Fordrazborka.zu8.ru manua79 ford lincoln mercury

GROUP AND PART INDEX
IDENTIFICATION CODES 10-01 VOLUME 1 CHASSIS
G E N E R A L W H E E L AND T I R E S E R V I C E
W H E E L HUBS AND BEARINGS - Front .
WHEELS AND T I R E S - Drop Center Rim
11-01
11-10
.11-02
DISC B R A K E S - Sliding Caliper
DRUM B R A K E S - Single Cylinder, Dual Piston
G E N E R A L H Y D R A U L I C B R A K E S E R V I C E . . . . . .
HYDRO-BOOST B R A K E BOOSTER
PARKING B R A K E - Cable'Actuated - Rear Wheels
VACUUM B R A K E BOOSTER - Dash Mounted . . . .
12-20
12-02
12-01
12-51
12-70
12-50
G E N E R A L S T E E R I N G S E R V I C E
I N T E G R A L POWER R A C K AND PINION S T E E R I N G G E A R - Ford.
- T R W
I N T E G R A L POWER S T E E R I N G G E A R - Ford .
- Saginaw
MANUAL S T E E R I N G G E A R - Rack and Pinion
- Worm and Recirculating Ball < <
NON-INTEGRAL POWER S T E E R I N G SYSTEM - Ford
POWER S T E E R I N G PUMPS - Ford Model Cll .
- Saginaw
S T E E R I N G COLUMNS - Conventional (Convoluted Absorber Type) .
- Mini (Extruded Absorber Type) .
- Modular I (Extruded Absorber Type)
S T E E R I N G LINKAGE
13-01
13-46
13-47
13-41
13-42
13-32
13-30
13-40
13-51
13-52
13-03
13-04
13-06
, 13-20
FRONT SUSPENSION - Spring on Lower Arm
- Spring on Upper Arm
— Single Arm . ,
G E N E R A L SUSPENSION S E R V I C E
R E A R SUSPENSION -
- Leaf Springs . ..
Coil Springs
14-03
14-04
14-05
14-01
14-32
14-30
* D R I V E SHAFT - Double Carden Type U-Joint
- Single Carden Type U-Joint .
DRIVING A X L E S AND D R I V E SHAFTS . . . . .
I N T E G R A L C A R R I E R A X L E - Conventional
- Ford (WGX)
REMOVABLE C A R R I E R A X L E - Ford
TRACTION-LOK LIMITED SLIP D I F F E R E N T I A L - Ford
SUSPENSION
GROUP 14 (3000 5000)
DRIVING AXLES
AND DRIVESHAFTS
GROUP 15 (4000)
http://fordrazborka.zu8.ru/

foreword . .
This 1979 Car Shop M a n u a l has been prepared to provide information covering normal service repairs a n d
maintenance for 1979 Ford for 1979 Ford Passenger Cars manufactured in the United States a n d C a n a d a .
It is divided into five volumes, each covering a specific major a r e a :
Volume 1 — Chassis
Volume 2 — Engine
Volume 3 — Electrical
Volume 4 — Body
Volume 5 — Maintenance a n d Lubrication.
Information in each volume is divided into Groups covering a general system. The table of contents on the
cover of each volume indicates the G r o u p title, number, a n d volume in which each G r o u p is located.
For 1979, the basic part number for components covered in the Groups is also included in parenthesis after
the G r o u p number.
Example: Cooling System G r o u p 27 (8000)
General System Covered Group Number Basic Part Number
in Group for Cooling System
Components
Some components covered within a G r o u p d o not have the same basic part number. In these cases, more
than one p a r t number will a p p e a r on the G r o u p index.
Example: Gasoline Engines G r o u p 21 (6000 & 9000)
General System
Covered in Group
Basic Part
Number for
Gasoline
Engine
Components
Intake and
Exhaust Manifold
Basic Part
Number Only
For easy reference, information in each G r o u p has been divided into smaller units or Parts. There is one Part
for each component in the system, as well as a General Service Part in some Groups to cover procedures
common to several components within the G r o u p . In general, each Part contains the Description, O p e r a t i o n ,
Diagnosis a n d Testing, Removal a n d Installation a n d Disassembly a n d Assembly procedures for the compo
nent covered in the Part. Diagnosis Charts are also included in some Parts to help you systematically locate
a n d service conditions encountered. In most cases, specifications are included at the end of each Part.
To aid in locating specific items in this m a n u a l , the index at the front of each volume provides an alphabeti
cal listing, with page number, for all Parts in the volume. The t a b locator on the right side of this index will
help you find the first p a g e of each G r o u p .

O n the first page of each G r o u p there is an index listing the Part title a n d Part number for each component
covered within the G r o u p . The first p a g e of each Part contains an index to locate service operations covered
in that Part. This Group-Part b r e a k d o w n is also indicated in the page number located at the top of each
p a g e .
E x a m p l e : 11-02-21 = ( G r o u p ) 11 — (Part) 0 2 — ( P a g e ) 21
Metric conversion tables have been included at the back of each volume to a i d in converting specifications
in this manual to the metric equivalent.
The descriptions a n d specifications in this manual were in effect at the time this manual was a p p r o v e d for
printing. Ford M o t o r C o m p a n y reserves the right to discontinue models at any time, or change specifica
tions or design without notice and without incurring obligation.
p p Ford Parts and Service Division
Training and Publications Department

10-01-1 Pre-Delivery, Maintenance a n d Lubrication 10-01-1
Identification Codes
P A R T
1 0 - 0 1
SUBJECT PAGE
GENERAL DESCRIPTION
Official Vehicle Identification
Number . . . 01-1
SUBJECT P A G E
GENERAL DESCRIPTION (Cont'd.
Vehicle Certification Label
IDENTIFICATION CODES
0 1 - 1
0 1 - 3
GENERAL DESCRIPTION
O F F I C I A L V E H I C L E I D E N T I F I C A T I O N
N U M B E R ' '
The official Vehicle Identification Number (VIN)(Fig.
1) for title and registration purposes is stamped on a
metal tab that is fastened to the instrument panel close
to the windshield on the driver's side of the car and is
visible from outside.
V E H I C L E C E R T I F I C A T I O N L A B E L
The Vehicle Certification Label (V.C. Label)(Fig. 1) is
affixed on the left front door lock face panel or door
pillar. The upper half of the label contains the name of
manufacturer, month and year of manufacture, Gross
Vehicle Weight Rating (GVWR), Gross Axle Weight
Rating (GAWR), and the certification statement.
The V.C. label also contains the Vehicle Identification
Number. This number is also used for w a r r a n t y
identification of the vehicle. The first number indicates
the model year. The letter following the model year
number indicates the manufacturing assembly plant.
The next two numbers designate the Body Serial Code
followed by a letter expressing the Engine Code.
The last six digits of the Vehicle Identification
Number indicate the Consecutive Unit Number of each
unit built at each assembly plant. The Consecutive Unit
Numbers begin as follows:
100 001 thru 600 0 0 0 — F o r d , LTD II, G r a n a d a ,
Mustang, Thunderbird, Fairmont, Pinto, Ranchero.
600 001 thru 999 999—Mercury, Cougar, Zephyr,
Monarch, Mercury Bobcat, Versaille, Capri, Lincoln,
Mark V.
The remaining information on the V.C. Label consists
of the following vehicle identification codes:
The COLOR code consists of two or four digits. The
first two digits represent the exterior body color. If the
vehicle is equipped with a vinyl roof, the second two
digits will indicate the style and color of the vinyl roof.
The DSO (District Sales Office) code is two digits,
designating the sales district where the vehicle was
ordered.
The BODY code consists of two numerals and one
letter, indicating the car line and body style.
The TRIM code consists of two letters. The first letter
indicates the type of trim and the second letter indicates
the color of the trim.
The SCHEDULE DATE is a t h r e e d i g i t c o d e
d e s i g n a t i n g the d a y a n d month the vehicle was
scheduled to be built.
The AXLE code consists of a single number. The
number indicates the ratio and type of axle installed in
the vehicle.
The T R A N S M I S S I O N code is a single letter
indicating the type and model of the transmission
installed in the vehicle.
The A.C. code is the letter A. It w i l l be shown on the
label if the vehicle is air conditioned.
The following charts provide the various codes and
their respective identification:

1 0 - 0 1 - 2 Identification Codes 1 0 - 0 1 - 2
9S63H100001 ^
(VEHICLE IDENTIFICATION NUMBER)
MFD. BY FORD MOTOR CO. IN U.S.A.
DATE: OK. 78
GAWR: FRONT 3222
THIS VEHICLE CONFORMS TO A L L
APPLICABLE FEDERAL MOTOR
VEHICLE SAFETY STANDARDS IN
EFFECT ON THE DATE OF MANU
FACTURE SHOWN ABOVE.
GVWR 65 38
REAR 3375
9S63H10000I
VEH/TOENT. NO.
F00I2/R0165-
PASSENGER
I TYPE
I BODY I TRIM
• E l
I SCH. DATE I AXLE I TRANS. | A/C
[08Hl ED QD 00
t ~ — r — t — r ~ t — f — r — t
©0© © ® ® ® ® ®
MFD. BY FORD MOTOR CO. IN U.S.A.
DATE: 0 8 7 8
GAWR: FRONT 3250
GVWR 6566
REAR 3375
THIS VEHICLE MANUFACTURED FOR
EXPORT ONLY ON DATE
SHOWN ABOVE.
F0000 R0227
9S63H100002 PASSENGER
VEH. I DENT. NO. I TYPE
COLOR | DSO I BODY | TRIM SCH. DATE | AXLE | TRANS. A/C
IicyaI fiol 1S3H I E m in QD LU
• ®
• ®
( E X P O R T )
( U N I T E D S T A T E S )
© CONSECUTIVE UNIT NO.
© BODY SERIAL CODE
© MODEL YEAR CODE
© ASSEMBLY PLANT CODE
© ENGINE CODE
© BODY COLOR CODE
© VINYL ROOF TYPE/COLOR
© DISTRICT - SPECIAL EQUIPMENT
© B O D Y TYPE CODE
© TRIM CODE (First Letter -
Type of Trim; Second Letter
Color of Trim)
@ SCHEDULED BUILD DATE
@ REAR AXLE CODE
@ TRANSMISSION CODE
( 5 ) AIR CONDITIONING
@ VEHICLE TYPE
(S) ACCESSORY RESERVE
MFD. BY FORD MOTOR CO. OF CANADA LTD.
NOTE:
CANADIAN LABEL
PARALLELS U.S.A.
LABEL EXCEPT
FOR WORDING
"MFD. BY FORD
MOTOR CO. OF
CANADA LTD.
VEH. IDENT. NO. I TYPE
COLOR | DSO TRIM I SCH. DATE j AXLE I TRANS. A/C
( C A N A D A )
FIG. 1 Vehicle Identification a n d Certification Labels

