DEMO - 1965 Comet Falcon Fairlane Mustang Shop Manual

Copyright © 2006, 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 Comet, Falcon, Fairlane and Mustang Shop Manual
(Form 7760-65, first printing September 1964)
ISBN 0-9673211-2-3
EAN: 978-0-9673211-2-7

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.

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
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FOREWORD

This shop manual provides the Service Technician with com-
plete information for the proper servicing of the 1965 Comet,
Falcon, Fairlane and Mustang cars.

The information is grouped according to the type of work
being performed, such as diagnosis and testing, frequently
performed adjustments and repairs, in-vehicle adjustments,
overhaul, etc. Specifications and recommended special tools
are included.

Refer to the opposite page for important vehicle identifica-
tion data.

The descriptions and specifications in this manual were in
effect at the time this manual was approved for printing. The
Ford Motor Company reserves the right to discontinue models
at any time, or change specifications or design, without notice
and without incurring obligation.

SERVICE DEPARTMENT
FORD MOTOR COMPANY



12 VEHICLE IDENTIFICATION

BODY STYLE EXTERIOR PAINT COLOR (WHITE) DATE CODE TRANSMISSION CODE

(FAIRLANE 500 INTERIOR TRIM (26TH DAY OF AUGUST) (DUAL RANGE AUTOMATIC (C-4))

2-DOOR SEDAN)

/ \
AXLE RATIO CODE
(TURQUOISE FABRIC AND / DETROIT

LT. TURQUOISE MET. VINYL) / DISTRICT (3.00:1 AXLE RATIO)

.BODY CCOLOR TRIM

*62B XM 27 26H

5F4IC IOOOOI

THI1 V E M C L E % MANUFACTURED UNDER UNITED STATES

AWD FAVREIOOM PATENT^ A N D PATENT APPLICATIONS

MODEL YEAR (1965) | \ CONSECUTIVE UNIT NUMBER

ASSEMBLY PLANT ENGINE CODE (8 CYL. 289 CID ENGINE) R1184-C
(DEARBORN) I
BODY SERIAL CODE (2-DOOR SEDAN)

F I G . 3—Fairlane Warranty Plate

EXTERIOR PAINT COLOR DATE CODE AXLE RATIO CODE

(WHITE) (6TH DAY APRIL) (3.00:1 AXLE RATIO) TRANSMISSION CODE
(DUAL RANGE
BODY STYLE \ INTERIOR TRIM
AUTOMATIC (C-4))
(2-DOOR HARDTOP) \ (PALOMINO VINYL) \ DETROIT DISTRICT

89 06D

5FO7A 110196

THI5 M HldlE IS MANUFACTURED UNDER UNITED STATES
A ND FOREIGN PAINTS AND PATENT APPLICATIONS

MODEL YEAR (1965) | \ CONSECUTIVE UNIT NUMBER
ASSEMBLY PLANT
(DEARBORN) ENGINE CODE
(8 CYL. 289 C10 ENGINE)

BODY SERIAL CODE (2-DOOR HARDTOP) N1406-A

FIG. 4-Mustang Warranty Plate

F I G . 5-Vehicle Identification I
Number Location—Comet, Falcon
and Mustang F I G . 6-Vehicle Identification
Number Location—Fairlane

VEHICLE IDENTIFICATION 1-3

Figures 1, 2, 3 and 4 illustrate the Comet, Falcon, Fairlane and Mustang FALCON
Warranty Plates. The warranty plate is located on the rear face (lock face)
of the left front door. Body Body

The official Vehicle Identification Number, for title and registration pur- Serial Style Body Type Model
poses, is stamped on the top upper flange of the left front fender apron for Code Code Standard
Falcon, Comet and Mustang (Fig. 5C) and on the vertical face of the left Sedan
front fender apron near the top for the Fairlane (Fig. 6C). Do not use the 0 2 . . . ..54A... .4-Door Sedan
Vehicle Warranty Number, which appears on the warranty plate, for title 0 2 . . . ..54D... 4-Door Sedan (RPO) Futura
or registration purposes. 0 1 . . . ..62A.. .2-Door Sedan
Station
VEHICLE DATA 0 1 . . . ..62D... 2-Door Sedan (RPO) Wagons
Ranchero
The vehicle data appears in a line across the top of the warranty plate 16... ..54B... 4-Door Sedan (Bench)
(Figs. 1, 2, 3 and 4). The first two letters and a number identify the Body 19... ..62B... 2-Door Sedan (Bench) Sedan
Style. The following one or two letters identify the Exterior Paint Color. The Delivery
next code consisting of two numbers, or a letter and a number, identifies 17... ..63B... 2-Door Hardtop (Bench)
the Interior Trim. The Date Code showing the date the car was manufac- 1 1 . . . ..63C... .2-Door Hardtop (RPO Bucket)
tured, follows the Trim Code and consists of two numbers and a letter. The
next code gives the district in which the car was ordered and consists of two 17... . .63H... .2-Door Hardtop Bucket (Less Console)
numbers. The next to the last code is the Axle Ratio Code and is designated 15... . 76A... Convertible (Bench)
by a number for a conventional axle or a letter for an Equa-Lock axle. The
last code in the vehicle data is the Transmission Code and consists of one 1 2 . . . ..76B... Convertible (RPO Bucket)
number. The charts that follow, list in detail the various vehicle data codes.
2 1 . . . ..59A... 2-Door Wagon
VEHICLE WARRANTY NUMBER 2 2 . . . ..71A... .4-Door Wagon

The vehicle warranty number is the second line of numbers and letters 2 4 . . . ..71B... 4-Door Wagon Deluxe
appearing on the Warranty Plate (Figs. 1, 2, 3 and 4). The first number indi- 26... ..71C... 4-Door Squire
cates the model year. The letter following the model year indicates the
assembly plant at which the car was manufactured. The next two numbers 2 7 . . . ,66A... .2-Door Standard Ranchero
designate the Body Serial Code. The letter following the Body Serial Code 2 7 . . . ..66B... .2-Door Deluxe Ranchero
designates the Engine Code. The remaining numbers indicate the Consecu- 2 7 . . . ..66G... 2-Door Standard (RPO Bucket W/Console)
tive Unit Number. The charts that follow, list the various Vehicle Warranty
Number codes. 2 7 . . . . .66H... .2-Door Standard (RPO Bucket W/Console)

2 9 . . . ..78A... Standard Sedan Delivery
2 9 . . . ,.78B... Deluxe Sedan Delivery

FAIRLANE

Body Body Body Type Model
Fairlane
Serial Style
Code Code Fairlane
500
3 1 . . . . 62A... .2-Door Sedan
3 2 . . . ..54A... 4-Door Sedan Sport Coupe
Station
4 1 . . . ,.62B... 2-Door Sedan Wagons
4 2 . . . ..54B... .4-Door Sedan
4 3 . . . ..65A... 2-Door Hardtop

4 7 . . . ..65B... 2-Door Hardtop*

3 8 . . . ,71D... 4-Door Ranch Wagon
4 8 . . . ..71B... .4-Door Custom Ranch Wagon

*Bucket Seats

BODY SERIAL AND STYLE CODES MUSTANG

The two-digit numeral which follows the assembly plant code identifies Body Body
the body series. This two-digit number is used in conjunction with the Body
Style Code, in the Vehicle Data, which consists of a two-digit number with a Serial Style Body Type Model
letter Suffix. The following chart lists the Body Serial Codes, Body Style Code Code Mustang
Codes and the Model.
0 9 . . . . 63A... 2-Door Fastback
07.. . 65A .. 2-Door Hardtop
0 8 . . . ..76A... 2-Door Convertible

COMET EXTERIOR PAINT COLOR CODES

Body Body A single letter code designates a solid body color and two letters denote
a two-tone—the first letter, the lower color and the second letter, the
Serial Style Body Type Series upper color
Code Code Comet

0 2 . . . ..54A... .4-Door Sedan* 202 M-30J/
0 1 . . . ..62A... 2-Door Sedan* Code M-32-J# Color
3 2 . . . ..71A... 4-Door Wagon* Comet
404 . .1724-A. Black
12... ..54B... 4-Door Sedan* A..
11... ..62B... .2-DoorSedan* Comet
11... ..62C... 2-DoorSedanf Caliente C. ..1736-A. Med. Ivy Gold Met
34... ..71B... .4-DoorWagon*
Cyclone D.. ..1625-A. Med. Turq. Met.
36... ..71C... 4-Door (Villager) Wagon*
H.. ..1544-A. Dk. Blue Met.

