1969 FORD MUSTANG Volume One Chassis

01-01-05
Vehicle Identification

01-01-05

INTERIOR TRIM CODES

Code Trim Schemes

1A Black Vinyl (Cougar, Falcon)

1A Black Cloth & Vinyl

IB Med. Blue Cloth/Lt. Blue Vinyl

IB Med. or Lt. Blue Vinyl

IB Dk. Blue Cloth & Vinyl

(Lincoln,
T-Bird, Mark III, Mercury)

IB Lt. Blue Cloth & Vinyl

(Ford,
Montego, Meteor)

ID Dk. Red Cloth and Vinyl

IF Med. Saddle Vinyl (Cougar)

1G Dk. Ivy Gold Cloth & Vinyl

1G Lt. Ivy Gold Vinyl (Cougar)

IK Lt. Aqua Cloth and/or Vinyl

IP
Med.
Grey Cloth & Vinyl (Mark III)

1Y Lt. Nugget Gold Vinyl (Cougar-Falcon)

1Y Lt. Nugget Gold Cloth & Vinyl

2A Black Vinyl

2A Black Leather & Vinyl (Lincoln)

2A Black Leather (Mark III)

2B Dk. or Lt. Blue Vinyl

2B Dk. Blue Leather & Vinyl (Lincoln)

2B Dk. Blue Leather (Mark III)

2D Dk. Red Vinyl

2D Dk. Red Leather & Vinyl (Lincoln)

2D Dk. Red Leather (Mark III)

2F Med. Saddle Vinyl (Cougar)

2F
Med.
Saddle Leather & Vinyl (Lincoln)

2F Med. Saddle Leather (Mark III)

2G Lt. or Dk. Ivy Gold Vinyl

2G Dk. Ivy Gold Leather & Vinyl (Lincoln)

2G Dk. Ivy Gold Leather (Mark III)

2K Lt. Aqua Vinyl

2K Lt. Aqua Leather & Vinyl (Lincoln)

2K Lt. Aqua Leather (Mark III)

2P
Med.
Grey Leather (Mark III)

2U Pastel Parchment w/Black Leather (Mark III)

2W Whitew/Black Vinyl

2W White w/Black Leather & Vinyl (Lincoln)

2W Whitew/Black Leather (Mark III)

2Y Lt. Nugget Gold Vinyl

2Y Lt. Nugget Gold Leather & Vinyl (Lincoln)

2Y Lt. Nugget Gold Leather (Mark III)

3A Black w/Red Knit and/or Vinyl (Mustang,

Montego)

3A Black Knit and/or Vinyl

3A Black Cloth & Vinyl

3A Black Leather & Vinyl (Lincoln)

3B Lt. Blue Knit and/or Vinyl

3B Lt. or Dk. Blue Cloth & Lt. Blue Vinyl

3B Lt. Blue Cloth & Vinyl

(Fairlane,
Ford,
Montego, Meteor)

3B Med. Blue Cloth & Lt. Blue Vinyl

3B Dk. Blue Cloth & Vinyl (T-Bird, Mercury)

3B Dk. Blue Leather & Vinyl (Lincoln)

3D Dk.Red Cloth & Vinyl

3D Dk. Red Knit and/or Vinyl

3G Dk. Ivy Gold Cloth & Vinyl

3G Dk. Ivy Gold Leather & Vinyl (Lincoln)

3K Lt. Aqua Cloth & Vinyl

3W White w/Black Knit and/or Vinyl

3W Whitew/Black Leather & Vinyl (Lincoln)

3Y Lt. Nugget Gold Cloth & Vinyl

3Y Lt. Nugget Gold Knit and/or Vinyl (T-Bird)

4A Black Cloth & Vinyl

4A Black Knit and/or Vinyl

4B Dk. Blue Vinyl

4B Dk. or Lt. Blue Vinyl

4D Dk.Red Vinyl

4G Dk. Ivy Gold Cloth & Vinyl

4G Dk. Ivy Gold Vinyl

4K Lt. Aqua Vinyl

4W White w/Black Vinyl

4Y Lt. Nugget Gold Knit and/or Vinyl

5A Black Cloth & Vinyl

5A Black Knit and/or Vinyl

5A Black Leather & Vinyl (Lincoln)

5B Lt. Blue Cloth and/or Vinyl

5B Lt. Blue Knit and/or Vinyl

5B Dk. Blue Leather & Vinyl (Lincoln)

5B Dk. Blue Cloth & Vinyl (Mercury)

5D Dk.Red Cloth & Vinyl (Montego)
INTERIOR TRIM CODES-(continued)

Code Trim Schemes

5D Dk. Red Knit and/or Vinyl

5D Dk. Red Leather & Vinyl (Lincoln)

5F
Med.
Saddle Leather & Vinyl (Lincoln)

5G Dk. Ivy Gold Knit and/or Vinyl

5G Dk. Ivy Gold Cloth & Vinyl

5G Dk. Ivy Gold Leather & Vinyl (Lincoln)

5K Lt. Aqua Cloth & Vinyl (Montego)

5K Lt. Aqua Vinyl

5K Lt. Aqua Leather & Vinyl (Lincoln)

5W White w/Black Knit and/or Vinyl

5W White w/Black Leather & Vinyl (Lincoln)

