oper­ation of the other portion of the dual­brake system. A dual-brake warning
light signals a failure of either the

front or rear brake system.

OPERATION

The dual-master cylinder used on

Fairlane, Falcon and Comet vehicles
equipped with power brakes have the
master cylinder outlet ports for the
rear brake system located on the bot­tom of the master cylinder body.
Master cylinder hydraulic system
bleed screws are located in the out­board side of those master cylinders
having secondary (rear brake) system
outlet ports in the bottom of the mas­ter cylinder castings (Fig. 29).

All Fairlane, Falcon and Comet ve-

hicles equipped with standard drum

brakes and all Mustang and Cougar

vehicles equipped with power disc,

power drum and standard drum
brakes have both the primary (front)
and secondary (rear) brake system
outlet ports located on the outboard
side of the dual-master cylinder body
castings. These master cylinders do

not require master cylinder bleed
screws (Figs. 27, 28 and 30).

The external appearance of the dual
master cylinders for the various ve­hicles also differ in configuration

of the covers. All vehicles having
standard drum brake systems and

Mustang, Cougar vehicles equipped
with power drum brakes have primary

and secondary master cylinder cover
domes of equal size. Dual master cyl-

inders for all other vehicles equipped
with power disc and power drum
brake systems have large primary

(front brake) and smaller secondary
(rear brake) cover domes.

A code letter is stamped on the
side or outer end of each master cyl­inder body casting for easy service

identification. The vehicle application,
type of brakes and the identification
code are shown in Fig. 3.

A brake pressure differential valve

assembly (Fig.

4)

incorporating an hy­draulically operated mechanical
switch is utilized to operate a dual­brake warning light, located on the
instrument panel.

Hydraulic pressure for both front
wheel brakes is provided from the pri­mary system (front) brake outlet port

and line, located opposite the primary

system inlet port of the differential

valve.

Hydraulic pressure for both rear
wheel brakes is provided from the sin­gle secondary (rear brake) outlet
line, located opposite the secondary
system inlet port of the differential
valve. On disc brake equipped ve­hicles, a proportioning valve is located
in the secondary (rear brake) system
line that leads to the brake hose
bracket on the rear axle housing. The
brake hose bracket serves as a junc­tion point for the individual brake
lines that lead to the wheel cylinders
of right and left rear brake com­ponents.

When the brake pedal is depressed,

both the primary (front brake) and

GROUP

2-Bra

kes

secondary (rear brake) master cylin­der pistons are moved simultaneously
to exert hydraulic fluid pressure on
their respective independent hydraulic
system. The fluid displacement of the
duallmaster cylinders is proportioned
to fulfill the requirements of, each of
the two independent hydraulic brake
systems (Fig. 2).

If a failure of the rear (secondary)
brake system should occur, initial
brake pedal movement causes the un­restricted secondary piston to bottom
in the master cylinder bore. Primary
piston movement displaces hydraulic
fluid in the primary section of the
dual-master cylinder to actuate the
front brake system.

Should the front (primary) brake

system fail, initial brake pedal move-

ment causes the unrestricted primary
piston to bottom out against the sec-

ondary piston. Continued downward

movement of the brake pedal moves

the secondary piston to displace hy­draulic fluid in the rear brake sys­tem, actuating the rear brakes.

The increased pedal travel and the

increased pedal effort required to com-

pensate for the loss of the failed
portion of the brake system provides
a warning that a partial brake system
failure has occured. When the ignition
switch is turned to the START posi­tion, a dual-brake warning light

pro-

FIG.

I-Power Disc Brake and Power Drum Brake Options

Car Model
Falcon
Fairlane
Mustang

Zi

Comet

Cougar

vides a visual indication the warning
lamp is functional. When the ignition

switch is turned to the

ON

or ACC
position, a dual-brake warning light
on the instrument panel also provides
a visual indication

if

one portion of
the dual-brake system has become
inoperative.

