DEMO - 1965 Ford and Mercury Shop Manual

FORD
and
MERCURY
SHOP M
Copyright © 2010, Forel Publishing Company, LLC, Woodbridge, Virginia
All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoever
without written permission of Forel Publishing Company, LLC. For information write to Forel
Publishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192
1965 Ford and Mercury Shop Manual
EAN: 978-1-60371-060-2
ISBN: 1-60371-060-4
Forel Publishing Company, LLC
3999 Peregrine Ridge Ct.
Woodbridge, VA 22192
Email address: webmaster@ForelPublishing.com
Website: http://www.ForelPublishing.com
This publication contains material that is reproduced and distributed under a license from Ford
Motor Company. No further reproduction or distribution of the Ford Motor Company material is
allowed without the express written permission of Ford Motor Company.
Note from the Editor
This product was created from the original Ford Motor Company’s publication. Every effort has
been made to use the original scanned images, however, due to the condition of the material;
some pages have been modified to remove imperfections.
Disclaimer
Although every effort was made to ensure the accuracy of this book, no representations or
warranties of any kind are made concerning the accuracy, completeness or suitability of the
information, either expressed or implied. As a result, the information contained within this book
should be used as general information only. The author and Forel Publishing Company, LLC
shall have neither liability nor responsibility to any person or entity with respect to any loss or
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this book. Further, the publisher and author are not engaged in rendering legal or other
professional services. If legal, mechanical, electrical, or other expert assistance is required, the
services of a competent professional should be sought.
1965
FOREWORD
This shop
information for the
plete
and
manual provides the
Mercury
performed,
performed
proper
grouped
such
adjustments
as
according to the type of
diagnosis
and
repairs,
and
testing,
opposite
frequently
in-vehicle adjustments,
recommended
special
tools
page
for important
vehicle
identifica
data.
The descriptions
and
specifications
in this
effect at the time this manual was approved
Ford Motor
Company
at
or change specifications or
any time,
and
work
included.
Refer to the
tion
com
servicing of the 1965 Ford
overhaul, etc. Specifications and
are
with
cars
The information is
being
Service Technician
without
incurring
reserves the right to
manual
for
printing.
discontinue
design,
were
in
The
models
without notice
obligation.
SERVICE DEPARTMENT
FORD MOTOR COMPANY
11
GROUP
VEHICLE
IDENTIFICATION
EXTERIOR PAINT COLOR
(WHITE)
\
BODY STYLE
DATE CODE
AXLE RATIO CODE
(26TH DAY AUGUST)
(3.00:1 AXLE RATIO)
\
\
INTERIOR TRIM
(GREEN VINYL)
(CUSTOM 500 2-DOOR SEDANM
M/
62B
03
TRANSMISSION CODE
(DUAL RANGE AUTOMATIC
I
DETROIT DISTRICT
BODY// COLOR,} TRIMJ> DATE,//
TRANSMISSION
(C-4))
1 AXLE ,'/TRANS
DSO)
26H
1
N
33
^6
VEHICLE WARRANTY NUMBER
N PT F\\R TITlE
II
II
iJregi:
If
JratM&n
THl| VEHCLEHS
AND
F<
MANUFACTURED UNDER UNITED STATES
bREICttN
II
if
OIA^
PURPOSES
PATEfWS AND PATENT APPLICATIONS
PROniWr
np
MODEL YEAR (1965
(
/Vff^r/lSi)
MOTOR COMPANY
CONSECUTIVE UNIT NUMBER
ASSEMBLY PLANT
ENGINE CODE (8 CYL. 289 CID ENGINE)
IN1319-C
(WArNE)
BODY SERIAL CODE (2-DOOR SEDAN)
FIG. 1-Ford
/
(DUAL RANGE AUTOMATIC)
INTERIOR TRIM
(RED VINYL)
(WHITE)
\
DEJP^l
AXLE RATIO CODE
DISTRICT
\
196!
MODEL YEAR
TRANSMISSION CODE
DATE CODE (26TH DAY AUGUST)
EXTERIOR PAINT COLOR
/
.
(3.50-1 AXLE
(WAYNI
RATIO)
Nil
:
ENGINE
Ol
ASSEMI
1
N1268-C
(2-\
EDAN
MONTEREY 4-Di
N1267-D
Figures 1
located
The
and
2
on
the
illustrate
rear
the Ford
(lock) lace
and
of
Mercury Warranty
poses is
Vehicle Identification Number for title
stamped on a tab attached to the top right
panel
in
the
engine compartment
Vehicle Warranty Number
or registration purposes.
which
Plates. The plate
the left front door.
official
the dash
(Figs. 3
appears on
FIG.
4-Mercury Vehicle
Identification Number Location
FIG. 2 -Mercury Warranty Plate
is
FIG. 3-Ford Vehicle Identification
Number Location
Plate
Warranty
BODY STYLE
(MONTEREY 4-DOOR SEDAN)
M1090-D
the
and
side
and
registration
(weld
4). Do
Warranty
pur
flange)
not
plate
of
use the
for title
VEHICLE DATA
data appears in a line across the top of the warranty plate
2). The first two letters and a number identify the Body Style.
The following one or two letters identify the Exterior Paint Color. The next
code consisting of two numbers, or a letter and a number, identifies the
Interior Trim. The Date Code showing the date the car was manufactured,
The
vehicle
(Figs. 1
and
VEHICLE IDENTIFICATION
1-2
follows the Trim Code and consists of two numbers and a letter. The next
code gives the district in which the car was ordered and consists of two
numbers. The next to the last code is the Axle Ratio Code and is designated
by a number for a conventional axle or a letter for an Equa-Lock axle. The
last code in the vehicle data is the Transmission Code and consists of one
number. The charts that follow, list in detail the various vehicle data codes.
FORD
(Cont.)
Galaxie 500 XL
68
69
Fastback*
63C
76B
2-Door
2-Door
57F
63F
4-Door Fastback
2-Door Fastback
71B
71C
4-Door 6 Passenger
4-Door 9 Passenger
71E
71A
4-Door 6 Passenger
4-Door 9 Passenger
Convertible*
Galaxie 500 Lt'd.
VEHICLE WARRANTY NUMBER
warranty number is the second line of numbers and letters
the Warranty Plate (Figs. 1 and 2). The first number indicates
year. The letter following the model year indicates the assembly
plant at which the car was manufactured. The next two numbers designate
the Body Serial Code. The letter following the Body Serial Code designates
the Engine Code. The remaining numbers indicate the Consecutive Unit
Number. The charts that follow, list the various Vehicle Warranty Number
The
vehicle
appearing
the model
60.
67
on
codes.
Station Wagons
72
74
Country Squire
76
78
BODY SERIAL AND STYLE CODES
?Bucket Seats
The two-digit numeral which follows the assembly plant code identifies the
body series. This two-digit number is used in conjunction 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.
EXTERIOR PAINT COLOR CODES
A single letter code designates a solid body color and two letters denote a
the first letter, the lower color and the second letter the upper color.
two-tone
MERCURY
Body
Body
Serial
Code
Style
Code
Body Type
Monterey
42
43
44
45
47
48
45
47
...
50A
....62A
...
...
...
.
54A
76A
63A
...57A
...
76G
63G
.
,
4-Door
2-Door
4-Door
2-Door
2-Door
4-Door
2-Door
2-Door
Sedanf
Sedan
Sedan
Convertible
H/T Fastback
H/T Fastback
...
...
50B
63B
57B
H/T
4-Door Sedan t
2-Door H/T Fastback
4-Door H/T Fastback
...50F
...76F
76C
63F
.
.
...63C
i
4-Door
;
2-Door
;
2-Door
;
2-Door
;
2-Door
Sedan t
Convertible
Convertible*
H/T Fastback
H/T Fastback*
Color
1724-A
Black
C
1736-A
Med. Ivy Gold Met.
D
1625-A
Med. Turq. Met.
F
1226-A.
H
1544-A
.
.
Med. Ivy Gold Met.
.
Dk. Blue Met.
1737-A
Lt. Beige Met.
Red
...1515-A
Fastback*
Parklane
62
65
65
67
67..
A
Convertible*
Montclair
52
57
58
M-30-J/
*M-32-J#
Code
1621-A
Med. Gray Met.
1619-A
White
1732-A
Lt. Peacock
p
1738-A
R
1879-A
Palomino Met.
Dk. Ivy Green Met.
T
1631-A
Lt. Beige
v
1729-A
Yellow
x-
1632-A
Y
1269-A...
Maroon Met.
Med. Blue Met.
Dk. Turq. Met.
5
1731-A
*M-32-J Acrylic Alternate with M-30-J.
Commuter
72
72
Colony
...71B
71C
i
4-Door 6 Passenger Station Wagon
4-Door 9 Passenger Station Wagon
Park
76
76
...
71A
71E
...
i4-Door 6 Passenger Station Wagon
t4-Door 9 Passenger Station
Wagon
INTERIOR TRIM CODES
Code
Trim Schemes
03
04
Green Vinyl
Beige Vinyl
Blue and Lt. Blue Met. Fabric & Vinyl
Red Fabric & Vinyl
12.
15
16
...
17
FORD
Ford Custom
53
54
..62E
.
54E
2-Door Sedan
Sedan
.4-Door
Ford Custom 500
52
51
54B
.
..62B
4-Door Sedan
2-Door Sedan
Galaxie 500
62
64...
66....
65
..54A
Sedan
4-Door Fastback
2-Door Fastback
.4-Door
.
57R
63B
76A.
2-Door Convertible
19
D6
22..
25
26
29
32
33
35
36
37.
38
39
E2
E3
.
Black Fabric & Vinyl
Turquoise and Lt. Turq. Met. Fabric & Vinyl
Palomino and Med. Palomino Fabric & Vinyl
White Pearl (W/Black) Vinyl
Lt. Blue Met. Vinyl
Red Vinyl
Black Vinyl
Med. Palomino Vinyl
Blue and Blue Met. Vinyl
Burgundy Vinyl
Red Vinyl
Black Vinyl
Turquoise
Ivy Gold
and
and
Turq. Met. Vinyl
Ivy Gold Vinyl
Med. Palomino Vinyl
Lt.
Palomino and
White Pearl (W/Blue) Vinyl
White Pearl (W/Burgundy) Vinyl
1-3
VEHICLE IDENTIFICATION
INTERIOR TRIM CODES (Cont.)
Code
Trim Schemes
E5
E6
E7
E8
E9
42
45
46
47
48
49
52
55
56
57
58
59
F6
62
of
.
.
.
...
'
,
model production
Year
to
the
show
year code
letters
day
are
Second
Model
Year
January
February
A
N
B
P
Q
March
C
April
D
R
May
E
S
June
F
T
July
G
U
August
H
V
September
J
W
October
K
X
November
L
Y
December
M
Z
Domestic Special Orders, Foreign Special Orders, Limited Production Options
Pre-Approved Special Orders have the complete order number recorded
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 regular production, only
the District code number will appear.
FORD
Code
11
12
Code
District
Boston
45
Davenport
Buffalo
51
Denver
13.....
New York
52
Des Moines
14
Pittsburgh
53
15
Newark
54
Kansas City
Omaha
St. Louis
21
Atlanta
55
22
Charlotte
61
Dallas
23
Philadelphia
62
Houston
24
Jacksonville
63
Memphis
25
Richmond
64
New Orleans
26
Washington
65
31
Cincinnati
71
Oklahoma City
Los Angeles
32
Cleveland
72
San Jose
33
Detroit
73
34
Indianapolis
74
35
Lansing
81
Salt Lake City
Seattle
Ford of Canada
36
Louisville
83
Government
41
Chicago
84
Home Office Reserve
American Red Cross
42
Fargo
85
43
Rockford
89
44
Twin Cities
90
Transportation Services
Export
District
MERCURY
Code
(Ford)
District
District
Code
11
Boston
34
Detroit
15
New York
41
16
Philadelphia
42
Chicago
St. Louis
17
Washington
51
Denver
21
Atlanta
52
Los Angeles
Oakland
Seattle
22
Dallas
53
Burgundy Leather
23
Jacksonville
54
Med. Palomino Leather
Red Vinyl
26
Memphis
81
31
Buffalo
84
32
Cincinnati
33
Cleveland
Palomino Vinyl
Black Vinyl
Palomino Vinyl
a numeral
and
(Ford)
Red Vinyl
Black Vinyl (Mercury), Fabric and Vinyl (Ford)
Turquoise Fabric & Vinyl
Med. Palomino Vinyl (Mercury). Fabric & Vinyl
Palomino Fabric & Vinyl
Palomino with Headrest Fabric & Vinyl
Burgundy Leather
Med. Palomino Leather
by
The second
exceeds 12 months.
DISTRICT CODES (DSO)
Lt. Blue Met. Vinyl
Red Vinyl
Black Vinyl
Turquoise Vinyl
Med. Palomino Vinyl
Lt. Blue Met. Vinyl (Mercury), Fabric & Vinyl
Burgundy Fabric & Vinyl
if the
month are preceded
car was completed.