5Y Lt. Nugget Gold Cloth & Vinyl

5Y Lt. Nugget Gold Knit and/or Vinyl (Mustang,

Fairlane)

5Y Lt. Nugget Gold Leather & Vinyl (Lincoln)

6A Black Knit and/or Vinyl

6A Black Cloth & Vinyl (Lincoln)

6A Black Leathe; & Vinyl (Cougar)

6B Dk. or Lt. Blue Vinyl

6B Dk. Blue Leather & Vinyl (Cougar)

6D Dk. Red Knit and/or Vinyl

6D Dk.Red Leather & Vinyl (Cougar)

6F
Med.
Saddle Leather I Vinyl

6G Dk. Ivy Gold Vinyl

6G Dk. Ivy Gold Leather & Vinyl (Cougar)

6K Lt. Aqua Vinyl

6K Lt. Aqua Leather & Vinyl (Cougar)

6W White w/Black Vinyl

6Y Lt. Nugget Gold Vinyl

6Y Lt. Nugget Gold Leather & Vinyl (Cougar)

7A Black Vinyl

7A Black Cloth & Vinyl (Fairlane)

7A Black Leather & Vinyl (Lincoln)

7B Lt. Blue Vinyl (Cougar, Montego, Ford)

7B Dk. Blue Cloth & Vinyl

7B Dk. Blue Leathe; & Vinyl (Lincoln)

7D Dk. Red Vinyl (Mustang)

7D Dk. Red Cloth & Vinyl

7G Dk. Ivy Gold Cloth and/or Vinyl

7G Dk. Ivy Gold Leather & Vinyl (Lincoln)

7K Lt. Aqua Cloth & Vinyl

7W White w/Black Vinyl

7W White Leather & Vinyl (Lincoln)

7Y Lt. Nugget Gold Cloth & Vinyl

7Y Lt. Nugget Gold Vinyl

(Ford,
Meteor, Mustang)

8A Black Knit and/or Vinyl

8A Black Leather & Vinyl (T-Bird)

8B Dk. or Lt. Blue Knit and/or Vinyl

8D Dk. Red Knit and/or Vinyl

8F Med. Saddle Knit and/or Vinyl

8G Dk. Ivy Gold Knit and/or Vinyl

8K Lt. Aqua Knit and/or Vinyl

8W White w/Black and/or Vinyl

8W White w/Black Leather & Vinyl (T-Bird)

8Y Lt. Nugget Gold Knit and/or Vinyl

9A Black Knit and/or Vinyl

9A Black Cloth & Vinyl (Ford, Meteor)

9B Lt. Blue Knit and/or Vinyl

9B Dk. Blue Cloth & Vinyl (Ford, Meteor)

9D Dk. Red Knit and/or Vinyl

9D Dk. Red Cloth & Vinyl (Ford-Meteor)

9G Dk. Ivy Gold Cloth & Vinyl

9K Lt. Aqua Cloth & Vinyl

9Y Lt. Nugget Gold Cloth and/or Vinyl

9Y Lt. Nugget Gold Knit and/or Vinyl

AA(1W)
White Vinyl
With Black (Cougar)

AA Black Cloth & Vinyl (Lincoln)

AB(1W) White Vinyl With Blue (Cougar)

AB Lt. Blue Cloth & Vinyl (Lincoln)

AD(1W) White Vinyl With Red (Cougar)

AG(1W) White Vinyl With Ivy Gold (Cougar)

AG Lt. Ivy Gold Cloth & Vinyl (Lincoln)

AK (1W) White Vinyl With Aqua (Cougar)

AK Lt. Aqua Cloth & Vinyl (Lincoln)

AL Lt. Silver Cloth & Vinyl (Lincoln)

AY Lt. Nugget Gold Cloth & Vinyl (Lincoln)

AY(1W) White Vinyl With Nugget Gold (Cougar)

BA(2W) White Vinyl With Black (Cougar)

BA Black Vinyl (Fairlane)

BB(2W) White Vinyl With Blue (Cougar)procarmanuals.com

01-01-06

Vehicle Identification
01-01-06

INTERIOR TRIM CODES-(continued)

Code Trim Schemes

BB Lt. Blue Vinyl (Fairlane)

BB Lt. Blue Leather & Vinyl (Lincoln)

BD(2W) ..White Vinyl With Red (Cougar)

BG(2W) White
Vinyl
With Ivy Gold (Cougar)

BG Lt. Ivy Gold Leather & Vinyl (Lincoln)

BK(2W) White Vinyl With Aqua (Cougar)

BY(2W) White Vinyl With Lt. Nugget Gold (Cougar)

BY Lt. Nugget Gold Vinyl (Fairlane)

CA Black Cloth & Vinyl

CA Black Vinyl (Montego)

CB Dk. Blue Cloth & Vinyl

CB Lt. Blue Vinyl (Montego)

CD Dk. Red Cloth & Vinyl

CD Dk. Red Vinyl

CG Dk. Ivy Gold Cloth & Vinyl

CG Lt. Ivy Gold Leather & Vinyl (Lincoln)

CK Lt. Aqua Cloth & Vinyl

CY Lt. Nugget Gold Cloth & Vinyl

CY Lt. Nugget Gold Vinyl (Montego)

DA Black Cloth & Vinyl

DA(4W) White
Vinyl
With Black (Cougar)