Should a failure of either the front

or rear brake hydraulic system occur,

the hydraulic fluid pressure differen­tial resulting from the pressure loss
of the failed brake system forces the

valve toward the low pressure area to

illuminate the brake warning light

(Fig: 4).

A

mechanically operated electrical

switch is located on the side of the

pressure differential valve assembly
between the front and rear brake sys­tem inlet ports. The inner-end of the
spring loaded switch-plunger contacts
the bottom of a tapered shoulder
groove in the center of the valve (Fig.

4). O-ring seals are retained in seal
ring lands near each end of the
valve.

Should a failure

of the rear brake
system occur, hydraulic fluid pressure
in the rear brake system would drop.
During brake pedal operation the fluid
pressure build-up of the front brake
system forces the valve to move to­ward the low pressure area, or toward

3

Standard with Mustang GT equipment group option, Fairlane GT model.

Mustang brake options available only on eight-cylinder models.

3

Standard for Acc. Fairlane and Comet 427

V-8

Engine,

Power Drum

RPO
RPO
RPO

.

RPO
RPO

FIG.

2-

Dual-Master Cylinder

Power Disc

Not Available

RPO

3

B

RPO

@

RPO

3

.

o

RPO

PART

2-2-Brake System

2-1

1

the rear brake system outlet port (Fig.

4).

Movement of the differential valve
forces the switch plunger upward over
the tapered shoulder of the valve to
close the switch electrical contacts and
light the dual brake warning lamp,
signalling a brake system failure.

In the event a front brake system
failure should occur, greater pressure
from the rear brake system during
brake pedal operation forces the valve

forward, moving the switch plunger

upward onto the valve ramp to light

the brake system warning lamp. How­ever, failure of either the front or

rear system does not impair operation

of the

other brake system.

DISC BRAKE ASSEMBLIES

Disc brakes are available as op-

tional equipment for the front wheels.
The hydraulic brake system employs
single

-anchor, internal expanding and
self-adjusting drum brake assemblies
on the rear wheels of vehicles with
disc brakes, and on the front and rear
wheels of all others.

A

vacuum booster is available as

optional equipment.

The master cylinder converts phys­ical force from the brake pedal (and
booster if so equipped) into hydraulic
pressure against the pistons in the

I

calipers (disc brakes) or in the wheel

Car Model Type Of Brake

Identifiation Code

Power Disc

B

Fairlane and Falcon Power Drum S

Standard Drum T
Power Disc M

Mustang Power Drum

X

Standard Drum T

Comet Power Disc

B

Power Drum

S

Standard Drum T

Cougar Power Disc M

Power Drum

X

Standard Drum T

FIG. 3-Dual Master Cylinder Identification

cylinders (drum brakes). The pistons
in turn convert hydraulic pressure
back into physical force at the brake
shoes.

RELATION AND FUNCTION

OF COMPONENT PARTS
The disc brake is a fixed caliper,

opposed piston, non-energized, venti-

lated disc type, actuated by a hy­draulic system (Fig. 5). There is no
lateral movement of either the disc
(rotor) or the caliper. The caliper
assembly consists of two caliper
housings bolted together with each
half containing two cylinder bores
of

1 15/16 inch diameter. Each cyl-

inder bore contains a piston with an
attached molded rubber dust boot

I

BRAKE WARNIFIS LAMP SWITCH BRAKE WARNING LAMP SWITCH

I

VALVE PISTON HAS MOVED TO LOW PRESSURE AREA.

VALVE PISTON

;S

CENTRALIZED.

WARNING LAMP SWITCH PLUNGER IS DEPRESSED,

BRAKE

FLUID

PRIMARY AND SECONDARY SYSTEM

LIGHTING THE BRAKE WARNING LAMP PRESSURES ARE EQUALIZED

H1471-A

FIG. 4-Pressure Differential Valve and Brake Warning Lamp Switch Operation

CALIPER

TO

ROTOR

CLEARANCE

I

WTRANSFER

TUBE

FIG.

