Ford Service Repair Manual by ferrymul

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2-2                                                     GROUP 2 - BRAKES

TABLE 1-Disc           Brake Trouble Symptoms and Possible Causes
                                                                                       TROUBLE SYMPTOMS


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Shoe and Lining Knock-back after violent cornering or
 rough road travel                                                  X
Piston and Shoe and Lining Assembly Not Properly
  Seated or Positioned                                              X                                                         X
Air Leak or Insufficient Fluid in System or Caliper                 X                                                         X
                                         PART 2- 1 - GENERAL BRARE SERVICE   2-3

TABLE 2-Drum            Brake Trouble Symptoms and Possible Causes




                    Possible Causes of
                    Trouble Symptoms




 Sticking Booster Control Valve
                                                                               I
                                                 GROUP 2 -BRAKES

BRAKE BOOSTER TROUBLE DIAGNOSIS GUIDE

                                            If the preliminary tests show that        leaking or collapsed condition. Re-
                                         the booster is inoperative or if a           pair or replace parts as necessary.
                                         hard pedal condition still exists after         If the foregoing procedure does
                                         eliminating the causes of Hard               not eliminate the trouble, remove
                                         Pedal listed in Table 2, the trouble         the booster from the car. Separate
                                         may be caused by vacuum leakage.             the booster body from the end plate,
   BOOSTER INOPERATIVE-                  Disconnect the vacuum line (two              and check the bellows, booster body,
   HARD PEDAL                            lines if equipped with an automatic          and diaphragm assembly for damage
                                         transmission) at the booster, remove         that would cause leaks. When assem-
                                         the vacuum manifold and check                bling, be sure that the diaphragm as-
                                         valve assembly, and look for a stick-        sembly is properly positioned. Im-
                                         ing or faulty check valve. Check all         proper location could cause leakage
                                         vacuum connections for leakage or            between the vacuum and atmos-
                                         obstruction. Check all hoses for a           pheric sides of the diaphragm.


                                            If the brakes still drag or grab          assembly. Remove and disassemble
   BRAKES DRAG OR GRAB                   after eliminating the causes listed in       the booster. Clean, inspect, and re-
                                         Table 1, the condition is probably           place parts as necessary.
                                         caused by a sticking valve plunger


   SELF APPLICATION                        Remove and disassemble           the       seated atmospheric valve. Clean, in-
   O F BRAKES W H E N                    booster. Check the diaphragm       for       spect, and replace parts as necessary.
   ENGINE STARTS                         being out of locating radii in     the       Be sure that the diaphragm is prop-
                                         housing. Check for a sticking or   un-       erly located when assembling.



        COMMON ADJUSTMENTS AND REPAIRS
PARKING BRAKE                               pedal one notch from its normal              that the end of the screw just touches
LINKAGE ADJUSTMENT                          released position.                           the inner edge of the slot in the
                                                3. Raise the car.                        gauge. Do not set up side forces on
MUSTANG                                         4. Loosen the equalizer lock nut         the push rod. Side forces may break
    Check the parking brake cables          and turn the adjusting nut forward           the valve plunger.
when the brakes are fully released.          against the equ&zer-until a mod-               This is an approximate adjustment
If the cables are loose, adjust them         erate drag is felt when turning the         only. The push rod should not move
as follows:                                 rear wheels (Fig. 2). Tighten the            more than 0.015 inch as it contacts
    1. Fully release the parking brake       lock nut.                                   the master cylinder piston. No move-
by turning the handle counterclock-             5. Release the parking brake,            ment (exact contact) is ideal.
wise and pushing it inward.                 and' make sure that the brake shoes
  . 2. Pull the parking brake handle        'return to the fully released position.      HYDRAULIC SYSTEM
outward to the third notch from its                                                      BLEEDING
normal released position.                   POWER BRAKE MASTER                              When any part of the hydraulic
    3. Raise the car.                       CYLINDER PUSH ROD                            system has been disconnected for re-
   4. Turn the locking adjustment nut       ADJUSTMENT                                   pair or replacement, air may get
forward against the equalizer (Fig.            The push rod is provided with an          into the lines and cause spongy pedal
1) until a moderate drag is felt when       adjustment screw to maintain the             action. Bleed the hydraulic system
turning the rear wheels in the direc-       correct relationship between the             after it has been properly con-
tion of forward rotation.                   booster control valve plunger and            nected to be sure that all air is
    5. Release the parking brake, and       the master cylinder piston. Failure          expelled from the brake cylinders
make sure that the brake shoes              to maintain this relationship will pre-      or disc brake calipers, and lines.
return to the fully released position       vent the master cylinder piston from            The hydraulic system can be bled
and no drag is felt when turning the        completely releasing hydraulic pres-         manually or with pressure bleeding
rear wheels.                                sure and can cause the brakes to             equipment.
                                            drag, or cause excessive brake pedal            With disc brakes, more pumping
COMET-FALCONFAIRLANE                        travel.                                      of the pedal is required and more
   Check the parking brake cables              T o check the adjustment of the           frequent checking of the master cyl-
when the brakes are fully released.         screw, fabricate a gauge of the di-          inder may be necessary while bleed-
If the cables are loose, adjust them        mension shown in Fig. 3. Then place          ing.
as follows:                                 the gauge against the master cylin-             On a car with disc brakes, remove
   1. Fully release the parking brake       der mounting surface of the booster          the front wheels and tires to gain
pedal.                                      body as shown in Fig. 4 or 5. The            access to the bleeder fitting on the
   2. Depress the parking brake             push rod screw should be adjusted so         disc brake calipers.
                                           PART 2-1 -GENERAL BRAKE SERVICE                                             2-5




                             \FRONT     CABLE


FIG. 1-Parking       Brake Linkage-Mustang

            ADJUSTMENT NUT    LOCKNUT


                                                 r #16 G A U G E
                                                    SHEET STEEL




                EQUALIZER       H 1405-A


FIG. 2-Parking Brake
Linkage Adjustment Comet-
Fairlane-Falcon
                                                                                      FIG. 4-Push      Rod Adjustment
MANUAL BLEEDING                                                                       -Midland-Ross
   Bleed the longest lines first. Keep
the master cylinder reservoir filled                                                     1. Position a bent %-inch box
with new Rotunda R-103-A (B7AZ-                                                       wrench on the bleeder fitting on the
19542-A) brake fluid during the                                                       rieht rear brake wheel cylinder (Fig.
bleeding operation.                                                        14,208-B   6; Attach a rubber drain tube to
   Never use brake fluid which has                                                    the bleeder fitting. The end of the
been drained from the hydraulic sys-            FIG. 3-Push        Rod Gauge          tube should fit snugly around the
                                                                                                           -
tem.                                            Dimensions                            bleeder fitting.
                                                  GROUP 2 - BRAKES

                                                4. When the fluid is completely            sealed o n the master cylinder o r
                                             free of air bubbles, close the bleeder        leakage will occur.
                                             fitting and remove the drain tube.        '       3. Position a %-inch box wrench
                                                5. Repeat this procedure o n the           on the bleeder fitting on the right
                                             brake cylinders o r disc calipers at          rear brake wheel cylinder (Fig. 6).
                                             each wheel in order: left rear, right         Attach a rubber drain tube to the
                                             front, and left front. Refill the mas-        bleeder fitting. The end of the tube
                                             ter cylinder reservoir after each             should fit snugly around the bleeder
                                             brake cylinder is bled and when the           fitting.
                                             bleeding operation is completed. T h e           4. Open the valve o n the bleeder
                                             fluid level should be within 3/8 inch         tank to admit pressurized brake fluid
                                             of the top of the reservoir. T h e dia-       to the master cylinder reservoir.
                                             phragm-type gasket should be prop-                5. Submerge the free end of the
                                             erly positioned in the reservoir cap          tube in a container partially filled
                                             before the cap is installed.                  with clean brake fluid, and loosen
                                                 6. On a car with disc brakes,             the bleeder fitting.
                                             pump the brake pedal until the front
                                                                                               6 . When air bubbles cease to ap-
                                             brake pistons are returned to their
                                                                                           pear in the fluid at the submerged
                                             normal positions and that the shoe
                                                                                           end of the drain tube, close the
                                             and lining assemblies are properly
                              /              seated.                                       bleeder fitting and remove the tube.
    FIG. 5-Push-Rod          Adjustment-        7. Before driving the car, check               7. Repeat this procedure on the
    Bendix                                   the operation of the brakes and be            brake cylinder o r disc caliper at each
                                             sure that a firm pedal is obtained.           wheel in order: left rear, right front,
      APPROXIMATELY 45"
                                                                                           and left front. Refill the master cyl-
               \                             PRESSURE BLEEDING                             inder reservoir after each brake cyl-
                                                Bleed the longest lines first. Never       inder is bled.
                                             use brake fluid which has been                    8. When the bleeding operation is
                                             drained from the hydraulic system.            completed, close the bleeder tank
                                                The bleeder tank should contain            valve and remove the tank hose from
                                             enough new heavy-duty brake fluid             the adapter fitting.
                                             to complete the bleeding operation,               9. ~ k m o v ethe adapter cap, re-
                                             and it should be charged with 10-30           fill the master cylinder reservoir to
                                             pounds of air pressure.                       within %-inch from the top of the
    FIG. 6-Brake          Bleeder Wrench                                                   reservoir. Be sure that the dia-
                                                 1. Clean all dirt from the master
       2. Submerge the free end of the       cylinder reservoir cap.                       phragm-type gasket is properly po-
    tube in a container partially filled         2. Remove the master cylinder             sitioned in the reservoir cap, and then
    with clean brake fluid. Loosen the       reservoir cap, install an adapter              install the cap.
    bleeder fitting approximately % turn.
                                  I          cap to the reservoir, and attach the              10. On a car with disc brakes,
       3. Push the brake pedal down          bleeder tank hose to the fitting on           pump the brake pedal until the front
    slowly through its full travel. Close    the adapter cap.                              brake pistons are returned to their
    the bleeder fitting, then return the         An adapter cap can be fabricated          normal positions and the shoe and
    pedal to the fully-released position.    byecutting a hole in the center of a          lining assemblies are properly seated.
    Repeat this operation until air          reservoir cap and smoldering a fitting         +  11. Before driving the car, check
    bubbles cease to appear at the sub-      at the hole. T h e adapter cap must           the operation of the brakes and be
    merged end of the tube.                  b e , securely seated and completely          sure that a firm pedal is obtained.



            CLEANING AND INSPECTION
I
I
I
    DISC BRAKES
       1. Remove the wheel and tire,
                                                3. With the shoe and lining as-
                                             semblies installed, insert a feeler
                                                                                              4. T o check rotor runout, first
                                                                                           eliminate the wheel bearing end play
    caliper splash shield, and the shoes     gauge between the lining and rotor.           by tightening the adjusting nut.
    and linings as outlined in Part 2-2,     If the clearnace is not within 0.002-         After tightening the nut make cer-
    Section 2.                               0.010-inch, check for shoe and lining         tain that the rotor can still be ro-
       2. Make three thickness measure-      assemblies not being properly seated          tated.
    ments with a micrometer across the       on the caliper bridges, for a piston             5. Clamp a dial indicator to the
    middle section of the shoe and lin-      pushed back in the cylinder bore, for         caliper housing so that the stylus

i   ing. T a k e one reading a t each side   a seized piston, o r for malfunction          contacts the rotor at a point approxi-
    and one in the center. If the assem-     of a piston seal.                             mately 1 inch from the outer edge.
    bly has worn to a thickness of              Ordinarily, the clearance should           Rotate the rotor and take an indica-
    0.195-inch (shoe and lining together)    be 0.002-0.010 inch. However, if the          tor reading. If the reading exceeds
    at any one of the three measuring lo-    car was stopped by a brake applica-           0.0025 inch total indicator runout,
    cations, replace all (4) shoe and lin-   tion just prior to checking the clear-        replace the rotor. D o not attempt to
    ing assemblies on both front wheels.     ance, the brakes may drag slightly.           refinish a rotor that indicates runout
                                          PART 2-1 - GENERAL BRAKE SERVICE

in excess of specification. When the           3. Inspect the brake shoes for ex-    and replace     any that are worn or
runout check is finished be sure to         cessive lining wear or shoe damage.      damaged.
adjust the bearings as outlined in          If the lining is worn to within '132        7. Inspect    the brake drums and,
Group 3, in order to prevent bearing        inch of the rivet heads or if the        if necessary,   refinish. Refer to Part
failure.                                    shoes are damaged, they must be re-      2-2, Section    4 for refinishing.
   6. Check the rotor for scoring.          placed. Replace any lining that has
Minor scores can be removed with            been oil saturated. Replace the lin-     BOOSTER UNITS
a fine emery cloth. If the rotor is         ing in axle sets. Prior to replacement      Disassembled views of the brake
excessively scored, replace it.             of the lining, the drum diameter         booster are shown in Figs. 40, 49 and
   7. Visually check the caliper. If it     should be checked to determine if        SO, Part 2-2.
is cracked it should be replaced. If        oversize linings must be installed.         After disassembly, immerse all
leakage o r seized pistons is evident,         4. Check the condition of the         metal parts in a suitable solvent.
disassemble and repair the caliper as       brake shoes, retracting springs, and     Use-only alcohol on rubber parts o r
required.                                   drum for signs of overheating. If the    parts containing rubber. After the
   8. If upon disassembly the caliper       shoes have a slight blue coloring, or    parts have been thoroughly cleaned
is found to be distorted or damaged,        if the springs show a change in free     and rinsed in cleaning solvent, the
or if the cylinder bores are scored         length, indicating overheating, re-      metal parts which come in contact
or excessively worn, replace the as-        placement of the retracting and hold     with hydraulic brake fluid or rub-
sembly.                                     down springs is necessary. Over-         ber parts should be rewashed in
   The two halves of the caliper as-        heated springs lose their force and      clean alcohol before assembly. Use
sembly should never be separated.           could cause the new lining to wear       an air hose to blow dirt and cleaning
Damage or failure of one requires           prematurely if they are not replaced.    fluid from the recesses and internal
replacement of both as a unit.                 5. If the car has 30,000 or more      passages. When overhauling a power
                                            miles of operation on the brake lin-     booster, use all parts furnished in the
D R U M BRAKES                              ings, or signs of overheating are        repair kit. Discard all old rubber
   1 Remove the wheel from the
     .                                      present when relining brakes, the        parts.
drum, and remove the drum as out-           wheel cylinders should be disassem-         Inspect all other parts for damage
lined in Part 2-2, Section 2. Wash          bled and inspected for wear and dirt     or excessive wear. Replace damaged
all the parts except the brake shoes        in the cylinder. The cylinder cups       or excessively worn parts. If the in-
in a cleaning fluid and dry with com-       and other parts contained in the         side of the booster body is rusted
pressed air.                                overhaul kit should be replaced,         or corroded, polish it with steel wool
   2. Brush all dust from the carrier       thus avoiding future problems.           or fine emery cloth.
plate and interior of the brake drum.          6. Inspect all other brake parts
        PART                    BRAKE SYSTEM

                                                                                                                           .
Section                                                           '       Page    Section                                                                  Page
  1 Description and Operation . . . . . . . . . . . . . . . . ..2-8                    Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . .2-24
    Hydraulic Self-Adjusting Brake System . . . . . . .2-8                             Brake Tube Replacement . . . . . . . . . . . . . . . . .2-24
    Disc Brake Assemblies . . . . . . . . . . . . . . . . . . .2-8 .                   Brake Hose Replacement . . . . . . . . . . . . . . . . . ..2-24
    Booster System-Bendix              . . . . . . . . . . . . . . . . . .2-11      3 Removal and Installation . . . . . . . . . . . . . . . . .2-24
    Booster System-Midland-Ross                    . . . . . . . . . . . .2-13         Master Cylinder-Standard             Brakes . . . . . . . . .2-24
    Parking Brake . . . . . . . . . . . . . . . . . . .: . . . . . .2-14          .    Master Cylinder-Power             Brakes . . . . . . . . . .2-24
 2 In-Car Adjustments and Repairs . . . . . . . . . . ..2-16 .                         Booster Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
    Brake Shoe Adjustments . . . . . . . . . . . . . . . . ..2-16                      Brake Pedal-Manual          Shift Transmission ... .2-25
    Front Brake Drum . . . . . . . . . . . . . . . . . . . . . . . .2-17               Brake Pedal-Automatic            Transmission . . . . . .2-27
    Rear Brake Drum . . . . . . . . . . . . . . . . . . . . . . ..2-17                 Parking Brake Control Assembly . . . . . . . . . . . .2-27
    Brake Shoes and Adjusting Screw . . . . . . . . . . .2-17                        . Parking Brake Equalizer to Control Cable . . . .2-27
    Disc Brake Shoe and Lining Replacement . . . .2-18                                 Parking Brake Equalizer to Rear Wheel Cable .2-30
    Disc Brake Caliper Assembly . . . . . . . . . . . . .2-19                       4 Major Repair Operations . . . . . . . . . . . . . . . . .2-3 1
    Front Wheel Hub and Rotor Assembly-Disc                                            Brake Drum Refinishing . . . . . . . . . . . . . . . . . ..2-3 1
      Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19        Brake Shoe Relining . . . . . . . . . . . . . . . . . . . . .2-3 1
    Disc Brake Rotor Splash Shield . . . . . . . . . . . . .2-20                       Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 1
    Proportioning Valve . . . . . . . . . . . . . . . . . . . . .2-20                  Disassembly of Bendix Type Booster . . . . . . . . .2-33
    Wheel Cylinder Repair . . . . . . . . . . . . . . . . . . ..2-21                   Assembly of Bendix Type Booster . . . . . . . . .2-34
    Wheel Cylinder Replacement . . . . . . . . . . . . . . .2-2 1                      Disassembly of Midland-Ross Type Booster . . .2-35
    Brake Carrier Plate Replacement . . . . . . . . . . . .2-24                        Assembly of Midland-Ross Type Booster . . . . .2-36