DA Black Knit and/or Vinyl

DB Dk. Blue Cloth & Vinyl

DB Dk. Blue Vinyl (Mercury)

DB(4W) White Vinyl With Blue (Cougar)

DD(4W) White Vinyl With Red (Cougar)

DD Dk. Red Knit and/or Vinyl

DD Dk. Red Cloth & Vinyl

DG Dk. Ivy Gold Vinyl

DG Dk. Ivy Gold Cloth & Vinyl

DK Lt. Aqua Cloth & Vinyl

DW White w/Black Knit and/or Vinyl

DY Lt. Nugget Gold Cloth & Vinyl

DY Lt. Nugget Gold Vinyl (Mercury)

EA Black Knit and/or Vinyl

EA Black Cloth & Vinyl

EB Dk. Blue Cloth & Vinyl

ED Dk. Red Cloth & Vinyl

EG Dk. Ivy Gold Cloth & Vinyl

EK Lt. Aqua Cloth & Vinyl

EW White w/Black Knit and/or Vinyl

EY Lt. Nugget Gold Cloth & Vinyl

FA Black Knit and/or Vinyl

FA(6W) White
Vinyl
With Black (Cougar)

FB Lt. or Dk. Blue Vinyl

FB(6W) White Vinyl With Blue (Cougar)

FD Dk. Red Knit and/or Vinyl

FD(6W) White Vinyl With Red (Cougar)

FG Dk. Ivy Gold Vinyl

FG(6W) White
Vinyl
With Ivy Gold (Cougar)

FK(6W) White Vinyl With Lt. Aqua (Cougar)

FW White w/Black Knit and/or Vinyl

FY Lt. Nugget Gold Vinyl

FY(6W) White Vinyl With Nugget Gold (Cougar)

GA Black Vinyl

GB Lt. Blue Vinyl

GD Dk. Red Vinyl

GG Dk. Ivy Gold Vinyl

GY Lt. Nugget Gold Vinyl

HA Black Knit and/or Vinyl

HA(8W) White Vinyl With Black (Cougar)

HA Black Leather & Vinyl (Mercury)

HB Lt. Blue Vinyl

HB (8W) White Vinyl With Blue (Cougar)

HD Dk. Red Vinyl

HD Dk. Red Leathe; & Vinyl (Mercury)

HD(8W) White Vinyl With Dk. Red (Cougar)

HG Dk. Ivy Gold Vinyl

HG(8W) White Vinyl With Ivy Gold (Cougar)

HK Lt. Aqua Vinyl

HK(8W) White Vinyl With Lt. Aqua (Cougar)

HW White w/Black Leather & Vinyl (Mercury)

HW White w/Black Vinyl (Fairlane)
INTERIOR TRIM CODES-(contlnuad)

Code Trim Schemes

HY(8W) White Vinyl With Nugget Gold (Cougar)

HY Lt. Nugget Gold Knit and/or Vinyl

JA Black Knit and/or Vinyl

JB Lt. Blue Cloth & Vinyl (Lincoln)

JG Lt. Ivy Gold Cloth & Vinyl

JW .....White w/Black Knit and/or Vinyl

JY Lt. Nugget Gold Knit and/or Vinyl

JY Lt. Nugget Gold Cloth & Vinyl (Lincoln)

KA Black Knit and/or Vinyl

KA Black Cloth & Vinyl (Ford-Mercury-Meteor)

KA Black Leather & Vinyl (Lincoln)

KB Dk. Blue Cloth & Vinyl

KB .....Med. Blue Cloth & Lt. Blue Vinyl (Ford-Montego)

KB Dk. Blue Leather & Vinyl (Lincoln)

KD Dk. Red Cloth & Vinyl

KG Dk. Ivy Gold Leather & Vinyl (Lincoln)

KG Dk. Ivy Gold Cloth & Vinyl

KL Lt. Silver Leather & Vinyl (Lincoln)

KW White W/Black Leather & Vinyl (Lincoln)

KY Lt. Nugget Gold Knit and/or Vinyl

KY Lt. Nugget Gold Cloth & Vinyl

LA Black Knit and/or Vinyl

LA Black Leather & Vinyl (Lincoln)

LB Lt. Blue Knit and/or Vinyl

LB Dk. Blue Leather & Vinyl (Lincoln)

LD Dk. Red Knit and/or Vinyl

LE Lt. & Med. Beige Vinyl

LG Dk. Ivy Gold Leather & Vinyl (Lincoln)

LW White w/Black Knit and/or Vinyl

LW White w/Black Leather & Vinyl (Lincoln)

LY Lt. Nugget Gold Knit and/or Vinyl

MA Black Vinyl

MB Lt. Blue Vinyl

MD
Dk
Red Vinyl

MW White w/Black Vinyl

NA Black Knit and/or Vinyl

NB Lt. Blue Vinyl

NY Lt. Nugget Gold Knit and/or Vinyl

PA Black Vinyl

PB Lt. Blue Vinyl

PY Lt. Nugget Gold Vinyl

QA Black Knit and/or Vinyl

)B
. Lt
Blue Vinyl

JW White Knit and/or Vinyl

Lt. Nugget Gold Vinyl

Black Knit and/or Vinyl

RA Black Leather & Vinyl

RB Lt. Blue Knit and/or Vinyl

RD Dk. Red Knit and/or Vinyl

RD Dk. Red Leather & Vinyl

RW White w/Black Leather & Vinyl

RW White W/Black Knit and/or Vinyl

RY Lt. Nugget Gold Knit and/or Vinyl

SB Lt. Blue Leather & Vinyl (Lincoln)