Month
Black Vinyl
Black with Headrest Vinyl
Turquoise Vinyl
Turquoise with Headrest Vinyl
Lt. Ivy Gold D/L Vinyl
Ivy Gold with Headrest Vinyl
Med. Palomino Vinyl
Med. Palomino with Headrest Vinyl
White Pearl (W/Black) Vinyl
78
K8
79
K9
M6
used
the
First
White Pearl (W/Ivy Gold) Vinyl
White Pearl (W/Ivy Gold) with Headrest Vinyl
White Pearl (W/Palomino) Vinyl
White Pearl (W/Palomino) with Headrest Vinyl
Med. Blue Met. Vinyl
Blue with Headrest Vinyl
Red Vinyl
Red with Headrest Vinyl
f
letters for the
month when
Model
.White
.
code
the
to be
Lt. Ivy Gold Vinyl
Med. Palomino Vinyl
White Pearl (W/Blue) Vinyl
Pearl (W/Blue) with Headrest Vinyl
White Pearl (W/Burgundy) with Headrest Vinyl
White Pearl (W/Burgundy) with Headrest Vinyl
White Pearl (W/Red) Vinyl
White Pearl (W/Red) with Headrest Vinyl
White Pearl (W/Black) Vinyl
White Pearl (W/Black) with Headrest Vinyl
White Pearl (W/Turq.) Vinyl
White Pearl (W/Turq.) with Headrest Vinyl
K7
Y5
Y9
Z6
29
The
White Pearl (W/Red) Vinyl
White Pearl (W/Black) Vinyl
White Pearl (W/Turq.) Vinyl
White Pearl (W/Ivy Gold) Vinyl
White Pearl (W/Palomino) Vinyl
Med. Blue Met. Vinyl
Red Vinyl
Black Vinyl
Turquoise Vinyl
Lt. Ivy Gold D/L Vinyl
Med. Palomino Vinyl
Blue and Blue Met. Fabric & Vinyl
Red Fabric & Vinyl
Black Fabric & Vinyl
Turquoise and Turq. Met. Fabric & Vinyl
Ivy Gold Fabric & Vinyl
Palomino and Med. Palomino Fabric & Vinyl
White (W/Black) Vinyl
Blue Met. and Lt. Blue Met. Vinyl
Red Vinyl
Black Vinyl
Med. Turq. and Lt. Turq. Vinyl
65
66
67
68
69
G2
L2
G3
L3
G5
L5
G6
L6
G7
L7
G8
L8
G9
L9
72
K2
75
K5.
76
K6
77
82
85
86
87
89
92
93
95
96
97
99
A9.
P9
B3
B9
C3
C9
DATE CODES
90-99
Ford of Canada
Home Office Reserve
Export
VEHICLE IDENTIFICATION
14
A number designates
Lock axle.
a conventional axle, while a
3.00:1
3.25:1
3.50:1
3 89:1
1
4
5
8
9
letter designates
an Equa-
Type
Code
3-Speed Manual-Shift
Overdrive
Cruise-O-Matic (Ford) Multi-Drive (Mercury)
4-Speed Manual-Shift
C-4 Automatic Dual Range
1
2
Ratio
Code
CODES
TRANSMISSION
AXLE RATIO CODES
4.11:1
Ratio
Code
3.00:1
3.25:1
3.50:1
3.89:1
4.11:1
A
E
F
H
1
4
5
6
,
ENGINE CODES
Engine
Code
MODEL YEAR CODE
The
numeral
M
P
R
V
X
Y
5 designates 1965.
ASSEMBLY PLANT CODES
Code
Assembly
Letter
Plant
A
D
E
F
G
H
J
K
L
Cylinder 289 Cu. In. (4V Prem.)
Cylinder 390 Cu. In. (2V Spec.)
Cylinder 427 Cu. In. (4V OH Cam)
Cylinder 427 Cu. In. (8V OH Cam)
Cylinder 390 Cu. In. (4V Spec.)
Cylinder 427 Cu. In. (8V Hi Perf.)
Cylinder 240 Cu. In. (IV)
Cyl. 352 Cu. In. (4V)
Cylinder 390 Cu. In. (2V)
Cylinder 390 Cu. In. (4V)
Cyl. *240 Cu. In. (IV)
Cylinder *289 Cu. In. (4V)
8 Cylinder *390 Cu. In. (4V)
8
8
8
8
8
8
6
8
8
8
6
8
C
H
L
Atlanta
Dallas
Mahwah
Dearborn
Chicago
Lorain
Los Angeles
Kansas City
Michigan Truck
Code
Letter
5
Plant
N
P
R
S
T
U
W
Y
Z
Z
Assembly
...
Norfolk
Twin Cities
San Jose
Pilot Plant
Metuchen
Louisville
Wayne
Wixom
St. Louis
3
9
*Low Compression.
CONSECUTIVE UNIT NUMBER
Each assembly plant,
number
car
built.
with each model
100001 (Ford)
or
year,
500001 (Mercury)
begins
and
with consecutive unit
continues
on
for
each
PART
2-1
GENERAL BRAKE SERVICE
PAGE
.
2-2
PART
PART
2-1
.
.2-6
Diagnosis
PRELIMINARY
Repairs
and
AND
TESTS
level
in
to
times
several
in the
all
exhaust
Then, depress
system.
.
open
the
brake
screw
long
enough
drops
of
the
the pedal
hold it in the
and
Start the
position.
heavy-duty SAE 70R3
Inspection
.2-5
applied
If the
engine.
vac
bleeder
cylinder
to let
out
brake fluid. This
FoMoCo
add
and
cylinder,
and
TESTING
pedal
fluid
Cleaning
2-3
vacuum
the
3
2-1
Testing
and
Page
Section
Page
DIAGNOSIS
if
.2-24
GENERAL BRAKE SERVICE
2 Common Adjustments
master
PAGE
SPECIFICATIONS
.2-1
Section
1. Check
2-3
PAGE
BRAKE SYSTEM
1
PART
operation will release
a
few
bleeding
brakes, but
the
fluid
brake
is operating, the
system
uum
pedal
it
will
not
the
correct
cause
the
of
required.
tend
will
2. With
brakes,
power
down
the
If
the
and
the
pedal
between
halfway
position
for
pedal
while
go
or
the
adjustment
floor,
and
the
for
the
and
binding
lation.
Follow
scribed
under
adjuster
or
the
plied
the
compo
improper instal
de
procedure
"Brake Shoe Adjust
plied
hydraulic
Make
several
reverse
uniform
brake
adjustment
at
all
wheels.
3. On
with
the
stop the
ing
with
power
transmission
engine
and
in
brakes.
this
all
Depress the
the
ap
the
pressure,
leaking.
is
to
air
Also,
or
service
brake
4. Should
locked
and
the
of
ear
the
must
brakes
at a speed
25-30
istence
of
trouble
the
listed in Table 1,
those resolved
of
brake
tests and
with
in
symptoms
the
For
eliminate
listed in Table 1. To
feels
system
and
check
for
be
moved.
the
lightly
or
at
causes
each
check
which
surge,
of
check
apply
approximately
are
for
the
50
mph.
For booster
tion
removal
procedures,
Section
sembly
brakes
encountered,
chatter
brakes
exception
the preliminary
chatter.
also
lines
be
to check for the ex
mph
and
insufficient fluid.
one
the
tested
safely stop
for
See Section 2, "Hydraulic
Bleeding".
S\stem
the
Apply
will
symptoms
neutral,
park
the car.
road
the
pedal movement
from
be
should
Check
and connections
the hydraulic
bleed
remove
car
if the brakes
only
brake
spongy,
leaks
apply the
brake. Depress the
under
The
of
exhaust
leaks.
cvlinder.
cars
not
the pedal gradually
system
tubing hoses,
is felt,
is
TEST
ROAD
Guide'1
hold it in
If
If the brake
stops
off,
system.
trouble.
re
procedures
Diagnosis
and
pedal
position.
system
the
shut
engine
falls away
all
booster
in the
vacuum
action
no
be
in the ap
pedal
Follow
"Booster
the
With the
in Part 2-2, Section 2.
to ensure
vacuum
under
away
pressure will
If
position.
functioning.
in
less
hold the
to
quired
fall
to
pressure and
brake
adjusters.
check adjuster operation, check
shoes
nents
than
system
brake
the
will
still.
the brake
automatic
To
it
running
the
push
as
more
released
check
in
standing
travels
the
far
as
is
engine
vacuum
enough
car
the
foot
3. For
refer
and
to
Section 4. For cleaning
tion refer
Part
disassembly
procedures, refer
installa
and
to Part
and
2-2,
as
2-2,
inspec
to Part 2-1, Section 3.
GROUP 2
2-2
TABLE 1
-Brake
Trouble Symptoms
and
-BRAKES
Possible Causes
Trouble Symptoms
CD
oo
cd
>
*o
bo
OO
Possible Causes
of
Trouble Symptoms
00
oo
cd
cd
u
u
Q
CD
00
cd
CD
"O
0)
cd
u
PQ
Mechanical Resistance
at
Pedal
or
Shoes
Brake Line Restricted
Leaks
X
Oh
o
U
cd
C
O
<
X
X
X
X
X
Insufficient Fluid
or
Distorted
or
or
Worn Wheel
Bearing
o
Oh
oo
Oil
or
Grease
c
o
a
00
Ui
CD
cd
c
u
o
o
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Tire Tread Worn
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PART 2-1
BRAKE
BOOSTER
TROUBLE
DIAGNOSIS GUIDE
If the preliminary tests
the booster
is inoperative
the
causes
nating
listed in table
by
caused
INOPERATIVE-
HARD PEDAL
nect
the
the
vacuum
If the
elimi-
booster,
manifold
check
the
be
valve
look for a sticking or
faulty check valve. Check all vacuum
connections for leakage or obstruction.
Check all hoses for a leaking or
If the brakes
drag
still
or grab
valve
sticking
plunger
Remove
after
does
not
the
remove
that the diaphragm assembly
Improper localeakage between the
positioned.
and
atmospheric sides
and
the
of
disassemble the booster.
Clean, inspect,
and
replace
parts
as
necessary.
assembly.
Remove
and
disassemble the
booster. Check the diaphragm for being out of locating radii in the housing. Check for a sticking or unseated
SELF APPLICATION
OF BRAKES WHEN
ENGINE STARTS
procedure
trouble,
diaphragm.
eliminating the causes listed in Table
1, the condition is probably caused by
a
the
tion could cause
vacuum
col-
BRAKES DRAG
OR GRAB
sure
is properly
and
assembly,
replace
or
booster from the car. Separate the
booster body from the end plate, and
check the bellows, booster body, and
diaphragm assembly for damage that
would cause leaks. When assembling,
transmis-
remove
and
foregoing
eliminate
line (two lines if
vacuum
Repair
Pedal"
Discon-
leakage.
condition.
parts as necessary.
the trouble may be
1,
vacuum
at
hard
a
after
"Hard
of
equipped with an automatic
sion)
if
lapsed
that
show
or
pedal condition still exists
BOOSTER
23
BRAKE SERVICE
-GENERAL
atmospheric valve.
Clean, inspect,
replace parts as necessary.
the
diaphragm
is
Be
and
sure that
properly
located
when assembling.
COMMON ADJUSTMENTS AND REPAIRS
PARKING
BRAKE
2. Depress
LINKAGE
pedal
ADJUSTMENT
one
released
Check
when
If the
as
parking brake cables
the brakes are fully released.
3.
the
cables
are
loose,
adjust
them
follows:
4. Turn
moderate
release the
parking brake
pedal.
normal
#16
GAUGE
SHEET STEEL
car.
the
equalizer
is felt
drag
wheels
nut
adjusting
the
against
ward
brake
parking
from its
position.
Raise the
the rear
1. Fully
the
notch
for
until
a
turning
when
(Fig. 1).
5. Release the parking brake, and
make sure that the brake shoes re
to the
turn
POWER
fully
released
BRAKE
CYLINDER
position.
MASTER
PUSH
ROD
ADJUSTMENT
The
push
adjustment
correct
to
control
master
2634
provided
to
the
this
with an
maintain
valve
cylinder
maintain
prevent
2853 REF.
is
relationship
booster
the
rod
screw
the
plunger
and
Failure
piston.
relationship
master
the
between
cylinder
will
piston
from completely releasing hydraulic
pressure
ADJUSTING NUl
H1353A
and
cause
can
the
brakes
to drag.
H1208-A
To
FIG. 1
-Parking
Brake
Linkage Adjustment
screw,
check
the
fabricate
mensions
shown
adjustment
a
gauge
of
in Fig. 1.
of
the
the
di
Remove
FIG. 2-Push Rod Gauge
Dimensions
2
GROUP
24
the
heavy-duty brake fluid
bleeding operation. If
new
the
during
the
filled
reservoir
cylinder
master
with
-BRAKES
is
reservoir
diaphragm
kept
not
gasket
may
down to the bottom
of
the
full,
brake
use
sucked
the
master
brake fluid
use
from
drained
has
which
hydraulic
the
to
complete
it
and
system.
brake
rear
right
bleeder
the
on
wrench
box
%-inch
bent
a
fitting
on
be
should
1. Clean
charged
cylinder
wheel
the
cylinder
master
cap, install
an adapter
the
on
FIG. 3-Push Rod Adjustment
filter assembly and push the
bellows back into the booster body.
the air
the
place
cylinder
gauge
master
surface
mounting
of
the
for Bleeding
to
slot
in the
forces
the
break the
This
port
push
is
an
the
up side
it may
as
to
adjust
To verify the adjustment,
the
piston
should
0.015 inch
more than
No
the push rod.
The
master
not
it
as
move
contacts
(exact
movement
contact) is ideal.
bleeder
the
the
tube
a
drain tube
rubber
fitting. The
fit snugly
should
tube
in
with
clean
the
repair
into
or
replacement,
lines
the
pedal
system
action.
and
Bleed
it
air
may
cause
the
get
a
container
around
fitting.
the
of
end
filled
partially
brake fluid,
has
been properly
connected to be sure that all air is
expelled from the brake cylinders
and lines.
after
manually
or
system can
with
pressure
be bled
bleeding
equipment.
the
brake
pedal
down
its full travel. Close the
slowly thru
bleeder fitting, then
return
the pedal
to the fully-released position. Repeat
this operation until air
Bleed the longest lines first.
at
fit snugly
drain tube to the
end
the tube
of
the bleeder
around
of
bleeder
air
fitting
bubbles
with
the
tighten
and remove the
container
a
brake fluid,
clean
the
of
end
filled
partially
and
loosen
cease
to ap
bleeder fitting.
6. When
bubbles
air
in the fluid
the
at
submerged
end
of
drain
the
tube,
the
drain
fitting
7. Repeat this
brake
ing
wheel
the tube.
procedure
at
each
in the follow
cylinder
left rear,
order:
the
close
and remove
right
front,
and
left front.
