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-rERMEDIATE
STANQ
SH9PMA
 Copyright 2006, Forel Publishing Company, LLC, Woodbridge, Virginia

All Rights Reserved. No part of this book may be used or reproduced in any manner
whatsoever without written permission of Forel Publishing Company, LLC. For
information write to Forel Publishing Company, LLC, 3999 Peregrine Ridge Ct.,
Woodbridge, VA 22192

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

(Form 7760-67, First printing March 1967)
ISBN: 0-9673211-4-X
EAN: 978-0-9673211-4-1

Forel Publishing Company, LLC

3999 Peregrine Ridge Ct.
Woodbridge, VA 22192

Distributed by MustangShopManual.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.
 ,

GROUP INDEX
VEHIa! IDENTIFICATION

BRAKES
..
D
SUSPEN~ON, STEERING, WHEfIS AND TIRES D

COUGAR REAR AKlE

DRIVE SHAFT AND ClUTCH

D
H
MANUAL SHIFT TRANSMISSION D
FAIRLANE AUTOMATIC TRANSMISSION

ENGINE
B
1m!
FALCON IGNITION SYSTEM

FUEL SYSTEM
0
II!)

MERCURY- CooUNG SYSTEM

EXHAUST SYSTEM
1m
mI
INTERMEDIATE CHARGING SYSTEM

STARTING SYSTEM
Ikl
IC:I

MUSTANG UGHTING SYSTEM, HORNS AND INSTRUMENTS

VENTILATING, HEATING AND ACCESSORIES

I"~
It;
BODY, DOORS AND WINDOWS IfA
TRIM, SEATS AND CONVERTIBLE TOP II:.
SCHEMATICS IE)
~~ SERVICE PUBLICATIONS
SPECifiCATIONS AND SPECIAL SERVICE TOOLS
~'AST .... ''''T' .... _ " ......: ... 'M' AT END Of EACH GROUP
C '"' "OItD MO TOR CQ .. .. ",,,V Oo.IIIK)RN. ""C"'O" ..
 FOREWORD

This shop manual provides the Service Technician with information

for the proper servicing of the 1967 Cougar, Fa irlane, Falcon,
Mercury Intermediate, Comet and Mustang cars.
The maintenance schedule and procedures for maintenance oper-
ations are published in the 1967 Passenger Car Maintenance and
Lubrication Manual.
The information in this manual is grouped according to the type
of work being performed, such as diagnosis and testing, frequent-
ly performed adjustments and repairs, in-vehicle adjustments, over-
haul, etc. Specifications and recommended special tools areincluded.
Refer to the opposite page for important vehicle identification data.
The descriptions and specifications in this manual were in effect at
the time this manual was approved for printing. The Ford Motor
Company reserves the right to discontinue models at any time, or
change specifications or design, without notice and without incur-
ring obligation.

~SERVICE PUBLICATIONS
 1" 1

GROUP

Vehicle Iclentification

ASSEMBLY PLANT CODE BODY SERIAL CODE

MODEL Y EAR CODE ,----ENGINE CODE

, - - - - CO NSECUTIVE UNIT NUMBER

FIG . 2-Mercu ry, Comet

(Intermediate- Size)
Ide nt if icat ion Number Loca tion
TRANSMISSION CODE
BODY TYPE CODE DATE CODE

REAR AXLE CODE

COLOR COD

TRIM CODE DISTRICT or DISTRICT AND

SPECIAL EQUIPMENT CODE
N 1587_A

FIG. 7- Typical Warra nty Plate-Fairlane Shown

I
FIG . 3- Couga r Identification FIG. 4-Mustang Iden ti fication
Number l ocatio n Num ber Location
VEHICLE WARRANTY NUMBER OFFICIAL VEHICLE IDENTIFICATION NUMBERS
The vehicle warranty number is the first li ne al numbers and le tters appearing Th e officia l Vehicle identification Numbe rs for titles and reg istration purposes
on the Warranty Plat e (Fig. l). The first number indicates the model year. The are stamped in the following locations:
letter follo wing the model year number indicates the manufacturing assembly
plant. The neIt two numbers designate the Body Serial Code followed by a Mercury, Comet (Intermediate-size), Fairlane, Falcon - On the top surface of
letter expressing the Engine Code. The group of si x digits remai ning on the the radiatur and front fender apro n support (near the radia tor fill cap) Fig. 2.
first line indicate the Consecutive Unit Number.
Couga r - On the top upper flange of the left front fender apron (Fig. 3).

VEHICLE DATA MUSTANG - On the top upper ftange of the teft hont fendel 'plOn ( f ig. 4).

The veh icle data appears on the second or lower line on the Warranty Plate.
The first two number s and a lett er iden tify the Body Style. A letter or anum
ber appea rs next ind ica ting the Ext erior Paint Colo r followed by a nu mber
letter combination designating the Interior Trim. To the right of this code aj}
pears the Da te Code ind ica ting the date the car was manufactured. A two-digit MODEL YEAR CODE
number ne xt designates the distr ict in which the car was ordered and may
appear in conjunctio n with a Domestic Spec ia l Order or Foreign Special Order
number wh en applica ble . The fina l two spaces in dicate the Rear Axle Ratio
(numbers for regu lar ax les, leUers fo r lock ingtypes) and the Transmission type The number 7 designates 1967 .
(numbers for manual, lett ers for automatic ).
1-2 GROUP 1-Vehicle Identification

BODY SERIAL AND STYLE CODES BODY SERIAL AND STYLE CODES-(continued)
FAIRLANE
The twodigit numeral which follows the assembly plant code identifies
the body series. This twodigit number is used in conjunction with the Body Body Body
Style Code, in the Vehicle Date, which consists of a two-digit number with Serial Style
a letter suffix. The following chart lists the Body Serial Codes, Body Style Code Code Body Type Model
Codes and the model.
31 54A 4Door Sedan I Fairlane
30 62A 2Door Sedan I
MERCURY -COMET (I NTERMEDIA TE-S IZE)
34 54B 4Door Sedan I Fairlane 500
33 62B 2Door Sedan .1
Body Body 35 63B 2Door Hardtop I'
Serial Style 36 76B 2Door Convertible I
Code Code Body Type Model
40 63C 2Door Hardtop 2 Fairlane 500XL
02 54A 4Door Sedan j Comet 202 41 76C 2Door Convertible 2
01 62A 2Door Sedan (1
42 63D 2Door Hardtop 2' Fairlane 500GT
OS 54B 4.Door Sedan 1 Comet Capri 43 76D 2Door Convertible'
07 63B 2Door Hardtop 1

32 7tD 4Door Station Wagon

10 54D 4Door Sedan :1' Caliente 37 7lB 4Door
11 63D 2Door Hardtop j) 3S 7IE 4Door
12 76D 2Door Convertible
47 66A 2Door 1) Ranchero
15 63E 2Door Hardtop .2 Cyclone 48 66B 2.Door I
16 76C 2Door Convertible .2 49 66D 2Door ,
17 63H 2Door Hardtop 2 GT I Bench Seat
IS 76H 2Door Convertible 2 2 Bucket Seat
03 71A 4Door 6 Passenger Comet Voyager
Villager
FALCON
OS 7lC 4Door 6 Passenger
Bench Seat Body Body
Bucket Seat Serial Style
Code Code Body Type Model
10 62A 2Door Club Coupe I Standard
COUGAR 11 54A 4Door Sedan 1
20 62B 2Door Club Coupe I Futura
Body Body Body Type 21 54B 4Door Sedan 1
Serial Style-------------------I
Code 22 62C 2.Door 2' Sport Coupe
Code
91 65A 2door Hardtop (Bucket Seat) 12 71A 4Door Wagon (Std.)
91 65B 2Door Hardtop (Bucket Seat) 'I,'
91 65D 2Door Hardtop (Bench Seat) 1: 23 7lB 4Door Wagon (Deluxe)
91 65C 2Door Hardtop (Bench Seat)
I' Bench Seat
1 Luxury Model 'l Bucket Seat

CONSECUTIVE UNIT NUMBER

MUSTANG Each model year, each assembly plant begins production with number
500001 (Mercury, Comet or Cougar) or 100001 (Fairlane, Falcon, Mustang)
Body Body and continues on for each unit built.
Serial Style
Code Code Body Type
2.Door Fastback 1
ENGINE CODES
02 63A
01 65A 2Door Hardtop 1 Code Type
03 76A 2.Door Convertible I
02 63B 2.Door Fastback I

~:l:, ~ ~~: l:: 11~l

3
01 65B 2.Door Hardtop I
JC ::::::::::::::::::::::::::::::::::::::::::::::::::::i
3
03 76B 2.Door Convertible I ~

01 65C 2Door Hardtop 2 ...........................................................s Cyl. 289 Cu. In. (2V)

03 76C 2Door Convertible 2
3 ...........................................................8 Cyl. 1 289 Cu. In. (2V)
A ...........................................................8 Cyl. 289 Cu. In. (4V) Premo Fuel
'I, Bucket Seat K ...........................................................SCyl. 289 Cu. In. (4V) HiPerf.
2)
Bench Seat y ...........................................................8 Cyl. 390 Cu. In. (2V)
3, Luxury Model H ...........................................................SCyl. 390 Cu. In. (2V)
S ...........................................................SCyl. 390 Cu. In. (4V)
W...........................................................SCyl. 427 Cu. In.(4V) HiPerf.
R...........................................................SCyl. 427 Cu. In. (8V) HiPerf.
Low Compression
 GROUP 1-Vehicle Identification 1-3

TRANSMISSION CODES
Code Type
1.............................................................................................3Speed Manual
2.............................................................................................Overdrive
3.............................................................................................3Speed Manual
5 .............................................................................................4Speed Manual
W............................................................................................Automatic (C4)
U.............................................................................................Automatic (C6)
DISTRICT CODES (DSO)
Units built on a Domestic Special Order, Foreign Special Order, or other spe
cial orders will have the complete order number in this space. Also to appear
in this space is the two-digit code number of the ~istrict which ordered the
unit. If the unit is a regular production unit, only the District code number
will appear.

