Werkstatthandbuch Book 1 · Seiten 1–100

Volume1&2 ChassisandEngine

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

r IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual doing the work This Shop Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability. There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the individual doing the work. This Manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this Manual must first establish that he compromises neither his personal safety nor

GROUP AND PART INDEX IDENTIFICATION CODES 10-01 VOLUME i CHASSIS I GENERAL WHEEL AND TIRE SERVICE 11-01 WHEEL HUBS AND BEARINGS - Front 11-10 WHEELS AND TIRES- Drop Cente

10-00-1 Identification Codes 10-00-1 GROUP IDENTIFICATION CODES 10 - PART Vehicle Identification 10-01 GENERAL DESCRIPTION OFFICIAL VEHICLE IDENTIFICATION NUMBER The official Vehicle Identification Number VIN Fig. 1 for title and registration purposes is stamped on a metal tab that is fastened to the instrument panel close to the windshield on the driver’s side of the car and is visible from outside. 8S63H1OOOO1 r MID. BY FORD MOTOR GO, IN U.S.A. VEHICLE IDENTIFIcATIoN NuMBERI MFD. BY FORD MOTOR CO.

10-01-2 Car Identification Codes 10-01-2 VEHICLE CERTIFICATION LABEL The Vehicle Certification Label V.C. Label The remaining information on the V.C. Label Fig. 1 is affixed on the left front door lock face consists of the following vehicle identification panel or door pillar. The upper half of the label codes: contains the name of manufacturer, month and The BODY code is two numerals and a letter year of manufacture, Gross Vehicle Weight Rating identifying the body style. GVWR, Gross Axle Weight Rating GAWR, and The COL color code is a number and letterthe certification statement. indicating the exterior paint color code

10-01-3 Car Identification Codes 10-01-3 IDENTIFICATION CODES DISTRICT CODES DISTRICT CODES ASSEMBLY PLANT CODES LINCOLN-MERCURY FORD Code Letter District Code District Code District A Atlanta 00 Special 00 Special B Dakville lCanadal 11 Boston II Bos

10-01-4 Car Identification Codes 10-014 BODY SRIAL AND STYLE CODES Body Body Body Body Sefial Styla Sent Styli V.Stl. Code Coda Body Type Modal Vahith Cod. Code Body Type Model PINTO 10 62B 2-Dr. Sedan Base COUGAR 92 530 4-Dr. Pillar Hardtop Cougar 11 648 3-Dr. Sedan Base 61 650 2-Or. Hardtop Cougar

11-01-1 Wheels and Tires 11-01-1 GROUP WHEELS AND TIRES 11 PARTTITLE PARTPIO. PARTTITLE PARTNO. - Refer to General Wheel and Tire Service 11-01 Wheel Hubs and Bearings - Rear Wheels and Tires - Drop Center Rim 11-02 Rear Axles, Parts 15-02, 15-03, 15-06 or 15-10 Wheel Hubs and Bearings - Front 11-10

11-01-2 General Wheel and Tire Service 11-01-2 Bolt Wheel No. of Circle Car Line Code Color/Style Size Bolts Die. Offset Tire usege Size Pinto/Bobcat GM Yellow-Yellow 13x 5 4 4.25 .62 A1O, A18, 078, BRIB, BAlD -13 Mustang II MM Styled-Steal 13x 5 4 4.25 .62 AiD, A78, BIB, BAJa, BAlD -13 Orange-violet SM Al

11-013 General Wheel and Tire Service 11-01-3 Bolt Wheel No. of Circle Car Lieu Code Color/Style Size Bolt, Die. Offset Tire Ueap Size Cougar Sedans/LTD 112-Door HG Styled-Steel 14x 1 5 4.50 .25 HR7S -14 Spt. Sedan Option lte-Red Ford/Mercury YB Orange-Orange 15 itS 5 5.00 .45 HRIB, JRIS, GRIOt -15 ZN Brown-