IDENTIFICATION CODES
ASSEMBLY PLANTS.AND CODE L E T T E R S
Code District Model
A Atlanta Ford
G . Chicago Thunderbird
F Dearborn Mustang-Capri
K Kansas City Fairmont-Zephyr
H Lorain LTD ll-Cougar-XR7-
Ranchero
J Los Angeles Ford-Thunderbird
U Louisville Ford
E Mahwah Granada-Monarch-Fairmont-
Zephyr
T Metuchen Pinto-Bobcat
S (Pilot) Allen Park All
Z St. Louis Mercury
R San Jose Pinto-Bobcat-Mustang
W Wayne Granada-Monarch-Versailles,
Y Wixom Lincoln-Mark V
B Oakville
Passenger Ford
X St. Thomas Fairmont-Zephyr
ENGINE CODES
Code No.of Cyls. Litres CID Venturi
Y 14 2.3 139/2V
W 1 4 2.3 139/2VT. C.
z V6 2.8 169/2V
T 1 6 3.3 200/IV
L 16 4.1 250/IV
F V8 5.0 302/2V
. H V8 5.8 351/2V
S V8 6.6 400/2V
T . C . - Turbo Charged
TRANSMISSION CODES
Code Type
MANUAL
5 4 Speed Overdrive
6 4 Speed @
7 4 Speed (b)
AUTOMATIC
V XP(C-3)
W XP(C-4)
X FMX
U XPL(C-6)
Z XPL (Special)
S JATCO
Y Borg Warner
@Borg-Wamer (b) Hummer
DISTRICT CODES
LINCOLN-MERCURY
Code
00 Special
11 Boston
15 New York
16 Philadelphia
17 Washington
21 Atlanta
22 Dallas
23 Jacksonville
26 Memphis
31 Buffalo
32 Cincinnati
33 Cleveland
34 Detroit
41 Chicago
42 St. Louis
'46 Twin Cities
51 Denver
52 Los Angeles
53 Oakland
54 Seattle
84 Home Off. Reserve
90's Export
FORD OF CANADA
Mercury Ford
Code Region Code
A1 . Central B1
A2 . Eastern B2
A3 . Atlantic B3
A4 . Midwestern . B4
A 6 . . . . Western B6
A7 . Pacific B7
A8 . Great Lakes B8
12 12
REAR A X L E RATIO CODES
Code
Conv / Lock Axle Ratio
G 2.26
B . . . . 2.47
*1 . J 2.50
8 . H 2.73
2 . K . . . . 2.75
3 . L 2.79
6 . 0 . . . . 3 0 0
Y 3.08
F . w . . . . 3.45
*Numeric one (1)
DISTRICT CODES
FORD
EXTERIOR PAINT COLOR CODES
Code District
00 Special
11 Boston
12 Buffalo
13 New York
14 Pittsburgh
15 Newark
16 Philadelphia
17 Washington
21 Atlanta
22 Charlotte
23 Memphis
24 Jacksonville
25 Richmond
26 New Orleans
28 Louisville
41 Chicago
42 Cleveland
43 Milwaukee
45 Lansing
46 Indianapolis
47 Cincinnati
48 Detroit
52 Dallas
53 Kansas City
54 Omaha
55 St. Louis
56 Davenport
57 Houston
58 Twin Cities
71 Los Angeles
72 San Jose
73 Salt Lake City
74 Seattle "~
75 Phoenix
76 Denver
83 Government
84 Home Off. Reserve
85 American Red Cross
86 Recreational Veh. Pool
87 Body Company
89 Transportation Services
90's. : Export
Code Ref.#= Color Spec Code Ref.# Color Spec Code Ref.# Color Spec
1C 1724A Black J A S A X X A 62 5531A Antique Gold HVFAXXA CLEAR COAT (POLISH)
1G 5299A Silver Metallic. S P L C X X A 64 5574A Bright Yellow G V T A X X A 1S 5537A Med. Gray Metallic GPUCWWA
1N 5476A Dove Grey E P L A X X A 76 5610A Light Medium Pine MMLAXXA 1Y 5586A Silver Metallic FPLWWWA
1P 5523A Med. Grey Metallic CPPCXXA 8N 5496A Dk. Cordovan Metallic EFSCXXA 2W 5646A Light Red Metallic CDKWWWA
2J 3059 A Maroon J D Q A X X A 83 5524A Light Chamois GTJAXXA 2D 5614A Lt. Amethyst Metallic MJJWWWA
2P 5647A Bright Red MDUAXXA 85 5533A Tangerine G E J A X X A 23 5552A Dk. Red Metallic CDPWWWA
2M 3413A Dark Red NDNAXXA 9D 5418A White ZWFAXXA 3Q 5588A Dk. Blue Metallic MBRCWWA
3F 5608A Light Medium Blue M B L A X X A 38 5563A Diamond Blue Metallic GBLWWWA
3J 5593A Bright Blue MBQAXXA GLAMOUR COLORS " D " NON POLISH 4B 5603A Dark Beryl Metallic MKQCWWA
3L 5616A Dark Blue Metallic MBRCXXA 2H 5636A Medium Red Metallic MDTDXXA 4C 5602A Med. Beryl Metallic MKMWWWA
34 5041A Wedgewood Blue SBPAXXA 3H 5613A Lt.Wedgewood Blue Met. 5A 5571A Dk. Champagne Met. GUQCWWA
4D 5635A Dark Pine Metallic MMPCXXA MBMDXXA 5C 5570A Lt. Champagne Met. GUUWWWA
46 5328A Dark Jade Metallic A K Q C X X A 5N 5698A Med. Dark Orange Met. MENDXXA 5R 5534A Dk. Cordovan Met. EFSCWWA
5P 5607A Pastel Chamois MFGAXXZ 5W 5599A Med. Vaquero Met. MZMDXXA 66 5565A Jubilee Gold Met. GYLWWWA
5Q 5477A Dark Brown Metallic Y T Q C X X A 7L 5483A Med. Jade Metallic E R L D X X A 88 5572A Lt. Apricot Met. CCLWWWA
52 5535A Light Champagne G U H A X X A 75 5609 A Med. Pine Metallic MMMDXXA
Lt. Apricot Met.
6P 5406A Cream A V F A X X A 8J 5484A Med. Tan Metallic EUMDXXA
6W 5439 A Light Gold C V L A X X A 8W 5491A Chamois Metallic ETTDXXA
CY1411-2L

BODY SERIAL AND STYLE CODES
Body Body Body Body
Serial Style Serial Style
Vehicle Code Code Body Type Model Vehicle Code Code Body Type Model
Pinto 10 62B 2 Door Sedan Base Bobcat 20 64H 3 Door Sedan U.S.A. & Canada
11 64B 3 Door Sedan Base 22 73H Wagon (2 Door) U.S.A. & Canada
12 73B Wagon (2 Door) Base 23 62B 2 Door Sedan Canada Only
Mustang 02 60 F 2-Dr. Notchback Base
24 64B 3 Door Sedan Canada Only
03 69F 3-Dr. Hatchback Base 25 73B Wagon {2 Door) Canada Only
05 69R 3-Dr. Hatchback Mach I Capri 14 61D 3 Door Fastback
04 60H 2-Dr. Notchback Ghia 16 61H 3 Door Fastback Ghia
Fairmont 92 54B 4 Door Sedan Base Zephyr 32 54D 4 Door Sedan Base
91 66B 2 Door Sedan Base 31 66D 2 Door Sedan Base
93 36 R 2 Door Sedan Sporty Coupe 35 36R 2 Door Sedan Sporty Coupe
94 74B Wagon Wagons (4 Door) 36 74D Wagon Wagons (4-Dr.)
Granada 82 54H 4 Door Sedan Base Monarch 34 54H 4 Door Sedan Base
81 66H 2 Door Sedan Base 33 66H 2 Door Sedan Base
LTD II 27 53B 4-Dr. Pillar Hardtop LTD II S Versailles 84 54M 4 Door Sedan
25 65B 2-Dr. Hardtop LTD II S Cougar 92 53D 4-Dr. Pillar Hardtop Cougar
31 53D 4-Dr. Pillar Hardtop LTD II 91 65D 2 Door Hardtop Cougar
30 65D 2-Dr. Hardtop LTD II 93 65L 2 Door Hardtop Cougar XR 7
47 97D 500 LTD II Ranchero
48 97 R GT LTD II Ranchero Mercury 62 54H 4 Door Sedan Marquis
49 97K Squire LTD II Ranchero 61
64
63
74
66H
54K
66K
74H
2 Door Sedan
4 Door Sedan
2 Door Sedan
Marquis
Marquis
Marquis Brougham
Marquis Brougham
Wagons (4 Door)
Ford 63
62
63
54 H
66 H
54H
4 Door Sedan
2 Door Sedan
4 Door Sedan
$ Custom 500
S Custom 500
LTD
61
64
63
74
66H
54K
66K
74H
2 Door Sedan
4 Door Sedan
2 Door Sedan
Marquis
Marquis
Marquis Brougham
Marquis Brougham
Wagons (4 Door)
62 66H 2 Door Sedan LTD Canada Only 62 54H 4 Door Sedan Meteor
65 54K 4 Door Sedan LTD Landau
61 66H 2 Door Sedan Meteor
64 66K 2 Door Sedan LTD Landau 74 74H Meteor Wagon (4 Door)
74
74
74H
74H
SCu
$ Custom 500
LTD
Wagons (4 Door)
Wagons (4 Door)
- RPO
74
74
74H
74H
SCu
$ Custom 500
LTD
Wagons (4 Door)
Wagons (4 Door)
- RPO
Mark V 89 65D 2 Door Hardtop Base
74
74
74H
74H
SCu itorn 500 for Canada
Wagons (4 Door)
Wagons (4 Door)
- RPO
Lincoln 82 53B 4-Dr. Pillar Hardtop Base
81 60B 2-Dr. Pillar Hardtop Base
Thunderbird 87 60H 2-Dr.Pillar Hardtop Base
81 60B 2-Dr. Pillar Hardtop Base
CY1615-2F
VINYL ROOF TYPE AND COLOR IDENTIFICATION
Code Vinyl Type Code Vinyl Color Code Vinyl Color
7 Amethyst Y Gold, Jubilee
K Beryl, Medium S Gray, Dove
A Black R Jade/Dark Midnight
B Blue, Diamond/Blue, Light M Pine
Q Blue, Midnight 8 Red Dark (Versailles Only)
V Camel/Cream Red Midnight
T Chamois D Red Dark (Others)/Red Bright/
J Champagne, Dark Red Medium
U Champagne, Light P Silver
F Cordovan, Dark Z Vaquero
N Cordovan, Light w White
H Grande Full
P Grande Half
W Lugano Full
X Lugano Half
K Lugano Front Half
V Valino Full
Y Valino Half
Z Valino Front Half
T Valino Coach
C Convertible Rood, Simulated, Diamond
J Cavalry Twill - Coach
When a Vinyl Rood is installed the type and color codes will be reflected after the two digit Exterior Paint Color Code.
CY1615-1F1

T 1 - 0 1 - 1 Wheels and Tires 11-01-1
PART TITLE PART NO.
General Wheel and Tire Service 11-01
Wheels and Tires - Drop Center Rim 11-02
Wheel Hubs and Bearings - Front 11-10
PART TITLE
Wheel Hubs and Bearings - Rear - Refer to
Rear Axles, Parts 15-02, 15-03,15-06 or 15-10
General Wheel and Tire Service
PART
11-01
Applies to All Models
SUBJECT PAGE SUBJECT PAGE
ADJUSTMENTS
Front Wheel Bearing Maintenance
Tire Sizes
Wheel Balancing
.01-1
.01-1
.01-1
CLEANING AND INSPECTION
Tire Inspection
Wheel Inspection
01-3
.01-3
SPECIFICATIONS . . 0 1 4
CF2809-2A
ADJUSTMENTS
W H E E L B A L A N C I N G
Use the instructions provided with the Rotunda
Wheel Balancer or equivalent dynamic type wheel
balancer to balance the wheels.
Be sure brakes are not dragging before spinning the
wheels. On vehicles equipped with disc brakes, push the
brake shoes into the caliper to free the rotor.
F R O N T W H E E L B E A R I N G M A I N T E N A N C E
Wheel bearings can be adjusted to correct bearing
and spindle shoulder wear. Long bearing life depends
on proper adjustment and correct lubrication.
If bearings are too tight, they will overheat and
wear rapidly. Loose bearings can cause pounding
a n d contribute to u n e v e n tire w e a r , s t e e r i n g
difficulties, and inefficient braking.
Check bearing adjustment at regular inspection
intervals. Refer to Part 11-10 for front wheel bearing
service instructions.
TIRE S I Z E S
It is m a n d a t o r y t o use o n l y t h e t i r e sizes
recommended on the tire chart attached to the vehicle.
Larger or smaller tires can damage the vehicle and
affect durability and m a y require changing the
speedometer drive gears. Be sure wheel size and
offsets match those recommended for the tire in use
(Figs. 1 and 2).
Be sure all tires (including snow tires) and wheels on
the vehicle are the same size, type, and load-carrying
capacity. Never mix radial, belted, and conventional-
type tires.
Use the instructions provided with the Rotunda Tire
Changer 35-0010 or equivalent to install tires.

11-01-2 General W h e e l a n d Tire Service 1 1 - 0 1 - 2
Car Line Code Color/Stripe
Wheel
Size
No. of
Bolts
Bolt
Circle
Dia. Offset Tire Usage Size
Pinto/Bobcat GM Yellow-Yellow 1 3 x 5 4 4.25 .62 A70,A78,B78,BR78,BR70 -13
MH Styled-Steel
(Argent)
Pink-Pink
1 3 x 5 4 4.25 .62 A70,A78,B78,BR78,BR70 -13
SH Alum.-Forged 13 x 5.5 4 4.25 .39 A78,B78,BR78,BR7() -13
RW Alum.-Forged
Painted White
13 x 5.5 4 4.25 .39 BR70,B78,BR78,A78 -13
MH Pink-Pink
Styled-Steel
1 3 x 5 4 4.25 .62 A78,B78,BR78,BR70 -13
es Cast-Alum. 13 x 5.5 4 4.25 .39 A78,B78,BR70,BR78 13
Mustang/Capri TS Semi-Styled
(Black)
Green-Orange
1 3 x 5 4 4.25 1.12 B78,C78 13
TS Semi-Styled
(Argent)
Green-Orange
1 3 x 5 4 4.25 1/12 B78,C78 13
RV Styled-Steel
(Argent)
Red-Violet
14 x 5.5 4 4.25 1.12 B78,C78,BR78,CR78 14
MF Brown-Pink 1 4 x 5 4 4.25 1.12 B78,C78,BR78,CR78 14
- Cast-Alum. 14 x 5.5 4 4.25 1.12 B78,C78,BR78,CR78 14
_ Forged-Alum.
TRX
390x 150 4 4.25 1.00 190/65 390
Fairmont/Zephyr MF Brown-Pink 1 4 x 5 4 4.25 1.12 B78,BR78,C78,CR78,DR78 -14
Alum.-Cast 14 x 5.5 4 4.25 1.12 C78,CR78,DR78 -14
RV Styled-Steel
(Argent)
Red-Violet
14 x 5.5 4 4.25 1.12 CR78 -14
WN Yellow-Green 14 x 5.5 4 4.25 1.12 CR78,OR78 -14
OH Orange-Violet
(Pol./Tax./F!eet)
14x5.5 4 4.25 1.12 195/70HR, DR70,DR78,CR78 -14
Granada/Monarch HR Green-Green 1 4 x 6 5 4.50 .00 DR78,ER78,FR78,D78 F78* -14
KZ Styled-Steel
Orange-Orange
1 4 x 6 5 4.50 .00 DR78,ER78,FR78 -14
BZ Alum.-Cast 14 x 6 5 4.50 .00 DR78,ER78,FR78 -14
WP Alum.-Cast
White
1 4 x 6 5 4.50 .00 DR78,ER78,FR78 -14
NR Violet-Yellow 1 4 x 6 5 4.50 0.0 OR78,ER78,FR78,D78*,F78* -14
Versailles MM Alum.-Forged 1 4 x 6 5 4.50 .00 FR78 -14
NR Green-Green 1 4 x 6 5 4.50 .00 F78* -14
Ranchero HG Styled-Steel
White-Red
1 4 x 7 5 4.50 .25 HR78 -14
GK White-Brown 1 4 x 6 5 4.50 .25 HR78 -14
LTD II - Cougar El Pink-Pink 1 5 x 6 5 4.50 .45 HR78.H78 -15
AK Pink-Green 15x6.5 5 5.00 .45 Police Interceptor -15
JL Violet-Violet 14 x 5.5 5 4.50 .25 HR78,H78* -15
HG Styled-Steel 1 4 x 7 5 4.50 .25 HR78 -14
LTD II - Cougar - Cougar
XR-7 - Th under bird
AL Alum.-Cast 15 x 6.5 5 4.50 .45 GR78 -15
Cougar XR-7 - Thunderbird El Pink-Pink 1 5 x 6 5 4.50 .45 HR78 -15
FA Gray-Gray 15x6.5 •5 4.50 .45 HR70 -15
GG Poly-Cast
Red-Brown
1 5 x 6 5 4.50 .45 HR78 -15
GC Yellow-Brown 1 5 x 6 5 4.50 .45 H70,HR70 -15
AL Alum.-Cast 15 x 6.5 5 4.50 .45 HR70,HR78 -15
Cougar XR-7 GG Poly-Cast
Red-Brown
1 5 x 6 5 4.50 .45 HR78 -15
F1820-2N1
FIG. 1 C a r T i r e / W h e e l Combinations

