1969 FORD MUSTANG ECO mode
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FOREWORD
The five volumes of
this
shop manual provide the Service Technician
with complete information for the proper servicing of all the 1969 line
of Ford Passenger Cars.
The information is grouped according to the type of work being per-
formed,
such as frequently performed adjustments and repairs, in-
vehicle adjustments, major repair, etc. Specifications, maintenance
information and recommended special tools are
included.
The descriptions and specifications in this manual were in effect at the
time this manual was approved for printing. Ford Motor Company
reserves the right to discontinue models at any time, or change specifi-
cations
or design, without notice and without incurring obligation.
SERVICE PUBLICATIONSprocarmanuals.com
Page 6 of 413
01-01-02
Vehicle Identification
01-01-02
VEHICLE WARRANTY NUMBER
The vehicle warranty number is the first line of numbers and
letters appearing on the Warranty Plates (Fig. 1). The Warranty
Plate is riveted to the left front door lock face panel. The first
number indicates the model year. The letter following the model
year number indicates the manufacturing assembly plant. The next
two numbers designate the Body Serial Code followed by a letter
expressing the Engine Code. The group of six digits remaining on
the first line indicate the Consecutive Unit Number.
VEHICLE DATA
The vehicle data appears on the second or lower line on the
Warranty Plate. The first two numbers and a letter identify the
Body Style. A letter or a number appears next indicating the
Exterior Paint Color followed by a number-letter combination
designating the Interior Trim. To the right of this code appears the
Date Code indicating the date the car was manufactured. A two-
digit number next designates the district in which the car was
ordered and may appear in conjunction with a Domestic Special
Order or Foreign Special Order number when applicable. The final
two spaces indicate the Rear Axle Ratio (numbers for regular axles,
letters for locking-types) and the Transmission type (numbers for
manual,
letters for automatic).
OFFICIAL VEHICLE IDENTIFICATION NUMBER
The official Vehicle Identification Number (VIN) for title and
registration purposes is stamped on an aluminum tab that is riveted
to the instrument panel close to the windshield on the driver's side
of the car and is visible from outside (Fig. 2).
MODEL YEAR CODE
The number 9 designates 1969.
ASSEMBLY PLANT CODES
COUGAR
Code
Letter
Code
Letter
A
B
C
D
E
F
G
H
J
K
Atlanta
L
Oakville (Canada)
N
Ontario Truck
P
Dallas
R
.,
Mahwah
S
Dearborn
T
Chicago
U
Lorain
W
Los Angeles
X
Kansas City
Y
Z
Michigan Truck
Norfolk
Twin Cities
San Jose
.
(Pilot). ...Allen Park
Metuchen
Louisville
Wayne
St. Thomas
Wixom
St. Louis
BODY SERIAL AND STYLE CODES
The two-digit numeral which follows the assembly plant code
identifies the body series. This two-digit number is used in con-
junction with the Body Style Code, in the Vehicle Data, which
consists of a two-digit number with a letter suffix. The following
chart lists the Body Serial Codes, Body Style Codes and the model.
LINCOLN CONTINENTAL
Body Body
Serial Style
Code Code Body Type
82
53A
4-Door Sedan
80
65A
2-Door
Hardtop
CONTINENTAL MARK
III
Body Body
Serial Style
Code Code Body Type
89
65A
2-Door
Hardtop
Body
Serial
Code
91
92
93
94
91
Body
Style
Code
65A
76A
65B
76B
65C
® Bench Seat
MERCURY
Body
Serial
Code
44
46
48
45
40
41
42
54
56
58
63
66
68
65
63
66
68
60
61
72
72
74
74
76
76
Body
Style
Code
54A
65A
57A
76A
53M
65M
57M
54C
65B
57B
53F
65F
57 F
76F
53C
65C
57C
63G
63H
71B
71C
71F
71G
71E
71A
©Bench Seat
Body
Type
2-Door
Hardtop©
Convertible©
2-Door
Hardtop©
Convertible®
2-Door
Hardtop®
Model
Standard
XR-7 Luxury
Standard
©Split Bench ©Bucket Seats
Body Type
4-Door Sedan©
2-Door
Hardtop-Formal®
4-Door Hardtop®
Convertible®
CANADA ONLY
4-Door Hardtop Sedan®
2-Door
Hardtop-Formal®
4-Door Hardtop®
4-Door Sedan®
2-Door
Hardtop-Formal®
4-Door Hardtop®
4-Door Hardtop Sedan®©
2-Door
Hardtop-Formal®©
4-Door Hardtop®®