FORD

REAR AXLE RATIO CODES Code District

A number designates a conventional axle, while a letter designates a locking 11 .................................................................................. Boston
differential 13 ..................................................................................New York
15 ..................................................................................Newark
Code Ratio Code Ratio 16 ..................................................................................Philadelphia
17 ..................................................................................Washington
1.............................................3.00: 1 A...........................................3.00:1 21 ..................................................................................Atla nta
2............................................ 2.83:1 22 ..................................................................................Charlotte
3............................................. 3.20:1 C...........................................3.20: 1 24 .................................................................................Jacksonville
4.............................................3.25:1 D...........................................3.25: 1 25 ..................................................................................Richmond
5.............................................3.50: 1 E...........................................3.50: 1 27 ..................................................................................Cincinnati
6............................................. 2.80: 1 28 .................................................................................. Louisville
32 ..................................................................................Cleveland
33 .................................................................................. Oetroit
34 ..................................................................................lndianapolis
35 .................................................................................. Lansing
37 ..................................................................................Buffalo
DATE CODES 38 ..................................................................................Pittsburgh
41 ..................................................................................Chicago
A number signifying the date precedes the month code letter. A secondyear 42 ..................................................................................Fargo
code letter will be used ~ the model exceeds 12 months. 43 ..................................................................................Milwaukee
44 ..................................................................................Twin Cities
45 ..................................................................................Oavenport
51 ..................................................................................Oenver
Code Code 52 ..................................................................................0es Moines
Month First Year Second Year 53 .................................................................................Kansas City
54 ..................................................................................0maha
January ...............................................A ............................................... N 55 ..................................................................................St. Louis
February .............................................B............................................... P 61 ....................... ,..........................................................Oa lIa s
March ..................................................C...............................................Q 62 ..................................................................................Houston
April ....................................................D...............................................R 63 .................................................................................. Memp his
May ..................................................... E...............................................S 64 ..................................................................................New Orleans
June ...................................................,F ............................................... T 65 ..................................................................................Oklahoma City
July .....................................................G...............................................U 71 .................................................................................. Los Angeles
August .................................................H...............................................v 72 ..................................................................................San Jose
September ......................................... J ................................................w 73 ..................................................................................Salt Lake City
October ............................................... K............................................... X 74 ..................................................................................Seattle
November ........................................... L ...............................................Y 75 ..................................................................................Phoenix
December ........................................... M............................................... z 81 ..................................................................................Ford of Canada
83 ..................................................................................Government
84 .................................................................................. Home Office Reserve
85 ..................................................................................American Red Cross
89 ..................................................................................Transportation Services
ASSEMBLY PLANT CODES 9099 .............................................................................Export

Code
Lettl!f'
A........................................... Atlanta
B...........................Oakville (Canada)
C.................................Ontario Truck
o............................................. Oallas
E..........................................Mahwah
F......................................... Oearborn
G...........................................Chicago
H............................................. Lorain
J..................................... Los Angeles
K..................................... Kansas City
Code
Letter
L................................... Michigan Truck
N............................................... Norfolk
P..........................................Twin Cities
R.............................................San Jose
S...........................................Pilot Plant
T............................................ Metuchen
U............................................ Louisville
W................................................Wayne
Y.................................................Wixom
Z............................................. St. Louis
MERCURY
Code District
11 ...................Boston
16 ................... Philadelphia
15 ................... New York
17 ...................Washington
21 .................. .Atlanta
22 ................... 0allas
23 ...................Jacksonville
26 ................... Memphis
31 ................... Buffalo
32 ...................Cincinnati
33 ...................Cleveland
Code District
34 ................... 0etroit
41 ................... Chicago
42 ................... St. Louis
46 .................. .T win Cities
51 ................... 0enver
52 ................... Los Angeles
53 ................... 0akland
54 ...................Seattle
84 ................... Home Office Reserve
90 ................... Export
1-4 GROUP 1-Vehicle Identification

EXTERIOR PAINT COLOR CODES INTERIOR TRIM CODES~continu.d)

M-3O.J
Code M-32J Color
A..................................... 1724A ...................................... Black
B. .................................. .1734A ...................................... Lt. Aqua
f.:::::::::::::::::::::::::::::::::::::::::::~~:t~ ::::::::::::::::::::::::::::::::::::::~i~e ~~r.e
Met.
K. ................................... 1903A ......................................Ok. Blue Met.
M................................... 1619-A ......................................White
Q................................... 1624A ......................................Med. Blue Met.
T. ................................... .2008A ......................................Red
V.................................... 2066A ...................................... Bronze Met.
~.::::::::::::::::::::::::::::::::::::::::::l~~t~ ::::::::::::::::::::::::::::::::::::::~:~o~~e~et.
y .....................................2039A ...................................... Ok. Green Met.
Z. ................................... .1 915A ......................................Med. Gold Met.
2 . ................................... 1633A ......................................Yellow
Code Trim Schemes
8G .................................. .Ivy Gold Vinyl
8K .................................. .AQua Vinyl
8U .................................. Parchment Vinyl W/Black
9A .................................. Black Cloth and Black Vinyl
9B .................................. Ok. Blue Cloth and Ok. Blue Vinyl
90 .................................. Ok. Red Cloth and Ok. Red Vinyl
9K .................................. .AQua Cloth and Aqua Vinyl
9U .................................. Parchment Cloth and Parchment Vinyl W/Black
FA .................................. Parchment Vinyl W/Black
FB .................................. Parchment Vinyl W/Blue
FO .................................. Parchment Vinyl WIRed
FG .................................. Parchment Vinyl W/lvy Gold
FK................................. Parchment Vinyl W/Aqua
GA .................................. Black Vinyl W/Parchment

i:::::::::::::::::::::::::::::::::::::::::::!~H ::::::::::::::::::::::::::::::::::::::r~:~:Y Met.

GB .................................. Blue Vinyl W/Parchment
GO .................................. Red Vinyl W/Parchment
GG .................................. Ivy Gold Vinyl W/Parchment
GF ..................................Saddle Vinyl W/Parchment
GK .................................. .AQua Vinyl W/Parchment
LB . ................................. Red Vinyl
LO .................................. Blue Vinyl
LU . ................................. Parchment Cloth and Parchment Vinyl W/Black
OU .................................. Parchment Vinyl
INTERIOR TRIM CODES UA .................................. Parchment Vinyl W/Black
UB................................ Parchment Vinyl W/Blue
UO .................................. Parchment Vinyl WIRed
Code Trim Schemes UF. ............................... Parchment Vinyl W/Saddle
UG .................................. Parchment Vinyl W/lvy Gold
IB . ................................. Blue Cloth and Blue Vinyl UK .................................. Parchment Vinyl W/AQua
10 . ................................. Red Cloth and Red Vi~1
1K.................................AQua Cloth and Aqua inyl
1U . ................................. Parchment Cloth and Parchment Vinyl W/Black
2A .................................. Black Vinyl
2B .................................. Blue Vinyl
20 .................................. Red Vinyl
2F ..................................Saddle Vinyl
2G .................................. Ivy Gold Vinyl
2K .................................. AQua Vinyl
2U .................................. Parchment Vinyl W/Black
3B . ................................. Blue Cloth and Blue Vinyl
3G .................................. ..Ivy Gold Cloth and Ivy Gold Vinyl
3K ..................................AQua Cloth and Aqua Vinyl
3U .................................. Parchment Cloth and Parchment Vinyl W/Black
4A .................................. Black Vinyl
4B .................................. Blue Vinyl
40 .................................. Red Vinyl
4G .................................. .lvy Gold Vinyl
4K .................................. .AQua Vinyl
4U .................................. Parchment Vinyl
5A .................................. Black Cloth and Black Vinyl
5B .................................. Oark Blue Cloth and Blue Vinyl
5K .................................. .AQua Cloth and Aqua Vinyl
5U .................................. Parchment Cloth and Parchment Vinyl W/Saddle
6A .................................. Black Vinyl
6B .................................. Oark Blue Vinyl
60 .................................. Red Vinyl
6F .................................. Saddle Vinyl
6G .................................. Ok. Ivy Gold Vinyl
6K .................................. .AQua Vinyl
6U .................................. Parchment Vinyl
7A .................................. Black Vinyl
7B . ................................. Blue Vinyl
7U .................................. Parchment Cloth and Parchment Vinyl
8A .................................. Black Vinyl
8B .................................. Blue Vinyl
80 .................................. Red Vinyl
8F .................................. Saddle Vinyl
 2- 1
-
GROUP