1 1 - 0 1 - 3 General Wheel a n d Tire Service 1 1 - 0 1 - 3
W H E E L I N S P E C T I O N
Inspect the hub nuts and torque to 80-105 ft-lbs
(109-142 N.m). Loose hub nuts can cause shimmy and
vibration, and may also distort the stud holes in the
wheels.
Be sure wheels and hubs are clean. Stones wedged
between the wheel and rotor or rear drum or lumps of
mud and grease can unbalance the wheel.
Check for wheel damage. Wobble or shimmy caused
by a d a m a g e d wheel will eventually d a m a g e the
bearings. Inspect the rims for dents that could leak air.
1978 CAR TIRE/WHEEL COMBINATIONS
Car Line Code Color/Style
Wheel
Size
No. of
Bolts
Bolt
Circle
Dia. Offset Tire Usage Size
Cougar Sedans/LTD II 2-Door
Spt. Sedan Option
HG Styled-Steel
White-Red
. 1 4 x 7 5 4.50 .25 HR78 -14
Lincoln/Mark V YA Red-Green 1 5 x 6 5 5.00 .45 JR78, 225, LR78, 230, L78* -15Lincoln/Mark V
AD Alum.-Forged 1 5 x 6 5 5.00 .45 JR78, 225, LR78, 230 -15
Lincoln/Mark V
EW Alum.-Cast 1 5 x 6 5 5.00 .45 JR78,225, LR78, 230 -15
Lincoln/Mark V
XA White-Yellow 15-5.5 5 5.00 .45 J76* -15
YS Orange-Brown
(Alt)
1 5 x 6 5 5.00 .45. JR78, 225, LR78, 230
L78*
-15
* Collapsible Spare
F1820-2N2
FIG. 2 C a r T i r e / W h e e l Combinations
Inspect the front hubs and bearings whenever the
hubs are removed, or at regular inspection intervals.
TIRE I N S P E C T I O N
Inspect tires for wear. Abnormal or excessive wear
may be caused by incorrect wheel alignment, wheel/tire
imbalance, or improper tire pressure. Figure 3 shows
typical wear patterns.

11-01-4 General W h e e l a n d Tire Service 1 1 - 0 1 - 4
INCORRECT TOE-IN OR EXTREME CAMBER FEATHERING DUE TO MISALIGNMENT F1467-2E
FIG. 3 Tire W e a r Conditions
SPECIFICATIONS
TORQUE LIMITS - FT-LBS (N-m)
Wheel Attaching Nuts
- All Cars 80-105 (109-142)
CF2559-1B

11-02-1 Wheels a n d T i r e s — D r o p Center Rim 11-02-1
Wheels and Tires
Drop Center Rim
PART
11-02
Applies to ASI Vehicles
DESCRIPTION
Collapsible Spare Tire
Front Wheel Assembly
Rear Wheel Assembly
REMOVAL AND INSTALLATION
Hoisting Instructions
02-1
02-1
02-1
02-2
REMOVAL AND INSTALLATION (Cont'd.)
Removing and Installing Tire 02-2
Wheel and Tire Installation 02-2
Wheel and Tire Removal 02-2
DESCRIPTION
COLLAPSIBLE SPARE TIRE
The Collapsible Spare Tire for Thunderbird,
Continental Mark V, Lincoln Continental, Granada,
Monarch, Versailles, LTD II, Cougar and Cougar XR-7
is installed on the wheel in a deflated condition and
protrudes barely beyond the rim of the wheel.
The collapsible space saver spare tire is designed to
provide more luggage room. A can of tire inflation
propellant is provided with the tire, and is located in
the l u g g a g e c o m p a r t m e n t . B e s u r e , t o r e a d all
instructions on the can and collapsible spare tire
before u s e . Do not u s e t h i s tire for e x t e n d e d
m i l e a g e or for s p e e d s a b o v e 50 n i p h . Do not
exceed the vehicle maximum load rating. Do not
use tire chains with this tire. Do not exceed 35 psi air pres
sure.
Directions For Use
1. If temperature is 1 0 ° F or below, warm inflator
before use. Place inflator over defroster outlet of
car, set heater for "defrost" at highest temperature
and run blower at highest setting for a minimum of
10 minutes.
2. Install Collapsible Spare Tire and wheel assembly
on car with air valve at bottom before inflating tire
(see diagram on inflator bottle).
3. Remove plastic cap from inflator and valve cap
from tire. Push inflator onto valve stem until sound
of gas entering tire can be heard.
While inflating, keep hands off the metal parts
of the inflator, since it becomes extremely cold
during discharge. W h e n c o m p l e t e l y used, the
inflator will fill the tire within specifications.
4. One minute after sound stops, remove inflator and
replace valve cap. When first filled or after car has
been standing for a considerable length of time, the
tire may not appear fully inflated. In this case, drive
slowly for the first mile; this will increase, the
pressure in the tire.
5. Dispose of the inflator in a safe waste receptable.
Do not incinerate or puncture.
6. Remove the Collapsible Spare Tire as soon as the
conventional tire can be repaired or replaced. The
Collapsible Spare Tire is not designed for use as
a conventional tire. To deflate Collapsible Spare
Tire, remove valve core. Flatten tire and replace
core and cap.
7. The tire inflator is not rechargeable. If you must use
it, be sure to obtain a replacement for the next
emergency use.
8. For Granada, Monarch or Versailles use Ford Part
D5DA-19F514-AA or equivalent. For Thunderbird,
LTD II, Cougar, Cougar XR7/ Continental Mark V
and Lincoln Continental use D60A-19F514-AA or
equivalent.
Ordinarily, a vehicle is operated with only the
original spare in the trunk. In the event that the
original spare and the Collapsible Spare Tire are
stored together, the Collapsible Spare Tire must be
considered as luggage weight of 50 pounds when
utilizing the rated luggage load information.
F R O N T W H E E L A S S E M B L Y
Each front wheel is bolted to the hub and rotor
assembly. Two opposed and tapered roller bearings and
a grease retainer, to prevent leakage onto the braking
surface, are installed in the hub.
An adjusting nut, nut lock, and cotter pin attach the
front wheel assembly including the hub and rotor to the
spindle (Figs. 1 and 2, Part 11-10).
R E A R W H E E L A S S E M B L Y
The rear wheel brake drum or disc brake rotor is
attached to studs on the rear axle shaft hub flange. The
wheel and tire mounts on the same rear axle shaft
flange studs and is held against the hub and drum or
rotor by the wheel nuts. The rear wheel bearing is

1 1 - 0 2 - 2 Wheels a n d T i r e s — D r o p Center Rim 1 1 - 0 2 - 2
pressed onto the axle shaft just inside the shaft flange,
and the entire assembly is held in the rear axle housing
by the bearing retainer plate or disc brake axle adapter
which is bolted to the housing flange or by C-locks which
retain the axle shaft in the differential case.
H O I S T I N G I N S T R U C T I O N S
Incorrect hoisting can damage steering linkage
components and front-end suspension struts.
On two-post hoists, place the adaptors under the
lower arms, or (except Pinto and Mustang) the No. 1
crossmember. M a k e sure t h e a d a p t o r s d o not rest
on the steering linkage. If the adaptors are placed
under the crossmember, place a block of wood 2 x 4
x 16 inches on the hoist channel between the adaptors
to prevent damage to, the struts.
W H E E L A N D TIRE R E M O V A L
1. Remove the wheel cover. Loosen, but do not
remove, the hub nuts.
2. Raise the vehicle until the tire clears the floor.
3. Remove the hub nuts and pull the wheel off the hub.
W H E E L A N D TIRE I N S T A L L A T I O N
1. Clean all dirt from the hub mounting surface.
2. Place the wheel on the hub. Install the hub nuts and
tighten them alternately to draw the wheel evenly
against the hub.
3. Lower the vehicle and torque the hub nuts to
specification, listed in Part 11-01.
R E M O V I N G A N D I N S T A L L I N G TIRE
Follow the instructions provided with Rotunda Tire
Changer 35-0010 or equivalent. Additional information
about this tire changer can be found under Adjustments, Part
11-01.
W h e n e v e r a radial ply tire is removed from a
w h e e l , it s h o u l d b e m a r k e d s o it c a n n o t b e
installed in a reversed position.

Wheel Hubs and Bearings—Front 11-10-1
Wheel Hubs and Bearings—Front
PART
11-10
-Applies to All Models
ADJUSTMENTS
Front Wheel Bearing Adjustment
Hoisting Instructions
DESCRIPTION
Front Wheel Assembly
.10-2
.10-2
.10-1
Front Wheel Grease Seal and Bearing
Replacement and Lubrication 10-2
Front Hub and Rotor Assembly 10-3
Hoisting Instructions 10-2
SPECIAL SERVICE T O O L S . . . 10-4
DESCRIPTION
F R O N T W H E E L A S S E M B L Y
Each front wheel is bolted to the hub and rotor
assembly. Two opposed and tapered roller bearings and
a grease retainer, to prevent grease leakage onto the
rotor, are also installed in the hub.
An adjusting nut, nut lock, and cotter pin attach the
assembly to the spindle (Fig. 1).
The front wheel spindle has a dog-nosed outer end
fastened by a smaller, copper-colored nut lock and a
heavier cotter pin. These parts cannot be used on
models built prior to 1974.
HUB A N D ROTOR
ASSEMBLY
ADJUSTING
NUT
WHEEL
ASSEMBLY
COTTER
PIN
FIG. 1 Front Hub, Bearing and Grease Retainer—Disc Brakes