5-Typical Disc Brake Assembly

to seal the cylinder bore from con-

tamination (Fig. 6). Square-section
rubber piston seals are positioned in

grooves in the cylinder bores.

The piston seals perform three im-

portant tasks:

1.

They provide hydraulic sealing

between the cylinders and pistons.

2.

They return the pistons to re­leased position, when hydraulic pres­sure is released.

3.

They maintain the shoes in cor-

rect adjustment at all times (com­parable to the automatic adjusters in
drum-type brakes).

The cylinders are connected hy­draulically by means of internal pas­sages in the caliper housing and an

external transfer tube between the

two halves of the caliper assembly.
One bleeder screw and fluid inlet
fitting is provided on each caliper

assembly.

The shoe and lining assemblies are
located between parallel machined

abutments within the caliper, and
are supported radially by tabs on the
outer ends of the shoe assemblies
(Fig. 25). The shoes slide axially in
the caliper abutments by means of
the tabs which ride on machined

ledges (bridges) when hydraulic pres-

sure is applied to the piston (Fig.

6). A shoe and lining assembly con­sists of friction material bonded to a

metal

platc called the shoe. It is re­placed as a unit. Brake torque is ab­sorbed by the mating of the shoe end
against the caliper abutments (Fig.

25). Two spring clips are attached to
the top of the caliper to retain the

FIG.

6-Typical Caliper Assembly-Sectional View

PISTON

1

BRAKES APPLIED

FIG.

7-Function of Piston Seal

shoe and lining assemblies. The cali­per assembly is mounted to a bracket
located between the spindle and rotor
splash shield, to the front of the
wheel vertical centerline.

The cast iron disc is of the venti­lated rotor type. incorporating forty
fins and is attached to, and rotates
with, the wheel hub. The outside

'

diameter of the rotor is 11.290 in-

ches and the inside diameter is 7.170,

inches. This type of design increases

cooling area and permits circulation
of air through the rotor resulting in

-

more rapid cooling of the brake. A
splash shield bolted to the spindle is
used primarily to prevent road con-

taminants from contacting the inboard

rotor and lining surfaces (Fig. 17).
The wheel provides protection for the
outboard surfaces of the rotor.

As the brake pedal is depressed,
hydraulic pressure from the master
cylinder forces the pistons out of the
caliper bores against their respective
shoe and lining assemblies. The
force of the pistons against the shoes
moves the linings against both sides

BRAKES RELEASED

til3m~

of the revolving rotor to effect brak-

ing action.

During brake application, the rub­ber seal on each piston stretches as
the piston moves against the shoe
(Fig. 7). When the hydraulic pres-

sure against the piston is released,
the seal relaxes or rolls back. This

roll-back action pulls the piston away
from the shoe just enough to relieve
the force of the lining against the
rotor and, thereby, provide the re-

quired running clearance. Also, inher­ent rotor

runout contributes to the

maintenance of running clearance.

Automatic adjustment is achieved by

the pistons sliding in the seals out­ward from the cylinder bores. The pis­ton gradually changes its position rela­tive to the seal as the lining wears
and, thus, maintains the correct ad-

justment location at all times.

-

When the brakes- are in the un­applied position, there is no hydrau­lic pressure to the calipers because
the fluid source at the master cylin­der by-passes the residual check
valve.

PART

2-2-Brake System 2-1

3

CLIP MUST NOT TOUCH OR COVER

RUBBER

RING AROUND OUTSIDE

OF VALVE

ASS,EMBLY

A

DlSC BRAKE PRESSURE

CONTROL VALVE
ASSEMBLY-ZBOPI B0LT-376459-S2

INSTALLATION-DISC BRAKES ONLY

TUBE-2265

TORQUE TO 6.15 LB. FT.