I.. ..1737-A. Lt. Beige Met.

2 2 . . . ..54C... .4-Door Sedanf J.. ..1515-A. Red
2 2 . . . ..54D... 4-Door Sedan*
2 3 . . . ..63C... 2-Door Hardtopf (Fastback) K.. . .1621-A. Med. Gray Met.
2 3 . . . ..63D... 2-Door Hardtop* (Fastback)
2 5 . . . ..76B... 2-Door Convertible! M. . .1619-A. White
25... ..76D... .2-Door Convertible*
O.. . .1732-A. Lt. Peacock

P.. . 1738-A. Palomino Met.

R.. ..1879-A. Dk. Ivy Green Met

2 3 . . . ..63E... .2-Door Hardtopf (Fastback) V.. . 1729-A. Yellow

X.. ..1632-A. Maroon Met.

*Bench Seat Y.. . 1269-A. Med. Blue Met.
tBucket Seats
5.. ..1731-A. Dk. Turq. Met.

14 VEHICLE IDENTIFICATION

INTERIOR TRIM CODES DATE CODES

Code Trim Codes A number signifying the date precedes the month code letter. A second-year
code letter will be used if the model exceeds exceeds 12 months.
04 Beige Vinyl
12 Med. Blue and Lt. Blue Met. Fabric and Vinyl Month Code Code
15 Red Fabric and Vinyl First Year Second Year
16 Black Fabric and Vinyl January...
17 Med. Turq. and Lt. Turq. Met. Fabric and Vinyl February.. ....N
19 . . Palomino and Med. Palomino Fabric and Vinyl March P
22 Med. and Lt. Blue Met. Vinyl (Comet), April Q
May R
Fabric and Vinyl (Except Comet) June S
25 . . . . Red Vinyl (Comet), Fabric and Vinyl (Except Comet) July T
26 Black Vinyl August... U
27 Med. and Lt. Turquoise Met. Vinyl (Comet), September. V
October...
Fabric and Vinyl (Except Comet) November. w
28 Ivy Gold and Lt. Ivy Gold D/L Fabric and Vinyl December.
29 Palomino Vinyl (Comet), Fabric and Vinyl (Except Comet) X
32 Med. Blue and Lt. Blue Met. Fabric and Vinyl (Comet) Y
Z
Vinyl (Except Comet)
35 Red Fabric and Vinyl (Comet) Vinyl (Except Comet) DISTRICT CODES (DSO)
36 Black Fabric and Vinyl (Comet) Vinyl (Except Comet)
37 Med. Turquoise and Lt. Turq. Met. Fabric and Vinyl (Comet) Units built on a Domestic Special Order, Foreign Special Order, or other
special orders will have the complete order number in this space. Also to
Vinyl (Except Comet) appear in this space is the two-digit code number of the District which
38 Ivy Gold Fabric and Vinyl (Comet) Vinyl (Except Comet) ordered the unit. If the unit is a regular production unit, only the District
39 Palomino and Med. Palomino Fabric and Vinyl (Comet) code number will appear.

Vinyl (Except Comet) COMET District Code District
42 White and Blue Vinyl
45 White and Red Vinyl Code Boston 34 Detroit
46 White and Black Vinyl Philadelphia
48 White and Ivy Gold Vinyl 11 41 Chicago
49 Med. Palomino Vinyl 16 New York
52 Med. Blue and Lt. Blue Met. Fabric and Vinyl (Comet), 15 Washington 42 St. Louis
14
Vinyl (Except Comet) 21 Atlanta 45 Twin Cities
55 Red Fabric and Vinyl (Comet), Vinyl (Except Comet) 22 Dallas
56 Black Fabric and Vinyl (Comet), Vinyl (Except Comet) 23 51 Denver
59 Palomino and Med. Palomino Fabric and Vinyl (Comet), 26 Jacksonville
31 Memphis 52 Los Angeles
Vinyl (Except Comet) 32 Buffalo
F2 White Pearl (W/Red) Fabric and Vinyl 33 Cincinnati 53 Oakland
F5 White Pearl (W/Black) Fabric and Vinyl Cleveland
F6 White Pearl (W/Turquoise) Fabric and Vinyl 54 Seattle
F8 White Pearl (W/Gold) Fabric and Vinyl
F9 White Pearl (W/Palomino) Fabric and Vinyl 81 Ford of Canada
62 Lt. Blue Met. Vinyl
65 Red Vinyl 84 .. Home Office Reserve
66 Black Vinyl
67 Turquoise Vinyl 90-99... Export

68 Ivy Gold Met. and D/L Vinyl FALCON, FAIRLANE AND MUSTANG
69 Med. Palomino Vinyl
G2 White Pearl (W/Blue) Vinyl Code District Code District
G5 White Pearl (W/Red) Vinyl
G6 White Pearl (W/Black) Vinyl 11 Boston 45 Davenport
G7 White Pearl (W/Turquoise) Vinyl 12 Buffalo 51 Denver
G8 White Pearl (W/Gold) Vinyl
G9 White Pearl (W/Palomino) Vinyl 13 New York 52 Des Moines
72 Lt. Blue Met. Vinyl
75 Red Vinyl 14 Pittsburgh 53 Kansas City
76 Black Vinyl
77 Lt. Turq. Met. Vinyl 15 Newark 54 Omaha
78 Ivy Gold D/L Vinyl 21 Atlanta
79 . . Med. Palomino Vinyl 55 St. Louis
H2 White (W/Blue) Vinyl
H5 White (W/Red) Vinyl 22 Charlotte 61 Dallas
H6 White (W/Black) Vinyl
H7 White (W/Turquoise) Vinyl 23 Philadelphia 62 Houston
H8 White (W/Gold) Vinyl
H9 White (W/Palomino) Vinyl 24 Jacksonville 63 Memphis
82 Lt. and Med. Blue Met. Vinyl
85 Red Vinyl 25 Richmond 64 New Orleans
86 Black Vinyl
87 Lt. Turq. Met. Vinyl 26 Washington 65 Oklahoma City
88 Lt. Ivy Gold Met. Vinyl
89 Med. Palomino Vinyl 31 Cincinnati 71.... Los Angeles
92 Blue Vinyl
95 Red Vinyl 32 Cleveland 72 San Jose
96 Black Vinyl (Except Fairlane) Fabric and Vinyl (Fairlane)
99 Palomino Vinyl (Except Fairlane) Fabric and Vinyl (Fairlane) 33 Detroit 73.... Salt Lake City

