DEMO - 1965 Ford and Mercury Shop Manual

FORD and

MERCURY

SHOP M

Copyright © 2010, Forel Publishing Company, LLC, Woodbridge, Virginia All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoever without written permission of Forel Publishing Company, LLC. For information write to Forel Publishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192

1965 Ford and Mercury Shop Manual EAN: 978-1-60371-060-2 ISBN: 1-60371-060-4 Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192 Email address: [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 damage caused, or alleged to be caused, directly or indirectly by the information contained in this book. Further, the publisher and author are not engaged in rendering legal or other professional services. If legal, mechanical, electrical, or other expert assistance is required, the services of a competent professional should be sought.

1965

FOREWORD

This shop

information for the

plete

and

manual provides the

Mercury

performed,

performed

proper

grouped

such

adjustments

as

according to the type of

diagnosis

and

repairs,

and

testing,

opposite

frequently

in-vehicle adjustments,

recommended

special

tools

page

for important

vehicle

identifica

data.

The descriptions

and

specifications

in this

effect at the time this manual was approved

Ford Motor

Company

at

or change specifications or

any time,

and

work

included.

Refer to the tion

com

servicing of the 1965 Ford

overhaul, etc. Specifications and

are

with

cars

The information is

being

Service Technician

without

incurring

reserves the right to

manual

for

printing.

discontinue

design,

were

in

The

models

without notice

obligation.

SERVICE DEPARTMENT FORD MOTOR COMPANY

11

GROUP

VEHICLE IDENTIFICATION EXTERIOR PAINT COLOR

(WHITE)

\

BODY STYLE

DATE CODE

AXLE RATIO CODE

(26TH DAY AUGUST)

(3.00:1 AXLE RATIO)

\ \

INTERIOR TRIM (GREEN VINYL)

(CUSTOM 500 2-DOOR SEDANM

M/

62B

03

TRANSMISSION CODE

(DUAL RANGE AUTOMATIC

I DETROIT DISTRICT

BODY// COLOR,} TRIMJ> DATE,//

TRANSMISSION

(C-4))

1 AXLE ,'/TRANS

DSO)

26H

1

N

33

^6

VEHICLE WARRANTY NUMBER

N PT F\\R TITlE

II

II iJregi:

If

JratM&n

THl| VEHCLEHS AND

F


*o

bo OO

Possible Causes

of

Trouble Symptoms

00

oo

cd

cd

u

u

Q

CD

00

cd

CD

"O

0)

cd u

PQ

Mechanical Resistance

at

Pedal

or

Shoes

Brake Line Restricted Leaks

X

Oh o U

cd

C

O




cd U

u 00

CD

Q

DQ

cd

oo

X

Booster Control Valve

X -

X

X

X

X

X

PART 2-1

BRAKE

BOOSTER

TROUBLE

DIAGNOSIS GUIDE

If the preliminary tests the booster

is inoperative

the

causes

nating listed in table

by

caused

INOPERATIVE-

HARD PEDAL

nect

the

the

vacuum

If the

elimi-

booster,

manifold

check

the

be

valve

look for a sticking or faulty check valve. Check all vacuum connections for leakage or obstruction. Check all hoses for a leaking or

If the brakes

drag

still

or grab

valve

sticking

plunger

Remove

after

does

not

the

remove

that the diaphragm assembly

Improper localeakage between the

positioned.

and

atmospheric sides

and

the

of

disassemble the booster.

Clean, inspect,

and

replace

parts

as

necessary.

assembly.

Remove and disassemble the booster. Check the diaphragm for being out of locating radii in the housing. Check for a sticking or unseated

SELF APPLICATION OF BRAKES WHEN ENGINE STARTS

procedure

trouble,

diaphragm.

eliminating the causes listed in Table 1, the condition is probably caused by a

the

tion could cause vacuum

col-

BRAKES DRAG OR GRAB

sure

is properly

and

assembly,

replace

or

booster from the car. Separate the booster body from the end plate, and check the bellows, booster body, and diaphragm assembly for damage that would cause leaks. When assembling,

transmis-

remove

and

foregoing

eliminate

line (two lines if

vacuum

Repair

Pedal"

Discon-

leakage.

condition.

parts as necessary.

the trouble may be

1,

vacuum

at

hard

a

after

"Hard

of

equipped with an automatic

sion)

if

lapsed

that

show

or

pedal condition still exists

BOOSTER

23

BRAKE SERVICE

-GENERAL

atmospheric valve.

Clean, inspect,

replace parts as necessary.

the

diaphragm

is

Be

and

sure that

properly

located

when assembling.

COMMON ADJUSTMENTS AND REPAIRS PARKING

BRAKE

2. Depress

LINKAGE

pedal

ADJUSTMENT

one

released

Check when

If the as

parking brake cables the brakes are fully released.

3.

the

cables

are

loose,

adjust

them

follows:

4. Turn moderate

release the

parking brake

pedal.

normal

#16

GAUGE

SHEET STEEL

car.

the

equalizer

is felt

drag

wheels

nut

adjusting

the

against

ward

brake

parking from its

position.

Raise the

the rear

1. Fully

the

notch

for

until

a

turning

when

(Fig. 1).

5. Release the parking brake, and make sure that the brake shoes re to the

turn

POWER

fully

released

BRAKE

CYLINDER

position.

MASTER

PUSH

ROD

ADJUSTMENT The

push

adjustment

correct

to

control

master

2634

provided

to

the

this

with an

maintain

valve

cylinder

maintain

prevent

2853 REF.

is

relationship

booster the

rod

screw

the

plunger

and

Failure

piston.

relationship

master

the

between

cylinder

will

piston

from completely releasing hydraulic pressure

ADJUSTING NUl H1353A

and

cause

can

the

brakes

to drag. H1208-A

To

FIG. 1

-Parking

Brake

Linkage Adjustment

screw,

check

the

fabricate

mensions

shown

adjustment a

gauge

of

in Fig. 1.

of

the

the

di

Remove

FIG. 2-Push Rod Gauge Dimensions

2

GROUP

24

the

heavy-duty brake fluid bleeding operation. If

new

the

during the

filled

reservoir

cylinder

master

with

-BRAKES

is

reservoir

diaphragm

kept

not

gasket

may

down to the bottom

of

the

full,

brake

use

sucked

the

master

brake fluid

use

from

drained

has

which

hydraulic

the

to

complete

it

and

system.

brake

rear

right

bleeder

the

on

wrench

box

%-inch

bent

a

fitting

on

be

should

1. Clean

charged

cylinder

wheel

the

cylinder

master

cap, install

an adapter

the

on

FIG. 3-Push Rod Adjustment filter assembly and push the bellows back into the booster body.

the air

the

place

cylinder

gauge

master

surface

mounting

of

the

for Bleeding

to

slot

in the

forces

the

break the This

port

push

is

an

the

up side it may

as

to

adjust

To verify the adjustment, the

piston

should

0.015 inch

more than

No

the push rod.

The

master

not

it

as

move

contacts

(exact

movement

contact) is ideal.

bleeder

the

the

tube

a

drain tube

rubber

fitting. The fit snugly

should

tube

in

with

clean

the

repair

into

or

replacement,

lines

the

pedal system

action.

and

Bleed it

air

may

cause

the

get

a

container

around

fitting.

the

of

end

filled

partially

brake fluid,

has

been properly connected to be sure that all air is expelled from the brake cylinders and lines. after

manually

or

system can

with

pressure

be bled

bleeding

equipment.

the

brake

pedal

down

its full travel. Close the

slowly thru

bleeder fitting, then

return

the pedal

to the fully-released position. Repeat this operation until air

Bleed the longest lines first.

at

fit snugly

drain tube to the end

the tube

of

the bleeder

around

of

bleeder

air

fitting

bubbles

with

the

tighten

and remove the

container

a

brake fluid,

clean

the

of

end

filled

partially and

loosen

cease

to ap

bleeder fitting.

6. When

bubbles

air

in the fluid

the

at

submerged

end

of

drain

the

tube,

the

drain

fitting

7. Repeat this brake

ing

wheel

the tube.

procedure

at

each

in the follow

cylinder

left rear,

order:

the

close

and remove

right

front,

and

left front.

5. Repeat this

brake fill

in

of

tube.

rear,

brake fluid

cease

the submerged end

bubbles,

bleeder

the

valve on

5. Submerge the free

bleeder

wheel right

the

pleted. within

front, brake

after each

procedure

cylinder

master

and

The %

at

left

reservoir

is bled

operation

of

each

order:

left front. Re

cylinder

fluid

inch

in

cylinder

bleeding

reservoir.

Keep

rubber

right

(Fig. 4).

cylinder

wheel

wrench

the

on

to the master cylinder reservoir.

pear

4. When the fluid is completely free

ket

MANUAL BLEEDING

a

fitting

tank to admit pressurized

tube

when the

The hydraulic

solder

and

loosen

and

bleeder fitting approximately 3A

3. Push

spongy

hydraulic

cutting

bleeder fitting. The should

turn.

BLEEDING

When any part of the hydraulic system has been disconnected for

brake

4. Open the

2. Submerge the free

to appear

SYSTEM

a

%-inch box

a

bleeder

the

of

end

the tube.

HYDRAULIC

ing

a

filler cap the hole.

fitting

cap can hole in

adapter

by

at

on

the bleeder fitting.

the master cyl

booster.

the

(rear)

make-up

installing

when

cylinder

not set rod

approximate

through

inder

of

valve plunger.

ment only.

look

Do

gauge.

on

the screw

edge

an

center of a

Attach

justed

of

or

the

rear

(Fig. 4). Attach

that the end

be used,

be fabricated

on

Brake

filter assembly as shown in Fig. The push rod screw should be ad 3. so

can

fitting

Adapter cap 2162

cap.

3. Position 4- Wrench

FIG.

air

just touches the inner

adapter

then

and

the

against

the

the

HI 300- A

directly

booster body,

the

against

cap

attach

and

reservoir,

bleeder tank hose to the

filter

master

45

APPROXIMATELY

air

10-30

with

dirt from the

all

2. Remove

the

contain

should

cylinder reservoir cap.

reservoir

Re-install

system.

pressure.

air

of

been

has

which

heavy-duty brake fluid the bleeding operation,

new

pounds

1. Position

fluid

The bleeder tank enough

Never

the

Bleed the longest lines first. Never

drained from the hydraulic

be

cylinder.

been

PRESSURE BLEEDING

level the

is

top of The diaphragm-type

be the gas

be properly positioned in the reservoir cap, before the cap is installed. should

bleeding the

close

valve

remove

from

and

the adapter

operation

bleeder

the

is

tank

hose

tank

fitting.

and

com

should

8. When the completed,

9. Remove the the

master

within

cap, refill

reservoir

% inch from the top

reservoir,

The

adapter

cylinder

and

of

install the filler

diaphragm-type

gasket

to

the cap.

should

be properly installed in the cap be fore it is installed.