Brakes
i 2
PART 2-1 PAGE PART 2-3 PAGE
Genera I Brake Serv ice .. . . 2-1 Specifications ..... ...... 3-34
PART 2-2
Brake System ... .. ......... .. .. .. 2-9

PART 2-1- General Brake Service

Sec tio n Pl.l~(, Sec tion Page
1 Di agnos is and Tes tin g ..... 2-1 Hydraul ic Sy st em Bleeding and
Brake System T ests. ...... 2-1 C entr a liz ing of the Differential Val ve ....... 2~4
R oad Test. .. ......... . . ...... 2-3 3 Clea ning a nd In specti on ......... . . ... ... ...... ....... 2- 6
2 C ommon Adju st ment s a n d Repai rs ........ 2-3 Di sc (Front) Brakes.......... . .............. 2- 6
Park ing Brake Link age A djustm e nt ....... 2-3 Rear Brakes ................... . .. ... ......... 2-6
P o wer Brake M aster Cv lind er Pu sh
Rod Adju stm ent ............... .... . . . .. . . 2-4

D DIAGNOSIS AND TESTING

BRAKE SYSTEM TESTS
BRAKE FLU ID LEVEL
AND HYDRA U LI C S YS TEM
I. Always check the flu id level In
the brake master cy linde r rese rv oirs
befo re pcr ro rming the les t procedures.
If the fluid level is not w ithi n 1/ 4 to
1/2 in ch o f the top of the ma s ter cy l-
inder reservo irs. add the spe c ifi ed brake
fl uid. Add Rotunda Brake F tuid -
Ext ra Hea vy Dut y - Pa rt Numbe r
C 6A Z -19 542-A (ESA - M 6C25- A ) o r
eq ui va lent for all di sc brak e appli ca-
tion s and Rotunda Brak e Fluid -
I-!cavy Duty - Part Numbe r B7AZ-
19542-A, R- I03-A o r equi va lent
for power drum or s ta ndard drum
appli c<lli ons. T he di sc bra ke ext ra
heavy duty brake fluid is co lored
blue for identification purposes. Do
not mix low te mpe ratu re brake flu id s
with t he specified di sc bra ke fluid .
D U AL MASTER CY LI NDE R
IIRAKE S YSTEM
I. Turn the ignition switc h t o the
ACe or ON position. If the li gh t on
the brake warning lamp remain s o n,
the conditi o n may be caused by a
defect ive s witc h. grounded s witc h wires
o r the dirrerential pressure va lve is not
ce nte red . Cent rali ze t he differential
press ure va lve as o utlined under H y-
d rau li c S ys te m Bleeding a nd Cen-
tra liz ing of the Diffe rentia l Va lve in
this sect ion o f the manual. If the
warning light remains on. chec k the
s wi tch connecto r and wi re fo r a
grou nded co nditi on and rep air o r
repl ace the wire assembly. If the
co nditi on o f the wi re is good , rep lace
the b rake warning lamp sw itch.
2. Turn the ignition s wi tc h to the
start pos ition. If the brake warn ing
lamp docs not light , c heck the lig ht
a nd wiring fo r defects and replace
o r repai r wiring.
3 . If the..: brake warnin g lam p docs
not li g ht when a press ure differe nt-
ial conditi o n ex is ts in the b ra ke sys-
tem . th e warning lamp may be
burned o ut . the warning lam p
s wit ch is inoperative or the s wit c h to
la mp wirin g ha s an open ci rc ui t.
C hec k the bulb and rep lace it , if re -
quired . C he c k the s wit ch t o lamp wi res
fo r an o pen c irc uit and repair or re
pla ce the m, if requ ired . If the warn -
in g lamp s titl docs not lig ht , rep lace
the s wit c h.
BRAKE P EDAL FRE E
HEIGHT AND TRAVEL
MEASU R EME NTS
W ith the e ngi ne running for full
p o wer b rake opera t io n, meas ure the
brake peda t free he ight , and check
the bra ke ped a l travel with the use
of the Brake Pedal P ress ure Gauge ,
Too l WRE- 500-50 as follows:
Brake Pe dal Free
Hei ght Me asurem en t
I. Inse rt a slende r, s harp po inted
prod throug h the ca rpel a nd so und
deadncr to th e das h panel meta l a nd
meas ure the di s tan ce to the brake
pe da l (F ig. I).
2. If the pos iti o n of the pedal is
nll t within s peci ficat ion. check the
brake pedal lin kage for miss ing
bu s hings o r loose attachin g bolt s
and rep la ce them . if requi red .
3. If the ped a l free height is still
o ut of s pec ific;Hion , c heck the b rake
pedal booster push rod (if so equipped)
o r mas ter cy li nder to be sure the co r-
rec t pa rts are ins ta ll ed. Replace the
defective part s as necessary.
2-2 GROUP 2-Brakes

STEERING WHEel R~~\ pedal measurement under a 50

9<)'
TDEBDA PiJ OR
DASH METAL
VEHICLE
F:'LCON-CO:.~ET -FAIRUNE
FALCON-COI/.e T -FAIRLANE
FALCON eOtAET FAIR LANE
F AlCON-COt.IET -FAIRUNE
!.lUST ANG-COUGAR
~'\US T A N G-COUGAR
MUSTANG COUG AR
NOTE: A DIMENSION T0 ~E
B DIMENSI ON TO BE MEASURED PARAL LE L 1 0 THE VER TI CAL CENTERLI NE OF TH(
STE ERIN G COLUMN WI TH ,\ 50 POUND LOAD APPLIED TO THE CE NTERLINE OF TH E
i3R AKE PEDA L PAD. ((ti EC KS ON POWER BRAKE VE HICLES MADE WITH ENGIN E RUNNlt!(;' \
FIG . 7-Brake Pedal He ight a nd Tra ve l Mea su reme nts
pound load shou ld be within the speci-
\ fied ma xi mum peda l tra vel service
\ s pec ifica tion B in Fig. I.
5. If the pedal travel is more than
-\ the spec ified maximum shown in Fig.
STEERING COLUMN I. dimert" ion B, make several sharp
revt:rsc stops (equivalent to 50 pounds
pedal pressure) with a forward stop
befo re eac h. Move the car in rcvt:rst:
a nd forward for a distance of ap-
pr oxi matel y ten feel ; then appl y the
brakes s ha rply and hold the bra ke
A
pedal down until the car is completely
STEE RING COLUMN stopped. This will actuate the brake
se lf-adjuste rs. Jr these stops do not
STEEL MEASURING TIIPE
bring the brake peda l travel with -
in specification. make st:vt:ral addi-
PEDAL FREE
ti o nal fo rvo'ard and reverst: stops as
TYPE PEDAL TRAVEL Il o utlined above.
HEIGHT A
NON.PQI,' ER DRUM 803 !l 81 2.74 6. If the seco nd ser ies of stops do
PO.... E P. QRur,\ SO~ ) 14 not bring the b rakc pedal travel
PQNER DI.~C 639.!9Q '"
2.08 within spec ification. remove the bra ke
No.".PO"'ER DISC aOJ 681 2.0B drums and check the brak e adjusters
NOi~POWER DRUM 6.98 603 2.68 to make s ure thc ), arc fun cti on ing.
POWER DRUM HI 4 60 La2 C heck the brake linings for wear or
POWER DISC HI J 60 1.B1 damage . Repair or rep lacc all worn
or damaged parts and non fun ct ion-
"IEASURED TO SHEET ME T Al
in g adjusters. Adjust the brakl.! lin-
in g out s ide diameter to the appro:.;,i-
H1551- A matt: ins ide diameter of the brake
drum with Rotund a Too! I-IR E g650
(Figs. II and 12, Part 2-2).
7_ If all the brake adjustt:rs.
brake drums and lin ings arc func -
ti ona l and the b rake pedal travel is
not within spt:cificati ons. chl.!ck tht:
pedal linkage for miss ing bushings.
o r loose alt ach ment s. Bleed the brake
and centralizc tht: differentia l va lve.