          DESCRIPTION AND OPERATION
   Disc brakes are available as op-                     ondary brake shoe by means of the                    gressively wear.
tional equipment for the front wheels                   cable guide. The adjuster spring is                     With the car moving forward and
on Mustang 8-cylinder cars. The hy-                     hooked to the primary brake shoe                     the brakes applied, the secondary
draulic brake system employs duo-                       and to the lever. The automatic ad-                  shoe is against the anchor pin and
servo single anchor, internal expand-                   juster operates only when the brakes                 the primary shoe is moved toward
ing and self-adjusting drum brake as-                   are applied while the car is moving                  the drum.. Therefore, the adjuster
semblies on the rear wheels of cars                     rearward and only when the second-                   does not operate.
with disc brakes, and of front and                      ary shoe is free to move toward the                     The rear brake assembly is basic-
rear wheels of all others.                              drum beyond a predetermined point.                   ally the same as the front brake.
   A vacuum booster is available as                        With the car moving rearward                      The conventional parking brake
optional eqipment on all models ex-                     and the brakes applied, the wrap-                    lever, link, and spring are used in
cept Mustangs equipped with disc                        around action of the shoes follow-                   the rear brake.
brakes.                                                 ing the drum forces the upper end                       The anchor pins on all brakes are
   The master cylinder converts phys-                   of the primary shoe against the                      fixed and are non-adjustable.
ical force from the brake pedal                         anchor pin. The action of the wheel
(and booster if so equipped) into                       cylinder moves the upper end of the
hydraulic pressure against the pistons                  secondary shoe away from the an-                     DISC BRAKE ASSEMBLIES
in the calipers (disc brakes) or in                     chor pin. The movement of the sec-
the wheel cylinders (drum brakes).                      ondary shoe causes the cable to pull                 RELATION AND FUNCTION OF
The pistons in turn convert hy-                         the adjusting lever upward and                       COMPONENT PARTS
draulic pressure back into physical                     against the end of a tooth on the                       The disc brake is a fixed caliper,
force at the brake shoes.                               adjusting screw star-wheel. The up-                  opposed piston, non-energized, venti-
                                                        ward travel of the lever increases as                lated disc type, actuated by a hy-
SELF ADJUSTING D R U M                                  lining wear increases. When the lever                draulic system (Fig. 3). There is no
BRAKE ASSEMBLIES                                        can move upward far enough, it                       lateral movement of either the disc
   The self-adjusting brake mecha-                      passes over the end of the tooth and                 (rotor) or the caliper. The caliper
nism consists of a cable, cable guide,                  engages the tooth. When the brakes                   assembly consists of two caliper
adjusting lever, and adjuster spring                    are released, the adjusting spring                   housings bolted together with each
(Fig. 1 and 2). The cable is hooked                     pulls the lever downward causing the                 half containing two cylinder bores
over the anchor pin at the top and is                    star-wheel to turn and expand the                   of l1jllc; inch diameter. Each cylinder
connected to the lever at the bottom.                   shoes. The star-wheel is turned one                  bore contains a piston with an at-
The cable is connected to the sec-                       tooth at a time as the linings pro-                 tached molded rubber dust boot to
                                           PART 2-2 - BRAKE SYSTEM                                                     2-9



             RK
     ,RKING B A E
     fER RETAINING




                                                         RK
                                                  RKlNG B A E

                             REAR BRAKE                                            FRONT BRAKE
                                                                                                                   H 1323-A

FIG. I-Self-Adjusting     Brake Assemblies-9     lnch Drum



        AL
       C B E ANCHOR                                                   R K EE
                                                             PARKING B A E L V R
                                                                RETAININGCLIP      WaCUFP              RK
                                                                                              PARKING B A E LINK




 I.
FG     2-Self    Adjusting Brake Assemblies-10     lnch Drum
seal the cylinder bore from contami-         2. They return the pistons to re-       draulically by means of internal pas-
nation. (Fig. 4). Square-section rub-     leased position, when hydraulic pres-      sages in the caliper housing and an
ber piston seals are positioned in        sure is released.                          external transfer tube between the
grooves in the cylinder bores.               3. They maintain the shoes in cor-      two halves of the caliper assembly.
  The piston seals perform three im-      rect adjustment at all times (com-         One bleeder screw and fluid inlet
portant tasks:                            parable to the automatic adjusters in      fitting is provided on each caliper
   1. They provide hydraulic sealing      drum-type brakes).                         assembly.
between the cylinders and pistons.           The cylinders are conneced hy-             The shoe and lining assemblies are
                                                   GROUP 2 - BRAKES

                                                                        CALIPER TOROTORCLEARANCE
                                                                                     I
                                                                                                              TRANSFER               TUBE



                                             CALIPER HOUSING                                                          PISTON DUST BOOT
                                                                                                                      RETAINING GROVE




                                             PISTON SEAL
                                                                                                                          CALIPER DUST
                                                                                                                         BOOT RETAINER




 BLEEDER SCREW   /    CALIPER ASSEMBLY I
                     CALIPER SPLASH-SHIELD
                                                                                                                                H1369-A


                                             FIG. 4-Typical         Caliper Assembly-Sectional      View
FIG. 3-Typical           Disc Brake          OPERATION                                       matic adiustment is achieved bv the
Assembly                                                                                     pistons sliding in the seals outward
                                                As the brake pedal is depressed,             from the cylinder bores. The piston
                                             hydraulic pressure from the master              gradually changes its position rela-
located between parallel machined            cylinder forces the pistons out of the
abutments within the caliper, and                                                            tive to the seal as the lining wears
                                             caliper bores against their respective          and, thus, maintains the correct ad-
are supported radially by tabs on the        shoe and lining assemblies. The
outer ends of the shoe assemblies                                                            justment location at all times.
                                             force of the pistons against the shoes             When the brakes are in the un-
(Fig. 35). The shoes slide axially in        moves the linings against both sides
the caliper abutments by means of                                                            applied position, there is no hydrau-
                                             of the revolving rotor to effect brak-          lic pressure to the calipers because
the tabs which ride on machined              ing action.
ledges (bridges) when hydraulic pres-                                                        the fluid source at the master cvlin-
sure is applied to the piston (Fig.             During brake application, the rub-           der by-passes the resid"a1 check
19). A shoe and lining assembly con-         ber seal on each piston stretches as            valve.
sists of friction material bonded to a       the piston moves against the shoe                  A warning sound feature is incor-
metal plate called the shoe. It is re-       (Fig. 5). When the hydraulic pres-              porated in the design of the brake
placed as a unit. Brake torque is ab-        sure against the piston is released,            shoes. Metal tabs on the ends of
sorbed by the mating of the shoe end         the seal relaxes or rolls back. This            the shoes create an audible metallic,
against the caliper abutments (Fig.          roll-back action pulls the piston               scraping noise, when the linings be-
35). A splash shield is attached to          away from the shoe approximately                come worn enough to allow the tabs
the top of the caliper to retain the         0.005 inch to relieve the force of              to contact the rotor. This metal-to-
shoe and lining assemblies and re-           the lining against the rotor and,               metal contact warns the driver that
duce contamination. The caliper as-          thereby, provide the required run-              the shoes need replacing and is not
sembly is mounted to a bracket lo-           ning clearance. Also, inherent rotor            detrimental to the function of the
cated between the spindle and rotor          runout contributes to the mainte-               disc brake.
splash shield, to the front of the           nance of running clearance. Auto-                  A proportioning valve located be-
wheel vertical centerline.
    The cast iron disc is of the venti-                    PISTON
lated rotor type incorporating forty
fins and is staked to, and rotates
with, the wheel hub. The outside
diameter of the rotor is 11.375                                                          F
 inches and the inside diameter is
7.375 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 pre-
vent r6ad contaminants from con-                                               DUST BOOT
 tacting the inboard rotor and lining
surfaces (Fig. 20). The wheel pro-                BRAKES APPLIED
                                                                                   * '
                                                                                                BRAKES RELEASED   '   H1370-B
                                                                                                                                 1
vides protection for the outboard
 surface of the rotor.                       FIG. 5-Function         of Piston Seal
        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


                   1966 Comet, Falcon, Fairlane and Mustang Shop Manual
                                   ISBN: 0-9673211-3-1
                                 EAN: 978-0-9673211-3-4


                               Forel Publishing Company, LLC
                                   3999 Peregrine Ridge Ct.
                                    Woodbridge, VA 22192
                         Email address: webmaster@FordManuals.com
                           Website: http://www.FordManuals.com




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




                                           Disclaimer
Although every effort was made to ensure the accuracy of this book, no representations or warranties of
any kind are made concerning the accuracy, completeness or suitability of the information, either expressed
or implied. As a result, the information contained within this book should be used as general information
only. The author and Forel Publishing Company, LLC shall have neither liability nor responsibility to any
person or entity with respect to any loss or damage caused, or alleged to be caused, directly or indirectly by
the information contained in this book. Further, the publisher and author are not engaged in rendering legal
or other professional services. If legal, mechanical, electrical, or other expert assistance is required, the
services of a competent professional should be sought.
                                          BART 2-2 - BRAUE SYSTEM

tween the master cylinder and the        rear shell. A synthetic rubber seal          site end has a piston head which
rear brake wheel cylinders provides      is used between the valve hub and            enters the diaphragm plate. A seal,
balanced braking action between the      the rear shell. The seal and the valve       located in the front shell, seals the
front and the rear brakes under a        hub are protected from dirt by a             opening between the hydraulic push
wide range of braking conditions.        rubber guard connected between the           rod and the shell.
(Fig. 21). By regulating the hydrau-     air filter at the end of the hub and            Engine manifold vacuum is sup-
lic pressure applied to the rear wheel   a flange on the rear shell. The con-         plied to the booster through a
cylinders, the valve limits rear brak-   trol valve assembly fits into the hub        vacuum check valve located in the
ing action when high pressures are       and is connected to the brake pedal          front shell. Air is admitted through
required at the front brakes. In this    by the valve operating rod. The con-         the air filter located at the end of
manner, premature rear wheel skid        trol valve assembly consists of a            the valve hub. The hydraulic push
is prevented. The proportioning          plunger, a valve body which supports         rod is actuated by pedal
valve is serviced as an assembly and     a single poppet of flexible rubber,          assisted by the diaphragm, which de-
is never adjusted or overhauled.         and two return springs. When the             rives power from the pressure differ-
                                         brake pedal is in the released posi-         ential existing between the vacuum
BOOSTER SYSTEM-BENDlX                    tion the valve return spring holds           on its front side and atmospheric
TYPE                                     the valve assembly and operating rod         pressure on its rear side. A passage
                                         away from the diaphragm plate. In            in the diaphragm plate permits
   The diaphragm type brake booster      this position, the poppet on the valve       vacuum to pass from the front to
is a self contained vacuum-hydraulic     body is off the vacuum port seat             the rear side of the diaphragm when
braking unit mounted on the engine       which is a part of the diaphragm             the vacuum port opens as the brakes
side of the dash panel.                  plate. The poppet return spring l i k e      are released.
   The vacuum power chamber con-         wise holds the poppet against the
sists of a front and rear shell locked   atmospheric port seat which is a part
together. Within the vacuum cham-                                                     RELEASED POSITION
                                         of the plunger.
ber are the rubber diaphragm and            The hydraulic master cylinder                With the engine running and the
the integral valve hub and diaphragm     which contains all of the components         brakes released (Fig. 7), vacuum
plate. The rubber diaphragm fits         of the conventional master cylinder          from the intake manifold is adrnit-
over the plate, and the outer bead       is bolted to the booster front shell.        ted through the check valve to the
of the diaphragm is locked between       The hydraulic push rod forms the             front (constant vacuum) chamber of
the front and rear shells (Fig. 6).      link between the master cylinder pis-        the power unit. Zn the released posi-
The diaphragm return spring is lo-       ton and the vacuum power dia-                tion (no pressure applied to the brake
cated between the diaphragm plate        phragm assembly. The end of the              pedal), the valve operating rod and
and the front shell.                     push rod, that enters the master cyl-        valve plunger are held to the rear
   The valve hub section of the dia-     inder piston, is equipped with a self-       in the valve hub by the valve return
phragm plate protrudes from the          locking adjusting screw. The oppo-           spring to CLOSE the atmospheric

                                                                          REAR SHE1

MASTER CYLINDER \
                                                FRONT S H E L L
                                                       \                    /




 I.
F G 6-Cutaway View of Vacuum Booster-Bendix-Type
                                             GROUP 2 - BRAKES

                                                                                push rod and master cylinder piston
                                                                                forward to close the compensating
                                                                                port and force hydraulic fluid under
                                                                                pressure through the residual check
                                                                                valve and brake tubes into the brake
                                                                                wheel cylinders. As hydraulic pres-
                                                                                sure is developed in the brake master
                                                                                cylinder, a counter force (to. the
                                                                                rear) acting through the hydraulic
                                                                                push rod, sets up a reaction force
                                                                                against the power diaphragm assem-
                                                                                bly and valve plunger through the
                                                                                rubber reaction disc (located at the
                                                                                end of the hydraulic push rod). The
                                                                                rubber reaction disc acts similar to
                                                                                a column of fluid to distribute the
                                                                                pressure between the vacuum power
                                                                                diaphragm assembly and the valve
                                                                                plunger in proportion to their re-
                                                                                spective contact areas. The pressure
                                                                                acting against the valve plunger and
                                                                                valve hub assembly to close off the
                                                                                the valve plunger slightly to the rear
                                                                                in relation to the diaphragm and
                                                                                valve hub assembly to close off the
                                                                      H1325-A   atmospheric port. The driver is thus
                                                                                assured a feel of the brake, since
FIG. 7-Booster      in Released Position-Bendix-Type                            part of the counter force reacts
port and OPEN the vacuum port.          admit atmosphere through the air        through the        plunger,        'p-
With the valve in this position, the    cleaner and passages in the dia-        crating rod* and pedal linkage
rear (control vacuum) chamber is        phragm plate to the rear side of the    against the driver's foot. This re-
also open to vacuum through the         power chamber. With vacuum              action force 's in direct proportion
porting in the diaphragm and valve      present on the front side of the dia-       the            pressure
hug assembly. The diaphragm is then     phragm and valve housing and at-                 the brake 'ystem.
balanced or suspended in vacuum,        mospheric pressure present on the
since vacuum is present on both         rear side of the diaphragm, a force     HOLDING POSITION
sides of the power diaphragm. With      is developed to move the vacuum           During brake application, the re-
the power diaphragm balanced in         power diaphragm assembly, hydraulic     action force which opposes the
vacuum, the diaphragm return spring
holds the diaphragm and hydraulic
push rod in the fully released posi-
tion. With the hydraulic push rod in
this position, the hydraulic compen-
sating port in the hydraulic master
cylinder is OPEN. The open port
permits brake fluid to either return
from the brake system to the fluid
reservoir or enter the brake system
from the fluid reservoir to compen-
sate for any gain or loss in fluid
volume.

APPLIED POSITION
   When the brakes are applied (Fig.
8), the valve operating rod and valve
plunger move forward in the valve
hub section of the diaphragm plate
to compress the valve return spring
and force the poppet against the vac-                                                                 IC PORT OPEN
uum valve seat in the diaphragm
plate to CLOSE the vacuum port.
Any additional movement of the  '

valve operating rod in the applied
direction moves the valve plunger
away from the poppet valve to
OPEN the atmospheric port and           FIG. 8-Booster      in Applied Position-Bendix-Type
                                          PART 2-2 - BRAKE SYSTEM

force applied by the driver, tends to    power brake application may be           and vacuum chamber, it is possible
close the atmospheric port. When         made from the vacuum in the              to obtain several power assisted
both atmospheric and vacuum ports        booster. With the engine off and no      brake applications with the engine
are CLOSED, the booster is said to       vacuum in the power system, the          shut off. This arrangement makes a
be in the holding position (Fig. 9).     brakes can be applied in the conven-     vacuum reservoir unnecessary.
                                                                                     Wither vacuum from the forward
                                                                                  side of the diaphragm or air from
                                                                                  the bellows (atmospheric chamber)
                                                                                  can be connected to the rear side of
                                                                                  the diaphragm through porting in
                                                                                  the ,control valve hub and the
                                                                                  plunger assembly.

                                                                                  APPLYING POSITION
                                                                                     As the brake pedal is depressed,
                                                                                  the valve operating rod and valve
                                                                                  plunger assembly move forward
                                                                                  compressing the plunger return
                                                                                  spring (Fig. 10). The initial move-
                                                                                  ment of the plunger closes the port-
                                                                                  ing from the vacuum chamber pre-
                                                                                  venting further evacuation of the
                                                                                  area back of the diaphragm. Fur-
                                                                                                        -    -

                                                                                  ther movement of the plunger forces
                                                                                  the atmospheric valve off its seat so
                                                                                  that atmospheric pressure from the
                                                                                  bellows can enter the hub porting
                                                                                  that leads to the rear side of the
                                                                                   diaphragm.
                                                                                     With vacuum on the front side of
    VACUUM SOURCE                                                                 the diaphragm and atmospheric
                                                                       H 1327-A
                                                                                  pressure on the back side of the dia-
FIG. 9-Booster      in Holding Position-Bendix-Type                               phragm, a force is developed to
                                                                                  move the diaphragm, push rod and
                                                                                  master cylinder piston forward to
With both valves closed, any degree      tional manner by applying more
of brake application attained will be                                             close the compensating port and
                                         physical effort to the brake pedal.
                                                                                  force hydraulic fluid under pressure
held until either the atmospheric
                                                                                  through the residual pressure check
port is reopened by an increase in       BOOSTER SYSTEM-                          valve and brake tubes to the wheel
pedal pressure to further increase the
                                         MIDLAND-ROSS                             brakes. As hydraulic pressure is de-
brake application or by a decrease
                                            The optional power brake booster      veloped in the hydraulic system, a
in pedal pressure to reopen the vac-
                                         is installed on the engine side of the   reaction counter-force acts against
uum port to decrease the brake ap-
plication. Whenever the pressure ap-     dash panel and is connected to the       the reaction lever and ring assembly.
                                         brake pedal through a lever assem-       This reaction lever and ring assem-
plied to the brake pedal is held con-                                             bly is designed to transmit the reac-
stant for a moment, the valve            bly and push rod link.
                                            The booster consists of a vacuum      tion forces back through the actuat-
returns to its holding position. How-
                                         chamber, atmospheric valve, control      ing control valve assembly to the
ever, upon reaching the fully applied
                                         valve plunger assembly, diaphragm,       brake pedal and provide the driver
position the force applied to the
brake pedal overrules the reaction       and an atmospheric chamber (Figs.        with a resistance that is in propor-
force. In this position the valve        10, 11 and 12).                          tion to the brake hydraulic apply
                                            Atmospheric pressure is present at    forces. This is the means of provid-
plunger and atmospheric valve seat
are held away from the valve poppet      all times in the atmospheric cham-       ing the proper driver feel to the
to admit maximum atmospheric pres-       ber at the front side of the atmos-      power brake unit.
sure to the rear chamber. With the       pheric valve. The air intake to the
front chamber open to manifold           atmospheric chamber is protected by      HOLDING POSITION
vacuum, full power application is at-    an air filter. The atmospheric cham-        When the forward motion of the
tained which is referred to as the       ber is separated from the vacuum         brake pedal is stopped and held, the
run-out of the power unit. Any in-       chamber by the bellows assembly          valve operating rod ceases to move
crease in hydraulic pressure beyond      within the vacuum chamber.               the control valve plunger forward.
this point must be supplied by phys-        Vacuum is present at all times in     However, the unbalanced forces of
ical effort of the driver.               that area of the vacuum chamber          atmospheric pressure and vacuum on
                                         forward of the diaphragm. Vacuum         each side of the diaphragm will con-
NO POWER CONDITION                       is supplied through a hose from the      tinue to move the outer sleeve of
  It should be noted that in case of     intake manifold to the vacuum mani-      the control valve plunger forward
engine failure and consequent loss       fold and check valve on the booster      keeping the vacuum porting closed.
of engine vacuum, at least one full      body. With this integral check valve     At the same time, the reaction force
                                              GROUP 2 - BRAKES

                                                                                    and the hydraulic fluid, to return
                                                                                    the master cylinder piston and push
                                                                                    rod to the released positioned.
                                                                                       With the piston and push rod in
                                                                                    the released position, the hydraulic
                                                                                    compensating port in the master cyl-
                                                                                    inder is open. The open port per-
                                                                                    mits fluid to either return from the
                                                                                    brake system to the fluid reservoir,
                                                                                    o r enter the brake system from the
                                                                                    reservoir.