PART 2-1

2-5

GENERAL BRAKE SERVICE

-

CLEANING AND INSPECTION BRAKE

ASSEMBLY

1. Remove

from the drum, then remove the drum as out lined in Part 2-2, Section 2. Wash all the parts except the brake shoes in a cleaning fluid and dry with compressed

2. Brush plates

and

the

wheel

air.

dust from the interior of the

all

springs, and drum for signs of over heating. If the shoes have a slight blue coloring, indicating overheat

ing,

replacement

hold

and

If the

lining lining is

of the rivet

brake

damaged, they Replace

or

if the

must

for ex damage. %2 inch

shoes

worn within

heads

be

shoes are replaced.

has been any lining oil saturated. Replace lining in axle sets. Prior to replacement of lining, the drum diameter should be check ed to determine if oversize linings must be installed.

4. Check the

that

condition

of

to

and

could

lining

they

are not replaced.

5. If the of

linings

wear or shoe

pull

new

miles

3. Inspect the brake

is strongly

springs

Overheated

recommended.

lose their

retracting

wear

the

prematurely,

if

brake

shoes, retracting springs, hold-down

or

signs

on

or

more

brake

the

of

overheating are present when relining brakes, the wheel cylinders should be disassem bled and inspected for wear and entrance

The

of

dirt into the

cylinder

placed,

thus

cups

cylinder.

be

should

avoiding

future

re

prob

lems. 6. Inspect and

replace

is

view of

the brake

in Fig.

27, Part

shown

2-2.

After

in

alcohol

only

immerse

all

a suitable solvent.

Use

disassembly,

metal parts

on

parts

rubber

or

containing rubber. After the parts have been thoroughly cleaned and rinsed in cleaning solvent, the parts

has 30,000

car

operation

A disassembled booster

springs

cause

carrier

drums.

cessive

down

the

of

UNIT

BOOSTER

all

other

any

that

brake are

metal

parts

which

in

come

hydraulic brake fluid

with

contact

or rubber

be rewashed in clean before assembly. Use an air hose to blow dirt and cleaning fluid from the recesses and internal pas

parts

should

alcohol

sages.

When

booster,

overhauling a power furnished in parts

use

the

repair

ber

parts.

all

kit. Discard

old

all

rub

parts

worn

Inspect

or

damaged.

or

all other parts

excessive

wear.

or

7. Inspect the brake drums and, if necessary, refinish. Refer to Part 2-2, Section 4 for refinishing.

excessively worn inside of the booster or corroded, polish it or

fine emery

cloth.

for damage

Replace damaged parts.

body

is

If

the

rusted

with steel wool

2-6

PART 2-2

BRAKE SYSTEM

Section

2- 6 2-10

1 Description and Operation 2 In-Car Adjustments and Repairs

Page

Section

Page

3 Removal

and

Installation

.2-15

4 Major Repair Operations

.2-20

DESCRIPTION AND OPERATION HYDRAULIC SELF-ADJUSTING

back into

BRAKE SYSTEM

shoes.

physical

force

the brake

at

to the lever. The automatic ad

and

juster are

The hydraulic brake ploys

single

anchor,

and

panding

self

system

em

internal

ex

adjusting

brake

assemblies.

anism

The

cylinder

converts

force from the brake

booster into hydraulic

against the pistons

in turn,

consists

of

a

lever,

spring (Fig. 1). The

master

inders. The

self-adjusting

guide, adjusting

over

physical and

The

wheel

convert

in the

pedal

pressure

wheel cyl

cylinder

hydraulic

pistons, pressure

ANCHOR PIN PLATE WASHER

is

brake cable, and

cable

tom. The

to the lever

cable

secondary brake

is

adjuster

at

top

by

and

shoe

ondary

drum

the

when

only

while

only

when

is free to

beyond

the brakes

the car is moving the

sec

move toward predetermined

a

point.

and

With

the bot

connected to

shoe

rearward

cable

is hooked

the anchor pin at the

connected

mech

operates

applied

means

the

and

the of

car

moving rearward brakes applied, the "wrap

around"

action of the

ing

the drum

the cable guide. The adjuster spring

of the

is hooked to the primary brake

chor

shoe

the

primary shoe

pin.

ANCHOR PIN PLATE

The

shoes

forces the

upper

against

action

PRIMARY

of

follow end

the an

the wheel

SHOE- TO-ANCHOR

SPRING

PARKING BRAKE LEVER BRAKE

RETAINING

CYLINDER

CLIP

SECONDARY SHOE

PRIMARY SHOE

AUTOMATIC

ADJUSTER SPRING

CABLE HOOK PARKING BRAKE CABLE AND HOUSING

HI 394- A

FIG. 1

Self-Adjusting

Brake Assembl les

PART 2-2 -BRAKE SYSTEM

27

cylinder moves the upper end of the

secondary

adjusting

lever

the

of

against

adjusting

lining

screw

can

upward

tooth

a

the

over

end

the

engages are

spring

pulls

When

the

as

the

far enough, the tooth

of

When

tooth. the

released,

lever

the

causing the

the

The

turned one

at

tooth

linings progressively With the is

primary

the

drum. not

time

a

the

is

is

^\

and

secondary pin

and '

toward

moved

Therefore,

^r^s^r

the

as

(Qfl^>

the anchor

shoe

CLOSED

and

wear.

applied,

against

the

turn

star-wheel

moving forward

car

brakes

adjusting downward

to

starwheel

expand the shoes.

does

and

on

VACUUM PORT

brakes

shoe

an

lever increases

increases.

move upward

passes

the

the

the sec

of

star-wheel. The up

the

of

wear

lever

and

end

travel

ward

it

away from

shoe causes the cable to pull

ondary the

shoe

The movement

chor pin.

ATMOSPHERIC PORT OPEN

the

adjuster

operate. VACUUM

The

brake assembly is basic the same as the front brake. ally The conventional brake parking rear

lever, link,

and

are

spring

used

^

ATMOSPHERE

in

the rear brake.

The

fixed

anchor pins on all

and

brakes

are

non-adjustable. H1357-A

FIG. BOOSTER

2 Booster

optional

is installed

dash

bly

brake booster

power

is

and

and push rod

The booster

and

lever

a

assem

Vacuum is

2, 3,

consists of a vacuum

and

control

valve,

diaphragm,

assembly,

atmospheric

area

forward

link.

atmospheric

plunger

an

(Figs.

chamber

4).

intake ifold

times

chamber

pressure

in the

at

atmospheric

the

front

to the

atmospheric

tected

by

pheric

the

an

air

chamber

vacuum

present

atmospheric

side

The

valve.

is

air

chamber

filter. The is

chamber

separated

by

of

of

the

vacuum

manifold

body. With and

control

hub

valve

and

the

hose from the

to the vacuum

integral

several

applications

This

off.

vacuum

pro

atmos

from

the bellows

APPLYING POSITION

diaphragm. Vacuum

man

the booster check valve

chamber, it is

vacuum

obtain

shut

this

chamber

possible

power

assisted

the

with

engine

arrangement makes

reservoir

a

unnecessary.

the

intake is

the

and check valve on

brake

all

the

times in

present at all

of

supplied through a

to

Atmospheric at

cham

plunger assembly.

that

is

valve

vacuum

ber.

to the

connected

through

pedal

chamber,

the

within

on the engine side of the

panel

brake

Applying Position

SYSTEM assembly

The

in

As the brake the

valve

plunger

(Fig.

2).

The

from

the

side

of

vacuum

the

from the forward

diaphragm

the

bellows

can

be

the

diaphragm

or

(atmospheric

air

from

chamber)

to the

rear side of

through

in

connected

porting

return

initial

ment of the plunger closes

ing

valve

forward

plunger

vacuum

move

the port chamber

preventing further evacuation of the area back of the diaphragm. Further movement of the plunger

Either

depressed, and

move

assembly the

is

rod

operating

compressing spring

pedal

forces

atmospheric valve off

its

atmospheric

from

lows

can

leads to phragm.

pressure

enter

the

the

rear

seat so that

the

hub porting side

the

of

the

bel that

dia

2

GROUP

2-8

-BRAKES

lever assembly

When

3).

(Fig.

sition

vacuum

closed

of

passage

to the

pressure

atmospheric

valve

atmospheric

any further

off

cut

will

remain

will

supply the

and

com

these

the porting to

bined forces balance, the

po

closed

to the

valve

atmospheric

the

move

tend to

will

be

area

hind the diaphragm. Therefore, the the

on

acting

stabilize

will

piston

cylinder

master

VACUUM PORT

force

assist

power

the and the hydraulic force applying

CLOSED

brakes

be

will

at

maintained

con

a

level.

stant

POSITION

RELEASED ^-^

When

the

leased from the

from

away

the

the

allowing

the the

draws

and

of the

the

diaphragm, the

move

side of

atmospheric

back

side

diaphragm,

the

front

the

of

force is developed to

a

push

port

compensating

force hydraulic fluid

As

brakes.

hydraulic

and

wheel

pressure

developed in the hydraulic

is

system,

a reaction counter-force acts against

the

reaction

bly. This

lever

reaction

and

lever

ring and

assem

ring

as

sembly is designed to transmit the reaction

actuating the

forces

brake

driver

back

control

with

pedal a

power

proper

brake

of

valve and

through

the

assembly to provide

resistance

that

the

is in

the

control

a

by

However,

the

to

control

keeping At the

held,

the

(large

differential

plunger

forward.

and,

forces

of

the

outer plunger

sleeve

of

forward

time, the

acting through the

reaction

reaction

with

it,

released

ing

the

position.

permits

the

wheel

cylinder

fluid,

valve

piston

and

released

position.

hub

plunger

and

to

This releasing brake

shoe

and

the

the ac

retract

through

return

and

cylinder

pressure

valve

back

pistons

to

force

ring

the

acting

springs,

draulic

This

assembly

front

the

on

side.

side

atmospheric

and

moves

diaphragm

tion

hub

is

vacuum

diameter)

(small

diameter)

to move

the vacuum porting closed.

same

elimin

differential

pressure

ceases

rod

valve

is

the presence of

valve

(bellows)

the diaphragm will con

move

the

the

atmospheric pressure and vacuum on

tinue

the

against

rod

pressure

rear

of

motion

the unbalanced

each side of

the

on

stopped and

valve

dia

unit.

When the forward

operating

force

push

cylinder

master

of

valve

With

the

of

sides

rear

ated.

HOLDING POSITION

is

from the

air

phragm, the assist

created

pedal

both

on

Also,

brake

chamber

vacuum

the

the

opens

plunger

feel"

"driver

under pressure

brake tubes to the

and

to the

the

means

to

through the residual pressure check valve

apply forces. This is the

providing

hydraulic

brake

the

to

proportion

and

rod

forward

piston

cylinder

master close

the

on

pressure

the

rearward

the power diaphragm.

of

side

out

the

time,

same

vacuum

and

of the

diaphragm.

the

of

side

rear

porting from the

on

against

seat

connects

movement

vacuum

to

chamber

At

diaphragm

valve

from the hub porting that to

With

plunger

the bellows

valve closes off

FIG. 3 Booster in Holding Position

plunger

hub (Fig. 4). This seating

the ATMOSPHERE

H1358-A

the

the

atmospheric

valve

re rod

operating

moves

spring

return

VACUUM

valve

assembly,

plunger

and

is

pressure

pedal

the

the

hy

master

push rod to the

PART 2-2 With the

piston

the released

is

brake or

The

in

rod

master

to the fluid reservoir,

brake

the

the

open port per

to return from the

either

system

enter

in

port

open.

fluid

mits

push

position, the hydraulic

compensating cylinder

and

2-9

SYSTEM

-BRAKE

from the

system

reservoir.