5. Repeat this
brake
fill
in
of
tube.
rear,
brake fluid
cease
the submerged end
bubbles,
bleeder
the
valve on
5. Submerge the free
bleeder
wheel
right
the
pleted.
within
front,
brake
after each
procedure
cylinder
master
and
The
%
at
left
reservoir
is bled
operation
of
each
order:
left front. Re
cylinder
fluid
inch
in
cylinder
bleeding
reservoir.
Keep
rubber
right
(Fig. 4).
cylinder
wheel
wrench
the
on
to the master cylinder reservoir.
pear
4. When the fluid is completely
free
ket
MANUAL BLEEDING
a
fitting
tank to admit pressurized
tube
when the
The hydraulic
solder
and
loosen
and
bleeder fitting approximately 3A
3. Push
spongy
hydraulic
cutting
bleeder fitting. The
should
turn.
BLEEDING
When any part of the hydraulic
system
has been disconnected for
brake
4. Open the
2. Submerge the free
to appear
SYSTEM
a
%-inch box
a
bleeder
the
of
end
the tube.
HYDRAULIC
ing
a
filler cap
the hole.
fitting
cap can
hole in
adapter
by
at
on
the bleeder fitting.
the master cyl
booster.
the
(rear)
make-up
installing
when
cylinder
not set
rod
approximate
through
inder
of
valve plunger.
ment only.
look
Do
gauge.
on
the screw
edge
an
center of a
Attach
justed
of
or
the
rear
(Fig. 4). Attach
that the end
be used,
be fabricated
on
Brake
filter assembly as shown in Fig.
The
push rod screw should be ad
3.
so
can
fitting
Adapter cap 2162
cap.
3. Position
4- Wrench
FIG.
air
just touches the inner
adapter
then
and
the
against
the
the
HI 300- A
directly
booster body,
the
against
cap
attach
and
reservoir,
bleeder tank hose to the
filter
master
45
APPROXIMATELY
air
10-30
with
dirt from the
all
2. Remove
the
contain
should
cylinder reservoir cap.
reservoir
Re-install
system.
pressure.
air
of
been
has
which
heavy-duty brake fluid
the bleeding operation,
new
pounds
1. Position
fluid
The bleeder tank
enough
Never
the
Bleed the longest lines first. Never
drained from the hydraulic
be
cylinder.
been
PRESSURE BLEEDING
level
the
is
top of
The diaphragm-type
be
the
gas
be properly positioned in
the reservoir
cap, before the cap is
installed.
should
bleeding
the
close
valve
remove
from
and
the adapter
operation
bleeder
the
is
tank
hose
tank
fitting.
and
com
should
8. When the
completed,
9. Remove the
the
master
within
cap, refill
reservoir
% inch from the top
reservoir,
The
adapter
cylinder
and
of
install the filler
diaphragm-type
gasket
to
the
cap.
should
be properly installed in the
cap be
fore it is installed.
PART 2-1
2-5
GENERAL BRAKE SERVICE
-
CLEANING AND INSPECTION
BRAKE
ASSEMBLY
1. Remove
from the
drum, then remove the drum as out
lined in Part 2-2, Section 2. Wash
all the parts except the brake shoes
in a cleaning fluid and dry with
compressed
2. Brush
plates
and
the
wheel
air.
dust from the
interior of the
all
springs, and drum for signs of over
heating. If the shoes have a slight
blue coloring, indicating overheat
ing,
replacement
hold
and
If the
lining
lining is
of the rivet
brake
damaged, they
Replace
or
if the
must
for ex
damage.
%2 inch
shoes
worn within
heads
be
shoes are
replaced.
has been
any lining
oil saturated. Replace lining in axle
sets. Prior to replacement of lining,
the drum diameter should be check
ed to determine if oversize linings
must be installed.
4. Check the
that
condition
of
to
and
could
lining
they
are not replaced.
5. If the
of
linings
wear or shoe
pull
new
miles
3. Inspect the brake
is strongly
springs
Overheated
recommended.
lose their
retracting
wear
the
prematurely,
if
brake
shoes, retracting springs, hold-down
or
signs
on
or
more
brake
the
of
overheating are
present
when
relining brakes, the
wheel cylinders should be disassem
bled and inspected for wear and
entrance
The
of
dirt into the
cylinder
placed,
thus
cups
cylinder.
be
should
avoiding
future
re
prob
lems.
6. Inspect
and
replace
is
view of
the brake
in Fig.
27, Part
shown
2-2.
After
in
alcohol
only
immerse
all
a suitable solvent.
Use
disassembly,
metal parts
on
parts
rubber
or
containing rubber. After the
parts have been thoroughly cleaned
and rinsed in cleaning solvent, the
parts
has 30,000
car
operation
A disassembled
booster
springs
cause
carrier
drums.
cessive
down
the
of
UNIT
BOOSTER
all
other
any
that
brake
are
metal
parts
which
in
come
hydraulic brake fluid
with
contact
or rubber
be rewashed in clean
before assembly. Use an air
hose to blow dirt and cleaning fluid
from the recesses and internal pas
parts
should
alcohol
sages.
When
booster,
overhauling a power
furnished in
parts
use
the
repair
ber
parts.
all
kit. Discard
old
all
rub
parts
worn
Inspect
or
damaged.
or
all other parts
excessive
wear.
or
7. Inspect the brake drums and,
if necessary, refinish. Refer to Part
2-2, Section 4 for refinishing.
excessively worn
inside of the booster
or corroded, polish it
or
fine emery
cloth.
for damage
Replace damaged
parts.
body
is
If
the
rusted
with steel wool
2-6
PART
2-2
BRAKE SYSTEM
Section
2- 6
2-10
1 Description and Operation
2 In-Car Adjustments and Repairs
Page
Section
Page
3 Removal
and
Installation
.2-15
4 Major Repair Operations
.2-20
DESCRIPTION AND OPERATION
HYDRAULIC SELF-ADJUSTING
back into
BRAKE SYSTEM
shoes.
physical
force
the brake
at
to the lever. The automatic ad
and
juster
are
The hydraulic brake
ploys
single
anchor,
and
panding
self
system
em
internal
ex
adjusting
brake
assemblies.
anism
The
cylinder
converts
force from the brake
booster into hydraulic
against the pistons
in turn,
consists
of
a
lever,
spring (Fig. 1). The
master
inders. The
self-adjusting
guide, adjusting
over
physical
and
The
wheel
convert
in the
pedal
pressure
wheel cyl
cylinder
hydraulic
pistons,
pressure
ANCHOR PIN PLATE
WASHER
is
brake
cable,
and
cable
tom. The
to the lever
cable
secondary brake
is
adjuster
at
top
by
and
shoe
ondary
drum
the
when
only
while
only
when
is free to
beyond
the brakes
the car is moving
the
sec
move toward
predetermined
a
point.
and
With
the bot
connected to
shoe
rearward
cable
is hooked
the anchor pin at the
connected
mech
operates
applied
means
the
and
the
of
car
moving rearward
brakes applied, the "wrap
around"
action of the
ing
the drum
the cable guide. The adjuster spring
of the
is hooked to the primary brake
chor
shoe
the
primary shoe
pin.
ANCHOR PIN PLATE
The
shoes
forces the
upper
against
action
PRIMARY
of
follow
end
the an
the wheel
SHOE- TO-ANCHOR
SPRING
PARKING
BRAKE LEVER
BRAKE
RETAINING
CYLINDER
CLIP
SECONDARY
SHOE
PRIMARY
SHOE
AUTOMATIC
ADJUSTER
SPRING
CABLE HOOK
PARKING
BRAKE CABLE
AND HOUSING
HI 394- A
FIG. 1
Self-Adjusting
Brake Assembl les
PART 2-2 -BRAKE SYSTEM
27
cylinder moves the upper end of the
secondary
adjusting
lever
the
of
against
adjusting
lining
screw
can
upward
tooth
a
the
over
end
the
engages
are
spring
pulls
When
the
as
the
far enough,
the tooth
of
When
tooth.
the
released,
lever
the
causing the
the
The
turned one
at
tooth
linings progressively
With the
is
primary
the
drum.
not
time
a
the
is
is
^\
and
secondary
pin
and
'
toward
moved
Therefore,
^r^s^r
the
as
(Qfl^>
the anchor
shoe
CLOSED
and
wear.
applied,
against
the
turn
star-wheel
moving forward
car
brakes
adjusting
downward
to
starwheel
expand the shoes.
does
and
on
VACUUM PORT
brakes
shoe
an
lever increases
increases.
move upward
passes
the
the
the sec
of
star-wheel. The up
the
of
wear
lever
and
end
travel
ward
it
away from
shoe causes the cable to
pull
ondary
the
shoe
The movement
chor pin.
ATMOSPHERIC
PORT OPEN
the
adjuster
operate.
VACUUM
The
brake assembly is basic
the
same
as
the front brake.
ally
The
conventional
brake
parking
rear
lever, link,
and
are
spring
used
^
ATMOSPHERE
in
the rear brake.
The
fixed
anchor pins on all
and
brakes
are
non-adjustable.
H1357-A
FIG.
BOOSTER
2 Booster
optional
is installed
dash
bly
brake booster
power
is
and
and push rod
The booster
and
lever
a
assem
Vacuum is
2, 3,
consists of a vacuum
and
control
valve,
diaphragm,
assembly,
atmospheric
area
forward
link.
atmospheric
plunger
an
(Figs.
chamber
4).
intake
ifold
times
chamber
pressure
in
the
at
atmospheric
the
front
to the
atmospheric
tected
by
pheric
the
an
air
chamber
vacuum
present
atmospheric
side
The
valve.
is
air
chamber
filter. The
is
chamber
separated
by
of
of
the
vacuum
manifold
body. With
and
control
hub
valve
and
the
hose from the
to the vacuum
integral
several
applications
This
off.
vacuum
pro
atmos
from
the bellows
APPLYING POSITION
diaphragm. Vacuum
man
the booster
check valve
chamber, it is
vacuum
obtain
shut
this
chamber
possible
power
assisted
the
with
engine
arrangement makes
reservoir
a
unnecessary.
the
intake
is
the
and check valve on
brake
all
the
times in
present at all
of
supplied through a
to
Atmospheric
at
cham
plunger assembly.
that
is
valve
vacuum
ber.
to the
connected
through
pedal
chamber,
the
within
on the engine side of the
panel
brake
Applying Position
SYSTEM
assembly
The
in
As the brake
the
valve
plunger
(Fig.
2).
The
from
the
side
of
vacuum
the
from the forward
diaphragm
the
bellows
can
be
the
diaphragm
or
(atmospheric
air
from
chamber)
to the
rear side of
through
in
connected
porting
return
initial
ment of the plunger closes
ing
valve
forward
plunger
vacuum
move
the port
chamber
preventing further evacuation of the
area back of the diaphragm. Further
movement of the plunger
Either
depressed,
and
move
assembly
the
is
rod
operating
compressing
spring
pedal
forces
atmospheric valve off
its
atmospheric
from
lows
can
leads to
phragm.
pressure
enter
the
the
rear
seat so that
the
hub porting
side
the
of
the
bel
that
dia
2
GROUP
2-8
-BRAKES
lever assembly
When
3).
(Fig.
sition
vacuum
closed
of
passage
to the
pressure
atmospheric
valve
atmospheric
any further
off
cut
will
remain
will
supply
the
and
com
these
the porting to
bined forces balance,
the
po
closed
to the
valve
atmospheric
the
move
tend to
will
be
area
hind the diaphragm. Therefore, the
the
on
acting
stabilize
will
piston
cylinder
master
VACUUM PORT
force
assist
power
the
and the hydraulic force applying
CLOSED
brakes
be
will
at
maintained
con
a
level.
stant
POSITION
RELEASED
^-^
When
the
leased from the
from
away
the
the
allowing
the
the
draws
and
of the
the
diaphragm,
the
move
side of
atmospheric
back
side
diaphragm,
the
front
the
of
force is developed to
a
push
port
compensating
force hydraulic fluid
As
brakes.
hydraulic
and
wheel
pressure
developed in the hydraulic
is
system,
a reaction counter-force acts against
the
reaction
bly. This
lever
reaction
and
lever
ring
and
assem
ring
as
sembly is designed to transmit the
reaction
actuating
the
forces
brake
driver
back
control
with
pedal
a
power
proper
brake
of
valve
and
through
the
assembly to
provide
resistance
that
the
is in
the
control
a
by
However,
the
to
control
keeping
At the
held,
the
(large
differential
plunger
forward.
and,
forces
of
the
outer
plunger
sleeve
of
forward
time, the
acting through the
reaction
reaction
with
it,
released
ing
the
position.
permits
the
wheel
cylinder
fluid,
valve
piston
and
released
position.
hub
plunger
and
to
This releasing
brake
shoe
and
the
the
ac
retract
through
return
and
cylinder
pressure
valve
back
pistons
to
force
ring
the
acting
springs,
draulic
This
assembly
front
the
on
side.
side
atmospheric
and
moves
diaphragm
tion
hub
is
vacuum
diameter)
(small
diameter)
to move
the vacuum porting closed.
same
elimin
differential
pressure
ceases
rod
valve
is
the presence of
valve
(bellows)
the diaphragm will con
move
the
the
atmospheric pressure and vacuum on
tinue
the
against
rod
pressure
rear
of
motion
the unbalanced
each side of
the
on
stopped and
valve
dia
unit.
When the forward
operating
force
push
cylinder
master
of
valve
With
the
of
sides
rear
ated.