                                                                                    'PARKING B R A K E L M U S T A N G
                                                                                        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
                                                                                     lever which is attached to the equal-
                                                                                     izer assembly. The rear brake cables
                                                                                     connect the equalizer assembly to the
                                                                                     parking brake.lever at each rear sec-
                                                                                     ondary shoe as shown in Figs. 1 and
                                                                                     2.
                                                                                        When the hand1e.i~  pulled the pri-
                                                                                     mary and secondary brake shoes are
                                                                                     forced against the rear brake drums.
                                                                                    The handle is held in the applied
                                                                                    position by the engagement of a
                                                                                     spring loaded pawl with a ratchet.
                                                                                    Turning the handle counterclockwise
                                                                                    disengages the pawl from the ratchet
                                                                                    to release the brakes.

                                                                                    PARKING BRAKE
                                                                                    COMET, FAIRLANE AND
                                                                                    FALCON
                                                                                       An independent foot-operated
                                                                                    parking brake control actuates the
FIG. 10-Booster       in Applied Position-Midland-Ross                              rear wheel brake shoes through a
                                                                                    cable linkage. The operating cable
acting through the reaction ring and     valve closes off the bellows chamber       is routed from the parking brake
lever assembly will tend to move the     from the hub porting that connects         control assembly to the equalizer.
atmospheric valve to the closed posi-    to the rear side of the diaphragm.         The rear brake cables connect the
tion (Fig. 11). When these combined      At the same time, the rearward             equalizer assembly to the parking
forces balance, the porting to the       movement of the plunger opens the          brake lever at each rear secondary
vacuum supply will remain closed         porting from the vacuum chamber            shoe (Fig. 1).
and the atmospheric valve will cut       and draws out the air from the rear           When the pedal is depressed the
off any further passage of atmos-        side of the power diaphragm. With          secondary brake shoes are forced
pheric pressure to ..the area behind     vacuum on both sides of the dia-           against the rear brake drums. The
the diaphragm. Therefore, the power      phragm, the assist force against the       pedal is held in the applied,position
assist force acting on the master cyl-   master cylinder push rod is elimi-         by the engagement of a spring-loaded
inder piston will stabilize and the      nated.                                     pawl with a ratchet in the control
hydraulic force applying the brakes         Also, a pressure differential is cre-   assembly (Fig. 29).
will be maintained at a constant         ated by the presence of vacuum on             The parking brake control assem-
level.                                   the rear (small diameter) side of the      bly is mounted to the cowl inner side
                                         valve hub and atmospheric (bellows)        panel. The pedal pivots on a station-
RELEASED POSITION                        pressure on the front (large diam-         ary pedal mount. A spring-loaded
   When the pedal pressure is re-        eter) side. This pressure differential     pawl and a release lever are assem-
leased from the valve operating rod      moves the valve hub and, with it,          bled to the pedal. A ratchet is as-
and plunger assembly, the plunger        the valve plunger and diaphragm as-        sembled to the upper end of the
return spring moves the plunger          sembly back to the released position.      pedal. The pawl contacts the rachet
away from the atmospheric valve          This releasing action permits the          at such an angle that the rachet
allowing the valve to seat against the   brake shoe retracting springs, acting      teeth will slide over the pawl as the
hub (Fig. 12). This seating of the       through the wheel cylinder pistons         pedal is depressed; however, when
                                         PART 2-2 - BRAKE SYSTEM                                            2-15




FIG. 1 1-Booster in Holding Position-Midland-Ross
the applying motion stops and the       brakes in the applied position.       tion of the lever on the pawl cam
pedal starts to release, the pawl en-     When the manual release lever is    pin will disengage the pawl from the
gages the ratchet and thus locks the    pulled back, (Fig. 29), the cam ac-   ratchet to release the brakes.
2-16                                        GROUP 2 -BRAKES




 FIG. 1 2-Booster     in Released Position-Midland-Ross



         IN-CAR ADJUSTMENTS AND REPAIRS
 BRAKE SHOE ADJUSTMENTS                  move the drum and knock-out slug.
    The hydraulic service brakes are     (Install a standard adjusting hole
 self-adjusting and require a manual     cover in the carrier plate when as-
 adjustment only after the brake         sembling).
 shoes have been relined, replaced, or      When adjusting the rear brake
 when the length of the adjusting        shoes, check the parking brake
 screw has been changed while per-       cables for proper adjustment. Make
 forming some other service opera-       sure that the equalizer operates
 tion. The manual adjustment is per-     freely.
 formed with the drums removed, us-         To adjust the brake shoes:
 ing the tool and the procedure de-         1. Using Rotunda Tool HRE
 tailed below.                           8650, (Fig. 13) determine the inside
     In case a brake drum cannot be      diameter of the drum braking sur-
 removed in the normal manner, an        face.
 access knock-out slug is provided in       2. Reverse the tool as shown in
                                         Fig. 14 and adjust the brake shoe      FIG. 13-Measuring      Drum
 the brake carrier plate. Knock the
 slug out with a punch and then re-      diameter to fit the gauge. Hold the    ing screw, to prevent burring the
 lease the brake shoe as detailed        automatic adjusting lever out of en-   screw slots. Make sure the adjust-
 under Brake Drum-Removal. Re-           gagement while rotating the adjust-    ing screw rotates freely. If neces-
                                             PART 2-2 - BRAKE SYSTEM

                                                                                      hole in the carrier plate, and disen-
                                                                                      gage the adjusting lever from the ad-
                                                                                      justing screw. While holding the
                                                                                      adjusting lever away from the adjust-
                                                                                      ing screw, back off the adjusting
                                                                                      screw with the brake adjusting tool
                                                                                      (Fig. 15). Be very careful not to
                                                                                      burr, chip or damage the notches in
                                                                                      the adjusting screw; otherwise, the
                                                                                      self-adjusting mechanism will not
                                                                                      function properly.
                                                                                         If the adjustment was backed off,
                                                                                      make sure that the adjuster lever is
                                                                                      properly seated in the shoe web.
    FIG. 14-Measuring       Shoes

    sary, lubricate the adjusting screw                                                  1. Remove the protective. coating
    threads with a thin, uniform coating    FIG. 15-Backing        Off Brake          from a new drum with carburetor
    of Cl AZ-19590-B Grease.                Adjustment                                degreaser.
       3. Rotate Tool       HRE 8650                                                     2. Adjust the brakes as outlined
    around the brake shoes to be sure                                                 under Brake Shoe Adjustments in
    of the setting.                            4. Pull the hub and drum assem-
                                            bly off the wheel spindle.                this section.
       4. Apply a small quantity of high                                                 3. Place the drum over the brake
    temperature grease to the points                                                  assembly and into position. Install
    where the shoes contact the carrier     INSTALLATION                              the three Tinnerman nuts and tighten
    plate, being careful not to get the          .
                                               1 If the drum is being replaced,       them securely. Install the wheel on
    lubricant on the linings.               remove the protective coating from        the axle shaft flange studs against
       5. Install the wheel on the drum     the new drum with carburetor de-          the drum, and tighten the attaching
    and tighten the mounting nuts to        greaser. Install new bearings and         nuts to specifications.
    specification.                          grease retainer. Soak the new grease
       6. Complete the adjustment by        retainer in light engine oil at least
    applying the brakes several times                                                 BRAKE SHOES AND
                                            30 minutes before installation if re-     ADJUSTING SCREW
    while backing the car.                  tainer is of a leather composition.
       7. After the brake shoes have        Rubber seals need not be treated          REMOVAL
    been properly adjusted, check the       with oil before installation. Pack the
    operation of the brakes by making                                                   1. With the wheel and drum re-
                                            wheel bearings, install the inner bear-   moved, install a clamp over the ends
    several stops while operating in a      ing cone and roller assembly in the
    forward direction.                                                                of the wheel cylinder as shown in
                                            inner cup, and install the new grease     Fig. 16.
                                            retainer. See Part 3-5, Section 4 for
    FRONT BRAKE DRUM                        procedure.
                                               If the original drum is being in-
    REMOVAL                                 stalled, make sure that the grease in
        1. Raise the car until the wheel    the hub is clean and adequate.
    and tire clear the floor. Remove the       2. Adjust the brakes and install
    wheel cover or hub cap, and remove      the drum assembly as outlined under
                                            "Brake Shoe Adjustments" in this
    the wheel and tire from the drum.       section.
        2. Remove the drum. If the drum
                                               3. Install the outer wheel bearing,
    will not come off, knock the access
                                            washer and adjusting nut.
    slug out of the brake carrier plate,
                                               4. Adjust the wheel bearing as
    using a punch. Insert a narrow
                                            outlined in Part 3-5,Section 2, then
    screwdriver through the slot and
                                            install the cotter pin grease cap. In-
    disengage the adjusting lever from
    the adjusting screw. While holding
                                            stall the wheel and hub cap.              FIG. 16-Retracting       Spring
    the adjusting lever away from the                                                 Removal-Typical
    screw, back off the adjusting screw     REAR BRAKE DRUM
    with the brake adjusting tool (Fig.                                                  2. Remove the brake retracting
     15). Be very careful not to burr,      REMOVAL                                   springs using Tool 2035-N or
'
    chip, or damage the notches in the         1. Raise the car so that the wheel     2086-L (Fig. 16).
    adjusting screws; otherwise the self-   is clear of the floor.                       3 Disconnect the brake shoe hold-
                                                                                          .
    adjusting mechanism will not func-         2. Remove the hub cap and              down springs and remove the brake
    tion properly.                          wheel. Remove the three Tinnerman         shoe assemblies along with the com-
        3. Remove the grease cap from       nuts and remove the brake drum.           plete automatic adjustment mecha-
    the hub. Remove the cotter pin, nut     1f the drum will not come off, knock      nism.
    lock, adjusting nut, and flat washer    the excess slug out of the brake car-        4. Disassemble the brake shoes.
    from the spindle. Remove the outer      rier plate, using a punch. Insert a          5. On rear brakes, remove the
    bearing cone and roller assembly.       narrow screwdriver through the            parking brake link and spring from
                                            '   GROUP 2 -BRAKES

the brake assemblies. Disconnect            7. Apply a small amount of high-         action of the adjuster by pulling the
the parking brake cable from the         temperature grease to the threads           section of the cable between the
parking brake lever.                     and the socket end of the adjusting         cable guide and the adjusting lever
   6. After removing the rear brake      screw. Turn the adjusting screw into        toward the secondary shoe web far
shoes disassemble the parking brake      the adjusting pivot nut to the limit       enough to lift the lever past a tooth
lever from the secondary shoe by re-     of the threads and then back off '/2        on the adjusting screw wheel. The
moving the retaining clip and spring     turn.                                       lever should snap into position be-
washer (Fig., 1 and 2).                     Interchanging the brake shoe ad-         hind the next tooth,, and release of
                                         justing screw assemblies from one           the table should cause the adjuster
                                         side of the car to the other would          spring to return the lever to its origi-
INSTALLATION '                                                                       nal position. This return action of
                                         cause the brake shoes to retract
   1. Before installing the rear brake   rather than expand each time the            the lever will turn the adjusting
shoes, assemble the parking brake        automatic adjusting mechanism op-           screw one tooth.
lever to the secondary shoe and se-      erated. T o prevent accidental instal-         If pulling the cable does-not pro-,
cure it with the spring washer and       lation of the adjusting screw on the        duce the action described, or if the
retaining clip.                          wrong side of the car the socket end       lever action is sluggish instead of
   2 Apply a light coating of high-
    .                                    of the adjusting screw is stamped          positive and sharp, check the posi-
temperature grease at the points         with an R or L (Fig. 18). The ad-           tion of the lever on the adjusting
where the brake shoes contact the                                                    screw toothed wheel. With the brake
backing plate.                                                                       in a vertical position (anchor at the
   3. Position the brake shoes on the                                                top), the lever should contact the
backing plate and secure them with                                                   adjusting wheel 3/16 inch (plus or mi-
the hold down springs. On the rear                                                   nus Ihz inch) above the centerline
brake, install the parking brake link                                               of the screw. If the contact point is
and spring. Connect the parking                                                      below the centerline, the lever will
brake cable to the parking brake                                                    not lock oncthe teeth in the adjusting
lever.                    . ,                                                       screw wheel, and the screw will not
   Install the cable guide on the                                                   be turned as the lever is actuated
secondary shoe web with the flanged             \       ADJUSTING SCREW             by the cable.
hole properly fitted into the hole in    IDENTIFICATION LINES                           To determine the cause of this
                                                                          H1143-B
the secondary shoe web. Install the                                                  condition:
secondary shoe to anchor spring                                                         a. Check the cable end fittings.
(Figs. 1 and 2).                         FIG. 1 8--~djustin~   Screw and
                                                                                    The cable should completely fill dr
   5. Place the cable eye over the an-   Lever ldentificati'on                      extend slightly beyond the crimped
chor pin with the crimped side to-       justing ,pivot nuts can be distin-         section of the fittings. If it does not
ward the backing plate. Install the                                                 meet this specification, possible dam-
                                         guished by the number of grooves
primary shoe to anchor spring with                                                  age is indicated and the cable assem-
the tool shown in Fig. 17.               machined around the body of the
                                         nut. Two grooves indicate .a right-        bly should be replaced.
                                         hand nut: one groove indicates a left-         b. Check the cable length. The
                                         hand nut.                                  cable should measure 83/16 inches on
                                            8. Place the adjusting socket on        9 inch brakes or 10% inches on 10
                                         the screw and install this assembly        inch brakes from the end of the cable '
                                         between the shoe ends with the ad-         anchor to the end of the cable hook.
                                         justing screw toothed wheel nearest            c. Check the cable guide for dam-
                                         the secondary shoe.                        age. The cable groove should be
                                                                                    parallel to the shoe web, and the
                                            9. Hook the cable hook into the         body of the guide should lie flat
                                         hole in the adjusting lever. The ad-       against the web. Replace the guide
                                         justing levers are stamped with an         if it shows damage.
                                         R or L to indicate their installation
                                         on a right or left brake assembly              d. Check the pivot hook on the
                                         (Fig. 18).                                 lever. The hook surfaces should be
                                                                                    square with the body of the lever
                                            10. Position the hooked end of          for proper pivoting. Replace the
FIG. 17-Retracting       Spring          the adjuster spring completely into        lever if the hook shows damage.
Installation-Typical                     the large hole in the primary shoe
                                         web. The last coil of the spring               e. See that the adjusting screw
                                                                                    socket is properly seated in the notch
   6. Thread the cable around the        should be at the edge of the hole.
                                                                                    in the shoe web.
cable guide groove.                      Connect the loop end of the spring
   It is imperative that the cable be    to the adjuster lever hole (Figs. 1        DISC BRAKE SHOE A N D
positioned in this groove and not be-    and 2).                                    L I N I N G REPLACEMENT
tween the guide and the shoe web.           1 . Pull the adjuster lever, cable
                                              1                                         After any brake service work,
Be certain that the cable' eye is not    and automatic adjuster spring down         pump the brake pedal to obtain a
cocked or binding on the anchor pin      and toward the rear to engage the          firm pedal before moving the car.
when installed. All parts should be      pivot hook in the large hole in the        Riding the brake pedal (common on
flat on the anchor pin. Remove the       secondary shoe web.                        left foot applications) should be
brake cylinder clamp.                       12. After installation, check the       avoided when driving the car.
                                          PART 2-2 - BRAKE SYSTEM