POW E R BR A K E
FUNCTI ONA LT EST

I. With the trans mi ss ion in neutral.

FIG . 2- Bra ke Pedal Effort G o uge Insta lled -
Brak e Pedal Tra ve l
M ea sure m e nt
l. I nstal1 a Brake Peda l Press ure
Gauge on the brake pedal pad (Fig.
2).
2. Hoo k a steel measu rin g tape
to the brake peda l as shown in fig .
\. Meas ure and record the distanct:
from the b rake peda l free heigh t po
s it ion to the re ference point. wh ich is
at the s ix o'cloc k position o n the steer-
ing whee l rim .
Typical
3. With the steel tape st ill hookt:d
to the brakt: pedal depress the brake
by pressi ng downward on the brake
pedal effo rt gauge . Apply
po und load to the cente r of the pedal
by observing the press ure gauge,
:t!1d meas ure the d is tance from the
brake pedal to tht: fixed rcfert:nce
po int on the stee ring wheel rim.
parallel to the cente rl ine of the steer
ing col umn.
4. The Llifference between the brake
pedal free height and the depressed
stop the eng ine and app ly the parking
brake. lXpress thl.! bra kt: pcdal sev-
eral timt:s to t:xha ust all vacuum in
the syste m.
2. With the eng ine shut off. de-
prt:ss the brake pedal and hold il in
the applied position . If the Ix;dal
gradually falls away undl.!r thi s
pressu re, the hydrauli c s)'s tl.!l11 is
1c ~lkin g. Check all tubing. hoses.
ca lipe rs (if so equipped). wheel cyl-
inders and co nnectio ns fur leaks.
If the br"lk t: pedal move ment feels
s po ngy, bleed tht: hydrauli c sys tem
to rem ove air from the sys tem . Refer
a 50 to Hydraulic Sys tem Bleeding. Part
I. &:ct io n 2. J\ls o. check for le aks or
ins uffic.:ien t fluid .
.1. With the cngi ne shut off and
all vac uum in tht: system ex hau stt:d .
dt:press the pedal and hold il in the ap-
plied pos ition. Start tht: engine. If the
vac uum sys tem is ope ratin g. I hI.!
peda l will tend to fall away under
foot pressu re and less press ure will
 PART 2-1-G eneral Brake Service
be required to hold the pedal in the
applied position. If no action is fell ,
the vacuum booster system is not
lunctioning.
LO C KED WHEEL BRAKE
Should one of the wheel brakes be
locked and the car must be moved ,
open the bleeder sc rew long enough
to let out a few drops of brake fluid.
This bleeding operation will release
the brakes bur will not correct the
ca use of trouble.
PARKING BRAKE
Visuall y check the operation of the
parking brake link age as the park-
ing brake controls arc moved to the
EJ COMMON ADJUSTMENTS AND REPAIRS
PARKING BRAKE
LINKAGE ADJUSTMENT
MUSTANG - COUGAR
Check the parking brake cables
when the parking brakes are fully
released. If the cab les arc loose, ad-
just them as follows:
I. Fully release the parking
brake by turning the handle co un-
terclockwise and pushing it inward.
2. Pull the park ing brake handle
outward to the third notch from its
normal released position .
3. Raise the vehicle. Remove the
whee l cover. In sta ll To ol T66L-
4204-L o n [he rea r whee l (Fig. 3).
4. Turn the lOCking adjustment
nut forward against the cable guide
on the equalizer (Fig. 4) unt il there
is 100 ft-lbs break-away torque at
the rear wheel when turning the rear
wheels in the direction of forw urd ro-
tatio n with a torque wrench (Fig. 3).
The torque measurement must be
made relative to the ce nterline of the
wheel.
5. Release the parking brake and
make s ure the brake shoes return to
the full y released position und no
drag is felt when turning the rear
whee ls.
6. Remove T oo l T66L-4204- L. In-
sta ll the wheel attac hing bolts and
torque them to spec ification. Install
the wheel cover. Lower the vehicle.
COMET- FALCON-
FAIRLANE
Check the parking brake cClbles
when the brakes arc full y rcleClsed.
applied position . Then, chec k the opera-
tion of the brake link age when the
parking brake con trols are moved to
the released position. These c hecks
shou ld indicate whether the manual
parking brake con trol linkage is op-
erating properly or require s repair
o r adjustment due to in abi lity of the
parking brake to hold agai nst mod -
erate veh icle move ment.
ROAD TEST
A road tesl sho uld only be con-
ducled when ttN.' operator is sure Ihe
brakes will stol) the vehicle.
During a road tesl, apply the ve-
hicles brakes at a road speed of 20
mph for all problem co nd itions listed
in Fi gs. II and 12 with the excep-
Tool- T66L,J10d A
FIG. 3- Checking Parking Brake Break-Away Torque
If the cab les arc loose, adj ust them
as fo ll ows:
I. Full y rel ease the pa rking brake
pedal.
2. Raise the ve hicle. Loosen tht!
equalizer lock nut (Fig. 5) and turn
the nut forw a rd aga inst the cable
gu ide on the equa li ~er until there is
22 to 27 pounds tension on the left
rea r cab le o r there is 100 fI -!bs
break-away lOrquc when turnin g the
rear wheels in the d irection of forward
rotati on with ~I torque wrench and
Tool T66L-4204 - L as shown III
Fi g. 3. The lorque I11l'3s ureml'nt
must bl' madl' relative 10 the cen(er-
linl' of the wheel. Tighten thl: lock nu l.
3. Make sure then' is no
whl' n turning Ihl' rear wheels.
4. Lowc. r thc vehicle. Remove thc
2-3
tion of those resolved in the Brake Sys-
tem Tests and brake chatter. To check
for brake chatte r o r s urge, app ly the
bra ke s li ghtly at 50 mph . For each
of the symptoms en co untered, check
and eliminate the ca uses which are
listed in Fi gs . II and 12.
If the road test revea ls one or morc
prob lem co nd itions li sted in Figs. II
and 12, cor rect all malfunctions of
the vacuum system, bra ke booster
and hyd r<lu li c sys tem prior to re-
moving br<lke drum s. brake c<l lipcrs
(if so equipped), brake shoes and
linin gs or backing plates.
ADJUSTME NT NUT -3799JO . S2 ~
'21
EQUALIZER RDO -262S
EQUALIZER LEVER
2A60S
H 1552A
FIG . 4-Park ing Broke linkage
Adjustment - Mustang and Cougar
torque wrcnch and Tool T66L-4204 -L.
drag
if rcquircd . Install the whed atta c h-
ing nuts and turljuc them to speci fi-
cation. InslaJlthc whcc l cove r.
 2-4 GROUP 2-Brakes

RETAINER - (j. RETAINER-2A6t6 NUT

L
74'l775 ,(;.alE ASSEMBLY 33798-58
2A6G.l 7- 10 La.FT.
EQ UALIZER _iA602
-- "j ,p:;

,
~'''''--,---:I)(ir:~~\ ~. ~- .
.. J'
ALL MODELS EXCEPT
SPRING-2A651 I
CONVER T! BlE NUT-3392358
PARKING
eRA KE CA3LE
MlO CONDUIT *'
i __ RETAINER-7~2ns t
ASSE M(3l Y-2853 \
PR ING_2M5 1 ; CABlE ASSE MBLY

\S l,-
-........... ' 2A604
............ \ NUT - 33Q23 58
"\\ 1
'~.-
==--:.:: :-:,-.. :b~\! ......."
I NUT -3 3798-58
~" \' 7- 10LB. FT .
~ '-':
EQUAllZER - 2A602
~~RETA IN ER_2A616
CONvERTIBLE ONLY HI553-A

FIG. 5-Parking Brake Linkage

Adjustme nt - Comet, Fairlan e and
Fa lco n FIG . 7-P ush Rod Ad just me nt -
Midland Ross H 1330 B

