DEMO - 1965 Ford Thunderbird Shop Manual

1965
FORD
SHOP MA
Copyright © 2009, 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 Thunderbird Shop Manual
EAN: 978-1-60371-015-2
ISBN: 1-60371-015-9
Forel Publishing Company, LLC
3999 Peregrine Ridge Ct.
Woodbridge, VA 22192
Email address: [email protected]
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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services of a competent professional should be sought.
GROUP INDEX
VEHICLE IDENTIFICATION
BRAKES
SUSPENSION-STEERING-WHEELS & TIRES
REAR AXLE
CLUTCH -DR I VELINE
MANUAL TRANSMISSION (Not
Applicable)
AUTOMATIC TRANSMISSION
ENGINE
IGNITION SYSTEM
.
,SK
FUEL SYSTEM 0
COOUNG
;
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5T0I,
CHAJfcGtHG
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VINtlUTING-rKATIW^
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SOn IRIM-CONVIRTIBII W
p
MAINTENANCE SCHEDULE
MAINTENANCE OPERATIONS
LUBRICATION CHARTS
INDEX
SERVICE
FORD
DEPARTMENT
DIVISION
(^g^MOTOR
FIRST PRINTING
1964
FORD MOTOR
SEPTEMBER.
COMPANY.
SPECIFICATIONS AND SPECIAL SERVICE TOOLS
AT END OF EACH GROUP
COMPANY
1964
DEARBORN, MICHIGAN
Reproduced under License # 5008 from Ford Motor
Company May
-
2000
FOREWORD
This shop
complete
the Service Technician
manual provides
information for the
proper
with
servicing of the
1965 Thunderbird
The information is
work
being
frequently
grouped
performed,
such
according to the type of
as
diagnosis
performed adjustments and
adjustments,
overhaul,
mended special
Refer to the
etc.
testing,
and
repairs, in-vehicle
Specifications
recom
and
tools are included.
opposite page
for important
vehicle
identi
fication data.
The descriptions
in
effect at
ing.
the time this
The Ford Motor
discontinue
or
and specifications
design,
w
models
at
in this
manual were
manual was approved
Company
any time,
reserves
for
the
print
right
to
or change specifications
ithout notice and without incurring obligation.
SERVICE
DEPARTMENT
FORD MOTOR COMPANY
1-1
GROUP
VEHICLE
IDENTIFICATION
DATE CODE
EXTERIOR PAINT COLOR (WHITE
BODY STYLE
AXLE RATIO CODE
26TH DAY AUGUST)
(3.00:1 AXLE
I
NTERIORTRIM
(2 DOOR LANDAU)
(WHITE VINYL)
RATIO)
TRANSMISSION CODE
(3-SPEED DUAL
RANGE AUTOMATIC)
DETROIT DISTRICT
1
-\
i
BODY// COLOR)) TRIIVUJDATE/V
63B
I
1
UAXL E IITRANS
dso/
N
20'
My
33
26H
6
VEHICLE WARRANTY NUMBER
IEWS MANUFACTURED JNDER UNITED STATES
D
-QPEICftN
PaA\NTS AND PATENT APPLICATIONS
A P\\ODl\VT OF
MODEL YEAR
(1965)
ASSEMBLY PLANT
(WIXOM)
BODY SERIAL CODE (2-DOOR
\^ord
COMPAN'
MOTOR
CONSECUTIVE UNIT NUMBER
"^ENGINE CODE (8 CYL. 390 CID ENGINE)
LANDAU)
M1087-C
Fig. 1 -Thunderbird Warranty Plate
a Thunderbird Warranty plate. The warranty plate is
to the rear (lock) face of the left door.
The official Vehicle Identification Number for title and registration purposes
is stamped on the hood support top surface to the right of the hood lock
plate (Fig. 2). Do not use the Vehicle Warranty Number which appears on the
warranty plate for title or registration purposes.
letter for an Equa-Lock axle. The last code in the
data is the Transmission Code and consists of one number. The
that follow, list in detail the various vehicle data codes.
Figure 1 illustrates
a conventional axle or a
attached
vehicle
charts
VEHICLE WARRANTY NUMBER
warranty number is the second line of numbers and letters
the Warranty Plate(Fig. 1). The first number indicates the model
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 codes.
The
vehicle
appearing
on
BODY SERIAL AND STYLE CODES
The two-digit
follows the assembly plant code identifies
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 body type.
the
body
Body Serial
Body Style
Code
Code
81
63D
63A
76A
63B
M1088-B
83...
85
Identification
Fig. 2
Number Location
-Vehicle
VEHICLE DATA
The vehicle data appears in a line across the top of the warranty plate
(Fig. 1). 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, 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
numeral which
series.
87
Body Type
2-Door Landau Special
2-Door Hardtop
Convertible
2-Door Landau
EXTERIOR PAINT COLOR CODES
Code
A
B
c
G
M-32-J
Number
1724-A
1450-A
1736-A
1446-A
1226-A
1743-A.
Color
Black
Dk. Turq. Met.
Med. Ivy Gold Met.
Med. Silver Mink Met.
Lt. Blue
Lt. Ivy Gold
VEHICLE IDENTIFICATION
EXTERIOR PAINT COLOR CODES (Continued)
1544-A
1515-A
.
P
DISTRICT CODES
Dk. Blue Met.
Red
White
Platinum
1619-A
921-A
1738-A
1624-A
1879-A
1744-A
1631-A
1070-A
1555-A
1632-A
1630-A
1734-A
a Domestic Special Order, Foreign Special Order, or
Pre-Approved Order have the complete order number recorded in this
space. Also appearing 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.
Thunderbirds built to
Palomino Met.
Med. Blue Met.
Dk. Ivy Green Met.
Dk. Grey Met.
Lt. Beige
Med. Turq. Met.
Rose Beige Met.
.....
Maroon Met.
Med. Beige Met.
Lt. Aqua
INTERIOR TRIM CODES
Code
Trim Schemes
Silver Mink Cloth and Vinyl
Silver Mink (W Headrest) Cloth
11
41
12
42
16
46
19
49
20
50
21
51
22.
52
24
54
25
55
26.
56
27
57
28
29
59
30
60
32
62
33
63
35
65
36
66
39
69
DATE
The
of
code
the
letters
.
and
Vinyl
Blue Cloth and Vinyl
Blue(W Headrest) Cloth and Vinyl
Black Cloth and Vinyl
Black (W, Headrest) Cloth and Vinyl
Palomino Cloth and Vinyl
Palomino (W Headrest) Cloth and Vinyl
White Vinyl
White (W Headrest) Vinyl
Lt. Silver Mink Met. Vinyl
Lt. Silver Mink Met. (W Headrest) Vinyl
Lt. Blue Met. Vinyl
Lt. Blue Met. (W Headrest) Vinyl
Lt. Beige Met. Vinyl
Lt. Beige Met. (W Headrest) Vinyl
Red Vinyl
Red(W Headrest) Vinyl
Black Vinyl
Black (W Headrest) Vinyl
Lt. Aqua Metallic Vinyl
Lt. Aqua Metallic (W Headrest) Vinyl
Lt. Gold Metallic (W Headrest) Vinyl
Med. Palomino Vinyl
Med. Palomino (W Headrest) Vinyl
White Pearl Leather
White Pearl (W Headrest) Leather
Lt. Blue (Low Met.) Leather
Lt. Blue (Low Met.) (W Headrest) Leather
Burgundy Leather
..
...
month when
are
to be
the Thunderbird
by
a numeral
was completed.
used if model production exceeds
12
The
March
April
E.
F
G.
May
July
August
September
October
November
December
...
...H.
J
K.
.
.
L
M
Kansas City
Omaha
St. Louis
Dallas
Houston
Charlotte
Philadelphia
Jacksonville
Richmond
Washington
Cincinnati
Cleveland
Detroit
34
35
Indianapolis
36
Louisville
Chicago
Fargo
Rockford
Twin Cities
Lansing
AXLE
Memphis
74
81
83
84
85
89
90-99
New Orleans
Oklahoma City
Los Angeles
San Jose
Salt Lake City
Seattle
Ford of Canada
Government
Home Office Reserve
American Red Cross
Transportation Services
Export
RATIO CODE
Ratio
TRANSMISSION CODE
Code
Type
6
3-Speed Dual Range Automatic
MODEL
The
the
day
year code
YEAR
number
ASSEMBLY
5 designates 1965
PLANT CODES
Code
Letter
Assembly
A
D
E
G
H
J
K
L
Atlanta
Dallas
Mahwah
Chicago
Plant
Lorain
Los Angeles
Kansas City
Michigan Truck
Code
Letter
Assembly
Plant
N
P
R
Twin Cities
San Jose
S
Pilot Plant
T
U
W
Y
Z
Metuchen
Norfolk
Louisville
Wayne
Wixom
St. Louis
N
ENGINE CODES
P
....D
June
53
54
55
61
62
63
64
65
71
72
73
Second
Model Year
A
B
C
....
Davenport
Denver
Des Moines
months.
First
January
February
I istrict
45
51
52
3.00:1
show
second
Model Year
Month
to
Code
Boston
Buffalo
New York
Pittsburgh
Newark
Atlanta
Code
CODES
month are preceded
District
11
12
13
14
15
21
22
23
24
25
26
31
32
33
REAR
Burgundy (W Headrest) Leather
Red Leather
Red (W, Headrest) Leather
Black Leather
Black (W. Headrest) Leather
Med. Palomino (Leather Print) Leather
Med. Palommo(Leather Print)(W, Headrest) Leather
letters for the
Code
41
42
43
44
-
.
(DSO)
.
.
.
Q
Code
R
S
T
U
Z
9
V
W
X
Y
Z
Type
8 Cylinder 390 Cubic Inch (4 barrel)
8 Cylinder 390 Cubic Inch (4 barrel Low
Compression)
CONSECUTIVE UNIT NUMBER
The assembly plant, with each model year, begins
number 100001 and continues on for each unit built.
with consecutive
unit
PART 2-1
GENERAL BRAKE SERVICE
PAGE
.
PART 2-2
BRAKE SYSTEM
PAGE
PART 2-3
SPECIFICATIONS
.2-1
2-26
2-7
PART
2-1
GENERAL BRAKE SERVICE
Section
Page
Section
Page
Diagnosis and Testing
2 Common Adjustments and Repairs
3
2-1
2-4
1
Cleaning
and
Inspection,
.
.2-6
DIAGNOSIS AND TESTING
1. Check
in
level
fluid
the
SAE
add
cylinder, and
master
parking brake. Depress the
brake pedal several times to
TESTING
PRELIMINARY
the
70R3re
quired.
as
it
running
and
will
the
car
tween
the released
check
the
To
eration,
check
the
tion
the
ad
press the
follow the
under
"Brake
in Part 2-2, Sec
several
reverse
uniform
brake
stops
front
the
adjustment
is
a
engine
Check
will
shut
pedal and
position.
hydraulic
off,
ex
De
hold it in
system.
If the
pedal
auto
system
is leaking.
tubing, hoses, calipers,
cylinders, and connections for
all
permanent
cylinder.
pedal movement
bleed the hydraulic
feels
system
from the lines and
See "Hydraulic System
Section 2. Also, check for
insufficient fluid.
remove
built-in feature.
tral,
the
stop the
transmission
engine
and
in
apply
neu
the
leaks
operation
cause of
will
re
will
not
the trouble.
ROAD TEST
The
car
should
be
road
tested
only if the brakes will safely stop
the car. Apply the brakes at a speed
of
25-30
to check for the exist
mph
trouble symptoms listed
in Table 1, with the exception of
brake chatter and those symptoms
resolved in the
preliminary tests. For
of
the symptoms
encountered,
check and eliminate
the causes which
listed in Table 1. To check
for brake chatter or surge,
apply the
brakes lightly at
50
are also
approximately
If the brake
to
the
correct
each
air
Bleeding,"
3. With
bleeding
enough
brake fluid.
lease the brakes, but it
under this pres
leaks.
the
long
under
pressure
in the
gradually falls away
sure, the
screw
to let out a few drops of
This
be moved,
the car must
ence of the
brake
applied
and
the bleeder
to
all vacuum
spongy,
the
less
and
locked
open
Chatter
mph.
adjustment at
disc brakes,
away
Guide."
the
and
to fall
hold the pedal in the
applied position. If no action is felt,
the vacuum booster system is not
functioning. Follow the procedures
in the "Booster Diagnosis
haust
rear wheels.
matic
pressure
required
wheel
ensure
On
foot
be
op
or
hold it in the
and
tend
will
adjuster
binding
Then, de
Start the engine. If
system is operating, the
4. With the
2.
Make
to
and
be
adjustment
for
described
Adjustments"
If the
halfway
shoes and
improper installation
procedure
is
pedal
adjusters.
components
Shoe
engine
the system
position
brake
rear
as
still.
brake
the
automatic
check
juster
than
more
floor,
and
is in
is standing
travels
pedal
the
while
go
vacuum
or
down
pedal
system.
applied position.
the vacuum
2. Push the brake
far
the pedal
press
Wagner 21B(301) brake fluid if
in the
all vacuum
service
exhaust
or
5. Should
one
of
the
brakes be
or
surge will
apply
entirely to rear brakes only.
For booster removal and installa
almost
tion
procedures,
Section 3. For
refer
sembly procedures,
Section 4. For
tion refer to
to
Part 2-2,
disassembly
refer
and
to Part
as
2-2,
cleaning and inspec
Part 2-1, Section 3.
2-2
GROUP 2
TABLE 1 -Front
(Disc)
Brake Trouble Symptoms
and
-BRAKES
Possible Causes
CD
c/>
ro
CD
"So
CD
e
CL
E
CC
CD
o
</>
oo
CD
CL
ro
Li_
a.
tr
~ro
o
-o
tr
ro
CD
Q_
oo
<_>
<C
oo
ro
tr
o
lit
ro
Q
a.
CD
>
CO
>-
~ro
-j
GO
POSSIBLE CAUSES OF TROUBLE
Shoe
Lining
and
Piston
Shoe
and
Air Leak
or
Knock-back
and
Violent
after
Lining Assembly
Insufficient Fluid
in
System
Loose Wheel
Bearing Adjustment
Damaged
Worn Caliper Piston Seal
or
not
or
Cornering
or
Rough Road Travel
Properly Seated
or
Positioned
Caliper
Rotor
Excessively
Frozen
or
and
or
CD
a.
o
CD
:>
>
0
</>
CD
oo
in
0)
Jd
CD
oc
c_>
CO
O
r-
UJ
to
oc
X
m
a.
Rotor
Loose Caliper Attachment
Slightly Increase
Excessive Clearance Between Shoe
Shoe Hold Down Clips Missing
Operator
Riding Brake
or
Up in
of
Parallel
ro
ro
a5
CO
I
<5
X
X
X
X
X
a5
o
z.
X
and
X
X
X
X
X
X
X
X
Caliper
or
X
Between Shoe
and
Splash Shield
X
Improperly Positioned
X
X
Pedal
X
the Cylinder Bore
with
oc
JZI
-O
ro
X
or on
the Piston Surface
X
X
Bleeder Screw Still Open
Caliper Out
>^
ro
X
Scores in the Cylinder Bore
Corrosion Build
<5
CD
JC
CO
oo
tr
LSe
X
Decrease Pedal Effort
or
tr
CD
UJ
X
X
Need to
o
o
oo
<_)
8=
X
Booster Inoperative
with
CD
CO
UJ
X
Alignment
CD
-tr
oo
Z>
Proportioning Valve Malfunction
of
"cd
:e
X
tr
X
Lining Worn Below Specifications
Caliper Out
ro
CD
z>
at
D
>
CD
ro
X
Linings
on
jr
tr
">o
X
Parallel
Grease
CD
tx
CD
tr
CD
X
Seized Pistons
Brake Fluid, Oil
Shoe
out of
-a
CUJ
Q
~TO
X
Rotor
of
rj
LU
tr
-Z
CD
TO
o
-o
CQ
CD
a.
X
Improper Booster Push Rod Adjustment
Excessive Lateral Run-Out
tr
o
CD
tr
Q_
ro
DO
O
C/5
CO
</
ui
oo
tr
:>
CD
?-
CD
Q
Rotor
X
PART 2-1
TABLE 2 -Rear
(Drum)
Brake
and
-GENERAL
2-3
BRAKE SERVICE
General System Trouble Symptoms
and
Possible Causes
(A
*
o
O
Li.