 REMOVAL                                 assembly on each side of the rotor        hose should be checked for correct
     .
   1 Remove the wheel and tire           so that the lining faces the rotor. Be    routing.
from the hub and rotor assembly.         sure that the tabs on the shoe flanges       4. Bleed the brake system as out-
Be careful to avoid damage or in-        seat fully against the caliper bridges    lined in Section 2-1. Check the mas-
terference with the caliper splash       (Fig. 19).                                ter cylinder fluid level, and the
shield, bleeder screw fitting or bans-      2. Install the caliper splash shield   specified brake fluid as required.
fer tube.                                and secure the shield to the caliper         5. Pump the brake pedal several
   2. Remove the two bolts that          with two retaining bolts (Fig 3).         times to actuate the piston seals and
attach the caliper splash shield, and       3. Pump the brake pedal several        to position the shoe and lining as-
remove the shield (Fig. 3).              times .until a firm pedal is obtained     semblies.
   3. T o facilitate removal and in-     and the shoe and lining assemblies           6. Install the wheel and tire.
stallation of the shoe and lining        are properly seated.                         7. Road test the car.
assemblies, the pistons must be             4. Install the wheel and tire on
pushed into their bores. Apply a         the hub and rotor assembly.               FRONT WHEEL HUB A N D
steady inward pressure against each         5. Check and refill the master         ROTOR ASSEMBLY-DISC
shoe and lining assembly toward its      cylinder reservoir with specified         BRAKES
respective caliper housing on each       brake fluid as required.
side of the rotor (Fig. 4). Maintain        6 . Road test the car.                 REMOVAL
the pressure for at least a minute.         It should not be necessary to bleed
If the pistons will not go in easily,    the system after a shoe and lining             .
                                                                                      1 Remove the wheel and tire
force them in with water pump            replacement.                              from the hub and rotor assembly
pliers.                                                                            (Fig. 20). Be careful to avoid dam-
   4. Grasp the metal flange on the      DISC BRAKE CALIPER                        age or interference with the caliper
outer end of the shoe with two pairs     ASSEMBLY                                  splash shield, bleeder screw fitting or
of pliers and pull the shoe out of the                                             transfer tube.
caliper (Fig. 19).                       REMOVAL                                      2. Remove the caliper assembly
                                            1 Remove the wheel and tire
                                              .                                    from the spindle and the rotor. If
                                         from the hub and rotor assembly.          the caliper does not require servicing,
                                         Be careful to avoid damage or in-         it is not necessary to disconnect the
                                         terference with the caliper splash        brake hose or remove the caliper
                                         shield, bleeder screw fitting or trans-   from the car. Position the caliper
                                         fer tube.                                 out of the way, and support it with
                                            2. Disconnect the front brake          a wire to avoid damaging the caliper
                                         flexible hose from the brake tube at      or stretching the hose. Insert a clean
                                         the bracket on the frame (Fig. 24).       cardboard spacer between the linings
                                            3. Remove the two bolts that           to prevent the pistons from coming
                                         attach the caliper to the mounting        out of the cylinder bores while the
                                         bracket.                                  caliper is removed.
                                            Take care to avoid loosening the          Handle the rotor and caliper as-
                                         bridge bolts that hold the two halves     semblies in such a way as to avoid
                                         of the caliper together.                  deformation of the rotor and nicking
                                            4. Lift the caliper assembly off       or scratching of the brake linings.
                                         the rotor.                                   3. Remove the grease cap from
                                                                                   the hub. Remove the cotter pin, nut
                                         INSTALLATION                              lock, adjusting nut, and flat washer
                                            1 Position the caliper assembly
                                             .                                     from the spindle. Remove the outer
                                         on the rotor, and mate the mounting       bearing cone and roller assembly.
                                         bolt holes in the caliper with those         4. Remove the hub and rotor as-
                                         in the spindle. It may be necessary       sembly from the spindle.
                                         to push the caliper pistons into the      INSTALLATION
FIG. 19-Removing Disc Brake              cylinder bores to obtain clearance           1. If the rotor is being replaced,
Shoe and Lining Assembly-                between the shoe and lining assem-        remove the protective coating from
Typical                                  blies and the rotor. The shoe and         the new rotor with carburetor de-
                                         lining assemblies should be seated        greaser. Pack a new set of bearings
                                         properly on the bridges.                  with specified grease, and install the
CLEANING AND INSPECTION                     2. Install the caliper to mounting     inner bearing cone and roller assem-
   When the shoe and lining assem-       bracket attaching bolts and torque        bly in the inner cup. Pack grease
blies are replaced, remove the dust      to specification. Check to insure that    lightly between the lips of a new
boots from the pistons. Check the        the rotor runs squarely and centrally     grease retainer and install the re-
condition of the boots, and inspect      between the two halves of the cali-       tainer (Fig. 20).
each piston surface for damage or        per. There should be approximately           If the original rotor is being in-
corrosion. Thoroughly clean each         0.090-0.120 inch clearance between        stalled, make sure that the grease in
dust boot and surrounding area be-       the caliper and the rotor outside         the hub is clean and adequate, that
fore installing.                         diameter (Fig. 4).                        the inner bearing and grease retainer
                                            3. Connect the front wheel brake       are lubricated and in good condition,
INSTALLATION                             flexible hose to the brake tube at the    and that the rotor braking surfaces
   .
  1 Position a new shoe and lining       bracket on the frame (Fig. 24). The       are clean.
2-20                                               GROUP 2 - BRAKES

                                                       CALIPER PARTS-ZBIZO-R.H. -2B121-L.H.




                                                                         ING ASSEMBLIES

                                                                                              TRANSFER TUBE




                                                                                              OUTBOARD HOUSING



                                                                                                                    WHEEL-1007




21




                        ROTOR SPLASH SHIELD
                            ZK004.R.H.
                            2KOOS.L.H.                                                                                       COVER-I 130
                                                                                                          1131
                                                                                                                                 H1401-A


FIG. 20-Disc      Brake Disassembled

   2. Install the hub and rotor as-              INSTALLATION                                     RETAINING B O L T PROPORTIONING VALVE
sembly on the spindle.                           1. Install the gasket.
   3. Lubricate and install the outer            2. If the shield is bent, straighten
wheel bearing, washer and adjusting           it out before installation. Position
nut.                                          the shield to the mounting bracket,
   4. Adjust the wheel bearings to            install the attaching nuts, and torque
specification, and then install the           to specification (Fig. 20).
nut lock, cotter pin, and grease cap.            3. Install the hub and rotor assem-
The wheel bearing adjustment is es-           bly and the caliper as outlined under
pecially important with disc brakes.          Installation in the foregoing proce-
   5. Mount the caliper assembly on           dure.
the mounting bracket and torque the
two mounting bolts to specification.
If necessary, push the caliper pistons        PROPORTIONING VALVE
into the cylinder bores to obtain                The proportioning valve is serv-
clearance between the shoe and lin-           iced as an assembly and is never
ing assemblies and the rotor. Be sure         adjusted or overhauled.
that the shoe and lining assemblies
are seated on the bridges. Check the          REMOVAL
flexible hose for correct routing.               1. Disconnect and remove the
   6. Install the wheel and tire on           Master cylinder - to - proportioning
the hub and rotor assembly.                   valve brake tube (Fig. 23).
                                                 2. Disconnect the front-to-rear
DISC BRAKE ROTOR SPLASH                       brake tube from the proportioning
SHIELD                                        valve.                                             MOUNTING TANG    FENDER APRON H1365-A
                                                 3. Working underneath the left
REMOVAL                                       fender, remove the bolt that attaches              FIG. 21-Removing or
   1. Remove the caliper and the              the porportioning valve to the fender
                            '

                                              apron and remove the valve through                 Installing Proportioning Valve
hub and rotor assembly as outlined
under Removal in the foregoing pro-           the access hole (Fig. 21).
cedure.                                                                                          apron so that the mounting tang ex-
   2. Remove the four nuts that               INSTALLATION                                       tends through the hole in the fender
attach the splash shield to the mount-           1. From underneath the left fen-                apron as shown in Fig. 21. Install
ing bracket and remove the shield             der, install the proportioning valve               the attaching bolt.
(Fig. 20).                                    through the access hole in the fender                 2. Connect the front-to-rear brake
   3. Remove the gasket.                      apron. Position the valve to the                   tube to the valve (Fig. 23).
	



            GROUP INDEX

             Vehicle Identification                1
                   Brakes                          2
     Suspension, Steering, Wheels and Tires        3
                 Rear Axle                         4
          Drive Shaft and Clutch                   5
           Manual Transmission                     6
          Automatic Transmission                   7
                   Engine                          8
                Ignition System                    9
               Fuel System                         10
              Cooling System                       11
              Exhaust System                       12
             Charging System                       13
              Starting System                      14
    Lighting System, Horns and Instruments         15
    Ventilating, Heating, and Accessories          16
        Body, Doors and Windows                    17
    Trim, Seats, and Convertible Tops              18
          Maintenance Schedule                     19
          Maintenance Operations                   20
             Lubrication Chart                     21
                Schematics                         22

        SPECIFICATIONS AND SPECIAL SERVICE TOOLS
                  AT END OF EACH GROUP
                                                  PART 2-2 - BRAKE SYSTEM

   3. Position and connect the mas-             the internal parts require replacing,               2. Place a clamp over the ends of
ter cylinder-to-proportioning valve             all should be replaced.                          the wheel cylinder as shown in Fig.
brake tube.                                        3. Inspect the cylinder bore for               16.
   4. Bleed the brake system.                   score marks or rust. If either con-                 3. Remove the brake shoe assem-
                                                dition is present, the cylinder bore             blies, following procedures outlined
WHEEL CYLINDER REPAIR                           must be honed. However, the cylin-               in this section.
   It is not necessary to remove the            der should not be honed more than                   4. Disconnect the brake line from
wheel cylinder from the backing                 0.003 inch beyond its original                   the brake cylinder. On a car with a
plate to disassemble, inspect, or hone          diameter. A baffle in the front wheel            vacuum brake booster, be sure the
and overhaul it. Removal is necessary           cylinder of the 6-cylinder Falcon                engine is stopped and there is no
only when the cylinder is damaged               and Mustang models prevents hon-                 vacuum in the booster system be-
or scored beyond repair.                        ing; therefore, the cylinder must be             fore disconnecting the hydraulic
                                                replaced.                                        lines.
DISASSEMBLY                                        4. Check the bleeder hole to be                  T o disconnect the hose at a front
   1. With the wheel in a raised                sure that it is open.                            cylinder, loosen the tube fitting that
position, remove the wheel and the                                                               connects the opposite end of the
drum.                                           ASSEMBLY                                         hose to the brake tube at a bracket
   2. Place a clamp over the ends of                                                             on the frame. Remove the horseshoe-
the brake cylinder as shown in Fig.                 1. Apply a coating of heavy-duty
                                                brake fluid to all internal parts.               type retaining clip from the hose and
16.                                                                                              bracket, disengage the hose from the
   3. Remove the brake shoe assem-                  2. Thread the bleeder screw into
                                                the cylinder and tighten securely.               bracket, then unscrew the entire hose
blies following procedures outlined                                                              assembly from the front wheel cyl-
in this section.                                    3. Insert the return spring, cups,
                                                and pistons into their respective posi-          inder.
                                                                                                    At a rear cylinder, unscrew the
   4. The 6-cylinder Falcon and                 tion; in the cylinder boie ( ~ i ~ . - 2 2 ) .   tube fitting that connects the tube
Mustang models are not provided                 'lace a boot Over each end of the                to the cylinder. Do not pull the
with links. Remove the rubber boots             cylinder. On 8-cylinder model Mus-
                                                tangs and Falcons and all Comets                 metal tube away from the cylinder.
from the ends of the piston.                                                                     Pulling the tube out of the cylinder
   On 8-cylinder models and on all              and Fairlanes, install the links in
                                                                                                 connection will bend the metal tube
Comets and Fairlanes, remove the                the ends of the brake cylinders.
                                                                                                 and make installation difficult. The
links and rubber boots from the ends                4. Install the shoe and adjuster as-
                                                                                                 tube will separate from the cylinder
of the piston. Remove the pistons,              semblies, then adjust the shoes as
                                                                                                 when the cylinder is removed from
cups, and return spring from the                           in this section'
                                                                                                 the carrier plate.
cylinder bore (Fig. 22).                            5. Install the brake drum and
                                                                                                    5. Remove the wheel cylinder at-
   5. Remove the bleeder screw                  wheel, then bleed the brakes as out-
                                                                                                 taching bolts and lock washers and
from the cylinder.                              lined in this section.
                                                                                                 remove the cylinder.
INSPECTION                                      WHEEL CYLINDER                                   lNSTALLATION
  1. Wash all parts in clean de-                REPLACEMENT                                         Wipe the end(s) of the hydraulic
natured alcohol. If alcohol is not                                                               line to remove any foreign matter
available, use specified brake fluid.           REMOVAL                                          before making connections.
Dry with compressed air.                           1. With the wheel in a raised posi-              1. To install a front cylinder:
  2. Check all the internal parts for           tion, remove the wheel and the                      a. Position the cylinder in place
excessive wear or damage. If any of             drum.                                            against the carrier plate. Install the
                                                                                                 two lock washers and attaching bolts.
                                                                                                 Torque them to specifications.
BOOT
                                                                                                    b. Install a new copper gasket
                                                                                                 over the hose fitting. Thread the



8      PISTON


                                        FRONT
                                                                      PISTON
                                                                                                 hose assembly into the cylinder and
                                                                                                 tighten it securely.
                                                                                                    c. Engage the opposite end of the
                                                                                                 hose to the bracket on the frame,
                                                                                                 install the horseshoe-type retaining
                                                                                                 clip, and connect the brake tube to
                                                                                                 the hose with the tube fitting nut.
                                                                                                 Tighten the nut to specifications.
                                          B E D R SCREW
                                           LEE
                                                                                                    2. To install a rear cylinder:
                                                                                                    a. Position the rear wheel cylinder
                                                                                                 in place against the carrier plate. En-
                                                                                                 ter the tubing into the cylinder, and
                                                                                                 start the tube fitting nut into the
                                                                                                 threads of the cylinder.
            t                                                                                       b. Secure the cylinder to the car-
          PISTON                                                                                 rier plate with the attaching bolts
                                         REAR                                   H I 197-B        and lock washers.
                                                                                                    c. Tighten the tube fitting nut to
FIG. 22-Front       and Rear Wheel Cylinders                                                     specifications.
                                                                          POWER BRAKE INSTALLATION
                                                           (390 ENGINE)   (EXCEPT 390 ENGINE)
                                                                                                     BEND CLIP TO
                                                                                                     RETAIN TUBE




                                                                                                             H 1aBA


:IG. 23-Hydraulic   Brake System-Comet-Fairlane   and Falcon
FIG. 24-Hydraulic   Brake System-Mustang
                                               GROUP 2 -BRAKES

   3. Install the links. in the ends of   axle housing flange. Insert the axle       brake tubing to fit underbody or
the wheel cylinder (8-cylinder mod-       shaft into the housing so that the         rear axle contours, be careful not to
els only on Falcon and Mustang and        splines engage the differential side       kink or crack the tube.
all Comet and Fairlane models).           gear with the bearing retainer sliding        All brake tubing should be flared
   4. Install the brake shoes as de-      onto the retaining bolts and against       properly to provide good leak-proof
tailed in this section.                   the carrier plate. Install the attaching   connections. Clean the brake tubing
   5. Adjust the brakes as detailed in    nuts through the access hole in the        by flushing with clean denatured
Part 2-2, Section 2.                      axle shaft flange.                         alcohol, before installation.
   6. Install the brake drums and            Position a new front carrier plate         When connecting a tube to a hose,
wheels.                                   to the wheel spindle and install the       tube connector, disc caliper, or brake
   7. Bleed the brakes as detailed in     attaching bolts and nuts.                  cylinder, tighten the tube fitting nut
Part 2-1, Section 2.                         2. Install the wheel cylinder and       to specified torque with Milbar tool
                                          connect the brake line as outlined in      1112-144 or equivalent.
BRAKE CARRIER PLATE                       this section.
REPLACEMENT                                  3. Install the brake shoe and ad-       BRAKE HOSE REPLACEMENT
                                          juster assemblies as outlined in this         A flexible brake hose should be
REMOVAL                                   section. On a rear brake, connect the      replaced if it shows signs of soften-
   1 Remove the wheel and brake
     .                                    parking brake cable to the lever.          ing, cracking, or other damage.
drum. Disconnect the brake line              4. Adjust the brake shoes (Section         When installing a new front brake
from the brake cylinder.                  2).                                        hose, position the hose to avoid con-
   2. Remove the brake shoe and ad-          5. Install the brake drum and           tact with other chassis parts. Place
juster assemblies and the wheel cyl-      wheel and bleed the brake system as        a new copper gasket over the hose
inder as outlined in this section. On     outlined in Part 2-1, Section 2.           fitting and screw the hose assembly
the rear wheels, disconnect the park-                                                into the front brake cylinder. Engage
ing brake lever from the cable.           HYDRAULIC LINES                            the opposite end of the hose to the
   3. If the rear carrier plate is be-      Steel tubing is used throughout          bracket on the frame. Install the
ing replaced, rotate the axle shaft so    the brake system with the exception        horseshoe-type retaining clip, and
that the hole in the axle shaft flange    of the flexible hoses at the front         connect the tube to the hose with the
lines up with the carrier plate retain-   wheels and at the rear axle housing        tube fitting nut.
ing nuts and remove the nuts. Pull        brake tube connector (Figs. 23 and             A rear brake hose should be in-
the axle shaft assembly out of the        24).                                       stalled so that it does not touch the
housing with tool 4235-C and a               Always bleed the entire hydraulic       muffler outlet pipe or shock ab-
slide hammer (Part 4-2), then re-         system after any hose or line re-          sorber.
move the carrier plate.                   placement.                                     Since the rear brake hose is inte-
   If the front carrier plate is being                                               gral with the rear brake tube con-
replaced, remove the bolts and nuts       BRAKE TUBE REPLACEMENT                     nector, the entire hose and connector
 that secure the plate to the front          If a section of the brake tubing        is replaced as an assembly. Mount
wheel spindle and remove the plate.       becomes damaged, the entire section        the connector to the rear axle hous-
                                          should be replaced with tubing of the      ing with the retaining bolt (axle
INSTALLATION                              same type, size, shape and length.         vent) and lock washer. Connect the
   1. Position a new rear carrier         Copper tubing should not be used           two rear wheel brake tubes to the
plate on the attaching bolts in the       in a hydraulic sydem. When bending         connector.