To check the adjustme nt of the FIG . 8-Push -Rod Ad justment -

2 contacts the ma ster cy lind er pi s ton .
HI :xis-a
FIG. 6-P us h Ro d Gau ge Dime nsions
POWER BRAKE MASTER
CYLINDER PUSH ROD
ADJUSTMENT
The pu sh rod is provided wi th an
adjustment sc rew to mainta in the co r-
rect relat ionshi p between the booste r
co ntrol v<.llve plunger and the master
cylinde r pistons. Fai lure to maint ai n
this relationship will p reve nt the mas te r
cy l in der piston fr o m co mplete ly re-
leasi ng hydrau lic p ressure a nd can
cause the brakes to drag , or ca use
excessive b ra ke ped al trave l.
sc rew, fabri cate a gauge o f the
dimens ion shown in Fig. 6. Then p lace
t he gauge against the mas te r cy l-
in der mounting s urfa ce of the booster
body as s how n in F igs. 7 or 8. The
pus h rod sc rew s ho uld be adjus ted
so that the end o f the scre w j ust to uch-
es t he in ne r edge o f the slot in the
ga uge. Do not se t up s ide forces o n
t he pus h rod. S ide fo rces may break
the valve p lunge r.
This is a n approx im ate a djust-
me nt o nl y. The pus h rod s hou ld not
move mo re th a n 0 .015 inch as it
No moveme nt (exact con tact) is id ea l.
HYDRAULIC SYSTEM BLEEDING
AND CENTRALIZING OF THE
DIFFERENTIAL VALVE
When any parl of the hydrau li c
sys tem has been di scon nected for re-
pair or replacement, <ii r may en ter
the syste m and ca use s pongy peda l
act io n. Bl eed the hyd rau lic sys tem
a fter it has been properly connected,
to be s ure that a ll a ir is e xpe lled.
MAN UAL Il LEE DING
T he pr imary and seco ndary ( front
and rca r) hydra ul ic b ra ke sys tems
are ind ividua l systems a nd a re b led
sepa rate ly. Bleed t he lo ngest li ne
first on ', he ind ividual sys tem be ing
servired . During the co mplete bl ee ding
o pera ti on, 00 NOT a llow the rese r-
voir t o run d ry . Keep the mas ter cy l-
inder reservo irs fi ll ed wi t h Rotunda
Fluid - Extra Heavy Duty - Pa rl
Numbe r C6AZ- 19542-A (ESA-
M6C25 A) . T he d isc bra ke ex tra
Bend ix
hea vy duly bra ke fluid is colored
blue fo r id e ntificati on purp oses. Do
not mix lo w te mpera ture bra ke fluid s
with the s pecified fluid d uring the
bleed ing ope rati o ns. Ne ve r re-usc
bra ke fI ui d whic h has bee n dra ined
fr o m the hydra uli c syste m.
I. Loose n t he bleed sc rew located
o n t he s ide of the maste r cy linde r.
Do not use the seco nd ary pis l on st op
sc rew, loc ated o n the bott o m of the
maste r cy lind e r t o bleed the brake
syste m. Loose ning o r re moving this
sc re w could result in da mage t o the
second ary pis ton o r st o p screw .
2. To bleed the secondary (rear)
b ra ke sys te m, position a s uitab le
3/8 inch box wrench (Fig. 9) on
the bleede r fitt ing o n the brake wheel
cylinder. Attach a rubber drain
tube to the bleede r filling . T he e nd of
the tube s ho uld fit s nugly a round
the bleede r Iitling.
3. Subme rge the free end of the
tube in a co ntainer pa rti ally filled
wit h clean bmke fluid , an d loosen
the b leeder filling approximately
3/4 turn .
4. P us h the b rake peda l dow n
s low ly through its f ull t ravel. Close
the b leeder fitt in g, the n ret urn the
pedal to t he fully- re leased pos it io n.
Re pea t th is ope rati o n unt il a ir b ub-
b les cease to appea r at the s ub-
merged end of the bleeder tube .
S. Whe n the fl uid is co mpletely
free of a ir bubb les, cl ose the bleede r
fitting and remove the bleede r tube .
6. Repeat t his procedu re at t he
brake wheel cyli nder on t he o pposite
s ide. Refi ll the master cy linder rese r-
voir after each whee l cy li ndl! r is bled

