This product was created from the original Ford Motor Company's publication. ...
This shop manual provides the Service Technician with .... Galaxie 500 XL .....
Guide'1. With the engine shut off, exhaust all vacuum in the system. Depress the.
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