11-10-2 Wheel Hubs cwtd Bearings—front 1 1 - 1 0 - 2
ADJUSTMENTS
H O I S T I N G INSTRUCTIONS
Refer to Part 11-02 for Hoisting Instructions.
F R O N T W H E E L B E A R I N G A D J U S T M E N T
If the wheel is loose on the spindle or does not rotate
freely, adjust the front wheel bearings as follows:
2. Remove the wheel cover. Remove the grease cap
from the hub.
3. Wipe the excess grease from the end of the spindle.
Remove the cotter pin and nut lock.
4. Loosen the adjusting nut three turns and rock the
wheel, hub and rotor assembly in and out several
times to push the shoe and linings away from the
rotor.
5. While rotating the wheel, hub, and rotor assembly,
torque the adjusting nut to 17 to 25 ft-lbs (24-33
N*m), to seat the bearings. (Fig. 2).
6. Loosen the adjusting nut one-half turn, then
retighten to 10 to 15 in-lbs (1.2-1.6 N«m), using a
torque wrench.
7. Place the nut lock on the adjusting nut so the
castellations on the lock are in line with the cotter
pin hole in the spindle.
8. Install a new cotter pin and bend the ends around
the castellated flange of the nut lock.
9. Check front wheel rotation. If the wheel rotates
properly, reinstall the grease cap and wheel cover.
If rotation is noisy or rough, follow the inspection,
© ©
WITH W H E E L ROTATING, BACK ADJUSTING
TORQUE ADJUSTING NUT, NUT O F F 1/2 T U R N
TO 17-25 FT-LBS (24-33 N»m)
© ©
TIGHTEN ADJUSTING INSTALL THE LOCK
NUT TO 10-15 IN-LBS AND A NEW COTTER PIN
(1.2-1.6 N'm)
F1417-1B
FIG. 2 Front Wheel Bearing Adjustment
lubrication and replacement procedures given
under Removal and Installation in this Part.
10. Before driving the vehicle, pump the brake pedal
several times to restore normal brake pedal travel.
H O I S T I N G I N S T R U C T I O N S
Refer to Part 11-02 for Hoisting Instructions.
F R O N T W H E E L G R E A S E S E A L A N D B E A R I N G
R E P L A C E M E N T A N D L U B R I C A T I O N
1. Raise the vehicle until the tire clears the floor and
remove wheel from hub and rotor.
2. Remove the caliper from the anchor plate, as
outlined in Group 12 and wire it to the underbody
to prevent damage to the brake hose.
3. Remove the grease cap from the hub. Remove the
cotter pin, nut lock, adjusting nut, and flat washer
from the spindle. Remove the outer bearing cone
and roller assembly. (Fig. 1).
4. Pull the hub and rotor assembly off the spindle.
5. Using Tool 1175-AC remove and discard the grease
retainer. Remove the inner bearing cone and roller
assembly from the hub.
6. Clean the inner and Outer bearing cups with solvent.
Inspect the cups for scratches, pits, excessive wear,
and other d a m a g e . If the cups are worn or
damaged, remove them with Tool T69L-1102-A
(Fig. 3).
7. Wipe out all old lubricant from the spindle and the
inside of the hub. Cover the spindle with a clean
cloth, and brush all loose dust and dirt from the dust
shield. Carefully remove the cloth from the
spindle, to prevent dirt f r o m falling on it.
8. If the inner or outer bearing cups were removed,
install replacement cups using the tools or
equivalent shown in Fig. 4. Be sure t o seat the
cups properly in the hub.
9. T h o r o u g h l y clean a l l o l d g r e a s e f r o m the
surrounding surfaces.
10. Using a bearing packer, pack the bearing cone and
roller assemblies with the specified grease. If a
packer is not available, work as much grease as
possible between the rollers and cages. Grease the
cone surfaces.
11. Place the inner bearing cone and roller assembly
in the inner cup. Apply a light film of grease to the
lips of a new grease retainer and install the retainer
with Tool 1175-AH shown in Fig, 5. Be sure the
retainer is properly seated.

Wheel Hubs and Bearings—front 1 1 - 1 0 - 3
FIG. 3 Removing Front W h e e l Bearing Cups
F1263-1D
FIG. 4 Installing Front W h e e l l e e r i n g Cups
12. Install the hub and rotor assembly on the spindle.
K e e p the hub c e n t e r e d on the s p i n d l e to
p r e v e n t d a m a g e to the r e t a i n e r a n d the
spindle threads.
F1443-1A
FIG. 5 Installing Grease Retainer—Disc
13. Install the outer bearing cone, roller assembly, and
flat washer on the spindle. Install the adjusting nut
finger tight (Fig. 1). Adjust wheel bearings as
outlined in this Part.
14. Install the caliper to the anchor plate, as detailed
in Group 12.
15. Install the wheel and tire on the hub.
16. Lower the vehicle and torque the lug nuts to 80-150
ft-lbs. (109-203®m). Reinstall the wheel cover.
several times to restore normal broke pedal travel.
F R O N T H U B A N D R O T O R A S S E M B L Y -
R E M O V A L A N D I N S T A L L A T I O N
A new grease retainer must be installed when the hub
and rotor assembly is replaced.
Remove wheel cover. Remove the wheel and tire
from the hub and rotor assembly.
2. Remove the caliper from the anchor plate as
outlined in Group 12, and wire it to the underbody
to prevent damage to the brake hose.
3. Remove the grease cap from the hub. Remove the
cotter pin, nut lock, adjusting nut, and flat washer
from the spindle. Remove the outer bearing cone
and roller assembly (Fig. 1).
4. Pull the hub and rotor off the spindle.
5. Remove the protective coating from the new hub
and rotor with carburetor degreaser.

11-10-4 Wheel Hubs and Bearings—Front 1 1 - 1 0 - 4
Using a bearing packer, force new grease into the
bearing cone and roller assemblies. If a packer is
not available, work as much grease as possible
between the rollers and cages. Grease the cone
surfaces.
Place the inner bearing cone and roller assembly
in the inner cup. Apply a light film of grease to a
new grease retainer and install the retainer with
Tool 1175-AH. (Fig. 5) Be sure the retainer is
properly seated.
Install the new hub and rotor assembly to the wheel
spindle. Keep the hub centered on the spindle
to prevent damage to the retainer.
9. Install the outer bearing cone roller assembly and
flat washer on the spindle. Install the adjusting nut.
Adjust the bearings as outlined in this Part.
10. Install the caliper to the spindle and tighten the
bolts to specification, as detailed in Group 12.
11. Place the wheel and tire on the new hub and rotor.
Install the hub nuts and tighten them alternately to
draw the wheel evenly against the hub and rotor.
12. Lower the vehicle and torque the wheel nuts to
specification.
several times to restore normal brake pedal travel.
SPECIAL SERVICE TOOLS
Tool No. Description Tool No. Description
Tool-1175-AC Grease Seal Remover Tool-1217-K *Front Wheel Bearing Cup (Inner)
T69L-1102-A Front Wheel Bearing Remover Installer-Disc
T60K-1217-A Front Wheel Bearing Cup
(Outer) Installer-Disc Tool-1175-AH Grease Seal Installer-Disc
*Pinto, Bobcat, Mustang, Capri, Fairmont, Zephyr, Granada, Monarch and Versailles only.
CF1826-2E

1 2 - 0 1 - 1 Brakes 1 2 - 0 1 - 1
BRAKES
PART TITLE PART NO. PART TITLE
Disc Brakes - Single Piston, Sliding Caliper 12-20
Drum Brakes - Single Cylinder, Dual Piston 12-02
General Hydraulic Brake Service 12-01
ADJUSTMENTS
Brake Vacuum Booster Pushrod-To-Master
Cylinder 01-18
Centralizing the Pressure
Differential V a l v e . . . 01-20
Hydraulic System Bleeding 01-18
Brake Booster 01-31
Brake H o s e . . . . 01-31
Brake Tubing 01-31
Disc Brakes . . 01-30
Disc Brake Service Precautions 01-30
Drum Brakes 01-31
Hydraulic Lines 01-31
DESCRIPTION
Control Valve Assembly 01-2
Dual Brake System . . 01-2
DIAGNOSIS AND TESTING
Brake Control Valve Diagnosis Guide 01-12
Brake Pedal Free Height Measurements 01-15
G R O U P
12
( 2 0 0 0 )
PART NO.
Hydro-Boost Brake Booster 12-51
Parking Brake - Cable Actuated, Rear Wheels.... 12-70
Vacuum Brake Booster - Single Diaphragm,
Dash Mounted 12-50
PART
1 2 - 0 1
PAGE
DIAGNOSIS AND TESTING (Cont'd.)
Brake Pedal Travel Measurement 01-15
Diagnostic Techniques 01-14
General Brake System Diagnosis 01-3
General Brake System Diagnosis Guide 01-4
Hydro-Boost Power Brake Diagnosis Guide
Hydraulic System Diagnosis 01-13
Master Cylinder Diagnosis Guide 01-10
Master Cylinder Diagnosis and
Testing 01-13
Power Brake Functional Test -
Hydro-Boost . . . . 0 1 - 1 7
Power Brake Functional Test -
Vacuum Booster 01-17
OVERHAUL
Dual Master Cylinder 01-29
Brake Control Valve Assembly 01-23
Brake Pedal , 01-28
Dual Master Cylinder 01-20
SPECIFICATIONS AND
SPECIAL SERVICE TOOLS 01-32
General Hydraulic Brake Service
Applies To All Cars
SUBJECT PAGE SUBJECT

1 2 - 0 1 - 2 General Hydraulic Brake Service 1 2 - 0 1 - 2
DESCRIPTION
D U A L B R A K E S Y S T E M
A dual brake system, incorporated in all models,
provides increased safety. The system consists of a dual
master cylinder and a brake control valve assembly. The
control assembly may consist of a pressure differential
valve, a metering valve and a proportioning valve. A
switch on the differential valve activates a brake
warning light on the instrument panel if unequal
hydraulic pressure occurs.
The master cylinder reservoir closest to the dash
panel is used to supply brake fluid to the front wheel
brakes. The reservoir closest to the radiator is used to
supply brake fluid to the rear wheels.
C O N T R O L V A L V E A S S E M B L Y — ( P R E S S U R E
D I F F E R E N T I A L , M E T E R I N G , A N D
P R O P O R T I O N I N G V A L V E S )
The brake control valve assembly (Figs. 1 and 2) may
consist of a pressure differential valve, a metering
valve, and a proportioning valve. These valves are
housed within a single cast-iron valve body (housing).
The pressure differential and metering valves are
located in the central bore of the valve body. The
proportioning valve is located in a separate angular or
vertical bore.
Metering Valve
The metering valve is located in the front end of the
control valve central bore between the front brake
system inlet port and the front brake outlet ports. Its
function is to regulate the hydraulic pressure to the front
disc brakes. The metering valve location at the front end
of the housing center bore provides easy accessibility
to the valve bleeder rod during bleeding of the front
brake system (see Brake System Bleeding—this Part).
Pressure Differential Valve
The brake warning light switch is mounted at the
center of the valve body with the spring-loaded plunger
fitting into a tapered shoulder groove in the center of
the piston. With the piston in a centralized position the
switch contacts remain open.
Should there be a loss of pressure in either the front
or rear brake system, when the brake pedal is applied,
the piston will move off center, closing the switch
contacts and turning on the warning light.
After repairs are made and the brake system bled,
the piston will center itself upon brake application and
the switch contacts will open, turning off the warning
light. - '
Proportioning Valve
The proportioning valve regulates the rear brake
system hydraulic pressure and is located between the
rear brake system inlet and outlet ports (Fig. 3).
When the brake pedal is applied, the full rear brake
fluid pressure passes through the proportioning valve
to the rear brake hydraulic system until the valve split
p o i n t is a t t a i n e d . A b o v e the s p l i t p o i n t , the
proportioning valve reduces hydraulic pressure to the
rear brakes for balanced braking. The proportioning
split point and slope are listed in the Specification
Section of this Part.
WAGNER E L E C T R 4 C D E S I G N K E L S E Y - H A Y E S D E S I G N
H1964-2C
FIG. 1 Control V a l v e Assembly—Disc/Drum Brakes

FRONT B R A K E
F L U I D INLET
B R A K E WARNING
LIGHT SWITCH
O U T L E T T O
FRONT B R A K E
FRONT B R A K E
F L U I D I N L E T
B R A K E WARNING
LIGHT SWITCH
O U T L E T TO
FRONT B R A K E
O U T L E T TO
R E A R BRAKES
O U T L E T TO PRESSURE
FRONT B R A K E
D I F F E R E N T I A L PROPORTIONING V A L V E
O U T L E T TO PRESSURE
FRONT B R A K E D I F F E R E N T I A L
V A L V E
PROPORTIONING
V A L V E
WAGNER E L E C T R I C DESIGN K E L S E Y - H A Y E S DESIGN
FIG. 2 Control V a l v e A s s e m b l y — 4 - W h e e l Disc Brakes
FRONT I N L E T
REAR
INLET
FRONT O U T L E T
F R O N T O U T L E T
H1948-1B
FIG. 3 Pressure Differential and Proportioning
Vaiv©
DIAGNOSIS AND TESTING
G E N E R A L B R A K E S Y S T E M D I A G N O S I S
Diagnosis of the combined mechanical and hydraulic
problems associated with the brake system is covered
in the General Brake System Diagnosis Guide in this
Section.
In addition to the General Brake System Diagnosis
Guide, further specific Diagnosis Guides are furnished
for the Master Cylinder, Brake Control Valve and the
Hydro-Boost Power Brake.