DlSC BRAKE CONTROL

TUBE-2265

PROPORTIONING VALVE

I

ASSEMBLY-26272 TUBE-2B113

FLAT SlDE 0F"D" SHAPED HOLE
MUST BE LOCATED ON INBOARD
SlDE OF HOSE BRACKET

HOSE-2A448

BOLT-376459.52

INSTALLATION-DISC BRAKES SAME AS

INSTALLATION-DISC

i3RAKE ALTERNATE ONLY

MAIN VIEW EXCEPT AS SHOWN

H1561-A

NG.

8-Disc Brake Pressure Control Valve

REAR BRAKE

NG.

9-Self-Adjusting Brake Assemblies-9 Inch Drum

A

disc brake pressure control valve
located between the pressure differen­tial valve and the rear brake wheel
cylinders provides balanced braking
action between the front and the rear
brakes under a wide range of braking
conditions (Fig.

8).

By regulating the
hydraulic pressure applied to the rear
wheel cylinders, the valve limits rear
braking action when high pressures
are required at the front brakes. In
this manner.

Dremature rear wheel

skid is

prevdnied.

The

proportioning

valve is serviced as an

assemblv and

is never adjusted or overhauled.

HYDRAULIC SELF-ADJUSTING

BRAKE SYSTEM

The self-adjusting brake mecha­nism consists of a cable, cable guide,
adjusting lever, and adjuster spring
(Figs.

9

and 10). The cable is hooked
over the anchor pin at the top and is
connected to the lever at the bottom.
The cable is connected to the sec­ondary brake shoe by means of the

cable guide. The adjuster spring is
hooked to the primary brake shoe
and to the lever. The automatic ad­juster operates only when the brakes
are applied while the car is moving

rearward and only when the second­ary shoe is free to move toward the
drum beyond a predetermined point.

With the vehicle moving rearward
and the brakes applied, the wrap­around action of the shoes follow­ing the drum forces the upper end
of the primary shoe against the
anchor pin. The action of the wheel
cylinder moves the upper end of the
secondary shoe away from the an­chor pin. The movement of the sec­ondary shoe causes the cable to pull
the adjusting lever upward and
against the end of a tooth on the
adjusting screw star-wheel. The up­ward travel of the lever increases as
lining wear increases. When the lever
can move upward far enough, it
passes over the end of the tooth and
engages the tooth. When the brakes
are released, the adjusting spring

FRONT BRAKE

pulls the lever downward causing the
star-wheel to turn and expand the
shoes. The star-wheel is turned one
tooth at a time as the linings pro­gressively wear.

With the vehicle moving forward
and the brakes applied, the secondary
shoe is against the anchor pin and
the primary shoe is moved toward
the drum. Therefore, the adjuster
does not operate.

The rear brake assembly is basic­ally the same as the front brake.
The conventional parking brake lever,
link, and spring are used in the rear

brake.

The anchor pins on all brakes are

fixed and are non-adjustable.

BRAKE BOOSTER SYSTEM

The diaphragm-type brake booster

is a self-contained vacuum-hvdraulic
braking unit mounted on thd engine
side of the dash panel. The brake
booster is of the vacuum suspended
type which utilizes engine intake

2-1

4

GROUP

2-Bra

kes

FIG.

10-Self

Adiusting Brake Assemblies-

10

Inch Drum

manifold vacuum and atmospheric pres-

forced against the rear brake drums.

drums. The pedal is held in the ap-

sure for its power. The handle is held in the applied plied position by the engagement of

Adjllstment of the push rod is the

position by the engagement of a a spring-loaded pawl with a ratchet

only service permitted on a brake

spring loaded pawl with a ratche!. in the control assembly (Fig.