>
TS
>
C/0
</>
oo
ro
Ul
POSSIBLE CAUSES OF TROUBLE
Mechanical Resistance
at
Pedal
or
Leaks
or
"ro
O
-o
o
00
CD
o
ro
Q_
co
o
e
o
ro
a.
cn
to
CD
CD
tr
X
ro
CD
CL
rr
X
X
X
X
Improperly Adjusted Brake Shoe
of
Round
Lining Glazed
or
Grease
on
Oil
or
oo
"=)
CD
a_
it
CO
ro
O
tr
O
00
CD
a_
CD
o
CD
>
00
CD
o
_*:
CD
ro
O
CO
X
UJ
X
X
X
X
X
X
X
X
X
X
Worn
Lining
X
"ro
r>
ro
CD
C
<
-2d
o
oo
o
"ro
JC
-o
ro
CD
CD
o
-tr
Dirty Brake Fluid
X
Faulty Master Cylinder
X
X
X
X
X
X
X
X
Operating
Insufficient Shoe-to-Carrier Plate Lubrication
Tire Tread Worn
Loose Front Suspension
Cracked Drum
o
a
O
OO
CD
OO
o
X
ro
CO
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
to Drum Contact
Left by Drum
X
X
Air in Hydraulic System
"Threads"
z
X
X
Lining
"o
ro
Z
CO
CL
CL
<
jQ
c5
CD
Drum-Lining Surface
Self Adjusters Not
lo
X
Faulty Brake Cylinder
Poor
CD
>
=5
Scored Drum
on
CO
<3
a.
oo
tr
c
-o
cn
X
Loose Lining
Dirt
OS.
X
X
X
Loose Carrier Plate
CD
O
CD
X
Faulty Retracting Spring
Drum Out
-O
-tr
ro
X
Improper Tire Pressure
or
CD
ro
'
X
Insufficient Fluid
Distorted
o
"35
-tr
OO
ro
"ro
c_>
-J
01
O
Shoes
Brake Line Restricted
CO
Q
JC
at
tr
CD
D
O
BO
Q
CO
ro
00
CD
CD
OO
CD
CD
(A
00
CD
o
0.
X
X
Turning Tool Pulls Shoes Sideways
X
X
X
24
GROUP 2
-BRAKES
BOOSTER DIAGNOSIS GUIDE
If the preliminary tests show that
booster is inoperative or if a
the
hard
BOOSTER INOPERATIVEHARD PEDAL
pedal condition still exists after
the causes of "Excessive
eliminating
Pedal
in Tables 1
Effort"
caused
nect the
vacuum
remove
the
all
If the
after
Check
probably
caused
all
Check
2,
causes
the
by
hoses for
drag
still
a
or
grab
listed in
is
condition
for
shell.
being
Check
out of
the
locating
housing. Check for
a
radii
foregoing
front
shell
check
the
from the
diaphragm
assemblies
sure that
are
between the
assemble
as-
positioned.
cause leak-
could
atmos-
diaphragms.
Remove
assembly.
plunger
When
the diaphragm
vacuum and
pheric sides of the
and
damage
for
properly
Improper location
assembly
plates
leaks.
cause
sembling, be
age
rod
assemblies
would
shell, and
rear
and
the
Separate the
car.
valve
does
remove
disc, diaphragm
reaction
that
procedure
the trouble,
booster from the
the booster.
and
dis-
Clean, inspect,
and replace parts as necessary.
the
seated
the
and
diaphragms
in the
or
sticking
If the
not eliminate
valve
sticking
and
disassemble
Remove
Check for a leak in
rear
a
Re-
booster.
SELF APPLICATION OF
BRAKES WHEN
ENGINE STARTS
a
for leakage
condition.
collapsed
and
and
look for
check valve.
brakes
1
booster,
manifold
and
connections
eliminating the
Tables
the
at
assembly,
or obstruction.
or
line
vacuum
faulty
or
vacuum
leaking
listed
2 the trouble may be
vacuum leakage. Discon-
by
sticking
Pedal"
and
check valve
BRAKES DRAG OR GRAB
"Hard
or
pair or replace parts as necessary.
located
necessary.
as
parts
sure that the
Clean, inspect
poppet.
valve
replace
diaphragms
when
are
Be
properly
assembling.
un-
COMMON ADJUSTMENTS AND REPAIRS
8. Release the parking
PARKING BRAKE LINKAGE
ADJUSTMENT
Check
the
when
parking
brakes are
If the cables
as follows:
1.
are
fully
loose,
cables
released.
them
adjust
to make
shoes
return
to
sure
the
that
brake,
fully
10. Release
and
the brake
released
again,
and
9. Depress the parking brake
brake
parking
depress the pedal
the
then
Viinch. The brakes
with the pedal
position.
If the
pedal
two inches. Under normal conditions,
lease,
this will satisfactorily hold the car.
or
the parking brake
down the manual
Fully release
by pushing
pedal
rear
check
should
not
drag
depressed Vz inch.
brakes do
the
binds. Free the
not
cables
fully
for
re
kinks
cables as required.
U-CLIP
lever.
release
2. Raise the
3. Adjust
against
car.
the
pedal
shown
in
nut on
the
dimension
the
lever
equalizer
the cable spring on the
to
cable
brake
the
check
Fig. 1.
4. Loosen the adjusting
equalizer
in front
nut
and
rod,
of
then turn the lock
the
equalizer several
turns forward.
LEVER-TO-CABLE
ADJUSTING NUT
5. Depress the parking brake pedal
1% inches from its normal released
position.
6. While turning the
a
rearward
justing
until
a
rear wheels
turn
direction,
nut
against
moderate
the
drag
the
in
ad
equalizer
is felt
(Fig.
EQUALIZER LEVER
1).
7. When the
cables
are
CABLES TO
REAR WHEELS
properly
H1307-A
adjusted, tighten the locknut against
the
equalizer.
FIG. 1
-Parking
Brake Adjustments
PART 2-1
#15 OR #16 U.S.S. GAUG E SHEET STEEL
MASTER CYLINDER PUSH
ROD ADJUSTMENT
The
push
rod
is designed
with
to
adjustment screw
self-locking
booster
the
and
piston
is
screw
the
is bled
completed. The
is
bleeding
fluid level should be within % inch
The
reservoir.
of the
the
of
a
pro
the
original
top
t
adjustment
does
adjustment screw
ing
any further attention provid
the push rod assembly remains
in the
However,
original unit.
a new push
is
rod
push
assembly is transferred to
other unit, the distance from the
rod
the
of
surface
mounting
body
a
should
be
the
rechecked either with
gauge
0.990-0.995
to a
inch,
di
height gauge as shown in Fig. 2.
The details for making a height
in Fig. 3.
gauge are given
adjust
serrated
the push rod, hold the
end
be sure that all air is expelled
from the brake cylinders, disc brake
calipers, and lines.
The hydraulic system can be bled
to
or with
a
To
the rod with
of
with
or
pressure
of
in
frequent
checking
cylinder
be
may
the
of
to
or
shorten,
out
to
cup in the hydraulic cylinder should
just clear the compensating port hole
when the unit is in the fully released
This
position.
a
be
can
few drops
checked
by
brake fluid
of
the compensating port and ap
plying light air pressure to the output
over
the
of
master
bubbles appear, the
the primary piston
If
cylinder.
is
port
cup
open.
overlaps
compensating port, there
flow
be
will
air
no
the compensating
port. If this condition exists, the ad
the
screw should
be turned into
push rod a slight amount or until
the compensating port
is
open.
HYDRAULIC SYSTEM BLEEDING
When any
has
system
repair
or
part
been
after
of
Bleed
for
ajr
get
and cause
the
hydraulic
the
disconnected
replacement,
into the lines
action.
may
pedal
spongy
hydraulic system
it has been properly
connected
tire
disc
the
is
bleeding
to complete the
it
and
be
should
pounds
MANUAL BLEEDING
dirt from the
all
2. Remove
the
the
Push Rod
SCREW
Gauge
(301) brake fluid during the
Never
an
adapter
cap
attach
the
and
reservoir,
by
has
which
a
bleeder
wrench on the
right rear
brake
4). Attach
a
box
%-inch
bent
fitting
rubber
the
on
(Fig.
wheel cylinder
drain tube to
the bleeder fitting. The
end
the
of
fit snugly around the
bleeder fitting.
2. Submerge the free end of the
tube in a container partially filled
with clean brake fluid, and loosen
tube
should
the bleeder
approximately Va
fitting
on
at the
will
cap
and
hole. The
the
on
cap can be fabricated
hole in the center of a
seated and
master
a
soldering
adapter
cap
completely
cylinder
or
fitting
must
be
sealed
leakage
occur.
3. Position a %-inch box wrench
the bleeder fitting on the right
on
rear
brake
wheel
cylinder
(Fig. 4).
drain tube to the
bleeder fitting. The end of the tube
Attach
a
rubber
fit snugly around the bleed
fitting.
4. Open the valve on the bleeder
should
er
tank to admit pressurized
brake fluid
to the master cylinder reservoir.
5. Submerge the free end of the
in a container partially filled
tube
clean brake fluid, and loosen
bleeder fitting.
6. When air bubbles cease to ap
pear in the fluid at the submerged
with
turn.
3. Push
brake
the
pedal
down
slowly thru its full travel. Close the
bleeder fitting, then return the pedal
to the fully-released
to
a
cutting
reservoir
system.
appear
the
at
Repeat
bubbles cease
the
position.
submerged
45'
APPROXIMATELY
of
end
the tube.
of air
fitting
the
each
front,
fluid
bubbles,
this
cylinders
wheel
and
in
the bleeder
procedure
or
disc
on
calipers
left rear,
front. Refill
order:
left
is completely
close
the drain tube.
and remove
5. Repeat
brake
Rod Adjustment
bleeding
been drained from the hydraulic
1. Position
fitting
adapter
securely
brake fluid
use
4. When
-Push
2 IB
operation.
free
H1086-A
filled
70R3-Wagner
SAE
new
An
Keep
reservoir
cylinder
master
master
cylinder
master
cap, install
the
10-30
cap.
reservoir
reservoir
operation,
charged with
the adapter cap.
Bleed the longest lines first.
with
be
obtained.
air pressure.
of
cylinder
to
calipers.
pedal
drained from the hydraulic system.
The bleeder tank should contain
enough new heavy-duty brake fluid
access
gain
on
firm
a
1. Clean
this operation until air
ADJUSTMENT
FIG. 2
while
and
wheel
in order to
bleeder fittings
the
brake
If
the
of air through
justment
that
check
and
Bleed the longest lines first. Never
brake fluid which has been
use
bleeding.
to
seated.
car,
bleeder tank hose to the
After assembly of the master cyl
inder to the power section, the piston
port
master
necessary
Remove the front
the
driving
lin
and
shoe
properly
PRESSURE BLEEDING
cross-
turn the adjustment
lengthen.
placing
bleeding
With disc brakes, more pumping
the pedal is required and more
assemblies
milled pliers and
screw
7. Before
sure
manually
are
assemblies
the operation of the brakes
equipment.
depth
micrometer
mension of
end
booster
the
of
an
to
screw
adjustment
FIG. 3-Push Rod Guage
Dimensions
that the
and
positions
ing
when
the
used or
H1087-C
not re
quire
are returned to their normal
pistons
-%"*
service
normal
reservoir
the
properly
installed.
cap before the cap is
6. Be sure that the front brake
1
*1-1/16'S-
Under
unit.
at
in
be
should
gasket
positioned
0.995"
the
of
assembly
cylinder
diaphragm-type
l3/4"
master
to the correct height
set
the time of
power
The
piston.
each
when
and
operation
0.990"
cylinder
after
reservoir
cylinder
master
brake
H
~
'
relationship between
vide the correct
the
-
25
BRAKE SERVICE
-GENERAL
the
at
right
the
HI 300 A
FIG. 4-Brake Bleeder Wrench
2-6
GROUP 2
end
of
drain
the
tube,
the
close
bleeder fitting and remove the tube.
7. Repeat this procedure on the
brake cylinder or disc caliper at each
in
wheel
left rear, right front,
front. Refill the master
order:
left
and
cylinder
reservoir
cylinder
is bled.
8. When the
after
brake
each
close
valve
remove
bleeding
bleeder
tank
tank
hose
the
from the adapter fitting.
9. Remove the adapter cap,
the master cylinder reservoir to
in Yh inch from the top
Be sure that the
is properly
gasket
10. Be
refill
to their normal
lining
that the shoe and
positions and
with
positioned
in
install the
the reservoir cap, and then
front brake
the
that
sure
are returned
pistons
the res
of
cap.
assemblies are
11. Before
diaphragm-
ervoir.
type
is
operation
the
completed,
and
-BRAKES
the
that
sure
check
be
the brakes and
of
firm
a
the car,
driving
operation
seated.
properly
is
pedal
obtained.
CLEANING AND INSPECTION
FRONT BRAKES
When the
be
1. Remove the
wheel
tire as
and
Group 3, in
bearing failure.
shoe
lining
and
assemblies
as
out
lined in Part 2-2, Section 2.
2. Make three thickness measure
ments with
middle
micrometer across the
section
ing. Take
and
a
in
one
gether)
to
(shoe
0.030
terial only)
at
lining
and
front
the
as
a
thickness
lining
(lining
one
measuring locations,
shoe
side
and
inch
any
each
If
center.
worn
or
at
reading
the
sembly has
0.195 inch
the shoe and lin
of
one
of
to
ma
replace
assemblies
(4)
all
both
on
the
shoe
insert
installed,
semblies
between the
If the clearance is
lining
gauge
0.010
inch,
lining
the
for
on
piston
pushed
and
shoe
a seized
function
of
a
bridges, for
the
just
plication
prior
the
eliminate
by
the
checking the
to
brakes
rotor
wheel
the
tightening
After tightening the
drag
may
Clamp a dial
housing so
caliper
contacts
the
end
play
nut.
adjusting
to see
nut check
be
indicator
that
the
to
the
stylus
rotor at a point approxi
reading.
If the reading
edge.
indi
exceeds
0.002 inch total indicator runout,
place
the
refinish
out
in
a
rotor.
rotor
excess
hold
is
Over
of overheating are
relining brakes, the
wheel cylinders should be disassem
bled and inspected for wear and dirt
in the cylinder. The cylinder cups
and
other
in the
parts contained
or
removal
8. If
seized
indicate
pistons
disassembly
upon
or
if the
or
excessively worn,
the caliper
damaged,
or
bores
cylinder
are
scored
the
replace
as
springs
could
cause
halves
The two
assembly
caliper
be sepa
failure of one
replacement of both as a
should
Damage
requires
the
of
never
or
necessary.
lose their
the
pull
lining
new
prematurely if
they
are
and
to
not
replaced.
5. If the
miles
linings,
car
has 30,000
operation
of
or
more
brake
signs
kit
be replaced, thus
should
avoiding future
6. Inspect all
and
or
the
on
when
overhaul
sembly.
rated.
springs
heated
present
disassembly.
and
is found to be distorted
problems.
other
any that
replace
brake
are
parts
worn
or
damaged.
7. Inspect the brake drums and,
if necessary, refinish. Refer to Part
2-2, Section 4 for refinishing.
unit.
REAR BRAKES
drum,
and
Do
not
attempt
that indicates
of specification.
re
to
run
the
from
wheel
remove
the
in
brake
the parts except the
all
cleaning fluid
a
pressed
and
dry
lining
cessive
are
with com
dust from the
all
interior
of the
3. Inspect the brake
If the
shoes
air.
plate and
wear
or
is
worn
of the rivet
heads
lining
damaged, they
carrier
brake drum.
for ex
damage.
shoes
shoe
to
or
must
within
if the
be
Vx2
shoes
replaced.
Replace any lining that has been oil
saturated. Replace the lining in axle
Prior
sets.
to
replacement
lining, the drum diameter
checked
ings
to
must
determine if
brake
shoes,
drum for
of
should
oversize
the
condition
of
be
lin
the
retracting springs, and
If the
signs of overheating.
Clean
UNIT
all metal
parts
After the
in
a suitable
have
been thoroughly cleaned, those parts
which came in contact with brake
fluid should be re-washed in alcohol.
solvent.