PARKING

BRAKE

independent

An

parking brake rear

from

routed

control

lever

is

brake

equalizer

to the

17).

(Fig.

assembly

brake cables

the

attached

connect

a

cable

parking

to

assembly

which

izer

through

shoes

the

the

actuates

linkage. The operating

cable

is

brake

wheel

foot-operated

control

equal

The

the

rear

equalizer

assembly to the parking brake lever each rear

at

secondary

Two types

5) is

type (Fig.

Parklane. All

other

When

the

release

Mercury

models

(Fig.

type

^)

VACUUM

fo3

ATMOSPHERE

the

use

16).

depressed

is

pedal

release

automatic

or

manual

the

CLOSED

control

pedal

automatic

used on

release

manual

(either

brake

of

The

used.

are

ATMOSPHERIC PORT

(Fig. 1).

shoe

type) the secondary brake shoes are

forced The

against the rear

held

is

pedal

by

position

the

in the

in

the

of

assembly (Figs. 5

control

a

ratchet

a

with

H 1359- A

4 Booster

FIG.

in Released Position

applied

engagement

pawl

spring-loaded

brake drums.

When the lever is the

manual

the

cam

trol assembly is panel pedal

parking brake

mounted

action

cam

to the dash

on

pivots

a

The

I

brakes.

the

of

a

release

pedal. upper

A

lever

contacts the

that the

pawl

stops

thus

is

assembled

to the

The

pawl

ratchet at such an

angle

the ratchet

however,

the

to the

and

pawl

as

the

when

the

pedal.

teeth will pedal

the

pedal

engages

slide

starts

the

motion

to release,

ratchet

locks the brakes in the

position.

over

is depressed;

applying

to

ratchet

lever

release

the

a

the

lever

release

slight

pivots against the pawl,

the

movement

will

the

type,

unit

power

will

rivet

vac

in

from

brakes to

the

lever

release

pin

release

the pawl

allowing

The

the

of

disengage

ratchet

release.

automatic

lever. Since the

tached to the release

the

pivots

pedal

on

mount

5).

(Fig.

the

release

and

assembled

the

of

end

pawl

are

ratchet

on

disengage

will

the

lever

pedal

stationary

spring-loaded

16),

a

On the uum

A

mount.

pin

from

paw

the

con

and the cowl upper panel.

on

and

pawl

of

(Fig.

type

release

16).

Either type

back

pulled

and

parking

moved

not

engine

release

when neutral

engine with

the or

lever

selector

into any drive running.

position

selector

or

will

however, is

position

park

running,

lever

is

with

The brakes

automatically,

in

with

in any

The

when

automatically

transmission

the

the

brakes

the the

position

mounting control ated

of

out

ratchet

The

power

unit

piston

rod

is

at-

a

of

of

with

to

the

vacuum actu unit

is

con

the

upper

end

lever to

move

the

with

the

rod

engagement

5).

The lower

lever

extends

manual

release

(Fig.

release

event

the to

unit

riveted

The

within

release

alternate

applied

bracket is

by

the

pawl

power

assemblv.

piston

nected

the

the engine off.

vacuum

vacuum

power

end

of

out

for

in

the

failure

or

GROUP 2

2-10

.VACUUM

-BRAKES

for

POWER UNIT

at

release

manual

optional

any

time.

PAWL (UPPER END) PISTON ROD

Hoses PEDAL MOUNT

REVE

and

/

the

release

sion

neutral

6).

tion

the

engine

release

actuating

The

unit.

to

link to

pull

will

connect

to one

in the

piston

cause

posi

running

valve

pressure

will

created

5

transmission

the

engine manifold vacuum

of the

(Fig.

switch

safety

the

vac

in the transmis

Moving

with

open

to a

lever into any drive

selector

unit

power

manifold

valve

uum

and

the

connect engine

side

power

differential thus the

piston

and

lever.

the release

TO VACUUM POWER

CABLE CLEVIS

UNIT

? NEUTRAL SAFETY (VACUUM

SWITCH

RELEASE VALVE)

TO ENGINE MANIFOLD VACUUM

STEERING

VACUUM JUNCTION BLOCK

COLUMN

H1286-A

H1350-A

5

FIG.

Parking

Brake Control

FIG. 6 Connections for Automatic Parking Brake Release

Assembly with

Automatic Release

The

the carrier

ADJUSTMENTS

SHOE

BRAKE

car should

be

Before

raised with the

self-adjusting

service

and

brakes

require

a

are

manual

only after the brake have been relined, replaced, or the length of the adjusting

adjustment shoes when

has been

screw

forming

some

changed other

while

service

per

the grease will

seal

not

brake

normal room

justing

drums

be

temperature when

the brake shoes. If the

adjusted and

drag

should

when

expanded,

when

the

drums

the

shoes

are

at ad

shoes

the

drums

cool

are

may and

contracted.

from

the

the

from the

carrier

adjusting

screw

been sure other

or

until

is

the

turned,

have been in adjusting screw has install the drum. Be shoes

that all excess grease, oil,

foreign

and

material are wiped off

wipe

a

the

grease.

that

so

within

retainers

2. Remove cover

the

screw

coating 19590-B Grease.

Any may

other

cause

screw

with

adjustment

of

with

a

C1AZ-

procedure

damage to the adjusting consequent self

adjuster

hole

plate

and,

plate side, turn the

to

upward

expand

7). Expand the

drag is

the

uniform

problems.

adjusting

carrier

thin

felt

shoes

the drum

when

rotated.

3. Remove the drum. tooth

on

lever While

contacts

out

1. After the stalled

spindle,

be damaged.

the shoes (Fig.

The

hot

wheel

Lubricate

screw.

brake drum

the

opera

tion.

are

Install

hub

drum.

and

completely free of the drum carefully

spindle

The hydraulic

plate

installing

front

on the

the floor.

wheels off

REPAIRS

AND

ADJUSTMENTS

IN-CAR

ing

of

the

the

If finger

back

of a

where

adjusting

engagement

%

Mark the

wheel

the

holding

screw,

screw

star

adjusting with

off

lever

the adjust

the

adjusting

turn with the fingers.

movement will not turn the

screw, free it up; otherwise, the

adjusting

the

screw.

lever

will

not

turn

Brake Shoe

Adjusting

Tool

H1122-A

self-

the

FIG.

7

Expanding Brake Shoes

PART 2-2

4.

Apply

a small

temperature

of high-

quantity to

grease

the

points

bearing

where

the shoes contact the carrier

grease

plate,

being

tion 4.

lubricant

careful

to

not

the

get

the linings. Install the

on

drum.

On

wheel

bearing,

outer

washer, and adjusting nut, then adjust the wheel bearings

in Part

rear

Section 2. the three install wheels,

Tinnerman

nuts and tighten securely.

as outlined

On

5. Install the

on

wheel

the

tighten

and

3-5,

to

nuts

mounting

cables

for

the

the rear

and adequate.

clean

3. Install the washer and

outlined

brake

stall

oper

have

shoes

Adjust

outlined under

"Brake

Adjustments"

3. Install

in this

Tinnerman

three

the

Install the

nuts and tighten securely. on

wheel

the

flange

axle shaft

drum,

the

against

to

section.

studs

the

tighten

and

specifications.

retaining

nuts

outer wheel

BRAKE

SHOES AND SCREW

the

in Part

Section

grease cap.

hub

and

REMOVAL

bearing as 2, then

wheel

3-5,

cotter pin

the wheel

bearing,

nut.

adjusting

ADJUSTING

In

1. With the install

wheel

a

moved,

the

ends of

and

clamp

brake

cylinder

drum

re

over

the

as shown

in Fig. 9.

cap.

BRAKE

REAR

DRUM

Tool-2035N

2086-1

or

REMOVAL

is

1. Raise the

car so

clear of the

floor.

that the

wheel

the

check

adjusted,

the hub and cap Remove the three Tinnerman and remove the brake drum.

2. Remove

brakes.

the

operation of

grease

section.

cover

Make

lever

brake

8. After the been properly

assembly

the brakes as

brake

over the

position.

into

and

brake

parking

equalizer

2. Place the drum

Adjustments"

freely.

ates

being in

the

2. Install the drum assembly and adjust the brakes as outlined under in this "Brake Shoe

install the

adjustment.

proper

that

sure

the

check

that

sure

4. Adjust

7. When adjusting shoes,

drum is

original make

in the hub is

specification.

6. Install the adjusting hole on the brake carrier plate.

assembly in install the new See Part 3-5, Sec

and

Shoe

If the

drum

the

2-11

SYSTEM

and roller

retainer.

stalled,

front wheel, install the

a

cone

inner cup,

the

-BRAKE

wheel. nuts

DRUM

BRAKE

FRONT

REMOVAL

1. Raise the tire

and

tire

and

wheel

the

wheel

Remove the

hub cap,

wheel cover or

the

until

car

the floor.

clear

and remove

from

assembly

the drum.

2. Remove the drum. If the drum will not come off, insert a narrow

justing hole brake

the

through

screwdriver

screw

adjusting

with

from the

ad

screw. While holding the adjust lever away from the screw, back

off

the

8).

(Fig.

tool

adjusting

with

screw

adjusting

will

the

adjusting

the

from the

bearing

spindle.

cone

4. Pull sembly

the

off

the

hub

drum

and

1. If the drum is remove

the

new

greaser.

the

MOVE HANDLE

drum Install

grease retainer.

being

with new

replaced,

coating from

carburetor

bearings

Soak the

new

de-

and

toward the

will go.

lever,

cable

spring down

to

rear

unhook

the

the hole.

4. Remove the HI 144-A

8-Backing

spring

the

otherwise, anism

burr,

to

not

chip,

or

the

1).

shoe

to

spring with the tool shown in Fig. 9. With the same tool, re damage

in the adjusting screw;

will not

automatic adjuster

adjusting lever (Fig.

anchor

Adjustment

notches

and

5. Remove the secondary

Off Brake

self-adjusting mech function properly.

and

the

spring

from the

the

unhook

anchor

cable

eye

anchor pin.

6. Remove the

anchor

7. Remove

cable

the

the secondary shoe

INSTALLATION

to

shoe

primary

and

pin

guide

(Fig.

plate.

from

1).

grease

in light engine oil at least 30 minutes before installation. Pack the wheel bearings, install the inner retainer

and

it

the

back

and

UPWARDS

careful

protective

side of

upward

adjuster

automatic

move

INSTALLATION

lever

adjusting

hook from the large hole in the secondary shoe web. Do not at tempt to pry the pivot hook out of

FIG. as

lever

pulling

pivot

spindle.

wheel

by

outboard

screw

and

roller assembly.

and

follows:

adjusting screw

3. Pull the adjusting

flat washer Remove the outer

nut,

the

the pivot nut as far as

off

the hub. Remove the cotter pin, nut

lock, adjusting

as

shoes

Be

cap from

grease

Disengage

b. Move the

erly.

3. Remove

2. Contract the

(Fig. 1).

function prop

not

Retracting Spring

Removal

a.

very careful not to burr, chip, or damage the notches in the adjusting screw; otherwise the self-adjusting mechanism

9

FIG.