HOLDING POSITION
is
from the
air
phragm, the assist
created
pedal
both
on
Also,
brake
chamber
vacuum
the
the
opens
plunger
feel"
"driver
under pressure
brake tubes to the
and
to the
the
means
to
through the residual pressure check
valve
apply forces. This is the
providing
hydraulic
brake
the
to
proportion
and
rod
forward
piston
cylinder
master
close
the
on
pressure
the
rearward
the power diaphragm.
of
side
out
the
time,
same
vacuum
and
of the
diaphragm.
the
of
side
rear
porting from the
on
against
seat
connects
movement
vacuum
to
chamber
At
diaphragm
valve
from the hub porting that
to
With
plunger
the bellows
valve closes off
FIG. 3 Booster in Holding Position
plunger
hub (Fig. 4). This seating
the
ATMOSPHERE
H1358-A
the
the
atmospheric
valve
re
rod
operating
moves
spring
return
VACUUM
valve
assembly,
plunger
and
is
pressure
pedal
the
the
hy
master
push rod to the
PART 2-2
With the
piston
the released
is
brake
or
The
in
rod
master
to the fluid reservoir,
brake
the
the
open port per
to return from the
either
system
enter
in
port
open.
fluid
mits
push
position, the hydraulic
compensating
cylinder
and
2-9
SYSTEM
-BRAKE
from the
system
reservoir.
PARKING
BRAKE
independent
An
parking brake
rear
from
routed
control
lever
is
brake
equalizer
to the
17).
(Fig.
assembly
brake cables
the
attached
connect
a
cable
parking
to
assembly
which
izer
through
shoes
the
the
actuates
linkage. The operating
cable
is
brake
wheel
foot-operated
control
equal
The
the
rear
equalizer
assembly to the parking brake lever
each rear
at
secondary
Two types
5) is
type (Fig.
Parklane. All
other
When
the
release
Mercury
models
(Fig.
type
^)
VACUUM
fo3
ATMOSPHERE
the
use
16).
depressed
is
pedal
release
automatic
or
manual
the
CLOSED
control
pedal
automatic
used on
release
manual
(either
brake
of
The
used.
are
ATMOSPHERIC
PORT
(Fig. 1).
shoe
type) the secondary brake shoes are
forced
The
against the rear
held
is
pedal
by
position
the
in the
in
the
of
assembly (Figs. 5
control
a
ratchet
a
with
H 1359- A
4 Booster
FIG.
in Released Position
applied
engagement
pawl
spring-loaded
brake drums.
When the lever is
the
manual
the
cam
trol assembly is
panel
pedal
parking brake
mounted
action
cam
to the dash
on
pivots
a
The
I
brakes.
the
of
a
release
pedal.
upper
A
lever
contacts the
that
the
pawl
stops
thus
is
assembled
to the
The
pawl
ratchet at such an
angle
the ratchet
however,
the
to the
and
pawl
as
the
when
the
pedal.
teeth will
pedal
the
pedal
engages
slide
starts
the
motion
to release,
ratchet
locks the brakes in the
position.
over
is depressed;
applying
to
ratchet
lever
release
the
a
the
lever
release
slight
pivots against the pawl,
the
movement
will
the
type,
unit
power
will
rivet
vac
in
from
brakes to
the
lever
release
pin
release
the pawl
allowing
The
the
of
disengage
ratchet
release.
automatic
lever. Since the
tached to the release
the
pivots
pedal
on
mount
5).
(Fig.
the
release
and
assembled
the
of
end
pawl
are
ratchet
on
disengage
will
the
lever
pedal
stationary
spring-loaded
16),
a
On the
uum
A
mount.
pin
from
paw
the
con
and the cowl upper panel.
on
and
pawl
of
(Fig.
type
release
16).
Either type
back
pulled
and
parking
moved
not
engine
release
when
neutral
engine
with
the
or
lever
selector
into any drive
running.
position
selector
or
will
however,
is
position
park
running,
lever
is
with
The brakes
automatically,
in
with
in any
The
when
automatically
transmission
the
the
brakes
the
the
position
mounting
control
ated
of
out
ratchet
The
power
unit
piston
rod
is
at-
a
of
of
with
to
the
vacuum actu
unit
is
con
the
upper
end
lever to
move
the
with
the
rod
engagement
5).
The lower
lever
extends
manual
release
(Fig.
release
event
the
to
unit
riveted
The
within
release
alternate
applied
bracket is
by
the
pawl
power
assemblv.
piston
nected
the
the engine off.
vacuum
vacuum
power
end
of
out
for
in
the
failure
or
GROUP 2
2-10
.VACUUM
-BRAKES
for
POWER UNIT
at
release
manual
optional
any
time.
PAWL (UPPER END)
PISTON ROD
Hoses
PEDAL MOUNT
REVE
and
/
the
release
sion
neutral
6).
tion
the
engine
release
actuating
The
unit.
to
link to
pull
will
connect
to one
in the
piston
cause
posi
running
valve
pressure
will
created
5
transmission
the
engine manifold vacuum
of the
(Fig.
switch
safety
the
vac
in the transmis
Moving
with
open
to a
lever into any drive
selector
unit
power
manifold
valve
uum
and
the
connect
engine
side
power
differential thus
the
piston
and
lever.
the release
TO VACUUM
POWER
CABLE CLEVIS
UNIT
?
NEUTRAL
SAFETY
(VACUUM
SWITCH
RELEASE VALVE)
TO ENGINE
MANIFOLD
VACUUM
STEERING
VACUUM
JUNCTION BLOCK
COLUMN
H1286-A
H1350-A
5
FIG.
Parking
Brake Control
FIG. 6 Connections for
Automatic Parking Brake Release
Assembly with
Automatic Release
The
the carrier
ADJUSTMENTS
SHOE
BRAKE
car should
be
Before
raised with the
self-adjusting
service
and
brakes
require
a
are
manual
only after the brake
have been relined, replaced, or
the length of the adjusting
adjustment
shoes
when
has been
screw
forming
some
changed
other
while
service
per
the grease
will
seal
not
brake
normal room
justing
drums
be
temperature when
the brake shoes. If the
adjusted
and
drag
should
when
expanded,
when
the
drums
the
shoes
are
at
ad
shoes
the
drums
cool
are
may
and
contracted.
from
the
the
from the
carrier
adjusting
screw
been
sure
other
or
until
is
the
turned,
have been in
adjusting screw has
install the drum. Be
shoes
that all excess grease, oil,
foreign
and
material are wiped off
wipe
a
the
grease.
that
so
within
retainers
2. Remove
cover
the
screw
coating
19590-B Grease.
Any
may
other
cause
screw
with
adjustment
of
with
a
C1AZ-
procedure
damage to the adjusting
consequent self
adjuster
hole
plate
and,
plate side, turn the
to
upward
expand
7). Expand the
drag is
the
uniform
problems.
adjusting
carrier
thin
felt
shoes
the drum
when
rotated.
3. Remove the drum.
tooth
on
lever
While
contacts
out
1. After the
stalled
spindle,
be damaged.
the shoes (Fig.
The
hot
wheel
Lubricate
screw.
brake drum
the
opera
tion.
are
Install
hub
drum.
and
completely free of
the drum carefully
spindle
The hydraulic
plate
installing
front
on the
the floor.
wheels off
REPAIRS
AND
ADJUSTMENTS
IN-CAR
ing
of
the
the
If finger
back
of a
where
adjusting
engagement
%
Mark the
wheel
the
holding
screw,
screw
star
adjusting
with
off
lever
the adjust
the
adjusting
turn with the fingers.
movement will not turn the
screw, free it up; otherwise, the
adjusting
the
screw.
lever
will
not
turn
Brake Shoe
Adjusting
Tool
H1122-A
self-
the
FIG.
7
Expanding Brake Shoes
PART 2-2
4.
Apply
a small
temperature
of high-
quantity
to
grease
the
points
bearing
where
the shoes contact the carrier
grease
plate,
being
tion 4.
lubricant
careful
to
not
the
get
the linings. Install the
on
drum.
On
wheel
bearing,
outer
washer, and adjusting
nut, then adjust the wheel bearings
in Part
rear
Section 2.
the three
install
wheels,
Tinnerman
nuts and tighten securely.
as outlined
On
5. Install the
on
wheel
the
tighten
and
3-5,
to
nuts
mounting
cables
for
the
the rear
and adequate.
clean
3. Install the
washer and
outlined
brake
stall
oper
have
shoes
Adjust
outlined under
"Brake
Adjustments"
3. Install
in this
Tinnerman
three
the
Install the
nuts and tighten securely.
on
wheel
the
flange
axle shaft
drum,
the
against
to
section.
studs
the
tighten
and
specifications.
retaining
nuts
outer wheel
BRAKE
SHOES AND
SCREW
the
in Part
Section
grease cap.
hub
and
REMOVAL
bearing as
2, then
wheel
3-5,
cotter pin
the wheel
bearing,
nut.
adjusting
ADJUSTING
In
1. With the
install
wheel
a
moved,
the
ends of
and
clamp
brake
cylinder
drum
re
over
the
as shown
in Fig. 9.
cap.
BRAKE
REAR
DRUM
Tool-2035N
2086-1
or
REMOVAL
is
1. Raise the
car so
clear of the
floor.
that the
wheel
the
check
adjusted,
the
hub
and
cap
Remove the three Tinnerman
and remove the brake drum.
2. Remove
brakes.
the
operation of
grease
section.
cover
Make
lever
brake
8. After the
been properly
assembly
the brakes as
brake
over the
position.
into
and
brake
parking
equalizer
2. Place the drum
Adjustments"
freely.
ates
being in
the
2. Install the drum assembly and
adjust the brakes as outlined under
in this
"Brake Shoe
install the
adjustment.
proper
that
sure
the
check
that
sure
4. Adjust
7. When adjusting
shoes,
drum is
original
make
in the hub is
specification.
6. Install the adjusting hole
on the brake carrier plate.
assembly in
install the new
See Part 3-5, Sec
and
Shoe
If the
drum
the
2-11
SYSTEM
and roller
retainer.
stalled,
front wheel, install the
a
cone
inner cup,
the
-BRAKE
wheel.
nuts
DRUM
BRAKE
FRONT
REMOVAL
1. Raise the
tire
and
tire
and
wheel
the
wheel
Remove the
hub cap,
wheel cover or
the
until
car
the floor.
clear
and remove
from
assembly
the drum.
2. Remove the drum. If the drum
will not come off, insert a narrow
justing hole
brake
the
through
screwdriver
screw
adjusting
with
from the
ad
screw. While holding the adjust
lever away from the screw, back
off
the
8).
(Fig.
tool
adjusting
with
screw
adjusting
will
the
adjusting
the
from the
bearing
spindle.
cone
4. Pull
sembly
the
off
the
hub
drum
and
1. If the drum is
remove
the
new
greaser.
the
MOVE HANDLE
drum
Install
grease retainer.
being
with
new
replaced,
coating from
carburetor
bearings
Soak the
new
de-
and
toward the
will go.
lever,
cable
spring down
to
rear
unhook
the
the hole.
4. Remove the
HI 144-A
8-Backing
spring
the
otherwise,
anism
burr,
to
not
chip,
or
the
1).
shoe
to
spring with the tool shown
in Fig. 9. With the same tool, re
damage
in the adjusting screw;
will not
automatic adjuster
adjusting lever (Fig.
anchor
Adjustment
notches
and
5. Remove the secondary
Off Brake
self-adjusting mech
function properly.
and
the
spring
from the
the
unhook
anchor
cable
eye
anchor pin.
6. Remove the
anchor
7. Remove
cable
the
the secondary shoe
INSTALLATION
to
shoe
primary
and
pin
guide
(Fig.
plate.
from
1).
grease
in light engine oil at least
30 minutes before installation. Pack
the wheel bearings, install the inner
retainer
and
it
the
back
and
UPWARDS
careful
protective
side of
upward
adjuster
automatic
move
INSTALLATION
lever
adjusting
hook from the large hole in
the secondary shoe web. Do not at
tempt to pry the pivot hook out of
FIG.
as
lever
pulling
pivot
spindle.
wheel
by
outboard
screw
and
roller assembly.
and
follows:
adjusting
screw
3. Pull the adjusting
flat washer
Remove the outer
nut,
the
the pivot nut as far as
off
the hub. Remove the cotter pin, nut
lock, adjusting
as
shoes
Be
cap from
grease
Disengage
b. Move the
erly.
3. Remove
2. Contract the
(Fig. 1).
function prop
not
Retracting Spring
Removal
a.
very careful not to burr, chip, or
damage the notches in the adjusting
screw; otherwise the self-adjusting
mechanism
9
FIG.
H1146-B
from the adjusting
backward on the
adjust
ing
ing
Too/-LM-l 19
the
brake adjusting tool (Fig. 8). Be very
disengage
and
plate,
the adjusting lever
brake
the
off
the inner side of the
at
carrier
brake
If the drum will not come off,
insert a narrow screwdriver through
the brake adjusting hole in the car
rier plate, and disengage the adjust
ing lever from the adjusting screw.
While holding the adjusting lever
away from the adjusting screw, back
1. Remove the
from
a
new
degreaser.
protective
drum
with
coating
carburetor
8. Remove
the
shoe
hold-down
springs, shoes, adjusting screw, pivot
nut,
and
socket.
GROUP 2
2-12
9. On
brakes,
rear
parking brake link
Dis
spring.
the
parking brake
from the parking brake lever.
connect
cable
be
parking brake lever from the
shoe
removing the retaining clip
washer (Fig. 1).
and
Remove
the
Apply
shoes,
lever
to
secure
retaining
2.
the
washer
spring
light coating
grease
brake
the
the
of
the
than
the
at
shoes
points
the
contact
wrong
plate
and
shoes on
the
secure
bly
with
the hold down
the
rear
brake, install
ad
would
to
mechanism
installation
prevent
on
the cable should
inal
position.
the
lever
screw
positive
and
tion
the
the car, the socket end
adjust-
of
assem
in
anchor
pin
ing
anchor pin plate on
screw
the
crimped
the primary
spring (Fig. 10).
or
^
side
shoe
to
FIG. 1 1 Adjusting Screw
Lever Identification
ing
pivot nuts can
the
number
around
of
indicate
grooves
section
meet this
a
indicates
and
between the
justing
Two
nut.
hand nut;
left hand nut.
right
a
install
socket on
this
shoe ends
toothed
screw
by
machined
the
of
10. Place the adjusting
the screw
H1147-B
Spring
guide
with
the ad
wheel
nearest
the
cable
guide
L to indicate their installation
on a right or left brake
assembly
(Fig. 11).
on
the
between the
anchor
Fig. 10.
cable
and
be
not
guide and the shoe web.