Wash
all
plate
dirt
out
metal
parts
all plastic parts and
center
and
recesses
seal
in
the
rubber
Blow
alcohol.
cleaning solvent from
and
internal passages.
When
overhauling the booster, use
furnished in the repair kit.
Discard all old rubber parts ex
all
parts
cept
is
the
be installed.
4. Check
BOOSTER
the drum as out
lined in Part 2-2, Section 2. Wash
inch
rotated.
outer
mately 1 inch from the
Rotate the rotor and take an
cator
first
runout,
bearing
that the rotor can still
5.
re
overheating,
the retracting and
leakage
2. Brush
check
indicating
length,
wear
1. Remove
should
slightly.
4. To
slight
a
cessively scored replace it.
7. Visually check the caliper. If it
is cracked or if excess leakage is
evident, it should be replaced. Slight
seal.
clearance
be 0.002-0.010 inch. However, if the
Vehicle was stopped by a brake ap
clearance,
springs show a change
placement of
a
cylinder
have
if the
piston, or for mal
piston
Ordinarily,
and
properly
back in the
bore, for
rotor.
order to pre
blue coloring, or
in free
shoes
down
feeler
a
being
not
caliper
seated
as
not within 0.002-
check
assemblies
lining
and
as
6. Check the rotor for scoring.
Minor scores can be removed with a
fine emery cloth. If the rotor is ex
the three
of
wheels.
3. With
vent
bearings
the
adjust
in
outlined
sembly, caliper splash shield, and the
is finished
runout check
to
sure
the
not
center
plate
seal
which
replaceable.
Inspect
all
that
parts
parts and replace
are
chipped.
If
bore
scored,
is
the
damaged,
hydraulic
rusted,
those
worn
pitted
seal
place
or
it. If the center plate
is defective or damaged, re
etched, replace
or
or
cylinder
the plate and seal assembly.
2-7
PART
2-2
Page
Section
Description
1
BRAKE SYSTEM
2-7
Operation
and
2 In-Car Adjustments and Repairs
3 Removal and Installation
2-12
4 Major Repair Operations
2-2 1
2-18
DESCRIPTION AND OPERATION
1965"
The
system
front
employs
wheels
ternal
Thunderbird
disc brakes
and
and
the
anchor, in
single
expanding
brake
on
self-adjusting
brake assemblies on the rear wheels.
The system is powered by a vacuum
booster as standard equipment.
The
master
cylinder
converts
force from the brake pedal
booster into hydraulic pressure
physical
and
the
against
(front
in
pistons
the
calipers
or
in the
wheels)
(rear wheels). The
cylinders
in turn
and
hydraulic pressure
force at the discs
convert
back into
wheel
pistons
physical
brake
contains
piston
with
an
attached
dust boot to
bore
from
the
seal
(bridges)
is
ton seals are
in
11).
in the
bores.
cylinder
The piston seals
important tasks:
1.
They
2.
They
leased position,
sure
3.
is
three
perform
cylinders
and
pistons.
the pistons to re
return
when
hydraulic
pres
released.
They
The disc brake is
opposed
piston,
a
adjustment
The
at
movement
or
assembly
the
of
ven
consists
of
The
two
housings bolted together
hy
no
the disc
either
caliper.
replaced
is
absorbed
end
shoe
the
shoes
in
(com
times
all
cor
in
are
internal
passages in the caliper housings and
an external
transfer tube between
the two halves of the caliper as
sembly. One bleeder screw and fluid
inlet fitting is provided on each cali
The
lining
shoe and
caliper
abutments
half containing two cylinder bores of
diameter. Each cylinder bore
l^ie"
the
the
ends
of
(Fig.
25).
The
caliper,
and
by
tabs on the
shoe
assemblies
radially
outer
assemblies are
parallel machined
within
are supported
as a
bonded
material
by
the
to
the
shoe
mating
the
top
splash
of
and
the
of
abut
caliper
shield
the
lining
assembly is
front
wheel
spindle
is
caliper
assem
The
and reduce contamination.
caliper
It
Brake torque
unit.
against
to retain the
mounted
on
to the
rear
the
of
the wheel vertical centerline.
fins
cast
rotor
is
iron disc is
type
of the
ven
incorporating forty
to, and rotates
hub. The outside
diameter of the rotor is 11.87 inches
and
the inside diameter is 7.875
inches. This type of design increases
and
the
with,
cooling
staked
wheel
area and permits circulation
the rotor resulting in
cooling of the brake. A
shield bolted to the spindle is
of air through
shoes
slide
axially
splash
used
primarily to
prevent road con
from contacting
the in
board rotor and lining surfaces (Fig.
12). The wheel provides protection
for the outboard surface of the rotor.
taminants
CALIPER TO ROTOR CLEARANCE
ALIPER
EMBLY
(Fig.
assembly
more rapid
located in between
each
of
per assembly.
caliper
with
connected
means
piston
lining
and
(Fig. 25). A
ments
attached
The
cylinders
hydraulically by
fixed caliper,
non-energized,
disc type, actuated by a
draulic system (Fig.l). There is
(rotor)
is
blies
maintain
to the
friction
of
hydraulic
when
applied
shoe
means of
machined
to a metal plate called the shoe.
tilated
tilated
lateral
A
consists
hydraulic sealing
provide
between the
grooves
on
ride
ledges
drum-type brakes.
RELATION AND FUNCTION
OF COMPONENT PARTS
which
pressure
positioned
by
caliper abutments
tabs
rubber pis
contamination
parable to the automatic adjusters
DISC BRAKE ASSEMBLIES
-FRONT
WHEELS
in the
the
(Fig. 2). Square-section
cylinder
rect
shoes.
a
molded rubber
CALIPER HOUSING
TRANSFER TUBE
PISTON DUST BOOT
RETAINING GROVE
PISTON
SHOE
LINING
PISTON SEAL
CALIPER DUST
BOOT RETAINER
EDER
CALIPER
SCREW
SPLASH SHIELD
EXTERNAL
TRANSFER
HUB AND ROTOR
TUBE-
ASSEMBLY-
H1368-A
H1369-A
FIG. 1
-Disc
Brake
Assembly
FIG. 2 -Caliper
Assembly
Sectional View
2-8
GROUP 2
-BRAKES
PISTON
CALIPER
In this
the front brakes.
required
at
manner,
premature
HOUSING
is
The
prevented.
is
valve
is
adjusted
skid
wheel
proportioning
as an
serviced
never
rear
assembly
and
overhauled.
or
SELF-ADJUSTING BRAKE
ASSEMBLIES-REAR WHEELS
The
adjusting lever,
BRAKES APPLIED
BRAKES RELEASED
Piston Seal
of
The
cable
pin
at
the
lever
A proportioning
As the brake
pedal is depressed,
hydraulic pressure from the master
cylinder forces the pistons out of the
caliper bores against their respective
shoe
and
force
of
shoes
lining
the
both
of the
sides
braking
effect
the
against
linings
the
moves
The
assemblies.
pistons
against
rotor
revolving
to
tween
master
valve
and
the
brake wheel cylinder provides
balanced braking action between the
front
and
wide
range
(Fig. 20).
lic
the
rear
braking
of
By
brakes
a
conditions
to the
cylinders, the valve limits
high
when
rear
means
are
is
brake
secondary
of
the
to
cable
cable
guide.
spring is hooked to the
primary brake shoe and to the lever.
The automatic adjuster operates only
when
brakes
is moving
the
the car
are
applied
rearward and
the secondary shoe
the
toward
predetermined
brak
bottom. The
the
anchor
connected
adjuster
move
rear wheel
pressures
The
when
regulating the hydrau
pressure applied
action
under
by
shoe
located be
cylinder
rear
ing
action.
the
to
is
as
(Fig. 4).
the
over
and
at the
connected
OPERATION
top
guide,
screw
adjusting
is hooked
the
mecha
cable
cable,
sembly, and adjuster spring
H1370-A
FIG. 3-Function
brake
self-adjusting
nism consists of a
With the
drum
while
only
is free to
beyond a
point.
car
moving
rearward and
brake application, the rub
in each piston stretches as
During
ber
seal
the
piston
(Fig.
sure
the
moves
the
against
3). When the hydraulic
the
against
seal
relaxes
roll-back
action
ANCHOR PIN
rolls
the
pulls
ance.
the
required
running
ment is
achieved
in the
ing
as
seals
its
by
the
location
all
ANT1-RATTLE CLIP
PARKING BRAKE
LEVER
PARKING BRAKE
CABLE
LINK
GUIDE-
of
adjust
LINK SPRING
the pistons slid
from
piston
correct
the
gradually
relative
wears
and,
to
the
thus,
adjustment
times.
When the brakes
are
in the unap
hydraulic
position, there is no
pressure
fluid
runout
outward
lining
maintains
plied
rotor
maintenance
position
the
at
clear
Automatic
bores. The
changes
seal
the
to
clearance.
cylinder
running
inherent
Also,
contributes
CABLE ANCHOR FITTING
WASHER
the rotor and, thereby,
against
provide
ANCHOR PIN PLATE
RETAINING CLIP
piston
away from the shoe approximately
0.005 inch to relieve the force of the
lining
PARKING BRAKE LEVER
is released,
back. This
piston
or
FORWARD
shoe
pres
because the
to the calipers
at
source
the
,by-passes
the
cylinder
master
residual
check
valve.
A warning sound feature is incor
in the design of the brake
PRIMARY SHOE
CABLE HOOK
PIVOT HOOK
PARKING BRAKE CABLE
porated
HOUSING RETAINER
ADJUSTING LEVER
shoes. Metal tabs on the ends of the
shoes
create
scraping noise,
come
to
contact
shoes
need
detrimental
disc brake.
to
metallic,
audible,
the
when
enough
the
contact
metal
the
worn
an
to
rotor.
warns
AUTOMATIC
SOCKET
ADJUSTER SPRING
linings be
allow
This
the tabs
ADJUSTING SCREW
PIVOT NUT
metal-to-
PARKING BRAKE CABLE
the driver that
AND HOUSING
replacing and is not
the function of the
H1384-A
FIG. 4-Thunderbird Self
Adjusting
Brake Assembly-Rear Wheel
PART 2-2
brakes
the
"wrap
the
applied,
The
assembly.
phragm
atmospheric
around"
action
of
the shoes follow
port
ing
the drum forces, the upper end
plunger
of
the
valve
shoe
primary
pin. The
anchor
cylinder
anchor
the
secondary
upper
shoe
end
movement
the
causes
the
of
to
cable
the adjusting lever upward and
against the end of a tooth on the
pull
adjusting
screw
travel
ward
lining
as
and
move
the
over
are
causing
the
expand
the
is turned
and
the
the
secondary
and
pin
anchor
primary shoe is moved toward
drum. Therefore, the adjuster
the
the
does
operate.
not
The
lever, link,
brake
parking
in
used
spring are
brake. The anchor
the rear
fixed
and
pins
are
non-adjustable.
and
the
other
adjustment
head
end.
The
diaphragms
power
vacuum
the
and
make
which
components
up
the valve assembly are connected to
brake
the
the
valve
is
valve
from
ber
type
to
seal
body
return
against
A
for
released
rub
by
the
supplied
a
of
position
seal
rear
to
vacuum
end
the
used
is
intake
manifold
engine
utilizes
for its
It
power.
basic
The three basic
1. A
which
piston
inder.
The
of
hy
the hydraulic
cyl
located
plate
center
into four
unit
power
hub
threaded
and
maintains
between the two
forward
through
center
a set
front
the
of
the
backward
dia
and
in the
seal
a
rear
separation
vacuum power
moving
phragms,
chambers.
on
to the hub
plate attaches
tionary
the
and
the two diaphragms divides
A long,
plate
power
vacuum
assembly
draulic
the
the
sta
plate.
OPERATION
Released Position. With the
running and the brakes
gine
leased,
manifold
vacuum
(left)
the
valve
Air
through
the
valve
the
front
the
to the
and
to the front
(left)
diaphragm (Fig. 6). In
to
position
brake
the
operating
are
through
to
chamber
chamber
released
valve
valve
re
intake
the
admitted
rear
applied
er
is
check
vacuum
vacuum
plate.
Master
from
vacuum
en
held
(no
pressure
pedal),
rod and valve
to
the
housing by
the
right
valve
the
plung
in
the
return
REAR SHcLL
CENTER PLATE
FRONT SHELL
REAR DIAPHRAGM
REAR DIAPHRAGM PLATE
AND VALVE HUB ASSEMBLY
three
into
a
consists
center
are:
elements
chamber
power
vacuum
a
shell,
diaphragms
(Fig. 5).
unit
single
of
consists
combined
elements
FRONT DIAPHRAGM
the
pressure
atmospheric
and
vacuum
between
link
of
check
admitted
seals
chamber
vacuum
vacuum cham
opening between the
ber and the hydraulic push rod.
The hydraulic push rod forms the
valve
front housing.
the
operation
the
spring holds the
type
and
is
to
DESCRIPTION
type which
dirt from getting into the
mechanism. A seal located in
and
valve
pedal.
is
between
opening
the
in
rod
the atmospheric port
special
sleeve
located
of the vacuum suspended
dust
keeps
guard
pressure
flexible
supported
body. In the
poppet
seat.
is
and
of
valve
rubber
housing.
valve
rod
returns
brake
the
is
poppet
assem
valve
when
to
moves
spring
and
position
released
the
return
plunger
The
valve
which
plunger
valve
valve
connected
the power diaphragm
A
bly.
is
rod
operating
the
linkage. The
rod and pedal
operating
valve
through
pedal
Vac through
The tandem diaphragm type Mas
ter Vac is a self-contained vacuum
hydraulic power braking unit. It is
A
the
within
silencer
between
Vacuum
BOOSTER SYSTEM
rod
push
at one end with a piston
screw
poppet
conventional
cylinder
master
locking
the
of
elements
self
a
the valve
and
cylinder which con
brake
the released
applied,
against
has
within
wear.
power
a
the front
for the hydraulic
which
the
within
vacuum
and
the
of
all
except
valve
assembly.
conventional
at
the
of
moves
which
3. A hydraulic
tains
star-wheel
moving forward
car
brakes
is
turn
one tooth at a time as the
With the
shoe
adjuster
to
The
shoes.
the
downward
lever
the
star-wheel
linings progressively
the
When
the
released,
pulls
spring
the tooth
of
end
tooth.
the
engages
brakes
the lever
increases. When the
upward far enough,
of
wear
lever can
it passes
The up
increases
star-wheel.
part
a
housing
diaphragm
of
away from the
shoe
The
pin.
the wheel
action of
moves
the secondary
the
against
is
seat
2-9
SYSTEM
-BRAKE
of a
front
diaphragm,
rod
and a vacuum
a
front
a
plate,
rear
and a rear
diaphragm
a
and
hydraulic
push
return
spring.
2. A mechanically
actuated control
the
valve
integral
power
diaphragms that
degree
or
power
of
release
foot
in
of
a
The
the
vacuum
valve
to
VALVE PLUNGER
with
The
single
the
control
poppet
the
RETURN SPRING
valve
brake
the
through
the
application
accordance
rod
operating
linkage.
pedal
atmospheric
vacuum
controls
brake
applied
pressure
consists
with
valve
with
FRONT DIAPHRAGM
PLATE AND
HUB ASSEMBLY
an
port and a vacuum port.
port
body
seat
is
attached
a
part
H1373-A
of
to the dia
FIG. 5-Booster Unit-Sectional View
2-10
GROUP 2
-BRAKES
the
The
hydraulic
contact
The
rod
CLOSE the atmospheric
port and OPEN the vacuum port.
With the valve in this position, the
chambers
to
front
rear
to
and
the
of
through
vacuum
through
hub
the
housing.