11-01-4 General Wheel and Tire Service 11-01-4 CUPPING--UNDERINFLATION AND/OR MECHANICAL IRREGULARITIES SUCH AS CUT-OF-BALANCE CONDITION OF WHEEL ANDIOR TIRE, AND BENT OR DAMAGED WHEEL

11-02-1 Wheels and Tires-Drop-Center Rim 11-02-1 Wheels and Tires- 11-02 Drop Center Rim Applies to All Vehicles SUBJECT PAGE SUBJECT PAGE DESCRIPTION REMOVAL AND INSTALLATION Cont’d. Collapsible Spare Tire 02-1 Removing and Installing Tire 02-2 Front Wheel Assembly 02-1 Wheel and Tire Installation 02-2 Rear Wheel Assembly 02-1 Wheel and Tire Removal 02-2 REMOVAL AND INSTALLATION Hoisting Instructions

11-02-2 Wheels and Tires-Drop.Center Rim 11-02-2 wheel and tire mounts on the same rear axle shaft and the entire assembly is held in the rear axle housing flange studs and is held against the hub and drum or by the bearing retainer plate or disc brake axle adapter rotor by the wheel nuts. The rear wheel bearing is which is bolted to the housing flange or by C-locks which pressed onto the axle shaft just inside the shaft flange, retain the axle shaft in the differential case. REMOVAL AND INSTALLATION HOISTING INSTRUCTIONS WHEEL AND TIRE INSTALLATION Incorrect hoisting can damage steering linkage 1. Clean all dirt from the hub mounting surface. components and front.end suspension struts. 2. Place the wheel on the hub

______ 11-10-1 Wheel Hubs and Bearings-Front 11-10-1 PART Wheel Hubs and Bearings-Front 11-10 Applies to All Models SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS REMOVAL AND INSTALLATION Front Wheel Bearing Adjustment 10-2 Front Wheel Grease Seal and Bearing Replacement and Lubrication 10-2 Hoisting Instructions 10-2 Front Hub and Rotor Assembly 10-4 DESCRIPTION

11-10-2 Wheel Hubs and Bearings-Front 11-10-2 ADJUSTMENTS HOISTING INSTRUCTIONS Refer to Part 11-02 for Hoisting Instructions. FRONT WHEEL BEARING ADJUSTMENT If the wheel is loose on the spindle or does not rotate 6. Loosen the adjusting nut one-half turn, then freely, adiust the front wheel bearings as followst retighten to 10 to 15 in-tb, using a torque wrench. 1. Raise the vehicle until the tire clears the floor, 7. Place the nut lock on the adjusting nut so the 2. Remove the wheel cover. Remove the grease cap castellations on the lock are in line with the cotter from the hub. pin hole in the sp

11-10-3 Wheel Hubs and Bearings-Front 11.104 TGOK-1217.A S ‘ N A Fizea1c F1476.1A FIG. 3 Removing Front Wheel Bearing Cups FIG. 4 Installing Front Wheel Bearing Cups 5. Using Tool 1 175AC remove and discard the grease 13. Install the outer bearing cone, roller assembly, and

11-10-4 Wheel Hubs and Bearings-Front 11-10-4 14. Install the caliper to the anchor plate, as detailed 6. Using a bearing packer, force new grease into the in Group 12. bearing cone and roller assemblies. If a packer is 15. Install the wheel and tire on the hub. not available, work as much grease as possible between the rollers and cages. Grease the cone16. Lower the vehicle and torque the lug nuts to surfaces. specification 70-115 ft-lbs.. Reinstall the wheel cover. 7. Place the inner bearing cone and r

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

12-02-1 Drum Brakes-Single Cylinder, Dual Piston 12-02-1 Drum Brakes - 12"j2 Single Cylinder, Dual Piston Afflilies To All Cars Except Lincoln Versailles and Continental Mark V SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS REMOVAL AND INSTALLATION Cont’d. Brake Shoes 02-2 Brake Drums 02-3 Brake Pedal 02-5 OESCRIPTION Brake Shoes