34 Indianapolis 74.. .. Seattle

35 Lansing 81 Ford of Canada

36 Louisville 83.... Government

41 Chicago 84 .Home Office Reserve

42 Fargo 8 5 . . . . American Red Cross

43 Rockford 89 Transportation Services

44 Twin Cities 90-99.. Export

VEHICLE IDENTIFICATION 15

REAR AXLE RATIO CODES ASSEMBLY PLANT CODES

A number designates a conventional axle, while a letter designates an Code Assembly Code Assembly
Equa-Lock differential. Letter Plant Letter Plant

Code Ratio Code Ratio A Atlanta N Norfolk
D Dallas P Twin Cities
1.... .3.00:1 A... .3.00:1 E R
F Mahwah S.... San Jose
3 .3.20:1 C... 3.20:1 G Dearborn T Pilot Plant
H Metuchen
4.... .3.25:1 D... .3.25:1 J Chicago Wu Louisville
.3.50:1 Lorain
5 .2.80:1 E.... .3.50:1 K Y Wayne
L Los Angeles Z Wixom
6 .3.80:1 F.... .2.80:1 Kansas City St. Louis
. .Michigan Truck
7 .3.89:1 G.... .3.80:1

8 .4.11:1 H... .3.89:1

9 I .4.11:1

TRANSMISSION CODES ENGINE CODES

Code Type A 8 Cyl. 289 Cu. In. (4V Prem.)
C 8 Cyl. 289 Cu. In. (2V)
1 3-Speed Manual K 8 Cyl. 289 Cu. In. (4V Hi-Perf.)
2 3-Speed Manual W/Overdrive T 6 Cyl. 200 Cu. In. (IV)
5 4-Speed Manual U 6 Cyl. 170 Cu. In. (IV)
6 Dual Range Automatic (C-4) 2 6 Cyl. *200 Cu. In. (IV)
3 8 Cyl. *289 Cu. In. (2V)
4 6 Cyl. *170 Cu. In. (IV)

MODEL YEAR CODE CONSECUTIVE UNIT NUMBER

The number 5 designates 1965. Each model year, each assembly plant begins production with the number
100001 (Falcon, Fairlane or Mustang) or 500001 (Comet) and continues on
for each unit built.



2-2 G R O U P 2-BRAKES
TABLE 1 —Disc Brake Trouble Symptoms and Possible Causes—Mustang 8 Cyl.

Trouble Symptoms

Possible Causes
of

Trouble Symptoms
Excessive Pedal Travel
Brake Roughness or Chatter

(Pedal Pumping)
Excessive Pedal Effort

Pull
Rattle
Brakes Heat Up During
Driving and Fail to Release
Leaky Wheel Cylinder
Grabbing or Uneven
Braking Action
No Braking Effect When
Pedal is Depressed

Shoe and Lining Knock-back after violent cornering or X
rough road travel
X X
Piston and Shoe and Lining Assembly Not Properly X X
Seated or Positioned X
X XX
Air Leak or Insufficient Fluid in System or Caliper
Loose Wheel Bearing Adjustment X XX
Damaged or Worn Caliper Piston Seal X X
Excessive Lateral Run-out of Rotor
Rotor Excessively Out of Parallel XX X
Frozen or Seized Pistons XX X
Brake Fluid, Oil or Grease on Linings X X
Shoe and Lining Worn Below Specifications X
Proportioning Valve Malfunction
Caliper Out of Alignment with Rotor X
Loose Caliper Attachment X
Excessive Clearance Between Shoe and Caliper or
X
Between Shoe and Splash Shield X
Shoe Hold-Down Clips Missing or Improperly Positioned
Operator Riding Brake Pedal X
Scores in the Cylinder Bore X
Corrosion Build-up in the Cylinder Bore or on the
X
Piston Surface X
Bleeder Screw Still Open
Caliper Out of Parallel with Rotor X

BOOSTER DIAGNOSIS GUIDE—FALCON, COMET, MUSTANG

BOOSTER INOPERATIVE- If the preliminary tests show that dition. Repair or replace parts as
HARD PEDAL the booster is inoperative or if a necessary.
hard pedal condition still exists after
eliminating the causes of "Excessive If the foregoing procedure does
Pedal Effort" or "Hard Pedal" not eliminate the trouble, remove the
listed in Tables 1 and 2, the trouble booster from the car. Separate the
may be caused by vacuum leakage. front shell from the rear shell, and
Disconnect the vacuum line at the check the valve and rod assembly
booster, remove the vacuum mani- reaction disc, diaphragm plate, and
fold and check valve assembly, and diaphragm assembly for damage that
look for a sticking or faulty check would cause leaks. When assembling,
valve. Check all vacuum connections be sure that the diaphragm assembly
for leakage or obstruction. Check all is properly positioned. Improper lo-
hoses for a leaking or collapsed con- cation could cause leakage between
the vacuum and atmospheric sides of
the diaphragm.

CONTINUED ON NEXT PAGE

P A R T 2-1-GENERAL BRAKE SERVICE 23

TABLE 2—Drum Brake Trouble Symptoms and Possible Causes

Trouble Symptoms

Possible Causes of One Brake
Trouble Symptoms Drags
All Brakes
Drag
Hard Pedal
Spongy Pedal
Car Pulls to
One Side
One Wheel
Locks
Brakes Chatter
Excessive Pedal
Travel
Pedal Gradually
Goes to Floor
Brakes Uneven
Shoe Click
Release
Noisy or
Grabbing Brakes
Brakes Do Not
Apply

Mechanical Resistance at Pedal or Shoes XX
Damaged Linkage

Brake Line Restricted XXX X

Leaks or Insufficient Fluid X XX X

Improper Tire Pressure XX

Improperly Adjusted or Worn Wheel Bearing X X

Distorted or Improperly Adjusted Brake Shoe X X X XX X X

Faulty Retracting Spring XX

Drum Out of Round X XX

Linings Glazed or Worn X XXXX XX

Oil or Grease In Lining X XXX X XX

Loose Carrier Plate X XX

Loose Lining XX

Scored Drum XX

Dirt on Drum-Lining Surface X

Faulty Wheel Cylinder X XX X

Dirty Brake Fluid XX XX

Faulty Master Cylinder X XX X

Air in Hydraulic System XX X X

Self Adjusters Not Operating XXX

Insufficient Shoe-to-Carrier Plate Lubrication X X

Tire Tread Worn X

Poor Lining to Drum Contact X

Loose Front Suspension X

"Threads" Left by Drum Turning Tool X
Pull Shoes Sideways

Cracked Drum X

Sticking Booster Control Valve X X

BOOSTER DIAGNOSIS GUIDE—FALCON, COMET, MUSTANG (Continued)

BRAKES DRAG If the brakes still drag or grab plunger assembly. Remove and dis-
OR GRAB after eliminating the causes listed in assemble the booster. Clean, inspect,

Tables 1 and 2, the condition is and replace parts as necessary,
probably caused by a sticking valve

SELF APPLICATION OF Remove and disassemble the valve poppet. Clean, inspect, and re-
BRAKES WHEN booster. Check for a leak in the rear place parts as necessary. Be sure that
ENGINE STARTS shell. Check the diaphragm for being the diaphragm is properly located
out of locating radii in the housing. when assembling.
Check for a sticking or unseated
CONTINUED ON NEXT PAGE