32).

booster. The booster unit is to be

Turning the handle counterclockwise

The. parking brake control assem-

exchanged when it is inspected, check-

disengages the pawl from the ratchet

bly

is

mounted

to

the

cowl

inner

side

ed and found to be defective.

to release the brakes.

panel. The

cedal ~ivots on a station-

PARKING BRAKES-MUSTANG
AND COUGAR

PARKING

BRAKES-

COMET, FAIRLANE AND

An independent hand-operated park­ing brake control actuates the rear
wheel brake shoes through a cable
linkage. The operating cable is routed
from the parking brake control as­sembly to the equalizer pivot lever
which is attached to the equalizer

assembly to the floor pan. The rear
brake cables connect the equalizer

assembly to the parking brake lever

at each rear secondary shoe as shown

in Figs.

9,

10

and

3

1.

When the handle is pulled the pri­mary and secondary brake shoes are

FALCON

An independent foot-operated park­ing brake control actuates the rear
wheel brake shoes through a cable
linkage. The operating cable is routed
from the parking brake control as­sembly to the equalizer. The rear
brake cables connect the equalizer as­sembly to the parking brake lever at
each rear secondary shoe (Fig.

9).

.

When the pedal is depressed the
primary and secondary brake shoes
are forced against the rear brake

ary pedal 'mouni. A spring-loaded

pawl and a release lever are assem­bled to the pedal. A ratchet is as­sembled to the upper end of the

pedal. The pawl contacts the ratchet
at such an angle that the ratchet
teeth will slide over the pawl as the

pedal is depressed; however, when
the applying motion stops and the
pedal starts to release, the pawl en­gages the ratchet and thus locks the
brakes in the applied position.

When the manual release lever is

pulled back (Fig.

32),

the cam ac­tion of the lever on the pawl cam
pin will disengage the pawl from the

ratchet to release the brakes.

IN-VEHICLE ADJUSTMENTS AND REPAIRS

Alter any brake service work, ob-

BRAKE SHOE ADJUSTMENTS

tain a firm brake pedal before moving

-DRUM BRAKE

the vehicle. Riding the brake pedal

(common on left foot applications)

The hydraulic service brakes are

should

be avoided when driving the

self-adjusting and require a manual

vehicle.

adjustment only after the brake

shoes have been relined, replaced, or
when the length of the adjusting
screw has been changed while per-

forming some other service opera­tion.

The manual adjustment is per-

formed with the drums removed,

us-

Tool

-

HRE8650

FIG. 1 ]-Measuring Drum

ing the tool and the procedure de­tailed below.

When adjusting the rear brake
shoes, check the parking brake ca­bles for proper adjustment. Refer to
Parking Brake Linkage Adjustment,
Part 2-1, Section 2. Make sure that
the equalizer operates freely.

To adjust the brake shoes:

1. Using Rotunda Tool

HRE

8650,

(Fig.

I

I)

determine the inside
diameter of the drum braking sur­face.

2.

Reverse the tool as shown

in

Fig. 12 and adjust the brake shoe
diameter to fit the gauge. Hold the
automatic adjusting lever out of en­gagement while rotating

the adjust­ing screw, to prevent burring the
screw slots. Make sure the adjust­ing screw rotates freely. If neces-

sary, lubricate the adjusting screw
threads with a thin, uniform coating

of CIAZ- 19590-B Grease.

3.Rotate Tool HRE

8650

around the brake shoes to be sure
of the setting.

4.

Apply a small quantity of high
temperature grease to the points
where the shoes contact the carrier
plate and anchor pin, being careful

not to get the lubricant on the linings.

5.

Install the drums. Install the

Tinnerman nuts and tighten securely.

Install the wheel on the drum and
tighten the mounting nuts to specifi­cation.

6.

Complete the adjustment by ap­ply ing the brakes several times with
a minimum of 50 Ibs pressure on the
pedal while backing the car. After

each stop, the vehicle must be moved

forward.

7.

After the brake shoes have
been properly adjusted, check the
operation of the brakes by making

several stops while operating in a
forward direction.

FRONT BRAKE DRUM

REMOVAL

1.