8. Install the
spring
secondary
with
or
12. Position
the hooked end of
the adjuster
spring completely into
the large hole in the
shoe
primary
The
should be
web.
groove
(Fig. 1).
It is imperative that the
positioned in this groove
secondary shoe.
11. Hook the cable hook into the
hole in the adjusting lever. The ad
justing levers are stamped with an
R
secondary shoe web with the flanged
hole fitted into the hole in the sec
ondary shoe web. Thread the cable
around
or
the centerline
above
shoe
to
the tool shown in
last
at
coil
Connect the loop
13. Pull the
will
actu
cause
this
of
is
spring
the
cable
end
should
specification, possible dam
indicated
cable
should
(plus
or
end
the
and
cable
c.
age.
minus
The
inches
HVs
%4 inch) from the
hook.
Check the cable guide for dam
The cable groove should be
to
parallel
body
of
the
the
shows
d. Check the
lever. The hook
square
shoe
guide
web,
should
web. Replace
damage.
the
against
if it
measure
as
the cable anchor to the end
of
of the cable
with
the
pivot
the
lie
flat
the
hook
surfaces
body
and
of
guide
the
on
be
lever
should
the
for proper pivoting. Replace the
lever if the hook shows damage.
See that the adjusting screw
is properly seated in the
notch in the shoe web.
e.
socket
end
of
the spring
adjuster
automatic adjuster
and
toward the
rear
lever,
It is
cable
spring down
to engage the
hook in the large hole in
shoe
web
(Fig. 1).
the
CYLINDER REPAIR
WHEEL
lever hole.
and
secondary
lever is
the
the edge of the hole.
to the adjuster
pivot
the
of
the screw
and
as
sembly should be replaced.
b. Check the cable length.
assembly
the
cable
(plus
fittings.
completely fill or
slightly beyond the crimped
of the fittings. If it does not
cable
extend
and
be distinguished
grooves
body
the
one groove
7. Install the
the
contact
inch
the cable.
Check
The
age
FIG. 1 0 Retracting
Installation
;He
determine the
a.
H1143-B
2086-L
Tool-LM-119
adjusting
condition:
ADJUSTING SCREW
IDENTIFICATION LINES
6. Install
Too/-2035-N
by
ated
the
over
toward the carrier plate.
anchor
should
wheel,
be turned
To
with
the
With the brake
(anchor at the
the screw. If the contact point is
below this centerline, the lever will
not lock on the teeth in the adjust
parking
Connect the
eye
position
of
the posi
check
on
pro
if the
instead
sluggish
lever
%2 inch)
not
or
of
the
the anchor pin.
cable
does
wheel
adjusting
not
5. Place the
cable
of
adjusting
described,
lever
the
action
the
sharp,
vertical
a
minus
On
return
turn
screw toothed wheel.
top),
the
lever to its orig
tooth.
one
the
brake link and spring.
parking brake cable to the parking
brake lever (Fig. 1).
4. Install the
This
will
the adjuster
cause
the
return
op
the
ADJUSTING LEVER
springs.
should
If pulling the
duce the action
lever action is
retract
time
each
ad
one
adjusting screw is stamped
R or L (Fig. 1 1). The
with an
3. Position the brake
other
shoes
expand
side of
the
of
to the
adjusting
To
erated.
assemblies
car
shoe
from
far
tooth
a
ihe
lever
spring to
the brake
brake
cause
rather
carrier plate.
carrier
side
automatic
a
temperature
justing
screw
lever
the adjusting
adjusting screw wheel. The
snap into position be
hind the next tooth, and release of
on
of
Vi turn.
off
and
of high-
the
cable
and
to lift the lever past
enough
grease
the adjusting pivot
to the limit of the threads and
the
of
guide
the
check
pulling the
between the
toward the secondary shoe web
clamp.
into
screw
and
clip.
Apply
where
shoe
secondary
the
with
rear
section
cable
installation,
by
the adjuster
action of
pin.
socket end
Turn
screw.
14. After
an
parts
anchor
cylinder
the
and
Interchanging
brake
installing
assemble
the parking brake
the
the
is
eye
the
on
high-temperature
adjusting
nut
1. Before
cable
installed. All
on
brake
the
then back
INSTALLATION
flat
to the threads
justing
spring
the
binding
or
when
pin
chor
9.
that
certain
cocked
not
should
10. After removing the rear brake
disassemble
the
shoe,
secondary
by
Be
the
remove
and
-BRAKES
brake
to
not
necessary to remove the
from the carrier plate
cylinder
disassemble, inspect,
overhaul
the
cylinder.
or
hone
and
Removal is
necessary only when the cylinder is
damaged or scored beyond repair.
PART 2-2
BOOT
inder to
BLEEDER
CYLINDER
2-13
SYSTEM
-BRAKE
BOOT
SCREW
RETURN
PISTON
the
the
anchor
from
cylinder
Remove
pin.
the
pin.
anchor
PISTON
SPRING
INSTALLATION
Wipe the end(s) of the hydraulic
line to remove any foreign matter
before making connections.
1. To install
CUP
FRONT
Position
a.
CUP
BRAKE CYLINDER
the
ing
SCREW
to specification.
BOOT
the
nut on
anchor pin, and
CUP
REAR
FIG. 1 2 -Front
BRAKE
CUP
CYLINDER
100- A
HI
b. Install a new copper gasket over
hose fitting. Screw the hose as
sembly into the cylinder.
the
to
nut
2. To install
1. Remove the links and the rub
ber boots from the ends of the brake
cylinder. Remove the pistons, cups,
return spring from the
bore (Fig. 12).
and
2. Remove
the
from the cylinder.
cylinder
REMOVAL
the cylinder, and start the tube
1. With the
sition,
remove
3.
Dry
If
alcohol.
use
the
de
clean
is not
brake fluid.
alcohol
specified
with compressed air.
2. Check
internal
all
excessive wear or
for
parts
damage. If any
of
the internal parts require replacing,
all should
be
marks
cylinder
If
rust.
or
bore for
con
either
dition is present, the cylinder bore
be honed. However, the cylin
must
der
not
should
0.003
inch
be honed
beyond
its
than
more
di
original
4. Check the bleeder hole
sure that it is open.
be
to
a
coating of heavy-duty
all internal parts
section.
the
cylinder
3. Insert the
and
sitions
12).
the
into
pistons
in
Place
the
a
cvlinder.
tighten
and
their
To disconnect the hose
the
over
bore
each
Bleed the brake
po
(Fig
end
of
system
opposite
front
at a
fitting
that
of
the
end
hose to the brake tube at a bracket
Remove the horse
on the frame.
shoe-type
retaining
clip
from
hose
hose
bracket, disengage
from the bracket, then
screw
the
entire
front
wheel
and
a
rear
fitting
unscrew
the
metal
from the
the tube
nection will
out of
the
bend the
cylinder
Pull
cylinder con
metal
tube
and
wheel
from the
is
cylinder when
removed
from
the
4. Install
rear
c\linder
washers
retaining
and
der. On the front
and
washer
wheel, remove the
remove
bolts
and
the cylin
wheel, remove the
that retains the cyl
ends of
install the
and
brake
the
shoes
adjust
drum
and
the brakes
(Part 2-2,
Section 2), and bleed the brakes as
outlined in Part 2-1, Section 2.
adjust
BRAKE
CARRIER
1. Remove the
PLATE
wheel
brake
line
and
drum. Disconnect the brake
from the brake cylinder.
2. Remove the
adjuster
cylinder
On the
brake
assemblies
as
and
shoe
the
in this
outlined
and
wheel
section.
disconnect the
parking brake lever from the cable
rear
3. If the
ing
so
wheels,
rear
that
the
retaining
Pull the
the
carrier
is be
the
axle
shaft
hole in
the
axle
shaft
axle
the carrier plate
with
nuts and
housing
plate
rotate
replaced,
flange lines up
plate.
4. On the
nut
cylinder.
to
nut
the shoes as outlined in this section.
installation difficult. The tube
make
lock
connects
fitting
1112-144.
tool
assemblies,
REMOVAL
to the cylinder. Do not pull the
the
adjuster
the
tube
away
that
the retaining
3. Install the links in the
un
the
tube
the tube
with
REPLACEMENT
cylinder.
cylinder,
to the car
cylinder
the wheel cylinder,
and
fitting
lockwashers.
Tighten
the
hose assembly from
tubing into
of the cylinder.
by installing
specification
cylinder, loosen the tube
carrier
cups.
respective
cylinder
boot
securely.
spring,
return
into
screw
and
c.
wheel,
will separate
2. Thread the bleeder
plate
bolts
outlined
lines.
ing
brake fluid to
shoe assem
procedures
vacuum
tube
ASSEMBLY
b. Secure the
cylinder
wheel
the
into the threads
nut
the
Disconnect the brake line from
brake cylinder. On a car with
At
Apply
and
wheel
po
brake booster, be sure
the engine is stopped and there is
no vacuum in the booster system be
fore
disconnecting the hydraulic
a
the
ameter.
1.
a raised
rear
Enter
position.
rier
connects
replaced.
3. Inspect the
score
in
2. Remove the brake
screw
INSPECTION
in
the
Place the
a.
wheel
blies, following
parts
rear cylinder:
into
in this
all
a
WHEEL CYLINDER
REPLACEMENT
drum.
bleeder
tool
with
specification
1112-144.
Rear Wheel Cylinders
and
DISASSEMBLY
available,
torque
c. Engage the opposite end of the
hose to the bracket on the frame, in
stall the horseshoe-type retaining clip,
and connect the brake tube to the
hose with the tube fitting nut. Tighten
fiSli
natured
the
on
the
PISTON
1. Wash
cylinder
washer and cylinder retain
BLEEDER
CYLINDER
cylinder:
the carrier plate.
anchor pin against
Install the
BOOT
front
a
remove
shaft
with
the nuts.
assembly
tool-4235C
slide
hammer
move
the carrier plate.
(Part
4-2).
out
of
and
then
a
re
GROUP 2
2-14
If the front
2. Install the
is being
carrier plate
replaced, remove the bolts and nuts
that
the
secure
plate
to
wheel spindle and remove
the
front
the
plate.
connect
this
3. Install the brake
1. Position
bolts in the
sert
so
new
a
on
gaskets
and
plate
the
carrier
retaining
ential
tion
splines engage
side gear with
the
as
bearing
re
axle
shaft
a new
front
of
flange.
and
brake,
ad
and
at
the
rear
and gasket to the wheel spindle and
and nuts.
TO LEFT FRONT CYLINDER
type,
ful
not
exception
the
axle
be flared
leak-proof
Clean the brake tubing
by flushing
with
good
clean
denatured
alcohol, before installation.
When
front
housing
be
When
should
provide
connections.
at
should not
system.
rear axle
All brake tubing
throughout
the
tubing
of
and
shape,
brake tubing to fit under
contours, be care
to kink or crack the tube.
bending
body or
(Sec
tubing
with
size,
hydraulic
a
properly to
used
with
in
used
LINES
system
replaced
same
length. Copper
bleed the brake system
in Part 2-1, Section 2.
flexible hoses
the
be
should
the
connect
shoes
REPLACEMENT
TUBE
If a section of the brake tubing
becomes damaged, the entire section
in this
brake tube connector (Fig. 13).
Always bleed the entire system
after any hose or line replacement.
carrier plate
install the retaining bolts
shoe
brake
the
tubing is
the brake
wheels
Position
and
Steel
the retaining nuts through the access
hole in the
rear
a
HYDRAULIC
retaining bolts
the carrier plate. Install
against
2),
outlined
the differ
tainer sliding onto the
and
On
4. Adjust
the axle shaft
that the
in
the parking brake cable to the lever.
Install the brake drum and wheel.
housing flange. In
into the housing
axle
BRAKE
and
as outlined
outlined
as
assemblies
section.
INSTALLATION
cylinder
wheel
the brake line
section.
juster
rear
-BRAKES
hose,
inder,
torque
1112-144
to
a
connector, or brake cyl
tighten the tube
specified
tube
a
connecting
tube
or
fitting
with
nut
Milbar
to
tool
equivalent.
FROM MASTER CYLINDER
TO RIGHT
CYLINDER
REAR END OF HOSE
TO
Ml 196
LEFT'
CYLINDER
/CLAMP
'372323
-
3 REQD.
S>
.BRACKET
'REAR
/BRAKE
.TUBE
'CONNECTOR
LINE
41196
VIEW
S8,
Uj
3 REQD.
VIEW
VIEW
APPLY A FORCE TO
fTHE BRAKE PEDAL
PAD TO PRODUCE
r 1300
TO1600 P.S.I.
J LINE PRESSURE TO
/TEST BRAKE SYSTEM/MUST BE FREE
TYPICAL 5 PLACES
Z\
Yj
MARKED*
BEND CLIPS TO RETAIN
TUBE AT ASSY.
2267
2A448
ASSY.
LEAKS."
/OF
2078
2 REQD.
2268
2263
V
-2A040\|
FRAME
CROSSMEMBER
k VI EW V
2264
o o
FRAME
BRACKET
2073 V
2149,
FRONT END OF
REAR HOSE
/
2 REQD.I
VIEW
VIEW WJ
X.
TO MAIN
JUNCTION
\
TO MAIN
JUNCTION
2265
2A448~
ASSY.
RETAINING
r
41196 S8
5 REQD.
-
41196
FRONT
HOSE
"?
X//
Mf
-41196
-
S8
FRAME
"BRACKET!
2A0S6 L.H.
2082 R.H.
S8
f^-*'2 REQD.
FIG. 1 3-Service Brake System
H 1354- A
PART 2-2
BRAKE
HOSE
REPLACEMENT
into
A flexible brake hose
if it
replaced
ing,
a
or
new
be
installing
a new
front brake
avoid con
gasket
hose
the
REMOVAL AND
STANDARD
BRAKES
the
connect
A
REMOVAL
from the
rear end of
inder in the
boot
rubber
passenger compartment.