2-4 G R O U P 2-BRAKES

BRAKE BOOSTER TROUBLE DIAGNOSIS GUIDE—FAIRLANE

BOOSTER INOPERATIVE- If the preliminary tests show that leaking or collapsed condition. Re-
HARD PEDAL the booster is inoperative or if a pair or replace parts as necessary,
hard pedal condition still exists after
eliminating the causes of "Hard If the foregoing procedure does
Pedal" listed in Table 2, the trouble not eliminate the trouble, remove
may be caused by vacuum leakage. the booster from the car. Separate
Disconnect the vacuum line (two the booster body from the end plate,
lines if equipped with an automatic and check the bellows, booster body,
transmission) at the booster, remove and diaphragm assembly for damage
the vacuum manifold and check that would cause leaks. When assem-
valve assembly, and look for a stick- bling, be sure that the diaphragm
ing or faulty check valve. Check all assembly is properly positioned. Im-
vacuum connections for leakage or proper location could cause leakage
obstruction. Check all hoses for a between the vacuum and atmos-
pheric sides of the diaphragm.
BRAKES DRAG OR GRAB If the brakes still drag or grab
after eliminating the causes listed in assembly. Remove and disassemble
Table 1, the condition is probably the booster. Clean, inspect, and re-
caused by a sticking valve plunger place parts as necessary,

SELF APPLICATION Remove and disassemble the seated atmospheric valve. Clean, in-
OF BRAKES WHEN booster. Check the diaphragm for spect, and replace parts as necessary,
ENGINE STARTS being out of locating radii in the Be sure that the diaphragm is prop-
housing. Check for a sticking or un- erly located when assembling.

COMMON ADJUSTMENTS AND REPAIRS

HANDBRAKE
HANDLE ASSEMBLY

•FRONT CABLE H-1328-A

F I G . 1 — Parking Brake Linkage

P A R T 2-1-GENERAL BRAKE SERVICE 25

PARKING BRAKE ( H1330-A AIR FILTER
LINKAGE ADJUSTMENT
FIG. 3—Push Rod Adjustment H1349-A
Check the parking brake cables drag, or cause excessive brake pedal
when the brakes are fully released. travel. FIG. 5-Push Rod Adjustment
If the cables are loose, adjust them —Fairlane
as follows: To check the adjustment of the
screw, fabricate a gauge of the di- the inner edge of the slot in the
1. Fully release the parking brake mension shown in Fig. 2. Then place gauge. Do not set up side forces on
by turning the handle counterclock- the gauge against the master cylinder the push rod. Side forces may break
wise and pushing it inward. mounting surface of the booster the valve plunger.
body as shown in Fig. 3. The push
2. Pull the parking brake handle rod screw should be adjusted so that This is an approximate adjustment
outward to the third notch from its the end of the screw just touches only. The master cylinder piston
normal released position. should not move more than 0.015
H12O8-A inch as it contacts the push rod. No
3. Raise the car. FIG. 4—Push Rod Gauge movement (exact contact) is ideal.
Dimensions—Fairlane
4. On a Falcon, Comet or Fair- POWER BRAKE MASTER
lane, turn the lock nut in front of CYLINDER PUSH ROD
the equalizer (Fig. 1) several turns ADJUSTMENT—FAIRLANE
forward.
The push rod is provided with an
5. On all cars, turn the adjustment adjustment screw to maintain the
nut forward against the equalizer correct relationship between the
until a moderate drag is felt when booster control valve plunger and
turning the rear wheels in the direc- the master cylinder piston. Failure
tion of forward rotation. to maintain this relationship will
prevent the master cylinder piston
6. When the cables are properly from completely releasing hydraulic
adjusted on a Falcon, Comet or Fair- pressure and can cause the brakes
lane, tighten the lock nut against to drag.
the equalizer.
To check the adjustment of the
7. Release the parking brake, and screw, fabricate a gauge of the di-
make sure that the brake shoes re- mensions shown in Fig. 4. Remove
turn to the fully released position the air filter assembly and push the
and no drag is felt when turning bellows back into the booster body.
the rear wheels. Re-install the air filter directly
against the booster body, and then
POWER BRAKE MASTER place the gauge against the master
CYLINDER PUSH ROD cylinder mounting surface of the air
ADJUSTMENT—COMET AND filter assembly as shown in Fig. 5.
MUSTANG The push rod screw should be ad-
justed so that the end of the screw
The push rod is provided with an just touches the inner edge of the
adjustment screw to maintain the slot in the gauge. Do not set up side
correct relationship between the forces on the push rod as it may
booster control valve plunger and the break the valve plunger.
master cylinder piston. Failure to
maintain this relationship will pre- This is an approximate adjustment
vent the master cylinder piston from only. To verify the adjustment, look
completely releasing hydraulic pres-
sure and can cause the brakes to

HI 32 9-1

FIG. 2—Push Rod Gauge
Dimensions

2-6 G R O U P 2-BRAKES

through the make-up (rear) port right rear brake wheel cylinder (Fig. cap to the reservoir, and attach the
when installing the master cylinder 6). Attach a rubber drain tube to bleeder tank hose to the fitting on
to the booster. The master cylinder the bleeder fitting. The end of the the adapter cap.
piston should not move more than tube should fit snugly around the
0.015 inch as it contacts the push bleeder fitting. An adapter cap can be fabricated
rod. No movement (exact contact) by cutting a hole in the center of a
is ideal. 2. Submerge the free end of the reservoir cap and soldering a fitting
tube in a container partially filled at the hole. The adapter cap m^st
HYDRAULIC SYSTEM BLEEDING with clean brake fluid, and loosen be securely seated and completely
the bleeder fitting approximately % sealed on the master cylinder or
When any part of the hydraulic turn. leakage will occur.
system has been disconnected for re-
pair or replacement, air may get 3. Push the brake pedal down 3. Position a 3/s-inch box wrench
into the lines and cause spongy pedal slowly through its full travel. Close on the bleeder fitting on the right
action. Bleed the hydraulic system the bleeder fitting, then return the rear brake wheel cylinder (Fig. 6).
after it has been properly connected pedal to the fully-released position. Attach a rubber drain tube to the
to be sure that all air is expelled Repeat this operation until air bub- bleeder fitting. The end of the tube
from the brake cylinders or disc bles cease to appear at the sub- should fit snugly around the bleeder
brake calipers, and lines. merged end of the tube. fitting.

The hydraulic system can be bled 4. When the fluid is completely 4. Open the valve on the bleeder
manually or with pressure bleeding free of air bubbles, close the bleeder tank to admit pressurized brake fluid
equipment. fitting and remove the drain tube. to the master cylinder reservoir.