The
phragms
are
vacuum
then
The
phragms.
phragm
the
balanced
vacuum
phragms
power
is
then
dia
on
sus
rear
fully
push
ing
in
port
to
open
the brake
enter
fluid
tend to move the valve plunger
to
expansion
the brake
to
in
right
and
close
port.
counter
force
housing
the
off
Since
pheric
atmos
part
(to the
to
relation
valve
the
of
reacts
right)
and
the
the
and
hydraulic
close
the
left
dia
pressure
front
force
vacuum
is
piston
and
de
power
diaphragm assembly, hydraulic
left to
both
power
rear
atmospheric
move
of
sides
the
vacuum on the
front
a
to
to
vacuum
diaphragms,
veloped
the
through
valve
valve
plunger
rod
operating
to
compensating
push
driver's foot, a
effort
is provided.
assure
sistent
with
the
The
the
braking
amount
to
maximum
the
the
of
valve
power con
assurance
that
the
"feel"
always
amount
applied.
direct
the
is designed into the Master
plunger
Vac to
driver
of
transmitted
reaction
and
against
maintains
of
This
brake that is
reaction
proportion
the
pressure
port
systems.
of
a
developed
to
force
being
is
in
hydraulic
the
within
the
brake
hy
master
permit
brake
VACUUM SOURCE
ATMOSPHERIC
from the
SOURCE
for
compensate
loss
of/or
the
diaphragm
compensat
system
to
reservoir
right
rear
of
rod
fluid to either return from the
brake system to the fluid reservoir
or
the
operating
released
hydraulic
the
is
cylinder
the
hydraulic
the
position,
in
rod
the
and
right
through
passages
side
dia
With the
position.
released
draulic
the
free
spring
to return the diaphragm assembly
with the hydraulic push rod to the
valve
against
valve
"feel"
and
and
the
of
atmospheric
atmosphere
diaphragms. With
valve
or
at
front
side
power
return
admit
filter
air
plate
in vacuum, since vacuum is
on both sides of both dia
pended
present
the
the
and
chambers
portings
of
port
the
center
the
to their respec
"OPEN"
to
valve
both the
open
vacuum power
acting
and
plunger
assembly
are
the
the edge of the
around
and
rear
diaphragm
a
the
areas.
pressures
slightly
the
proportion
to
similar
and
assembly
end
piston.
distribute
to
between the
in
rod
reacts
fluid
pressure
valve
to
disc
rubber
through
the
at
push
of
tive
spring
disc
column
plunger
FIG. 6-Booster in Released Position
pres
the
plunger
reaction
diaphragm
H1374-A
in
valve
and
rubber
the
of
ATMOSPHERIC PRESSURE
As hydraulic
hydraulic
(to the
cylinder, a counter force
right) acting through the hydraulic
push
rod
sets up a reaction force
vacuum
power
against
the
dia
phragm
VACUUM
under
check
residual
brake tubes into the brake
cylinders.
is developed
sure
ATMOSPHERIC
SOURCE
the
through
valve and
wheel
fluid
hydraulic
force
and
pressure
fluid from
of
system.
Applied Position. As the brakes
are
by
applied
rod
operating
to
move
phragms
poppet
vacuum
driver,
and
assembly to
spring
into
valve
valve
seat
port
ment
the
of
the
applied
vilve plunger
Any
valve
the
bring
the
with
the
in
the
the
operating
ATMOSPHERIC PRESSURE
t
move
rod
moves
away from the
VACUUM Lv
valve
vacuum
additional
direction,
dia
compress
contact
to
(Fig. 7).
plunger
power
and
"CLOSE"
housing
the valve
valve
left in the
the
return
valve
the
in
H1375-A
the
poppet
FIG. 7-Booster in Applied Position
PART 2 -2
2-11
SYSTEM
-BRAKE
With the
full
uum,
tained
to
open
power
is
which
beyond this
ATMOSPHERIC
supplied
would
point
by
entirely
unit.
power
hydraulic
at
the
as
pressure
have to be
effort
physical
driver.
of the
SOURCE
the
of
point
is
to
referred
Any increase in
vac
manifold
application
out"
"run
VACUUM SOURCE
to the left of the
chambers
diaphragms
BRAKES
PARKING
foot
independent
An
parking brake
the
tuates
through
rear
9)
brake
wheel
ac
shoes
linkage. The
cable
a
operated
-
(Fig.
control
oper
ating cable is routed from the park
ing brake control assembly to the
lever
equalizer
VACUUM
the
brake
ATMOSPHERIC PRESSURE
which
is
The
the
connect
cables
attached
assembly.
equalizer
to
rear
equalizer
assembly to the parking brake lever
at each rear
H1376-A
FIG. 8-Booster in
Lap
or
Holding
Part 2-1
When the
Position
Lap
or
Holding Position. During
the
of
brakes
"re
the
action"
the valve
against
the
against
working
the atmospheric
port.
plunger
driver
to
is
close
With both
at
mospheric and vacuum ports closed,
to be in the
the Master Vac is said
"lap"
or
holding
both
When
valves
til
either
attained will
the
reopened
by
pressure
to
or
closed
are
"lapped off", any degree
application
8).
(Fig.
position
of
braking
be held
atmospheric
un
port
is
increase in pedal
further
increase the
an
brake
in
application
vacuum
to
tion.
upon
to
the
the
front
is held
the
posi
the
the
to
rear
valve
seat
valve
atmospheric
chambers
valve
the
to
pres
right
diaphragms.
the
control
assembly.
A
with
into
drive
any
release
the
when
engine
lever
position
The brakes
automatically, how
selector
is in
lever
running,
or
parking
brake
mounted
position
sembly
on
mount
(Fig.
9).
and
control
a
bled to the
a
release
pedal.
TO VACUUM
POWER UNIT
as
to the left cowl
(Fig. 22). The
panel
pivots
pawl
in any
the engine off.
sembly is
LINK
release
will
the neutral or park position with the
side
PISTON
in the
automatically
the engine running.
not
ever,
spring-
a
the transmission selector
moved
will
of
ratchet
a
brakes
parking
when
is
with
vacuum power unit
The
PEDAL MOUNT
the applied position
engagement
pawl
the
forced
are
brake drums. The
loaded
with
VACUUM POWER UNIT
shoes
rear
is held in
pedal
by
valve
reaching
position,
and
brake
pressure
is held away from the
maximum
the
holding
or
atmospheric
poppet
admit
the
pedal
moment,
"lap"
its
applied
plunger
of
brake
a
However,
fully
sure
the
for
to
returns
decrease
a
reopen
Whenever the
application.
applied
to
to decrease
port
constant
by
or
pressure
pedal
the
against
is depressed the
pedal
brake
secondary
application
secondary shoe (Fig. 1,
Fig. 22).
and
pedal
as
stationary pedal
A spring-loaded
lever
A
are
assem
ratchet
is
as-
CONNECTS WITH
VENTILATION
SYSTEM
NEUTRAL
SAFETY
SWITCH
(VACUUM
RELEASE
VALVE)
RELEASE LEVER
TO ENGINE
MANIFOLD
LEFT
SIDE
VIEW
RIGHT SIDE
VACUUM
VIEW
H1313-A
H1312-A
FIG.
9-Parking Brake
Control
Assembly
FIG. 10-Connections for
Automatic Parking Brake Release
2-12
GROUP 2
sembled
to
The
pawl
such
an
the
the
stationary
contacts
the
it
angle that
teeth
ratchet
mount.
ratchet
will slide
at
the
pedal
when
the
plying
and
motion
to
starts
the
applied
slight
lever
the
the
pawl
position.
the
The
a manual
assembly.
piston
by
the
release
the pawl,
out
of
handle
release
is
nected
release
from
pawl
is
which
power
The
tuated
allowing the brakes to
release lever is actuated
ratchet
vacuum
control
pedal
through
the
unit
is
the unit
within
the
neutral
safety
ac
10).
end
the release handle which actuates
of
lever to
nate
manual
vacuum
tional
end
extends
failure
manual
release
the re
of
for
out
in the
release
power
pawl
the ratchet
with
(Fig. 9). The lower
lease handle
the
move
engagement
alter
event
for
or
of
op
any time.
at
in
valve
con
upper
to
(Figs.
switch
fold
to
to
pressure
ated
will
open
the
the
the
unit.
power
thus
piston
manual
in turn,
of
side
differential
cause
the
pull
one
in the
piston
The
which,
and
connect engine mani
vacuum
actuating
9
position with
will
running
release valve
vacuum
the transmission selec
Moving
engine
a
transmission
the
lever into any drive
tor
the
to
power unit and
manifold
release
vacuum
the
connect
engine
with
to
riveted
link to the
a
Hoses
a
(Fig. 9).
pin
mounting bracket
engages
the
of
disengage
The
lever
the
rivet
brakes
Since the
pivots against
movement
will
release.
by
the
is
ap
thus locks the
and
lever
release
a
stops
release,
the ratchet
in
as
slot and
over
depressed; however,
to
connected
-BRAKES
cre
and
link
handle
release
the release
actuates
lever.
IN-CAR ADJUSTMENTS AND REPAIRS
After
brake service work,
firm brake pedal before
moving the car. Riding the brake
pedal (common on left foot appli
cations) should be avoided when
obtain
any
INSTALLATION
a
driving
the
car.
1. Position
assembly
that
so
Be
sure
flanges
on
the
fully
1. Remove the wheel and tire as
sembly from the hub and rotor as
sembly. Be careful to avoid dam
interference
or
per
the
with
shield, bleeder
transfer tube.
splash
fitting
or
cali
screw
the
caliper
3. To
splash
(Fig. 1).
facilitate
removal
stallation
the shoe and
of
semblies, the
the
on
the
shoe
caliper
splash
Apply
times
until
the
a
firm
shoe
and
pedal
lining
properly seated.
4. Install the wheel
on
the
hub
and refill
reservoir
as
lining
is
obtained
assemblies
tire
as
rotor
as
and
and
with
the master cyl
specified
brake
required.
as
pushed
tive
housing
caliper
the
(Fig.
rotor
for
pressure
pistons
4.
Maintain
pump
the
of
shoe
the
caliper
AND
CLEANING
When the
blies
boots
are
each
piston
corrosion.
dust boot
the
of
the
boots,
and
transfer tube.
bracket on the frame (Fig. 20).
3. Remove the two bolts that re
tain the caliper to the spindle.
Take care to avoid loosening the
bridge bolts that hold the two
halves of the caliper together.
4. Lift the caliper assembly off the
rotor,
and
Check the
inspect
surrounding
or
taining bolts
cation.
lengths.
USE SECOND
PAIR OF
PLIERS HERE
H 1366
be
rotor.
on
The
should
shoe
be
the bridges.
caliper
to spindle re
torque to specifi
and
Note the difference in bolt
Check to insure that the
rotor
-
A
each
area
assembly on
mounting
the
assemblies
properly
2. Install the
and
clean
caliper
mate
the
and
lining
and
assem
the dust
for damage
Thoroughly
fore installing.
lining
as
2. Disconnect the front brake flex
ible hose from the brake tube at
seated
remove
tire
interference with the caliper
shield, bleeder screw fitting
semblies
INSPECTION
pistons.
surface
the
two
11).
and
shoe
replaced,
from
condition
(Fig.
on
and
bolt holes in the caliper with those
in the spindle. It may be
necessary
to push the caliper pistons into the
cylinder bores to obtain clearance
between the shoe and lining as
the shoe out
pairs of pliers and pull
of
the
with
or
the
pliers.
flange
wheel
splash
1. Position the
of
If the
a minute.
the metal
end
side
1. Remove the
sembly from the hub and rotor as
sembly. Be careful to avoid damage
INSTALLATION
respec
in easily, force
go
water
with
Grasp
outer
not
will
them in
each
on
2).
least
at
its
toward
assembly
and
rotor.
ward pressure against each shoe and
lining
after a shoe
DISC BRAKE CALIPER
ASSEMBLY
or
steady in
a
system
replacement.
the
5. Check
inder
fluid
lining
the shield to the caliper
are
sembly
bleed the
car.
be necessary to
not
shield
two retaining bolts (Fig. 1).
3. Pump the brake pedal several
and
should
REMOVAL
caliper
in
and
be
pistons must
into their bores.
re
and
shield,
shield
the
remove
rotor
rotor.
sembly.
2. Remove the two bolts that
tain
tabs
the
with
REMOVAL
age
secure
the
faces
against
lining
and
of
11).
2. Install the
and
shoe
side
lining
that
bridges (Fig.
FRONT (DISC) BRAKE SHOE
AND LINING REPLACEMENT
new
each
the
seat
a
6. Road test the
It
FIG. 1 1 -Removing Disc Brake
Shoe and Lining Assembly
runs
squarely and centrally
between the two halves of the cal
iper. There should be
approximately
0.090-0.120 inch clearance between
the
caliper
and
the
diameter (Fig. 2).
rotor
outside
PART 2-2
3. Connect the front
brake
wheel
flexible hose to the brake tube at
the bracket on the frame (Fig. 20).
The hose should be checked for
correct
in
master
5.
Section
as
out
Check
the
fluid level, and the
brake fluid as required.
Pump
times to
and
system
2-1.
cylinder
specified
to
deformation
ing
or
the
of
as
to
avoid
the brake lin
the brake
the
actuate
the
position
pedal several
piston
seals
lining
shoe and
3. Remove the
Remove
lock, adjusting
from the
bearing
cotter
outer
assembly.
roller
4. Remove the hub
sembly from the
washer
Remove the
and
nut
pin,
flat
and
nut,
spindle.
cone
cap from the
grease
the
and
as
rotor
assemblies.
the
wheel
tire
and
as
sembly.
car.
the
new
with
wheel
and
tire as
sembly from the hub and rotor
sembly (Fig. 12). Be careful
damage
fitting
or
in
does
from
caliper
out of
it
with a wire
caliper or
a
the
clean
the
and
not
require
tion,
faces
bores
the
car.
Position
the
avoid
and
support
damaging
the
stretching the hose. Insert
cardboard spacer between
linings
from
remove
or
to
coming
while
the
prevent
out
the
of
caliper
the
is
pistons
cylinder
removed.
Pack
lips
of
a
install the
blies
obtain
rotor.
lining
Be
assem
bridges.
the
on
and
shoe
the
and
seated
are
to
the
correct
clean
bearing
lubricated
and that
the
is
adequate, that
and
bearing,
wheel
and
in
good
the rotor
wheel
install the
and
sur
outer
adjusting
bearings
to
install the
nut
wheel
cap.
The
adjustment
is
pin, and grease
bearing
the hub
2. Remove the three bolts that
re
tain the splash shield to the spindle,
and remove
the
shield
3. Remove the
(Fig. 12).
gasket.
INSTALLATION
1. Install the gasket.
2. If the shield is bent,
it
specification, and then
cotter
caliper and
assembly as outlined under
in the foregoing pro
"Removal"
and rotor assem
washer
the
on
assembly.
condi
braking
nut.
4. Adjust
tire
and
wheel
rotor
1. Remove the
and rotor
and grease retainer
and
the
and
REMOVAL
being
spindle.
3. Lubricate
hub
DISC BRAKE ROTOR
SPLASH SHIELD
are clean.
on
lock,
the
cedure.
in
that the grease in
2. Install the hub
bly
cup.
the
rotor
stalled, make sure
are
roller
retainer, and
original
hub is
the way,
to
If the
inner
serv
install
and
(Fig. 12).
retainer
the
the brake hose
caliper
grease
the
caliper
necessary to discon
not
new
inner
the
de-
bearings
and
cone
lightly between
grease
replaced,
of
set
grease,
bearing
assembly
the rotor. If
transfer tube.
or
2. Remove the
from the spindle
nect
to
interference with
splash shield, bleeder
caliper
icing, it is
as
new
a
specified
assembly
1. Remove the
caliper
between
coating from
carburetor
with
rotor
inner
the
being
protective
Pack
greaser.
REMOVAL
the
bores
cylinder
If
pistons
caliper
that the shoe and
sure
two
the
specification.
the
assemblies
assembly
torque
to
push
6. Install
is
rotor
the
remove
FRONT WHEEL HUB AND
ROTOR ASSEMBLY
screw
the
caliper
and
bolts
clearance
lining
the
spindle
necessary,
into
INSTALLATION
1. If the
7. Road test the
the
the
routing.
6. Install
avoid
5. Mount
on
Check the flexible hose for
spindle.
disc
with
brakes.
mounting
hub.
important
especially
rotor and nick
of
scratching
caliper as
ings.
routing.
4. Bleed the brake
lined
Handle the rotor and
semblies in such a way
2-13
SYSTEM
-BRAKE
CALI PER PARTS
out
before
straighten
installation.
Position
install the
the shield to the spindle,
retaining bolts, and torque to
fication (Fig. 12).
3. Install
sembly
under
ing
-2B120-R.H.
and
the
the
hub
and
caliper
"Installation"
speci
rotor
as
in the
as
outlined
forego
procedure.