12-02-2 Drum Brakes-Single Cylinder, Dual Piston 12-02-2 PARKING BRAKE LINK SHOE GUIDE ANCHOR PIN PLATE ANCHOR PIN /SHO. RETRACTING SPRING PARKING BRAKE CABLE AND HOUSING 111843.1B FIG. 2 Self-Adjusting Drum Brake Assembly Pinto, Bobcat and Mustang ADJUSTMENTS BRAKE SHOES After any brake service work, obtain a firm brake pedal before moving the vehicle. Adjusted brakes must not drag; wheels must tur

12-02-3 Drum Brakes-Single Cylinder, Dual Piston 12-024 being careful not to get the lubricant on the on the pedal non-power brakes or 25 lbs. pressure linings. power brakes while backing the vehicle. After 5. Install the drums. Install the drum retaining nuts and each stop, the vehicle must be moved forward. tighten securely. 8. After the brake shoes have been properly adjusted, 6. Install the wheels on the drums and tighten the nuts check the operation of the brakes by making to specification. several stops from varying forward speeds. 7. Complete the adjustment by applying the brakes several times wit

12-02-4 Drum Brakes-Single Cylinder, Dual Piston 12-02-4 the vehicle to the other would cause the brake Figs. 1 and 2. A tang on the parking brake shoes to retract rather than expand each time lever engages the secondary shoe on 9-inch the automatic adjusting mechanism operated. brakes. To prevent installation on the wrong side of 2. Apply a light coating of high temperature the vehicle, the socket end of the adjusting grease COAZ-19553-A or equivalent at the screw is stamped with an R or L Fig. 7. points where the brake shoes contact the backing plate. 3. Position the brake shoes on the backing plate. The

12-02-5 Drum Brakes-Single Cylinder, Dual Piston 12-02-5 as possible and that the end fitting is pointing 3. Tighten the tube fitting nut to specification with toward the shoe guide. Tool 1112-144 Tube Nut Wrench. b.Check the cable end fittings. The cable should 4. Install the links 10 and 11-inch brakes in the ends completely fill or extend slightly beyond the of the wheel cylinder and install the shoes and crmped section of the fittings. If it does not meet adjuster assemblies. this specification, possible damage is indicated 5. Adjust the brakes as described in this Part. Install and the c

12-02-6 Drum Brakes-Single Cylinder, Dual Piston 12-02-6 diameter shown an the drum is exceeded either through interior is wet with brake fluid. Excessive fluid at this wear or refinishing, the drum must be replaced. point indicates leakage past piston cups and a need for wheel cylinder overhaul. NOTE: A slight amount of Check the inside diameter of the brake drum with a fluid is nearly always present and acts as abrake drum micrometer Tool 10-001 0. lubricant for the piston. It is not necessary to remove After a drum is refinished, wipe the refinished surface the brake cylinder from the backing plat

12-02-7 Drum Brakes-Single Cylinder, Dual Piston 12-02-7 SPECIFICATIONS AND SPECIAL TOOLS DRUM BRAKE LINING DIMENSIONS INCHES FORD-MERCURY BRAKE LINING SIZE MODELS POSITION COLOR CODE SIZE FRONT REAR All Ford, Mercury, Station Wagons Primary Black-Black 11 N/A 2.50 x 9.38 and Sedans includes Police Secondary Blue-Blue 11

12-02-8 Drum Brakes-Single Cylinder, Dual Piston 12-02-8 BORE DIAMETERS - BRAKE DRUM, WHEEL CYLINDER AND MASTER CYLINDER Wheel Cylinder Bore Master Cylinder Bore Brake Drum Diameter Diameter Inside Boring Limit With Power Less Power Car Line Models Diameter Max. t32 Front® Rear® Brake Brake Ford, Mercury All 11.030 11.090 N/A 1.000 1.000