With disc brakes, more pumping 5. Repeat this procedure on the 5. Submerge the free end of the
of the pedal is required and more brake cylinders or disc calipers at tube in a container partially filled
frequent checking of the master cyl- each wheel in order: left rear, right with clean brake fluid, and loosen
inder may be necessary while bleed- front, and left front. Refill the mas- the bleeder fitting.
ing. ter cylinder reservoir after each
brake cylinder is bled and when the 6. When air bubbles cease to ap-
On a Mustang with disc brakes, bleeding operation is completed. The pear in the fluid at the submerged
remove the front wheel and tire as- fluid level should be within 3/s inch end of the drain tube, close the
semblies in order to gain access to of the top of the reservoir. The dia- bleeder fitting and remove the tube.
the bleeder fitting on the disc brake phragm-type gasket should be prop-
calipers. erly positioned in the reservoir cap 7. Repeat this procedure on the
before the cap is installed. brake cylinder or disc caliper at each
MANUAL BLEEDING wheel in order: left rear, right front,
Bleed the longest lines first. Keep 6. On a Mustang with disc brakes, and left front. Refill the master cyl-
be sure that the front brake pistons inder reservoir after each brake cyl-
the master cylinder reservoir filled are returned to their normal posi- inder is bled.
with new SAE 70R3-Wagner 2IB tions and that the shoe and lining
(301) brake fluid during the bleeding assemblies are properly seated. 8. When the bleeding operation is
operation. completed, close the bleeder tank
7. Before driving the car, check valve and remove the tank hose from
Never use brake fluid which has the operation of the brakes and be the adapter fitting.
been drained from the hydraulic sys- sure that a firm pedal is obtained.
tem. 9. Remove the adapter cap, refill
PRESSURE BLEEDING the master cylinder reservoir to with-
1. Position a bent %-inch box in 3/8-inch from the top of the res-
wrench on the bleeder fitting on the Bleed the longest lines first. Never ervoir. Be sure that the diaphragm-
use brake fluid which has been type gasket is properly positioned in
APPROXIMATELY 45C drained from the hydraulic system. the reservoir cap, and then install
the cap.
HI 300-A The bleeder tank should contain
enough new heavy-duty brake fluid 10. On a Mustang with disc
FIG. 6-Brake Bleeder Wrench to complete the bleeding operation, brakes, be sure that the front brake
and it should be charged with 10-30 pistons are returned to their normal
pounds of air pressure. positions and that the shoe and lin-
ing assemblies are properly seated.
1. Clean all dirt from the master
cylinder reservoir cap. 11. Before driving the car, check
the operation of the brakes and be
2. Remove the master cylinder sure that a firm pedal is obtained.
reservoir cap, install an adapter

CLEANING AND INSPECTION

DISC BRAKES 2. Make three thickness measure- inch (shoe and lining together) or
ments with a micrometer across the 0.030 -inch (lining material only) at
1. Remove the wheel and tire as- middle section of the shoe and lin- any one of the three measuring loca-
sembly, caliper splash shield, and the ing. Take one reading at each side tions, replace all (4) shoe and lining
shoe and lining assemblies as out- and one in the center. If the assem- assemblies on both front wheels.
lined in Part 2-2, Section 2. bly has worn to a thickness of 0.195-
3. With the shoe and lining assem-

P A R T 2-1-GENERAL BRAKE SERVICE 2-7

blies installed, insert a feeler gauge The two halves of the caliper as- 6. Inspect all other brake parts
between the lining and rotor. If the sembly should never be separated. and replace any that are worn or
clearance is not within 0.002-0.010- Damage or failure of one requires damaged.
inch, check for shoe and lining as- replacement of both as a unit.
semblies not being properly seated 7. Inspect the brake drums and,
on the caliper bridges, for a piston DRUM BRAKES if necessary, refinish. Refer to Part
pushed back in the cylinder bore, for 2-2, Section 4 for refinishing.
a seized piston, or for malfunction 1. Remove the wheel from the
of a piston seal. drum, and remove the drum as out- BOOSTER UNIT—COMET
lined in Part 2-2, Section 2. Wash
Ordinarily, the clearance should all the parts except the brake shoes A disassembled view of the brake
be 0.002-0.010-inch. However, if in a cleaning fluid and dry with com- booster is shown in Fig. 41, Part 2-2.
the vehicle was stopped by a brake pressed air.
application just prior to checking After disassembly, immerse all
the clearance, the brakes may drag 2. Brush all dust from the carrier metal parts in cleaning solvent.
slightly. plate and interior of the brake drum. Clean the plastic parts in alcohol
only, taking care to avoid chipping
4. To check rotor runout, first 3. Inspect the brake shoes for ex- or damage. Replace all rubber parts.
eliminate the wheel bearing end play cessive lining wear or shoe damage. Use an air hose to blow out dirt and
by tightening the adjusting nut. After If the lining is worn to within 1/32- cleaning solvent from recesses and
tightening the nut check to see that inch of the rivet heads or if the internal passages. When overhauling
the rotor can still be rotated. shoes are damaged, they must be re- a vacuum booster, use all parts fur-
placed. Replace any lining that has nished in the repair kit.
5. Clamp a dial indicator to the been oil saturated. Replace the lin-
caliper housing so that the stylus ing in axle sets. Prior to replacement BOOSTER UNIT—FAIRLANE
contacts the rotor at a point approxi- of the lining, the drum diameter
mately 1-inch from the outer edge. should be checked to determine if A disassembled view of the brake
Rotate the rotor and take an indica- oversize linings must be installed. booster is shown in Fig. 50, Part 2-2.
tor reading. If the reading exceeds
0.002-inch total indicator runout, re- 4. Check the condition of the After disassembly, immerse all
place the rotor. Do not attempt to brake shoes, retracting springs, and metal parts in a suitable solvent.
refinish a rotor that indicates runout drum for signs of overheating. If the Use only alcohol on rubber parts or
in excess of specification. When the shoes have a slight blue coloring, or parts containing rubber. After the
runout check is finished be sure to if the springs show a change in free parts have been thoroughly cleaned
adjust the bearings as outlined in length, indicating overheating, re- and rinsed in cleaning solvent, the
Group 3, in order to prevent bear- placement of the retracting and hold metal parts which come in contact
ing failure. down springs is necessary. Over- with hydraulic brake fluid or rubber
heated springs lose their pull and parts should be rewashed in clean
6. Check the rotor for scoring. could cause the new lining to wear alcohol before assembly. Use an air
Minor scores can be removed with prematurely if they are not replaced. hose to blow dirt and cleaning fluid
a fine emery cloth. If the rotor is from the recesses and internal pas-
excessively scored, replace it. 5. If the car has 30,000 or more sages. When overhauling a power
miles of operation on the brake lin- booster, use all parts furnished in
7. Visually check the caliper. If it ings, or signs of overheating are the repair kit. Discard all old rub-
is cracked or if excess leakage is evi- present when relining brakes, the ber parts.
dent, it should be replaced. Slight wheel cylinders should be disassem-
leakage or seized pistons indicate re- bled and inspected for wear and dirt Inspect all other parts for damage
moval and disassembly. in the cylinder. The cylinder cups or excessive wear. Replace damaged
and other parts contained in the or excessively worn parts. If the
8. If upon disassembly the caliper overhaul kit should be replaced, thus inside of the booster body is rusted
is found to be distorted or damaged, avoiding future problems. or corroded, polish it with steel wool
or if the cylinder bores are scored or fine emery cloth.
or excessively worn, replace the as-
sembly.