-2B121-L.H.
CALIPER ASSEMBLY
?2BU8-R.H.
*2BI19-L.H.
SPINDLE
20990-
ROTOR SPLASH SHIELD
2K004-R.H.
2K005-L.H.
COVER
FIG. 12 -Disc Brake Disassembled
1130
H1371-A
2-14
GROUP 2 -BRAKES
PROPORTIONING VALVE
temperature
the
where
REMOVAL
being
plate,
1. Disconnect
master
and
cylinder
to
-
lubricant
the
remove
-
Tinnerman
-
Working
left
the
underneath
fender
valve to the
apron and remove
the valve through
cover
the
7. Check
for proper
brake
Make
1. From
fender
the
the
proportioning valve
hole in the
Position the
that
so
apron
as
valve
to
mounting
the hole in
shown
in Fig.
13. Install the retaining bolt.
the front-to-rear
2. Connect
tube
the
to
3. Position
cylinder
brake
valve
to
-
(Fig.
and connect
-
20).
the
proportioning
valve
be
the floor.
car should
raised with
and require a man
brake
the
after
only
has been
screw
changed
other
some
while
per
drums
brake
adjusted
hot
and
be
should
temperature
room
the
are
when
when
the
drums
the
ad
If the shoes
the drums are
expanded,
when
at
shoes
may
are
cool
and
contracted.
the
1. After the
PROPORTIONING VALVE
have been in
shoes
adjusting screw has
install the drum. Be
the
or
stalled
that all excess grease, oil, and
sure
foreign
other
the
carrier
material are wiped off
from
from the
drum is
side, turn the
the
when
brakes.
of the
1. Raise the
and
until
car
the
wheel
tire clear the floor.
2. Remove the hub cap and wheel.
Remove the three Tinnerman nuts
insert
brake drum. If the
will not come off
hole in the
the brake adjusting
and
disengage the
rier
plate,
ing
lever from the adjusting
While
holding
easily,
through
a narrow screwdriver
the
car
adjust
screw.
adjusting
lever
away from the adjusting screw, back
the adjusting screw with the brake
adjusting tool (Fig. 15). Back off
off
the
adjustment
be
cannot
ful
not
if the drum
Be very care
chip, or damage
only
removed.
to
burr,
in the adjusting screw;
otherwise, the self-adjusting mech
notches
If the
will
function
not
adjustment was
expand
Expand
is felt
the
check
REMOVAL
certain
to
have
shoes
adjusted,
properly
that
the
seated
properly.
changed, make
adjuster
in the
shoe
lever
is
web.
the
rotated.
the
drum.
Mark
the
star
wheel
where
the
3. Remove
the
tooth
on
lever
contacts
While
14).
drag
a
and,
oper
REAR BRAKE DRUM
anism
plate
upward
(Fig.
until
hole
adjusting
carrier
screw
shoes
shoes
the
the
carrier plate
adjusting
the
operation
the
drum.
and
plate
2. Remove
cover
brake
the
properly
brake drum
shoes.
-
drag
been
and remove the
brake
The
lever
equalizer
opera
service
tion.
been turned,
RETAINING BOLT
brakes
service
have been relined, replaced, or
the length of the adjusting
shoes
justing
system.
SHOE ADJUSTMENTS
REAR WHEELS
off
adjustment
forming
master
BRAKE
wheels
self-adjusting
ual
normal
4. Bleed the brake
hydraulic
rear
are
when
brake
tube.
The
The
the
through
extends
fender
4-Expanding Brake Shoes
access
apron.
apron
FIG. 1
-A
parking
adjustment.
freely.
8. After
[HI 389
the left fend
underneath
install
through
the
that
sure
INSTALLATION
the
specifica
6. Install the adjusting hole
the brake carrier plate.
ates
tang
tire. Tight
wheel and
cables
the access hole (Fig. 13).
the
three
nuts.
on
the bolt that retains
remove
proportioning
er,
Install the
with
tion.
fender,
the
to get the
the mounting nuts to
en
valve.
3.
not
the linings.
5. Install the
2. Disconnect the front to rear
brake tube from the proportioning
-
the carrier
careful
on
points
contact
drum. Secure the drum
proportioning
brake tube (Fig. 20).
valve
the
to
grease
shoes
the
screw.
adjusting
the
holding
adjusting
out of engagement with the
lever
adjusting
screw, back off the adjusting screw
Va of a turn with the fingers. If
finger
movement
screw,
it
free
will
up;
not
turn
otherwise,
the
the
self-adjusting lever will not turn the
Lubricate the screw with a
screw.
thin
uniform
coating of high-tem
(see Specifications).
perature grease
Any
MOUNTING
TANG
FENDER APRON H1365-A
may
ing
FIG. 13 -Removing or Installing
the Proportioning Valve
UPWARDS
other adjustment procedure
cause
damage to the
adjust
H1144-A
screw with consequent self ad
juster
4.
MOVE HANDLE
problems.
Apply
a small
quantity
of high-
FIG. 1 5 -Backing
Adjustment
off
Brake
PART 2-2
INSTALLATION
7. Remove the
1. Remove the protective coating
from a new drum with carburetor
2. Place the drum over the brake
assembly and into position. If re
adjust
the brakes as outlined
Adjustments"
"Brake Shoe
in
this section. Make sure the adjust
ing lever is properly seated in the
under
shoe web.
3. Install
nuts
and
the wheel
the
tighten
Install
securely.
the
on
Tinnerman
three
axle
the
retaining nuts to
Install the hub cap.
flange
shaft
drum,
studs against the
tighten
and
specifications.
REAR BRAKE SHOE
REPLACEMENT
8. Remove
and
nut,
brake
the
wheel
the
and
the
on
lever
adjusting
b. Move the
outboard
screw
side
pivot nut as
far
of
and
upward
10. After removing the secondary
shoe, disassemble the parking brake
lever from the shoe by removing the
retaining
(Fig. 4).
will go.
3. Pull the adjusting lever,
adjuster
toward the
and
pivot
spring down
hook from the large hole in
secondary shoe web. Do
attempt to pry the pivot hook
the
of
the hole.
4. Remove the
and
spring
the
with
the tool
the secondary
same
shoe
spring and unhook the
from the anchor pin.
6. Remove
and
the
the
shoe
primary
in Fig. 16. With the
move
out
1. Before
shoes, back
off
adjustment.
Then
brake
anchor
to
shown
tool,
to
re
anchor
cable
pin
the
lever
secure
and
Apply
secondary
the
spring
high-
of
the
shoes
points
contact
the
brake
the
plate
and
shoes
secure
the
on
as
sembly with the hold-down springs.
Install the parking brake link and
spring.
parking brake
parking brake lever
Connect the
to
the
4. Install the
pin
anti-rattle
plate
on
clip
and
the anchor
eye
plate
5. Place
the
pin
cable
with
eye
the
over
the
side
crimped
6. Install the
cable
guide
on
the
flanged
hole properly fitted into the hole in
the
secondary shoe web. Thread
secondary
cable
groove
shoe web with the
around
the
guide
cable
(Fig. 4).
the
of
brake
shoe
assemblies
from
to the
other
car
the
cause
retract
brake
than
rather
time the
automatic
chanism
operated.
stallation
on
to
shoes
expand
each
adjusting
me
To
the wrong
prevent
of
side
in
the
car, the socket end of the adjusting
is stamped with an R or L
(Fig. 18). The adjusting pivot nuts
can be distinguished
by the number
grooves
of
body
cate
of
a
machined
the nut. Two
hand nut; one
left hand nut.
a
the
screw
It is imperative that the cable
be positioned in this groove and
between the guide and the
not
and
between the
the
around
grooves
right
indicates
indi
groove
socket
on
install this assembly
shoe ends
with
the
ad
toothed wheel nearest
screw
the secondary shoe.
11. Hook the cable hook into the
hole in the adjusting lever. The ad
justing levers are stamped with an
R or L to indicate their installation
on
a
right
or
sembly (Fig.
adjuster
left hand brake
as
18).
12. Position
the
shoe web.
anti-rattle clip.
side
justing
pin.
anchor
screw
10. Place the adjusting
(Fig. 4).
anchor
ad
screw
3. Position
the carrier
pin.
grease
socket end of
the
Interchanging
to
at
parts
anchor
screw
adjusting
would
the
an
Turn the
screw.
adjusting
one
grease
brake
the
brake
parking
with
the
is
eye
the
high-temperature
Apply
the
on
installed. All
on
to the threads and the
brake
carrier plate.
the
be flat
shown
cable
binding
or
chor pin when
9.
the tool
that the
certain
cocked
assemble the park
retaining clip.
a light coating
temperature
the
Be
not
to
shoe
primary
with
into the adjusting pivot
nut to the limit of the threads and
then back off Vi turn.
the
installing
the
spring
in Fig. 4.
justing
toward the carrier plate.
adjusting lever (Fig. 4).
spring
5. Remove
anchor
not
adjuster
automatic
washer
spring
cable
to unhook the
rear
and
clip
INSTALLATION
cable
it
as
the
back
8. Install
anchor
should
where
(Fig. 4).
and automatic
from the parking brake
cable
lever.
ing
2. Contact the shoes as follows:
a. Disengage
the adjusting lever
from the adjusting screw by pulling
the
pivot
9. Remove the parking brake link
spring. Disconnect the parking
2.
off
hold-down
shoe
to
shoe
the
secondary
spring (Fig. 17).
anchor
socket.
washer and
1. Remove
brake drum.
adjusting
the
7. Install
from
guide
(Fig. 4).
and
shoe
REMOVAL
backward
cable
shoe
springs, shoes, adjusting screw,
degreaser.
quired,
the secondary
2-15
SYSTEM
-BRAKE
the
hooked
end
of
spring completely into
large hole in the primary shoe
The last coil of the
spring
should be at the edge of the hole.
Connect the loop end of the
spring
to the adjuster lever hole.
the
web.
3&Z
ADJUSTING LEVER
JTv0
WASHFR%
S^KET
ADJUSTING SCREW
H1390-A
FIG. 1 6-Retracting
Removal
Spring
H1391-A
FIG. 17-Retracting
Installation
Spring
IDENTIFICATION LINES
HI 14 3
FIG. 1 8-Adjusting Screw
Lever Identification
and
B
2-16
GROUP 2
13. Pull the
lever,
adjuster
and
automatic adjuster
and
toward the
cable
spring down
secondary
installation,
by
action of the adjuster
section
cable
the
of
guide
the
(Fig. 4).
shoe web
14. After
BOOT
BOOT
to engage the
rear
hook in the large hole in
pivot
-BRAKES
the
check
pulling the
between the
cable
PISTON
the adjusting lever
and
CYLINDER
PISTON
RETURN SPRING
SCREW
toward the secondary shoe web far
enough to lift the lever past a tooth
the
on
lever
adjusting
hind the
the
next
cable
screw
tooth,
should
The
be
wheel.
snap into
should
position
and
release
the
cause
of
adjuster
spring to return the lever to its orig
inal position. This return action
of the lever will turn the
adjusting
screw
tooth.
one
H1385-A
FIG. 1 9-Rear Brake Wheel Cylinder
REAR WHEEL CYLINDER
tion,
REPAIR
drum.
lt is
necessary to remove the
brake cylinder from the carrier plate
2. Remove
not
disassemble, inspect,
to
hone
or
and
Removal is necessary only
the cylinder is damaged or
positive
and
sharp,
tion
the
lever
of
the
check
the
on
posi
toothed wheel. With the brake
in
vertical
the
the
lever
the
top),
minus
\fa inch)
line
the
is
of
this
lined in this
not
be
turned
actuated
by
the
will
the
in
the
the
is
this
of
section
completely fill or
slightly beyond the crimped
of the fittings. If it does not
indicated
is
should
sembly
b. Check
(plus
or
be
body
The
of
against
if it
guide
for
with
See
notch
in
the
lie
flat
hook
surfaces
the
that
is
1. Wash
body
shows
the
shoe
from
screw
Dry
use
is
alcohol
not
fluid.
brake
specified
de
clean
with compressed air.
2. Check
placing,
all
parts
the
marks
for
If
any
re
require
be
replaced.
bore
cylinder
If
rust.
or
parts
damage.
or
should
3. Inspect
score
internal
all
wear
internal
the
of
If
alcohol.
natured
either
for
con
dition is present, the cylinder bore
must be honed. However, the cyl
not
should
be honed
than 0.003 inch beyond its
more
original
diameter.
4. Check the bleed hole to be
sure
that it is open.
guide
1.
Apply
2. Thread
the
cylinder
of
on
should
the
be
lever
the
Replace
heavy-duty
coating
all internal parts.
the
bleeder
and
tighten
3. Insert the
tions
Place
a
return
into
screw
securely.
spring,
cups,
into their
respective posi
cylinder
bore (Fig. 19).
in the
boot
over
each
end
of
the
cylinder.
REAR
adjusting
seated
WHEEL
CYLINDER
web.
screw
in
the
REMOVAL
1. With the
fitting
that con
Do
cylinder.
tube away from
Pulling the tube out
metal
connection
will
from the
is
cylinder
the
when
from the
removed
car
plate.
4. Remove the brake
taining bolts
remove
the
and
lock
cylinder
washers
re
and
cylinder.
INSTALLATION
Wipe the end(s)
lic line to
ter
remove
before making
1. Place
into
the
the
of
hydrau
any foreign
mat
connections.
wheel
rear
cylinder
Enter the tubing into
the cylinder, and start the tube fit
ting nut into the threads of the cyl
inder.
position.
2. Secure the
cylinder
by installing
plate
lock
and
washers.
3. Tighten the tube
specification
144
or
its
to the car
the retaining
with
fitting
nut
to
1112-
Milbar tool
equivalent.
4. Bleed the brake hydraulic
tem as detailed in Section 2.
sys
REAR BRAKE CARRIER
PLATE REPLACEMENT
REMOVAL
the
damage.
rier
rier
of
brake fluid to
be
hydraulic
the
the
to
cylinder
cylinder
bolts
a
the
cylinder.
the
of
separate
in
parts
REPLACEMENT
properly
the
bleeder
no
system
bend the metal tube and make
installation difficult. The tube will
all
and pistons
pivot
lever if the hook
e.
and
Replace the
pivoting.
proper
socket
web,
should
damage.
d. Check the
lever. The hook
square
should
groove
shoe
web.
the
the
ASSEMBLY
for
guide
cable
cable
the
shows
from the
to the end
anchor
to the
the
inches
HVs
Vm inch)
the
parallel
The
length.
cable
measure
19).
INSPECTION
inder
hook.
Check
c.
as
cable
replaced.
cable
of the cable
damage.
be
minus
the
of
the
and
the
should
cable
end
fittings.
end
cable
this specification, possible dam
meet
age
the
should
cable
extend
bore (Fig.
excessive
Check
a.
not pull
tube
the
the
sure
there is
in the booster
Unscrew the tube
and
available,
condition:
The
Remove the pistons, cups,
return spring from the cylinder
Be
and
stopped
disconnecting
nects
screw
lever
cause
rub
fore
lines.
brake
lever
the
cable.
determine
To
the
and
ends of the
as
out
section.
cylinder.
is
cylinder.
the cylinder.
the
as
1. Remove the links
ber boots from the
contact point
and
wheel,
DISASSEMBLY
2. Remove
teeth
the
on
screw
adjusting
If the
or
brake
the
engine
repair.
shoe
procedures
3. Disconnect the brake line from
vacuum
center-
centerline,
lock
not
contact
the
above
screw.
below
will
should
at
^ir inch (plus
wheel
adjusting
(anchor
position
beyond
scored
adjusting
screw
a
when
brake
the
the
and
wheel
following
semblies,
overhaul.
If pulling the cable does not pro
duce the action described, or if the
lever action is sluggish instead of
the
remove
1. Remove
in
a raised posi
wheel
brake
and
Disconnect the brake
from the brake cylinder.
2. Remove
wheel
the
drum.
adjuster
the
assemblies
brake
and
shoe
the
line
and
wheel
PART 2 -2
cylinder
as
On the
rear
in this
outlined
section.
disconnect the
parking brake lever from the cable.