H1146-B

from the adjusting backward on the

adjust

ing ing

Too/-LM-l 19

the

brake adjusting tool (Fig. 8). Be very

disengage

and

plate,

the adjusting lever

brake

the

off

the inner side of the

at

carrier

brake

If the drum will not come off, insert a narrow screwdriver through the brake adjusting hole in the car rier plate, and disengage the adjust ing lever from the adjusting screw. While holding the adjusting lever away from the adjusting screw, back

1. Remove the from

a

new

degreaser.

protective

drum

with

coating

carburetor

8. Remove

the

shoe

hold-down

springs, shoes, adjusting screw, pivot

nut,

and

socket.

GROUP 2

2-12

9. On

brakes,

rear

parking brake link

Dis

spring.

the parking brake from the parking brake lever. connect

cable

be

parking brake lever from the

shoe

removing the retaining clip washer (Fig. 1).

and

Remove

the

Apply

shoes,

lever

to

secure

retaining 2.

the

washer

spring

light coating grease

brake

the

the

of

the than

the

at

shoes

points

the

contact

wrong

plate

and

shoes on

the

secure

bly

with

the hold down

the

rear

brake, install

ad

would

to

mechanism

installation

prevent

on

the cable should

inal

position.

the

lever

screw

positive

and

tion

the

the car, the socket end adjust-

of

assem

in

anchor

pin

ing

anchor pin plate on

screw

the

crimped

the primary spring (Fig. 10).

or

^

side

shoe

to

FIG. 1 1 Adjusting Screw Lever Identification

ing

pivot nuts can

the

number

around

of

indicate

grooves

section

meet this

a

indicates and

between the

justing

Two

nut.

hand nut; left hand nut.

right a

install

socket on

this

shoe ends

toothed

screw

by

machined

the

of

10. Place the adjusting the screw

H1147-B

Spring guide

with

the ad

wheel

nearest

the

cable

guide

L to indicate their installation on a right or left brake assembly (Fig. 11). on

the

between the anchor

Fig. 10.

cable and

be not

guide and the shoe web.

8. Install the

spring

secondary

with

or

12. Position

the hooked end of the adjuster spring completely into the large hole in the shoe

primary

The should be web.

groove

(Fig. 1). It is imperative that the positioned in this groove

secondary shoe. 11. Hook the cable hook into the hole in the adjusting lever. The ad justing levers are stamped with an R

secondary shoe web with the flanged hole fitted into the hole in the sec ondary shoe web. Thread the cable around

or

the centerline

above

shoe

to

the tool shown in

last at

coil

Connect the loop 13. Pull the

will

actu

cause

this

of

is

spring

the

cable

end

should

specification, possible dam

indicated

cable

should

(plus

or

end

the

and

cable

c.

age.

minus

The

inches

HVs

%4 inch) from the

hook.

Check the cable guide for dam The cable groove should be to

parallel

body

of

the

the

shows

d. Check the

lever. The hook square

shoe

guide

web, should

web. Replace damage.

the

against

if it

measure

as

the cable anchor to the end

of

of the cable

with

the

pivot

the

lie

flat

the

hook

surfaces

body

and

of

guide

the

on

be lever

should

the

for proper pivoting. Replace the lever if the hook shows damage. See that the adjusting screw is properly seated in the notch in the shoe web. e.

socket

end

of

the spring

adjuster

automatic adjuster

and

toward the

rear

lever,

It is cable

spring down

to engage the

hook in the large hole in shoe

web

(Fig. 1).

the

CYLINDER REPAIR

WHEEL

lever hole.

and

secondary

lever is

the

the edge of the hole.

to the adjuster

pivot

the

of

the screw

and

as

sembly should be replaced. b. Check the cable length.

assembly

the

cable

(plus

fittings. completely fill or slightly beyond the crimped of the fittings. If it does not

cable

extend

and

be distinguished grooves

body

the

one groove

7. Install the

the

contact

inch

the cable.

Check

The

age

FIG. 1 0 Retracting Installation

;He

determine the

a. H1143-B

2086-L

Tool-LM-119

adjusting

condition:

ADJUSTING SCREW

IDENTIFICATION LINES

6. Install

Too/-2035-N

by

ated

the

over

toward the carrier plate.

anchor

should

wheel,

be turned

To

with

the

With the brake (anchor at the

the screw. If the contact point is below this centerline, the lever will not lock on the teeth in the adjust

parking Connect the

eye

position

of

the posi

check

on

pro

if the

instead

sluggish

lever

%2 inch)

not or

of

the

the anchor pin. cable

does

wheel

adjusting

not

5. Place the

cable

of

adjusting

described,

lever

the

action

the

sharp,

vertical

a

minus

On

return

turn

screw toothed wheel.

top),

the

lever to its orig

tooth.

one

the

brake link and spring. parking brake cable to the parking brake lever (Fig. 1). 4. Install the

This

will

the adjuster

cause

the

return

op

the

ADJUSTING LEVER

springs.

should

If pulling the duce the action lever action is

retract

time

each

ad one

adjusting screw is stamped R or L (Fig. 1 1). The

with an

3. Position the brake

other

shoes

expand

side of

the

of

to the

adjusting

To

erated.

assemblies

car

shoe

from

far

tooth

a

ihe

lever

spring to

the brake

brake

cause rather

carrier plate.

carrier

side

automatic

a

temperature

justing

screw

lever

the adjusting

adjusting screw wheel. The snap into position be hind the next tooth, and release of on

of

Vi turn.

off

and

of high-

the

cable

and

to lift the lever past

enough

grease

the adjusting pivot to the limit of the threads and

the

of

guide

the

check

pulling the between the

toward the secondary shoe web

clamp.

into

screw

and

clip.

Apply

where

shoe

secondary

the

with

rear

section cable

installation, by

the adjuster

action of

pin.

socket end

Turn

screw.

14. After

an

parts

anchor

cylinder

the

and

Interchanging brake installing assemble the parking brake the

the

is

eye

the

on

high-temperature

adjusting

nut

1. Before

cable

installed. All on

brake

the

then back

INSTALLATION

flat

to the threads

justing

spring

the

binding

or

when

pin

chor

9.

that

certain

cocked

not

should

10. After removing the rear brake disassemble the shoe, secondary

by

Be

the

remove

and

-BRAKES

brake to

not

necessary to remove the from the carrier plate

cylinder

disassemble, inspect,

overhaul

the

cylinder.

or

hone

and

Removal is

necessary only when the cylinder is damaged or scored beyond repair.

PART 2-2

BOOT

inder to

BLEEDER

CYLINDER

2-13

SYSTEM

-BRAKE

BOOT

SCREW RETURN

PISTON

the

the

anchor

from

cylinder

Remove

pin.

the

pin.

anchor

PISTON

SPRING

INSTALLATION Wipe the end(s) of the hydraulic line to remove any foreign matter before making connections. 1. To install

CUP FRONT

Position

a.

CUP

BRAKE CYLINDER

the

ing

SCREW

to specification. BOOT

the

nut on

anchor pin, and

CUP

REAR

FIG. 1 2 -Front

BRAKE

CUP

CYLINDER

100- A

HI

b. Install a new copper gasket over hose fitting. Screw the hose as sembly into the cylinder.

the

to

nut

2. To install

1. Remove the links and the rub ber boots from the ends of the brake cylinder. Remove the pistons, cups, return spring from the bore (Fig. 12). and

2. Remove the from the cylinder.

cylinder

REMOVAL

the cylinder, and start the tube

1. With the sition,

remove

3.

Dry

If

alcohol.

use

the

de

clean

is not brake fluid.

alcohol

specified

with compressed air.

2. Check

internal

all

excessive wear or

for

parts

damage. If any

of

the internal parts require replacing, all should

be

marks

cylinder

If

rust.

or

bore for con

either

dition is present, the cylinder bore be honed. However, the cylin

must

der

not

should

0.003

inch

be honed

beyond

its

than

more

di

original

4. Check the bleeder hole sure that it is open.

be

to

a

coating of heavy-duty all internal parts

section.

the

cylinder

3. Insert the and

sitions

12). the

into

pistons

in

Place

the a

cvlinder.

tighten

and

their

To disconnect the hose the

over

bore each

Bleed the brake

po

(Fig

end

of

system

opposite

front

at a

fitting

that

of

the

end

hose to the brake tube at a bracket Remove the horse on the frame. shoe-type

retaining

clip

from

hose hose

bracket, disengage from the bracket, then

screw

the

entire

front

wheel

and

a

rear

fitting

unscrew

the

metal

from the

the tube

nection will

out of

the

bend the

cylinder

Pull

cylinder con

metal

tube

and

wheel

from the

is

cylinder when

removed

from

the

4. Install

rear

c\linder

washers

retaining

and

der. On the front and

washer

wheel, remove the

remove

bolts

and

the cylin

wheel, remove the

that retains the cyl

ends of

install the and

brake

the

shoes adjust

drum

and

the brakes

(Part 2-2, Section 2), and bleed the brakes as outlined in Part 2-1, Section 2. adjust

BRAKE

CARRIER

1. Remove the

PLATE

wheel

brake line

and

drum. Disconnect the brake from the brake cylinder. 2. Remove the adjuster

cylinder

On the

brake

assemblies as

and

shoe

the

in this

outlined

and

wheel

section.

disconnect the parking brake lever from the cable rear

3. If the

ing so

wheels,

rear

that

the

retaining Pull the the

carrier

is be

the

axle

shaft

hole in

the

axle

shaft

axle

the carrier plate

with

nuts and

housing

plate

rotate

replaced,

flange lines up

plate.

4. On the

nut

cylinder.

to

nut

the shoes as outlined in this section.

installation difficult. The tube

make

lock

connects

fitting

1112-144.

tool

assemblies,

REMOVAL

to the cylinder. Do not pull the

the

adjuster

the

tube

away

that

the retaining

3. Install the links in the

un

the

tube

the tube with

REPLACEMENT

cylinder.

cylinder,

to the car

cylinder

the wheel cylinder, and

fitting

lockwashers.

Tighten

the

hose assembly from

tubing into

of the cylinder.

by installing

specification

cylinder, loosen the tube

carrier

cups.

respective

cylinder

boot

securely.

spring,

return

into

screw

and

c.

wheel,

will separate

2. Thread the bleeder

plate

bolts

outlined

lines.

ing

brake fluid to

shoe assem

procedures

vacuum

tube

ASSEMBLY

b. Secure the

cylinder

wheel

the

into the threads

nut

the

Disconnect the brake line from brake cylinder. On a car with

At

Apply

and

wheel

po

brake booster, be sure the engine is stopped and there is no vacuum in the booster system be fore disconnecting the hydraulic a

the ameter.

1.

a raised

rear

Enter

position.

rier

connects

replaced.

3. Inspect the score

in

2. Remove the brake

screw

INSPECTION

in

the

Place the

a.

wheel

blies, following

parts

rear cylinder:

into

in this

all

a

WHEEL CYLINDER REPLACEMENT

drum.

bleeder

tool

with

specification

1112-144.