12-20-1 Disc Brakes-Sliding Caliper 12-20-1 Disc Brakes-Single Piston- PART 12-20 Sliding Caliper Applies to All Models SUBJECT PAGE SUBJECT PAGE DESCRIPTION REMOVAL AND INSTALLATION Cont’d. All Cars Except Fairmont/Zephyr 20-1 Disc Brake Caliper Assembly - Front 20-4 Fairmont/Zephyr Front Disc Brake 20-2 Disc Brake Caliper Assembly - Rear 20-12 Rear Disc Brakes 20-4 Disc Brake Rotor Splash Shield - Front - . . . 20-12 Rotor -

12-20-2 Disc Brakes-Sliding Caliper 12-20-2 air to the brakes. The wheel provides protection for the must not be interchanged. Two rubber insulators with outboard surface of the rotor. plastic inner sleeves are installed in the caliper attaching holes. The insulators and sleeves prevent metal-to-metal FAIRMONT AND ZEPHYR FRONT DISC contact between the locating pins and the caliper. BRAKE SEE FIG. 3 ANCHOR PLATE CALIPER ASSEMBLY The anchor plate design for Fairmont/Zephyr vehicles is an all new design in that it is an integral part The calip

12-20-3 Disc Brakes-Sliding Caliper 12-20-3 A ASSY. 2BI19 L.H. 2B118 RH. 15 PISTON 2196 DUST BOOT 2207 2B299

12-20-4 Disc Brakes-Sliding Caliper 12-20-4 spindles are right or left hand and not interchangeable The parking brake lever is secured to the operating see Fig. 1 2. shaft by a nylon-patched screw. When the parking brake is applied, the cable rotates the lever and ROTOR AND SPLASH SHIELD operating shaft. The three 3 steel balls, located in The rotor is a cast iron disc design, similar to existing pockets on the opposing heads of the operating shaft designs, which attaches to the combination spindle/ and thrust screw, roll between ramps formed in these anchor plate in the same manner as existing

12-20-5 Disc Brakes-Sliding Caliper 12-20-5 2207 PISTON AND CYLINDER ON THE PISTON AND ADJUSTER GRANADA AND MONARCH CALIPERS ASSY, ‘ 25688 APE SMALLER THAN THOSE IN THE LARGE CAR CALIPERS, PISTON SEAL .28115 - ELEE DSP SCREW CALIPER HOUSING

12-20-6 Disc Brakes-Sliding Caliper 12-20-6 FIG. 7 Removing Front Caliper Assembly-Except Fairmont/Zephyr leakage, excessive wear or damage. Lightly sand 5. Install the outer brake shoe with the lower flange or wire brush any rust or corrosion from the caliper ends against the caliper leg abutments and the and anchor plate sliding surfaces and the inner brake shoe upper flanges over the shoulders on the brake shoe abutment surfaces. Inspect the brake caliper legs Fig. 9. The shoe upper flanges fit shoes for wear. If either lining is worn to within 1/8 tightly against the shoulder machined surfaces. If inch of the shoe surface, both shoe and lining the same brake shoe and lining ass

12-20-7 Disc Brakes-Sliding Caliper 12-20-7 FIG. 9 Installing Front Caliper Assembly-Except Fairmont/Zephyr 7. Pivot the caliper housing upward toward the rotor until the outer edge of the piston dust boot is approximately 1/4 inch from the upper edge of the inboard brake shoe Fig. 9, Step 2. 8. To prevent pinching the dust boot between the piston and the inboard shoe during caliper installation to the rotor and anchor plate, position clean light-weight cardboard between the inboard brake shoe and over the lower half of the piston dust boot Fig. 9, Step 3. 9. Rotate the caliper housing toward the rotor until a slight resistance is felt. 10. Pull the cardboard downward toward the rotor centerline while rotating the

12-20-8 Disc Brakes-Sliding Caliper 12-20-8 18. Install the wheel and tire assembly. Torc1ue the DISC BRAKE SHOE AND LINING-FRONT- wheel lug nuts to 70 to 115 ft-lb. Install the wheel ALL EXCEPT FAIRMONT/ZEPHYR cover. Remove the safety stands and lower the car. 19. Pump the brake pedal until a firm brake pedal Removal application is obtained, then road test the car for 1. Raise the car and install safety stands. Block both proper brake operation. rear wheels if a jack is used. 2. Remove the wheel and tire assembly from the hub. DISC BRAKE CALIPER ASSEMBLY-FRONT-