G E N E R A L B R A K E S Y S T E M D I A G N O S I S G U I D E
CONDITION POSSIBLE CAUSE RESOLUTION
• Brakes do not apply. • Insufficient brake fluid.
8 Binding or damaged brake pedal
linkage.
8 Binding or damaged brake booster
linkage.
8 Add fluid, bleed system, check for leaks.
8 Service as required.
• Excessive pedal travel or pedal goes
to floor.
8 Air in system.
8 Malfunctioning master cylinder.
8 Drum brakes — improperly adjusted.
8 On disc brakes, misaligned anchor
plate.
8 Outer shoe torque buttons not
properly seated in caliper holes
Fairmont/Zephyr/Mustang/Capri
8 Bleed system.
8 See Master Cylinder Diagnosis Guide.
8 Check adjustment. Inspect brakes. Service
as required.
a Check anchor plate.
8 Check and service.
• Excessive pedal effort to stop car. 8 Binding or damaged pedal linkage.
8 Engine vacuum loss.
8 Booster or hydro-boost inoperative.
8 Malfunctioning master cylinder,
t Worn or contaminated linings.
8 Brake system.
8 Inspect. Service as required.
• Check engine vacuum, and vacuum at check
valve to booster. Service as required.
8 Perform power brake function test.
8 Inspect. Replace if necessary.
8 Inspect wheel cylinders or caliper pistons,
restricted lines or hoses, contaminated
brake fluid, improper operation of pro
portioning or metering valve. Service
as necessary.
• Spongy pedal. 8 Air in system.
8 Loose or improper brake pedal, pedal
support, booster, master cylinder
attachment.
8 Brake system.
8 Bleed system.
8 Inspect for damaged or distorted parts
in brake caliper assemblies, cracked
brake drums, mis-machined anchor
plates.
CH2561-2C
FIG. 4 General Brake System Diagnosis Guide

• Brakes drag, slow or incomplete
release.
• Parking brake cable out of adjust
ment or binding.
• Front wheel bearings out of
adjustment.
• Blocked master cylinder compensator
ports.
• Brake adjustment (rear).
• Restriction in hydraulic system.
• Wheel cylinders or caliper piston
seizure.
• Brake system.
• Check cables for correct adjustment or
bind.
• Check bearings for adjustment, wear,
damage or bind.
• See Master Cylinder Diagnosis Guide.
• Check and adjust.
• Check and service.
• Check and service.
• Inspect and service.
• Noise at wheels when brakes are
applied - snap or clicks.
• On drum brakes in 3 places — brake
shoes binding at backing plate ledges.
• On drum brakes in 3 places — back-
in plate ledges worn.
§ Loose or missing disc brake caliper
attaching bolts.
0 On disc brake - rust on front edge
of inboard shoes.
• On disc brakes - loose or missing
anti-rattle clip.
• Other brake system components:
Loose outer shoe crimping, defective
caliper support spring or retaining
key, cracked welds at shoe web.
• Loose outer shoe retaining clip.
• Lubricate.
§ Replace backing plate and
lubricate ledges.
o Replace missing bolts, tighten
to proper torque.
• Inspect. Lubricate, replace if necessary.
• Replace.
• Inspect. Service or replace.
• Inspect. Service or replace.
• Noise at wheels when brakes are
applied - scrape or grind.
• Worn brake linings.
• Brake shoe interference with back
of drum. Binding at backing plate
guide ledges.
• Caliper to wheel or rotor interference.
e Other brake system components:
Warped or bent brake backing plate or
splash shield, cracked drums or rotors.
• Tires rubbing against chassis or body.
• Replace. Refinish drums or rotors if
heavily scored.
• Inspect. Replace as necessary. Lubricate.
i Replace as required.
CH2561-2C1
FIG. 5 General Brake System Diagnosis Guide Cont'd.

s Noise at wheels when brakes are
applied - squeaks, squeals, or
chatter.
NOTE: Brake friction materials
inherently generate noise and heat
in order to disipate energy. As a
result, occasional squeal is normal,
and is aggravated by severe envir
onmental conditions such as cold,
heat, wetness, snow, salt, mud, etc.
This occasional squeal is not a
functional problem and does not
indicate any loss of brake effect
iveness.
s Brake drums and linings, rotors and
pads worn or scored.
• On disc brakes - missing or damaged
brake pad insulators.
• On disc brakes - burred or rusted
calipers.
• Dirty, greased or glazed linings.
• Improper lining parts.
t On drum brakes — loose lining rivets,
weak, damaged or incorrect shoe
retracting springs, loose or damaged
shoe retaining pins, springs and clips,
and grooved backing plate ledges.
0 Inspect, service or replace.
0 Replace.
0 Clean or deburr.
0 Clean or replace.
0 Inspect for correct usage. Replace.
• Noise at wheels, brakes not applied
- squeak or squeal.
• Wheel cover attachment.
• Loose wheel attaching lug nuts.
• Bent or warped backing plate causing
interference with drum or rotor.
• Improper machining of drum,
causing interference with backing
plate or shoe.
• Loose or extra parts in brakes.
0 Drum or rear disc brake adjustment
too tight causing lining to glaze.
0 Worn, damaged, or insufficiently
lubricated wheel bearings.
0 On drum brakes - weak, damaged
or incorrect shoe retracting springs.
0 On drum brakes - grooved backing
plate ledges.
0 Improper positioning of shoe in
caliper.
0 Outside diameter of rotor rubbing
caliper housing.
0 Lack of correct lubricant on disc
brake caliper slides.
0 Improper installation of rear disc
brake anti-rattle clip.
0 Seat covers with a rubber mallet.
Service flanges or replace cover.
0 Tighten to correct torque. Replace wheel
if stud holes are damaged.
0 Service or replace.
0 Replace drum.
0 Inspect, service, replace as required.
CH2561-2C2
FIG. 6 General Brake System Diagnosis Guide Cont'd.

• Noise at wheels, brakes not applied
- growling, click or rattle.
• Outer shoe locating buttons not
seated in caliper holes. Usually
accompanied by lose of pedal.
• Stones or foreign material trapped
inside wheel covers.
• Loose grease cap.
t Loose wheel lug nuts.
8 Disc brake caliper - loose or missing
anti-rattle clips and support spring,
or crimping on outer shoe.
8 Drum brakes - loose or extra parts.
8 Worn, damaged or dry wheel bearings.
8 Check and replace if necessary.
8 Repair or replace.
8 Tighten to correct torque. Replace if
stud holes are elongated.
• Inspect, service or replace.
8 Inspect, remove or service.
8 Inspect, lubricate or replace.
8 Brakes pull to one side. 8 Unequal air pressure in tires.
8 Grease or fluid on linings. Glazed
linings.
8 Loose or missing disc brake caliper
attaching bolts.
8 Improper size or type lining on one
wheel.
8 Stuck or seized wheel cylinders or
calipers.
8 Restricted brake lines or hoses.
8 Other brake system components:
e Improper adjustment of drum
or rear disc brakes.
8 Improper positioning of disc
brake shoe and lining in the
caliper.
s Improperly adjusted, damaged or
worn wheel bearings.
8 Distorted drum brake linings.
8 Missing, broken or stretched re
tracting or retaining springs and
clips in drum brakes.
8 Inflate tires to correct pressure,
i Replace.
8 Replace missing bolts. Tighten to
proper torque.
8 Replace with correct brake lining in
axle sets.
8 Inspect, service or replace as
required.
CH2561-2C3
FIG. 7 General Brake System Diagnosis Guide—Cont'd.

• Brakes grab or lock-up when applied. 8 Tires worn or incorrect pressure.
§ Grease or fluid on linings — damaged
linings.
§ Improper size or type of linings.
s Bolts for caliper attachment loose
or missing.
8 Worn, damaged or dry wheel
bearings.
8 Improperly adjusted parking brake.
8 Inflate tires to correct pressure. Replace
tires with worn tread.
8 Replace with correct brake in axle sets.
8 Inspect, service or replace as required.
§ Brake warning light on. 8 Hydraulic system.
8 Shorted light circuit.
8 Parking brake not returned.
8 Brake warning switch.
8 Correct short in warning circuit.
8 See ''Parking brake will not release or
fully return" below.
8 Replace.
§ Intermittent loss of pedal. 8 Stop light switch. 8 Perform Master Cylinder Diagnosis test.
8 Perform steps under "Excessive pedal
travel or pedal travel goes to floor".
• Rough engine^idle or stall, brakes
applied - power brakes only.
8 Vacuum leak in neutral switch.
8 Vacuum booster.
8 Check lines for leaks. Service or
replace as required.
8 Check vacuum booster for internal leaks.
Replace if required.
• Parking brake control will not latch
(manual release).
8 Kinked or binding release cable.
8 Control assembly.
• Parking brake control will not latch
(automatic release).
8 Vacuum leak.
8 Vacuum switch.
8 Control assembly.
8 Test. Replace if necessary.
• Parking brake will not release or
fully return (manual release).
8 Cable disconnected.
8 Control assembly binding.
8 Parking brake linkage binding.
8 Rear brakes.
8 Connect cable or replace.
8 Check rear brakes shoe retracting springs
and parking brake levers. On rear disc
brakes verify levers return fully to re
leased position. Adjust cables or
service caliper as required.
t Parking brake will not release or
fully return (automatic release).
s Vacuum line leakage or improper
connections.
8 Neutral switch.
8 Control assembly.
8 Inspect and service.
8 Adjust or replace.
CH2561-2C4

1 2 * 0 1 - 9 General Hydraulic Brake Service 1 2 - 0 1 - 9
V I B R A T I O N W H E N B R A K E S A R E A P P L I E D
ROAD T E S T V E H I C L E FOR THE FOLLOWING:
• 25 TO 55 MPH FOR V E H I C L E VIBRATION WITHOUT APPLYING
B R A K E S PER PROCEDURE IN TRAINING HANDBOOK (0910-013).
• 55 TO 25 MPH FOR B R A K E VIBRATION WITH LIGHT AND MEDIUM
APPLICATION ON THE PEDAL,
• 50 TO 20 MPH FOR REAR B R A K E VIBRATION WITH MEDIUM APPLI
CATION ON THE PARKING B R A K E O N L Y . (NOTE: WITH MANUAL
R E L E A S E PARKING B R A K E CONTROL, HOLD THE PARKING B R A K E
R E L E A S E IN R E L E A S E POSITION DURING PARKING B R A K E APPLI
CATION.)
NOT OK
REPAIR V I B R A T I O N AS R E Q U I R E D PER PRO
C E D U R E IN TRAINING HANDBOOK (0910-013)
V E H I C L E V I B R A T I O N AND DIAGNOSIS.
IF V E H I C L E VIBRATION IS PRESENT WITHOUT
B R A K E APPLICATION, REPAIR THIS PROBLEM
FIRST, THEN R E - E V A L U A T E FOR B R A K E VIBRA
TION ON BOTH S E R V I C E B R A K E AND PARKING
B R A K E .
T "
OK
IF B R A K E VIBRATION IS PRESENT ON THE
S E R V I C E B R A K E , BUT NOT ON THE PARKING
B R A K E (REARS).
Z L
IF B R A K E VIBRATION IS PRESENT ON THE
PARKING B R A K E (REARS) BUT NOT ON THE
S E R V I C E B R A K E S .
IF B R A K E VIBRATION IS PRESENT ON BOTH
THE S E R V I C E B R A K E AND THE PARKING
B R A K E .
CHECK FRONT ROTORS FOR E X C E S S I V E RUNOUT.
REFINISH OR R E P L A C E AS REQUIRED. R E F E R TO
TSB NO. 50 DATED AUG. 17, 1974 FOR SERVICE
PROCEDURE.
CHECK R E A R DRUMS FOR E X C E S S I V E WEAR OR
RUNOUT. CHECK R E A R ROTORS FOR E X C E S S I V E
WEAR, RUNOUT AND/OR THICKNESS VARIATION.
REFINISH OR R E P L A C E AS REQUIRED.
CHECK BOTH FRONT AND R E A R DRUMS
AND/OR ROTORS FOR E X C E S S I V E WEAR,
RUN-OUT OR THICKNESS VARIATION (ROTORS
ONLY). REFINISH OR R E P L A C E AS R E Q U I R E D .
T
OK
VIBRATION CAN ALSO BE CAUSED BY:
• WORN OR IMPROPERLY ADJUSTED WHEEL
BEARINGS.
• C R A C K E D ROTORS.
CH2S61-21S

1 2 - 0 1 - 1 0 General Hydraulic Brake Service 1 2 - 0 1 - 1 0
MASTER CYLINDER DIAGNOSIS GUIDE
Brake Pedal Feel Conditions Diagnostic Action
Condition 1 - Pedal goes down fast and brake light
comes on.
Pump brake pedal rapidly:
If the brake pedal height builds up and holds, check
for the presence of air. (Use Diagnostic Technique No. 1.)
If the brake pedal height builds up and then sinks
down, check for an external leak (Use Diagnostic
Technique No. 4) or a master cylinder by-pass (Use
Diagnostic Technique No. 2.)
If the brake pedal height fails to build up, check the
fluid level in the master cylinder reservoir:
If a reservoir is empty, add fluid; bleed the sys
tem; and check for external leak. (Use Diagnostic
Techniques No. 3 and No. 4.)
If the reservoirs are full, check for a gross master
cylinder by-pass. (Use Diagnostic Technique No. 2).
Condition 2 - Pedal eases down slowly and brake
light comes on.
This condition could be caused by an external leak in the
brake system or an internal by-pass in the master cylinder.
Appiy the brakes several times while observing the fluid
levels in the reservoirs:
l.f the net fluid level in a reservoir eases down with
each stroke cycle, check for an external leak. (Use
Diagnostic Technique No. 4).
If the fluid level in a reservoir rises while the pedal
eases down and drops when the pedal is released, but
the net fluid level remains unchanged, then repaii or
replace the master cylinder for a fluid by-pass condition.
NOTE: All master cylinders in warranty must be replaced.
Condition 3 - Pedal is low and brake light does not
come on.
This condition may be caused by: air in the hydraulic
system,or no fluid in one reservoir.
If the reservoir is empty, add fluid, bleed, and check the system
for external leaks. (See Diagnostic Technique Nos. 3 and 4).
If the reservoir is full, check for the presence of air in
the hydraulic system. (Use Diagnostic Technique No. 1).
If this condition happens occasionally on a disc brake
equipped car, check the front wheel bearings for loose
ness. (Loose front wheel bearings allow the disc rotor
to knock the caliper piston back, creating excess lining
clearance.)
FIG. 10 Master Cylinder Diagnosis Guide
CH2294-2B