Rear Wheel Cylinders

and

DISASSEMBLY

available,

torque

c. Engage the opposite end of the hose to the bracket on the frame, in stall the horseshoe-type retaining clip, and connect the brake tube to the hose with the tube fitting nut. Tighten

fiSli

natured

the

on

the

PISTON

1. Wash

cylinder

washer and cylinder retain

BLEEDER

CYLINDER

cylinder:

the carrier plate.

anchor pin against

Install the

BOOT

front

a

remove

shaft

with

the nuts.

assembly

tool-4235C

slide

hammer

move

the carrier plate.

(Part

4-2).

out

of

and

then

a

re

GROUP 2

2-14

If the front

2. Install the

is being

carrier plate

replaced, remove the bolts and nuts that

the

secure

plate

to

wheel spindle and remove

the

front

the

plate.

connect

this

3. Install the brake

1. Position bolts in the sert so

new

a

on

gaskets

and

plate

the

carrier

retaining

ential

tion

splines engage

side gear with

the

as

bearing

re

axle

shaft

a new

front

of

flange.

and

brake,

ad

and

at

the

rear

and gasket to the wheel spindle and and nuts.

TO LEFT FRONT CYLINDER

type,

ful

not

exception

the

axle

be flared leak-proof Clean the brake tubing

by flushing

with

good

clean

denatured

alcohol, before installation.

When

front

housing

be

When

should

provide

connections.

at

should not system.

rear axle

All brake tubing

throughout

the

tubing

of and

shape,

brake tubing to fit under contours, be care to kink or crack the tube.

bending body or

(Sec

tubing

with

size,

hydraulic

a

properly to

used with

in

used

LINES

system

replaced

same

length. Copper

bleed the brake system in Part 2-1, Section 2.

flexible hoses

the

be

should

the

connect

shoes

REPLACEMENT

TUBE

If a section of the brake tubing becomes damaged, the entire section

in this

brake tube connector (Fig. 13). Always bleed the entire system after any hose or line replacement.

carrier plate

install the retaining bolts

shoe

brake

the

tubing is

the brake

wheels

Position

and

Steel

the retaining nuts through the access

hole in the

rear

a

HYDRAULIC

retaining bolts the carrier plate. Install

against

2),

outlined

the differ

tainer sliding onto the and

On

4. Adjust

the axle shaft

that the

in

the parking brake cable to the lever. Install the brake drum and wheel.

housing flange. In into the housing

axle

BRAKE

and

as outlined

outlined

as

assemblies

section.

INSTALLATION

cylinder

wheel

the brake line

section.

juster

rear

-BRAKES

hose, inder,

torque

1112-144

to

a

connector, or brake cyl

tighten the tube

specified

tube

a

connecting

tube

or

fitting

with

nut

Milbar

to

tool

equivalent.

FROM MASTER CYLINDER

TO RIGHT CYLINDER REAR END OF HOSE TO

Ml 196

LEFT'

CYLINDER /CLAMP

'372323

-

3 REQD.

S>

.BRACKET

'REAR

/BRAKE

.TUBE

'CONNECTOR

LINE 41196

VIEW

S8,

Uj

3 REQD.

VIEW

VIEW

APPLY A FORCE TO fTHE BRAKE PEDAL PAD TO PRODUCE r 1300 TO1600 P.S.I. J LINE PRESSURE TO /TEST BRAKE SYSTEM/MUST BE FREE

TYPICAL 5 PLACES

Z\

Yj

MARKED*

BEND CLIPS TO RETAIN TUBE AT ASSY.

2267

2A448 ASSY.

LEAKS."

/OF 2078 2 REQD.

2268

2263

V -2A040\|

FRAME CROSSMEMBER k VI EW V

2264 o o

FRAME BRACKET 2073 V

2149,

FRONT END OF REAR HOSE

/

2 REQD.I

VIEW

VIEW WJ

X.

TO MAIN JUNCTION

\

TO MAIN JUNCTION 2265

2A448~

ASSY. RETAINING

r 41196 S8 5 REQD. -

41196

FRONT HOSE

"? X// Mf

-41196

-

S8

FRAME "BRACKET! 2A0S6 L.H. 2082 R.H. S8

f^-*'2 REQD.

FIG. 1 3-Service Brake System

H 1354- A

PART 2-2 BRAKE

HOSE

REPLACEMENT

into

A flexible brake hose

if it

replaced

ing,

a

or

new

be

installing

a new

front brake avoid con

gasket

hose

the

REMOVAL AND

STANDARD

BRAKES

the

connect

A

REMOVAL

from the

rear end of

inder in the

boot

rubber

passenger compartment.

2. Disconnect the brake line from 3. Remove

the

der to the

dash

cylinder out and

rod

nuts

that secure the

(Fig.

boot from

panel

lift the

and

push

rod,

the

away from the

the

13).

(Fig.

should

it does

be in the

not touch

the master cylinder

of

the

cylinder

against the

2. Install

the

nuts

push

on

rod,

the mount

dash

lock

and

and

the

-

gasket

new

fitting

and

the

over

rear

the hose

screw

as

sembly into the rear brake tube con nector. Engage the front end of the hose to the bracket on the frame. Install the horseshoe-type retaining clip,

and

hose

with

the

fitting

tube

to

tube

the

connect

the

nut.

washers

torque

to

master

heavy-duty

with

within

the

from the cylinder at the line fitting. Then tighten the

escape

air

brake

fitting.

and

speci

the

reservoir

Install the cap from the

4. Fill the

3/a

filler

filler

352

hose

a

inch

of

cylinder

reser

brake fluid to

the

top.

Be

cap.

the

cap. master cylinder to

let

level

and wipe off

and

fill

specified.

any fluid

cylinder.

boot to the

rubber

cylinder.

MASTER

POWER

CYLINDER-

BRAKES

REMOVAL

sure

is properly seated in Install and tighten the

5. Bleed the

master

filler cap

the

to

7. Connect the

push

on

Place

6. Remove

that the gasket

boot

sorber.

panel.

3. Connect the brake line to the master cylinder fitting, but leave the brake line fitting loose.

the

rubber

with

nut

guide

mounting fication.

rubber

the push rod.

the

hose

end

studs

voir

INSTALLATION 1. With

tube to the

master cylin

Remove

1 5).

lock

and

and

brake hose

the master cyl

the master cylinder.

washers

the

clip,

that

so

over

ing the

frame. Install

ab

shock

or

pipe

outlet

muffler

hose to

retaining

fitting

rear

stalled

position

1. Disconnect

the

on

En

cylinder.

INSTALLATION

CYLINDER-

MASTER

the hose assembly

gage the opposite end of the

the tube

Place

parts.

over

screw

front brake

horseshoe-type

hose to

chassis

other

copper

and

the

the bracket

damage.

other

position the

tact with

should

shows signs of soften

cracking,

When

hose,

fitting

2-15

SYSTEM

-BRAKE

let

1. Remove the hydraulic line out fitting from the master cylinder.

2. Remove

the

retaining

nuts,

lock, washers, and the master cylin der from the booster unit (Fig. 14).

390 ENG. STD. TRANS. ONLY

6 CYL. & 289 ENG. STD. & AUTO TRANS.

375787

S

240 ENGINE

p* )'

MOUNTING STUD S2 4 REQD. 377102 -

SPACER BETWEEN PEDAL SUPPORT BRACKET AND DASH PANEL 2849

4 REQD.

PEDAL ASSEMBLY

AUTO.

352

FIG. 1

TRANs

390 ENG.

4 Booster Installation

H 1356- A

GROUP 2

2-16

3. Remove the the

outer

master

rubber

groove

the

at

the

of

end

cylinder.

the

distance

from

of the push rod

to the

cylinder,

check

the outer

end

the

mounting surface

master cylinder

the

at

sion

is

the

push rod

Adjustment,"

inder Push Rod 2-1, Section 2. 2. When the

is correct,

the

replace

in

just far

enough

hole to

clear

the

master

Be

cylinder.

the

the

master

cylinder

are

integral

with

the

4. Install

the pin,

the

nuts

attaching

and

to

damage

not

during

removal.

washers

and

the brake pedal pin

and

brake line fitting.

the

torque the nuts to

6. Bleed the

master

master

outlet

the

cylinder

ing

Slide

brake

hy

at

the

bushing

system.

%

Fill inch

dash ers

disconnect

transmission

transmission vacuum unit

PEDAL SHAFT RETAINER 74279 S

PEDAL SUPPORT BRACKET

-

SPRING WASHER S 358981

mission

with

an

connect

vacuum unit

slid

in

link

boot in the bracket-to-

nuts and wash

manifold

vacuum

If the

the booster.

to

bracket

by

rod

the

panel

studs.

and

and

Install

panel.

as

the mounting

push

hole

the

equipped

vac

the

is

car

automatic

trans

transmission

hose.

4. Connect the brake line to the

the

hose.

master cylinder outlet

fitting.

BRAKE PEDAL SHAFT PEDAL SHAFT BUSHINGS- 2461

(AUTOMATIC

1

-

2450

TRANSMISSION) 2478

CLUTCH PEDAL AND SHAFT ASSEMBLY (MANUAL SHIFT TRANSMISSION)

UPPER MOUNTING STUD 377102 S2 2 REQD.

SPACER BETWEEN PEDAL

the

and

panel

panel

onto

retaining (Fig. 14).

hose manifold

bracket

link boot

Install the four

the mounting

3. Connect the

master cylinder

car

matic

the

dash

off

disconnect

and

on

through

hose from the booster unit. If is equipped with an auto

uum

the

within

link boot

dash

the

Fig. 14.

in

studs

outlet

fitting.

cylinder

out

dash

spacers.

rod

push

2. Mount the booster

(Fig. 14).

3. Disconnect the 5. Install the

link the

push rod

assembly to the dash

specifications.

draulic line

of

panel.

1. Install the the hole in

spacers

then lift

from the

2. Open the hood and

dash

the

shown

switch outer

upward

careful

switch

nylon

booster

body. lockwashers

in

the master cylinder push rod and the

over the push rod onto the two studs

that

for the

straight

switch

pin.

3. Position

rod

side

INSTALLATION

hairpin retainer. Slide the stop light switch off from the brake pedal pin

Part

rubber seal

follows:

stop light switch the connector. Remove the

at

wires

push rod adjustment

the groove at the end of the

5. Remove the

from

push

engine

Remove the four

panel.

To do this,

pedal assembly.

the

Disconnect the

dimen

"Master Cyl

not correct, see

brake

proceed as

the end of the vacuum cylinder (Fig.

3, Part 2-1). If

from

1. Working from inside the car below the instrument panel, discon nect the booster push rod link from

master

sliding the

panel,

REMOVAL

installing

bracket-to-

four

the

dash panel retaining nuts and wash 14). Remove the booster ers (Fig. and bracket assembly from the dash

UNIT

BOOSTER

INSTALLATION

1. Before

4. Remove

from the top of the filler opening. Install the filler cap and gasket.

from

seal

-BRAKES

-

SUPPORT BRACKET AND DASH PANEL 2849 4 REQD.

BUSHING 7526

k\

LOWER MOUNTING STUD

ROD TO PEDAL -

377103 -S2 2 REQD.