        REMOVAL A N D INSTALLATION
MASTER CYLINDER-                             2. Install and torque the mounting
STANDARD BRAKES                           bolts to specification.                    MASTER CYLINDER-
                                             3. Connect the brake line(s) to         POWER BRAKES
REMOVAL                                   the master cylinder fitting, but leave     REMOVAL
   1. Disconnect the rubber boot          the brake line fitting(s) loose.             1. Disconnect the hydraulic line(s)
from the rear end of the master cyl-         4. Fill the master cylinder reser-      from the master cylinder.
inder in the passenger compartment.       voir with heavy-duty Rotunda brake            2. Remove the two nuts and lock
   2. Disconnect the brake line(s)        fluid to within 3/8 inch of the top. In-   washers that attach the master cyl-
from the master cylinder (Fig. 27)        stall and tighten the filler cap.          inder to the booser.
   3. Remove the bolts that secure           5. Bleed the master cylinder to let        3. Remove the master cylinder
the master cylinder to the dash panel     air escape from the cylinder at the        from the vacuum booster.
and lift the cylinder out and away        brake line fitting(s). Then tighten
from the push rod. Remove the rub-        the fitting(s).                            INSTALLATION
ber boot from the push rod.                  6. Remove the filler cap and fill          1. Before installing the master cyl-
                                          the reservoir to the level specified.      inder, check the distance from the
INSTALLATION                              Be sure that the diaphragm type gas-       outer end of the push rod to the
  1. With the rubber boot on the          ket is properly seated in the cap. In-     master cylinder mounting surface at
push rod, guide the master cylinder       stall the cap and wipe off any fluid       at the end of the vacuum cylinder
over the end of the push rod, and         from the cylinder.                         (Fig. 4 or 5, Part 2-1). If the push
position the cylinder against the dash       7. Connect the rubber boot to the       rod dimension is not correct, see
panel.                                    master cylinder.                           Master Cylinder Push Rod Adjust-
                                           PART 2-2 - BRAKE SYSTEM                                                    2-25

ment Part 2-1, Section 2.
   2. Position the master cylinder
over the push rod onto the two studs
that are integral with the booster
body.
   3. Install, but do not tighten the
attaching nuts and lock washers.
   4. Connect the hydraulic line(s)
to the master cylinder.
   5. Tighten the two master cylin-
der attaching nuts.
   6. Tighten all hydraulic line fit-
tings.
   7. Bleed the brake system. Fill the
master cylinder to 34 inch from the
top of the filler opening. Be sure that
the diaphragm type gasket is proper-
ly seated in the reservoir cap, and
install the cap.

BRAKE BOOSTER
REMOVAL
   1. Working inside the car below
the instrument panel, disconnect the
stop light switch wires at the connec-
tor.
   2. Remove the hairpin type re-
tainer. Slide the stop light switch off
the brake pedal pin just far enough
for the switch outer hole to clear the
pin, and then lower the switch away       FIG. 25-Vacuum         Booster Installation-Comet-Fairlane-Falcon
from the pin. Slide the master cyl-
inder push rod link and the nylon                                           BRACKET                           -
                                                                                                              B
washers and bushing off from the
brake pedal pin (Fig. 25 or 26).
   3. Working in the engine com-
partment, loosen the hose clamp, and
disconnect the vacuum hose from
the booster at the check valve.
   4. Remove the two master cylin-
der attaching nuts and pull the master
cylinder from the booster, without
disconnecting the hydraulic lines.
Secure the master cylinder out of
the way.
   5. Remove the four mounting
bracket-to-dash panel attaching bolts.
   6. Remove the booster and brac-
ket assembly from the dash panel,
sliding the push rod link out from                           BOOSTER ASSY.-2005                                    H1403-A
the engine side of the dash panel.
                                          FIG.. 26-Booster      Installation-Mustang
INSTALLATION
   1. Mount the booster and bracket          4. Working from inside the car,          parts to the pin with the hairpin type
assembly to the dash panel by slid-       install the inner nylon washer, the         retainer.
ing the push rod link in through the      master cylinder push rod link, and             5. Connect the stop light switch
hole in the dash panel. Install the       the bushing on the brake pedal pin.         wires to the connector, and install
four attaching bolts.                     Position the switch so that it strad-       the wires in the retaining clip.
   2. Position the brake master cyl-      dles the push rod with the switch slot      BRAKE PEDAL-MANUAL
inder to the booster assembly and in-     on the pedal pin and the switch outer       SHIFT TRANSMISSION
stall the attaching nuts.                 hole just clearing the pin. Slide the       REMOVAL
   3. Connect the vacuum hose to          switch completely onto the pin, and            1. On a Falcon, Comet or Fair-
the booster at the check valve, and       install the outer nylon washer as           lane, remove the clutch pedal assist
tighten the hose clamp.                   shown in Fig. 25 or 26. Secure these        spring, (Fig. 27).
2-26                                              GROUP 2 - BRAKES




                         '279-s   SPRING WASHER

                                                                PEDAL SUPPORT BRACKET




                                             BUSHING.~A~O~'           TYPICAL BUSHINGS AN0 SWITCH ASSEMBLY




FIG. 27-Master   Cylinder, Brake Pedal and Related Parts-Falcon,     Fairlane, Comet and Mustang
                                               BART 2-2 - BRAKE SYSTEM

       On a Mustang, remove the pedal         BRAKE P E D A L                           INSTALLATION
    bumper and bracket assembly from          AUTOMATIC TRANSMISSION                       1. Disengage the locking rod and
    the pedal support bracket to relieve                                                connect the ball end of the cable to
    the tension on the assist spring, and     REMOVAL                                   the slot on the control assembly.
    then remove the spring.                      1. Disconnect the stop light switch       2. Assemble the pulley to the con-
       2. Disconnect the clutch pedal-to-     wires at the connector.                   trol handle and the clevis pin.
    equalizer rod at the clutch pedal by        2. Remove the self-locking pin             3. Position the assembly against
    removing the hairpin type retainer        and slide the stop light switch off       the dash panel and instrument panel.
    and bushing.                              the brake pedal pin just far enough       Secure the assembly to the instru-
       3. Disconnect the stop light           for the switch outer hole to clear        ment panel with the two screws.
    switch wires at the connector.            the pin. Then lower the switch away          4. Install the insulator bracket
                                              from the pin. Slide the master cylin-     with the attaching screws (Fig. 28).
       4. Remove the switch retainer,         der push rod and the nylon washers
    and slide the stop light switch off the                                                5. Working from under the left
                                              and bushing off from the brake            front fender, install the two lock
    brake pedal pin just far enough for       pedal pin (Fig. 27).
    the switch outer hole to clear the                                                  washers and attaching nuts.
                                                 3. Remove the self-locking pin
    pin. Then lower the switch away           and washer from the brake pedal
    from the pin.                                                                       PARKING BRAKE CONTROL
                                              shaft, then remove the shaft, the         ASSEMBLY-FAIRLANE,
       5. Slide the master cylinder push      brake pedal assembly and the bush-        FALCON, COMET
    rod and the nylon washers and bush-       ings from the pedal support bracket.
    ing off from the brake pedal pin                                                    REMOVAL
    (Fig. 27).                                INSTALLATION                                 1. Make sure the parking brake is
       6. Remove the self-locking pin            1. Apply a coating of SAElO en-        completely released. Remove the 3
    and washer from the clutch and            gine oil to the bushings and locate       screws (Fig. 29) that attach the con-
    brake pedal shaft, then remove the        all the bushings in their proper          trol assembly to the cowl inner side
    clutch pedal and shaft assembly, the      places on the pedal assembly and          panel.
    brake pedal assembly, and the bush-       pedal support bracket. (Fig. 27).            2. Pull the control away from the
    ings from the pedal support bracket          2. Position the brake pedal assem-     cowl panel and remove the hair-
    (Fig. 27).                                bly to the support bracket, then in-      pin lock retaining the parking brake
                                              stall the pedal shaft through the sup-    cable housing to the control assem-
                                              port bracket and brake pedal assem-       bly.
    INSTALLATION                              bly. Install the washer and self-lock-       3. Disconnect the ball-end of the
                                              ing pin.                                  parking brake cable from the control
         .
        1 Apply a coating of SAE 10 en-          3. Install the inner nylon washer,     and remove the control assembly.
)   gine oil to the bushings and locate
    all bushings in their proper places on
                                              the master cylinder push rod, and
                                              the bushing on the brake pedal pin.       INSTALLATION
    the clutch and brake pedal assem-         Position the switch so that it strad-
    blies.
                                                                                             .
                                                                                           1 Connect the ball-end of the
                                              dles the push rod with the switch slot    parking brake cable to the control.
      -2. Position the brake pedal to the     on the pedal pin, and the switch
1   support bracket, then install the                                                      2. Install the hair-pin cable hous-
                                              outer hole just clearing the pin. Slide   ing retainer.
    clutch pedal and shaft asselnbly          the switch completely onto the pin,
    through the support bracket and           and install the outer nylon washer           3. Position the control assembly
    brake pedal assembly. Install the         as shown in Fig 27. Secure these          to the cowl side panel and install the
    spring washer and retainer. (Fig. 27).                                              attaching screws. Torque to 12-20
                                              parts to the pin with the self-locking
       3. Install the split bushing in the                                              ft-lb.
                                              pin.
    spring groove of the clutch pedal.           4. Connect the stop light switch
    Hook the clutch assist spring to the      wires to the connector, and install       PARKING BRAKE EQUALIZER
    groove and to the spring retainer.        the wires in the retaining clip.          TO HANDLE CABLE-
       4. Connect the clutch pedal to                                                   MUSTANG
    equalizer rod to the clutch pedal as-     PARKING BRAKE HANDLE-                     REMOVAL
    sembly with the bushing and the hair-     MUSTANG                                      1 Remove the attaching screws
                                                                                             .
    pin retainer. Apply SAE 10 engine
                                              REMOVAL                                   and insulator-bracket from the dash
    oil to the bushing.
       5. Install the inner nylon washer,        1. Remove the two screws that          panel (Fig. 28).
    the master cylinder push rod, and         hold the handle bracket on the in-           2. Remove the parking brake han-
    the bushing on the brake pedal pin.       strument panel. Remove the at-            dle assembly and disengage the cable
    Position the switch so that it strad-     taching screws and the insulator          from the handle as outlined in this
    dles the push rod with the switch slot    bracket (Fig. 28).                        section.
    on the pedal pin and the switch outer        2. Remove the two nuts and lock           3. Pull the cable down through
    hole just clearing the pin. Slide the     washers that secure the control           the hole in the dash panel.
    switch completely onto the pin, and       to the dash panel.                           4. Remove the hairpin retainer,
    install the outer nylon washer as            3. Remove the clevis pin that se-      and disengage the cable and housing
    shown in Fig. 27. Secure these parts      cures the pulley to the control han-      from the bracket on the crossmem-
    to the pin with the self-locking pin.     dle assembly.                             ber.
       6. Connect the stop light switch          4. Disengage the locking rod and          5. Disconnect the cable ball from
    wires to the connector, and install       remove the ball on the cable from         the equalizer lever, and remove the
    the wires to the retaining clip.          the slot in the control assembly.         cable from the car.
2-28                                                        GROUP 2 -BRAKES




                                        44722-58 2 REQD.


                                       55672.58 2 REQD.




                                                                                                            39883-58 2 REQD.

                              EQUALIZER ROD A5SY.-2A794




                                                                      ADJUSTING NUT   .




       EQUALIZER LEVER-2A6O


                 EQUALIZER T O H A N D L E CAB


                                            RETAINER-74277.S                      BRACKET-PA610


                                                 31497-52 2 REQD.
                                                                                                                        H1404.

FIG. 28-Parking       Brake Linkage-Mustang                                                       ,   , -   a
FIG. 29-Parking   Brake Linkage-Comet-Fairlane-Falcon
                                               GROUP 2-BRAKES                 .

INSTALLATION                                 10. Position the floor mat and in-          FAIRLANE A N D COMET
   1. Connect the cable lower ball to     stall the cowl side trim panel.                STATION W A G O N S A N D
the equalizer lever (Fig. 28).                                                           FALCON PASSENGER CAR
   2. Engage the cable and housing        PARKING BRAKE EQUALIZER
                                          TO REAR WHEEL CABLE                            REMOVAL AND INSTALLATION
to the bracket on the crossmember
                                            A single cable passing through the              1. Generally follow the procedure
and secure with the hairpin retainer.
                                          equalizer and cable guides connects            given above, omitting separation of
   3. Push the upper end of the cable
                                          both parking brake assemblies on               the cables, since the hand brake
up through the hole in the dash
                                          Comet and Fairlane station wagons              cable supplied for these ,models is
panel.
                                          and on Falcos and Mustang pas-                 in one piece. Removal and installa-
   4. Connect the cable upper ball
                                          senger cars. Separate cables for each          tion of both rear wheels, tires and
to the parking brake handle, and in-
                                          parking brake are used on Comet                drums will also be required.
stall the handle assembly as outlined
in this section.                          and F&lane passenger cars.
   5. Install the insulator bracket to                         /-                        MUSTANG
                                                           x

the dash panel and secure with the
two attaching screws.
                                          FAIRLANE AND COMET   -                         REMOVAL
                                          PASSENGER CARS                                    1. Remove the adjusting lock nut
                                          REMOVAL                                        and cable yoke from t h e equalizer
PARKING' BRAKE EQUALIZER
                                                                                         rod (Fig. 28), along .with the rear
TO PEDAL C A B L E F A I R L A N E ,         1. Remove the equalizer lock nut            cable assembly.
COMET, FALCON                             and adjusting nut, equalizer and                  2. Remove the hairpin retainers
REMOVAL                                   spring.                                        and disengage the cable rear hous-
                                             2. With the cables slack, discon-           ings from the brackets on the under-
     .
   1 Remove the two nuts that at-         nect the ball-ends from the connector
tach the cable to the equalizer and                                                     , h,-.rl.r .
                                                                                          "VU J

                                          (Fig. 29).                                        3. If an 8-cylinder model, remove
remove the equalizer and spring              3. Remove the cable from the
(Fig. 29).                                                                               the single bolt and clamp retaining
                                                                                                              '
                                          guide, if required.                            the cable housing to the underbody
   2. Remove the hair pin retainer           4. Remove the hair pin lock re-
holding the cable housing to the                                                         immediately behind the cable hous-
                                          taining the cable housing to the side          ing bracket.
frame bracket at the equalizer.           rail bracket.
   3. Working from inside the car,                                                          4. Remove the 'two bolts and
                                             5. Remove the wheel and tire           ,
                                                                                         clamp securing the cable housing to
remove the hair pin retainer holding      and the rear brake drum as outlined
the cable housing to the parking                                                         the underbody on all models.
                                          in Section 2.                                     5. Remove the, wheels and tires
brake control assembly.                      6. Disconnect the rear end of the
   4. Disconnect the ball end of the                                                     and the rear brake drums as 'out-
                                          cable from the parking brake lever             lined in Section 2.
cable from the parking brake control      on the brake shoe. Disengage the
arm.                                                                                        6 . Disconnect the rear ends of the
                                          cable housing retaining grommet                cable from the parking brake levers
   5. Remove the left front cowl side     from the carrier plate and withdraw
trim panel, roll back the floor mat                                                      on the brake shoes. Disengage the
                                          the cable and housing from the in-             cable housing retaining grommets
and pull the cable assembly from the      board side of the carrier plate.
floor.                                                                                   from the carrier plates and withdraw
                                             7. Slide the cable and housing out          the cable ends and housings from
INSTALLATION                              of the side rail bracket.                      the inboard sides of the carrier plates.
   1. Position the cable housing                                                            7. Slide the cable housings out of
through the opening in the floor and      INSTALLATION                                   the main side brackets and remove
pull the grommet into position from          1 Insert the rear end of the
                                               .                                         the cable assembly from the car.
under the car.                            cable through the side rail bracket
   2. Install the ball-end of the cable   and pull the cable and housing into           .INSTALLATION
in the parking brake control.             position.                                         1. Insert both cable ends and hous-
   3. Install the hair pin retainer to       2. Insert the rear end of the cable         ings through the holes in the carrier
lock the cable housing in position on     and housing through the hole in the            plates from the inboard side.
the parking brake control.                carrier plate from the inboard side.              2. Connect the cable ends to the
   4. Working from under the car,            3. Connect the cable to the park-           parking brake levers on the brake
position the cable housing in the         ing brake lever on the brake shoe,             shoes and engage the cable housing
frame bracket and install the re-         and install the cable housing retain-          retaining grommets to the carrier
tainer.                                   ing the grommet in the carrier plate.          plate.
   5. Position the spring and equal-         4. Position the cable housing in               3. Position the cable housings in
izer on the cable and install the ad-     the side rail bracket and install the          the main ,side brackets and install
justing nut.                              hair pin type retainer.                        the hairpin retainers.
   6 . Apply the parking brake one           5. Position the cable in the guide             4. Install the front clamp with
notch from the released position.         and install the connector, thus hook-          one bolt, if an 8-cylinder model.
   7. Tighten the adjusting nut until     ing the two cables together.                      5. Install the rear clamp with
a light to moderate drag is felt when        6. Insert the cable into the equal-         two bolts.
the rear wheels are rotated.              izer and install the equalizer, spring,           6. Position the cable yoke and
   8. Tighten the check nut securely.     adjusting nut and lock nut to the              cable on the equalizer rod and in-
   9. Fully release the parking brake.    front, parking brake control, cable.           stall the adjusting locknut.
No drag should be felt when the              7. Adjust the parking brake as di-             7. Adjust the parking brake as
wheels are rotated.                       rected in Part 2-1, Section 2.                 directed in Part 2-1, Section 2.
    This shop manual provides the Service Technician wlth com-

    plete information for the proper servicing of the 1966 Comet,

    Falcon, Fairlane and Mustang 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

    eflect 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 P U B L I C A T I O N S
                                          PART 2-2 - BRAKE SYSTEM