2-8

PART
2-2 BRAKE SYSTEM

Section Page Section Page
1 Description and Operation 2- 8 3 Removal and Installation 2-23
2 In-Car Adjustments and Repairs 2-16 4 Major Repair Operations 2-31

DESCRIPTION AND OPERATION

Disc brakes are available as op- SELF ADJUSTING DRUM ondary shoe causes the cable to pull
tional equipment for the front wheels the adjusting lever upward and
on Mustang 8-cylinder cars. The hy- BRAKE ASSEMBLIES against the end of a tooth on the
draulic brake system employs single adjusting screw star-wheel. The up-
anchor, internal expanding and self- The self-adjusting brake mecha- ward travel of the lever increases as
adjusting drum brake assemblies on nism consists of a cable, cable guide, lining wear increases. When the lever
the rear wheels of cars with disc adjusting lever, and adjuster spring can move upward far enough, it
brakes, and of front and rear wheels (Fig. 1 and 2). The cable is hooked passes over the end of the tooth and
of all others. over the anchor pin at the top and is engages the tooth. When the brakes
connected to the lever at the bottom. are released, the adjusting spring
A vacuum booster is available as The cable is connected to the sec- pulls the lever downward causing the
optional equipment on Comet and ondary brake shoe by means of the star-wheel to turn and expand the
Mustang models with an automatic cable guide. The adjuster spring is shoes. The star-wheel is turned one
transmission and on all Fairlane hooked to the primary brake shoe tooth at a time as the linings pro-
models. and to the lever. The automatic ad- gressively wear.
juster operates only when the brakes
A booster unit is not available on are applied while the car is moving With the car moving forward and
Mustang models equipped with disc rearward and only when the second- the brakes applied, the secondary
brakes. ary shoe is free to move toward the shoe is against the anchor pin and
drum beyond a predetermined point. the primary shoe is moved toward
The master cylinder converts phy- the drum. Therefore, the adjuster
sical force from the brake pedal (and With the car moving rearward does not operate.
booster if so equipped) into hydrau- and the brakes applied, the "wrap-
lic pressure against the pistons in the around" action of the shoes follow- The rear brake assembly is basic-
calipers (disc brakes) or in the wheel ing the drum forces the upper end ally the same as the front brake.
cylinders (drum brakes). The pistons of the primary shoe against the The conventional parking brake
in turn convert hydraulic pressure anchor pin. The action of the wheel lever, link, and spring are used in
back into physical force at the brake cylinder moves the upper end of the the rear brake.
shoes. secondary shoe away from the an-
chor pin. The movement of the sec- The anchor pins on all brakes are
fixed and are non-adjustable.

SPRING WASHER SECONDARY ANCHOR PIN WHEEL CYLINDER
SPRING
PARKING BRAKE
PARKING BRAKE LINK
LEVER RETAINING
LINK SPRING
CLIP

PRIMARY
SHOE

CABLE

ADJUSTING SHOE
HOLD-DOWN
LEVER
SPRING
PARKING BRAKE SOCKET BACKING

PLATE
ADJUSTER

SPRING
PIVOT NUT

CABLE AND HOUSING 'ADJUSTING SCREW

REAR BRAKE FRONT BRAKE H1323-A

F I G . 1 — Self Adjusting Brake Assemblies—Comet, Falcon, and Mustang 6-Cylinder Cars

P A R T 2 - 2 - BRAKE SYSTEM 2-9

CABLE ANCHOR PARKING BRAKE LEVER WASHER PARKING BRAKE LINK
CABLE GUIDE RETAINING CLIP LINK SPRING
PRIMARY SHOE

CABLE

CABLE HOOK

SECONDARY SHOE- PRIMARY SHOE PARKING BRAKE
CABLE HOUSING
TO- ANCHOR SPRING AUTOMATIC ADJUSTER °IVOT HOOK RETAINING GROMMET
SECONDARY SHOE ADJUSTING LEVER
PIVOT NUT SPRING AUTOMATIC ADJUSTER SPRING

SOCKET ' ADJUSTING SCREW

FRONT BRAKE PARKING BRAKE CABLE AND HOUSING* H122O-A

REAR BRAKE

FIG. 2—Self Adjusting Brake Assemblies—All Fairlane & Falcon, Comet & Mustang—8-Cylinder Cars

DISC BRAKE ASSEMBLIES sages in the caliper housing and an abutments within the caliper, and
external transfer tube between the are supported radially by tabs on the
RELATION AND FUNCTION OF two halves of the caliper assembly. outer ends of the shoe assemblies
COMPONENT PARTS One bleeder screw and fluid inlet (Fig. 36). The shoes slide axially in
fitting is provided on each caliper the caliper abutments by means of
The disc brake is a fixed caliper, assembly. the tabs which ride on machined
opposed piston, non-energized, venti- ledges (bridges) when hydraulic pres-
lated disc type, actuated by a hy- The shoe and lining assemblies are sure is applied to the piston (Fig.
draulic system (Fig. 3). There is no located in between parallel machined 18). A shoe and lining assembly con-
lateral movement of either the disc sists of friction material bonded to a
(rotor) or the caliper. The caliper HUB AND: metal plate called the shoe. It is re-
assembly consists of two caliper ROTOR ASSEMBLY^ placed as a unit. Brake torque is ab-
housings bolted together with each BLEEDER SCREW ' CALIPER ASSEMBLY sorbed by the mating of the shoe end
half containing two cylinder bores against the caliper abutments (Fig.
of 1-15/16" diameter. Each cylinder CALIPER SPLASH-SHIELD 36). A splash shield is attached to
bore contains a piston with an at- H 1400 - A the top of the caliper to retain the
tached molded rubber dust boot to shoe and lining assemblies and re-
seal the cylinder bore from contami- FIG. 3—Mustang Disc Brake duce contamination. The caliper as-
nation. (Fig. 4). Square-section rub- Assembly sembly is mounted to a bracket lo-
ber piston seals are positioned in cated between the spindle and rotor
grooves in the cylinder bores. splash shield, to the front of the
wheel vertical centerline.
The piston seals perform three im-
portant tasks: The cast iron disc is of the venti-
lated rotor type incorporating forty
1. They provide hydraulic sealing fins and is staked to, and rotates
between the cylinders and pistons. with, the wheel hub. The outside
diameter of the rotor is 11.375
2. They return the pistons to re- inches and the inside diameter is
leased position, when hydraulic pres- 7.375 inches. This type of design
sure is released. increases cooling area and permits
circulation of air through the rotor
3. They maintain the shoes in cor- resulting in more rapid cooling of
rect adjustment at all times (com- the brake. A splash shield bolted to
parable to the automatic adjusters in the spindle is used primarily to pre-
drum-type brakes).

The cylinders are connected hy-
draulically by means of internal pas-

2-10 G R O U P 2-BRAKES

CALIPER TO ROTOR CLEARANCE TRANSFER TUBE BOOSTER SYSTEM—COMET
PISTON DUST BOOT
CALIPER HOUSING RETAINING GROVE The diaphragm type brake booster
PISTON (optional on Comet and Mustang
SHOE CALIPER DUST models) is a self contained vacuum-
LINING BOOT RETAINER hydraulic braking unit mounted on
PISTON SEAL the engine side of the dash panel.