Convertible®®
4-Door Hardtop Sedan©
2-Door
Hardtop-Formal©
4-Door Hardtop©
Model
Monterey
Marquis
Monterey-Custom
Marquis
Brougham (Option)
2-Door
Hardtop (Tunnel Roof)®© Marauder
2-Door
Hardtop (Tunnel Roof)®®©
4-Door 2 Seat®
4-Door 3 Seat (Side Facing)®
4-Door
2
Seat®
4-Door 3 Seat (Side Facing)®
4-Door 2 Seat®©
4-Door 3 Seat (Side Facing)®©
Monterey Wagoi
Monterey-Custom Wagon
Marquis Colony Park
©Split Bench ©Bucket Seats
METEOR (CANADA)
Body
Serial
Code
20
21
23
Body
Style
Code
54A
54B
65B
Body Type
4-Door Sedan®
4-Door Sedan®
2-Door
Hardtop-Formal®
Model
Rideau
Rideau 500
30
54C
4-Door Sedan®
35
65C
2-Door
Hardtop-Formal®
35
65E
2-Door
Hardtop-Formal{5-33)®®
33
57C
4-Door Hardtop®
34
76C
Convertible®
34
76E
Convertible (S-33)®®
Montcalm
24
65F
2-Door
Hardtop-Formal®©
27
57F
4-Door Hardtop®®
LeMoyne
28
71B
Rideau 500-6 Passenger®
29
71C
Rideau 500-Dual Face Rear®
38
71E
Mo ntcalm-6 Passenger®
39
71A
Montcalm-Dual Face Rear®
Station Wagons.
©Bench Seat ©Splite Bench ©Bucket Seatsprocarmanuals.com
Page 11 of 413
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
Page 12 of 413
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
Page 17 of 413
02-01-06
Brakes
02-01-06
side.
Refill the master cylinder reser-
voir after each wheel cylinder is bled
and install the master cylinder cover
and gasket. Be sure the diaphragm
type gasket is properly positioned in
the master cylinder cover. When the
bleeding operation is completed, the
fluid level should be filled to within
1/4 inch of the top of the reservoirs.
7. If the primary (front brake) sys-
tem is to be bled. Repeat steps 2
through 6 at the right front brake cal-
iper or cylinder and ending at the left
front brake caliper or cylinder.
8. On disc brake equipped models
be sure that the front brake pistons
are returned to their normal positions
and that the shoe and lining assem-
blies are properly seated by depressing
the brake pedal several times until
normal pedal travel is established.
9. Centralize the pressure differen-
tial valve. Refer to the Centralizing
the Pressure Differential Valve proce-
dures which follow.
PRESSURE BLEEDING
The Lincoln Continental hydraulic
brake system is to be bled only with
pressure bleeding equipment.
Bleed the longest lines first. The
bleeder tank should contain enough
new Ford Brake Fluid to complete the
bleeding operation. Use Ford Brake
Fluid — Extra Heavy Duty — Part
Number C6AZ-19542-A (ESA-
M6C25-A) or equivalent for all brake
applications. The brake fluid is col-
ored blue for identification purposes.
Do not mix low temperature brake
fluid with the specified brake fluid
during the bleeding operations. Never
re-use brake fluid that has been
drained from the hydraulic system.
The tank should be charged with ap-
proximately 10 to 30 pounds of air
pressure. Never exceed 50 pounds
pressure.
1.
Clean all dirt from the master
cylinder reservoir cover.
2.
Remove the master cylinder res-
ervoir cover and rubber gasket, and
fill the master cylinder reservoir with
the specified brake fluid. Install the
pressure bleeder adapter tool to the
master cylinder, and attach the bleed-
er tank hose to the fittng on the
adapter.
Master cylinder pressure bleeder
adapter tools can be obtained from
the various manufacturers of pressure
bleeding equipment. Follow the in-
structions of the manufacturer when
installing the adapter.
3.
If the master cylinder is
equipped with a bleed screw, loosen
the bleed screw and bleed the master
cylinder until the fluid is free of air
bubbles; then, tighten the bleed screw.
Do not use the secondary piston stop
screw, located on the bottom of the
master cylinder, to bleed the master
cylinder.
4.
If the rear wheel cylinders, the
secondary brake system, are to be
bled, position a 3/8 inch box wrench
(Fig. 9) on the bleeder fitting on the
right rear brake wheel cylinder. At-
tach a bleeder tube to the bleeder fit-
ting. The end of the tube should fit
snugly around the bleeder fitting.
5. Open the valve on the bleeder
tank to admit pressurized brake fluid
to the master cylinder reservoir.