SG Lt. Ivy Gold Leather & Vinyl (Lincoln)

TG Lt. Ivy Gold Leather & Vinyl (Lincoln)

VA Black Knit and/or Vinyl

VB
Dk
Blue Vinyl

VG Dk. Ivy Gold Vinyl

VW White w/Black Knit and or Vinyl

VY Lt. Nugget Gold Vinyl

WA Black Knit and/or Vinyl

WW White w/Black Knit and/or Vinyl

WY Lt. Nugget Gold Knit and/or Vinyl

YA Black Cloth & Vinyl

YB Dk. Blue Cloth & Vinyl

YD Dk. Red Cloth & Vinyl

YG Dk. Ivy Gold Cloth
&
Vinyl

YK Lt. Aqua Cloth & Vinyl

YY Lt. Nugget Gold Cloth & Vinyl

ZA Black Cloth & Vinyl

ZB Dk. Blue Cloth & Vinyl

ZG Dk. Ivy Gold Cloth & Vinylprocarmanuals.com

01-01-07
Vehicle Identification

01-01-07

DATE CODES

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

second-year code letter will be used if the model exceeds 12 months.

Month
Code

First Year
Code

Second Year

January

February

March

April

May

June

July

August

September

October

November

December
....A..

...B..

...C.

...D..

...E..

...
F..

...
G.

...H.

...J..

..
K.

. ...L.

...M.

DISTRICT CODES (DSO)

Units built on a Domestic Special Order, Foreign Special Order,

or other special orders will have the complete order number in

this space. Also to appear in this space is the two-digit code number

of the District which ordered the unit. If the unit is a regular

production unit, only the District code number will appear.

FORD

Code
District
Code

District

11...

13
...

15...

16...

17...

21...

22
...

24...

25...

28...

32....

33...

35...

37...

38....

41...

43...

44...

46....

47...
Boston

...New York

Newark

...Philadelphia

Washington

Atlanta

Charlotte

...Jacksonville

Richmond

. ...Louisville

. ...Cleveland

.... Detroit

Lansing

...Buffalo

... .Pittsburgh

Chicago

Milwaukee

Twin Cities

...Indianapolis

Cincinnati
51

53

54

55

56

61

62

63

64

65

71

72

73

74

75

83

84

85

89

90's
..
... Denver

.. .Kansas City

.. Omaha

...St. Louis

.. Davenport

.. Dallas

... Houston

.. Memphis

.. New Orleans

.. .Oklahoma City

... Los Angeles

...San Jose

...Salt Lake City

...Seattle

.. .Phoenix

.. Government

... Home Office Reserve

.. American Red Cross

...Transportation Services

...Export
LINCOLN-MERCURY

Code
District

Code
District

11

15

16

17

21

22

23

26

31

32

33
Boston

New York

Philadelphia

Washington

Altanta

Dallas

Jacksonville

Memphis

Buffalo

Cincinnati

Cleveland
34

41

42

46

51

52

53

54

84

90's...
... Detroit

.. Chicago

..
St.
Louis

... Twin Cities

Denver

Los Angeles

Oakland

Seattle

Home Office Reserve

Export

FORD
OF
CANADA

Code
District
Code
District

Bl

B2

B3

II thru
17..
Central

Eastern

Atlantic

Export
B4.

B6.

B7.
Midwestern

Western

. Pacific

Note:
Canadian Lincoln-Mercury units use prefix
"A" in
place of«"B".procarmanuals.com

02-01-01

02-01-01

GROUP

2

PART
2-1
PAGE

General Brake Service 02-01-01

PART
2-2

Brake System 02-02-01
PART
2-3

Specifications
PAGE

02-03-01

Part
2-1
General Brake Service

COMPONENT INDEX

ANTI SKID CONTROL SYSTEM

Tests

BRAKE BOOSTER

Adjustments

Cleaning
and
Inspection

Tests

BRAKE PEDAL

Free Height Test

Total Travel Test

DISC BRAKES

Cleaning
and
Inspection

Service Precautions

DRUM BRAKES

Cleaning
and
Inspection

HYDRAULIC SYSTEM BLEEDING

PARKING BRAKE CONTROL

Vacuum Release Test

PARKING BRAKE LINKAGE

Adjustment

PRESSURE DIFFERENTIAL VALVE

Adjustment (Centralize)
MODEL APPLICATION
All
Models

01-04

01-07

01-02

01-01

01-01

01-07

01-07

01-08

01-05

01-07
Ford
N/A

01-03

01-03
Mercury
N/A

01-03

01-03
Meteor
N/A

01-03

01-03
Cougar
N/A

N/A

01-03
Fairlane
N/A

N/A

01-03
F

alcon
N/A

N/A

01-03
Montego
N/A

N/A

01-03
Mustang
N/A

N/A

01-03
Lincoln-
Continental
N/A

01-03

01-04
Thunderbird
01-03

01-03

01-04
Continental-
Mark III
01-03

01-03

01-04

A page number indicates that the item
is for the
vehicle listed
at
the head
of the
column.