        MAJOR REPAIR OPERATIONS
 BRAKE D R U M REFINISHING              4. Check the clearance between           2. Remove the snap ring from the
   The 6-cylinder ~~l~~~ and M ~ ~ the shoe and lining. The lining must
                                     -                                        bore at the rear of the cylinder with
 tang models are equipped with 9-    seat tightly against the shoe with not   tool 33621 (Fig. 32).
inch brake drums. All other models   more than .005 inch clearance be-           3. When disassembling a master
are equipped with 10-inch drums.     tween any two rivets.                    cylinder used with the standard
   Minor scores on a brake drum can                                           brake system, remove the piston as-
be removed with a fine emery cloth.  MASTER CYLINDER-                         sembly, cup, spring, check valve, and
A drum that is excessively scored or EXCEPT CARS W I T H DISC
                                                                              valve seat from the cylinder bore
shows a total indicator runout of    BRAKES                                   (Fig. 30).
over 0.007 inch should be turned     DISASSEMBLY                                 When disassembling a master cyl-
down. Remove only enough stock to
                                        1. Clean the outside of the cylin-    inder used with a booster, remove
eliminate the scores and true up the
                                     der, and remove the filler cap and       the piston assembly, cup, and the
drum. The refinished diameter must
not exceed 0.060 inch oversize.      gasket. Pour out any brake fluid that    spring and check valve assembly
                                     may remain in the cylinder or res-       from the cylinder bore. Remove the
   If the drum diameter is less than
0.030 inch oversize (9.030 inches    ervoir.                                  O-ring from the piston (Fig. 3 1).
6-cylinder Falcon or Mustang, or
 10.030 inches on other models after
refinishing, standard lining may be
installed. If the drum diameter is
more than 9.030 inches or 10.030
inches, oversize linings must be in-
                                                                                 PUSH ROD
stalled.
   After a drum is turned down, wipe
the refinished surface with a cloth
soaked in clean denatured alcohol.
If one drum is turned down, the                                                        PRIMARY CUP
opposite drum on the same axle
should also be cut down to the same                                                                               SECONDARY
size.                                                                                                                CUP
                                         FITTING

BRAKE SHOE RELINING
   Brake linings that are worn to
within      inch of any rivet or have
                                          b
                                                   NUT   LOCKWASHER
been saturated with grease or oil                                              VALVE

should be replaced. Failure to re-
place worn linings will result in a
                                         FIG. 30-Master     Cylinder With Standard Brake System
scored drum. When it is necessary
to replace linings, they must also be
replaced on the wheel on the oppo-
site side of the car.
   Inspect brake shoes for distortion,
cracks, or looseness. If this condi-
tion exists, the shoe should be dis-
carded. D o not repair a defective
brake shoe.
                                                                                                             SNAP RING
   1. Wash the brake shoes thor-
oughly in a clean solvent. Remove
all burrs or rough spots from the                                                                      \
shoes.
   2. Check the inside diameter of
the brake drum. If the diameter is
less than 9.030 or 10.030 inches,
                                                                                               q q i t qb           O-RING
standard lining may be installed. If                                                                 I   PISTON
the diameter is 9.030 to 9.060 or                                                                U
                                                                                                CP
10.030 to 10.060 inches, oversize lin-
ing should be installed.
   3. Position the new lining on the
shoe. Starting in the center, insert
and secure the rivets working alter-                          NUT
nately towards each end. Install all
parts supplied in the kit. Genuine re-
placement linings are ground and no
further grinding is required.            FIG. 3 1-Master Cylinder With Booster
ASSEMBLY                                                                            DISC BRAKE CALIPER
   1. Dip all parts except the master                                               DISASSEMBLY
cylinder body in clean Rotunda
 103-A heavy-duty brake fluid.                                                         Do not remove the bridge bolts
   2. Install the brake line fitting(s)                                             that hold the two halves of the cali-
on the cylinder and tighten them se-                                                per together. The two caliper hous-
curely.                                                                             ings are shown separated in Fig. 35
   3 When assembling a master cyl-
    .                                                                               for illustration purposes only.
inder used with the standard brake
                                                               MASTER CYLINDER         1. Remove the caliper assembly
system, install the valve seat, check                                               from the car as outlined in Section 2.
valve, spring, cup, and piston assem-                                                  2. Remove the two retaining bolts
bly in the cylinder bore (Fig. 30).                                                 and the caliper splash shield Fig. 35.
   When assembling a master cylin-                                                     3 Remove the two shoe and lin-
                                                                                        .
der used with a booster, install the                                                ing assemblies.
O-ring on the piston. Install the                                                      4. Remove the flexible brake hose
spring and check valve assembly,                                                    from the caliper.
cup, and piston in the cylinder bore                  SECONDARY CUP
                                                                                       5 Remove the external transfer
                                                                                        .
(Fig. 31).                                                                          tube.
                                                              /.
                                                       SNAP RINGI -                    6. Remove the four dust boots
   4. Install the snap-ring in the back
                                                                       H 1387 - A   from the caliper housings and piston
of the bore (Fig. 32).
                                                                                    grooves.
                                          FIG. 33-Master Cylinder Used                 7. Clamp the caliper in a vise and
                                          With Disc Brakes-Disassembled             secure it by the mounting flanges on
                                                                                    the inboard housing (Fig. 34).
                                          the snap ring in. the groove in the
                                          cylinder bore.
                                             5. Install a new diaphragm (only
                                          if the old one is defective) in the
                                          cover, and attach the cover to the
                                          cylinder with the s'pring clips.

                                          MASTER CYLINDER CLEANING
                                                                                     Tool   - T65P - 21 I8 - A
                                                                                                             -
                                                                                                                 NY
F I G . 32-Removing Snap Ring
                                          A N D INSPECTION
From Master Cylinder-Typical
                                             1. Clean all master cylinder parts
                                          in clean denatured alcohol, and in-
MASTER CYLINDER-                          spect the parts for wear or damage,
W I T H DlSC BRAKES                       replacing them as required. When
DISASSEMBLY                               using a master cylinder repair kit,
   1. Press in against the piston while   install all of the parts supplied.
removing the snap ring retainer, and         2. Check the ports and vents in
then remove the piston assembly,          the master cylinder to make sure
cup, spring, residual check valve and     that all are open and free of foreign
seat. (Fig. 33).                          matter. Check the condition of the
   2. Remove secondary cup from           diaphragm type gasket.
the piston. Remove the cover by              3 A leaf-type valve is riveted to
                                              .
                                          the front end of the piston in a
releasing the spring clips on the
                                          master cylinder used with the stand-
                                                                                    FIG. 34-Removing             or
sides, and remove the diaphragm.                                                    Installing Pistons
                                          ard brake system (Fig. 30). If this
                                          valve is loose or has moved so that
ASSEMBLY                                  the piston ports are open, replace           8. Remove the four pistons from
  1. Clamp the master cylinder hous-      the piston.                               the cylinder bores with the special
ing in a vise. Dip the hydraulic cyl-        When inspecting a master cylin-        tool shown in Fig. 34. To prevent
inder parts in brake fluid and assem-     der used with a booster, check the        cocking with consequent damage to
ble the check valve seal, residual        ports in the piston to make sure that     the piston or bore, rotate the piston
check valve, and piston return spring     they are open and free of foreign         with the tool while pulling it out-
in the bore of the cylinder in the        material (Fig. 31).                       ward at the same time. Be-careful
order shown in Fig. 33.                      4. Inspect the cylinder walls for      to avoid scratching or damaging the
   2. If the secondary piston cup was     scores or rust, and recondition them      outside diameter surface or dust boot
removed from the piston, dip the          if necessary. Hone the cylinder walls     retaining groove of the piston. Such
cup in brake fluid and assemble the       no more than necessary (0.003 inch        damage causes poor sealing.
cup in the groove of the piston with      maximum). Oversize pistons and               If a piston is so completely seized
the lip of the cup as shown.              cups are not available for excessively    in the cylinder bore that it can not
   3 Place the primary cup on the
    .                                     honed cylinders.                          be removed with the special tool,
end of the piston assembly, and              5. Remove any burrs or loose           force the cylinder out of the bore
guide it into the cylinder bore.          metal that may have resulted from         by ;positioning two screwdrivers in
   4. Press in against the piston to      the honing operation, and clean the       the piston dust boot retaining groove
compress the spring while seating         cylinder with denatured alcohol.          and prying outward. To prevent
                                            BART 2-2 - BRAKE SYSTEM

cocking, tap the end of the piston         off. Check the caliper dust boot re-        piston seal and the installation of
lightly around the circumference           tainer for wear or damage.                  the seal. If the piston still will not
with a hammer, while the prying                                                        go in with bore in good condition
force is being applied. Be careful to      ASSEMBLY                                    and the piston seal properly installed,
avoid damaging the dust boot re-              1. Clamp the caliper in a vise and       use the tool shown in Fig. 34. Ro-
tainer in the caliper housing (Fig.        secure it by the mounting flange on         tate the piston with the tool while
3 ) If this method of removal is
 5.                                        the inboard housing.                        pushing it inward at the same time.
used, the pistons must be replaced.           2. If a new caliper dust boot re-           5. Carefully install four new dust
   If the caliper dust boot retainer or    tainer is to be installed, thoroughly       boots on the caliper housings and pis-
retaining groove is damaged or             clean the contact area on the caliper       tons. Be sure that each boot is fully
scratched, pry the retainer out of the     housing and apply Loctite Sealant,          seated in the groove of its respective
caliper housing with screwdrivers.         Grade H to the retainer surface that        caliper housing and piston (Fig. 3 )5.
   9. Remove the rubber piston seals       seats in the housing. Install the re-       D o not use the old dust boots.
from the grooves in the cylinder           tainer in the caliper housing.                 6. Install the external transfer
bores by carefully inserting the point        3. Apply a film of clean brake           tube.
of a small knife or other pointed in-      fluid to new caliper piston seals and          7. Install the flexible brake hose to
strument under the seal and raising        install them in the grooves of the          the caliper.
the seal up far enough to be pulled        cylinder bore. The seal should be              8. Install the caliper assembly on
out with the fingers.                      positioned at one area in the groove        the spindle, and install the shoe and
                                           and gently worked around. D o not           lining assemblies and the splash
CLEANING AND INSPECTION                    use the old seals.                          shield as outlined in Section 2.
   Clean all metal parts with alcohol         4. Coat the outside diameter of             9. Check the caliper for fluid leaks
or a suitable solvent (Fig. 3 ) Use
                              5.           the pistons with brake fluid and in-        under maximum pedal pressures. D o
clean, dry compressed air to clean         stall them in the cylinder bores so         not move the car until a firm brake
out and dry the grooves and passage-       that the open end of the piston and         pedal is obtained.
ways. Be sure that the caliper bore        the boot retaining groove face out of
and component parts are completely         the bore. To avoid cocking, locate          DISASSEMBLY O F BOOSTER-
free of any foreign material.              the piston squarely in the bore and         BENDIX TYPE
   Check the cylinder bores and pis-       apply a slow, steady pressure. If a            1. Remove the speed nuts that at-
tons for damage or excessive wear.         piston will not easily go all the way       tach the mounting plate to the rear
Replace the piston if it is pitted,        into the bore, remove it and thor-          shell and remove the plate.
scored, or the chrome plating is worn      oughly inspect the cylinder bore, the          On a Mustang, remove the retain-
                                                                                       ing nuts and lockwashers and remove
                                                                                       the mounting brackets from the rear
                                                                                       shell (Fig. 40.)
                                                                                          2. Pull the hydraulic push rod and
                                            CALIPER ABUTMENTS
                                                                                       front seal (Fig. 36) from the front
                                                                                       shell.
                                                                                          3. Scribe an index mark across the
                                                                                       front and rear shells.
              DUST BOOT RETAINING GROOVE                                                  4. Place the booster in a vise
                                                                                       as shown in Fig. 37. Press downward
                                                                                       on the rear shell and at the same
                                                                                       time, turn it counterclockwise with a
                                                                                       flat bar to release it from the front
                                                                                       shell. Release the pressure on the
                                                 DUST BOOT (4)
                                                                                       rear shell slowly to prevent the dia-

                                                SHOE AND LINING ASSEMBLIES


                                                                                                                      FRONT
                                                                                                                      SHELL




                                                                                                                      FRONT
                                                                                                                       SEAL




                                                                                                      PUSH ROD
      FLEXIBLE HOSE                                                                                                   H I 334-A
                                                                             H1367-A
                                                                                       FIG. 36-Removing Front Seal
FIG. 35-Caliper        Assembly-Disassembled                                           and Push Rod-Bendix Booster
2-34                                           . -- GROUP 2 - BRAKES

                                                  FILTER
                                                 RETAINER   \   fl
                                                            \ 1-1        FILTER                              6 PUSH R O D


                                                                                                                  SLOT




FIG. 37-Separating Booster
Shells-Bendix Booster
                                              FIG. 3 8 - ~ e m o v i n ~Diaphragm     FIG. 39-Removing or
phragm plate return spring from fly-          -Bendix Booster                         Installing Valve Retainer-Bendix
ing out.                                                                              Booster
   5. Separate the two shells and re-
move the return spridg.                          9. Hold the diaphragm plate so
                                              that the valve retainer is facing       shell with a punch or screwdriver.
   6. ~ i i h d r a wthe diaphragm plate      downward. Press the valve push rod      (Fig. 40). Discard the seal.
and diaphragm from the rear shell.            inward to release the tension on the       13. Working from the inside of
Remove the dust shield.                       retainer and allow it to drop out of    the front shell, cut the bead off the
   7. Remove the diaphragm from               the plate (Fig. 39).                    check valve grommet. Remove the
the diaphragm plate as shown in Fig.           . 10. Withdraw the valve and rod       check valve.
38.                                           from the plate.
   8. Pry the filter retainer off the            11. Press the reaction disc out of   ASSEMBLY O F BOOSTER-
diaphragm plate being careful not to          the diaphragm plate.                    BENDIX-TYPE
chip or damage the plate.                        12. Drive the seal out of the rear     1. Place the rear -shell on two




                                                                                                         VACUUMCHECK VALVE




                                   VALVE Al



                                    SEAL




DUST SEAL



                      REAR S H ~ L (COMET)
                                   L
                                                                                       \
FIG. 40-Vacuum           Booster Disassembled-Booster
                                            PART 2-2 - BRAKE SYSTEM

                                          shell and compress the spring until          5. Disconnect the lever assembly
                  1/4 INCH.   SEAL
                                          the tangs on the rear shell contact       from the end plate brackets by re-
                                          the notched sections of the front         moving the retainer clip and pivot
                                          shell, and then rotate it clockwise to    pin.
                                          lock it in place.                            6. Disconnect the push rod link
                                             11. Apply lubricant sparingly to       from the lever assembly by remov-
                                          the stem of the hydraulic push rod        ing the retainer and connecting pin.
                                          keeping it away from the adjusting           7. Remove the attaching nuts, and
                                          screw area. Apply silicone grease         disassemble the brackets from the
                                          liberally to the piston area of the       end plate.
                                          push rod and to the reaction disc.           8. Remove the rubber boot from
                                             12. Center the reaction disc on the    the valve operating rod.
                                          push rod piston. Guide the disc and
                                          push rod into the base of the dia-        SEPARATION OF MAJOR
                                          phragm plate, and press the rod in-       COMPONENTS
                                          ward until the disc is bottomed (Fig.
                                                                                       1. Scribe a line across the booster
FIG. 41 -Installing Rear Shell            42).
                                                                                    body, clamp band, and end plate.
Seal-Bendix Booster                                                                    2. Remove the clamp band screw
                                                                                    and nut, and separate the clamp
wood blocks as shown in Fig. 41.                                                    band, booster body, and end plate
Press a new seal, plastic side first,                                               (Fig. 49).
into the recess on the inside of the                                                   3. Push the bellows assembly into
shell to a depth of '/4 inch.                                                       the vacuum chamber (Fig. 43), and
   2. Dip a new check valve grom-                                                   separate the bellows, control valve,
met (Fig. 40) in alcohol and install                                                diaphragm assembly, and end plate
                                                              HYDRAULIC PUSH ROD
it in the front shell making sure that                                              from the booster body.
                                                                          H1347-A
the beveled edge is toward the inside.
Make sure that the grommet is seated.     FIG. 42-Installing Reaction               BOOSTER B O D Y
Dip the shoulder of the check valve       Disc, Push Rod and Front Seal
in alcohol and install it in the grom-    -Bendix Booster
met. Press the check valve into the
grommet until the flange contacts
the grommet.                                 13. Press a new front seal into
   3. Apply silicone grease to the        the front shell until it bottoms in
outer surface of the diaphragm plate      the recess (Fig. 42).
hub of the diaphragm plate. Push             14. Install a new dust seal over the
surfaces of the valve.                    push rod and onto the rear shell.
   4. Insert the valve and rod into the      15. On a Comet, position the
hub of the diaphragm plate. Push          mounting plate. on the rear shell and
the rod inward until the retaining        secure it in place with speed nuts.
groove is aligned with the slot, and         On a Mustang, position the two
then slide the retainer into the groove   niounting brackets on the rear shell
(Fig. 39).                                studs, and install the retaining nuts     FIG. 43-Bellows to Booster
   5. Tuck the filter into place in the   and lock washers (Fig. 40).
                                                                                    Body Engagement-Midland-Ross
plate hub. Press the filter retainer
onto the hub being careful not to         DISASSEMBLY OF BOOSTER-
chip or damage the plastic. (Fig.         MIDLAND-ROSS TYPE                           4. Push the valve, tail stock, and
38).                                                                                diaphragm assembly out of the end
   6. Install the diaphragm on the        REMOVAL OF EXTERNAL                       plate.
diaphragm plate, making sure that         PARTS                                       5. Remove the rear seal from the
the diaphragm lip is tucked in all           1. Remove the two attaching nuts       end plate (Fig. 44).
around the recess between the hub         and lockwashers, and separate the
and the plate (Fig. 38).                  master cylinder from the booster
   7. Place the rear shell in a vise.     body.                                     DISASSEMBLY OF BELLOWS,
Apply silicone lubricant generously          2. Remove the air filter assembly      PUSH ROD AND VALVE
to the top outer flange of the shell.     from the booster body. Separate the       ASSEMBLY FROM DIAPHRAGM
Apply silicone grease to the seal in      cover and retainer, and remove the          1. Remove the large bellows clamp
the rear shell.                           air filter (Fig. 49).                     and separate the bellows, bellows
   8. Carefully guide the valve rod          3. Remove the vacuum manifold          support rings, and bellows protector
and diaphragm plate hub through the       and check valve assembly and the          from the diaphragm and valve as-
seal in the rear shell.                   rubber grommet from the booster           sembly (Fig. 45).
   9. Center the large end of the re-     body (Fig. 49).                              2. Remove the two support rings
turn spring on the diaphragm plate.          4. Disconnect the valve operating      and the protector from the bellows.
    10. Align the index mark on the       rod from the lever assembly by re-          3. Remove the push rod assembly
front shell with the one on the rear      moving the retainer clip and con-         and the reaction lever assembly from
shell. Place a flat bar on the front      necting pin (Fig. 49).                    the control hub (Fig. 46).
2-36                                         GROUP 2 - BRAKES