12-01-11 General Hydraulic Brake Service 12-01-11
MASTER CYLINDER DIAGNOSIS GUIDE (Cont'd.)
Brake Pedal Feel Diagnostic Action
Condition 4 - Pedal feels spongy. This may be normal as modern brake systems
are not designed to produce as hard a pedal as in the
past. To verify this, compare the pedal feel with another
like car.
Check for the presence of air in the hydraulic system.
(Use Diagnostic Technique No. 1).
Condition 5 - Pedal goes down fast and brake light
does not come on.
Prior to diagnosing, verify that the brake
system warning light is functional.
Pump the brake pedal rapidly:
If the brake pedal height fails to build up, check the
fluid level in the master cylinder reservoirs:
If both reservoirs are empty, add fluid, bleed the
system, and check for external leaks. (Use Diag
nostic Techniques No. 3 and No. 4).
If the reservoirs are full, check for air in the hy
draulic system. (Use Diagnostic Technique No. 1).
Or check for brake pedal reserve. (Use Diagnostic
Technique No. 5).
If the brake pedal height builds up, check for insuffi
cient drum brake adjustment.
Condition 6 - Pedal erratic - no light. This may be caused by imcomplete brake re
lease, loose wheel bearings, incorrect parking brake ad
justment or blocked compensator holes in the master
cylinder. To verify, check wheel rotation and bearing
free play, parking brake tension and refer to Diagnostic
Technique No. 6 for master cylinder compensator hole
check.
Condition 7 - Pedal effort excessive - no light. This may be caused by a bind or obstruction
in the pedal/linkage, insufficient booster vacuum or
hydroboost pressure. To verify, detach master cylinder
from dash or booster and stroke pedal fully. Check
vacuum or hydroboost pressure per procedure.
CH2295-2B
FIG. 11 Master Cylinder Diagnosis Guide—Cont'd.

BRAKE CONTROL V A L V E DIAGNOSIS GUIDE
Complaint Diagnosis and Resolution
1. Premature front brake lock-up on wet or icy road
during light pedal application and cold engine fast
idle operation.
1. Check tires and tire pressures.
2. Check brake linings for fluid, grease or other contam
ination.
3. Check and adjust engine idle for normal driving.
4. On vehicles equipped with a metering valve, check it
by installing pressure gauges in front and rear bleed
screws. Apply 200 psi to the system. Front brake
system should read 100 to 150 psi while rear system
reads 200 psi.
5. Replace the brake pressure control valve if out of
specification.
2. Rear brake lock-up during light brake pedal force. 1. Check tires and tire pressures.
ination.
3. Install pressure gauges in the front and rear bleeder
screw ports and apply 1,000 psi to the front brake
system. The rear brake system pressure must be ap
proximately 550 to 750 psi.
4. Replace brake pressure control valve assembly if rear
brake pressure is not within specification.
3. No rear brake lock-up under heavy brake pedal force. 1. Check tires and tire pressures.
ination.
3. Install pressure gauges in the front and rear wheel cyl
inder bleeder screw ports and apply 1,000 psi to the
front brake system. The rear brake system pressure
must be approximately 550 to 750 psi.
4. If no pressure is obtained, check for damaged tubing.
5. Replace the brake pressure control valve assembly if
rear brake pressure is not within specifications.
CH229G-2C
FIG. 12 Brake Control V a l v e Diagnosis Guide

HYDRO-BOOST POWER BRAKE DIAGNOSIS GUIDE
Complaint Possible Causes Resolution
Excessive Brake Pedal Effort (Poor power
steering assist in both directions also) at idle
speed.
1. Loose or broken steering pump belt.
2. Power steering fluid reservoir low or empty.
3. Power steering hose leaking.
4. Leaking at tube fittings - power steering
or booster connections.
5. Low idle speed.
6. Restriction in pressure hose to booster.
7. Low power steering pump pressure.
1. Tighten or replace belt.
2. Fill reservoir and check for leaks.
3. Replace hose.
4. Tighten fitting. If it still leaks, check tube flare.
Replace hose if flare is damaged. Check tube
seat, repair if damaged.
5. Adjust idle speed to specification.
6. Replace hose.
7. Perform pump pressure test.
Excessive Brake Pedal Effort (Power steering
normal in both directions at idle speed).
1. Binding in pedal and/or pedal linkage.
2. Contamination.
3. Nicked/burred spool valve.
1. Repair and lubricate as required.
2. Hold steering wheel against stop (maximum
five (5) seconds) and apply brake pedal sharply
several times. If contamination is dislodged,
flush system.
3. Replace hydro-boost.
Slow or Incomplete Brake Pedal Return. 1. Binding in the pedal and/or pedal linkage.
2. Restriction in return line from booster to
pump reservoir.
3. Internal restriction in the hydro-boost fluid
return system.
2. Replace return hose.
3. Replace the hydro-boost.
Brake Pedal Chatter, Pulsation 1. Power steering pump belt slipping.
2. Power steering pump reservoir fluid low.
3. Power steering pump.
4. Spool valve dimensional error.
1. Tighten belt.
2. Fill reservoir, check for leaks.
3. Repair pump.
Oversensitive Braking 1. Binding in the pedal and/or pedal linkage.
2. Faulty spool action.
Noise 1. Power steering pump fluid level low or
empty.
2. Power steering fluid aerated.
3. Power steering pump belt loose.
4. Restriction in hoses.
1. Fill reservoir.
2. Bleed system.
3. Tighten belt.
4. Replace hose.
CH2259-2C
FIG. 13 Hydro-Boost Power Brake Diagnosis Guide
A l w a y s check the f l u i d l e v e l in the master
cylinder before performing the test procedures. If
the fluid level is not within 1/4 inch of the top of the
master cylinder reservoirs, add Brake Fluid-—Ford Part
No. C6AZ-19542-A or DOT 3 equivalent for all brake
applications.
If a brake is locked and the vehicle must be
moved, open a bleeder screw on front and rear
w h e e l s to let out e n o u g h fluid to r e l i e v e the
pressure. This bleeding operation will release the
brakes but will not correct the cause of trouble.
H Y D R A U L I C S Y S T E M S D I A G N O S I S
There is only one major problem which occurs in the
hydraulic brake system and that is LEAKS, internal or
external. Hydraulic brake systems, including master
cylinder and valves, DO NOT cquse pulling, grabbing,
vibrations, pulsating pedals, squeaks, squeals, clunks,
or, in most cases, dragging brakes.
It is therefore a good policy to first check the entire
system for leaks when diagnosing a brake problem.
M A S T E R C Y L I N D E R D I A G N O S I S A N D
T E S T I N G
Pedal feel is usually the first indicator that something
is wrong in the brake system. The Master Cylinder
Diagnosis Guide (Figs. 10 and 11) uses the brake pedal
feel, the warning light and the brake fluid level as the
indicators in diagnosing master cylinder conditions.
N o t e that the procedures refer to the use of
diagnostic techniques. These techniques (Numbers 1
through 5) follow the diagnostic procedures.
Normal Conditions —The following conditions are
considered normal and are not indications that the
master cylinder is in need of service:

12-01-14 General Hydraulic Brake Service 1 2 - 0 1 - 1 4
C o n d i t i o n 1 — U n e q u a l b r a k e fluid l e v e l s in
master cylinder reservoirs on disc b r a k e vehicles.
This condition is caused by displacement of fluid from
the reservoir into the calipers to compensate for normal
lining wear. Top off the reservoirs.
Condition 2 — A momentary or slight squirt o f
b r a k e fluid from one or both master cylinder
reservoir chambers upon application of the brake
p e d a l . This c o n d i t i o n is c a u s e d b y the f l u i d
displacement through the reservoir compensating port(s)
as the master cylinder pistons move forward in the bore
when the brakes are applied.
C o n d i t i o n 3 — A s l i g h t t u r b u l e n c e in t h e
reservoir f l u i d occurring when the brake pedal is
released. Turbulence occurs as brake fluid returns to
the master cylinder after releasing the brakes.
Condition 4 — A trace of brake fluid exists on
booster shell b e l o w the master cylinder mounting
flange. This condition results from the lubricating action
of the master cylinder wiping seal.
A b n o r m a l Conditions —Changes in brake pedal
feel or travel are indicators that something could be
wrong in the brake system. The following diagnostic
procedures and techniques use brake pedal feel, the
warning light illumination and brake fluid level, as
indicators in diagnosing brake system complaints.
NOTE: Prior to performing a n y diagnosis, make
certain that the brake s y s t e m w a r n i n g light is
functional.
D I A G N O S T I C T E C H N I Q U E N O . 1
Air Entrapment in Brake System
1. Check the fluid level in the master cylinder. Fill the
reservoir if it is low or empty.
2. Place the cap loosely on the master cylinder.
3. With one technician acting as an observer at the
master cylinder, and another technician applying
the brakes, pump the brakes rapidly 20 times.
4. On the final application, hold the pedal in the
applied position.
5. Remove the cap and observe the fluid in the
reservoirs. Quickly release the brake pedal. A
geyser up to six (6) inches high will spout from the
reservoir of a system with air in it.
NOTE: Pumping the brake pedal compresses
trapped air. W h e n the brake pedal is released,
the compressed air e x p a n d s , forcing brake
f l u i d b a c k into the m a s t e r c y l i n d e r w i t h
sufficient force to form a geyser.
6. Bleed the system in which the geyser occurs.
Procedure for Checking a Master Cylinder By-pass
Condition
1. Remove the master cylinder reservoir cap and verify
that both reservoir chambers are filled with fluid.
2. With the reservoir cap removed, observe the fluid
levels in both chambers when the brake pedal is
slowly depressed for one stroke and then quickly
released.
a.If the fluid level in a reservoir rises while the pedal
goes down and drops when the pedal is released,
but the net (overall) fluid level in the reservoir
remains unchanged, the master cylinder is by
passing. Replace such a master cylinder.
Checking the Cause of an Empty Reservoir
Without an External Pressure Leak
An empty reservoir condition may be caused by two
types of non-pressure external leaks.
Type 1 — A n external leak may occur at the master
cylinder reservoir cap due to improper positioning of the
gasket and cap or a rust formation, between the cap
gasket and the reservoir sealing surfaces. Replace the
cover and gasket assembly. Remove any rust formations
from the master cylinder.
T y p e 2 — A n external leak may occur at the
mounting end of the master cylinder due to a bore end
seal leak. Replace such a master cylinder.
Checking for External Fluid Leaks in the Brake
System
It is possible that all evidence of fluid leakage may
have been washed off, if the vehicle has been operated
in rain or snow, as brake fluid is water soluble. Refill
the system, bleed, and apply the brakes several times.
Examine the system to verify that the reservoir level is
actually dropping. Locate and correct the external leak.
Checking for Brake Pedal Reserve—Vacuum-Power
Brake Equipped Car Lines
On vacuum-power brake equipped vehicles where a
low pedal or the feel of a bottomed out condition exists,
check for brake pedal reserve using the following
procedure:
1. Operate the engine at idle with the transmission in
either Park or Neutral position.
2. A p p l y the brake pedal until it stops moving
downward or increased resistance to the pedal
travel occurs.
N O T E : A clunk m a y be felt a s the p e d a l
reaches this point.
3. Hold the pedal in the applied position and raise the
engine speed to approximately 2,000 RPM.
4. Release the accelerator pedal and observe that the
brake pedal moves downward as the engine returns
to idle speed.
N O T E : The a d d i t i o n a l m o v e m e n t of the
b r a k e p e d a l is the result of the increased
engine manifold vacuum which exerts more
force on the brake booster during engine run
d o w n . This means that additional stroke is
available in the master cylinder, and the brake
system is not bottoming out as a customer may
believe.