N/A indicates that the item
is not
applicable
to
the vehicle listed.

1 BRAKE SYSTEM TESTS

Always check
the
fluid level
in the

master cylinder before performing
the

test procedures.
If the
fluid level
is not

within
1/4
inch
of the top of the mas-

ter cylinder reservoirs,
add
Ford

Brake Fluid
—
Extra Heavy Duty —

Part Number C6AZ-19542-A
(ESA-

M6C25-A)
or
equivalent
for all
brake

applications.
The
extra heavy duty

brake fluid
is
colored blue
for
identifi-

cation purposes.
Do not mix low tem-

perature brake fluids with
the
speci-

fied brake fluid.

Should
one of the
wheel brakes
be

locked
and the
vehicle must
be
moved,

open
the
bleeder screw long enough
to

let
out a few
drops
of
brake fluid.

This bleeding operation will release

the brakes
but
will
not
correct
the

cause
of
trouble.
BRAKE PEDAL FREE

HEIGHT
AND
TRAVEL

MEASUREMENTS

With
the
engine running
for
full

power brake operation, measure
the

brake pedal free height,
and
check
the

brake pedal travel with
the use of the

Brake Pedal Pressure Gauge, Tool

WRE-5OO-5O
as
follows:

BRAKE PEDAL FREE HEIGHT

MEASUREMENT

1.
Insert
a
slender, sharp pointed

prod through
the
carpet
and
sound

deadener
to the
dash panel metal
and

measure
the
distance
to the
brake

pedal
(Fig. 1).

2.
If the
position
of the
pedal
is not

within specification, check
the
brake
pedal linkage
for
missing, worn,
or

damaged bushings,
or
loose attaching

bolts
and
replace them,
if
required.

3.
If the
pedal free height
is
still

out
of
specification, check
the
brake

pedal booster
or
master cylinder
to be

sure
the
correct parts
are
installed.

Replace
the
worn
or
damaged parts
as

necessary.

BRAKE PEDAL TRAVEL

MEASUREMENT

1.
Install
a
Brake Pedal Effort

Gauge
on the
brake pedal
pad
(Fig. 2).

2.
Hook
a
steel measuring tape
to

the brake pedal
as
shown
in Fig. 1.

Measure
and
record
the
distance from

the brake pedal free height position
to

the reference point, which
is at the six
procarmanuals.com

02-01-02
Brakes

02*01-02

STEERING
WHEEL RIW

TOEBOARD
OR

DASH
METAL
CHECKING
POINTS

STEERING
COLUMN-

STEEL
MEASURING TAPE

VEHICLE

FORD,
MERCURY AND METEOR

FORD,
MERCURY AND METEOR

FORD,
MERCURY AND METEOR

FORD,
MERCURY AND METEOR

FAIRLANE,
MONTEGO AND FALCON

FAIRLANE,
MONTEGO AND FALCON

MUSTANG
AND COUGAR

MUSTANG
AND COUGAR

THUNDERBIRD

CONTINENTAL
MARK III

LINCOLN
CONTINENTAL
TYPE

NON-POWER
DRUM

POWER
DRUM & DISC

NON-POWER
DISC

POLICE
POWER DISC

NON-POWER
DRUM

POWER
DISC

NON-POWER
DRUM

POWER
DISC

POWER
DISC

POWER
DISC

POWER
DISC
PEDAL
FREE

HEIGHT-A

8.09-7.17

6.18-5.99

8.65-7.82

7.58-6.72

8.13-6.91

7.25-5.71

7.49-6.43

6.25-5.56
PEDAL
FREE

HEIGHT-B"

5.96-5.04

5.96-5.04

6.50-5.50
PEDAL

TRAVEL-C

3.10

3.27

2.18

3.27

2.90

2.35

2.58

1.75

3.00

3.00

2.25

NOTE:AgB
DIMENSION TO BE MEASURED TO SHEET METAL

C
DIMENSION TO BE MEASURED PARALLEL TO THE VERTICAL CENTERLINE OF THE

STEERING
COLUMN WITH A 50 POUND LOAD APPLIED TO THE CENTERLINE OF THE

BRAKE
PEDAL PAD. (CHECKS ON POWER BRAKE VEHICLES MADE WITH ENGINE RUNNING

H1630-A

FIG. 1 — Brake Pedal Height and Travel Measurements

Tool-WRE-l

HI525-A

FIG.
2—Brake Pedal Effort Gauge Installed
o'clock position on the steering wheel

rim.

3.
With the steel tape still hooked

to the brake pedal depress the brake

pedal by pressing downward on the

brake pedal effort gauge. Apply a 50

pound load to the center of the pedal

by observing the pressure gauge, and

measure the distance from the brake

pedal to the fixed reference point on

the steering wheel rim parallel to the

centerline of the steering column.

4.
The difference between the brake

pedal free height and the depressed

pedal measurement under a 50 pound

load should be within the specified

maximum pedal travel service specifi-

cation B in Fig. I.

5.
If the pedal travel is more than

the specified maximum shown in Fig.