                                                                                        'ITROL HUB




                                                                                        ,            LEVER




FIG. 44-Removing or
lnstalling Rear Seal to End Plate
-Midland-Ross




                                        FIG. 46-Push Rod Assembly, Reaction Lever and Control
                                        Hub-Midland-Ross

                                                                                   PLUNGER                   Snap R l n g
                                         TO INSTALL                TO REMOVE




F I G . 45-Removing or
lnstalling the el lows Assembly
-Midland-Ross
   4. Remove the two plastic guides
from the push rod. Remove the re-                                              CONTROLHUB                      Hl398-A
action cone retainer and the cone
from the push rod (Fig. 46).            DIAPHRAGM PLATE     CONTROLHUB AND     FIG. 48-Removing or
   5. Remove the valve operating rod                        PLUNGER ASSEMBLY   lnstalling Plunger to Control Hub
from the plunger. T o remove, hold
the rod firmly and force the plunger
off the rod breaking the plastic re-    FIG. 47-Removing or                    rubber valve, O-ring, and fiber
tainer. If the plunger is to be used    Installing Control Hub and             washer from the plunger (Fig. 49).
again, remove all the broken pieces     Plunger Assembly-Midland-Ross
of the plastic retainer from the                                               ASSEMBLY O F BOOSTER-
groove in the plunger.                                                                       TYPE
   6. Turn the control hub and          truding end of the plunger before
plunger assembly clockwise to sep-      it can be separated from the control   CONTROL VALVE PLUNGER
arate it from the diaphragm, and        hub.                                    1. Assemble the rubber valve,
then remove the tail stock and O-ring                                          valve plate, spring, O-ring, and
from the diaphragm (Fig. 47).           DISASSEMBLY OF CONTROL                 fiber washer on the plunger.
   7. Remove the retainer that holds    VALVE PLUNGER                             2. Compress the spring towards
the plunger to the control hub (Fig.      1. Compress the spring towards       the rubber valve a n d assemble the
48). ,Separate the control hub and      the rubber valve and remove the        spring retainer on the plunger with
plunger assembly. It may be neces-      spring retainer.                       the flange towards the spring (Fig.
sary to file the burr from the pro-       2. Remove the spring, valve plate,   49).
                                                 PART 2-2 - BRAKE SYSTEM

                                                                                                     REACTION C O N E
       V A C U U M MANIFOLD




            AIR FILTER

                                                                                     BELLOWS CLAMP
                                                           BODY RETAINING SCREW       /-




                              PLASTIC GUIDES   LEVER ASSEMBLY   /-




                                               VALVE OPERATING ROD

  OPERATI
 PLASTIC                                                                   LEVER




FIG. 49-Booster          Unit Disassembled-Midland-Ross

ASSEMBLY OF VALVE                              tainer, and two plastic push rod            and check valve assembly through
ASSEMBLY, PUSH ROD, A N D                      guides on the push rod. Install the         the grommet (Fig. 49).
BELLOWS TO DIAPHRAGM                           push rod assembly in the valve hub             3. Assemble the booster body to
                                               so that the push rod indexes in the         the end plate. Make sure that the
   1. Assemble the control valve               valve plunger.                              lip of the diaphragm is evenly posi-
plunger assembly into the control                 7. Install the two bellows support       tioned on the retaining radius of the
hub so that the round holes in the             rings and bellows protector on the          end plate and the booster body. Pull
rubber valve index with the raised             bellows. The support rings are posi-        the front lip of the bellows through
projections on the hub, and the flat           tioned in the two larger folds of the       the booster body and position it
on the valve plate indexes with the            bellows and the protector in the            evenly around the hole in the boost-
flat projection on the hub (Fig. 50).          smaller fold.                               er body (Fig. 46).
Compress the valve spring, and in-                8. Assemble the bellows on the              4. Install the clamp band over the
stall the retainer in the plunger              control hub so that the lip of the bel-     lips of the booster body and end
groove to secure the control valve             lows indexes in the groove on the           plate. Align the scribe lines, com-
plunger to the control hub (Fig. 48).          hub. Secure the bellows to the hub          press the assembly together, and se-
   2. Assemble the tail stock over the         by assembling the large bellows             cure with the clamp and band bolt.
plunger with the flat on the tail stock        clamp on the diaphragm end of the           Tap the clamp band with a fibre
indexing with the flat on the hub.             bellows approximately Ih2 inch from         hammer around its circumference as
                                               the end of the bellows (Fig. 45).           the bolt is being tightened. Tighten
   3. Assemble the O-ring over the
tail stock and into the "V" groove                                                         to 15 inch-pounds of torque.
                                               ASSEMBLY OF MAJOR
formed by the tail stock and hub.
                                               COMPONENTS                                  INSTALLATION OF EXTERNAL
   4. Assemble the tail stock and the                                                      PARTS
plunger and control hub assembly
                                                  1. Assemble the rear seal in the
to the diaphragm, and turn the hub
                                               end plate (Fig. 44) and position the           1. Install the rubber boot to the
                                               diaphragm, the control valve com-           valve operating rod and assemble
counterclockwise to secure these
                                               ponents, and the bellows as an as-          the plastic retainer to the end of the
parts together (Fig. 47).
                                               sembly into the end plate.                  rod. Insert the rod into the plungef
   5. Install the lever assembly in the           2. Install the rubber grommet in         so that the retainer engages the
control hub with the rubber protru-            the booster body with the large             groove in the plunger. Install the lip
sions toward the hub (Fig. 46).                diameter side to be outside of the          of the boot in the groove of the rear
   6. Assemble the reaction cone, re-          booster. Force the vacuum manifold          seal (Fig. 49).
2-38                                   ,GROUP 2 - BRAKES

                                                                     2. Connect the valve operating
                                                                  rod to the upper end of the lever,
                                                                  and connect the oush rod link to the
                                                                  center of the lever with the con-
                                                 MATCHING HOLES
                                                                  necting pins and clips.
                                                                     3. Position the mounting brackets
                                                                  to the end plate and install the re-
                                                                  taining nuts.
                                                                     4. Connect the lever assembly to
                                                                  the lower end of the mounting brack-
                                                                  ets with the pivot pin and clip.
                                                                     5. Position the air filter in the
                                                                  plastic filter cover and then snap the
                                                                  cover and filter on the metal hub
                                                                  with the filter between.
                                                                     6. Assemble the cover, filter, and
                                                                  hub assembly to the booster body
                                                                  with the metal hub against the
                                                                  booster body.
                                                                     7. Assemble the master cylinder
                                                                  to the booster body. Torque the
                                                                  master cylinder mounting nuts to
FIG. 50-Assembling   Valve Plunger to Hub-Midland-Ross            specification.
           PART                         SPECIFICATIONS
              2-3
LINING DIMENSIONS--INCHES
FALCON
                        MODELS                      POSITION            FRONT                              REAR       COLOR CODE
 Falcon                                            Primary            2.25 x 7.75                    1.5 x 7.75       Red-Blue
 Sedan & Hardtop-Six Cylinder                      Secondary          2.25 x 10.0                    1.5 x 10.0       Green
    Falcon                                         Primary            2.25 x 8.35                    2.25 x 8.35      Silver
    Station Wagons-Six       Cylinder              Secondary          2.25 x 10.75                   2.25 x 10.75     Yellow-Black
    Falcon                                         Primary            2.25 x 8.35                    1.75 x 8.35      Silver
    Sedans-Eight       Cylinder                    Secondary          2.25 x 10.75                   1.75 x 10.75     Yellow-White
    Station Wagon-Eight       Cylinder             Primary            2.50 x 8.35                    2.00 x 8.35      Yellow-Black
                                                   Secondary          2.50 x 10.75                   2.00 x 10.75     Black-Black

-
MUSTANG
                         MODELS                     POSITION            FRONT                              REAR       COLOR COO€
    All Six Cylinder                               Primary            2.25 x 7.75                     1.5 x 7.75      Red-Blue
                                                   Secondary          2.25 x 10.0                     1.5 x 10.0      Green
    All Eight Cylinder                             Primary            2.25 x 8.35                     1.75 x 8.35     Silver
                                                   Secondary          2.25 x 10.75                    1.75 x 10.75    Yellow-White
    All Eight Cylinder                             Disc               4.82 x 1.84                          -          White
FAIRLANE AND COMET
                         MODELS                     POSITION            FRONT                              REAR       COLOR CODE
    Fairlane & Comet 200 & 289                     Primary            2.25 x 8.35                     1.75 x 8.35     Silver
    Passenger Cars                                 Secondary          2.25 x 10.75                    1.75 x 10.75    Yellow-White
    Fairlane & Comet LPO Police &                  Primary            2.50 x 8.35                     2.00 x 8.35     Yellow-Black
      390 Passenger Cars                           Secondary          2.50 x 10.75                                    Black-Black
    Maximum Fade Res~st.                                                                              2.00 x 10.75
    Fairlane & Comet LPO Taxi-                      Primary           2.50 x 9.51                     2.00 x 9.51      Red
    Max. Wear Resist. (Bonded)                      Secondary         2.50 x 10.75                    2.00 x 10.75     White
    Station Wagons-Fairlane       & Comet           Primary           2.50 x 8.35                     2.00 x 8.35      Yellow-Black
      200 & 289                                     Secondary         2.50 x 10.75                    2.00 x 10.75     Black-Black
    Station Wagon                                   Primary           2.50 x 8.35                     2.50 x 8.35      Yellow-Black
    Fairlane & Comet 390                            Secondary         2.50 x 10.75                    2.50 x 10.75     Black-Black
CHECKS AND ADJUSTMENTLINCHES
FALCON
    Master Cylinder Bore Diameter
              Standard                                    1.000        Lining Maximum Wear Limit                               0.031
                                                                       (From Top of Rivets1
    Master Cylinder Maximum Allowable Hone                0.003
    Front Wheel Cylinder Bore Diameter                                 Lining Maximum Clearance to Shoe                        0.008
               9" Brake                                   1.062        (Midway Between Rivets)
              10" Brake                                   1.125
     Rear Wheel Cylinder Bore Diameter                                 Pedal T r a v e l S t a n d a r d                       6.50
                9" Brake                                  0.844        Pedal Travel-Power                                      4.50
               10" Brake                                  0.906        Push Rod Adjustment-Power            Brakes-        0.980-0.995
                                                                         Bendix-Midland-Ross                               0.995-1.005
    Wheel Cylinder Maximum Allowable Hone@                0.003        Hydraulic Line Diameter                                   0.188
     Drum Oiameter
               9" Brake                                      9.0       Parking Brake-Type
              10" Brake                                     10.0         Foot Operated with Pedal Mounted Below
     Drum Maximum Allowable Run-Out                        0.007          Left Side of the Instrument Panel
     Drum Maximum Boring Oiameter
               9" Brake                                    9.060
              10" Brake                                   10.060
@Front Wheel Brake Cylinders on Cars with 9" Brakes cannot be Honed
2-40                                                      GROUP 2 - BRAKES

CHECKS AND ADJUSTMENTS--INCHES (Continued)
...-- .....-
MIISTANG
                                                                          Lining Maximum Wear Limit                            0.031
 Master Cylinder Bore Diameter
            Standard                                        1.000         (From Top of Rivets)
            Power                                           0.875
 Master Cylinder Maximum Allowable Hone                     0.003         Lining Maximum Clearance to Shoe                     0.008
                                                                          (Midway Between Rivets)
                                                                          Pedal Ratio                                           6.3:l
 Front Wheel Cylinder Bore Diameter                                                                                             6.50
           6 Cylinder Eng~ne                                 1.062        Pedal Travel-Standard
           8 Cylinder Engine                                 1.125
                                                                          Pedal Travel-Power                                     3.54
 Rear Wheel Cylinder Bore.Diameter
           6 Cyllnder Eng~ne                                 0.844        Push Rod Adjustment-Power    Brakes
          8 Cylinder Engine                                  0.906          Bendix                                           0.980-0.995
                                                                            Midland-Ross                                     0.995-1.005

 Wheel Cylinder Maximum Allowable Hone@                      0.003
 Drum Diameter:                                                           Hydraulic Line Diameter                               0.188
          6 Cylinder Engine                                    9.0        Parking Brake-Type
          8 Cylinder Engine                                   10.0
                                                                            Hand Operated with Handle Mounted on Lower
 Drum Maximum Allowable Run-Out                              0.007          Left Side of the Instrument Panel

 Drum Maximum Boring Diameter
          6 Cylinder Englne                                  9.060
          8 Cylinder Engine                                 10.060

 FRONT WHEEL DISC BRAKE (RPO-8         CYLINDER ENGINE)
 Master Cylinder Bore Diameter                               0.938        Lining Thickness:                                     0.400
 Master Cylinder Maximum Allowable Hone                      0.003                                                             Nominal

 Caliper Cylinder Bore Diameter                              1.636        Lining Maximum Wear Limit                             0.030
                                                                          (From Surface of Shoe)
 Rotor Diameter:
           Outside                                          11.375        Lining to Rotor Clearance                          0.002-0.010
           Inside                                            7.375        (Brakes Released)
 Rotor Thickness                                             0.810        Pedal Travel (Non Power)                               6.50
 Rotor Maximum Allowable Runout                              0.002        Pedal Ratio                                           5.57:l
 Lining Area                                              34.00 sq. in.
@Front Wheel Brake Cylinders on 6 Cyl. Cars cannot be Honed
FAIRLANE AND COMET
  Master Cylinder Bore Diameter                               1.000       Lining Maximum Wear Limit                             0.031
                                                                          (From Top of Rivets or Shoe Rim)
 Master Cylinder Maximum Allowable Hone                      0.003
 Front Wheel Cylinder Bore Diameter
           Passenger-200 & 289                                1.125        Lining Maximum Clearance to Shoe                     0.008
           Station Wagon and 390 Car                          1.094       (Midway Between Rivets)
 Rear Wheel Cylinder Bore Diameter 390 Car                    0.875
           Passenger-200 & 289                                0.906        Pedal Travel-Standard                                 6.5
           Station Wagon-dl1                                  0.938        Pedal Travel-Power                                    4.5
  LPO Maximum Fade & Maximum Wear Resistant                                Push Rod Adjustment-Power    Brakes
    Wheel Cylinders (200 & 289)                                              Bendix                                          0.980-0.995
                                                                             Midland-Ross                                    0.995-1.005
  Front Wheel Cylinder Bore Diameter                          1.094
  Rear Wheel Cylinder Bore Diameter                           0.875        Hydraulic Line Diameter                              0.188
  Drum Diameter                                                10.0
  Drum Maximum Allowable Run-Out                              0.007        Parking Brake-Type
                                                                                                                Below Left
                                                                             Foot Operated With Pedal ~ o u h e d
  Drum Maximum Boring Diameter                               10.060          Side of the Instrument Panel
  Drum Width-Front
            Passenger                                          2.25
            Station Wagon-Maximum       Fade and Wear
            Resistant & 390 car                               2.50
  Drum Width-Rear
            Passenger                                         1.75
            Station Wagon                                     2.50
            Maximum Fade & Maximum Wear Resistant             2.00
                                                    PART 2-3 - SPECIFICATIONS                              2-41

TORQUE L I M I T G B R A K E S




 0.0005 to ,0065 Bearing end play at assembly.



                                      TORQUE L I M I T G D I S C BRAKES
                                                    Description                         tt-l bs
                                        Caliper Assembly to Mounting Bracket              45-60
                                        Mounting Bracket to Spindle                       35-45
                                        Caliper Bleeder Screw                  10 (120 in-lbs maximum)-
                                                                                   Must be leak proof
                                       Caliper Splash Shield                                7-9
                                       Caliper Bridge Bolts                               65-75
                                       Rotor Splash Shield to Spindle                     10-20
                                       Hub and Rotor Assembly to Front         17-25-Rotate rotor while
                                         Wheel Spindle                                  torquing.@
                                       Wheel Assembly to Front Wheel                  75-110 ft-lbs
                                         Hub and Rotor Assembly
                                       Brake Tube Flttlng Nuts to Propor-       70 in-lbs-maximum-
                                         tioning Valve                            Must be leak proof
                                         0.0005" to .0065" maximum bearing end play with torque specifi-
                                         cation of 17-25 ft./lbs.
                                      VEHICLE IDENTIFICATION

      BODY S T Y L E     . EXTERIOR PAINT COLOR (WHITE)              DATE CODE                TRANSMISSION CODE
     (FAIRLANE 500               /       INTFRIOR TRIM          (26TH DAY OF AUGUST) (DUAL RANGE AUTOMATIC (C-4))
     2.DOOR SEDAN)

     C     I         .    /             (RED CLOTH AND
                                            RED V!NYL)
                                                                     /
                                                                           DETROIT
                                                                           DISTR~FT
                                                                                       A X L E RATIO;ODE  '
                                                                                      (3.00:l A X L E RATIO)




                             1                                                               .,       -   -
                                                   \
                                        I
         MOOEL YEAR (1966)                       * C O N S ~ C U T I V EUNIT NUMBER
                               PLANT  ENGINE CODE (8 CYL. 289 CIO ENGINE)
                         (ATLANTA)
                                   BODY SERIAL CODE (2-DOOR SEDAN)           ,                                 R 1184.D

 .   FIG. 3-Fairlane                  Wprranty Plate
                   EXTERIOR PAINT COLOR           .
                                                  DATE CODE       A X L E RATIO CODE
                          (WHITE)              (6TH DAY APRIL)   (3.00:) AXLE RATIO)                             CODE
              BODY STYLE            INTERIOR TRIM
          (2-DOOR HARDTOP)        ,
                                     \-,-
                                      (RED VINYL)
                                                                \
                                                          DETROIT DISTRICT
                                                                                  -
                                                                                  I
                                                                                                    (DUAL RANGE
                                                                                                  AUTOMATIC (C.4))




     I                                                                                                                    I
     M0DE.L A s ~ ~ /
            YEAR (1966)       ~ ( ~ ~ - ' c u T l v r               UNIT NUMBER          .    z                               $



                                      (8 CYL. 289 CIO ENGINE)



     FIG. 4-Mustang Warranty Plate                                                                              . I . .