2. Disconnect the brake line from
3. Remove
the
der to the
dash
cylinder out and
rod
nuts
that secure the
(Fig.
boot from
panel
lift the
and
push
rod,
the
away from the
the
13).
(Fig.
should
it does
be in
the
not touch
the master cylinder
of
the
cylinder
against the
2. Install
the
nuts
push
on
rod,
the mount
dash
lock
and
and
the
-
gasket
new
fitting
and
the
over
rear
the hose
screw
as
sembly into the rear brake tube con
nector. Engage the front end of the
hose to the bracket on the frame.
Install the horseshoe-type retaining
clip,
and
hose
with
the
fitting
tube
to
tube
the
connect
the
nut.
washers
torque
to
master
heavy-duty
with
within
the
from the cylinder at the
line fitting. Then tighten the
escape
air
brake
fitting.
and
speci
the
reservoir
Install the cap
from the
4. Fill the
3/a
filler
filler
352
hose
a
inch
of
cylinder
reser
brake fluid to
the
top.
Be
cap.
the
cap.
master cylinder to
let
level
and wipe off
and
fill
specified.
any fluid
cylinder.
boot to the
rubber
cylinder.
MASTER
POWER
CYLINDER-
BRAKES
REMOVAL
sure
is properly seated in
Install and tighten the
5. Bleed the
master
filler cap
the
to
7. Connect the
push
on
Place
6. Remove
that the gasket
boot
sorber.
panel.
3. Connect the brake line to the
master cylinder fitting, but leave the
brake line fitting loose.
the
rubber
with
nut
guide
mounting
fication.
rubber
the push rod.
the
hose
end
studs
voir
INSTALLATION
1. With
tube to the
master cylin
Remove
1 5).
lock
and
and
brake hose
the master cyl
the master cylinder.
washers
the
clip,
that
so
over
ing
the
frame. Install
ab
shock
or
pipe
outlet
muffler
hose to
retaining
fitting
rear
stalled
position
1. Disconnect
the
on
En
cylinder.
INSTALLATION
CYLINDER-
MASTER
the hose assembly
gage the opposite end of the
the tube
Place
parts.
over
screw
front brake
horseshoe-type
hose to
chassis
other
copper
and
the
the bracket
damage.
other
position the
tact with
should
shows signs of soften
cracking,
When
hose,
fitting
2-15
SYSTEM
-BRAKE
let
1. Remove the hydraulic line out
fitting from the master cylinder.
2. Remove
the
retaining
nuts,
lock, washers, and the master cylin
der from the booster unit (Fig. 14).
390 ENG. STD. TRANS. ONLY
6 CYL. & 289 ENG. STD. & AUTO TRANS.
375787
S
240 ENGINE
p*
)'
MOUNTING STUD
S2 4 REQD.
377102
-
SPACER BETWEEN PEDAL SUPPORT
BRACKET AND DASH PANEL
2849
4 REQD.
PEDAL ASSEMBLY
AUTO.
352
FIG. 1
TRANs
390 ENG.
4 Booster Installation
H 1356- A
GROUP 2
2-16
3. Remove the
the
outer
master
rubber
groove
the
at
the
of
end
cylinder.
the
distance
from
of the push rod
to the
cylinder,
check
the outer
end
the
mounting surface
master cylinder
the
at
sion
is
the
push rod
Adjustment,"
inder Push Rod
2-1, Section 2.
2. When the
is correct,
the
replace
in
just far
enough
hole to
clear
the
master
Be
cylinder.
the
the
master
cylinder
are
integral
with
the
4. Install
the pin,
the
nuts
attaching
and
to
damage
not
during
removal.
washers
and
the brake pedal pin
and
brake line
fitting.
the
torque the nuts to
6. Bleed
the
master
master
outlet
the
cylinder
ing
Slide
brake
hy
at
the
bushing
system.
%
Fill
inch
dash
ers
disconnect
transmission
transmission vacuum unit
PEDAL SHAFT
RETAINER
74279 S
PEDAL SUPPORT BRACKET
-
SPRING
WASHER
S
358981
mission
with
an
connect
vacuum unit
slid
in
link
boot in the
bracket-to-
nuts and wash
manifold
vacuum
If the
the booster.
to
bracket
by
rod
the
panel
studs.
and
and
Install
panel.
as
the mounting
push
hole
the
equipped
vac
the
is
car
automatic
trans
transmission
hose.
4. Connect the brake line to the
the
hose.
master cylinder outlet
fitting.
BRAKE PEDAL SHAFT
PEDAL SHAFT
BUSHINGS- 2461
(AUTOMATIC
1
-
2450
TRANSMISSION)
2478
CLUTCH PEDAL AND SHAFT
ASSEMBLY (MANUAL SHIFT
TRANSMISSION)
UPPER MOUNTING
STUD 377102 S2
2 REQD.
SPACER
BETWEEN PEDAL
the
and
panel
panel
onto
retaining
(Fig. 14).
hose
manifold
bracket
link boot
Install the four
the mounting
3. Connect the
master cylinder
car
matic
the
dash
off
disconnect
and
on
through
hose from the booster unit. If
is equipped with an auto
uum
the
within
link boot
dash
the
Fig. 14.
in
studs
outlet
fitting.
cylinder
out
dash
spacers.
rod
push
2. Mount the booster
(Fig. 14).
3. Disconnect the
5. Install the
link
the
push rod
assembly to the dash
specifications.
draulic line
of
panel.
1. Install the
the hole in
spacers
then lift
from the
2. Open the hood
and
dash
the
shown
switch outer
upward
careful
switch
nylon
booster
body.
lockwashers
in
the master cylinder push rod and the
over the push rod onto the two studs
that
for the
straight
switch
pin.
3. Position
rod
side
INSTALLATION
hairpin retainer. Slide the stop light
switch off from the brake pedal pin
Part
rubber seal
follows:
stop light switch
the connector. Remove the
at
wires
push rod adjustment
the groove at the end of the
5. Remove the
from
push
engine
Remove the four
panel.
To do this,
pedal assembly.
the
Disconnect the
dimen
"Master Cyl
not correct, see
brake
proceed as
the end of the vacuum cylinder (Fig.
3, Part 2-1). If
from
1. Working from inside the car
below the instrument panel, discon
nect the booster push rod link from
master
sliding the
panel,
REMOVAL
installing
bracket-to-
four
the
dash panel retaining nuts and wash
14). Remove the booster
ers (Fig.
and bracket assembly from the dash
UNIT
BOOSTER
INSTALLATION
1. Before
4. Remove
from the top of the filler opening.
Install the filler cap and gasket.
from
seal
-BRAKES
-
SUPPORT BRACKET
AND DASH PANEL
2849 4 REQD.
BUSHING
7526
k\
LOWER
MOUNTING STUD
ROD TO
PEDAL
-
377103 -S2
2 REQD.
CLUTCH PEDAL
TO EQUALIZER
ROD 7A516
-
RETAINER
-
353467
S8
MASTER
CYLINDER
2140
BRAKE PEDAL ASSEMBLY
S2
34807- S2
4 REQD
33799
-
2455
-
NYLON WASHER
BUSHING
RETAINER
379897
-
2A 309
S2
MASTER
CYLINDER
PUSH ROD
-
2B129
STOPLIGHT
SWITCH
13480
H 1355
FIG. 1 5-Master Cylinder, Pedals
and
Stop
Light Switch
-
A
PART 2-2
5.
from inside the
Working
car
below the instrument panel, connect
the booster push rod link to the
brake
pedal
proceed as
Install
follows:
the inner
the
master
the
bushing
switch
push
Slide the
that it strad
so
rod
the
with
just
switch
switch
clearing the pin.
completely onto the
pin, and install the
nylon
in Fig. 14. Be
bend or deform the
shown
pin
and
the brake pedal pin.
on
hole
these
washer,
rod,
the pedal pin and the switch
slot on
outer
nylon
push
washer
as
careful not
to
Secure
switch.
to the pin with the hair
parts
Connect
retainer.
stop light
the
to the
switch wires
connector,
install the wires in the retaining
6. Bleed the brake
rod
push
the
with
slot on the pedal pin and
hole
outer
Slide
pin,
cylinder
Position the
dles the
To do this,
assembly.
dles the
just
the switch
and
the
clearing
pin.
onto the
nylon washer as
in Fig. 15. Be careful not to
deform the switch. Secure
shown
bend
switch
the switch
completely
install the
or
these parts to the
the hair
pin with
pin retainer.
switch
the connector, and install
the wires in the retaining clip.
to
5. Connect
the
equalizer rod to
sembly
with
the
pedal-to-
clutch
the
clutch pedal as
bushing
and
retainer.
Apply Lubriplate
bushing.
Adjust
free play to
clear
the
damage
to
the
Slide
moval.
during
switch
the
re
cylinder
master
the
if
the
off
brake
pin
pedal
(Fig. 15).
3. Remove
tainer
brake
and
pedal
the
hairpin
spring
washer
shaft, then
type
re
from the
remove
the
to
ings from the
clutch
specification
bushing
shaft, the brake pedal and the bush
the
pedal support
bracket.
pedal
required.
INSTALLATION
1. Apply a coating of Lubriplate
the bushings and locate all the
bushings in their proper places on
to
BRAKE PEDAL AUTOMATIC
TRANSMISSION
system.
the
port
REMOVAL
1.
Disconnect the stop light
switch
wires at the connector.
the
hole to
outer
switch
pin, and then lift the switch straight
upward from the pin. Be careful not
hairpin
clip.
REMOVAL
1. Disconnect
the
and
BRAKE PEDAL MANUAL
SHIFT TRANSMISSION
to-equalizer rod
2. Remove the hairpin retainer.
Slide the stop light switch off the
brake pedal pin just far enough for
push rod and the nylon washers and
4. Connect the stop light
wires
2-17
SYSTEM
-BRAKE
pedal
and
assembly
pedal
sup
bracket (Fig. 15).
2. Position
sembly to the
the
brake
support
pedal
bracket,
as
then
pedal-
clutch
the clutch pedal
at
by removing the hairpin
bushing (Fig. 15).
type
retain
er and
2. Disconnect the stop light
switch wires at the connector.
3. Remove the hairpin retainer.
Slide the stop light switch off the
brake pedal pin just far enough for
the
switch
upward
lift the
from the
damage
to
the
Slide
moval.
hole to
outer
and then
pin,
pin.
Be
the
careful not
during
switch
the
clear
switch straight
master
re
cylinder
push rod and the nylon washers and
bushing
brake
the
off
pedal
pin
(Fig. 15).
4. Remove
tainer
and
clutch
and
the
move
hairpin
the
type
pedal
clutch
shaft.
pedal
re
from the
washer
spring
brake
and
Re
shaft,
the brake pedal, and the bushings
from the pedal support bracket (Fig.
15).
INSTALLATION
1.
Apply
a
coating
to the bushings
ings in
clutch
their
and
clutch
support
Install
bracket,
then
and
shaft
pedal
bracket
the
and
spring
bush
on
the
assemblies.
pedal
2. Position the brake
support
all
places
proper
brake
Lubriplate
of
locate
and
pedal to the
install
the
through the
brake
washer
pedal.
and
re
tainer (Fig. 15).
3. Install the inner
the
master
the
bushing
Position the
cylinder
on
nylon washer,
push
the brake
switch
so
rod,
and
H1351-A
pedal pin.
that
it
strad
FIG. 1
6
Parking Brake Control
Assembly Manual
Release
GROUP
2-18
2
-BRAKES
BRACKET
CONTROL ASSEMBLY
PEDAL CABLE
2853
EQUALIZER LEVER
REAR WHEEL CABLES
EQUALIZER
H 1352
ROD
-
A
FIG. 1 7 Parking Brake System
install the
pedal
shaft
through
support
bracket
brake
sembly.
Install the spring
and
the
pedal as
washer and
retainer.
3. Install the inner
master
the
bushing
Position
dles the
outer
on the
nylon
push
brake
push
rod
with
washer,
parts to
pin
deform the
rod,
and
just
switch
the
pin
Secure
the hair
switch.
with
retainer.
stop light switch
wires to the connector, and install
the wires in the retaining clip.
the
it
the
clearing
completely
the
install the nylon washer as
in Fig. 15. Be careful not to
(Figs. 5, 16,
nut
remove
1.
Working
from the
engine com
and
the
passenger
bolt
and
panel.
control
panel,
assembly from
the hairpin
remove
that holds the cable
housing
assembly bracket, and
disconnect the ball end of the cable
from the clevis on the pedal (Fig.
to the
partment, remove the two nuts
the
that attach the control assembly
retainer
REMOVAL
parking
17).
and
from
2. Working
compartment,
the
retain
assembly to the dash
panel
the dash
PARKING BRAKE
CONTROL ASSEMBLY
pin.
onto the
that
control
3. Pull the
strad
switch
washers
brake
to the cowl upper
pedal pin.
the pedal pin and the switch
and
shown
cylinder
the switch so that
hole
Slide the
pin,
or
these
4. Connect
the
slot on
bend
17).
control
Disconnect
the
hose from the
PART 2-2
vacuum
power unit on
an automatic
release type control assembly.
INSTALLATION
brake
PARKING
BRAKE
EQUALIZER
gine
TO
REAR
WHEEL
CABLE
control
assembly with the en
running in all the transmission
selector
lever positions. With the
engine
ball
1. Connect the
cable to the clevis on
trol
pin
to the
and
con
the
running,
remain
should
"park"
or
and should
drive
power unit on
an automatic
type control assembly.
release
2. Install the two
in any
release
control
and
studs,
mounting
that the
so
assembly
studs enter the
the
position
(Fig. 17).
panel
3. Install
attach
bolt
the
control
cowl upper panel.
and
that
nut
assembly to the
Do not tighten at
this time.