3. Rotate
wheel,
the
axle
the hole in the axle
the
with
up
nuts
and
ing
move
(Part
plate
4-2),
the carrier
that
so
retaining
Pull the
of the
and
and
assemblies
drum
and
4. Adjust
tion
2),
and
as outlined
the
a
slide
then
housing
into the
bearing
retainer
Steel
retaining bolts
rier
plate.
and
axle
shaft
that the splines
side gear with
sliding
against
the
car
Install the retaining
hole in the
nuts
axle
the
wheels
tubing
this
wheel
brake line
cylinder
and
as outlined
in
section.
3. Install the brake
shoe
and
ad
properly to
tubing
provide
is
at
the
the exception
any
at
rear
hose
front
the
entire
Clean the brake tubing
connections.
line
or
be
replace
the brake
replaced
A flexible
hose,
tubing
tubing
of
the same type, size,
and
shape,
length. Copper tubing should not
be used in a hydraulic system.
When bending brake tubing to fit
if it
or
fitting
with
al
nut
Milbar
equivalent.
brake hose
or
installing
position
contact
with
should
be
shows signs of soften
cracking,
When
entire section
with
torque
specified
1112-144
tool
ing,
of
denatured
installation.
cylinder, tighten the tube
to the
replaced
section
clean
with
BRAKE HOSE REPLACEMENT
BRAKE TUBE REPLACEMENT
a
be flared
leak-proof
system
ment.
If
good
housing
axle
(Fig. 20).
connector
Always bleed the
after
throughout
used
flexible hoses
and
should
When connecting a tube to a hose,
disc caliper, or brake
system with
brake tube
should
2. Install the
2.
be
the
crack
or
tube connector,
becomes damaged, the
flange.
connect the
2-1, Section
contours,
axle
kink
tube.
by flushing
onto the
through the access
shaft
system
HYDRAULIC LINES
of
differential
engage the
the
so
brake
the
re
a new rear carrier plate
housing
bleed
in Part
(Sec
shoes
rear
to
not
cohol, before
plate.
retaining bolts in the
flange. Insert the axle
brake
the
or
underbody
careful
All brake
wheel.
hous
INSTALLATION
on
in this
outlined
cable
the brake
1. Position
as
Connect the parking brake
to the lever. Install the brake
section.
flange lines
the nuts.
assembly out
tool 4235C
with
hammer
shaft
carrier
remove
axle shaft
shaft
juster
2-17
SYSTEM
-BRAKE
damage.
other
a
the
other
new
hose
front brake
to
chassis
avoid
parts.
Place a new copper gasket over the
hose fitting and screw the hose as
sembly into the front disc brake
caliper. Place the opposite end of the
hose
at
the
Install the
bracket on the frame.
horseshoe-type retaining
TO APPORTIONING VALVE-2244
BRACKET-2073
TO LEFT WHEEL
2268
ASSY.
2814
REAR TUBE CONNECTOR
FRONT END OF HOSE
USE EXISTING NUT
2A448 ASSY. (REF.)
IMPORTANT -HOSE MUST LOOP DOWNWARD
374674 -S3
3I497-S8
354538-S8
FRONT HOSE ASSY.
-2078
APPORTIONING VALVE ASSY.
-2B091
H1364-A
FIG. 20-Service Brake System
2-18
GROUP 2 -BRAKES
clip,
and
hose
with the
connect
the
tube
tube
fitting
the
to
(Fig.
nut.
muffler
outlet
brake hose
that it does
rear
stalled so
be in
should
touch the
not
ab
shock
sorber.
hose
a
new
fitting
gasket
and
sembly into the
rear
the rear
over
screw
the hose
brake tube
clip,
con
with
bracket
the
at
Install
as
front
Place the
nector.
hose
Place
A
or
pipe
retaining
hose
the tube to the
fitting
the tube
frame.
the
horseshoe-type
the
and connect
the
of
end
on
nut.
REMOVAL AND INSTALLATION
MASTER CYLINDER
8. Bleed the brake
master cylinder
REMOVAL
top
1. Disconnect
the
brake
lines
from the outlet fittings (Fig. 20).
2. Remove the two nuts and lock
washers that secure the master cylin
der to the booster
Separate the
from the booster unit
master cylinder
unit.
and make sure that the master cylin
der does
3. Remove
push rod.
discard
and
that the gasket
the
filler cap,
outer
Do
power unit.
justing
disturb the
not
screw.
to
Apply
COAZ-19584-A
cant
end
the
of
allow
the
to
nydraulic
of
push
lubri
piston
rod
bore
the center
spring tower to be
inboard for obtaining
proceed
the
light
stop
retainer.
switch
Remove the
the connector.
at
Slide the stop light
pedal just
from the brake
far enough for the switch outer
hole to clear the pin, and then lift
switch straight upward
Slide the
the
and
nylon
from the
pin.
push
rod
cylinder
master
and
washer
posi
off
clear
from the brake
pedal
bushing
pin
(Fig.
21).
3. Remove the retaining nuts and
lock washers, and remove the master
from the booster. It is
necessary
lines.
4.
to
disconnect
Working inside
the
not
the
brake
car
below
5. Remove
dash
panel
the
four
retaining
nuts
bracket-toand
wash
ers.
6. Remove the booster and bracket
assembly from the dash panel, slid
ing the push rod link out from the
and
BUSHING-2A1
booster
the
of
loosen
the brace between the
guide the piston end of the push rod
into
and
To do this,
follows:
as
Disconnect
hose
vacuum
and
tioned
cylinder
light coating
a
the
link from the brake
push rod
assembly.
ance.
ad
INSTALLATION
1.
cap.
pedal
hairpin
2. Remove three bolts
from the
the push rod
install the
from the booster.
cowl
4. Remove
in
seated
booster
switch off
1. Disconnect
the master cylinder.
end of
sure
REMOVAL
the
at
is properly
and
Be
BOOSTER
BRAKE
the rubber
groove
opening.
the instrument panel, disconnect the
wires
one
from the
seal
the
not rest on
filler
the
of
Fill the
system.
to 3/s-inch from the
BUSHING-2461 2 REQD.
piston.
2. Twist the
tain
the
tomed
make cer
is bot
piston
WASHER
the reaction disc and
between the
pocket
air
no
the
of
against
is
there
end
PEDAL ASSY. -2455 (REF.)
to
push rod
the
reaction
with
the in
end of the push rod and
BOOSTER ASSY.
PUSH ROD LINK
disc.
3. Before proceeding
the
check
stallation,
the outer end of the
master
the
cylinder
rod
push
to the
surface
mounting
the
of
end
from
distance
at
RETAINER-379897-S2
f^fr^
2A039
cylinder
vacuum
VACUUM HOSE-372369-S
(Part 2-1, Fig. 2). This dimension
be from 0.990 to 0.995 inch
STOP LIGHT SWITCH ASSY.
should
measured
to metal. If the push
metal
is not correct, see
"Master Cylinder Push Rod Adjust
dimension
rod
4. When the
is
ter
push
install
correct,
in the
Section 2.
2-1,
ment", Part
groove
at
a
the
r*^
adjustment
rod
new
rubber
378319-S2
seal
the mas
end of
374759
cylinder.
2455 ASSY.
5. Position
over
the
that
are
the
push rod onto
integral
cylinder
master
with
the two studs
the
BOOSTER ASSY.
booster
body.
6. Install
lock
2454 ASSY.
-2005
20386-S8 2 REQD.
the
washers
attaching
and
nuts
and
torque the nuts to
34367-S8 2 REQD.
specifications.
7. Connect the brake lines to the
outlet fittings (Fig. 20).
.J
H1382-A
FIG. 2 1
-Brake
Booster
and
Pedal Installation
PART 2-2
engine side of the
dash
(Fie
S
panel
21).
7. Remove the dust
booster push rod link
it in the
slot
from the
seal
and
in the dash
position
panel
for
installation.
INSTALLATION
Working
inside the
car
below
instrument panel, install
mounting bracket-to-dash panel
taining nuts and washers. Leave
the
loose until
sembly has been
nuts
3.
Working
the pedal
after
instrument panel,
booster push rod link
pedal
assembly.
bushing
sition
the
pin
the switch
and
cylinder
on
the
push
so
push rod with
to the
in Fig. 21. Secure these
shown
as
parts
brake
and
the
pin.
Po
straddles
switch
the
slot on
and
straight
Connect
the
nylon
the
wires
light
the stop
in the retaining
master
and
retaining
support
cylinder
to
the lock washers
nuts,
and
holds
that
torque
to
the
and
off
(Fig. 21).
bolt
and
the
to
nut
pedal
bracket. Remove the brake
assembly from the
pedal
bracket,
port
pivot
pedal
Slide
rod
bushing
pin
pedal
clear
switch
pin.
push
and
washers
from the brake
the
from the
cylinder
4. Remove the
booster
specification.
booster, install
the
the
clip.
and torque the
retaining nuts to
5. Position the
wires
install
and
connector,
4. Tighten
switch
lift
then
upward
master
hole to
outer
switch
pin,
the
and
pedal
remove
sup
the bush
ings.
specification.
6. Position the
brace,
er
cowl to spring tow
install the bolts and nuts,
torque to specification.
and
the
vacuum
INSTALLATION
a coating of Lubriplate
bushings and locate all the
bushings in their proper places on
1.
to
hoses to
booster.
Apply
the
the
pedal
(Fig.
assembly
2. Install the brake
BRAKE PEDAL
and
bushings to the
1. Loosen
through
the
booster
mounting
nuts.
brake
pivot
2. Disconnect the stop light
switch
the
hairpin
the
pedal
bolt
assembly
support
bracket,
the
assembly.
Install
bolt
and
the
torque to specifi
3. Install the inner
retainer.
pivot
bracket
support
nut and
21).
pedal
cation.
wires at the connector.
3. Remove
install
then
and
REMOVAL
pedal
for the
the
washer, the
it
washer
proceed
rod,
that
the
below
connect
nylon
the brake
switch
as
the pin. In
nylon
Slide the stop light switch off from
the brake pedal pin just far enough
to the pin with the hairpin retainer.
re
the
outer
outer
Slide the
pin.
onto
completely
the
stall
7. Connect the
car
To do this,
follows:
Install the inner
master
the
connected.
inside the
the
as
pedal
switch
to
1. Mount the booster and bracket
assembly to the dash panel by slid
ing the bracket mounting studs and
the push rod link in through the
holes in the dash panel (Fig. 21).
2.
the
hole just clearing the
2-19
SYSTEM
-BRAKE
the
master
cylinder
nylon
push
washer,
rod,
and
EQUALIZER-TO-REAR
WHEEL CABLES
PART OF VENTILATION
SYSTEM INSTALLATION
FIG. 22 -Parking Brake System
H1309-A
2-20
the
GROUP 2 -BRAKES
bushing
Position
the brake pedal pin.
on
the switch so that it strad
dles the
push
rod
the
with
hole just clearing
Slide
the pin.
the switch completely onto the pin,
install the outer nylon washer as
in Fig. 21. Secure
shown
hairpin
to the pin with the
4. Connect
to
wires
the
the
5. Torque
retainer.
light
stop
connector,
install
cowl
mounting
control
Position
side
to
kick
with
car
on
the
two re
the
En
hoist.
a
to the frame
housing
U-clip
a
Install
1, Part
(Fig.
spring
and washer on the rear end of
lever
equalizer
7. Adjust the parking brake link
age as outlined in Part 2-1, Section
1. Raise the
justing
by
compartment,
the
car.
the
retaining
pad.
Re
kick
that
screws
retain
the air duct to the inner cowl panel,
and
then remove the
tain
access
from the
brake
Remove the
assembly.
air
duct to
air
the
to
ob
control
control
cable
duct.
5. Remove the
U-clip that retains
the cable housing to the parking
brake control housing (Fig. 22).
6. Remove
clevis
engage
the
the
cable,
hairpin
the
from the
pin
then
retainer
the
remove
assembly from the
Dis
clevis.
from the ball
clevis
cable
cable
and
going
2. Drill
the
parking brake
housing. Install the clevis on the ball
in
end
of
control
the
the
cable
and
connect
the
clevis
to the actuating arm with the
(Fig. 22). Secure the
pin
clevis
pin
clevis
with
2. Secure the
.parking
brake
the
hairpin
retainer.
to the
housing
control
housing
cable
with
'the U-clip.
3. Position the parking brake
con
brack-
trol assembly to the mounting
install the three retaining
and
iet
jbolts.
In the
passenger
the
retaining
that
screws
inner
then
the air duct to
remove
access
to the brake
Remove the
air
cowl
panel,
power
vacuum
brake
parking
two
3. Drill
that
or
out
the
off
grind
rivet
the vacuum piston link
connects
release
lever,
and
remove
from the
power unit.
assembly-
control
parking
(Fig. 22).
6. Remove the hairpin
retainer and
cable.
from the
bolts
cable
nuts.
vacuum piston
with
The
is to be positioned
bolt between the
and
link
wave
on
the
vacuum
the release lever. The
release
lever
must
pivot
freely.
"Installation"
under
in the
foregoing
procedure.
4. Test the lock
lease
operations of
control
assembly
running in
lector lever
all
should
the parking brake
the engine
with
the
transmission
se
With the
en
positions.
running,
gine
and automatic re
remain
the
parking
engaged
in
"park"
or
drive
and
position.
should
brake
"neutral"
release
in any
car,
into the hole in the floor
cable
2. From the inside,
housing
and
hole in the floor
hole
in
the
cable
the
the
of
through
brake
parking,
Install
housing.
ball end
the
pull
new
up through the
pan.
3. Position the
on
clevis
cable
the
control
the
connect
and
the clevis to the actuating arm with
the clevis pin
clevis
3. Install the parking brake control
assembly in the car as described
of the
underside
the upper end of the replace
pan.
shoulder
a
nut and wave washer.
link
housing
and
cable
car.
ment
and
the
assembly
housing.
down through the hole in the floor
pan and remove it from under the
1. Position the vacuum power unit
the parking brake control assem
bly and secure with two round head
bolt
the
of
control
cable and cable
7. Push
1. From the
lever
end
INSTALLATION
on
release
Remove the
Disengage
clevis.
from the ball
clevis
guide
2. Connect the
from the
retains
the
housing to
control housing
cable
clevis pin
INSTALLATION
to the
from the
cable
control
the
unit.
and
obtain
duct.
brake
control
air
and
control assembly.
to-mounting bracket bolts.
5. Remove the U-clip that
the
off
grind
the
retain
duct to the
the
or
out
the
to
piston
through
four
the
car.
remove
the left kick pad. Remove
screws and
the
that retain the
rivets
unit
link
cable
2. Lower the
compartment,
4. Remove the
procedure.
and
bracket.
"Removal"
washer
INSTALLATION
1, Part 2-1). Re
washer, spring,
3. Disconnect the hose
1. Remove the parking brake con
assembly from the car as de
in the fore
scribed under
shoulder
hole
of
by
cable
the
ad
and
spring seat. Remove the U-clip
disengage the cable housing from the
trol
end of
control
housing.
1. Position the
operation
PARKING BRAKE VACUUM
POWER UNIT
power
to-mounting bracket bolts.
and
the
check
assembly-
control
the
dis
and
from
cable
removing the
(Fig.
nut
vacuum
to the
the
justing
hoist
car on a
pedal
lever
equalizer
brake.
unit.
power
4. Remove
then
and
the parking
assembly.
3. Disconnect the hose from the
vacuum
2,
REMOVAL
passenger
left
four
bracket.
In the
remove
the
and
the
move
and
disengage the
and
from
2. Lower the
screws
hoist
a
1, Part 2-1). Re
U-clip
housing
cable
on
removing the ad
(Fig.
nut
the
move
car
the pedal cable from the
lever
equalizer
the cable.
of
REMOVAL
disconnect
half-
install the
and
type adjusting nut on the end
moon
the
connect
cable
seat,
the cable. Assemble the cable to the
PARKING BRAKE CONTROL
ASSEMBLY
1. Raise the
air
duct.
to
pad
with
REMOVAL
move
the cable
2-1).
the
air
screws.
6. Raise the
gage
with
to the
secure
inner
four
the
Connect
left
and
EQUALIZER.