Checking the Master Cylinder for Open
Compensator Port(s)
1. Push brake pedal and observe fluid in master
cylinder reservoirs.
2. A small geyser or ripple should appear in one or
both reservoirs upon brake application.
3. If no geyser or ripple appears, loosen the master
cylinder attaching bolts 1/4 inch, hold the master
cylinder out and check for open compensator port(s)
as above.
4. If compensation now occurs, verify booster pushrod
length per procedure and adjust if required (except
Fairmont and Zephyr). If not, replace master
cylinder.
5. If the booster push rod length is incorrect on
Fairmont/Zephyr, using the push rod g a u g e ,
replace the booster.
B R A K E P E D A L F R E E H E I G H T
M E A S U R E M E N T S
W i t h the engine running for full power brake
operation and the parking brake fully released, measure
the brake pedal free height, and check the brake pedal
travel with the use of the Brake Pedal Pressure Gauge,
Tool 21-0001 (Fig. 14) as follows:
1. Insert a slender, sharp-pointed prod through the
carpet and sound deadener to the dash panel
metal, and measure the distance to the center on
top of the brake pedal (Fig. 15) pad.
2. If the p o s i t i o n of the p e d a l is n o t w i t h i n
specification, check the brake pedal for missing,
worn, or damaged bushings, or loose attaching
bolts, and replace them, if required.
3. If the pedal free height is still out of specification,
check the brake pedal, booster or master cylinder
to be sure the correct parts are installed. Replace
the worn or damaged parts as necessary.
B R A K E P E D A L TRAWEL M E A S U R E M E N T
1. Install a Brake Pedal Effort Gauge (21 -0001) on the
brake pedal pad (Fig. 14).
2. Hook a steel measuring tape to the brake pedal as
in Fig. 15. Measure and record the distance from
the b r a k e p e d a l f r e e height position to the
reference point, which is at the six o'clock position
on the steering wheel rim.
3. With the steel tape still hooked to the brake pedal,
depress the brake pedal by pressing downward on
the brake pedal effort gauge. Apply a 25-pound
load to the center of the pedal. While maintaining
the pedal load, measure the distance from the
brake pedal to the fixed reference point on the
steering wheel rim parallel to the centerline of the
steering column.
4. The difference between the brake pedal free height
and the depressed pedal measurement under a 25-
pound load should be within the specified maximum
pedal travel service specification B in Fig. 15.
5. On self-adjusting drum brakes, if the pedal travel
is more than the maximum, as specified in Fig. 15,
dimension B, make several reverse stops with a
TOOL-21-0001
FIG. 14 Brake Pedal Effort G a u g e Installed
H1525-2A

GRANADA - MONARCH - V E R S A I L L E S
Pedal Free Maximum Pedal
Vehicle Type Height "A" (Inches) Travel (Inches)
Max. Min. "B"
Pinto, Bobcat Power Disc 7.3 6.4 2-1/4
Pinto, Bobcat Non-Power Disc 9.0 7.75 2-3/4
Fairmont, Zephyr Power Disc 7.0 6.0 2.0
Fairmont, Zephyr Non-Power Disc 8.8 7.6 3.0
Mustang, Capri Power Disc 7.4 6.6 2-1/4
Mustang, Capri Non-Power Disc 8.8 7.5 203/4
Granada, Monarch Power Disc 7.5 6.6 2-3/8
Granada, Monarch Non-Power Disc 9.1 7.8 2-1/2
Granada, Monarch 4-Wheel Disc 7.5 6.7 2-1/4
LTD II, Cougar Power Disc 7.8 7.0 2-1/2
LTD II, Police Power Disc 8.0 7.2 2-1/2
Thunderbird Power Disc 7.8 7.0 2-1/2
Continental Mark V 4-Wheel Disc 7.8 6.9 2-1/2
Lincoln Disc/Drum 9.1 8.2 2-1/4
Lincoln 4-Wheel Disc 9.1 8.2 2-1/2
Versailles 4-Wheel Disc 7.5 6.7 2-1/4 *
NOTE: Vehicles close to the maximum pedal travel specification may be improved by bleeding the brake system.
H1630-2R
FIG. 15 Brake Pedal Height a n d Travel Measurements

12-01-17 General Hydraulic Brake Service
forward stop before each. Move the vehicle in
reverse and forward for approximately ten feet;
then, apply the brakes and hold the brake pedal
down until the vehicle is completely stopped. This
will actuate the brake self-adjusters. If these stops
do not bring the b r a k e p e d a l t r a v e l w i t h i n
specification, make several additional forward and
reverse stops as outlined above.
6. On self-adjusting drum brakes, if the second series
of stops does not bring brake pedal travel within
specification, remove brake drums and check the
brake adjusters to make sure they are functioning.
Check brake linings for wear or damage. Repair or
replace all worn or d a m a g e d parts a n d non
functioning adjusters. Adjust the brake lining
outside diameter to the a p p r o x i m a t e inside
diameter of the brake drum with Rotunda Tool 11-.
0001 or equivalent described in Part 12-02.
7. If all the drum brake adjusters, brake drums and
brake shoe linings are functional, and the brake
travel is not within specifications, check the pedal
assembly for missing or worn bushings, or loose
attachments.
8. If the above actions do not bring the brake travel
within specifications, bleed the brake system.
P O W E R B R A K E F U N C T I O N A L T E S T -
V A C U U M B O O S T E R
W h e n p e r f o r m i n g the v a c u u m p o w e r b r a k e
functional checks a minimum of 12 inches of vacuum
(Hg) should be available at the brake booster hose
(check valve connection end), with the engine at idle
speed and the transmission in gear. Use Rotunda
Vacuum Tester 21-0014 or equivalent.
If the vacuum supply is below 12 inches (Hg) check
the vacuum available at the engine manifold, with the
engine at idle speed and the transmission in gear. If the
vacuum supply at the manifold is 12 inches (Hg) or
above, there is a leak or blockage in the vacuum supply
system.
Inspect all hoses and connections. All unused vacuum
connectors should be capped, hose connections properly
secured, and hoses in good condition with no holes and
no collapsed areas. Inspect the check valve on the
power unit for damage.
If the vacuum supply at the manifold is below 12
inches (Hg) perform the necessary engine adjustments
to bring the manifold vacuum up to a minimum of 12
inches of Mercury (Hg) check the booster operation as
follows:
1. Check the hydraulic brake system for leaks or
insufficient fluid.
2. With the transmission in neutral, stop the engine
and apply the parking brake. Depress the brake
pedal several times to exhaust all vacuum in the
system.
3. With the engine shut off and all vacuum in the
system exhausted, depress the pedal, and hold it
in the applied position. Start the engine. If the
vacuum system is operating, the pedal will tend to
fall away under foot pressure and less pressure will
be required to hold the pedal in the a p p l i e d
position. If no action is felt, the vacuum booster
system is not functioning.
4. Remove the vacuum hose from the brake booster
check valve connection. Manifold vacuum should be
available at the check valve end of the hose with
the engine at idle speed and the transmission in
neutral. Be sure that all unused vacuum outlets are
properly capped, hose connectors properly secured,
and that vacuum hoses are in good condition.
When it is established that manifold vacuum is
available to the booster, connect the vacuum hose
to the booster and repeat Step 3. If no downward
movement of the brake pedal is felt, replace the
brake booster.
5. Operate the engine a minimum of 10 seconds at
fast idle. Stop the engine and let the vehicle stand
for 10 minutes; then, depress the brake pedal with
approximately 20 pounds of force. The pedal feel
(brake application) should be the same as that
noted with the engine operating. If the pedal feels
hard (no power assist), replace the brake booster.
If the brake pedal movement feels spongy, bleed
the hydraulic system to remove air from the system.
Refer to Hydraulic System Bleeding, in this Part.
P O W E R B R A K E F U N C T I O N A L T E S T —
H Y D R O - B O O S T
The hydro-boost assembly is only one component in
the braking system, therefore, servicing of the hydro-
boost may involve the power steering hydraulic circuit,
the service brakes, or both.
Before performing any testing of the hydro-boost,
check and eliminate the following sources that could
affect proper operation of the brakes. Figs. 19, 20, 21
and 22 show hydro-boost power brake systems.
Preliminary Checks
Verify the condition by driving the vehicle and
comparing to a known quality vehicle for both steering
and braking.
The hydro-boost cannot cause noisy brakes, a fading
brake pedal, or pulling brakes. If one of these conditions
exists, components of the brake system other than the
hydro-boost may be the cause.
Check the fluid level in the master cylinder. If the
fluid level is not within 1/4 inch of the top of a
horizontal master cylinder reservoir or within 1/8 inch
of an inclined master cylinder reservoir, add Brake
Fluid—(ESA-M6C25-A) service part No. (C6AZ-19542-
A) or DOT-3 equivalent.
Check the power steering pump fluid level with the
engine off and the fluid at operating temperature. The
fluid level must show on the dipstick. Insufficient fluid
will affect both steering and braking power assist.
Check power steering pump belt tension and adjust
if required. Also inspect the belt for excessive wear or
glazing.
Inspect all power steering system hoses for leaks and
kinks. If the fluid smells burned, check hoses or cooler
for restrictions.
Check the e n g i n e idle s p e e d a n d a d j u s t to
specification.

Check the power steering hydraulic fluid for aeration
(shown by bubbles in the fluid). If there is air in the
system, bleed the system as follows:
Fill the reservoir to specification (the fluid must be
at normal operating temperature—165 ° to 175° F),
turn the steering wheel through its full travel three or
four times. Do not hold the wheels against their stops.
Recheck the fluid level.
After completing preliminary checks without finding
the source of the condition, check the function of the
hydro-boost by performing the Hydro-Boost Functional
Test covered in this Section.
If the hydro-boost is operating correctly, refer to the
Diagnosis Section for service brakes and check those
areas in the system that might cause the condition.
If the hydro-boost is not functioning, verify that the
power steering is operating normally by performing the
Power Steering Pump Flow and Pressure Test procedure
detailed in Part 13-01 of this Manual.
If power steering operation is normal, and the hydro-
boost is suspect, refer to the Hydro-Boost Diagnosis
Guide in this Section and check those items that might
cause the problem. If the hydro-boost is not functioning,
replace the hydro-boost as a complete assembly.
Hydro-Boost Functional Test
1. Check the hydraulic brake system for leaks or
insufficient fluid in the master cylinder reservoir.
2. With the transmission in neutral, stop the engine
and apply the brake pedal several times to deplete
all accumulator reserve.
3. Hold the pedal depressed with medium pressure
(25-35 lbs.), and start the engine. If the unit is
operating correctly, the brake pedal will fall slightly
and then push back against the foot. If no action
is felt, the indication is that the hydraulic booster
system is not functioning.
Accumulator Leakdown Test
1. Start the engine and operate at idle speed. Turn
the steering wheel to the stop. Hold for a maximum
of five seconds. Return the steering wheel to center
and turn off the engine.
2. Depress and release the brake pedal. Repeat this
procedure until a hard pedal is obtained. There
should be at least two (2) power assisted brake
applications with 20-25 lbs. applied to the brake
pedal.
3. Re-start the engine and let it idle. Turn the steering
wheel to the stop. There should be a light hissing
sound as the accumulator is charged. Hold lightly
against stop for a maximum of five seconds. Return
the steering wheel to center and turn off the engine.
4. Wait one hour and apply brake pedal (do not re
start the engine). There should still be at least two
(2) power mounted brake applications at 20-25 lbs.
pedal load before a hard pedal is encountered.
ADJUSTMENTS
B R A K E V A C U U M B O O S T E R P U S H R O D - T O -
M A S T E R C Y L I N D E R
The vacuum booster has an adjustable push rod
( o u t p u t rod) w h i c h is used to c o m p e n s a t e f o r
dimensional variations in an assembled booster. The
push rod length is adjusted after each booster power
unit has been assembled in production. A properly
adjusted pushrod that remains within the booster
with which it w a s assembled in production, should
never require a service adjustment*
A booster that is suspected of having an improper
pushrod length will indicate either of the following:
1. A pushrod which is too long will prevent the master
cylinder piston from completely releasing hydraulic
pressure and eventually cause the brakes to drag.
2. A pushrod which is too short will increase brake
pedal travel and cause a clunk noise from the
booster and master cylinder assembly.
If necessary, a booster pushrod length can be
verified with a pushrod gauge (see Fig. 6) using the
following procedure:
1. Without disconnecting the brake tubes, disconnect
the master cylinder and set it a w a y from the
booster power unit. The master cylinder must be
supported to prevent damaging the brake tubes.
2. With the engine running, gauge and adjust the
pushrod length as shown in Fig. 7. (A force of
approximately 5 pounds applied to the pushrod
with the gauge will assure that the pushrod is
seated within the power unit.
3. Install the master cylinder on the power unit and
alternate tightening the retaining nuts gradually to
the torque specified in this Part.
4. With the engine running and the master cylinder
reservoir cover removed, observe the fluid surface
in the reservoirs when the brake pedal is applied
rapidly. Some fluid movement should occur in
t h e f o r w a r d r e s e r v o i r . If f l u i d s u r f a c e
m o v e m e n t did not o c c u r , the p u s h r o d is
adjusted too long and the procedure must be
repeated to prevent eventual brake drag.
5. F a i r m o n t / Z e p h y r O n l y — F a i r m o n t / Z e p h y r
vehicles have the vacuum booster to master cylinder
push rod manufactured to a specific length. There
is no screw adjustment as found on other vehicle
booster installations. No adjustment can therefore
be made. However, the length of the push rod can
be checked using the gauge shown in Fig. 17. If not
within limits, the booster must be replaced.
H Y D R A U L I C S Y S T E M BLEEDING
When any part of the hydraulic system has been
disconnected for repair or replacement, air may enter
the system and cause spongy pedal action. Bleed the
hydraulic system after it has been properly connected,
to be sure that all air is expelled.