6. Submerge the free end of the
tube in a container partially filled with
clean brake fluid, and loosen the
bleeder fitting.
7.
When air bubbles cease to ap-
pear in the fluid at the submerged end
of the bleeder tube, close the bleeder
fitting and remove the tube.
8. Repeat steps 3 through 7 at the
left rear wheel cylinder.
9. If the vehicle is equipped with
disc brakes, repeat steps 4 through 7,
starting at the right front disc caliper
and ending at the left front disc cali-
per.
On Lincoln Continental models the
front wheel and tire assemblies must
be removed to gain access to the
bleeder fittings on the calipers. Also
on Lincoln Continental models the
metering valve release rod must be
pulled outward and held a minimum
of 1/16 inch (Fig. 10) while bleeding
the primary brake system.
10.
If the vehicle contains drum-
type front brakes and the primary
(front) brake system is to be bled, re-
peat steps 4 through 7, starting at the
right front wheel cylinder ending at
the left front wheel cylinder.
11.
When the bleeding operation is
completed, close the bleeder tank
valve and remove the tank hose from
the adapter fitting.
12.
On disc brake equipped ve-
hicles,
be sure that the front brake
pistons are returned to their normal
positions and that the shoe and lining
assemblies are properly seated by dep-
ressing the brake pedal several times
until normal pedal travel is esta-
blished.
13.
Remove the Pressure Bleeder
Adapter Tool. Fill the master cylinder
reservoirs to within 1/4 inch of the
top.
Install the master cylinder cover
and gasket. Be sure the Diaphragm
type gasket is properly positioned in
the master cylinder cover.
14.
Centralize the pressure differen-
tial valve as follows.
METERING VALVE
BLEEDER RETAINER
SEE
VIEW A
RELEASE ROD
FIG. 10—Disc Brake Metering Valve—Lincoln Continental
HI 644-Aprocarmanuals.com
Page 18 of 413
02-01-07
Brakes
02-01-07
CENTRALIZING THE
PRESSURE DIFFERENTIAL
VALVE
After a failure of the primary (front
brake) or secondary (rear brake) sys-
tem has been repaired and bled, the
dual-brake warning light will usually
continue to be illuminated due to the
pressure differential valve remaining in
the off-center position.
To centralize the pressure differen-
tial valve and turn off the warning
light after a repair operation, a pres-
sure differential or unbalance condi-
tion must be created in the opposite
brake system from the one that was
repaired or bled last.
1.
Turn the ignition switch to the
ACC or ON position. Loosen the dif-
ferential valve assembly brake tube
nut at the outlet port on the opposite
side of the brake system that was
wheel balanced, repaired and/or bled
last. Depress the brake pedal slowly to
build line pressure until the pressure
differential valve is moved to a cen-
tralized position and the brake warn-
ing light goes out; then, immediately
tighten the outlet port tube nut.
2.
Check the fluid level in the mas-
ter cylinder reservoirs and fill them to
within 1/4 inch of the top with the
specified brake fluid, if necessary.
3.
Turn the ignition switch to the
OFF position.
4.
Before driving the vehicle, check
the operation of the brakes and be
sure that a firm pedal is obtained.
CLEANING AND INSPECTION
DISC BRAKES
1.
Remove the wheel and tire and
the shoe and lining assemblies as out-
lined in Part 2-2, Section 2.
2.
On all models except Lincoln
Continental, make thickness measure-
ments with a micrometer across the
thinnest section of the shoe and lining.
If the assembly has worn to a thick-
ness of 0.230-inch (shoe and lining to-
gether) or 0.030-inch (lining material
only) at any one of three measuring
locations or if there is more than
0.125 taper from end to end or if lin-
ing shows evidence of brake fluid con-
tamination, replace all (4) shoe and
lining assemblies on both front wheels.
On Lincoln Continental brakes
make three thickness measurements
with a micrometer across the middle
section of the shoe and lining. Take
one reading at each side and one in
the center. If the assembly has worn
to a thickness of 0.231 inch (shoe and
lining together) or 0.066 inch (lining
material only) at any one of the three
measuring locations, replace all (4)
shoe and lining assemblies on both
front wheels.
3.
Check the caliper to spindle at-
taching bolts torque. Torque them to
specification, 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 con-
tact the rotor at a point approximate-
ly 1 inch from the outer edge. Rotate
the rotor and take an indicator read-
ing. If the reading exceeds 0.003 inch
total lateral runout on the indicator,
replace or resurface the disc brake
rotor. The following requirement must
be met when resurfacing disc brake
rotors:
Rotunda Disc Brake Attachment
FRE-2249-2 is the only approved tool
to be used to refinish the disc brake
rotors.