BRAKE
PARKING
TO-CONTROL ASSEMBLY CABLE
duct to
secure
cable
the
panel
taining
air
screws.
retaining
duct
spring
to specification.
hose
vacuum
and
panel,
bracket
clip.
booster
the
5. Position the
switch
and
in the retaining
the wires
nuts
these parts
the
the vacuum power unit.
switch
slot on the pedal pin and the switch
outer
4. Connect
pin
(Fig. 22). Secure the
the hairpin
with
4. Secure the
parking brake
retainer.
housing to the
control housing with
cable
U-clip.
the
5. Position the parking brake con
trol assembly to the mounting brack
et
and
install
the
bolts.
6. Connect the
vacuum
power
7. Position
inner
four
air
cowl
three
vacuum
retaining
hose to the
unit.
the
panel,
air
and
duct
to
secure
the
with
retaining screws. Connect the
duct control cable to the air
PART 2-2
duct. Position the left kick
the
side
panel
and
secure
retaining screws.
8. Raise the car
and
spring
on
the
(Fig. 1, Part
the
on
lever
the
end
to
cable
install
and
half-moon type adjusting
end of
cable
rear
Assemble the
equalizer
En
to the frame
spring seat,
washer
the cable.
of
hoist.
a
housing
a U-clip
the
two
3. Loosen the adjusting nut on the
equalizer rod and disengage the ball
end
gage the cable
bracket with
2-1). Install
to
pad
with
(Fig.
cable.
U-clip that retains
the
cable
housing to the frame
bracket. Disengage the housing from
bracket
the
and
hook (Fig. 22).
5.
the
Working
carrier
the
on
2,
retainer out of the
they
in the
brake.
can
pass
carrier
side
wheel
(Fig. 4),
plate
the prongs on the cable
then check the operation of
retainer
so
through the hole
plate.
Draw the
cable
hole.
6. With the spring tension off the
lever, lift the cable
REMOVAL
out
the slot in the lever
of
through the
move
1. Raise the car and remove the
cap. Remove the wheel and tire
1. Pull
assembly from the drum.
2. Remove the three Tinnerman
the
nuts
that
remove
brake
the
retain
drum,
the
of
housing
cable
that the end
so
hole from the
carrier plate access
inner
the slot
side and engaged with
in the parking brake lever.
drum.
the
end,
ing
stop
is
inches
between
shown
in
justable
hold
to
the
and
re
Fig.
adjustable
housing
hous
through the
distance
a
the
22.
two
stops
Crimp
the
stop against
dimension.
the
five
of
as
ad
to
cable
this
5. Insert the ball
into
the
the cable
cable
there
until
housing
U-clip
holding
against
the
pull
the
end
(Fig. 22).
4. While
cable
the
and
front
cable
Install
bracket.
re
hole.
the cable may be inserted through
of
the
engage
of
frame bracket,
the
cable through the
so
expand.
prongs
retainer
hole
access
plate
carrier
housing
cable
the
equalizer
end
the
of
and
cable
the
tighten
adjusting nut slightly.
6. Install the rear drum. Tighten
enough
through the
then
and
carrier plate
INSTALLATION
hub
the
3. Thread
of
compress
parking brake
PARKING BRAKE EQUALIZER TO
REAR WHEEL CABLE
into
from
slack
excess
insert the
tainer hook
that
the parking
the retainer
off
slip
the
Pulling
cable,
that the
1, Part 2-1).
9. Adjust the parking brake link
age as outlined in Part 2-1, Section
and
equalizer
2.
the
4. Remove the
the
nut on the
the cable from the
of
2-21
SYSTEM
-BRAKE
the
and
Tinnerman
three
tain the
hub
drum,
and
that
nuts
install the
re
wheel
cap.
7. Adjust the parking brake link
age as outlined in Part 2-1, Section
2.
MAJOR REPAIR OPERATIONS
DRUM
BRAKE
REAR
place
REFINISHING
Minor
be
removed with
or
brake drum can
fine emery cloth.
scores on a
A drum
a
a
is excessively
indicator
that
shows
the
eliminate
drum.
the
enough stock
true
and
scores
The
refinished
to
up
diameter
0.060 inch
must not exceed
runout
be turned
should
down. Remove only
to
replace
be
replaced
oversize
Inspect brake
or
crack's,
brake
may
drum diameter
the
If
drum is turned
a
surface
refinished
in
soaked
also
be
down,
turned
on
cut
the
lin
wipe
alcohol.
the
down,
1. Wash
down to the
same
REAR BRAKE SHOE
within
been
should
V32 inch
saturated
be
of
are
worn
to
the rivet or have
with
replaced.
not
should
repair
a
condi
be dis
defective
then
seat
brake
the
remove
cup, spring,
the
piston
piston
re
and
assembly,
residual check valve and
(Fig. 23).
2. Remove
the piston.
the
against
secondary cup
Remove the cover
from
by
re-
thor
shoes
Remove all
from the shoes.
a clean solvent.
or rough spots
COVER
2. Check the inside diameter of
brake drum. If the diameter is
less than 11.120 inches, standard
linings may be installed. If the diam
eter is
11.120-11.150 inches, over
size lining should be installed.
3. Position the
shoe.
Starting
secure
new
lining
on
in the center,
DIAPHRAGM
MASTER CYLINDER
the
the
insert
working al
end. Install
all parts supplied in the kit. Ford
replacement
linings are ground
and
no
further grinding is re
ternately
rivets,
towards
4. Check
that
for distortion,
each
the
clearance
the shoe and lining. The
seat
tightly
SPRI
SECONDARY CUP
quired.
RELINING
linings
shoe
1. Press in
moving the snap ring retainer,
the
and
axle
same
size.
Brake
the
car.
shoes
DISASSEMBLY
cloth
a
with
denatured
is
drum
opposite
should
clean
drum
one
oversize
be installed.
must
After
on
wheel
MASTER CYLINDER
also
shoe.
burrs
lining
the
Do
carded.
If the drum diameter is less than
0.030 inch oversize (11.120 inches)
ings
the
must
looseness. If this
tion exists,
oughly in
be installed. If the
is 11.120-11.150 inches,
the
on
opposite side of
(11.150 inches).
after refinishing, standard
linings, they
scored
total
0.007 inch
or over
linings will result in a
drum. When it is necessary
worn
scored
between
lining
must
bNAP
RING
H 1387
against the shoe with not
than 0.005
inch
grease
or
oil
more
Failure
to
re
tween any two rivets.
clearance
be
FIG. 23-Master CylinderDisassembled
-
A
2-22
GROUP 2
leasing
the
and remove
spring clips on the sides,
the hermetic diaphragm.
the
and
caliper
-BRAKES
splash
(Fig.
shield
25).
shoe and
lining
assemblies.
1.
Clamp
housing in a
the
Dip the hydraulic
in brake fluid and as
vise.
cylinder parts
semble the check valve seal, residual
check
and piston return
valve,
in the bore
of
order shown
in Fig. 23.
2. If
Jhe
spring
in the
cylinder
lip
the
of
as
cup
end of the piston
it into the
4. Press in
compress the
spring
5. Install
old
cylinder
the
and guide
caliper
four
housings
and piston
7.
to
piston
seating the
in the cylin
diaphragm
the
Clamp
it by
the
secure
inboard
the
(only
in the
shown
bores
the
ward
at
to
the
tool
from
special
while
it
pulling
Be
or
hold
that
caliper
the
together.
housings
25
Fig.
two
are
for
halves
The two
shown
of
diameter
piston
is
removed
so
surface
completly
bore that it
with
the
outward.
To
seized
can
not
tool,
the bore by
prevent
carefully
knife
seals
piston
the
cylinder
inserting
the point
in
or other pointed
with
the
under
strument
and
seal
raising
up far enough to be
the fingers.
pulled
cocking,
AND INSPECTION
CLEANING
Clean
or
special
cylinder out of
in
grooves
or
metal
all
suitable
a
dry,
clean,
Be
ways.
(Fig. 25). Use
compressed
dry
sure
that
free
of
any foreign
Replace
scored,
the
or
or
piston
the
completely
material
cylinder
for damage
bore
the caliper
component parts are
Check the
to clean
air
the grooves and passage
and
tons
alcohol
parts with
solvent
bores
and
excessive
if
it
chrome
is
pis
wear.
pitted,
plating
is
the
caliper
in
separated
illustration
by
out and
the cylinder
prying
bores
damaging
DISASSEMBLY
the bridge bolts
the
out
careful
force the
remove
from
out
positioning two screwdrivers in the
piston dust boot retaining groove and
not
Remove the rubber
piston
DISC BRAKE CALIPER
Do
or
with screwdrivers.
housing
caliper
the seal
the
sealing.
in
retainer or
damaged
is
groove
prevent
dust boot retaining groove of the
Such damage causes poor
a
dust boot
caliper
retaining
9.
piston.
be
be
pis
replaced.
on
damage to
rotate
scratching
outside
If
If the
is used, the
removal
of
method
of a small
24. To
the same time.
avoid
the
consequent
bore,
flanges
pistons
with
in Fig.
with
with
a vise and
(Fig. 24).
housing
cylinder
cocking
to the
cover
the spring clips.
in
caliper
the mounting
8. Remove the four
tool
force is
prying
being applied. Be careful to avoid
damaging the dust boot retainer in
the caliper housing (Fig. 25). If this
boots
dust
the
a
with
the
scratched, pry the retainer out of
the piston or
is defective)
attach
with
the
while
groove
new
one
and
cover,
a
on
bore.
against
snap ring in the
der bore.
the
from the
the
lightly
piston
circumference
while
tons must
6. Remove
the
shown.
assembly,
cylinder
transfer
external
tube.
the
3. Place the primary cup
if
from the caliper.
5. Remove the
grooves.
secondary piston cup was
removed from the piston, dip the
cup in brake fluid and assemble the
cup in the groove of the piston with
the
4. Remove the flexible brake hose
cylinder
master
hammer,
the
of
end
the
around
3. Remove the two
ASSEMBLY
the
tap
CALIPER ABUTMENTS
purposes
OUTBOARD CALIPER HOUSING
only.
1. Remove
from the
the
caliper
car as outlined
assembly
in Section 2.
DUST BOOT RETAINING GROOVE
2. Remove the two retaining bolts
Tool
-
T65P
-
2118- A
INBOARD
CALIPER HOUSING
H 1372
FIG. 24-Removing
Pistons
or
-
A
FLEXIBLE HOSE
H1367-A
Installing
FIG. 2 5 -Caliper Assembly-Exploded View
PART 2-2
worn
Check
off.
boot
for
retainer
the
dust
caliper
wear
damage.
or
7. Install
Clamp
a vise and
it by the mounting flange
inboard housing.
2. If
a
new
on
re
installed, thoroughly
clean the contact area on the caliper
housing
and apply Loctite Sealant,
Grade H to the retainer surface that
seats in the housing. Install the re
tainer in the caliper housing.
3. Apply a film
fluid to new caliper
install them in
the
grooves
use
the
worked
original
4. Coat the
pistons
in the
in the
retaining
bore. To
the
bores
a
piston
will
groove
avoid
into
slow
face
easily
bore,
the
out of
locate
cocking,
steady
not
so
bore
and
If
pressure.
go all the
a
way
it
and
cylinder
bore,
remove
thoroughly inspect
the
the
the installation of
piston seal and
the seal. If the
in
with
bore in
the
piston
use
the tool
piston
ing
it inward
condition
on
pistons.
shown
in Fig. 24. Rotate
the tool while push
with
dust
seated
caliper
sure
in
respective caliper
(Fig. 25). Do
that
housings
and
the
groove
housing
not
boot is
each
use
of
its
base
the
and
the
master cyl
mounting
bracket.
the
mounting
cylinder
master
lock
washers and
the master cylinder.
remove
3. Remove the retaining
lock
washers
nuts
the
and
and
mounting
brackets.
4.
valve rod
alcohol
the
and
dust guard,
valve
rod
small
diameter
guard
the hub
and
eye of
then
and
dust
the
remove
to the
bolt.
The
removed.
load
If the
the
of
from the
the
do
notched
shell
sections
soft
a
with
hammer to break the bond between
the front shell, the diaphragm and
the rear
shell.
of
bolts
so
rear
on
shells
the alignment of
the lances with the
the front
of
should
shells
as the
bolts is
shell
sections
flange. Loosen
outer
separate
while
5. Remove the hydraulic push rod
from the front shell and remove the
seal
center
front
the
notched
begin to
shell
(Fig. 28).
shell
the
shell
the
carefully
from the
the
at
counterclockwise
in
4. Press down
Apply
the
the
rear
tap
bolts to
to free the lock
lances
the
and
the
outer rim.
shell
not separate, check
nuts and
the
of
tighten the center bolt
3. Turn the bar
across
marks
shells, the
studs
and
studs
the hook
attach
enough
with
scribe
wrench
the
over
and
align
that
will
spring
firmly on
disconnecting
the
not
the front
the
diaphragm
fly
out
of
hook
return
the
as
sembly.
5. Remove the top clamp bar, the
bar wrench, the front shell, and the
return
spring from the diaphragm
and
shell
assembly.
push rod.
REMOVAL OF VALVE ROD
AND POPPET ASSEMBLY
1. With the
new
the
PARTS
at the same time.
the
Be
and
properly installed,
Carefully install four
boots
fully
good
seal
the
5.
piston still will not go
clamp bar
front shell,
just
obtained.
insert the
in the holes in the
base (Fig. 27).
REMOVAL OF EXTERNAL
flange
of the piston and
of the rear shell
the
1. Make
the base of Bendix tool
a vise and
until
inder
not
Clamp
73800 in
front
2. Remove
the piston squarely in the
apply
firm
a
DISASSEMBLY OF BOOSTER
groove
Do
around.
cylinder
the boot
until
car
is
pedal
and rear
diameter of the
brake fluid and in
open end
brake
front
seals.
that the
the
move
POWER SECTION
2. Place the bar
for fluid leaks
pressures. Do
caliper
under maximum pedal
not
splash
in Section 2.
outlined
9. Check the
shoe and
the
and
assemblies
as
be
outside
with
them
stall
the
of
should
seal
positioned at one area
gently
lining
assembly
install the
piston seals and
bore. The
and
brake
clean
of
caliper
on
OF
DISASSEMBLY
1.
the spindle, and
shield
dust boot
caliper
tainer is to be
cylinder
hose
flexible brake
the
8. Install the
in
the caliper
secure
the
external transfer tube.
to the caliper.
ASSEMBLY
1.
6. Install the
2-23
SYSTEM
-BRAKE
valve rod
in
a vertical
position, squirt alcohol down the rod
to wet the
valve
the
rubber
plunger
and
in the
grommet
the
ball
end
of
rod.
and piston
the
2.
Clamp the valve
leaving just
original
dust boots.
between
the
plastic valve
steel
hub
retainer
and
a
the
vise
on
open-
wrench near
pry to force the
a
the ball end of the
valve plunger off
valve rod
the
the side of the
Use the
as
vise
enough space
jaw for two medium-sized,
vise
end wrenches.
est
in
rod
(Fig. 26),
(Fig. 26).
When separating the valve rod
from the plunger, hold the power
to
unit
When
be
careful
plastic valve
with
Pry
the
to
not
from
the
falling.
wrenches
damage
the
hub.
3. Remove the
vise.
it
prevent
prying
valve rod
retainer
from the
off the
end of
housing being careful not
the plastic housing (Fig. 28).
the valve
to chip
FIG. 26-Removing Valve Rod
and Poppet Assembly
4. Remove the
valve return
spring,
the poppet retainer and the poppet.
H1379-A
FIG.
27-Disassembly
Assembly
of
and
Power Section
2-24
GROUP 2
6. Lift the diaphragm and plate
assembly from the rear shell, and
remove the rear shell from the fix
base.
ture
7. Place
bench
the
rear
the studs up,
with
the seal with
out
driver.
seal
Do
not
drive
or
screw
the
remove
rear
is defective
seal
is
or a new seal
and
a punch
the
unless
the
on
shell
RETAINER
AND PLUNGER
1. Wet the
retainer
with
seal
alcohol
and
remove,
using the fingers
only. Remove the
diaphragm from the rear plate
(Fig. 28).