12-20-9 Disc Brakes-Sliding Caliper 12-20-9 2. Remove the wheel and tire assembly from the hub. secured to the upper suspension arm. Do not Be careful to avoid damage or interference with the remove the anchor plate. Be careful not to caliper splash shield or bleeder screw fitting. stretch or twist the flexible brake hose. 3. Remove the caliper locating pins See Fig. 3. 2. Remove the grease cap from the hub. 4. Lift the caliper assembly from the integral spindle 3. Remove the cotter key, nut lock, and adjusting nut. anchor plate and rotor. Remove the outer shoe from 4. Grasp the hub and rotor assembly and pull it the caliper assembly See Fig. 11. outward far enough to lo

12-20-10 Disc Brakes-Sliding Caliper 122010 OLITEm SHOE INSTALLED TO CALIPER INNER SHOE IDENTIFICATION RH. OUTER SHOE INSTALLATION .08 RAD.

12-20-11 Disc Brakes-Sliding Caliper 12-20-11 CALIPER ASSI’. 28118 RH. 1 REOD. 28119 L.H. 1 REOD. COMBINATION CALIPER LOCATING AND ATTACHING PIN 202964 REOD. GREASE RETAINER 1190 2 REOD. INNER BEARING ASSY

12-20-12 Disc Brakes-Sliding Caliper 12-20-12 nicking, scratching or contamination of the brake DISC BRAKE ROTOR SPLASH SHIELD- linings. FRONT-ALL EXCEPT FAIRMONT/ZEPHYR 3. Remove the grease cap from the hub. Remove the Removal cotter pin, nut lock, adjusting nut, and flat washer from the spindle. Remove the outer bearing cone 1. Remove the caliper and the hub and rotor assembly and roller assembly Fig. 12. as outlined in preceding instructions. It is not 4. Remove the hub and rotor assembly from the necessary to disconnect hydraulic lines. spindle. 2. R

12-20-13 Disc Brakes-Sliding Caliper 12-20-13 THIS DISTANCE SHOULD BRACKET BRAKE HOSE ALWAYS BE SEVERAL L.H. 2A056

12-20-14 Disc Brakes-Sliding Caliper 12-20-14 remove the hollow retaining bolt that connects the hose fitting to the caliper. 4. Disconnect the parking brake cable from the lever Fig. 14.Use care to avoid kinking or cutting the cable or return spring. 5. Remove the retaining screw from the caliper retaining key Fig. 15. 6. Slide the caliper retaining key and support spring from the anchor plate Fig. 15. Use a hammer and a soft metal drift, if necessary. Use care to avoid damaging the key or sliding ways or hitting the parking brake lever. 7. Lift the caliper assembly away from the anchor plate by pushing the caliper downward against the anchor plate and then rotating the upper end out of the anchor plat

12-20-15 Disc Brakes-Sliding Caliper 12-20-15 2. If new shoe and lining assemblies are to be installed, the piston must be screwed back into the caliper bore using Tool T75P-2588-B to provide installation clearance. Remove the rotor and install the caliper, less shoe and lining assemblies, in the anchor plate with the key only. While holding the shaft, rotate the tool handle counterclockwise until the tool is seated firmly against the piston Fig. 16. Now, loosen the handle about 1/4 turn. While holding the handle, rotate the tool shaft clockwise until the piston is fully bottomed in its bore the piston will continue to turn even after it becomes bottomed. When there is no further inward movement o

12-20-16 Disc Brakes-Sliding Caliper 12-20-16 tube. Connect the brake tube to the hose and Installation torque the fitting nut to 10-15 ft-lbs. 1. If the rotor is being replaced, remove the protective 14. Connect the parking brake cable to the lever on the coating from the new rotor with carburetor caliper. degreaser. 15. Bleed the brake system. Then, with the engine 2. Properly identify right and left rotors before running, pump the service brake lightly about 40 installation. RIGHT and LEFT are cast into the inner times. Allow at least one 1 second between pedal surfaces of the rotor hat-sections. Install the right