The step-by-step resurfacing
procedure provided with the tool must
be adhered to.
The finished braking surface of the
rotor must be flat and parallel within
0.0007 inch; lateral runout must not
exceed 0.003 inch total indicator
reading, braking surface are to be 80/15
micro inches.
On all models except Lincoln Con-
tinental the minimum limiting dimen-
sion from the inboard bearing cup to
the inboard rotor face and the mini-
mum rotor thickness dimension, must
be observed when removing material
from the rotor braking surfaces. A
ball and gage bar (Rotunda Kit FRE
70160) is to be used when checking
minimum dimensions (Fig. 11).
FALCON-FAIRLANE
MUSTANG-COUGAR
MONTEGO
.046 MAX-**
.119
MAX.
FORD-MERCURY
METEOR - THUNDERBIRD
875
MIN
H1633-A
1.12
MIN.-^
??
— Disc Brake Rotor
Service Limits—All Models Except
Lincoln Continental
On Lincoln Continental models the
minimum limiting dimension (Fig. 12)
from the inboard bearing cup to the
inboard rotor face (dimension B)
and the outboard rotor surface and
the inboard bearing cup (dimension
A),
must be observed when remov-
ing material from the rotor braking
surfaces.
When the runout check is finished
be sure to adjust the bearings as out-
lined in Group 3, in order to prevent
bearing failure.
6. Check the rotor for scoring. Mi-
nor scores can be removed with a
fine emery cloth. If the rotor is ex-
cessively scored, refinish it as out-
lined in step 5 or replace the rotor,
if required.
7.
Visually check the caliper. If the
caliper housing is leaking it should be
replaced. If a seal is leaking the cali-
per must be disassembled and new
.seals installed. If a piston is seazed
in the bore a new caliper housing is
required.
On Lincoln Continental models the
two halves of the caliper assembly
should never be separated. Damage or
failure of one requires replacement of
both as a unit.
Check the brake hoses for signs of
cracking, leaks or abrasion. Replace
them if necessary.
DISC BRAKE SERVICE
PRECAUTIONS
1.
Grease or any other foreign ma-
terial must be kept off the caliper as-
sembly, surfaces of the rotor and ex-
ternal surfaces of the hub during serv-
ice operations. Handling of the rotor
and caliper assemblies should be done
in a way to avoid deformation of the
brake rotor and nicking or scratching
of brake linings.
2.
If a caliper piston is removed for
any reason, the piston seal must be re-
placed.
3.
During removal and installation
of a wheel assembly, exercise care not
to interfere with and damage the cali-procarmanuals.com
Page 22 of 413
02-02-03
Brake System
02-02-03
DESCRIPTION
Disc brakes are available as option-
al equipment for the front wheels on
Ford, Mercury, Meteor, Fairlane,
Montego, Falcon, Mustang and Cou-
gar models and are standard on Thun-
derbird, Continental Mark III, and
Lincoln Continental models. The
dual-master cylinder equipped hydrau-
lic brake system employs single an-
chor, internal expanding and
self-
adjusting drum brake assemblies on
the rear wheels of vehicles with disc
brakes, and on the front and rear
wheels of all others.
A vacuum booster is used with the
power disc brake system.
DUAL MASTER CYLINDER
BRAKE SYSTEM
The dual-master cylinder brake sys-
tem has been incorporated in all mod-
els to provide increased safety. The
system consists of a dual-master cylin-
der (Fig. 1), pressure differential valve
assembly and a switch (Fig. 2). The
switch on the differential valve acti-
vates a dual-brake warning light, lo-
cated on the instrument panel.
DISC BRAKE
The disc brake consists of a venti-
lated rotor and caliper assembly. The
caliper used on all models except Lin-
coln Continental is a single piston
floating caliper (Fig. 3). The caliper
used on Lincoln Continental models is
a four piston fixed caliper (Fig. 4).
A proportioning valve in the rear
hydraulic circuit provides balanced
braking action between front and rear
brakes.
On all models except Lincoln a
pressure impulse valve located at the
primary inlet of the pressure differen-
tial valve prevents brake fluid surge
back to the master cylinder reservoir.
On Lincoln Continental models a
metering valve, in the hydraulic line
between the differential valve and the
front wheel disc brakes, prevents the
front brakes from applying until ap-
proximately 125 psi is obtained in the
system (Fig. 21). This delaying action
is required to prevent the front brakes
from performing all the braking ac-
tion on low speed stops and thereby
increasing the rate of lining wear.