CLUTCH PEDAL TO EQUALIZER ROD 7A516

-

RETAINER

-

353467

S8

MASTER CYLINDER 2140

BRAKE PEDAL ASSEMBLY

S2 34807- S2 4 REQD

33799

-

2455

-

NYLON WASHER

BUSHING

RETAINER 379897

-

2A 309

S2

MASTER CYLINDER PUSH ROD

-

2B129

STOPLIGHT SWITCH 13480

H 1355

FIG. 1 5-Master Cylinder, Pedals

and

Stop

Light Switch

-

A

PART 2-2

5.

from inside the

Working

car

below the instrument panel, connect the booster push rod link to the

brake

pedal

proceed as

Install

follows: the inner

the

master

the

bushing

switch

push

Slide the

that it strad

so

rod

the

with

just

switch

switch

clearing the pin. completely onto the

pin, and install the

nylon

in Fig. 14. Be bend or deform the shown

pin

and

the brake pedal pin.

on

hole

these

washer,

rod,

the pedal pin and the switch

slot on outer

nylon push

washer

as

careful not

to

Secure

switch.

to the pin with the hair

parts

Connect

retainer.

stop light

the

to the

switch wires

connector, install the wires in the retaining

6. Bleed the brake

rod

push

the

with

slot on the pedal pin and

hole

outer

Slide pin,

cylinder

Position the dles the

To do this,

assembly.

dles the

just

the switch and

the

clearing

pin.

onto the

nylon washer as

in Fig. 15. Be careful not to deform the switch. Secure

shown

bend

switch

the switch

completely

install the

or

these parts to the

the hair

pin with

pin retainer. switch

the connector, and install the wires in the retaining clip. to

5. Connect

the

equalizer rod to

sembly

with

the

pedal-to-

clutch

the

clutch pedal as

bushing

and

retainer.

Apply Lubriplate

bushing.

Adjust

free play to

clear

the

damage

to

the

Slide

moval.

during

switch

the

re

cylinder

master

the

if

the

off

brake

pin

pedal

(Fig. 15).

3. Remove tainer

brake

and pedal

the

hairpin

spring

washer

shaft, then

type

re

from the

remove

the

to

ings from the

clutch

specification

bushing

shaft, the brake pedal and the bush

the

pedal support

bracket.

pedal

required.

INSTALLATION

1. Apply a coating of Lubriplate the bushings and locate all the bushings in their proper places on to

BRAKE PEDAL AUTOMATIC TRANSMISSION

system.

the port

REMOVAL 1.

Disconnect the stop light

switch

wires at the connector.

the

hole to

outer

switch

pin, and then lift the switch straight upward from the pin. Be careful not

hairpin

clip.

REMOVAL 1. Disconnect

the

and

BRAKE PEDAL MANUAL SHIFT TRANSMISSION

to-equalizer rod

2. Remove the hairpin retainer. Slide the stop light switch off the brake pedal pin just far enough for

push rod and the nylon washers and

4. Connect the stop light wires

2-17

SYSTEM

-BRAKE

pedal

and

assembly

pedal

sup

bracket (Fig. 15).

2. Position sembly to the

the

brake

support

pedal

bracket,

as

then

pedal-

clutch

the clutch pedal

at

by removing the hairpin bushing (Fig. 15).

type

retain

er and

2. Disconnect the stop light switch wires at the connector.

3. Remove the hairpin retainer. Slide the stop light switch off the brake pedal pin just far enough for the

switch

upward

lift the

from the

damage

to

the

Slide

moval.

hole to

outer

and then

pin,

pin.

Be

the

careful not

during

switch

the

clear

switch straight

master

re

cylinder

push rod and the nylon washers and

bushing

brake

the

off

pedal

pin

(Fig. 15). 4. Remove tainer

and

clutch

and

the

move

hairpin

the

type

pedal

clutch

shaft.

pedal

re

from the

washer

spring brake

and

Re

shaft,

the brake pedal, and the bushings from the pedal support bracket (Fig. 15).

INSTALLATION 1.

Apply

a

coating

to the bushings

ings in clutch

their and

clutch

support

Install

bracket,

then

and

shaft

pedal

bracket the

and

spring

bush

on

the

assemblies.

pedal

2. Position the brake support

all

places

proper

brake

Lubriplate

of

locate

and

pedal to the

install

the

through the

brake

washer

pedal.

and

re

tainer (Fig. 15).

3. Install the inner the

master

the

bushing

Position the

cylinder

on

nylon washer, push

the brake

switch

so

rod,

and

H1351-A

pedal pin.

that

it

strad

FIG. 1

6

Parking Brake Control

Assembly Manual

Release

GROUP

2-18

2

-BRAKES

BRACKET CONTROL ASSEMBLY

PEDAL CABLE

2853 EQUALIZER LEVER

REAR WHEEL CABLES

EQUALIZER

H 1352

ROD

-

A

FIG. 1 7 Parking Brake System install the

pedal

shaft

through

support

bracket

brake

sembly.

Install the spring

and

the

pedal as

washer and

retainer.

3. Install the inner master

the

bushing

Position dles the outer

on the

nylon push

brake

push

rod

with

washer,

parts to

pin

deform the

rod,

and

just

switch

the

pin

Secure the hair

switch.

with

retainer.

stop light switch wires to the connector, and install the wires in the retaining clip. the

it

the

clearing completely

the

install the nylon washer as in Fig. 15. Be careful not to

(Figs. 5, 16,

nut

remove

1.

Working

from the

engine com and

the

passenger

bolt

and

panel.

control

panel,

assembly from the hairpin

remove

that holds the cable

housing

assembly bracket, and disconnect the ball end of the cable from the clevis on the pedal (Fig. to the

partment, remove the two nuts

the

that attach the control assembly

retainer

REMOVAL

parking

17).

and

from

2. Working compartment,

the

retain

assembly to the dash

panel

the dash

PARKING BRAKE CONTROL ASSEMBLY

pin.

onto the

that

control

3. Pull the

strad switch

washers

brake

to the cowl upper

pedal pin.

the pedal pin and the switch

and

shown

cylinder

the switch so that

hole

Slide the pin,

or

these

4. Connect

the

slot on

bend

17).

control

Disconnect

the

hose from the

PART 2-2

vacuum

power unit on

an automatic

release type control assembly.

INSTALLATION

brake

PARKING

BRAKE

EQUALIZER

gine

TO

REAR

WHEEL

CABLE

control assembly with the en running in all the transmission selector lever positions. With the

engine

ball

1. Connect the

cable to the clevis on

trol pin

to the

and

con

the

running, remain

should

"park"

or

and should

drive

power unit on

an automatic

type control assembly.

release

2. Install the two

in any

release

control

and

studs,

mounting

that the

so

assembly

studs enter the

the

position

(Fig. 17).

panel

3. Install attach

bolt

the

control

cowl upper panel.

and

that

nut

assembly to the Do not tighten at

this time.

4.

install

partment, nuts

5.

the

the

washers

and

studs at

engine com

two attaching the

on

from the

tighten

compartment,

passenger

bolt

the

assembly to the Check and adjust

upper panel.

the parking brake

linkage, if

neces

sary.

housing

cable rear

end

retainer

at the trans

crossmember,

support

the cable assembly for the crossmember.

ward and out of

3. Remove the

Lower

4.

sion arm

(Fig. 17).

Remove

the

parking brake disconnect the

control

assembly

and

et and pull of

from the

cable

dure

under

Working

Brake Control

on

on

out of

5. Push

UNIT

and

pan

1. Remove

the

control

assembly described under

parking from the

"Removal"

brake car

in

to

7. With the spring tension out

the

of

lever, lift

brake

out

or

the

off

grind

two

the

brake

parking

the

from

piston

vacuum

lever

the release

rod

Remove

the

1. Pull

the

of

enough

housing

cable

that the end

so

the

slot

into

hole in

the

2. the

cable

Pulling

into the

the

carrier

plate

from

slack

excess

insert the

cable,

cable

housing

access

hole

so

that the retainer prongs expand.

in the floor

3. Connect the

stall

the

of the

end

pan.

the hole

upper

pan. of

end

front

the

housing

of

end

through the

rear

the sus

arm mounting bracket and install the hair pin retainer (Fig. 17).

in

outlined

the control assembly as

3. Thread cable

pension

the

the control assembly and

cable to

of

underside of

the

through

to

disconnect the

and

lever.

the

clip that

retainer

re

and

the carrier plate hole.

INSTALLATION

the

Working from inside the car, new cable and housing up

2.

control

pull

3. Remove the

rod

floor

the

upper

cable

replacement

the

the

guide

cable

may be inserted over in the parking brake lever on the rear brake shoe (Fig. 1).

Working from

1.

the

off

the

in the lever

slot

through the

the car,

assembly.

secures

under

INSTALLATION

the

rivets that attach the vacuum power unit

it from

remove

as

procedure.

2. Drill

housing

and

cable

car.

REMOVAL

foregoing

the

cable retainer

hole.

the

parking

of

compress the

the hole in the

Draw the

move through

down through the hole in the floor

out

the cable retainer so that

can pass through

Assembly"

PARKING BRAKE VACUUM POWER

housing

the wheel side

brake (Fig. 1),

proce

"Parking

attaches

rear suspen

the cable and

carrier plate.

control

in the

that

to the

the bracket (Fig. 17).

6.

"Removal"

as outlined

Part

1,

5. Remove the hair pin retainer holds the cable housing to the rear suspension arm mounting brack

the rear

car.

the

that

prongs

the

the equalizer (Fig.

housing

the underside of

at

retaining clip floor pan.

the

nut on

disconnect

and

Remove the clip

4.

from

housing

cable

and

drum.

the cable

they

and

nut that attaches the

hairpin

the

the brake shoes,

off

in

drum

brake

2-1).

lever

equalizer

from the lever (Fig. 17).

and then pull

the

hoist. Move

a

disconnect the ball

and

2. Remove

the

the

brake

parking

of the cable

car on

Tinnerman

three

the

rod,

from

cable

1. Raise the

mounting

the dash panel.

Working from

cowl

REMOVAL

the

remove

and

3. Loosen the adjusting equalizer

mission

Working from

back

remove the

PARKING BRAKE EQUALIZER TO CONTROL CABLE

forward

the

hold

that

place,

the

car

and wheel.

2. Remove the nuts

mount

holes in the dash

hub cap

position.

the

on

spacers

1. Raise the

"neutral"

in

engaged

REMOVAL

brake

parking

assembly bracket with the hair retainer. Connect the hose to the

vacuum

ing

the

of

the pedal,

housing

the cable

secure

end

2-19

BRAKE SYSTEM

-

4. Fasten the rear

suspension

cable

housing

to the

the retain

with

arm

'installation"

power

in the

unit.

procedure under Assembly."

"Parking Brake Control INSTALLATION

1. Position unit

on

the and

assembly head bolts

the

4. vacuum

power

brake

control

parking secure

with two round

and nuts.

2. Connect the vacuum piston rod release lever and secure with

Install the parking brake con trol assembly in the car as described

ber

release

lock

operations

hoist. Guide

cable

hole in the

support

with

the

assembly

transmission

crossmember.

Secure

hair

and

of

automatic

the

parking

pin

(Fig.

retainer

its

from the as shown

at

cable

the

6. Connect the the

equalizer

housing

in the

underside of

the

edge

of

lever.

parking brake linkage Part 2-1.

Adjust

ball the

as outlined

in

be installed

is 4-6 inches hose insulator

the

in Fig. 17.