1,
dimension C, make several sharp

reverse stops (equivalent to 50 pounds

pedal pressure) with a forward stop

before each. Move the vehicle in rev-

erse and forward for a distance of ap-

proximately ten feet; then, apply the

brakes sharply and hold the brake

pedal down until the vehicle is com-

pletely stopped. This will actuate the

brake self-adjusters. If these stops do

not bring the brake pedal travel within

specification, make several additional

forward and reverse stops as outlined

above.

6. If the second series of stops do

not bring the brake pedal travel within

specification, remove the brake drums

and check the brake adjusters to make

sure they are functioning. Check the

brake linings for wear or damage. Re-

pair or replace all worn or damaged

parts and non-functioning adjusters.

Adjust the brake lining outside diame-

ter to the approximate inside diameter

of the brake drum with Rotunda Tool

HRE-8650 (Fig. 12, Part 2-2).

7.
If all the brake adjusters, brake

drums and linings are functional and

the brake travel is not within specifi-

cations, check the pedal linkage for

missing or worn bushings, or loose at-

tachments. Bleed the brakes and cen-

tralize the differential valve.

POWER BRAKE

FUNCTIONAL TEST

1.
Check the hydraulic brake sys-

tem for leaks or insufficient fluid.

2.
With the transmission in neutral,

stop the engine and apply the parking

brake. Depress the brake pedal several

times to exhaust all vacuum in the

system.

3.
With the engine shut off and all

vacuum in the system exhausted, dep-

ress the pedal, and hold it in the ap-

plied position. Start the engine If theprocarmanuals.com

02-01-03
Brakes

02-01-03

vacuum system is operating, the pedal

will tend to fall away under foot pres-

sure and less pressure will be required

to hold the pedal in the applied posi-

tion. If no action is felt, the vacuum

booster system is not functioning.

If the brake pedal movement feels

spongy, bleed the hydraulic system to

remove air from the system. Refer to

Hydraulic System Bleeding, Part 1,

Section 2.

VACUUM TESTS—VACUUM

RELEASE PARKING BRAKES

Visually check the operation of the

brake linkage as the brake pedal is

depressed. Then, check the operation

of the brake linkage when the manual

release lever is activiated. These

checks should indicate whether the

manual parking brake control linkage

is operating properly or requires re-

pair or adjustment due to inability of

the parking brake to hold against

moderate vehicle movement. Perform

tests of the parking brake system and

controls after making certain the link-

age and manual controls operate

properly.

When testing a parking brake vacu-

um release system, a minimum of 10

inches of vacuum (Hg.) should be

available at all points where vacuum is

applied. This can be checked with a

Rotunda Fuel Pump Tester Gauge

(ARE345) and two Distributor Tester

hose adapters (Marked Q) connected

together with a coupling. This allows

the Fuel Pump Tester Gauge hose to
be adapted to any other vacuum hose

or rubber connector in the vacuum

systems.

Failure to maintain 10 inches of

vacuum (Hg.) during vacuum system

tests could be caused by a loose hose

connection, resulting in a vacuum

leak. When checking for vacuum be-

tween two points, trace the hose along

the entire routing to be sure it is not

crossed with another hose and con-

nected to the wrong connection.

All of the vacuum parking brake

control checks are to be performed

with the engine running at idle speed.

Leaks in the parking brake hoses or

a disconnected or improperly con-

nected hose can usually be found by

listening for a hissing sound along the

hose routings. Under no circumstances

should air pressure be applied to the

vacuum system as the actuator dia-

phragm in the parking brake vacuum

motor may be damaged.

1.
Start the engine and run it at

idle speed. With the transmission shift

control in neutral, depress the parking

brake pedal to apply the parking

brake. Move the transmission shift

control to D range and observe the

parking brake pedal to see that the

pedal moves upward and the parking

brake releases. If the parking brake

releases, the parking brake vacuum

control is working properly.

2.
If the parking brake does not re-

lease, test for vacuum at the steering

column neutral switch port in the

junction block, vacuum lines and the

parking brake release vacuum motor.

Use the Rotunda Vacuum and Fuel
Pump Tester 345. This can be accom-

plished by removing the hose from

each component and attaching it to

the vacuum gauge. Connect two dis-

tributor tester vacuum hose adapters

together with a coupling as a connec-

tor to attach the gauge. A minimum

of ten inches of vacuum is required to

actuate the parking brake vacuum

motor. Do not remove any of the vac-

uum hoses from the junction block

unless the junction block is being re-

placed, as the plastic nipples are thin

and very brittle and damage may re-

sult. If a minimum reading is not

present when checking each of the

aforementioned components, they

must be replaced.

ROAD TEST

A road test should be conducted

only when the operator is sure the

brakes will stop the vehicle.

If the road test reveals one or more

problem conditions, correct all mal-

functions of the vacuum system, brake

booster and hydraulic system prior to

removing brake drums, brake calipers,

brake shoes and linings or backing

plates.

ANTI-SKID CONTROL

SYSTEM TESTS

No adjustments or repairs are to be

performed on the skid control system.

Damaged or worn parts are to be re-

placed.

Refer to Ford Car and Truck Diag-

nosis Manual for Testing procedures.

COMMON ADJUSTMENTS AND REPAIRS

PARKING BRAKE LINKAGE

ADJUSTMENT

FORD, MERCURY, METEOR,

FAIRLANE, MONTEGO,

FALCON, MUSTANG

AND COUGAR

Check the parking brake cables

when the brakes are fully released. If1

the cables are loose, adjust them as

follows:

1.
Fully release the parking brake

pedal by pulling the release lever.