FLOATING CALIPER—
ALL MODELS EXCEPT
LINCOLN CONTINENTAL
The caliper asseml.y is made up of
a floating caliper housing assembly
and an anchor plate. The anchor plate
is bolted to .the wheel spindle arm by
two bolts. The floating caliper is at-
tached to the anchor plate by steel
stabilizers on Ford, Mercury, Meteor,
Thunderbird and Continental Mark
III models and by one stabilizer on
Fairlane, Montego, Falcon, Mustang
and Cougar models. The floating cali-
per slides on two locating pins which
also attach to the stabilizers. The
floating caliper contains the single cyl-
inder and piston assembly. The cylin-
der bore contains a piston with a
molded rubber dust boot to seal the
cylinder bore from contamination
(Fig. 5). A square section rubber pis-
ton seal is positioned in a groove in
the cylinder bore and is used to pro-
vide sealing between the cylinder and
piston (Fig. 7).
The outer brake shoe and lining as-
sembly is longer than the inner assem-
bly, and the shoe and lining
DISC BRAKES
RETURN SPRING
(SECONDARY)
RETAINER
PRIMARY SYSTEM BRAKE
FLUID RESERVOIR
BOOT
PUSH ROD
TUBE SEAT |
(SECONDARY)
BRAKE OUTLET
PORT
RESIDUAL \ ^
CHECK \
VALVE \
SECONDARY PISTON
ASSEMBLY
(PRIMARY)
BRAKE OUTLET
PORT
PRIMARY PISTON
ASSEMBLY
H 1545-A
FIG.
I
—
Dual
Master Cylinder—Typicalprocarmanuals.com
Page 23 of 413
BRAKE WARNING LAMP SWITCH
PISTON
BRAKE WARNING LAMP SWITCH
BRAKE WARNING LAMP SWITCH
PLUNGER IN THE ON POSITION
CONNECTOR
BRAKE WARNING LAMP SWITCH
PLUNGER IN OFF POSITION
VALVE PISTON HAS MOVED
TO LOW PRESSURE AREA.
WARNING LAMP SWITCH
PLUNGER IS DEPRESSED,
LIGHTING THE BRAKE
WARNING LAMP
LOW PRESSURE SIDE
U
VALVE PISTON IS
CENTRALIZED. PRIMARY
AND SECONDARY SYSTEM
PRESSURES ARE EQUALIZED
BRAKE WARNING LAMP
SWITCH PLUNGER IN
OFF POSITION
HIGH PRESSURE SIDE
DRUM BRAKES
TJ
CONNEiCTOR
BRAKE FLUID
BRAKE WARNING LAMP I
SWITCH PLUNGER IN
ON POSITION
REAR BRAKE INLET
CONNECTOR
FRONT BRAKE
INLET
FRONT BRAKE
OUTLET
VALVE PISTON IS CENTRALIZED.
PRIMARY AND SECONDARY SYSTEM
PRESSURES ARE EQUALIZED
OUTLET TO
PROPORTIONING VALVE
DISC BRAKES
\
REAR BRAKE
PROPORTIONING
VALVE IS BYPASSED
VALVE PISTON HAS MOVED TO LOW
PRESSURE AREA. WARNING LAMP SWITCH PLUNGER IS
DEPRESSED, LIGHTING THE BRAKE WARNING LAMP H1634-A
FIG. 2—Pressure Differential Valve and Brake Warning Light Switch
CALIPER ASSEMBLY
BLEEDER
SCREW
EXTERNAL
TRANSFERTU3E
H1567-B
HUB
AND
ROTOR
ASSEMBLY
H 1647-A
FIG. 3—Disc Brake Assembly-
Floating Caliper—All Models
Except Lincoln Continental
FIG. 4—Disc Brake Assembly—
Fixed Caliper—Lincoln
Continental
blies are not interchangable (Fig. 23).
The outboard shoe and lining is fixed
to the floating caliper and is retained
by two pins and spring clips. The shoe
and lining assembly consists of fric-
tion material bonded to a metal plate
called the shoe. It is replaced as a
unit.
FIXED CALIPER
LINCOLN CONTINENTAL
The caliper assembly is bolted di-
rectly to the wheel spindle arm by two
bolts.
The caliper assembly consists of
two caliper housings bolted together
with each half containing two cylinder
bores of 1.938 inch diameter. Each
cylinder bore contains a piston with
an attached molded rubber dust boot
to seal the cylinder bore from contam-
ination (Fig. 6). Square-section rubberprocarmanuals.com