Raise the vehicle untiI the

PART

2-2-Bra

ke

System

FIG. 12-Measu ring Shoes

wheel and tire clear the floor. Remove
the wheel cover or hub cap, and re­move the wheel and tire from the
drum.

2.

Remove the grease cap from
the hub. Remove the cotter pin, nut
lock, adjusting nut, and flat washer
from the spindle. Remove the outer
bearing cone and roller assembly.

3. Pull the hub and drum assem-

bly off the wheel spindle.

4.

If the drum will not come off,
remove the rubber cover from the
brake backing plate. Insert a narrow

screwdriver through the slot and

disengage the adjusting lever from
the adjusting screw. While holding
the adjusting lever away from the
screw, back off the adjusting screw

with the brake adjusting tool (Fig.

13).

Be

very careful not to burr,
chip, or damage the notches in the
adjusting screws; otherwise the self­adjusting mechanism will not func­tion properly.

INSTALLATION

I.

If the drum is being replaced,
remove the protective coating from
the new drum with carburetor

de-

greaser; then, sand lightly and wipe

with a cloth soaked with denatured

alcohol. Install new bearings and
grease retainer. Soak the new ser­vice-type grease retainer in light
engine oil for at least 30 minutes
before installation

if

retainer is

of a leather composition. Pack the

wheel bearings, install the inner
bearing cone and roller assembly in
the inner cup, and install the new
grease retainer. See Part 3-5, Sec­tion

4

for procedure.

If the original drum is being in-

stalled, make sure that the grease

in the hub is clean and adequate.

2.

Adjust the brakes and install the
drum assembly as outlined under
Brake Shoe Adjustments in this sec­tion.

FIG. 13- Backing

Off

Brake

Adiustment

3. Install the outer wheel bearing,

washer and adjusting nut.

4.

Adjust the wheel bearing as out-

lined in Part 3-5, Section 2, then in­stall the grease cap. Install the wheel
and hub cap or cover.

REAR BRAKE DRUM

REMOVAL

1. Raise the vehicle so that the

wheel is clear of the floor.

2.

Remove the hub cap and wheel.
Remove the three Tinnerman nuts
and remove the brake drum. If the

drum will not come off, remove the

rubber cover from the backing plate.
Insert a narrow screwdriver through

the hole in the backing plate, and
disengage the adjusting lever from

the adjusting screws. While holding
the adjusting lever away from
the adjusting screw, back off the ad­justing screw with the brake ad­justing tool (Fig. 13). Be very care-

ful not to burr, chip or damage the
notches in the adjusting screw; other­wise, the self-adjusting mechanism
will not function properly.

INSTALLATION

1.

Remove the protective coating

from a new drum with carburetor

degreaser; then, sand lightly and

wipe with a cloth soaked in denatured
alcohol.

2.

Adjust the brakes as outlined

under Brake Shoe Adjustments in this

section.

3. Place the drum over the brake
assembly and into position. Install
the three Tinnerman nuts and tighten
them securely. Install

the wheel on

the axle shaft flange studs against

the drum, and tighten the attaching

nuts to specifications.

GROUP

2-Bra

kes

BRAKE SHOES AND
ADJUSTING

SCREW

REMOVAL

1.

With the wheel and drum re­moved, install a clamp over the ends
of the wheel cylinder as shown in
Fig. 14.

2.

Remove the brake retracting

springs

+sing Tool 2035-N or 2086-

L

(Fig. 14).

3.

Disconnect the brake shoe hold-

down springs and remove the brake

shoe assemblies along with the com­plete automatic adjustment mecha­nism.

4.

Disassemble the brake shoes.

5.

On rear brakes, remove the
parking brake link and spring from
the brake assemblies. Disconnect the
parking brake cable from the parking
brake lever.

6.

After removing the rear brake
shoes disassemble the parking brake
lever from the secondary shoe by re-

moving the retaining clip and spring

washer (Figs.

9

and 10).

INSTALLATION

1.