" p ress ure.
H1300 A
FIG. 9- W rench for Bleed ing Brake
Hydraulic System
and install t he maste r cy li nder cover
and gasket. Be s ure the diaphrag m
ty pe gas ket is prope rl y pos iti o ned in
the master cy linde r cover. When the
bleeding ope ration is co mpleted , the
fluid le vel s hould be filled to within
1/ 4 to 1/ 2 inch from the top of
the rcsc n'oirs.
7. If the prima ry (front brake)
sys tem is to be b led, remo ....e the fron t
wheel cove rs, and the front wheel and
lire assemb lies to gai n access to the
bleede r fittings o n the disc b rake ca l-
ipers. Repeat steps 2 th rough 6 at
the right fron t d isc brake caliper and
ending at the left front disc brake
cal ipcr.
8. Be s u re that the fron t b rake
pis tons a re retu rned to their nO.rI~la l
posi t ions and t hat the s hoe and lining
assemblies arc p rope rl y sca Led by
dep ressing the brake pedal several
times unt il norma l peda l he ight exists.
I nstall the fron l wheel and tire asse m
blies on the front wheels, and torque
the mounting bo lts to spec ifi cat io n .
Ins ta ll t he wheel covers.
9. Cent ra lize the pressure di f-
ferent ia l va lve. Refer to the Cenlra liz
ing the Press ure D ifferentia l Valve
Proced ures which follow.
PR ESSU RE BL EE Df NG
Bl eed the lo ngest lines fi rst. The
bleede r tank s ho uld contain eno ugh
new Rotunda Brake F luid to co mplete
the bleedi ng opera t io n . Use Rot unda
Bra ke F luid - Extra Heavy Duty -
Par t Number C6AZ- 19542-A
(ESA-M6C25-A) or equ iva lent ror all
disc brake app li ca ti ons a nd Rot un da
Br ake Fluid - Heavy Duty - Pa rt
Numbe r B7AZ-19 542-A, RI03 -A
o r equ iva lent for power drum o r
standa rd drum applicat io ns. T he
bra ke flu id is colo re d blue fo r id e nti-
fica ti o n purp oses . Do not mi x low
te mpe rature b ra ke fluid with Ihe
s pec if ied disc bra ke fluid durin g the
bl ee ding ope rati o ns . e t'er re-use
br a ke fluid that has bee n dra ined
fr o m the hyd raul ic syste m. The tank
sh o ul d be c ha rged wit h app roxi-
ma tely 10 to 30 po unds o f air
PART 2-1 Gene ral Bra ke Service
p ressure. Ne t'e r exceed SO po unds
I. C lean all dirt from t he master
cy linde r reservoi r cove r.
2. Remove the ma s ter cylinder res-
e rv o ir cove r and rubber gasket , and
fi ll the mas ter cylinder reservoi r with
the spec ifi ed brake fluid . Insta ll the
p ressure bleeder adap te r tool to the
mas ter cy linde r, and attach t he
bleeder tan k hose to the fitt ing o n the
adapte r.
Master cy linder press ure blee der
adapte r tools ca n be obt a ined (ro m
the va ri ous ma nufacture rs of pres-
sure bleeding equi p ment. Follow the
ins tructio ns of the ma nu fac t urer
when insta ll ing the adapte r.
3. loosen t he pr imary and sec-
on d ary tube nuts at t he maste r cy l-
inder and bleed the master cy linder
until the flu id flow is free of air
bubbles. then tighten the t ube nuts
to the s peci fied torque. Refer to Figs.
20 a nd 2 1, Part 22. Do not ove r-
ti g hte n t he nuts.
4. If the rear wheel cy linde rs and
the seco ndary brake system is to be
bled . position a 3/8 inch box
wrench (F ig. 9) o n the bleede r fitt ing
on the right rear b rake wheel cyl inder.
Att ach a bleeder tube to the b leeder
filling. The e nd of the t ube s h ould
fil s nug ly a round the bl eeder fittin g.
5. Open the valve on the bleeder
tank to adm it pressurized b rake fluid
to the master cylinder reservo ir.
6. Submerge the free e nd o f the
tube in a co ntainer partially filled
with clean brake fluid, and -loosen
the bleeder fitting .
7. When air bubb les cease to ap-
JX!ar in the fluid a t the subme rged
end of the bleede r tube, close the
bleede r fitt ing and remove the t ube.
S. Repeat steps 3 th rough 7 at the
left wheel cyli nder of the secondary sys-
tem he ing bled.
9. If the primary (fronf brake)
sys te m is 10 be bl ed, re move the h o nt
wh eel co t'ers, a nd t he fr onl whee l :lnd
tire asse mbli es 10 ga in access 10 Ihe
bleeder fillings o n the d isc brake
ca lipers. Repeat s teps 4 th ro ug h 7,
s tarting at the right fr o nt disc ca li -
per and ending at the left front disc
ca l iper.
10. If the vehicle co ntains drum-
type front brakes a nd lhe primary
(f ron t) brake system is to be b led.
repeat s teps 4 through 7. starting
a t t he right fron t whee l cy linder and
endi ng at the left whee l cy linder.
2-5
II. W hen the bleeding operation
is comp leted , close the bleeder lank
va lve and remove the tank hose from
the ada pter fitting.
12. On di sc b rake equipped ve-
hicles, be s ure that the fr ont brake
pistons are returned to their no rma l
positions a nd that the s hoe and lining
assemblies a re properly seated by
dep ressing the brake peda l seve ral
times unti l normal peda l heig ht is
obta ined . I nsta ll t he fr on t whee l and
lire assemb lies on the front wheels , and
to rque the m ount ing bolts to s pec ifi-
c atio n. I ns ta ll the wheel covers.
13. Remove the Press ure Bleeder
Adapter Too l. Fi ll the maste r cy linder
rese rvoi rs to wi thi n 1/4 to 1/2 inch
fro m the top . Install the maste r cy l-
inder cove r and gasket. Be s ure the
di a phrag m-t y pe gas ket is pro pe rly
pos itioned in the mast e r cy linde r CO l'e r.
14. Ce ntralize the pressure dif-
ferential valve as follows :
CENTR ALI Z I NG T HE
PR ESSU RE DI FFE REN TI AL
VALVE
After a fai lure of the pr imary
(front brake) or secon dary ( rear
b r a ke) sys tem has been repaired
a nd bled, the dual-brake warning
light will usually co nt inue to be il-
lumina ted d ue to the pressure dif
ferent ial valve remaining in an off -
ce nter position.
To ce ntrali ze the p ressu re differ-
e nt ial valve and turn off the warning
lig ht a fter a repair opera t ion. a pres-
s ure differential or unbalance co n-
d ition m ust be c reated in the opposi te
brake system from the one that was
repaired and bled la st.
I. Turn the ignitIOn sw itch to the
A CC or ON pos iti o n. Loosen the dif-
ferentia l va lve a sse mbly bra ke tube
nut at the o utlet port on the oppos it e
s id e of lhe brake syste m tha t was
re paired a nd / or ble d last. Dep ress
the bra ke peda l s lowly to bu ild line
press ure u nti l the pre ss u re di ffe rentia l
va lve is moved to a centra lized posi.
tion and the b rake wa rn ing li ght
goes o ut : t hen , immedia te ly tighte n
the outlet port tube nu t to the spec i
fied torque. Rdert o Fig. 20 and 21.
2. C heck the fluid level in the
master cyli nder reservo irs and fill
them to with in 1/ 4 to 1/ 2 inch o f
the to p wi t h the sIX=ci fied brake fluid.
if necessary .
3. Turn t he ig nit io n sw itch to the
OFF pos ition .
4 . Befo re driving the ve h icle, check
the ope ra t ion o f t he b rakes and be
sure t haI a firm pedal is obtained.
2-6
EI CLEANING AND INSPECTION
DISC (FRONT) BRAKES
I. Remove the wheel and tire, cali-
per splash shield, and the shoe and lin-
ing assemblies as outlined in Part
2-2, Section 2.
2. Make three thickness measure-
ments with a micrometer across the
middle section of the shoe and lining.
Take one reading at each side and
one in the center. I f the assembly has
worn to a thickness of 0.23\ inch
(shoe and lining together) or 0.066
inch (lining material only) at any
one of the three measuring locations
or if the brake lining shows evidence
of brake fluid contamination, re-
place all four shoe and lining as-
semblies on both front wheels.
3. Check the caliper to spindle
attaching bolt and caliper bridge
bolt torque. Tighten them to the
specified torque, if required.
4. To check rotor runout, first
eliminate the wheel bearing end play
by tightening the adjusting nut.
After tightening the nut check to see
that the rotor can still be rotated.
5. Clamp a dial indicator to the
caliper housing so that the stylus
contacts the rotor at a point apprexi-
mately I inch from the outer edge.
Rotate the rotor and take an indica-
tor reading. If the reading exceeds
0.002 inch total lateral runout on
the indicator, replace or resurface
the disc brake rotor. The following
requirements must be met when re-
surfacing disc brake rotors:
Rotunda Disc Brake Attachment
FRE-2249-2 is the only apprmed
tool to be used to refinish the disc
brake rotors. The step-by-step resur-
facing procedure provided with the
tool must be adhered to.
The finished braking surfaces of
the rotor must be flat and parallel
within 0.0007 inch; lateral runout
must not exceed 0.002 inch total
indicator reading, and the surface
finish of the hraking surfaces are
to be 85/15 micro inches. The min-
imum limiting dimen~ions (Fig. 10)
from the inboard bearing cup to
the outboard rotor face (di mension
A) and from the inboard bearing
cup to the inboard rotor face (di-
GROUP 2-Brakes
mension B) must be observed when
re moving material from the rotor
braking surfaces.
When the runout check is finished,
be sure to adjust the bearings as
outlined in Group 3, in order to pre-
vent bearing failure.
6. Check the rotor for scoring.
Minor scores can be removed with a
fine emery cloth. If the rotor is exces-
sively scored, refinish it as outlined
in step 5 or replace the rotor, if re-
quired.
7. Visually check the caliper. If
excess leakage is evident, it should
be replaced. Slight leakage around
the pistons or seized pistons indicate
removal and disassembly.
H. If upon disassembly the cali-
per is found to be distorted or dam-
aged, or if the cylinder bores are
scored or excessively worn, replace
the assembly.
The two halves of the caliper as-
sembly should never be separated.
Damage or failure of one requires
replacement of both as a unit.
REAR BRAKES
I. Remove the wheel from the drum,
then remove the drum as outlined in
Part 2-2, Section 2. Wash all the
parts except the brake shoes in a
cleaning solvent and dry with com-
pressed air.
2. Brush all dust from the back-
ing plates and interior of the brake
drums.
3. Inspect the brake shoes for ex-
cessive lining wear or shoe damage.
If the lining is worn to within 1/32
inch of the rivet heads or if the shoes
are damaged, they must be re-
placed. Replace any lining that has
been contaminated with oil, grease
or brake fluid. Replace lining, in
axle sets. Prior to replacement of
lining, the drum diameter should be
checked to determine if oversize linings
must be installed.
4. Check the condition of the brake
shoes, retracting springs, and drum
for signs of overheating. If the springs
show any loss of load or change in
free length indicating overheating,
CampbellEnterprises.com
LATERIAL RUNOUT
0.002 MAXIMUM TOTAL
INDICATOR READING
EARING CUP
It..---DIMENSION "S"
1.117 MINIMUM
:~...II....--DIMENSION "A"
0.402 MAX IMUM
Hl563-A
FIG. 10- Disc Brake Rotor Service
Limits - Typical
replacement of the retracting and
hold down springs and the parking
brake cable is necessary. Overheated
springs lose their pull and could
cause the new lining to wear pre-
maturely if they are not replaced.
5. If the car has 30,000 or more
miles of operation, or signs of ex-
treme overheating are present when
relining brakes, the wheel cylinders
should be disassembled and inspected
for wear and dirt in the cylinder. The
cyl inder cups and other parts con-
tained in the overhaul kit should be
replaced thus avoiding future prob-
lems.
6. I nspect all other brake parts
and replace any that are worn or
damaged.
7. Inspect the brake drums and,
if necessary, refinish. Refer to Part
2-2, Section 4 for refinishing.
BOOSTER UNIT
Check the booster operation as
noted in Part 2-1, Section I, Power
Brake Functional Test. If the brake
booster is damaged or defective, re-
place it with a new booster. The
booster is serviced only as an assem-
bly.
 PART 2-1-General Brake Service 2-7
Trouble Symptoms
""f ~
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III
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0_ ~ Q)
~Q) 0 0
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possible Causes Of Trouble
Q).2
Q.,y. 3: ~

Shoe and Lining Knock-back after Violent Cornering or

Rough Road Travel X
Shoe and Lining Assembly not Properly Seated or Positioned X x
Leak or Insufficient Fluid in System or Caliper x x x
Loose Wheel Bearing Adjustment x x
Damaged or Worn Caliper Piston Seal x x x
Improper Master Cylinder Push Rod Adjustment x
Excessive Rotor Runout or Out of Parallel x
I - - - - - - - - - - - - - - - - - - - - - - - - - - _ + _ - - j - - - + - - - + - - + - - - l - - - - - - - - - - - - - - . - - .. - --- -
x X
X X x
Brake Fluid, Oil or Grease on Linings x X X
-----.----------~--4_-_+__4-~-+_-4__4-_4-_4-~~-~-4_.-

Shoe and Lining Worn Below Specifications X

Proportioning Valve Malfunction X
Booster Inoperative X
Caliper Out of Alignment with Rotor X \
Loose Caliper Attachment x x X X
Metering Valve Seal Leaks .\
Excessive Clearance Between Shoe and Caliper or Between
Shoe and Splash Shield
Shoe Hold Down Clips Missing or Improperly Positioned X
Operator Riding Brake Pedal
Scores in the Cylinder Bore
Corrosion Build-Up in the Cylinder Bore or on the Piston
Surface X X x
Bleeder Screw Still Open
Caliper Out of Parallel with Rotor x
One Section of Dual Brake System is Inoperative .\
Differential Pressure Valve Is Not Centered .\

Wiring To Warning Lamp or Switch Is Grounded X

Warning Lamp Switch Is Grounded X
\Varning Lamp Is Burned Out X
Warning Lamp or Switch Has An Open Circuit X
Warning Lamp Switch Is Inoperative X
Wiring To Warning Lamp Has Open Circuit X