12-20-17 Disc Brakes-Sliding Caliper 12-20-17 Ford, Mercury and Granada-Monarch- PRESSURE DIFFERENTIAL, METERING, AND Versailles car lines. On Continental Mark V, PROPORTIONING VALVES the left and right shields are unique and cannot be interchanged. Refer to Port 12-01 far Removal and Installation of Pressure Differential, Metering, and Proportioning Valves. DUAL MASTER CYLINDER BRAKE BOOSTER Refer to Part 12-01 for Removal, Installation and Refer to Part 12-50 or 12-51 for Removal and Overhaul of Dual Master Cylinder. Installation of Broke Booster

12-20-18 Disc Brakes-Sliding Caliper 12-20-18 6. Remove the piston/adjuster assembly by installing CAUTION: Use care not to damage the Tool T7SP-2588-A through the bock of the caliper polished surface In the thrust screw bore and housing and pushing the piston out. do not press or attempt to move the adjuster can. It is a press fit in the piston. 7. Remove and discard the piston seal, boot, thrust screw 0-ring seal, end retainer, 0-ring seal, and the end retainer l

12-20-19 Disc Brakes-Sliding Caliper 12-20-19 remain stationary, causing the nut to rotate. When 11. Coat the 0-ring seal and lip seal with a light film releasing the two parts, the nut must remain of silicone grease and install the end retainer in the stationary and the drive ring must rotate. If the caliper. Hold the operating shaft firmly seated action of the components does not follow this against the internal mechanism while installing the pattern, replace the piston/adjuster assembly. end retainer to prevent mislocation of the balls. If 5. Inspect ball pockets, threads, grooves, and bearing the lip seal is pushed out of position, re-seat the surfaces of the thrust screw and opera

12-20-20 Disc Brakes-Sliding Caliper 12-20-20 TOOL-T75P-2588.B/ FIG. 23 Bottoming Piston ROTOR REFINISHING All Models Equipped With Disc Brakes Refer to Brake Diagnostic Procedures in Port 12-01 for conditions necessitating rotor refinishing. Disc Brake Lathe 54-0020 or equivalent should Hi961.1 C be used to refinish disc brake rotors. FIG. 25 Gauging Front Rotor Inner Braking Front Rotor Surface Mustang II, Pinto, Bobcat, Rotor minimum thickness must not be less than Fairmont and Zephyr Shown shown in Fig. 24, nor less than the nu

12-20-21 Disc Brakes-Sliding Caliper 12-20-21 ball measurement. Rotor minimum thickness is also shown on *ach rotor. MICPOMETEP BASE LINE SETTING 0430’ 6. Position the rotor in the lathe arbor. Never use a lathe that cuts only one face of the rotor at a time; it must be a simultaneous straddle cut. Install a dial indicator to read rotor lateral run-out near the center of the rotor face. If run-out is 0.002 or below, proceed to machine rotor. If run-out is over 0.002, loosen rotor on the arbor and rotate the rotor 90 degrees. Re.read the run-out and if it is below 0.002, proceed to machine the rotor. If run-out is still over 0.002, again loosen the rotor an

12-20-22 Disc Brakes-Sliding Caliper 12-20-22 and subtract the minimum allowable thkkness cast 6. Set the cutting tool to just contact the high spats into the rotor, Total material removal combination on the rotor, then adjust the cutting tool to the of both sides must not exceed this amount. If the minimum depth required to clean up the rotor face. rotor thickness is less than the minimum the rotor If runout exceeds 0004 inch after resurfacing, must be replaced, regardless of the gauge bar and replace the rotor. thickness gauge measurement. Do not exceed either the allowable stock removal Position the rotor in the lathe arbor. Determine the from the inner braking