5. Insert the ball into the equalizer

end of

the cable

tighten

the

adjusting nut on the equalizer slightly (Fig. 1, Part 2-1).

end

the three the

hub cable rear end

should

centerline

6. Install the

retaining clip floor pan.

to the

the

17).

in the foregoing

procedure.

4. Test

a

car on

of

5. Engage the

3.

installation"

end

through the rear

retainer clip.

under

Raise the rear

The clip

clip.

that

so

the cable assembly to the crossmem

to the the

the

ing

and

drum,

and

drum. Tighten

rear

Tinnerman

nuts

install the

that retain wheel

and

cap.

7. Adjust the outlined

in

rear

Section

parking brake linkage Part 2-1, Section 2.

brake 2. as

shoes as

Adjust

the

outlined

in

GROUP 2 -BRAKES

2-20

MAJOR REPAIR OPERATIONS BRAKE

DRUM

After

REFINISHING

wipe

Minor scores on a brake drum be removed with a fine emery cloth. A drum that is excessively scored or shows a total indicator runout of over 0.007 inch should be turned down. Remove only enough stock

to

eliminate

the

scores

drum. The

the

with

a

one

size.

BRAKE

and

SHOE RELINING

Brake linings

0.060

%2 inch

within

been

saturated

that

of

are

should

be

replaced.

grease

or

Failure to

oil re

may be installed. If the drum diame ter is 11.060-11.090

replaced on

linings

must

inches,

carded.

brake

Do

repair

not

a

shoe.

1. Wash the brake shoes thor oughly in a clean solvent. Remove all burrs or rough spots from the shoes.

linings will result in a drum. When it is necessary to replace linings, they must also be

standard

refinishing,

be dis defective

tion exists, the shoe should

2. Check the inside diameter

of

the brake drum. If the

diameter is less than 1 1 inches, standard lin ing may be installed. If the diameter .060

If the drum diameter is less than 0.030 inch oversize (11.060 inches) after

cracks,

to

worn

the rivet or have

with

Inspect brake shoes for distortion, or looseness. If this condi

down,

turned surface

in clean denatured al drum is turned down, the opposite drum on the same axle should also be cut down to the same

If

cohol.

refinished

up diameter must not exceed inch oversize (11.090 inches).

refinished

cloth soaked

can

true

is

drum

a

the

place worn

lining

scored

oversize

be installed.

site side of

the

the

wheel on

the

oppo

is

11.060-11.090 inches, should be installed.

oversize

lining

3. Position the new lining Starting in the center,

car.

and secure

insert

the rivets, working alter each end. Install all in the kit. Replace

nately towards FILLER CAP

the

on

shoe.

parts

supplied

ment

linings

ground

are

and

no

further grinding is required. 4. Check the clearance between the shoe and lining. The

tightly

seat

against

more

than 0.008

tween

any two

MASTER

lining

must

the shoe with

inch

clearance

not

be

rivets.

CYLINDER

SECONDARY CUP

DISASSEMBLY

FITTING

1. Clean the

der,

and

may

remain

outside of

the cylin

the filler cap and gasket. Pour out any brake fluid that ~

NUT

^

LOCKWASHER

OUTLET CHECK VALVE

FIG. 1 8Master Cylinder

H1360.A

remove

in the

2. Remove with

Standard Brake System

the

bore

with

at

cylinder

sembly, GASKET SNAP RING

ring

from

(Fig. 20). with

remove

spring,

seat

from

the

the

a

master

standard piston as

check

the

valve,

cylinder

bore (Fig. 18). When disassembling a master cyl inder used with a booster, remove the

SEAL

cup,

valve

snap

disassembling

used

brake system, and

the

the rear of the cylinder

tool 33621

3. When FILLER CAP

cylinder or res

ervoir.

piston

assembly, cup,

and

the

spring and check valve assembly from the cylinder bore. Remove the O-ring from the piston (Fig. 19).

VALVE

SNAP RING PLIERS

PISTON

\ CUP

SPRING WASHER

NUT

H1291-A H1279-B

FIG. 1 9Master Cylinder

with

Booster

FIG. 20 Removing Snap Ring from Master Cylinder Typical

PART 2-2 BOOSTER

2-21

BRAKE SYSTEM

-

BODY

BELLOWS H1265-A H1363-A

FIG. 2 1

-Bellows-to-Booster

FIG. 22 Removing or Installing Rear Seal to End Plate

Body Engagement CLEANING, INSPECTION, AND REPAIR

bly in

1. Clean all master cylinder parts in clean denatured alcohol, and in spect the parts for wear or damage, replacing them as required. When

When assembling a master cylin der used with a booster, install the

using a master cylinder repair install all of the parts supplied.

2. Check the the

master

ports

and

to

cylinder

kit,

vents

make

in

sure

free of foreign Check the condition of the diaphragm type gasket.

O-ring

on

spring

and

cup,

bore (Fig. 18).

the cylinder

the

and piston

Install

piston.

check

valve

in the

bore

cylinder

3. A leaf-type valve is riveted to front end of the piston in a

4. Install the snap ring back of the bore (Fig. 20).

in

the

stand

BOOSTER

are

replace

open,

When der

inspecting a master cylin with a booster, check the

used

lockwashers,

and

nuts

separate

in the

ports

that

they

eign

are

open

material

(Fig.

4. Inspect the scores or

if

rust,

necessary.

free

and

sure

of

for

the

walls

and recondition

for

them

cylinder walls

Oversize

cups are not available

and

pistons

for excessively

cylinders.

any burrs or loose that may have resulted from

5. Remove metal

the

honing

cylinder

operation, and clean the

with

denatured

alcohol.

Dip

body in clean heavy-duty brake fluid. cylinder

and

the

the stop light

inder

and

tighten

brake

the master

FoMoCo

install the

valve

5. Remove the rear (Fig. 22).

the

valve

and

the end

of

from the

seal

from

and

the

booster

the

1. Remove clamp

lows

4. Disconnect the valve operating from the lever assembly by re retainer

clip

and connect

5. Disconnect the lever assembly end

moving the

brackets

plate

retainer

by

and

clip

re

pro and

assembly (Fig. 23). support rings

from the bellows.

the protector

3. Remove the push rod assembly lever assembly from

(Fig. 27).

from the

bellows

diaphragm

the

Remove the two

2. and

bellows, bel

rings, and

from

bellows

large

the

separate the

support

valve

ing pin

and

tector

(Fig. 27).

moving the

BELLOWS,

PUSH ROD AND VALVE

manifold

vacuum

assembly

grommet

DISASSEMBLY OF

and the reaction

the control hub (Fig. 24).

4. Remove the two plastic guides push rod. Remove the re

pivot

from the

pin.

6. Disconnect the retainer and

7. Remove disassemble

rod

push

by

link

removing

connecting

push rod

5. Remove

pin.

the retaining nuts,

and

brackets from

the

the

retainer

cone

action

from the

hold the

and

the

cone

(Fig. 24)

the

from the

rod

valve

plunger.

operating To remove,

firmly and force the breaking the plas

rod

end plate.

fitting

line

the cyl

securely.

3. When assembling a master cyl inder used with the standard brake system,

out

plate

plunger off the rod

switch on

them

valve,

end

plate.

rod

the

all parts except

2. Install

check

body

control

ASSEMBLY FROM DIAPHRAGM

from the lever assembly

ASSEMBLY

1.

and remove

retainer,

Remove the

rubber

cylinder

diaphragm assembly

booster

the

filter (Fig. 27).

3.

bellows,

the

end plate

cover and

and

19).

Hone the

maximum).

honed

make

than necessary (0.003 inch

more

no

to

piston

from

cylinder

body.

air

plate

end

and

4. Push the valve, tail stock,

1. Remove the two attaching

2. Remove the air filter assembly from the booster body. Separate the

ports

screw

clamp

3. Push the bellows assembly into (Fig. 21), and

PARTS

the

piston

body,

diaphragm assembly, and from the booster body.

master

the piston.

booster

band,

the

separate

and

nut,

the vacuum chamber

REMOVAL OF EXTERNAL

and

Installing

or

2. Remove the clamp band and

the

brake system (Fig. 18). If this valve is loose or has moved so that ard

the

separate

OF

DISASSEMBLY

the

master cylinder used with

Removing Bellows Assembly

(Fig. 27).

that all are open and matter.

23

FIG.

the

assembly,

19).

(Fig.

H1395-A

seat, check

valve, spring, cup, and piston

assem-

tic

8.

Remove the

the valve

rubber

operating

boot from

rod.

groove

COMPONENTS

1. Scribe

line

body, clamp band,

again,

pieces of

SEPARATION OF MAJOR

a

retainer.

used

the booster

and end

plate.

plunger all

is to be

the broken

plunger.

the

control

hub

and

assembly clockwise to sep it from the diaphragm plate.

plunger

arate

the

remove

the plastic retainer from the

in the

6. Turn across

If

GROUP 2

2-22

-BRAKES

ASSEMBLY OF VALVE

ASSEMBLY, PUSH ROD, AND BELLOWS TO DIAPHRAGM 1. Assemble

hub

CONTROL HUB

on

index

valve

on

projections

the

control

the raised

with

the flat indexes with the the hub (Fig. 28).

hub,

the

and

the valve plate

flat projection Compress the the

stall REACTION LEVER

valve

control

the round holes in the

so that

rubber

the

assembly into

plunger

on

valve

spring, and in the plunger

in

retainer

the control valve

groove

to

plunger

to the control

secure

hub (Fig. 26).

2. Assemble the tail stock over the plunger with the flat on the tail stock indexing with the flat on the hub. 3. Assemble

the tail stock and

formed

by

"O"

the

parts together

and

24 Push

Rod Assembly, Reaction Lever

then remove the tail stock and

O-ring

from the diaphragm (Fig. 25).

7. Remove the the

plunger

26). Separate the

holds hub (Fig. hub and

retainer that

to the control control

the

and

to

valve

sions

and

the

remove

retainer.

spring

toward the

2. Remove the spring, washer

"O"

valve,

from the

valve

plunger

plate,

fiber (Fig. 27).

ring,

and

hub (Fig. 24).

6. Assemble the

tainer,

two

and

reaction plastic

cone, re

push

rod

Install the push rod assembly in the valve hub so that the push rod indexes in the guides

rubber

these

secure

(Fig. 25).

control

Control Hub

rubber

the

5. Install the lever assembly in the hub with the rubber protru

H1396-A

FIG.

stock and

hub assembly diaphragm, and turn the hub control

and

counterclockwise PUSH ROD ASSEMBLY

groove

the tail stock and hub.

4. Assemble the tail plunger

to the

over

ring "V"

into the

the push rod.

on

valve plunger.

plunger assembly.

It may be necessary to file the burr from the protruding end of the plunger

from the

before it control

can

be

separated

hub.

VALVE PLUNGER

TO INSTALL

the

spring towards TO REMOVE

BOOSTER

fiber

the

rubber

valve,

"O"

valve

plate, spring, washer on

ring,

spring

smaller

the plunger.

and

assemble the

retainer on the plunger

with

the flange towards the spring (Fig.

27). PLUNGER

bellows

and

2. Compress the spring towards the rubber valve

7. Install the two bellows support and bellows protector on the bellows. The support rings are posi tioned in the two larger folds of the rings

CONTROL VALVE PLUNGER 1. Assemble

DISASSEMBLY OF CONTROL 1. Compress

ASSEMBLY OF

Snap Ring Pliers

and

the

in

protector

the

fold.