4.
install
partment,
nuts
5.
the
the
washers
and
studs at
engine com
two attaching
the
on
from the
tighten
compartment,
passenger
bolt
the
assembly to the
Check and adjust
upper panel.
the parking brake
linkage, if
neces
sary.
housing
cable
rear
end
retainer
at the trans
crossmember,
support
the cable assembly for
the crossmember.
ward and out of
3. Remove the
Lower
4.
sion arm
(Fig. 17).
Remove
the
parking brake
disconnect the
control
assembly
and
et and pull
of
from the
cable
dure
under
Working
Brake Control
on
on
out of
5. Push
UNIT
and
pan
1. Remove
the
control
assembly
described under
parking
from the
"Removal"
brake
car
in
to
7. With the spring tension
out
the
of
lever, lift
brake
out
or
the
off
grind
two
the
brake
parking
the
from
piston
vacuum
lever
the release
rod
Remove
the
1. Pull
the
of
enough
housing
cable
that the end
so
the
slot
into
hole in
the
2.
the
cable
Pulling
into the
the
carrier
plate
from
slack
excess
insert the
cable,
cable
housing
access
hole
so
that the retainer prongs expand.
in the floor
3. Connect the
stall
the
of the
end
pan.
the hole
upper
pan.
of
end
front
the
housing
of
end
through the
rear
the
sus
arm mounting bracket and
install the hair pin retainer (Fig. 17).
in
outlined
the control assembly as
3. Thread
cable
pension
the
the control assembly and
cable to
of
underside of
the
through
to
disconnect the
and
lever.
the
clip that
retainer
re
and
the carrier plate hole.
INSTALLATION
the
Working from inside the car,
new cable and housing up
2.
control
pull
3. Remove the
rod
floor
the
upper
cable
replacement
the
the
guide
cable
may be inserted over
in the parking brake lever on
the rear brake shoe (Fig. 1).
Working from
1.
the
off
the
in the lever
slot
through the
the car,
assembly.
secures
under
INSTALLATION
the
rivets that attach the vacuum power
unit
it from
remove
as
procedure.
2. Drill
housing
and
cable
car.
REMOVAL
foregoing
the
cable retainer
hole.
the
parking
of
compress the
the hole in the
Draw the
move through
down through the hole in the floor
out
the cable retainer so that
can pass through
Assembly"
PARKING BRAKE
VACUUM POWER
housing
the wheel side
brake (Fig. 1),
proce
"Parking
attaches
rear suspen
the cable and
carrier plate.
control
in the
that
to the
the bracket (Fig. 17).
6.
"Removal"
as outlined
Part
1,
5. Remove the hair pin retainer
holds the cable housing to the
rear suspension arm mounting brack
the rear
car.
the
that
prongs
the
the equalizer (Fig.
housing
the underside of
at
retaining clip
floor pan.
the
nut on
disconnect
and
Remove the clip
4.
from
housing
cable
and
drum.
the cable
they
and
nut that attaches the
hairpin
the
the brake shoes,
off
in
drum
brake
2-1).
lever
equalizer
from the lever (Fig. 17).
and then pull
the
hoist. Move
a
disconnect the ball
and
2. Remove
the
the
brake
parking
of the cable
car on
Tinnerman
three
the
rod,
from
cable
1. Raise the
mounting
the dash panel.
Working from
cowl
REMOVAL
the
remove
and
3. Loosen the adjusting
equalizer
mission
Working from
back
remove the
PARKING BRAKE EQUALIZER
TO CONTROL CABLE
forward
the
hold
that
place,
the
car
and wheel.
2. Remove the
nuts
mount
holes in the dash
hub cap
position.
the
on
spacers
1. Raise the
"neutral"
in
engaged
REMOVAL
brake
parking
assembly bracket with the hair
retainer. Connect the hose to the
vacuum
ing
the
of
the pedal,
housing
the cable
secure
end
2-19
BRAKE SYSTEM
-
4. Fasten the
rear
suspension
cable
housing
to the
the retain
with
arm
'installation"
power
in the
unit.
procedure under
Assembly."
"Parking Brake Control
INSTALLATION
1. Position
unit
on
the
and
assembly
head bolts
the
4.
vacuum
power
brake
control
parking
secure
with two round
and nuts.
2. Connect the vacuum piston rod
release lever and secure with
Install the parking brake con
trol assembly in the car as described
ber
release
lock
operations
hoist. Guide
cable
hole in the
support
with
the
assembly
transmission
crossmember.
Secure
hair
and
of
automatic
the
parking
pin
(Fig.
retainer
its
from the
as shown
at
cable
the
6. Connect the
the
equalizer
housing
in the
underside of
the
edge
of
lever.
parking brake linkage
Part 2-1.
Adjust
ball
the
as outlined
in
be installed
is 4-6 inches
hose insulator
the
in Fig. 17.
5. Insert the ball
into the equalizer
end of
the cable
tighten
the
adjusting nut on the equalizer
slightly (Fig. 1, Part 2-1).
end
the three
the
hub
cable rear end
should
centerline
6. Install the
retaining clip
floor pan.
to
the
the
17).
in the foregoing
procedure.
4. Test
a
car on
of
5. Engage the
3.
installation"
end
through the
rear
retainer clip.
under
Raise the
rear
The clip
clip.
that
so
the cable assembly to the crossmem
to the
the
the
ing
and
drum,
and
drum. Tighten
rear
Tinnerman
nuts
install the
that retain
wheel
and
cap.
7. Adjust the
outlined
in
rear
Section
parking brake linkage
Part 2-1, Section 2.
brake
2.
as
shoes as
Adjust
the
outlined
in
GROUP 2 -BRAKES
2-20
MAJOR REPAIR OPERATIONS
BRAKE
DRUM
After
REFINISHING
wipe
Minor scores on a brake drum
be removed with a fine emery
cloth. A drum that is excessively
scored or shows a total
indicator
runout of over 0.007 inch should be
turned down. Remove only enough
stock
to
eliminate
the
scores
drum. The
the
with
a
one
size.
BRAKE
and
SHOE RELINING
Brake linings
0.060
%2 inch
within
been
saturated
that
of
are
should
be
replaced.
grease
or
Failure to
oil
re
may be installed. If the drum diame
ter is 11.060-11.090
replaced on
linings
must
inches,
carded.
brake
Do
repair
not
a
shoe.
1. Wash the brake shoes thor
oughly in a clean solvent. Remove
all burrs or rough spots from the
shoes.
linings will result in a
drum. When it is necessary
to replace linings, they must also be
standard
refinishing,
be dis
defective
tion exists, the shoe should
2. Check the inside diameter
of
the brake drum. If the
diameter is
less than 1 1
inches, standard lin
ing may be installed. If the diameter
.060
If the drum diameter is less than
0.030 inch oversize (11.060 inches)
after
cracks,
to
worn
the rivet or have
with
Inspect brake shoes for distortion,
or looseness. If this condi
down,
turned
surface
in clean denatured al
drum is turned down,
the opposite drum on the same axle
should also be cut down to the same
If
cohol.
refinished
up
diameter must not exceed
inch oversize (11.090 inches).
refinished
cloth soaked
can
true
is
drum
a
the
place worn
lining
scored
oversize
be installed.
site side of
the
the
wheel on
the
oppo
is
11.060-11.090 inches,
should be installed.
oversize
lining
3. Position the new lining
Starting in the center,
car.
and secure
insert
the rivets, working alter
each end. Install all
in the kit. Replace
nately towards
FILLER CAP
the
on
shoe.
parts
supplied
ment
linings
ground
are
and
no
further grinding is required.
4. Check the clearance between
the shoe and lining. The
tightly
seat
against
more
than 0.008
tween
any two
MASTER
lining
must
the shoe with
inch
clearance
not
be
rivets.
CYLINDER
SECONDARY
CUP
DISASSEMBLY
FITTING
1. Clean the
der,
and
may
remain
outside of
the cylin
the filler cap and
gasket. Pour out any brake fluid that
~
NUT
^
LOCKWASHER
OUTLET CHECK
VALVE
FIG. 1 8Master Cylinder
H1360.A
remove
in the
2. Remove
with
Standard Brake System
the
bore
with
at
cylinder
sembly,
GASKET
SNAP RING
ring
from
(Fig. 20).
with
remove
spring,
seat
from
the
the
a
master
standard
piston as
check
the
valve,
cylinder
bore (Fig. 18).
When disassembling a master cyl
inder used with a booster, remove
the
SEAL
cup,
valve
snap
disassembling
used
brake system,
and
the
the rear of the cylinder
tool 33621
3. When
FILLER CAP
cylinder or res
ervoir.
piston
assembly, cup,
and
the
spring and check valve assembly
from the cylinder bore. Remove the
O-ring from the piston (Fig. 19).
VALVE
SNAP RING PLIERS
PISTON
\
CUP
SPRING
WASHER
NUT
H1291-A
H1279-B
FIG. 1 9Master Cylinder
with
Booster
FIG. 20 Removing
Snap Ring
from Master Cylinder Typical
PART 2-2
BOOSTER
2-21
BRAKE SYSTEM
-
BODY
BELLOWS
H1265-A
H1363-A
FIG. 2 1
-Bellows-to-Booster
FIG. 22 Removing or Installing
Rear Seal to End Plate
Body Engagement
CLEANING, INSPECTION,
AND REPAIR
bly in
1. Clean all master cylinder parts
in clean denatured alcohol, and in
spect the parts for wear or damage,
replacing them as required. When
When assembling a master cylin
der used with a booster, install the
using a master cylinder repair
install all of the parts supplied.
2. Check the
the
master
ports
and
to
cylinder
kit,
vents
make
in
sure
free of foreign
Check the condition of the
diaphragm type gasket.
O-ring
on
spring
and
cup,
bore (Fig. 18).
the cylinder
the
and piston
Install
piston.
check
valve
in the
bore
cylinder
3. A leaf-type valve is riveted to
front end of the piston in a
4. Install the snap ring
back of the bore (Fig. 20).
in
the
stand
BOOSTER
are
replace
open,
When
der
inspecting a master cylin
with a booster, check the
used
lockwashers,
and
nuts
separate
in the
ports
that
they
eign
are
open
material
(Fig.
4. Inspect the
scores or
if
rust,
necessary.
free
and
sure
of
for
the
walls
and recondition
for
them
cylinder walls
Oversize
cups are not available
and
pistons
for excessively
cylinders.
any burrs or loose
that may have resulted from
5. Remove
metal
the
honing
cylinder
operation, and clean the
with
denatured
alcohol.
Dip
body in clean
heavy-duty brake fluid.
cylinder
and
the
the stop light
inder
and
tighten
brake
the master
FoMoCo
install the
valve
5. Remove the rear
(Fig. 22).
the
valve
and
the end
of
from the
seal
from
and
the
booster
the
1. Remove
clamp
lows
4. Disconnect the valve operating
from the lever assembly by re
retainer
clip
and connect
5. Disconnect the lever assembly
end
moving the
brackets
plate
retainer
by
and
clip
re
pro
and
assembly (Fig. 23).
support rings
from the bellows.
the protector
3. Remove the push rod assembly
lever assembly from
(Fig. 27).
from the
bellows
diaphragm
the
Remove the two
2.
and
bellows, bel
rings, and
from
bellows
large
the
separate the
support
valve
ing pin
and
tector
(Fig. 27).
moving the
BELLOWS,
PUSH ROD AND VALVE
manifold
vacuum
assembly
grommet
DISASSEMBLY OF
and the reaction
the control hub (Fig. 24).
4. Remove the two plastic guides
push rod. Remove the re
pivot
from the
pin.
6. Disconnect the
retainer and
7. Remove
disassemble
rod
push
by
link
removing
connecting
push rod
5. Remove
pin.
the retaining nuts,
and
brackets from
the
the
retainer
cone
action
from the
hold the
and
the
cone
(Fig. 24)
the
from the
rod
valve
plunger.
operating
To remove,
firmly and force the
breaking the plas
rod
end plate.
fitting
line
the cyl
securely.
3. When assembling a master cyl
inder used with the standard brake
system,
out
plate
plunger off the rod
switch on
them
valve,
end
plate.
rod
the
all parts except
2. Install
check
body
control
ASSEMBLY FROM DIAPHRAGM
from the lever assembly
ASSEMBLY
1.
and remove
retainer,
Remove the
rubber
cylinder
diaphragm assembly
booster
the
filter (Fig. 27).
3.
bellows,
the
end plate
cover and
and
19).
Hone the
maximum).
honed
make
than necessary (0.003 inch
more
no
to
piston
from
cylinder
body.
air
plate
end
and
4. Push the valve, tail stock,
1. Remove the two attaching
2. Remove the air filter assembly
from the booster body. Separate the
ports
screw
clamp
3. Push the bellows assembly into
(Fig. 21), and
PARTS
the
piston
body,
diaphragm assembly, and
from the booster body.
master
the piston.
booster
band,
the
separate
and
nut,
the vacuum chamber
REMOVAL OF EXTERNAL
and
Installing
or
2. Remove the clamp band
and
the
brake system (Fig. 18). If this
valve is loose or has moved so that
ard
the
separate
OF
DISASSEMBLY
the
master cylinder used with
Removing
Bellows Assembly
(Fig. 27).
that all are open and
matter.
23
FIG.
the
assembly,
19).
(Fig.
H1395-A
seat, check
valve, spring, cup, and piston
assem-
tic
8.
Remove the
the valve
rubber
operating
boot from
rod.
groove
COMPONENTS
1. Scribe
line
body, clamp band,
again,
pieces of
SEPARATION OF MAJOR
a
retainer.
used
the booster
and end
plate.
plunger
all
is to be
the broken
plunger.
the
control
hub
and
assembly clockwise to sep
it from the diaphragm plate.
plunger
arate
the
remove
the plastic retainer from the
in the
6. Turn
across
If
GROUP 2
2-22
-BRAKES
ASSEMBLY OF VALVE
ASSEMBLY, PUSH ROD, AND
BELLOWS TO DIAPHRAGM
1. Assemble
hub
CONTROL HUB
on
index
valve
on
projections
the
control
the raised
with
the flat
indexes with the
the hub (Fig. 28).
hub,
the
and
the valve plate
flat projection
Compress the
the
stall
REACTION LEVER
valve
control
the round holes in the
so that
rubber
the
assembly into
plunger
on
valve
spring, and in
the plunger
in
retainer
the control valve
groove
to
plunger
to the control
secure
hub (Fig. 26).