FIG. 11-- Front Wheel Disc Brake Trouble Symptoms and Possible Causes
2-8 GROUP 2-B ra ke s
Trouble Symptoms
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Possible Causes Of Trouble 0

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Mechanical Resistance at Pedal or Shoes X X

Brake Line Restricted X X X X
Leaks or Insufficient Fluid X X X X
Improper Tire Pressure X X
Distorted or Improperly Adj usted Brake Shoe X X X X X X X
Faulty Retracting Spring X X
Drum Out of Round X X X
Lining Glazed or Worn X X X X X X X
Oil or Grease on Lining X X X X X X
Loose Carrier Plate X X X
Loose Lining X
Scored Drum X X
Dirt on Drum-Lining Surface X
Faulty Brake Cylinder X X X X
Dirty Brake Fl uid X X X X
Faulty Master Cylinder X X X X
Air in Hydraulic System X X X X
Self Adjusters Not Operating X X
Insufficient Shoe-to-Carrier Plate Lubrication X X X
Tire Tread Worn X
Poor Lining to Drum Contact X
Loose Front Suspension X
Threads Left by Drum Turning Tool Pulls
Shoes Sideways X
Cracked Drum X
One Section of Dual Brake System Is Inoperative X X
Differential Pressure Valve Is Not Centered X
Wiring To Warning Lamp or Switch Is Grounded X
Warning Lamp Switch Is Grounded X
Warning Lamp Is Burned Out X
Warning Lamp or Switch Has An Open Circuit X
Wiring to Warning Lamp Has Open Circuit X
Warning Lamp Switch Is Inoperative X

FIG. 12- Drum Brake and General System Trol..ble Symptoms and Possible Causes
 2-9

PART 2-2- Brake System

Section Page
Description and Operation .......................... 2-9
Dual-Master Cylinder Brake System ........... 2-9
Disc Brakes ........................................... 2-11
Hydraulic Self-Adjusting Brake System ........ 2-13
Booster System ...................................... 2-13
Parking Brakes ...................................... 2-14
2 In-Vehicle Adjustments and Repairs .............. 2-14
Front (Disc) Brake Shoe and Lining
Replacement ....................................... 2-17
Disc Brake Caliper Assembly .................... 2-18
Front Wheel Hub and Rotor Assembly ....... 2-18
Disc Brake Rotor Splash Shield ................. 2-19
Proportioning Valve ................................ 2-19
Brake Shoe Adjustments-Rear Wheels ........ 2-16
Rear Brake Drum ................................... 2-20
Rear Brake Shoe Replacement .................. 2-20
Rear Wheel Cylinder Repair ..................... 2-19
Rear Wheel Cylinder Replacement ............. 2-19
Rear Brake Backing Plate Replacement.. ..... 2-20
Hydraulic Lines .................................... 2-20
Section Page
Brake Tube Replacement ...................... 2-20
Brake Hose Replacement ...................... 2-20
3 Removal and Installation ............................ 2-23
Dual Master Cylinder - Standard Brakes ...... 2-23
Dual-Master Cylinder-Power Brakes ......... 2-24
Pressure Differential Valve Assembly .......... 2-24
Brake Booster ........................................ 2-25
Brake Pedal ........................................... 2-25
Parking Brake Control Assembly ............... 2-26
Parking Brake Equalizer to Control
Cable ..................................................... 2-26
Parking Brake Eq ualizer to Rear Wheel
Cable ................................................ 2-27
4 ~ajor Repair Operations ........................... 2-28
Brake Drum Refinishing .......................... 2-28
Rotor Refinishing ................................ 2-28
Brake Shoe Relining ............................... 2-29
Dual-Master Cylinder .............................. 2-29
Disc Brake Caliper ................................. 2-30

D DESCRIPTION AND OPERATION

Disc brakes are available as op-
tional equipment for the front wheels
on the various vehicle models listed
in (Fig. I).
The dual-master cylinder equipped
hydraulic brake system employes sin-
gle-anchor, internal expanding and
self-adjusting drum brake assemblies
on the rear wheels of vehicles with
disc brakes, and on the front and rear
wheels of all others (Fig. I).
DUAL-MASTER CYLINDER
BRAKE SYSTEM
The dual-master cylinder brake sys-
tem has been incorporated in all car
models to provide increased vehicle
safety. The system consists of a dual-
master cylinder, pressure differential
valve assembly and a switch. The
switch on the differential valve acti-
vates a dual-brake system warning
light, located on the instrument panel.
The dual-master cylinder brake sys-
tem is similar to a conventional
(single) brake master cylinder sys-
tem. In the dual-system, two master
cylinders are combined in a single
cast iron casting (Fig. 2). One por-
tion actuates the front brake system
and the other actuates the rear brake
system (Figs. 20 and 21). Hydraulic
fluid leakage or failure of one of
the systems does not impair the oper-
ation of the other portion of the dual-
brake system. A dual-brake warning
light signals a failure of either the
front or rear brake system.
The dual-master cylinder used on
Fairlane, Falcon and Comet vehicles
equipped with power brakes have the
master cylinder outlet ports for the
rear brake system located on the bot-
tom of the master cylinder body.
Master cylinder hydraulic system
bleed screws are located in the out-
board side of those master cylinders
having secondary (rear brake) system
outlet ports in the bottom of the mas-
ter cylinder castings (Fig. 29).
All Fairlane, Falcon and Comet ve-
hicles equipped with standard drum
brakes a nd all Mustang and Cougar
vehicles equipped with power disc,
power drum and standard drum
brakes have both the primary (front)
and secondary (rear) brake system
outlet ports located on the outboard
side of the dual-master cylinder body
castings. These master cylinders do
not require master cylinder bleed
screws (Figs. 27, 28 and 30).
The external appearance of the dual
master cylinders for the various ve-
hicles also differ in configuration
of the covers. All vehicles having
standard drum brake systems and
Mustang, Cougar vehicles equipped
with power drum brakes have primary
and secondary master cylinder cover
domes of equal size. Dual master cyl-
inders for all other vehicles equipped
with power disc and power drum
brake systems have large primary
(front brake) and smaller secondary
(rear brake) cover domes.
A code letter is stamped on the
side or outer end of each master cyl-
inder body casting for easy service
identification. The vehicle application,
type of brakes and the identification
code are shown in Fig. 3.
A brake pressure differential valve
assembly (Fig. 4) incorporating an hy-
draulically operated mechanical
switch is utilized to operate a dual-
brake warning light, located on the
instrument panel.
Hydraulic pressure for both front
wheel brakes is provided from the pri-
mary system (front) brake outlet port
and line, located opposite the primary
system inlet port of the differential
valve.
Hydraulic pressure for both rear
wheel brakes is provided from the sin-
gle secondary (rear brake) outlet
line, located opposite the secondary
system inlet port of the differential
valve. On disc brake equipped ve-
hicles, a proportioning valve is located
in the secondary (rear brake) system
line that leads to the brake hose
bracket on the rear axle housing. The
brake hose bracket serves as a junc-
tion point for the individual brake
lines that lead to the wheel cylinders
of right and left rear brake com-
ponents.
When the brake pedal is depressed,
both the primary (front brake) and
2-1 0
seco nd ary (rear brake) master cy lin -
der pistons are moved simultaneo usly
to exert hydra uli c fluid press ure on
their respective independent hydra ulic
sys tem . The fluid displacement of the
du al-master cylinders is proportioned
to fulfi ll the requirement s of each of
the two independent hydraulic brake
sys tems (Fig. 2).
If a failure of the rear (secondary)
brake syste m should occ ur, initial
brake peda l movement causes the un-
restricted secondary piston to bottom
in the master cylinder bore. Primary
piston movement displaces hydraulic
fluid in the primary sect ion of the
dual-master cy linder to actuate the
front brake system.
Should the front (primary) brake
sys tem fail , initial brake pedal move-
ment causes the unrestricted primary
piston to boltom out against the sec-
ondary piston. Continued downward
movement of the b rake pedal moves
the secondary piston to displace hy-
draulic fluid in the rear brake sys-
tem , act uating the rear brakes.
The increased pedal travel and the
increased pedal effort required to com-
pensate for the loss of the failed
portion of the brake system provides
a warning that a partial brake system
failure has occured. When the ignition
swi tch is turned to the START posi -
tion , a dual-bra ke warni ng light pro-
DISC BRAKES
RETUR N SPR ING
I SECONDARY)
SECONOARY BRAKE
FLUID RESERVOIR
FILLER CAP
./
SECCNOARY P1STON
ASSEMBl Y
FIG , 2- Dual -Masler Cylinde r
GROUP 2-Brakes
Car Model Power Dr um Powe r Disc
Falcon RPO Not Available
Fairlane RPO RPO ~
,
Mu stang , RPO RPO
Comet RPO RPO "-
'"
0'
Cougar RPO RPO
'I) Standard with Mu stang GT equ ipment group opt ion , Fairlane GT model.
M lI stang brake opt ion s availab le only on eight-cy linder models.
"," Standard for Ace. Fairlane and Co met 427 V-S Engine.
FIG, 1-Power Disc Brake and Power Drum Brake Options
vides a visual indication the warning switch is located on the side of the
lamp is fun ctiona l. When the ignition pressure differential valve assembly
switch is turned to the ON or ACe between the front and rear b rake sys -
pos ition , a dual -brake warning lig ht tem inlet ports. The inner-end of the
on the ins trument panel al so provides spring loaded sw itc h plunger contacts
a visual indication if one portion of the bollom of a tapered shoulder
the dua l-brake system ha s become g roove in the center of the valve (Fig .
inoperative. 4). O-ring seals are retained in seal
S hou ld a failure of either the fro nt ring lands near each end of the
o r rear brake hydraulic sys tem occ ur, valve ,
the hydraulic fluid pressure differen- Should a failure of the rear brake
tial resul ting from the pressure loss syste m occu r, hydraulic fluid pressure
of the fa iled brake system forces the in the rear brake sys tem would drop .
valve toward the low pressure area to Durin g brake pedal operation the fluid
illuminate the brake warning lig ht pressure build -up of the front brake
( Fig.4). sys tem forces the va lve to move to-
A mechanically operated e lectrical ward the low pressure area, or toward
RETAINER
PRIMARY SYSTEM BRAKE
FLU IO RESERVOIR
RETUR N SPR ING (PRIMARY)
PUSH ROD
P RIMARY PIS T ON
ASSE MBL Y
 PART 2-2-Brake System 2-1 1