8. Assemble the bellows on the hub so that the lip of the bel lows indexes in the groove on the hub. Secure the bellows to the hub by assembling the large bellows clamp on the diaphragm end of the bellows yS2" from the end of approximately the bellows (Fig. 23). control

ASSEMBLY OF MAJOR

COMPONENTS 1. Assemble the end plate

(Fig. 22)

diaphragm, ponents,

bly

the control

and

into the

rear

and

seal

in the

position valve

the bellows as

the

com

an assem

end plate.

2. Install the rubber grommet in booster body with the large di ameter side to be outside of the booster. Force the vacuum manifold the

DIAPHRAGM PLATE

CONTROL HUB AND PLUNGER ASSEMBLY

and

H1397-A

FIG. 25 Removing or Installing Control Hub and Plunger

Assembly

CONTROL HUB

FIG.

26

H1398-A

Removing

or

Installing

Plunger-to-Control Hub Retainer

check

valve

the grommet (Fig.

assembly

through

27).

3. Assemble the booster body to end plate. Make sure that the

the

of the

lip

diaphragm is evenly positioned

PART 2-2

-

BRAKE SYSTEM

2-23

BELLOWS SUPPORT RINGS

BOOSTER BODY VACUUM MANIFOLD

REACTION CONE

BELLOWS

GROMMET

FILTER

COVER HUB

BOOT

OPERATING ROD PLASTIC RETAINER

LEVER PIVOT

END PLATE

PIN

BRACKET

H1362-A

FIG. 27-Booster Unit Disassembled on

the retaining radius of the end the booster body. Pull the

cure with the

front lip of the bellows through the booster body and position it evenly around the hole in the booster body (Fig. 21).

around

is

press

Align the

scribe

the assembly

lines,

together,

its

being

circumference

tightened.

inch-pounds

of

as the

Tighten to

bolt 15

torque.

the

Insert

rod.

in

groove

lip

the

the

the

end

into

rod

of

the

that the retainer engages

plunger so

the

to

retainer

plastic

the

the

Install

plunger.

the boot in the groove of

of

(Fig. 27).

the rear seal

INSTALLATION OF

4. Install the clamp band over the lips of the booster body and end plate.

clamp band bolt. Tap with a fiber hammer

the clamp band

plate and

2. Connect

EXTERNAL PARTS

to the

rod

1. Install the

com

valve

and se

rubber

operating

rod

boot to the

and

assemble

and

the

upper

the

connect

valve end

of

push

operating the

rod

lever,

link to

the center of the lever with the con

necting

pins

and

clips.

RAISED PROJECTIONS

3. Position the mounting brackets MATCHING HOLES

to the

end

taining

plate

and

install the

re

nuts.

4. Connect the lever assembly to lower end of the mounting

the

brackets

with

the pivot pin and clip.

5. Position

the air filter in the filter cover, and then snap the cover and filter on the metal hub plastic

with

the

filter between.

6. Assemble the cover, filter, and assembly to the booster body with the metal hub against the booster body. hub

RUBBER VALVE

7. Assemble PLUNGER H1399-A

HUB

to

the

master

FIG.

28

Assembling Valve Plunger

to

Hub

booster cylinder

specification.

the

master

body.

cylinder

Torque

mounting

nuts

the to

2-24

PART 2-3

SPECIFICATIONS

LINING

DIMENSIONS INCHES

Models

Position

Ford Passenger Cars

Ford & Mercury-All 427 CID Engine & 8 Cylinder Police Maximum Fade Resistant

Ford

and

Mercury Station Wagons

Ford and Mercury Passenger Cars (240-289 CID Engine) All Taxi and 6 Cylinder Police-Maximum Wear Resistant

Mercury Passenger Cars

Primary Secondary

2.5 x 9.34 2.5 x 12.12

2.25 2.25

Primary Secondary

3.00 3.00

9.34 12.12

2.25 2.25

Primary Secondary

3.00 3.00

x

9.34 12.12

2.25 2.25

Primary Secondary

3.00 3.00

x

9.34

x

12.12

2.5 2.5

Primary

2.5 2.5

Secondary

CHECKS

AND

Rear

Front

x x

x

x

x

9.34 12.12

x

x

2.25 2.25

x x

x

x x x

9.34 12.12

Yellow-Black Blue-Black

9.34 12.12

Yellow-Black Blue-Blue

9.34 12.12

Silver Yellow-White

9.34 12.12 x x

9.34 12.12

ADJUSTMENTS INCHES

Master Cylinder Bore Diameter Standard

1.000

Power

0.875

Master Cylinder Maximum Allowable Hone

0.003

Front Wheel Cylinder Bore Diameter

Passenger, Police & Taxi Station Wagon

1.094

1.062

Rear Wheel Cylinder Bore Diameter

Passenger, Police & Station Wagon Taxi (Max. Wear Resistant)

0.969 0.875

Wheel Cylinder Maximum Allowable Hone

0.003

Drum Diameter

11.030

Drum Maximum Allowable Run-Out

0.007

Drum Maximum Boring Diameter

11.090

Drum Width-Front

Passenger Station Wagon, Maximum Wear & Maximum Fade Resistant

2.50 3.00

Drum Width-Rear

Passenger

2.25

Taxi

2.50

Lining Maximum Wear Limit Top of Rivets or Shoe Rim)

0.031

Lining Maximum Clearance (Midway Between Rivets)

0.008

(From

to Shoe

Pedal Travel-Standard

Pedal

7.00

Travel Power

Power Unit

4.00

Push-Rod

Self Adjustment Cable Length Hook-llVs inch Vu

End

Adjustment- 0.995-1.005

inches

Cable Anchor to End

Cable

of

of

Color Code

Pink Red-Red Silver Yellow-White

PART 2-3

TORQUE LIMITS Ft-lbs

Master Cylinder-To-Pedal Support Bracket

18-25

Pedal Pad to Brake Pedal Nut

12-16

Assembly-Parking Brake

Master Cylinder

to Cowl Side Bolt

15-19

Fitting

Left Hand Brake

6-12

Hose Front

to Connector Bolt

12-18

Wheel Cylinder Bleeder Screw

Vacuum Connector

FRONT

at

2-25

SPECIFICATIONS

TORQUE Description

Control

-

LIMITS

(Cont.)

REAR BRAKES

Ft-lbs

Description

Assembly Speednut

Drum

Assembly

to Axle Shaft

Wheel

Assembly

to Axle Shaft to Drum

Assembly Nuts

Brake Cylinder to Brake Carrier Plate Bolt Brake Carrier Plate to Axle

Hand Push Fit

75-110

10-20 30-40*

Housing

120 in-lbs Maximum

Engine Manifold

20-28

BRAKES

Carrier Plate Pin Nut

and

Cylinder Assembly Brake Shoe Anchor 20-30 POWER

Anchor Pin to Spindle Bolt

Wheel Assembly to Hub

and

BRAKES

80-106

Drum Assembly Nuts

Master Cylinder to Booster Body

10-13

Brake Booster to Pedal Support Bracket

18-25

75-110

Front Brake Carrier Plate to Spindle Nut

25-45 ?Models 59, 71 RPO

SERVICE

Heavy

TOOLS

Ford Tool No.

Former No. LM-119 2035N 2086L

TOOL-4235-C TOOL-33621

4235-C 33621 1112-144

Description Brake Cylinder Retaining Clamp Brake Shoe Retracting Spring Remover and Installer Axle Shaft and Bearing Remover Pump Shaft Bearing Retainer and Power Brake Pliers Inch-Pound Torque Wrench

Duty-

55-65 Foot Pounds

3-1

SUSPENSION, STEERING, WHEELS

GROUP

3

AND TIRES PART 3-1

AND TIRES GENERAL SERVICE

3-1

PART 3-2 SUSPENSION

Page

PART 3-5 SAGINAW POWER STEERING GEAR

Page

SUSPENSION, STEERING, WHEELS

.

.

PART 3-6

3-52

WHEELS AND TIRES

3-11

PART 3-7

PART 3-3

SPECIFICATIONS

MANUAL STEERING

3-40

.

.

3-55

.

3-19

PART 3-4 FORD

POWER

STEERING GEAR

PART 3-1

3-31

SUSPENSION, STEERING, WHEELS AND TIRES-GENERAL SERVICE

Section

Diagnosis

1

Section

Page

3

3-1

Testing

and

2 Common Adjustments

and

Repairs

Page

Cleaning

and

Inspection

..3-9

3-7

DIAGNOSIS AND TESTING STEERING

MANUAL

four

or

times.

lists

Table 1

manual

various

and

steering trouble symptoms and causes. Several of these possible

Do

hold the Recheck

not

pension,

frame, For

troubles.

that the the

this

cause

steering

and

the

be

tire sure

is in

trouble

the

linkage before

or

adjusting, repairing, of

and

reason,

of

gear

wheel

replacing any

or

the fluid level.

leakage

points.

Tighten

CHECK FLUID LEVEL

tings, and replace any damaged lines or defective seats.

stops.

STEERING-

POWER

PRELIMINARY TESTS The

following always

should

forming

preliminary

be

made

checks

before

any trouble-shooting

per

opera

tions.

AIR

BLEEDING

Air in the (shown

by be

should

that the cation

power

steering

bubbles

bled.

reservoir

(the fluid

in

system

engine

normal

temperature. wheel

all

making sure is filled to specifi be

at

On

a

lubricant

of

normal

when

pump

several

right

filler tube

with a straight

must

be to the bottom

the filler tube. If the level

add

fluid

enough

C1AZ-19582-A

level

to

stick

or

tube.

Do

F

the to

the

not

to

mark

bottom

overfill

is low,

transmission

automatic

raise

on of

the

the

the

dip

the filler

the and

steering wheel. 1. With the

Use only the specified type of belt. Refer to Part 3-3 for belt adjustment.

idling,

turn

ing

to turn the

required

car

dry

on

properly correct,

concrete,

to the left and right several

wheel

times to

warm

3. Attach

the fluid.

a pull scale

to the rim of

the steering wheel. Measure the pull required to turn the wheel one com revolution effort

steering

in

required

each

direction.

to rotate

the

wheel should not exceed

5.0

pounds.

PUMP-FLUID PRESSURE TEST fluid

whether

the

wheels pressures

the parking brakes. 2. With the engine warmed up and running at idle speed, turn the steer

A

CHECK FOR FLUID LEAKS engine

loose fit

all

set

plete

If the pump belt is broken, glazed, worn, replace it with a new belt.

With the

front tire

check the effort

The

the

temperature operating is made), turn the steering check its full travel three through wheel

With aligned

reservoir.

CHECK PUMP BELT

or

possible

CHECK TURNING EFFORT

the

times, and shut off the engine. Check the fluid level in the power

the

all

fluid is

the

until

operating

Then turn the steering way to the left and

fluid)

the

After

must

Run the at

steering reservoir. The level must be at the full mark on the dipstick.

parts.

steering

stop

Check

to sus

common

also

are

to

stop

times.

their

power

symptoms

from

wheel

steering several

wheels against

unit

in

pressure

the the

pump power

test or

will

show

some

other

steering

system

FORM 7098-65

LITHO IN U