2-2 GROUP 2 - BRAKES TABLE 1-Disc Brake Trouble Symptoms and Possible Causes TROUBLE SYMPTOMS u rn e; - - .- e B.a -2 .- w Possible Causes of - : c" n .z - e Trouble Symptoms U 2 :. = E "na= r.~, u h = = - al h h g = u QJ .- - e - 51 = w a -, r" L Un ~ a n z -&B2 c.- e;' a : .- n w n Ma g a O Y x al al C m Y Y Y cum Z L 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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