2.
Depress the parking brake pedal

until it is engaged in the first notch of

the control. On a vacuum release

brake, the first notch will be approxi-

mately two inches of pedal travel.

3.
Raise the vehicle. With the

transmission in neutral, turn the ad-

justing nut forward against the equal-

izer (Figs. 3 and 4) until there is 100
L.H. REAR WHEEL CABLE -2A809> 2A791 (2 REQUIRED)

EQUALIZER-TO-ACTUATOR CABLE-2A815

R.H. REAR WHEEL CABLE-2A635

ADJUSTING NUT-2A812

H 1537-C

FIG. 3—Parking Brake Adjustment—Ford, Mercury, Meteor,

Thunderbird and Continental Mark IIIprocarmanuals.com

02-01-04
Brakes

02-01-04

ft-lb breakaway torque.
The
breaka-

way torque
is the
torque required
to

turn
the
rear wheels
the
direction
of

forward rotation with
a
torque wrench

and tool shown
in Fig. 5. The
torque

measurement must
be
made relative
to

the center line
of the
wheel.

4.
Release
the
parking brake,
and

check
to
make sure that
the
brake

shoes return
to the
fully released posi-

tion.

5.
Depress
the
parking brake pedal

to
the
third notch. Under normal
con-

ditions, this will hold
the
vehicle satis-

factorily.

6. Release
the
parking brake again,

and check
as in
step
4.

7.
If the
rear brakes
do not
fully

release, check
the
cables
for
kinks
or

binds.
Free
the
cables
as
required.

8. Lower
the
vehicle. Remove
the

torque wrench
and
tool. Install
the

wheel attaching nuts
and
torque them

to specification. Install
the
wheel

cover.

RETAINER-*^ REAR WHEEL

(CABLE ASSEMBLY

EQUALIZER
NUT

PARKING

BRAKE CABLE

AND CONDUIT

ASSEMBLY-2853
SPRING-2A651

SPRING SEAT-2A616
JAM NUT

H1631-A

FIG. 4—Parking Brake Linkage

Adjustment—Fairlane, Montego,

Falcon,
Mustang
and
Cougar
THUNDERBIRD,

CONTINENTAL MARK
III,

AND LINCOLN

CONTINENTAL

Check
the
parking brake cables

when
the
brakes
are
fully released.
If

the cables
are
loose, adjust them
as

follows:

1.
Fully release
the
parking brake

pedal
by
pushing down
the
manual
re-

lease lever.

2.
Depress
the
parking brake pedal

1
1/4
inch from
its
normal released

position.

3.
Raise
the
vehicle with
the
trans-

mission
in
neutral.

4.
Loosen
the
lock
nut and
turn
the

adjusting
nut
forward against
the

equalizer (Figs.
3 and 6)
until there
is

100 ft-lbs breakaway torque.
The

breakaway torque
is the
torque
re-

quired
to
turn
the
rear wheels
the di-

rection
of
forward rotation with
a tor-

que wrench
and
tool shown
in Fig. 5.

The torque measurement must
be

made relative
to the
centerline
of the

wheel. Tighten
the
lock
nut.

5.
Release
the
parking brake,
and

check
to
make sure that
the
brake

shoes return
to the
fully released posi-

tion.

6. Depress
the
parking brake pedal

until
it is
fully engaged.

7.
Release
the
parking brake again,

and check
as in
step
5.

8. Depress
the
pedal
1/2
inch.
The

brakes should
not
drag.

9.
If the
rear brakes
do not
fully

release, check
the
cables
for
kinks
or

binds.
Free
the
cables
as
required.

10.
Lower
the
vehicle. Remove
the

torque wrench
and
tool. Install
the

wheel attaching nuts
and
torque them

to specification. Install
the
wheel

cover.

Tool-T59L
4204-A,

T65K
4204-A,

T66L-4204-A,

OR

Tool-4421UA

E1897-A
POWER BRAKE MASTER

CYLINDER PUSH
ROD

ADJUSTMENT

The push
rod is
provided with
an

adjustment screw
to
maintain
the cor-

rect relationship between
the
booster

control valve plunger
and the
master

cylinder.
If the
plunger
is too
long
it

will prevent
the
master cylinder piston

from completely releasing hydraulic

pressure
and can
cause
the
brakes
to

drag.
If the
plunger
is too
short
it
will

result
in
excess pedal travel
and an

undesirable clunk
in the
booster area.

The adjustment screw
is set to the

correct height
at the
time
of
original

assembly
of the
power unit. Under

normal service
the
adjustment screw

does
not
require
any
further attention

providing
the
original push
rod
assem-

bly remains
in the
original unit.

If
a
check
of the
push
rod
adjust-

ment
is
necessary,
the
push
rod
length

may
be
verified with
a
push
rod
length

gauge
and
measured with
the
engine

running
to
apply vacuum
to the
boost-

er (Fig.
7).