HI 369.A The vacuum power chamber con-
sists of a front and rear shell locked
F I G . 4—Typical Caliper Assembly—Sectional View together. Within the vacuum cham-
ber are the rubber diaphragm and
vent road contaminants from con- A warning sound feature is incor- the integral valve hub and diaphragm
tacting the inboard rotor and lining porated in the design of the brake plate. The rubber diaphragm fits
surfaces (Fig. 19). The wheel pro- shoes. Metal tabs on the ends of over the plate, and the outer bead
vides protection for the outboard the shoes create an audible metallic, of the diaphragm is locked between
surface of the rotor. scraping noise, when the linings be- the front and rear shells (Fig. 6).
come worn enough to allow the tabs The diaphragm return spring is lo-
OPERATION to contact the rotor. This metal-to- cated between the diaphragm plate
metal contact warns the driver that and the front shell.
As the brake pedal is depressed, the shoes need replacing and is not
hydraulic pressure from the master detrimental to the function of the The valve hub section of the dia-
cylinder forces the pistons out of the disc brake. phragm plate protrudes from the
caliper bores against their respective rear shell. A synthetic rubber seal
shoe and lining assemblies. The A proportioning valve located be- is used between the valve hub and
force of the pistons against the shoes tween the master cylinder and the the rear shell. The seal and the valve
moves the linings against both sides rear brake wheel cylinders provides hub are protected from dirt by a
of the revolving rotor to effect brak- balanced braking action between the rubber guard connected between the
ing action. front and the rear brakes under a air filter at the end of the hub and
wide range of braking conditions. a flange on the rear shell. The con-
During brake application, the rub- (Fig. 22). By regulating the hydrau- trol valve assembly fits into the hub
ber seal on each piston stretches as lic pressure applied to the rear wheel and is connected to the brake pedal
the piston moves against the shoe cylinders, the valve limits rear brak- by the valve operating rod. The con-
(Fig. 5). When the hydraulic pres- ing action when high pressures are trol valve assembly consists of a
sure against the piston is released, required at the front brakes. In this plunger, a valve body which supports
the seal relaxes or rolls back. This manner, premature rear wheel skid a single poppet of flexible rubber,
roll-back action pulls the piston is prevented. The proportioning and two return springs. When the
away from the shoe approximately valve is serviced as an assembly and brake pedal is in the released posi-
0.005-inch to relieve the force of is never adjusted or overhauled. tion the valve return spring holds
the lining against the rotor and, the valve assembly and operating rod
thereby, provide the required run- PISTON away from the diaphragm plate. In
ning clearance. Also, inherent rotor this position, the poppet on the valve
runout contributes to the mainte- BRAKES APPLIED body is off the vacuum port seat
nance of running clearance. Auto- which is a part of the diaphragm
matic adjustment is achieved by the F I G . 5—Function of Piston Seal plate. The poppet return spring like-
pistons sliding in the seals outward wise holds the poppet against the
from the cylinder bores. The piston atmospheric port seat which is a part
gradually changes its position rela- of the plunger.
tive to the seal as the lining wears
and, thus, maintains the correct ad- The hydraulic master cylinder
justment location at all times. which contains all of the components
of the conventional master cylinder
When the brakes are in the un- is bolted to the booster front shell.
applied position, there is no hydrau-
lic pressure to the calipers because BRAKES RELEASED
the fluid source at the master cylin-
der by-passes the residual check HI 370-A
valve.

P A R T 2 - 2 - BRAKE SYSTEM 2-11

FRONT SHELL REAR SHELL
DIAPHRAGM PLATE AND VALVE HUB ASSEMBLY
MASTER CYLINDER

DIAPHRAGM

DIAPHRAGM RETURN SPRING H1324-B

F I G . 6—Cutaway View of Vacuum Booster

The hydraulic push rod forms the front (constant vacuum) chamber of hub section of the diaphragm plate
link between the master cylinder pis- the power unit. In the released posi- to compress the valve return spring
ton and the vacuum power dia- tion (no pressure applied to the brake and force the poppet against the vac-
phragm assembly. The end of the pedal), the valve operating rod and uum valve seat in the diaphragm plate
push rod, that enters the master cyl- valve plunger are held to the rear to "CLOSE" the vacuum port. Any
inder piston, is equipped with a self- in the valve hub by the valve re- additional movement of the valve
locking adjusting screw. The oppo- turn spring to CLOSE the atmos- operating rod in the applied direc-
site end has a piston head which pheric port and OPEN the vacuum tion moves the valve plunger away
enters the diaphragm plate. A seal, port. With the valve in this position, from the poppet valve to "OPEN"
located in the front shell, seals the the rear (control vacuum) chamber the atmospheric port and admit at-
opening between the hydraulic push is also open to vacuum through the mosphere through the air cleaner
rod and the shell. porting in the diaphragm and valve and passages in the diaphragm plate
hub assembly. The diaphragm is then to the rear side of the power cham-
Engine manifold vacuum is sup- "balanced" or suspended in vacuum, ber. With vacuum present on the
plied to the booster through a since vacuum is present on both front side of the diaphragm and
vacuum check valve located in the sides of the power diaphragm. With valve housing and atmospheric pres-
front shell. Air is admitted through the power diaphragm balanced in sure present on the rear side of the
the air filter located at the end of vacuum, the diaphragm return spring diaphragm, a force is developed to
the valve hub. The hydraulic push holds the diaphragm and hydraulic move the vacuum power diaphragm
rod is actuated by pedal pressure push rod in the fully released posi- assembly, hydraulic push rod and
assisted by the diaphragm, which de- tion. With the hydraulic push rod master cylinder piston forward to
rives power from the pressure differ- in this position, the hydraulic com- close the compensating port and force
ential existing between the vacuum pensating port in the hydraulic mas- hydraulic fluid underpressure through
on its front side and atmospheric ter cylinder is OPEN . The open port the residual check valve and brake
pressure on its rear side. A passage permits brake fluid to either return tubes into the brake wheel cylinders.
in the diaphragm plate permits from the brake system to the fluid As hydraulic pressure is developed in
vacuum to pass from the front to reservoir or enter the brake system the brake master cylinder, a counter
the rear side of the diaphragm when from the fluid reservoir to compen- force (to the rear) acting through
the vacuum port opens as the brakes sate for any gain or loss in fluid the hydraulic push rod, sets up a re-
are released. volume. action force against the power dia-
phragm assembly and valve plunger
RELEASED POSITION APPLIED POSITION through the rubber reaction disc (lo-
cated at the end of the hydraulic
With the engine running and the When the brakes are applied (Fig. push rod). The rubber reaction disc
brakes released (Fig. 7), vacuum 8), the valve operating rod and valve acts similar to a column of fluid to
from the intake manifold is admit- plunger move forward in the valve
ted through the check valve to the

2-12 G R O U P 2-BRAKES

VACUUM PORT OPEN HOLDING POSITION
ATMOSPHERIC SOURCE
During brake application, the "re-
ATMOSPHERIC PORT CLOSED action" force which opposes the
force applied by the driver, tends to
VACUUM SOURCE H1325-A close the atmospheric port. When
both atmospheric and vacuum ports
F I G . 7—Booster in Released Position are CLOSED, the booster is said to
be in the holding position (Fig. 9).
distribute the pressure between the bly to close off the atmospheric With both valves closed, any degree
vacuum power diaphragm assembly port. The driver is thus assured a of brake application attained will be
and the valve plunger in proportion "feel" of the brake, since part of held until either the atmospheric
to their respective contact areas. The the counter force reacts through the port is reopened by an increase in
pressure acting against the valve valve plunger, valve operating rod, pedal pressure to further increase
plunger and valve operating rod and pedal linkage against the driver's the brake application or by a de-
tends to move the valve plunger foot. This reaction force is in direct crease in pedal pressure to reopen
slightly to the rear in relation to proportion to the hydraulic pressure the vacuum port to decrease the
the diaphragm and valve hub assem- developed within the brake system. brake application. Whenever the
pressure applied to the brake pedal
VACUUM PORT is held constant for a moment, the
CLOSED valve returns to its holding position.
However, upon reaching the fully
ATMOSPHERIC SOURCE applied position the force applied
to the brake pedal overrules the re-
action force. In this position the
valve plunger and atmospheric valve
seat are held away from the valve
poppet to admit maximum atmos-
pheric pressure to the rear chamber.
With the front chamber open to
manifold vacuum, full power appli-
cation is attained which is referred
to as the "run-out" of the power
unit. Any increase in hydraulic pres-
sure beyond this point must be sup-
plied by physical effort of the driver.