2. Set a piece of 1 Mo-inch hex
bar stock 2 inches long in the bench
rear
Set the diaphragm and plate
on the hex stock with the
hex opening in the front plate seated
2. Install the front diaphragm on
the front plate. Apply a light film
Bendix type
side
rear
plate
age
the
on
only
channel
ence
of
loosened,
the
pres
circumfer
being
cant
been
have
assembly from
complete the disassem
the bench
the front plate
with
down. Unscrew the
rear plate
com
pletely and carefully lift it off the
front plate hub, grasping the valve
and
plunger
hand
and
the
with
spring
hub.
plate
the
on
set
valve
the
of
recess
grommet
against
side
the
of the
down,
front
ring
shoulder
plate
on
the
rear plate threaded
screw
the
out
hub.
over the valve plunger.
place
firm
seal
rear
bore
Using
plate
to
hub. To tighten the
P/io-inch hex bar stock
in the vise, and set the
bly, front plate down,
other
MOUNTING
plate
on
assem
the
hex
BRACKETS
square
120
the
assembly from the vise.
6. Install the rear diaphragm
the
rear
the
center
retainer
and
of the
lip
fingers,
the
the
it
of
plate.
retainer
seats against
the center
of
shoulder
center
press
onto center plate until
the
on
lip
the
Assemble the dia
over the rear dia
plate.
phragm
Using
over
and
plate
phragm
plate.
OF DIAPHRAGM
ASSEMBLY
AND PLATES IN FRONT
AND REAR SHELLS
1.
talcum
Apply
inside
of
wall
the
the
to
oowder
diaphragm
rear
"O"
lubri
Apply Bendix type
cant liberally to the bearing seal in
the rear shell. Apply DC-4 lubricant
liberally to scalloped bearing surface
shell.
the front
of
2.
of
shell.
the
Clamp
holding
fixture base
Bendix tool 73800 in the
the
the
of
studs
vise and
shell
rear
matching holes of the
fixture (Fig. 27). When assembling
the center plate and diaphragm as
the
through
sembly in the rear shell, the
diaphragm and center plate
must
on
be
the
aligned
rear
the valve
bearing
Carefully
shell.
lugs
guide
sleeve through
in the
plate
rear
between the lances
housing
seal
the center
rear shell
the
keeping
diaphragms in
and
SPRING-VALVE PLUNGER RETURN
removing them from the
plate hub.
bore of the front
4. Remove the
from the shoulder
to
Remove
plates
pounds.
plate
in
hub,
plate
inch
180
to
insert
square
front
hands only,
front plate
plates,
the
shown,
plunger
and
side up.
4. Place the
ly
return
plunger
valve plunger as
spring
As
grommet.
rubber
the
semble
the
the
any lubri
to get
not
careful
on
5. Set the
plate.
plates
remove the
the vise and
bly
outside
the rear
3. After
on
atmospheric
or
assembly, seal
seal
lubri
Apply Bendix type
cant lightly to the front and rear
bearing surfaces of the valve plunger,
counterclockwise, using hand lever
sure
the
guide
the front
onto
in the
seal
3.
and
Twist the
and
plate
hub.
plate
bar. Hand-torque the
"O"
spring
bar.
lubricant to the
front
of
surface
first,
assembly
the
"O"
Apply liberally to the
center
plate.
Carefully
vise.
on
a
(Fig. 28).
center
diaphragm spring
rear
press
and
seal, plastic bearing face first,
into the recess in the rear shell.
Press the top outside flange of the
seal
approximately %o inch below
the flat shell surface next to the
outside
DISASSEMBLY OF DIA
down,
studs
wood,
new
of
available.
PHRAGM, PLATES,
of
-BRAKES
REAR PLATE
seal
ring
of the rear plate.
The ring seal may stick to the
der of the front plate hub.
shoul
5. Using a small rod or
driver through the center bore
screw
of the
front plate, push out the reaction
disc. Loosen the front diaphragm
from the
plate
move
center
plate
center
carefully
hub. Do
the
and slide
the
off
damage
not
the
front
re
or
GROMMET
(\
assembly from the
seal
center plate.
phragm
plate,
Remove the front dia
from the front
FRONT SEAL
plate.
6. To remove the vacuum check
from the front shell, work
from inside the front shell. Cut off
FRONT SHELL
valve
the
bead
move
Do
of the rubber grommet.
the
not
DIAPHRAGM RETURN SPRING
Re
HYDRAULIC PUSH ROD
check valve and grommet.
remove
the
valve
unless
it
is defective.
ASSEMBLY
OF BOOSTER
FRONT DIAPHRAGM
ASSEMBLY OF
PLUNGER, AND
1. Place the
CENTER PLATE
PLATES,
DIAPHRAGMS
rear shell
on a
block
AND SEAL ASSEMBLY
FIG. 28-Booster Disassembled
H1380-A
PART 2-2
correct
Work the
alignment.
rim
of the
rear
shell
outer
front diaphragm into the
that
so
front diaphragm
outer
is
rim
condition
of
be
allowed
Place the large diameter end of the
diaphragm return spring over the
front plate hub, and position the
front shell on the spring so that the
scribe marks on the front and rear
shells will be aligned when the shells
locked in
are
3. Place the bar
over
wrench
the
to
is
hub
to
and
first,
end
of
make
aligned
the
the
lock
bolt
the
front
the
on
front
the
to
center
Then twist
shell.
in
the
until
shell
relation
stop
is
4. Remove
bar
and
hold-down
the
from the
the
remove
and
wrench,
power unit
plate
fixture.
holding
disc
the
push
the adjustment
over
Press the
rod.
push
in the front
seal
4. If the
Make
in
shoulder
the
tire
the
flange bears
is
Wet
the
in
valve
al
the
check
the en
until
the
of
check
against the grom
ROD AND POPPET ASSEMBLY
PUSH ROD
1.
cant
the
1. Wet the
Apply Bendix
liberally to the
reaction
end of
disc
end
Bendix type
on
of
and
"O"
the rod of the
the
to
push
reaction
the
lubri
entire surface of
the hydraulic
28). Place the
piston
"O"
type
push
piston
rod
disc
(Fig.
on
rod.
the
Apply
lubricant sparingly
push
rod,
keeping
and assemble
housing,
pet
poppet valve
in alcohol,
the poppet in the valve
small
diameter
of
end
first (Fig. 28). Wet the
retainer
in the
in
alcohol
housing
Press in
certain
tainer is
against
and
with
the
the
pop
poppet
assemble
flange
retainer
to
it
out.
make
that the shoulder on the re
positioned
inside the
poppet.
the
guard
the dust
the
of
the
care
housing.
plastic
OF
housing
valve
the
of
over
flange
the
of
the
the
against
the
eye
the large end
seat
over
guard
of
the
not tear
the
guard
and
of
assemble
and
(Fig. 28). Do
Press the
guard.
diameter
small
in alcohol,
guard
valve rod
the
scalloped
Before
shell.
rear
mounting the master cylinder, check
the distance from the
draulic
push
of
rod
end
the
power
unit
the
of
hy
hydraulic
the
to
mounting face
cylinder
INSTALLATION OF VALVE
DISC AND HYDRAULIC
on
retainer
housing, being
valve
to chip
Dip
end
VALVE, REACTION
end
plunger.
valve
the
a
with
rod
EXTERNAL PARTS
1.
met.
CHECK
the
not
VACUUM
OF
ASSEMBLY
ful
dust
first.
side
Press
grommet
end of
in
the check valve
circumference
valve
the end of the
hammer to lock the ball
valve
end
plunger.
valve
soft
4. Assemble
of
valve
ball
the
Tap
into
grommet
shell.
assemble
into the
grommet
check
grommet.
was
valve
grommet
the
front
the
in the
of the valve rod
INSTALLATION
new
that
the
of
and
cohol,
housing,
into the
assemble
and
the
Guide the
alcohol.
silencers
and
spring,
in
rod
in
end
recess.
beveled
shell,
certain
seated
valve
the
press
and
front
the
the valve
ball
the
and
shell until
check
vacuum
wet
seal
as
rod
valve
grommet
rubber
plunger
valve
the rod in the
screw
of the
end
spring
return
shown.
support plate
bottoms in the
in
contacted.
reaction
and
the
alcohol
of
disc
recess
Tight
the
push rod
bubbles be
air
eliminate
the
removed,
clear
will
into
reaction
into the
on
end
the
3. Assemble the seal,
of the
the rim
until
clockwise
shell
rear
rim
rear shell.
front diaphragm
the
are
shell
Guide the
shell.
diaphragm into the
en
notched
the retaining lances
with
rear
front
the
on
sections
that the
certain
the
piston
the
reaction
with
piston.
rod
side
bolt,
rod
that
in
seated
Before
center
the
on
certain
make
disc
adjust
ball
over the
valve
retainer,
valve
and
3. Wet the
push
disc hub. Twist the
attach
the
the
reaction
the
tightening
the
the
2. Assemble
silencers,
threads.
disc
bolts.
of
the lubricant
on
get
adjusting
Under
rod.
reaction
front shell, and then
the clamp bar with the hook
studs
to
2. Insert
the
push
should
screw
ment
tween the
place.
the
of
no
rear shell.
from
away
end
screw
the
each
under
the retaining lances on the
of
lubricant
2-25
SYSTEM
-BRAKE
the
at
front
shown
as
in
Figure 2, Part 2-1. If the push rod
length is not correct, follow the push
rod
in
adjustment
Part
push
procedure
outlined
2-1, Section 2. When
rod
length
is
correct,
the
attach
the master cylinder to the power sec
tion
with
Torque the
tach
on
lock
washers
and
nuts.
nuts to specification.
At
mounting bracket to studs
rear shell with lock washers
the
the
and nuts and
torque to specifications.
2-26
PART
2-3
SPECIFICATIONS
DRUM BRAKE DIMENSiONS-IN INCHES
Lining Width
Lining Length
Limit
Primary
Secondary
Primary
Secondary
Wheel
Cylinder
Bore
Diameter
11.150
9.39
12.21
2.50
2.50
m
Drum
Maximum
Drum
Inside
Diameter
Boring
11.090
Master
Cylinder
Bore
Diameter
'8.
BRAKE CHECKS AND ADJUSTMENTS
Type
of
Check
or
Specification
Adjustment
Brake
Drum Diameter
11.120-11.150 inch
Brake Shoe Repair
Lining Required
Oversize
Brake Lining Clearance (Midway between Rivets) Maximum 0.008 inch
Lining Wear Limit (From Top
Rivets) Maximum V4* inch
of
Hydraulic Master Cylinder Bore, Honed Diameter. Maximum 0.9405 inch
Master Cylinder
Push Rod Adjustment 0.990-0.995 inch
Power Unit
Refinish if Total Indicator Runout Exceeds 0.007 inch
Drum Out-of-Round
Replace if Runout Exceeds 0.002 inch
Rotor Runout
DISC BRAKE SHOE AND LINING DIMENSIONS
TORQUE LIMITS
Ft
Description
Front Brake Hose Bracket to Chassis Bolt
Rear Brake Drum to Rear Axle Shaft Flange
Bonded Johns
10-15
Lining Size
5.36"
Hand Push Fit
Lining Area
10.03 Sq. In./segment
Shoe
0.600"
75-110
Rear Wheel to Axle Shaft to Drum
and
Lining Thickness
and
Bearing
1.90"
x
nominal
0.436"
Lining Thickness
Rear Brake Carrier Plate
to Axle Housing
Mansville 1398
Lining Material
Lbs
nominal
Retainer
50-70
Shoe and Lining Maximum
Wear Limit
0.195"
12-18
Master Cylinder to Booster
Lining Maximum Wear Limit
(from surface
Master Cylinder Tube
of
shoe)
0.030"
6-12
Fitting
Lining to Rotor Clearance
Brake Booster to Dash Panel
Support Bracket
and
(brakes released)
Pedal
15-25
Proportioning Valve
Parking Brake Control to Mounting Bracket
0.002-0.010"
15-19
450 PSI
cut
(43'/2 %
in
reduction
pressure over
450
in
rear
PSI)
line
2-27
PART 2-3 -SPECIFICATIONS
DISC BRAKE TORQUE SPECIFICATIONS
SERVICE TOOLS
Caliper Assembly to Spindle
75-100 Ft-Lbs
Caliper Bleeder Screw
10 Ft Lbs (120 in-lbs)
Maximum-must be leakproof
Caliper Splash Shield
7-9 Ft-Lbs
Caliper Bridge Bolts
65-75 Ft-Lbs
Rotor Splash Shield to Spindle
10-20 Ft-Lbs
Brake Tube Fitting Nuts to
Proportioning Valve
70
Hub
17-25
and
to
17-25 Ft-Lbs
maximum
-
Ft-Lbs
while
Wheel Assembly to Front Wheel
Hub and Rotor Assembly
.0005"
-
In-Lbs Maximum
bearing
must
rotor
torqueing*
play
with
Brake Adjusting Tool
2162
Adapter
Cap
Brake Shoe R & R Spring
2086-L
Snap Ring Pliers
33621
Internal
Milbar
1112-144
In. -lb. Torque Wrench
Bendix 73800
75-110 Ft-Lbs
end
2018 A
2035-N
TOOL-33621
Rotate
Description
Former No.
Brake Cylinder Retaining Clamp
-
be leakproof
Rotor Assembly to
Front Wheel Spindle
of
Ford Tool No.
Booster Disassembly
tool
torque specification
TOOL-4235C
4235C
HYDRAULIC FLUID AND LUBRICANT
Description
Brake Shoe Adjusting Screw Lubricant
Brake Fluid
Hydraulic Fluid
and Lubricant
General Chassis Grease
CIAZ-19590-B
SAE 70R3 Wagner 21 B(301)
Axle Shaft Remover
and
Assembly
3-1
SUSPENSION,
STEERING, WHEELS
GROUP
3
AND TIRES
PART 3-1
PART 3-2
SUSPENSION
PAGE
PART 3-4
PAGE
AND
WHEELS
SUSPENSION, STEERING,
TIRES-GENERAL SERVICE
3-1
WHEELS AND TIRES
.3-31
PART 3-5
SPECIFICATIONS
.
.
3-35
.
3-8
PART 3-3
STEERING
3-17
PART
3-1
Section
1 Diagnosis
SUSPENSION, STEERING, WHEELS AND
TIRES-GENERAL SERVICE
2 Common Adjustments
Page
Testing.
and
.
3
.3-1
Cleaning
and
3-5
Repairs
and
Inspection
3-6
DIAGNOSIS AND TESTING
Table
lists
1
various
suspension,
PRELIMINARY
steering, and wheel and tire trouble
symptoms
The
and
their possible
table
should
in
the
be
in
order
checked.
which
they
For example,
fer to the fourth trouble
re
symptom
in
Table 1, "Hard Turning When Sta
tionary". When checking the possi
ble causes, check item 1 (tire pres
sure)
and
item 2 (tire size) before
proceeding
21
as
with
items
12,
17,
and
indicated.
Table 2, for Movable
Column
Trouble Symptoms
Steering
and Possible Causes.
Refer
to
TABLE 1
Steering
following
should
always
forming
ations.
be
any trouble shooting
see Table 1.
oper
Also,
Air in the
(shown
by
power
system
steering
in
the
fluid)
be bled. After making sure
that the reservoir is filled to specifi
must
be
at
normal
temperature
when
the
operating
is made), turn the steering
wheel through its full travel three or
check
four times
with
the windshield wiper
their
not
hold the
Recheck
stops.
fluid level.
CHECK FLUID LEVEL
Run the
should
(the fluid
the
until the fluid is
operating temperature.
Then turn the steering wheel all the
way to the left and right several
at
bubbles
engine
normal
times, and shut off the engine.
Check the fluid level in the
power
steering reservoir. The level must be
at the full mark on the dipstick. If
the level is low, add enough auto
matic
fluid
transmission
19582-A to
raise
C1AZ-
the level to the F
Diagnosis Guide
POWER STEERING FLUID
Jerky
LEVEL LOW OR FLUID
Hard steering
LEAKAGE
Hard
steering.
loss
of pow
and/or
loss
of pow
and/or
loss
of pow
and/or
turning
when
stationary.
Steering
and
suspension
noises.
Steering
Shimmy
and suspension
noises.
er assist.
AIR IN POWER STEERING
Jerky
SYSTEM
Hard steering
er
OBSTRUCTION
preliminary checks
made before per
AIR BLEEDING
cation
Do
operation.
wheels against
The
causes.
listed in the
possible causes are
in
CHECKS
er
or
wheel
tramp.
assist.
Hard steering
IN POWER
STEERING LINES
steering.
assist.
Hard turning
Steering
Jerky
when
stationary.
and suspension noises.
steering.