12-20-23 Disc Brakes-Sliding Caliper 12-20-23 REAR DISC BRAKE DIMENSIONS AND SPECIAL SERVICE TOOLS Component Mercury and Ford Lincoln and Mark V Granada, Monarch and Versailles Lining Material Riveted Riveted Riveted Lining Size 6.02 x 1.90 6.02 1.90 6.02 a 1.90 Inner & Outer Inner & Outer Inner & Outer Lining Wear Limit From I/B

12-50-1 Vacuum Brake Booster-Single Diaphragm, Dash Mounted 12-50-1 Vacuum Brake Booster- ‘ 12-50 Dash Mounted Applies to All Car Lines SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS DIAGNOSIS AND TESTING Brake Booster to Master Cylinder Vacuum Power Brake Function Test 50-2 REMOVAL AND INSTALLATION Push Rod 50-1 Brake Booster Vacuum 50-2 OESCRIPTI ON 50-1

12-50-2 Vacuum Brake Booster-Single Diaphragm, Dash Mounted 12-50-2 3. Install the master cylinder on the power unit and alternate tightening the retaining nuts gradually to the torque specified in Part 12-01 - 4. With the engine running and the master cylinder ADJUSTPROVIDEPUSHA SLIGHTROD SCREWPRESSURETO reservoir cover removed, observe the fluid surface AGAINSTAPPROXIMATELYTHE GAUGELBS. in the reservoirs when the brake pedal is applied rapidly. Some fluid movement should occur in the forward reservoir. If fluid surface movement did not occur, the push rod is adjusted too long and the procedure must be repeated to prevent eventual brake drag. Fairmont/Zephyr Vehicles Fairmont/Zephyr vehicles have the vacuum booster to master cylinder pu

12-50-3 Vacuum Brake Booster-Single Diaphragm, Dash Mounted 12-50-3 Installation Same for all above vehicles except as accelerator cable to carburetor. Position vacuum noted solenoid on fender apron and install screw. Install Place booster in position on dash panel with check vacuum hose on solenoid. Install air cleaner on 4- valve in upper right side. cylinder and 6.cylinder engines. 2. Working inside vehicle, install inner nylon washer, b.Mustang 114-cylinder engines only booster push rod, and bushings on brake pedal pin. Place heater outlet tube in position on engine and Secure booster to dash panel with self-locking nuts install tube en

12-50-4 Vacuum Brake Booster-Single Diaphragm, Dash Mounted 12-50-4 4. Remove two 2 nuts attaching master cylinder to pin. Install stoplight switch wiring connector on brake booster assembly and remove master stoplight switch. cylinder. 3. Connect the manifold vacuum hose to the booster 5. Working inside the vehicle below the instrument using hose clamp. panel, remove the stoplight switch wiring connector 4. Position master cylinder assembly over booster push from the switch. Remove the hairpin retainer and rod and onto two 2 studs on booster assembly. outer nylon washe

12-50-5 Vacuum Brake Booster-Single Diaphragm, Dash Mounted 12-50-5 a.LTD II and Cougar Cars equipped with speed 2. Working inside vehicle, install inner nylon washer, control only. booster push rod, and bushing on brake pedal pin. Working in engine compartment, remove left cowl Secure booster to dash panel with self-locking nuts screen. Remove three 3 nuts that retain speed and torque to 1 3-25 ft-lbs. Position stoplight switch control servo mounting bracket to dash panel and so that it straddles booster push rod with switch slot move servo away from working area. toward pedal blade and hale just clearing pin. Slide 2. Working in engine compartment remove the master s

12-51-1 Hydro-Boost Brake Booster 12-51-1 PART Hydro-Boost Brake Booster 12-51 Applies to Ford, Mercury, Lincoln Continental, Continental Mark V. Granada, Monarch and Versailles SUBJECT PAGE SUBJECT PAGE DIAGNOSIS AND TESTING OPERATION Cont’d. - Refer to Part 12-01 Braking Position 51-3 GENERAL INFORMATION 51-1 Reserve System 51-3 OPERATION - REMOVAL AND INSTALLATION 51-5 Released Position - No Braking 51-3