the rear brake system outlet port (Fig.

4). Movement of the differential valve Car Model Type Of Brake Identification Code
forces the switch plunger upward over
the tapered shoulder of the valve to Power Disc B
close the switch electrical contacts and Fairlanc and Falcon Power Drum S
light the dual brake warning lamp,
signalling a brake system failure. Standard Drum T
In the event a front brake system
failure should occur, greater pressure Power Disc M
from the rear brake system during Mustang Power Drum X
brake pedal operation forces the valve
forward, moving the switch plunger Standard Drum T
upward onto the valve ramp to light
the brake system warning lamp. How- Comet Power Disc B
eYer, failure of either the front or Power Drum S
rear system does not impair operation
of the other brake system. Standard Drum T
Cougar Power Disc M
DISC BRAKE ASSEMBLIES
Power Drum X
Disc brakes are available as op-
tional equipment for the front wheels. Standard Drum T
The hydraulic brake system employs
single anchor, internal expanding and FIG. 3- Dual Master Cylinder Identification
self-adjusting drum brake assemblies
on the rear wheels of vehicles with cyl inders (drum brakes). The pistons lated disc type, actuated by a hy-
disc brakes, and on the front and rear in turn convert hydraulic pressure draulic system (Fig. 5). There is no
wheels of all others. back into physical force at the brake lateral movement of either the disc
A vacuum booster is available as shoes. (rotor) or the caliper. The caliper
optional equipment. assembly consists of two caliper
The master cylinder converts phys- RELATION AND FUNCTION housings bolted together with each
ical force from the brake pedal (and OF COMPONENT PARTS half containing two cylinder bores
booster if so equipped) into hydraulic of 1 15/16 inch diameter. Each cyl-
pressure against the pistons in the The disc brake is a fixed caliper, inder bore contains a piston with an
calipers (disc brakes) or in the wheel opposed piston. non-energized, venti- attached molded rubber dust boot

BRAKE WARNI~IG LAMP SWITCH BRAKE WARNING LAMP SWITCH

VALVE PISTON HAS MOVED TO LOW PRESSURE AREA. VALVE PISTON IS CENTRALIZED.
WARNING LAMP SWITCH PLUNGER IS DEPRESSED, ~ BRAKE FLUID PRIMARY AND SECONDARY SYSTEM
LIGHTING THE BRAKE WARNING LAMP PRESSURES ARE EQUALIZED H1471A

FIG. 4-Pressure Differential Valve and Brake Warning Lamp Switch Operation
 2-12
CALIPE R ASSE MBl Y
BLEEDER SCREW
H140G- B
FIG. S- Typical Disc Brake Assembly
to seal the cylinder bore from con-
tamination (F ig. 6). Squa re-secti on
rubber piston seals a re positioned in
grooves in the cy linder bores.
The piston seal s perform three im-
ponant tasks :
1. They provide hydraulic sealing
between the cy linders a nd pi stons.
2. They return th e pis t o ns to re-
leased position, when hydra ulic pres-
SUfe is released .
3. They maint a in the shoes in CO f-
rect adjustment at all times (com-
parable to the a ut o m at ic adjus ters in
drum -type brakes) .
The cy li nd ers are co nnected hy-
draulicall y by mea ns o f internal pa s-
sages in the ca liper ho usin g and a n
external transfe r tube between the
two halves of the c a liper asse mbl y.
One bleeder sc rew and fluid in let
fitting is provided on each ca liper
asse m bly.
The s hoe a nd lining assembli es a rc
located between para llel machined
ab utment s within the cal iper, and
a re supported radiall y by tabs on the
outer ends of the s hoe assemb lies
(Fig. 25) . The shocs slide axiall y in
the cal iper a butments by means o f
the tabs whi ch r id e o n m ac hined
ledges (bridges) whe n hydrauli c p res
s ure is a pplied to the pis ton (F ig .
6). A s hoe a nd linin g asse mbly co n-
s is ts of fri c t io n m ate ri a l bonded t o a
metal platt.: call ed th e s hoe. It is re-
pla ced a s a unit. Bra ke to rque is a b -
so rbed b) the ma ting o f the s hoe e nd
aga in st the ca liper abutment s (Fi g.
25). T wo s pring clips a re attac hed to
the lap o f th e calipe;r to retain the
GROUP 2-Brake s
CLE ARANCE
CAL IPER HUl" "'o \
PISTON
SHOE ----r:--li'l--_
LIN ING ----t"11'
PISTON SE AL _ _ _.>-c=-,--~U
FIG . 6- Typical Caliper Assembly-Sectional View
PISTON
CYLINDER BORE
BRAKES APPL IE D
FIG . 7-Function of Piston Seal
s hoe and lining assemblies. The cal I-
per assembly is m o unted t o a bracket
located between the s pindl e and rot o r
s p las h s hield , to the fr ont of the
wh eel vertica l center line .
The c ast iron d isc is o r the ve nti -
lated roto r type inco rp o rat in g forty
fin s and is att ached to , a nd rotates
with, the wheel hub. The outside
diameter of the rotor is 11. 290 in-
c hes a nd the in side di ame te r is 7.170
inches. This type of design increases
coo ling a rea and permits c irculation
o f a ir through t he rot o r res ulting in
m o re rapid cooling of the brake. A
s plas h s hie ld bolted t o the s pind le is
used primarily to prevent road con-
t a m ina nts from contactin g the inboa rd
rot o r a nd lining s urfaces (Fig . 17).
Th e wheel provides pro tect io n for the
o utboa rd s urfaces of the rotor.
As th e brake pedal is de pressed ,
hyd ra ulic press ure fro m the m as ter
cy linder force s the p isto ns o ut o f the
cal iper bores again st their res pective
s hoe a nd lining assemblies. The
fo rce of the p is ton s agains t the s hoes
moves the linings aga inst bot h s ides
le.I.....- TRANSFER TUBE
PISTON DUST BOOT
RETA INING GROVE
CALIPER DUST
BOOT RET AIN ER
H1J69 B
CALIPER
HOUSING
BRAKES RELEASE D HlJ7o.C
of the revol ving rotor to e ffect brak-
ing actio n .
During b rake applicatio n, t he rub-
ber seal o n each piston stret ches as
the pis to n moves against the s hoe
(Fig. 7). When the hydraulic pres-
s ure agai nst the piston is rele ased ,
the sea l rel axes or roll s bac k. This
roll~back act ion pulls the piston away
rro m the s hoe just enough to relieve
the force o f the lining aga inst the
rotor a nd , the reby, provide the re-
q uired running clearance. Also, inh e r~
c nl rotor run o ut contributes t o the
mainten a nce o f r un nin g clearance.
Au to matic adjustment is achieved by
the p is tons s liding in the seals out-
wa rd from the cy lind er bores. The pis-
ton g radua ll y changes its position rel a-
tive to the sea l as t he lining wears
a nd, thu s, maintains the correct ad-
jus tme nt location at all t imes.
When the brakes are in the un-
applied pos it ion , there is no hydrau-
li c press ure to the ca li pe rs beca use
the flu id s o urce at the master cy lin-
der by-passes the residual check
va lve .