Before installing the rear brake

shoes, assemble the parking brake

lever to the secondary shoe and se-

cure it with the spring washer and

retaining clip.

2.

Apply a light coating of high­temperature grease at the points
where the brake shoes contact the
backing plate.

3.

Position the brake shoes on the
backing plate and secure them with
the hold down springs. On the rear
brake, install the parking brake link

and spring. Connect the parking
brake cable to the parking brake
lever (Figs.

9

and 10).

Install the cable guide on the

secondary shoe web with the flanged

hole properly fitted into the hole in

the secondary shoe web. Install the
secondary spring (secondary shoe to
anchor spring) (Figs.

9

and 10).

5.

Place the cable eye over the an­chor pin with the crimped side to­ward the backing plate.

lnstall the
primary shoe to anchor spring with
the tool shown in Fig. 15.

6.

Thread the cable around the ca-

ble guide groove.

It is imperative that the cable be
positioned in this groove and not be­tween the guide and the shoe web.

Be

certain that the cable eye is not
cocked or binding on the anchor pin
when installed. All parts should be
flat on the anchor pin.

Remove the

brake cylinder clamp.

7.

Apply a small amount of high-

temperature grease (Part Number
CIAZ-19580-B) to the threads and
the socket end of the adjusting screw.
Turn the adjusting screw into the ad­justing pivot nut to the limit of
the threads and then back off

112

turn.

Interchanging the brake shoe ad­justing screw assemblies from one
side of the vehicle to the other would
cause the brake shoes to retract

rather than expand each time the

automatic adjusting mechanism op-

erated.

To prevent accidental instal­lation of the adjusting screw on the
wrong side of the vehicle the socket

end of the adjusting screw is stamped

with an R or

L

(Fig. 16). The ad-

justing pivot nuts can be distin-

guished by the number of grooves
machined around the body of the
nut. Two grooves indicate a right­hand nut; one groove indicates a left-

hand nut.

8.

Place the adjusting socket on

the screw and install this assembly

between the shoe ends with the

ad-

jpsting

screw toothed wheel nearest

the secondary shoe.

9.

Hook the cable hook into the

hole in the adjusting lever. The ad-

justing levers are stamped with an

R

or L to indicate their installation
on a right or left brake assembly
(Fig.

16):

10.

Position the hooked end of
the adjuster spring completely into
the large hole in the primary shoe
web. The last coil of the spring
should be at the edge of the hole.
Connect the loop end of the spring
to the adjuster lever hole (Figs.

9

and 10).

11.

Pull the adjuster lever, cable

and automatic adjuster spring down
and toward the rear to engage the
pivot hook in the large hole in the

secondary shoe web.

12.

After installation, check the ac­tion of the adjuster by pulling the sec­tion of the cable between the cable

guide and the anchor pin toward the
secondary shoe web far enough to
lift the lever past a tooth on the
adjusting screw wheel. The lever
should snap into position behind the

next tooth, and release of the cable

should cause the adjuster spring to

return the lever to its original posi­tion. This return action of the lever
will turn the adjusting screw one
tooth.

If

pulling the cable does not pro-

duce the action described, or

if

the
lever action is sluggish instead of
positive and sharp, check the posi­tion of the lever on the adjusting
screw toothed wheel. With the brake
in a vertical position (anchor at the

FIG.

14-Retracting Spring Removal

-Typical

NG.

15- Retracting Spring

Installation -Typical

top), the lever should contact the
adjusting wheel 3/16 inch (plus

or

minus 1/32 inch) above the center-

line of the screw. If the contact point

is below the centerline, the lever will

not lock on the teeth in the adjusting
screw wheel, and the screw will not
be turned as the lever is actuated by
the cable.

To determine the cause of this

condition:

a.

Check the cable end fittings,
The cable should completely fill or
extend slightly beyond the crimped

section of the fittings.

If

it does not
meet this specification, possible dam­age is indicated and the cable assem­bly should

be

replaced.

b.