FIG. 5-Vehicle Identification                                              FIG. 6-Vehicle ldentification
Number Location--Comet,                                                    Number Location-Fairlane
Falcon and Mustang
                                                                VEHICLE IDENTIFICATION                                                                         1-3
Figures 1, 2, 3 and 4 illustrate the Comet, Falcon, Fairlane and                      FALCON
Mustang Warranty Plates. The warranty plate is located on the rear                     Body                 Body
face (lock face) of the left front door.                                               Serial               Style
   The official Vehicle Identification Number, for title and registra-                 Code                 Code                Body Type                 Model
tion purposes, is stamped on the top upper flange of the left front                    0 2 ........         54A . . . . . . . . 4-Door Sedan              Standard
fender apron for Falcon. Comet and Mustang (Fig. 5) and on the                         01 . . . . . . . .   62A . . . . . . . . 2-Door Sedan              Sedan
vertical face o f the left front fender apron near the top for the Fair-
                                                                                       12 . . . . . . . .   548 . . . . . . . . 4-Door Sedan (Bench)
lane (Fig. 6). Do not use the Vehicle Warranty Number, which appears                   11 . . . . . . . .   62B . . . . . . . . 2-Door Sedan (Bench)       Futura
on the warranty plate, for title or registration purposes.                             14 . . . . . . . .   62C . . . . . . . . 2-Door Sport Coupe
                                                                                                                                  (Bucket)
                                                                                       22 . . . . . . . .   71A . . . . . . . .   &Door Wagon              Station
                                                                                       24 . . . . . . . .   71B ........          &Door Wagon Deluxe       Wagon
VEHICLE DATA                                                                           27 . . . . . . . .   66A . . . . . . . .   2-Door Standard Ranchero
  The vehicle data appears i n a line across the top of the warranty                   27 . . . . . . . .   66B ........          2-Door Deluxe Ranchero   Ranchero
                                                                                       27 . . . . . . . .   66D . . . . . . . .   2-Door Standard (RPO
plate (Figs. 1, 2, 3 and 4). The first two letters and a number                                                                     Bucket W/Console)
identify the Body Style. The following one or two letters identify
the Exterior Paint Color. The next code consisting of two numbers,
or a letter and a number, identifies the Interior Trim. The Date Code                 FAIRLANE
showing the date the car was manufactured, follows the Trim Code                       Body                 Body
and consists o f two numbers and a letter. The next code gives the                     Ser~al               Style
district i n which the car was ordered and consists of two numbers.                    Code                 Code                 Body Type                 Model
The next to the last code is the Axle Ratio Code and is designated                     31 ........          62A . . . . . . . . 2-Door Coupe               Fairlane
by a number for a conventional axle or a letter for an Equa-Lock                       32 . . . . . . . .   54A . . . . . . . . 4-Door Club Coupe
axle. The last code i n the vehicle data is the Transmission Code and                  41 . . . . . . . .   62B . . . . . . . . 2-Door Sedan               Fairlane
consists of one number. The charts that follow, list in detail the                     42 . . . . . . . .   548 . . . . . . . . 4-Door Sedan               500
various vehicle data codes.                                                            43 . . . . . . . .   638 . . . . . . . . 2-Door Hardtop,
                                                                                       45 . . . . . . . .   76B ........ 2-Door Convert~ble
                                                                                       46 . . . . . . . .   63C . . . . . . . . 2-Door Hardtop@            Fairlane
                                                                                       47 . . . . . . . .   76C . . . . . . . . 2-Door Convertible@        500 XL
VEHICLE WARRANTY NUMBER                                                                40 ........          63D . . . . . . . . 2-Door Hardtop?            Fairlane
                                                                                       44 ........          76D . . . . . . . . 2-Door Convert~bleO        500 GT
   The vehicle warranty number is the second line of numbers and                       38 . . . . . . . .   71D . . . . . . . . 4-Door Ranch Wagon         Station
letters appearing on the Warranty Plate (Figs. 1, 2, 3 and 4). The                     48 . . . . . . . .   718 ........ 4-Door Cust. Ranch Wagon          Wagons
first number indicates the model year. The letter following the model                  49 . . . . . . . .   71E . . . . . . . . 4-D00r Squire
year indicates the assembly plant at which the car was manufactured.                  @Bucket Seats
The next two numbers designate the Body Serial Code. The letter
following the Body Serial Code designates the Engine Code. The
remaining numbers indicate the Consecutive Unit Number. The charts                    MUSTANG
that follow, list the various Vehicle Warranty Number codes.                            Body               Body
                                                                                        Serial             Style
                                                                                        Code               Code                 Body Type                  Model
                                                                                        09 . . . . . . . . 63A . . . . . . . . 2-Door Fastback@            Mustang
B O D Y SERIAL A N D STYLE CODES                                                        07 . . . . . . . . 65A . . . . . . . . 2-Door Hardtop@
                                                                                        08 . . . . . . . . 76A ........ 2-Door Convertible@
   The two-digit numeral which follows the assembly plant code                          09 ........ 638 . . . . . . . . 2-Door Fastback@
                                                                                        07 . . . . . . . . 65B . . . . . . . . 2-Door Hardtop@
identifies the body series. This two-digit number is used in con-                       08 . . . . . . . . 76B . . . . . . . . 2-Door Convertible@
junction with the Body Style Code, i n the Vehicle Data, which con-                     07 . . . . . . . . 65C . . . . . . . . 2-Door Hardtop@
sists o f a two-digit number with a letter Suffix. The following chart                  08 . . . . . . . . 76C . . . . . . . . 2-Door Convertible@
lists the Body Series Codes, Body Style Codes and the Model.                            OStd. Bucket Seats
                                                                                        @Luxury Bucket Seats
                                                                                        BStd. Bench Seats
COMET
                                                                                      EXTERIOR P A I N T COLOR CODES
Body                   Body                                                              A single letter code designates a solid body color and two letters
Serial                 Style                                                          denote a two-tone-the         first letter, the lower color and the second
Code                   Code                   Body Type                    Model      letter, the upper color.
 02 . . . . . . . .      54A   ........ 4-Door Sedan@                      Comet                            M.301
 01 ........            62A    . . . . . . . . 2-Door Sedan@               202        Code                  M-32-I#                        Color
 06 . . . . . . . .      71A   . . . . . . . . 4-Door Wagon@                            A . . . . . . . . . 1724-A ............ Black
 12 . . . . . . . .     548    . . . . . . . . &Door Sedan@                Capri        F . . . . . . . . . 1226-A . . . . . . . . . . . . Lt. Blue
 13 . . . . . . . .      63B   . . . . . . . . 2-Door Hardtop@                          H . . . . . . . . . 1912-A . . . . . . . . . . . . Lt. Beige
 16 . . . . . . . .     71C    . . . . . . . . &Door (Villager) Wagon3                  K . . . . . . . . . 1903-A . . . . . . . . . . . . Dk. Blue Met.
 22 . . . . . . . .      54D   ........        4-Door Sedan@                            M . . . . . . . . . 1619-A . . . . . . . . . . . . White
 23 . . . . . . . .     63C    ........        2-Door Hardtop@             Comet        P . . . . . . . . . 1910-A . . . . . . . . . . . . Med. Palomino Met.
 23 . . . . . . . .      63D   . . . . . . . . 2-Door Hardtop@             Caliente     R . . . . . . . . . 1879-A . . . . . . . . . . . . Dk. Green Met.
 25 . . . . . . . .      76B   . . . . . . . . 2-Door Convertible@                      T ......... 2008-A . . . . . . . . . . . . Red
 25 . . . . . . . .      76D   . . . . . . . . 2-Door Convertible@                      U . . . . . . . . . 1070-A . . . . . . . . . . . . Med. Turquoise Met.
                                                                                        V . . . . . . . . . 1921-A . . . . . . . . . . . . Embernlo Met.
  27 . . . . . . . .    63E . . . . . . . .   2-Door   Hardtop             Cyclone                                                         ~aroon   Met.
  27 . . . . . . . .    63H . . . . . . . .   2-Door   Hardtop@ (GT)                                                                       Lt. Blue Met.
  29 . . . . . . . .    76C . . . . . . . .   2-Door   Convertible                                                                         Med. Sage Gold Met.
  29 . . . . . . . .    76H . . . . . . . .   2-Door   Convertible@ (GT)                                                                   Med. Silver Met.
 @Bench Seat                                                                                                                               Red
 @Bucket Seats                                                                                                                             Yellow
INTERIOR T R l M CODES                                  INTERIOR T R l M CODES (Cont'd.)
Code                                     Trim Schemes    Code                             Trim Schemes
 11 .......... Silver Cloth and Black Vinyl               H5 .......... White Vinyl W/Red
 12 .......... Blue Cloth and Blue Vinyl                  H6 .......... White Vinyl W/Black
 15 .......... Red Cloth and Red Vinyl                    H7 .......... White Vinyl W/Aqua
 17 .......... Aqua Cloth and Aqua Vinyl                  H8 .......... White Vinyl W/Palomino
 22 .......... Blue Vinyl
 25 .......... Red Vinyl
 26 .......... Black Vinyl
 2 7 .......... Aqua Vinyl                              DATE CODES
 32 .......... Blue Cloth and Blue Vinyl                A number signify in^ the date precedes the month code letter. A
 3 5 .......... Red Cloth and Red Vinyl                 second-year code letter will be used i f the model exceeds 12 months.
 36 .......... Black Vinyl                                                                             Code          Code
 3 7 .......... Aqua Cloth and Aqua Vinyl                       Month                                First Year  Second Year
 38 .......... Ivy Gold Cloth and Ivy Gold Vinyl
                                                             January ...........................A . . . . . . . . . N
 42 .......... Blue Vinyl                                   February ..........................B . . . . . . . . . P
 44 .......... Emberglo Vinyl                                March ............................ C ......... Q
 45 . . . . . . . . . . Red Vinyl                           April ............................. D ......... R
 46 .......... Black Vinyl                                   May ..............................E ......... S
 4 7 .......... Aqua Vinyl                                  June ............................. F ......... T
 48 .......... Ivy Gold Vinyl                               July .............................. G . . . . . . . . . U
 52 .......... Blue Cloth and Blue Vinyl                    August ........................... H ......... V
 55 .......... Red Cloth and Red Vinyl                      September ........................J . . . . . . . . . W
 57 .......... Aqua Cloth and Aqua Vinyl                    October .......................... K . . . . . . . . . X
 62 .......... Blue Vinyl                                   November .........................L ......... Y
                                                            December ......................... M ......... Z
 64 .......... Emberglo Vinyl
 65 .......... Red Vinyl
 66 .......... Black Vinyl
 67 .......... Aqua Vinyl
 68 .......... Ivy Gold Vinyl                           DISTRICT CODES (DSO)
 82 .......... Blue Vinyl                               Units built on a Domestic Special Order. Foreign Special Order, or
 8 4 .......... Emberglo Vinyl                          other special orders will have the complete order number in this
 85 .......... Red Vinyl                                space. Also to appear in this space is the two-digit code number of
 8 6 .......... Black Vinyl                             the District which ordered the unit. If the unit is a regular production
 8 7 .......... Aqua Vinyl                              unit, only the District code number will appear.
 88 .......... Ivy Gold Vinyl
 1D .......... Parchment Cloth and Parchment Vinyl
 2D .......... Parchment Vinyl                          COMET
 3D .......... Parchment Cloth and Parchment Vinyl
 4D .......... Parchment Vinyl                           Code                  District Code                               District
 5D .......... Parchment Cloth and Parchment Vinyl        11 ................. Boston    34 .................Detroit
 OD .......... Parchment Vinyl                            16 ............ Philadel~hia 4 1 ................ Chicago
 B1 .......... Parchment Vinyl W/Silver                   15 .............. New York     42 . . . . . . . . . . . . . . . St. Louis
 82 .......... Parchment Vinyl W/Blue                     17 ............ Wash~ngton 46 ............. Twin Cities
 84 .......... Parchment Vinyl W/Emberglo                 21 ................ Atlanta    5 1 ................. Denver
 8 5 .......... Parchment Vinyl W/Red                     22 ................. Dallas    52 ............ Los Angeles
                                                          23 ............ Jacksonville   53 ................ Oakland
 B6 .......... Parchment Vinyl WIBlack                    26 ............... Memohis     54 .................Seattle
 8 7 .......... Parchment Vinyl W/Aqua                    3 1 ................. Buffalo  8 1 . . . . . . . . . Ford of Canada
 B8 .......... Parchment Vinyl W/lvy Gold                 32 .............. Cincinnati   84 . . . . . . Home Office Reserve
 B9 .......... Parchment Vinyl W/Palomino                 33 .............. Cleveland    90-99 ............... Export
 C2 .......... Parchment Vinyl W/Blue
 C3 .......... Parchment Vinyl W/Burgundy
 C4 .......... Parchment Vinyl W/Emberglo
 C6 .......... Parchment Vinyl W/Black                  FALCON, FAIRLANE AND MUSTANG
 C7 .......... Parchment Vinyl W/Aqua                    Code                                District Code                              District
 C8 .......... Parchment Vinyl W/Gold                     11 ................. Boston                  45 ............... Davenport
 C9 .......... Parchment Vinyl W/Palomino                 12 . . . . . . . . . . . . . . . . Buffalo   5 1 ................ Denver
 D2 .......... Parchment Vinyl W/Blue                     13 .............. New York                   52 ............. Des Moines
 D3 .......... Parchment Vinyl W/Burgundy                 14 .............. Pittsburgh                 53 . . . . . . . . . . . . . Kansas City
 D4 .......... Parchment Vinyl W/Emberglo                 15 ................ Newark                   54 ................. Omaha
 D6 .......... Parchment Vinyl W/Black                    21 ................ Atlanta                  55 ............... St. Louis
 D7 .......... Parchment Vinyl W/Aqua                     22 .............. Charlotte                  61 ................. Dallas
 D8 .......... Parchment Vinyl W/Gold                     23 ............ Philadelphia                 62 ................ Houston
 D9 .......... Parchment Vinyl W/Palomino                 24 .............Jacksonville                 63 ............... Memphis
                                                          25 ...............Richmond                   64 . . . . . . . . . . . . New Orleans
 F2 .......... Parchment Vinyl W/Blue                     26 ............. Washington                  65 .......... Oklahoma City
 F3 .......... Parchment Vinyl W/Burgundy                 3 1 .............. Cincinnati                71 . . . . . . . . . . . . . Los Angeles
 F4 . . . . . . . . . . Parchment Vinyl W/Emberglo        32 ............... Cleveland                 72 ............... San Jose
 F6 .......... Parchment Vinyl W/Black                    33 ................. Detro~t 73 .......... Salt Lake C ~ t y
 F7 .......... Parchment Vinyl W/Aqua                     34 ............. Indianapolis                74 ................ Seattle
 F8 .......... Parchment Vinyl W/lvy Gold                 35 ................ Lansing                  8 1 . . . . . . . . . . Ford of Canada
 F9 . . . . . . . . . . Parchment Vinyl W/Palomino        36 ...............Louisville                 83 . . . . . . . . . . . . . Government
 H1 .......... White Vinyl W/Silver                       4 1 ................Chicago                  84 . . . . . Home Office Reserve
                                                          42 ..................Fargo                   85 ...... American Red Cross
 H2 .......... White Vinyl W/Blue                         43 ............... Rockford                  8 9 ... Transportation Services
 H4 .......... White Vinyl W/Emberglo                     44 ............. Twln C ~ t ~ e s 90-99 ...............Export
                                                 VEHICLE lDENTlFlCATlON                                                                1-5

REAR AXLE RATIO CODES                                                   ASSEMBLY PLANT CODES
A number designates a conventional axle, while a letter designates a      Code               Assembly           Code            Assembly
Locking differential.                                                    letter                Plant           Letter             Plant
   Code                   Ratio      Code                       Ratio      A .................. Atlanta        L ........... Michigan Truck
    1 ................. 3.00:l        A ................ 3.00:l            B ..........Oakville (Canada)       N .................. Norfolk
    2 ................. 2.83:l         L   ................   2.83:l       C ............. Ontario Truck       P .............. Twin Cities
    3 ................. 3.20:l        C ................ 3.20:l            D ................... Dallas        R ................ San Jose
    4 ................. 3.25:l         D ................ 3.251            E ................. Mahwah          S ............... Pilot Plant
    5 ................. 3.50:l        E ................ 3.50:l            F  ................ Dearborn        T ................ Metuchen
    6 ................. 2.80:l         F ................ 2.80:l           G ................. Chicago         U ................ Louisville
    8 ................. 3.89:l        H ................ 3.89:l            H ................... Lorain        W .................. Wayne
                                                                           J .............. Los Angeles        Y .................. Wixom
                                                                           K .............. Kansas City        Z .................St. Louis

TRANSMISSION CODES                                                      ENGINE CODES
Code                       Type                                           A   .............. 8 Cyl. 289 Cu. In. (4V Prem.)
 1 .................. 3-Speed Manual
                                                                          C   .............. 8 Cyl. 289 Cu. In. (2V)
 4 ..................Dual Range Automatic (C-6)
                                                                          K   .............. 8 Cyl. 289 Cu. In. (4V Hi-Perf.)
                                                                          T   .............. 6 Cyl. 200 Cu. In. (1V)
 5 .................. 4-Speed Manual                                      Y   .............. 8 Cyl. 390 Cu. In. (2V)
 6 .................. Dual Range Automatic (C-4)                         Z    .............. 8 Cyl. 390 Cu. In. (4V)
                                                                         2    .............. 6 Cyl. 0200 Cu. In. (1V)
                                                                         3    .............. 8 Cyl. 0289 Cu. In. (2V)
                                                                         @Low Compression
MODEL YEAR CODE
The number 6 designates 1966                                            CONSECUTIVE U N I T NUMBER
                                                                        Each model year, each assembly plant begins production with the
                                                                        number 100001 (Falcon, Fairlane or Mustang) or 500001 (Comet) and
                                                                        continues on for each u n ~ tbu~lt.
 




 
 




     

								
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