The push
rod
length verification
and

adjustment
of
Midland-Ross power

brake booster assemblies must
be

done according
to the
following proce-

dure:

REAR WHEEL ADJUSTING NUT

CABLES

EQUALIZER

SPRING

CABLE ASSEMBLY H1632-A

FIG. 6—Parking Brake Linkage

Adjustment—Lincoln Continental

FIG. 5—Checking Parking Brake Breakaway Torque
#16
U.J

\

0.980"

0.995"

FIG. 7—Push

Dimensions
>.S. GAUGE SHEET

i

1
STEEL

H1087-E

Rod Gaugeprocarmanuals.com

02-01-05
Brakes

02-01-05

1.
Disconnect the master cylinder

from the booster assembly and secure

away from the booster without discon-

necting the brake tubes.

2.
Reinstall the air filter assembly

on the booster if it was removed with

the master cylinder (Fig. 8).

3.
Install and tighten the master

cylinder retaining nuts to retain the

air filter assembly securely against the

booster body and to seal the booster

bellows against air leaks.

4.
Place the gauge against the

master cylinder mounting surface of

the air filter assembly.

5.
Adjust the push rod screw to

provide a slight tension against the

inner edge of the adjustment gauge

slot. (Approximately 5 pounds of ten-

sion against the push rod is required

to assure that the push rod is firmly

seated in the booster assembly.)

6. Remove the retaining nuts from

the booster master cylinder mounting

studs.

7.
Install the master cylinder on the

brake booster and tighten the retain-

ing nuts to the specified torque.

The push rod length verification of

the Bendix power brake booster

assemblies is accomplished as follows:

1.
Disconnect the master cylinder

from the booster assembly and secure

away from the booster without discon-

necting the brake tubes.

2.
Adjust the push rod screw to

provide a slight tension against the

inner edge of the adjustment gauge

slot. (Approximately 5 pounds of ten-
sion against the push rod is required

to assure that the push rod is firmly

seated in the booster assembly.) See

Figure 8.

3.
Install the master cylinder on the

brake booster and tighten the retain-

ing nuts to the specified torque.

Do not set up side forces on the

push rod as it may break the valve

plunger.

This is an approximate adjustment

only. To verify the adjustment, look

through the make-up (rear) port of the

master cylinder when installing the

master cylinder to the booster. The

master cylinder piston should not

move more than 0.015 inch as it con-

tacts the push rod. No movement

(exact contact) is ideal.

HYDRAULIC SYSTEM BLEEDING

AND CENTRALIZING OF THE

DIFFERENTIAL VALVE

When any part of the hydraulic sys-

tem has been disconnected for repair

or replacement, air may enter the sys-

tem and cause spongy pedal action.

Bleed the hydraulic system after it has

been properly connected, to be sure

that all air is expelled.

MANUAL BLEEDING

The Lincoln Continental hydraulic

brake system is to be bled only with

pressure bleeding equipment.

The primary and secondary (front

MANIFOLD CHECK VALVE-2365 19-25 IN. LB.

TIGHTEN RETAINING NUTS

TO SECURE AIR FILTER

AGAINST BOOSTER BODY

AND BELLOWS

ADJUST PUSH ROD SCREW TO

PROVIDE A SLIGHT TENSION

(APPROXIMATELY 5 LBS.)

AGAINST THE GAUGE

PUSH ROD GAUGE
and rear) hydraulic brake systems are

individual systems and are bled separ-

ately. Bleed the longest line first on

the individual system being serviced.

During the complete bleeding opera-

tion,
DO NOT allow the reservoir to

run dry. Keep the master cylinder res-

ervoirs filled with Ford Fluid—Extra

Heavy Duty — Part Number C6AZ-

19542-A (ESA-M6C 25-A). The extra

heavy duty brake fluid is colored blue

for identification purposes. Do not

mix low temperature brake fluids with

the specified fluid during the bleeding

operations. Never re-use brake fluid

which has been drained from the hy-

draulic systems.

1.
If the master cylinder is

equipped with a bleed screw, loosen

the bleed screw. Push the brake pedal

down slowly through its full travel.

Close the bleeder fitting and return

the pedal to the fully released posi-

tion. Repeat this operation until fluid

is free of air bubbles, then tighten the

bleeder screw. Do not use the second-

ary piston stop screw, located on the

bottom of the master cylinder to bleed

the brake system. Loosening or re-

moving this screw could result in dam-

age to the secondary piston or stop

screw.

2.
To bleed the secondary (rear)

brake system, position a suitable 3/8

inch box wrench (Fig. 9) on the bleed-

er fitting on the brake wheel cylinder.

Attach a rubber drain tube to the

bleeder fitting. The end of the tube

should fit snugly around the bleeder

fitting.

APPROXIMATELY 45°

PUSH ROD ADJUSTMENT-MIDLAND-ROSS

FIG. 8—Brake Booster Push Rod Measurement
PUSH ROD ADJUSTMENT-BENDIX

H1589-A
H1300-B

. 9—Wrench for Bleeding

Brake Hydraulic System

3.
Submerge the free end of the

tube in a container partially filled with

clean brake fluid, and loosen the

bleeder fitting approximately 3/4 turn.

4.
Push the brake pedal down slow-

ly through its full travel. Close the

bleeder fitting, then return the pedal

to the full-released position. Repeat

this operation until air bubbles cease

to appear at the submerged end of the

bleeder tube.

5.
When the fluid is completely free

of air bubbles, close the bleeder fitting

and remove the bleeder tube.

6. Repeat this procedure at the

brake wheel cylinder on the oppositeprocarmanuals.com