Check the cable length. The ca-

ble should measure 8 13/32 inches on

9

inch brakes or 9 314 inches on 10

inch brakes from the end of the cable

anchor to the end of the cable hook.

c.

Check the cable guide for dam-

age. The cable groove should

be

parallel to the shoe web, and the

body of the guide should lie flat

against the web. Replace the guide
if

it shows damage.

d.

Check the pivot hook on the

lever. The hook surfaces should

be

square with the body of the lever
for proper pivoting. Replace the
lever

if

the hook shows damage.

PART

2-2-Bra

ke

System-

2-1

7

be

done in a way to avoid deiorma-

tion

of the brake rotor and nicking

or scratching of brake linings.

3.

If the square sectioned rubber
piston seals are worn or damaged,
they should be replaced immediately.

4.

During removal and installation

ADJUSTING

SCREW

IDENTIFICATION LINES

H1143-0

FIG.

16-Adjusting Screw and Lever

Identification

e.

See that the adjusting screw
socket is properly seated in the notch
in the shoe web.

DISC BRAKE SHOE AND
LINING REPLACEMENT

DISC BRAKE SERVICE
PRECAUTIONS

1.

After any brake service work,
pump the brake pedal to obtain a

firm pedal before moving the car.

Riding the brake

pedal (common on
left foot applications) should be
avoided when driving the car.

2.

Grease or any other foreign

material must be kept off the caliper

assembly, surfaces of the rotor and

external surfaces of the hub during

service operations. Handling of the

rotor and caliper assemblies should

of a

wheei assembly, exercise care
not to interfere with and damage the
caliper splash shield, the bleeder
screw fitting or the transfer tube.

5.

Front wheel bearing end play is
critical and must be within specifica­tions.

6.

Be sure the vehicle is centered
on the hoist before servicing any front

end components, to avoid bending or
damaging the rotor splash shield on
full right or left wheel turns.

7.

The bridge bolts joining the two­caliper housings should not be re­moved or loosened.

8.

The proportioning valve should

not be disassembled or adjustments

attempted on it.

9.

The wheel and tire must be re-

moved separately from the brake ro­tor, unlike drum brakes where the
wheel, tire and drum are removed as

a unit.

REMOVAL

Refer to Fig. 17.

1.

Remove the wheel and tire

from the hub and rotor assembly.

Be

careful to avoid damage or in­terference with the bleeder screw fit­ting ortransfer tube.

2.

Remove the two bolts that
attach the caliper brake shoe retain­ing clips, and remove the clips (Fig.

17).

3.

To facilitate removal and in­stallation of the shoe and lining as­semblies, the pistons must be pushed
into their bores. Apply a steady in­ward pressure against each shoe and
lining assembly toward its respective

caliper housing on each side of the

rotor (Fig.

6).

Maintain the pressure
for at least a minute. If the pistons
will not go in easily, force them in

with water pump pliers.

4.

Grasp the metal flange on the
outer end of the shoe with two pairs
of pliers and pull the shoe out of the
caliper (Fig.

18).

INSTALLATION

Refer to Fig. 17.
When new shoe and lining assem-

blies are being installed to replace

worn linings, it will be necessary to
push the pistons all the way into the
caliper bore. This will displace fluid
from the caliper into the master
cylinder reservoir. Check the primary

(front) brake system reservoir level

and remove fluid to approximately
half-full before replacing brake shoes.
This will prevent overflow.

Do not

re-use the removed fluid.

1.

Position a new shoe and lining
assembly on each side of the rotor
so that the lining faces the rotor.

CALIPER PARTS-2BI2O-R.H. -2BI2I-L.H.

TRANSFERTUBE

UTBOARD HOUSING

20990-5

CALIPER

ASSEMBLY

WHEEL-1007

2

1

3105-R.H.

3lOh.L.H.

H1401-C

FIG.

17-Disc Brake Disassembled