57039-52 PEDAL SUPPORT 56350-52 563 20-52 380699-Slob 2 REO0

12-51-3 Hydro-Boost Brake Booster 12-51-3 OPERATION to the steering gear. Even under extremes of braking, the fluid flow to the steering gear is fully sufficient for RELEASED POSITION-NO BRAKING REFER steering the car. TO FIG. 2 RESERVE SYSTEM When the brake pedal is in released position no The reserve braking system consists of a chargingbraking, the spool valve return spring holds the spool valve, an accumulator valve and a compressed gasvalve open. In the open position, the spool valve

l4 .1. COMPRESSED GAS ACCUMULATOR BALL CHECK ACCUMULATOR VAL’JE PUMP PRES7DJRE

12-51-5 Hydro-Boost Brake Booster 12-51-5 DIAGNOSIS AND TESTING Diagnosis and testing procedures far the Hydra- Boost system are covered in General Hydraulic Brake Service, Part 12-01. REMOVAL AND INSTALLATION REFER TO FIG. 3 OR 4 The hydro-boast is serviced as an assembly in the dash panel. Loosely install the hydroonly. If the cause of the complaint is determined boost to dash panel attaching lock nuts Fig. 1.to exist in the booster, the unit should be replaced. Before removing the hydro-boost, dis 2. Working from inside the vehicle below the charge the accumulator by making several brake instrument

12-51-6 Hydro-Boost Brake Booster 12-514 PRESSURE PORT MASTER STEERING GEAR RETURN TO PUMP 12260 FIG. 3 Hydro-Boost Assembly-Ford, Mercury, Lincoln Continental, Continental Mark V RETURN TO PUMP RESERVOIR PRESSURE PORT - TIGHTEN HOSE FITTING MASTER WARNING: CLEAN

12-70-1 Parking Brake-Cable Actuated, Rear Wheels 12-70-1 Parking Brake-Cable Actuated- 12-70 Rear Wheels Applies Ta All Cars SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS REMOVAL AND INSTALLATION Parking Brake Linkage Adjustment 704 Parking Brake Control Assembly 70-4 Parking Brake Equalizer to DESCRIPTION Control Cable 70-17 Control Assemblies 70-1 Parking Brake Equalizer to

1-2-70-2 Parking Brake-Cable Actuated, Rear Wheels 12-70-2 Hoses connect the power unit and the engine On the manually-released type, a T-handle extends manifold to a vacuum release valve on the back-up light from under the left side of the instrument panel. Pulling switch. this handle releases the foot applied parking brake. .-

12-704 Parking Brake-Cable Actuated, Rear Wheels 12-70-3 112577-IA H2 57 0-lA FIG. 6 Parking Brake Control Assembly- FIG. 7 Parking Brake Control Assembly- Vacuum Release-Granada, Monarch, Vacuum Release-Lincoln Continental Versailles, LTD II, Cougar, Thunderbird and Mark V DIAGNOSIS AND TESTING VACUUM TESTS-VACUUM RELEASE 1. Start the engine and run it at idle speed. With the PARKING BRAKES transmission shift control in neutral, depress the parking brake pedal to apply the

12-70-4 Parking Brake-Cable Actuated, Rear Wheels 12-70-4 ADJUSTMENTS PARKING BRAKE LINKAGE ADJUSTMENT 3. Tighten the adjuster nut until the levers on the calipers just begin to move. Loosen the nut justRear Drum Brakes enough to obtain full return to the off position. If 1. Make sure that the parking brake is fully released. brake cables are replaced in any system having a 2. Place the transmission in neutral. Raise the vehicle foot-operated control assembly, stroke the parking on an axle-type hoist. brake control with approximately 100 lb. pedal

2A604 ASSY. REF PRONGS MUST RE SECURELY BEND END OF EXISTING CLIP FLOOR PANEL REF. LOCKED IN AS SHOWN 2 PLACES WITH 384676-52 3775-S 100 2 REDO NUT ‘A" 1016 Fl-LB 2780 ASSY XISTINGBRAOKET2 PLACES REF rYPICAL 2 PLACES MARKEO *