.250" GAGE
.250" DIM.
f
0.941"
t
T0.956
J _
r
.250" GAGE
" .250" DIM.
FIG. 16 Push Rod Gauge Dimensions
BOOSTER CHECK V A L V E
ADJUST PUSH ROD SCREW TO
PROVIDE A SLIGHT PRESSURE
(APPROXIMATELY 5 LBS.)
AGAINST THE GAUGE
PUSH ROD ADJUSTMENT—BENDIX
FIG. 17 Brake Booster Push Rod M e a s u r e m e n t —
Typical
Manual Bleeding
The p r i m a r y a n d s e c o n d a r y ( f r o n t a n d r e a r )
h y d r a u l i c b r a k e systems a r e i n d i v i d u a l systems
a n d are b l e d s e p a r a t e l y . Bleed t h e longest line
f i r s t o n t h e i n d i v i d u a l s y s t e m b e i n g s e r v i c e d .
During the complete b l e e d i n g operation D O NOT
a l l o w t h e r e s e r v o i r to r u n d r y . Keep the master
cylinder reservoirs filled with Brake Fluid—Extra Heavy
Duty (ESA-M6C25-A) Ford Part No. C6AZ-19542 or
DOT 3 equivalent. Never re-use brake fluid t h a t has
been d r a i n e d f r o m the h y d r a u l i c s y s t e m or has
been a l l o w e d t o stand in a n o p e n container for a n
e x t e n d e d period of time.
1. Do not use the secondary piston stop screw
( l o c a t e d o n t h e b o t t o m o f s o m e m a s t e r
c y l i n d e r s ) t o b l e e d t h e b r a k e s y s t e m .
Loosening or r e m o v i n g this screw could result
in d a m a g e t o t h e s e c o n d a r y p i s t o n or s t o p
screw.
2. To bleed the brake system, position a suitable box
wrench on the bleeder fitting on the brake wheel
cylinder. Attach a rubber drain tube to the bleeder
fitting. The e n d o f the t u b e should f i t snugly
around the bleeder f i t t i n g .
3. Submerge the free end of the tube in a container
partially filled with clean brake fluid, and loosen
the bleeder fitting approximately 3 / 4 turn.
4. Have a second person push the brake pedal down
slowly through its full travel. Close the bleeder
fitting, then return the pedal to the full-released
position. Repeat this operation until air bubbles
cease to appear at the submerged end of the
bleeder tube.
5. When the fluid is completely free of air bubbles,
secure the bleeder fitting and remove the bleeder
tube.
6. Repeat this procedure at the brake wheel cylinder
on the opposite side. Refill the master cylinder
' reservoir after each wheel cylinder is bled and
install the master cylinder cover and gasket. Be
sure t h e d i a p h r a g m - t y p e g a s k e t is p r o p e r l y
positioned in the master cylinder cover. W h e n
the bleeding operation is completed, t h e f l u i d
level should be filled t o full or w i t h i n 1/4 inch
o f the t o p o f the reservoirs on level master
c y l i n d e r s a n d w i t h i n 1 / 8 inch o n a n g l e d
master cylinders.
7. If the primary (front brake) system is to be bled,
repeat Steps 2 through 6 at the right front brake
caliper or cylinder and ending at the left front brake
caliper or cylinder.
8. On disc brake equipped models, be sure that disc
brake pistons are returned to their normal positions,
and that shoe and lining assemblies are properly
seated by depressing the brake pedal several times
until normal pedal travel is established.
Pressure Bleeding—All Models
For pressure bleeding, use a bladder-type bleeder
tank only. This type bleeder separates the brake fluid
f r o m the pressurized air c h a r g e w i t h a r u b b e r
diaphragm.
Bleed the longest lines first. The bleeder tank should
contain enough new brake fluid to complete the
bleeding operation. Use Ford Brake Fluid—Extra Heavy
Duty (ESA-M6C25-A) Ford Part No. C6AZ-19542-A or
DOT-3 equivalent for all brake applications. Never re
use brake fluid that has been drained from the hydraulic
system. The tank should be charged with approximately
10 to 30 pounds of air pressure. Never exceed 50
pounds pressure.
1. Clean all dirt from the master cylinder reservoir
cover.
2. Remove the master cylinder reservoir cover and
rubber gasket, and fill the master cylinder reservoir
with the specified brake fluid. Install the pressure
bleeder adapter tool to the master cylinder, and
attach the bleeder tank hose to the fitting on the

adapter. M a s t e r c y l i n d e r p r e s s u r e b l e e d e r
a d a p t e r teals can be o b t a i n e d f r o m v a r i o u s
m a n u f a c t u r e r s . Follow the instructions of the
manufacturer when installing the adapter.
3. Do not use the secondary piston stop screw,
l o c a t e d o n t h e b o t t o m o f s o m e m a s t e r
cylinders, to bleed the master cylinder.
4. If the rear wheel cylinders (the secondary brake
system), are to be bled, use a 3/8-inch box wrench
on the bleeder fitting on the right rear brake wheel
cylinder, and attach a bleeder tube snugly a r o u n d
the bleeder f i t t i n g .
5. O p e n the valve on the bleeder tank to admit
pressurized brake fluid to the master cylinder
reservoir.
6. Submerge the free end of the tube in a container
partially filled with clean brake fluid, and loosen
the bleeder fitting.
7. When air bubbles cease to appear in the fluid at
the submerged end of the bleeder tube, close the
bleeder fitting and remove the tube.
8. Repeat Steps 4 through 7 at the left rear wheel
cylinder.
9. If the vehicle is equipped with disc brakes repeat
Steps 4 through 7, starting at the right front disc
caliper and ending at the left front disc caliper. On
all models with metering valves the release rod must
be pulled outward and held a minimum of 1/16
inch (Fig. 18) while bleeding the primary brake
system. Remove the tool after bleeding.
10. When the bleeding operation is completed, close
the bleeder tank valve and remove the tank hose
from the adapter fitting.
11. O n disc brake-equipped vehicles, be sure that disc
brake pistons are returned to their normal positions,
and that shoe and lining assemblies are properly
seated by depressing the brake pedal several times
until normal pedal travel is established.
12. Remove the Pressure Bleeder Adapter Tool. Fill the
master cylinder reservoirs to full or within 1/4 inch
of the top. Install the master cylinder cover and
METERING V A L V E B L E E D E R
- T O O L J - 2 2 7 4 2
COMPRESS T O O L AND POSITION ONTO
V A L V E . R E L E A S E TO ALLOW SPRING
ACTION TO F O R C E B L E E D E R ROD OUT.
FIG. 18 Disc Brake M e t e r i n g V a l v e Bleeding
Tool
gasket. Be sure the d i a p h r a g m - t y p e gasket is
p r o p e r l y p o s i t i o n e d i n t h e m a s t e r c y l i n d e r
cover.
C E N T R A L I Z I N G T H E P R E S S U R E
D I F F E R E N T I A L V A L V E
After any repair or bleeding of the primary (front
brake) or secondary (rear brake) system, the dual-brake
warning light switch should be centralized.
To centralize the pressure differential valve and turn
off the warning light after a repair operation:
1. Turn the ignition switch to the ACC or O N position.
2. Depress the brake pedal and the piston will center
itself, causing the brake warning light to go out (if
it was illuminated).
3. Turn the ignition switch to the OFF position.
4. Before driving the vehicle, check operation of the
brakes and be sure that a firm pedal is obtained.
D U A L M A S T E R C Y L I N D E R
Removal—-Non-Power Brakes
Refer to Figs. 19 through 22.
1. Disconnect the negative battery cable.
2. Disconnect the stoplight switch wires at the
connector. Remove the spring retainer. Slide the
stop light switch off the brake pedal pin just far
enough to clear the end of the pin, then remove the
switch from the pin. Use care t o a v o i d switch
d a m a g e during r e m o v a l .
3. Loosen the master cylinder attaching nuts or bolts
from the inside of the engine compartment and slide
the master cylinder push rod and the nylon washers
and bushings off the brake pedal pin.
4. Remove the brake tubes from the primary and
secondary outlet ports of the master cylinder.
5. R e m o v e t h e lock nuts or c a p screws a n d
lockwashers that secure the master cylinder to the
dash panel and lift the cylinder f o r w a r d and
upward from the vehicle.
Installation—Non-Power Brakes
1. Carefully insert the master cylinder push rod and
boot through the dash panel opening and position
the master cylinder on the panel.
2. Install the lock nuts or cap screws at the dash panel
and leave loose.
3. Coat the nylon bushings with S A E 10W40 o i l .
Install the nylon washer and bushing on the brake
pedal pin.

FIG* 21 Cylinder a n d Brake Pedal I n s t a l l a t i o n — N o n - P o w e r — M u s t a n g a n d Capri
H2297-2D
FIG. 2 2 M a s t e r Cylinder a n d Brake Pedal I n s t a l l a t i o n — N o n - P o w e r — G r a n a d a and M o n a r c h

4. Position the stop light switch and master cylinder
push rod on the brake pedal pin, install the nylon
bushing and washer and secure them in position
with the spring retainer.
5. Connect the wires at the stop light switch connector.
6. Tighten the master cylinder attaching nuts or bolts
and connect the brake lines to the master cylinder.
7. Fill the master cylinder with the specified brake
fluid to full or within 1/4 inch of the top of a
horizontal master cylinder reservoir or within 1/8
inch of an inclined master cylinder reservoir. Use
Brake Fluid—Extra Heavy Duty (ESA-M6C25-A)
Ford Part No. C6AZ-19542-A or DOT-3 equivalent
for all drum brake applications.
8. Bleed the dual master cylinder and the primary and
secondary brake systems. Centralize the pressure
differential valve. Refer to Hydraulic System
Bleeding and Centralizing of the Differential Valve
for proper procedure.
9. Operate the brakes several times, then check for
external hydraulic leaks.
Removal—Power Brakes
Refer to Figs. 23 through 30.
1. Remove the brake tubes from the primary and
secondary outlet ports of the master cylinder.
2. Remove the two nuts attaching the master cylinder
to the brake booster assembly.
3. Slide the master cylinder forward and upward from
the vehicle.
Installation—Power Brakes
1. Position the master cylinder assembly over the
booster push rod and onto the two studs on the
booster assembly (Figs. 23 thru 30).
2. Install the attaching nuts a n d torque them to
specifications.
3. Install the front and rear brake tubes to the master
cylinder outlet fittings.
4. Fill the master cylinder with the specified brake
fluid to full or within 1 / 4 inch of the top of the dual
reservoirs on level master cylinders and 1/8 inch on
angled master cylinders. Use Brake Fluid—Extra
Heavy Duty (ESA-M6C25-A) Ford Part No. C6AZ-
19542-A or equivalent (DOT-3) for all brake
applications.
5. Bleed the dual master cylinder and the primary and
secondary brake systems. Centralize the pressure
differential valve. Refer to Hydraulic System
Bleeding and Centralizing of the Differential Valve
for the proper procedure.
6. Operate the brakes several times, then check for
external hydraulic leaks.
B R A K E C O N T R O L V A L V E A S S E M B L Y
Removal
1. Disconnect the brake warning light switch wire
harness connector from the warning light switch.
2. Disconnect the front brake system inlet tube and
the rear system inlet tube from the brake control
valve assembly.
FIG. 23 Master Cylinder and Brake Pedal Installation—Vacuum-Power—Pinto and Bobcat

381298-SX12A - HOSE 381298-SX11A - HOSE
2.8L ENG. 5.0L ENG.
TRANS. VAC.
TUBE REF.
381298-SX13A - 2.3L ENG. WITHOUT TURBO
ROUTE HOSE BETWEEN AIR CLEANER AND
AUTO. TRANS. VACUUM TUBE
N620481-S2
10-20 FT-LBS,
(14-27 N
CLUTCH
INSTALLATION
PUSHROD
2B195 ASSY.
REF.
N610957-S2
380699-S100
DIRECTION OPTIONAL
ROUTE VAC. TUBE
THRU HOLE IN
2501508
57048-S2
3-25 FT-LBS
(18-33 N-m)
2455 ASSY.
R E F
— J d J '&
380699-S100 REF u
VIEW Y
FOR SPEED CONTROL ONLY
V A L V E SPEED
CONTROL DUMP
REF.)
FIG. 24 Master Cylinder and Brake Pedal Installation—Vacuum-Power—Mustang and Capri
FIG. 25 Master Cylinder and Brake Pedal Installation—Vacuum Powei •Fairmont and Zephyr

FIG. 26 M a s t e r Cylinder a n d Brake Pedal Installation—Vacuum-Power—Granada a n d M o n a r c h

384989-S2 ASSY.
2 REQ'D.
MASTER
CYLINDER
- 2 1 4 0
" Y " BRACE
6501524 REF.
382802-S100
15-25 FT-LB
2A48? FOR DIAMOND JUBI LEE
THUNDERBIRD O N L Y
FIG. 27 Master Cylinder a n d Brake Pedal Installation—Vacuum-Power—LTD II, Cougar a n d
Thunderbird
FIG. 28 M a s t e r Cylinder a n d Brake Pedal Installation—Hydro-Boost Power Brak< •Continental M a r k V

1 2 - 0 1 - 2 ? General Hydraulic Brake Service 1 2 - 0 1 - 2 7
FIG, 29 Master Cylinder and Brake Pedal Installation—Hydro-Boost Power Brake—Lincoln Continental
FIG. 30 M a s t e r Cylinder a n d Brake Pedal Installation—Hydro-Boost Power Brake— Versailles

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