NO POWER CONDITION

It should be noted that in case
of engine failure and consequent loss
of engine vacuum, at least one full
power brake application may be
made from the vacuum in the
booster. With the engine off and no
vacuum in the power system, the
brakes can be applied in the conven-
tional manner by applying more phy-
sical effort to the brake pedal.

VACUUM SOURCE ATMOSPHERIC PORT OPEN BOOSTER SYSTEM—FAIRLANE
Hi 326-A
F I G . 8—Booster in Applied Position The optional power brake booster
is installed on the engine side of the
dash panel and is connected to the
brake pedal through a lever assem-
bly and push rod link.

The booster consists of a vacuum
chamber, atmospheric valve, control
valve plunger assembly, diaphragm,
and an atmospheric chamber (Figs.
10, 11 and 12).

Atmospheric pressure is present at
all times in the atmospheric cham-
ber at the front side of the atmos-
pheric valve. The air intake to the
atmospheric chamber is protected by
an air filter. The atmospheric cham-
ber is separated from the vacuum

P A R T 2-2-BRAKE SYSTEM 2-13

ATMOSPHERIC SOURCE valve operating rod ceases to move
the control valve plunger forward.
ATMOSPHERIC PORT CLOSED However, the unbalanced forces of
atmospheric pressure and vacuum on
VACUUM SOURCE H1327-A each side of the diaphragm will con-
tinue to move the outer sleeve of
F I G . 9—Booster in Holding Position ther movement of the plunger forces the control valve plunger forward
the atmospheric valve off its seat so keeping the vacuum porting closed.
chamber by the bellows assembly that atmospheric pressure from the At the same time, the reaction force
within the vacuum chamber. bellows can enter the hub porting acting through the reaction ring and
that leads to the rear side of the lever assembly will tend to move the
Vacuum is present at all times in diaphragm. atmospheric valve to the closed posi-
that area of the vacuum chamber tion (Fig. 11). When these combined
forward of the diaphragm. Vacuum With vacuum on the front side of forces balance, the porting to the
is supplied through a hose from the the diaphragm and atmospheric pres- vacuum supply will remain closed
intake manifold to the vacuum mani- sure on the back side of the dia- and the atmospheric valve will cut
fold and check valve on the booster phragm, a force is developed to off any further passage of atmos-
body. With this integral check valve move the diaphragm, push rod and pheric pressure to the area behind
and vacuum chamber, it is possible master cylinder piston forward to the diaphragm. Therefore, the power
to obtain several power assisted close the compensating port and assist force acting on the master cy-
brake applications with the engine force hydraulic fluid under pressure linder piston will stabilize and the
shut off. This arrangement makes a through the residual pressure check hydraulic force applying the brakes
vacuum reservoir unnecessary. valve and brake tubes to the wheel will be maintained at a constant
brakes. As hydraulic pressure is de- level.
Either vacuum from the forward veloped in the hydraulic system, a
side of the diaphragm or air from reaction counter-force acts against RELEASED POSITION
the bellows (atmospheric chamber) the reaction lever and ring assembly.
can be connected to the rear side of This reaction lever and ring assem- When the pedal pressure is re-
the diaphragm through porting in bly is designed to transmit the reac- leased from the valve operating rod
the control valve hub and the tion forces back through the actuat- and plunger assembly, the plunger
plunger assembly. ing control valve assembly to the return spring moves the plunger
brake pedal and provide the driver away from the atmospheric valve
APPLYING POSITION with a resistance that is in propor- allowing the valve to seat against the
tion to the brake hydraulic apply hub (Fig. 12). This seating of the
As the brake pedal is depressed, forces. This is the means of provid- valve closes off the bellows chamber
the valve operating rod and valve ing the proper "driver feel" to the from the hub porting that connects
plunger assembly move forward power brake unit. to the rear side of the diaphragm.
compressing the plunger return At the same time, the rearward
spring (Fig. 10). The initial move- HOLDING POSITION movement of the plunger opens the
ment of the plunger closes the port- porting from the vacuum chamber
ing from the vacuum chamber pre- When the forward motion of the and draws out the air from the rear
venting further evacuation of the brake pedal is stopped and held, the side of the power diaphragm. With
area back of the diaphragm. Fur- vacuum on both sides of the dia-
phragm, the assist force against the
master cylinder push rod is elim-
inated.

Also, a pressure differential is cre-
ated by the presence of vacuum on
the rear (small diameter) side of the
valve hub and atmospheric (bellows)
pressure on the front (large diam-
eter) side. This pressure differential
moves the valve hub and, with it,
the valve plunger and diaphragm as-
sembly back to the released position.
This releasing action permits the
brake shoe retracting springs, acting

2-14 G R O U P 2-BRAKES

F I G . 10—Booster in Applying Position through the wheel cylinder pistons
and the hydraulic fluid, to return
the master cylinder piston and push
rod to the released position.

With the piston and push rod in
the released position, the hydraulic
compensating port in the master cyl-
inder is open. The open port per-
mits fluid to either return from the
brake system to the fluid reservoir,
or enter the brake system from the
reservoir.

H1357-A PARKING BRAKES

An independent hand - operated
parking brake control actuates the
rear wheel brake shoes through a
cable linkage. The operating cable
is routed from the parking brake
control assembly to the equalizer
lever which is attached to the equal-
izer assembly. The rear brake cables
connect the equalizer assembly to the
parking brake lever at each rear sec-
ondary shoe as shown in Figs. 1
and 2.

When the handle is pulled the pri-
mary and secondary brake shoes are
forced against the rear brake drums.
The handle is held in the applied
position by the engagement of a
spring loaded pawl with a ratchet.
Turning the handle counterclockwise
disengages the pawl from the ratchet
to release the brakes.

PART 2-2-BRAKE SYSTEM 2-15

VACUUM PORT
CLOSED

H1358-A

F I G . 1 1 — Booster in Holding Position

2-16 G R O U P 2-BRAKES

ATMOSPHERIC
PORT CLOSED

VACUUM
ATMOSPHERE

H1359-A

F I G . 1 2—Booster in Released Position

IN-CAR ADJUSTMENTS AND REPAIRS

BRAKE SHOE ADJUSTMENTS 1. After the shoes have been in- 3. Remove the drum. Mark the
stalled or the adjusting screw has tooth on the star-wheel where the
The car should be in a raised posi- been turned, install the drum. Be adjusting lever contacts it. While
tion with the wheels off the floor. sure that all excess grease, oil, and
other foreign material are wiped off Brake Shoe Adjusting Tool H I 1 22-A
The hydraulic service brakes are the backing plate and drum.
self-adjusting and require a manual F I G . 13—Expanding Brake Shoes
adjustment only after the brake Before installing the brake drum
shoes have been relined, replaced, or on the front wheel spindle, wipe the
when the length of the adjusting spindle completely free of grease.
screw has been changed while per- Install the drum carefully so that
forming some other service opera- the grease seal retainers within the
tion. hub will not be damaged.

The brake drums should be at 2. Remove the adjusting hole
normal room temperature when ad- cover from the backing plate. Work-
justing the brake shoes. If the shoes ing from the backing plate side, turn
are adjusted when the drums are the adjusting screw upward to ex-
hot and expanded, the shoes may pand the shoes (Fig. 13). Expand
drag when the drums are cool and the shoes until a drag is felt when
contracted. the drum is rotated.