2. Assemble the tail stock over the
plunger with the flat on the tail stock
indexing with the flat on the hub.
3. Assemble
the tail stock and
formed
by
"O"
the
parts together
and
24 Push
Rod Assembly, Reaction Lever
then remove the tail stock and
O-ring
from the diaphragm (Fig. 25).
7. Remove the
the
plunger
26). Separate the
holds
hub (Fig.
hub and
retainer that
to the control
control
the
and
to
valve
sions
and
the
remove
retainer.
spring
toward the
2. Remove the spring,
washer
"O"
valve,
from the
valve
plunger
plate,
fiber
(Fig. 27).
ring,
and
hub (Fig. 24).
6. Assemble the
tainer,
two
and
reaction
plastic
cone, re
push
rod
Install the
push rod assembly in the valve hub
so that the push rod indexes in the
guides
rubber
these
secure
(Fig. 25).
control
Control Hub
rubber
the
5. Install the lever assembly in the
hub with the rubber protru
H1396-A
FIG.
stock and
hub assembly
diaphragm, and turn the hub
control
and
counterclockwise
PUSH ROD ASSEMBLY
groove
the tail stock and hub.
4. Assemble the tail
plunger
to the
over
ring
"V"
into the
the push rod.
on
valve plunger.
plunger assembly.
It may be necessary to file the burr
from the protruding end of the
plunger
from the
before it
control
can
be
separated
hub.
VALVE PLUNGER
TO INSTALL
the
spring towards
TO REMOVE
BOOSTER
fiber
the
rubber
valve,
"O"
valve
plate, spring,
washer on
ring,
spring
smaller
the plunger.
and
assemble the
retainer on the plunger
with
the flange towards the
spring (Fig.
27).
PLUNGER
bellows
and
2. Compress the spring towards
the rubber valve
7. Install the two bellows support
and bellows protector on the
bellows. The support rings are posi
tioned in the two larger folds of the
rings
CONTROL VALVE PLUNGER
1. Assemble
DISASSEMBLY OF CONTROL
1. Compress
ASSEMBLY OF
Snap Ring
Pliers
and
the
in
protector
the
fold.
8. Assemble the bellows on the
hub so that the lip of the bel
lows indexes in the groove on the
hub. Secure the bellows to the hub
by assembling the large bellows clamp
on the diaphragm end of the bellows
yS2"
from the end of
approximately
the bellows (Fig. 23).
control
ASSEMBLY OF MAJOR
COMPONENTS
1. Assemble the
end plate
(Fig. 22)
diaphragm,
ponents,
bly
the control
and
into the
rear
and
seal
in the
position
valve
the bellows as
the
com
an assem
end plate.
2. Install the rubber grommet in
booster body with the large di
ameter side to be outside of the
booster. Force the vacuum manifold
the
DIAPHRAGM PLATE
CONTROL HUB AND
PLUNGER ASSEMBLY
and
H1397-A
FIG. 25 Removing or
Installing
Control Hub and Plunger
Assembly
CONTROL HUB
FIG.
26
H1398-A
Removing
or
Installing
Plunger-to-Control Hub Retainer
check
valve
the grommet (Fig.
assembly
through
27).
3. Assemble the booster
body to
end plate. Make sure
that the
the
of the
lip
diaphragm is evenly
positioned
PART 2-2
-
BRAKE SYSTEM
2-23
BELLOWS SUPPORT RINGS
BOOSTER BODY
VACUUM MANIFOLD
REACTION CONE
BELLOWS
GROMMET
FILTER
COVER HUB
BOOT
OPERATING ROD
PLASTIC RETAINER
LEVER
PIVOT
END PLATE
PIN
BRACKET
H1362-A
FIG. 27-Booster Unit Disassembled
on
the retaining radius of the end
the booster body. Pull the
cure with the
front lip of the bellows through the
booster body and position it evenly
around the hole in the booster body
(Fig. 21).
around
is
press
Align the
scribe
the assembly
lines,
together,
its
being
circumference
tightened.
inch-pounds
of
as the
Tighten to
bolt
15
torque.
the
Insert
rod.
in
groove
lip
the
the
the
end
into
rod
of
the
that the retainer engages
plunger so
the
to
retainer
plastic
the
the
Install
plunger.
the boot in the groove of
of
(Fig. 27).
the rear seal
INSTALLATION OF
4. Install the clamp band over the
lips of the booster body and end
plate.
clamp band bolt. Tap
with a fiber hammer
the clamp band
plate and
2. Connect
EXTERNAL PARTS
to the
rod
1. Install the
com
valve
and se
rubber
operating
rod
boot to the
and
assemble
and
the
upper
the
connect
valve
end
of
push
operating
the
rod
lever,
link to
the center of the lever with the con
necting
pins
and
clips.
RAISED PROJECTIONS
3. Position the mounting brackets
MATCHING HOLES
to the
end
taining
plate
and
install the
re
nuts.
4. Connect the lever assembly to
lower end of the mounting
the
brackets
with
the pivot pin and clip.
5. Position
the air filter in the
filter cover, and then snap
the cover and filter on the metal hub
plastic
with
the
filter between.
6. Assemble the cover, filter, and
assembly to the booster body
with
the
metal
hub against the
booster body.
hub
RUBBER VALVE
7. Assemble
PLUNGER
H1399-A
HUB
to
the
master
FIG.
28
Assembling Valve Plunger
to
Hub
booster
cylinder
specification.
the
master
body.
cylinder
Torque
mounting
nuts
the
to
2-24
PART
2-3
SPECIFICATIONS
LINING
DIMENSIONS INCHES
Models
Position
Ford Passenger Cars
Ford & Mercury-All 427 CID Engine &
8 Cylinder Police Maximum Fade Resistant
Ford
and
Mercury Station Wagons
Ford and Mercury Passenger Cars
(240-289 CID Engine) All Taxi and
6 Cylinder Police-Maximum Wear Resistant
Mercury Passenger Cars
Primary
Secondary
2.5 x 9.34
2.5 x 12.12
2.25
2.25
Primary
Secondary
3.00
3.00
9.34
12.12
2.25
2.25
Primary
Secondary
3.00
3.00
x
9.34
12.12
2.25
2.25
Primary
Secondary
3.00
3.00
x
9.34
x
12.12
2.5
2.5
Primary
2.5
2.5
Secondary
CHECKS
AND
Rear
Front
x
x
x
x
x
9.34
12.12
x
x
2.25
2.25
x
x
x
x
x
x
9.34
12.12
Yellow-Black
Blue-Black
9.34
12.12
Yellow-Black
Blue-Blue
9.34
12.12
Silver
Yellow-White
9.34
12.12
x
x
9.34
12.12
ADJUSTMENTS INCHES
Master Cylinder Bore Diameter
Standard
1.000
Power
0.875
Master Cylinder Maximum Allowable Hone
0.003
Front Wheel Cylinder Bore Diameter
Passenger, Police & Taxi
Station Wagon
1.094
1.062
Rear Wheel Cylinder Bore Diameter
Passenger, Police & Station Wagon
Taxi (Max. Wear Resistant)
0.969
0.875
Wheel Cylinder Maximum Allowable Hone
0.003
Drum Diameter
11.030
Drum Maximum Allowable Run-Out
0.007
Drum Maximum Boring Diameter
11.090
Drum Width-Front
Passenger
Station Wagon, Maximum Wear &
Maximum Fade Resistant
2.50
3.00
Drum Width-Rear
Passenger
2.25
Taxi
2.50
Lining Maximum Wear Limit
Top of Rivets or Shoe Rim)
0.031
Lining Maximum Clearance
(Midway Between Rivets)
0.008
(From
to Shoe
Pedal Travel-Standard
Pedal
7.00
Travel Power
Power Unit
4.00
Push-Rod
Self Adjustment Cable Length
Hook-llVs inch Vu
End
Adjustment- 0.995-1.005
inches
Cable Anchor to End
Cable
of
of
Color Code
Pink
Red-Red
Silver
Yellow-White
PART 2-3
TORQUE LIMITS
Ft-lbs
Master Cylinder-To-Pedal Support Bracket
18-25
Pedal Pad to Brake Pedal Nut
12-16
Assembly-Parking Brake
Master Cylinder
to Cowl Side Bolt
15-19
Fitting
Left Hand Brake
6-12
Hose Front
to Connector Bolt
12-18
Wheel Cylinder Bleeder Screw
Vacuum Connector
FRONT
at
2-25
SPECIFICATIONS
TORQUE
Description
Control
-
LIMITS
(Cont.)
REAR BRAKES
Ft-lbs
Description
Assembly Speednut
Drum
Assembly
to Axle Shaft
Wheel
Assembly
to Axle Shaft to Drum
Assembly Nuts
Brake Cylinder to Brake Carrier Plate Bolt
Brake Carrier Plate to Axle
Hand
Push Fit
75-110
10-20
30-40*
Housing
120 in-lbs
Maximum
Engine Manifold
20-28
BRAKES
Carrier Plate
Pin Nut
and
Cylinder Assembly Brake Shoe Anchor
20-30
POWER
Anchor Pin to Spindle Bolt
Wheel Assembly to Hub
and
BRAKES
80-106
Drum Assembly Nuts
Master Cylinder to Booster Body
10-13
Brake Booster to Pedal Support Bracket
18-25
75-110
Front Brake Carrier Plate to Spindle Nut
25-45
?Models 59, 71 RPO
SERVICE
Heavy
TOOLS
Ford Tool No.
Former No.
LM-119
2035N 2086L
TOOL-4235-C
TOOL-33621
4235-C
33621
1112-144
Description
Brake Cylinder Retaining Clamp
Brake Shoe Retracting Spring
Remover and Installer
Axle Shaft and Bearing Remover
Pump Shaft Bearing Retainer and
Power Brake Pliers
Inch-Pound Torque Wrench
Duty-
55-65 Foot Pounds
3-1
SUSPENSION,
STEERING, WHEELS
GROUP
3
AND TIRES
PART 3-1
AND TIRES GENERAL SERVICE
3-1
PART 3-2
SUSPENSION
Page
PART 3-5
SAGINAW POWER STEERING GEAR
Page
SUSPENSION, STEERING, WHEELS
.
.
PART 3-6
3-52
WHEELS AND TIRES
3-11
PART 3-7
PART 3-3
SPECIFICATIONS
MANUAL STEERING
3-40
.
.
3-55
.
3-19
PART 3-4
FORD
POWER
STEERING GEAR
PART
3-1
3-31
SUSPENSION, STEERING, WHEELS AND
TIRES-GENERAL SERVICE
Section
Diagnosis
1
Section
Page
3
3-1
Testing
and
2 Common Adjustments
and
Repairs
Page
Cleaning
and
Inspection
..3-9
3-7
DIAGNOSIS AND TESTING
STEERING
MANUAL
four
or
times.
lists
Table 1
manual
various
and
steering trouble symptoms and
causes.
Several of these
possible
Do
hold the
Recheck
not
pension,
frame,
For
troubles.
that the
the
this
cause
steering
and
the
be
tire
sure
is in
trouble
the
linkage before
or
adjusting, repairing,
of
and
reason,
of
gear
wheel
replacing any
or
the fluid level.
leakage
points.
Tighten
CHECK FLUID LEVEL
tings, and replace any damaged lines
or defective seats.
stops.
STEERING-
POWER
PRELIMINARY TESTS
The
following
always
should
forming
preliminary
be
made
checks
before
any trouble-shooting
per
opera
tions.
AIR
BLEEDING
Air in the
(shown
by
be
should
that the
cation
power
steering
bubbles
bled.
reservoir
(the fluid
in
system
engine
normal
temperature.
wheel
all
making sure
is filled to specifi
be
at
On
a
lubricant
of
normal
when
pump
several
right
filler tube
with a straight
must
be to the bottom
the filler tube. If the level
add
fluid
enough
C1AZ-19582-A
level
to
stick
or
tube.
Do
F
the
to
the
not
to
mark
bottom
overfill
is low,
transmission
automatic
raise
on
of
the
the
the
dip
the filler
the
and
steering wheel.
1. With the
Use only the specified type of belt.
Refer to Part 3-3 for belt adjustment.
idling,
turn
ing
to turn the
required
car
dry
on
properly
correct,
concrete,
to the left and right several
wheel
times to
warm
3. Attach
the fluid.
a pull scale
to the rim of
the steering wheel. Measure the pull
required to turn the wheel one com
revolution
effort
steering
in
required
each
direction.
to rotate
the
wheel should not exceed
5.0
pounds.
PUMP-FLUID PRESSURE TEST
fluid
whether
the
wheels
pressures
the parking brakes.
2. With the engine warmed up and
running at idle speed, turn the steer
A
CHECK FOR FLUID LEAKS
engine
loose fit
all
set
plete
If the pump belt is broken, glazed,
worn, replace it with a new belt.
With the
front
tire
check the effort
The
the
temperature
operating
is made), turn the steering
check
its full travel three
through
wheel
With
aligned
reservoir.
CHECK PUMP BELT
or
possible
CHECK TURNING EFFORT
the
times, and shut off the engine.
Check the fluid level in the power
the
all
fluid is
the
until
operating
Then turn the steering
way to the left and
fluid)
the
After
must
Run the
at
steering reservoir. The level must
be at the full mark on the dipstick.
parts.
steering
stop
Check
to sus
common
also
are
to
stop
times.
their
power
symptoms
from
wheel
steering
several
wheels against
unit
in
pressure
the
the
pump
power
test
or
will
show
some
other
steering
system
FORM 7098-65
LITHO IN U