Specifications

I
Section Page
..........................
1 Description and Operation 2-9
...........
Dual-Master Cylinder Brake System 2-9
Disc Brakes
........................................... 2-1 1
Hydraulic Self-Adjusting Brake System ........ 2-13
Booster System
..................................... .2-13
Parking Brakes ...................................... 2-14
2 In-Vehicle Adjustments and Repairs .............. 2-14
Front (Disc) Brake Shoe and Lining
Replacement
....................................... 2-17
Disc Brake Caliper Assembly
.................... 2-18
....... Front Wheel Hub and Rotor Assembly
2-18
Disc Brake Rotor Splash Shield
................. 2-19
Proportioning Valve..
.............................. 2-19
........
Brake Shoe Adjustments-Rear Wheels 2-16
Rear Brake Drum.
.................................. 2-20
Rear Brake Shoe Replacement
................. .2-20
Rear Wheel Cylinder Repair
..................... 2-19
Rear Wheel Cylinder Replacement
............. 2-19
Rear Brake Backing Plate Replacement
....... 2-20
Hydraulic Lines
.................................... 2-20
Section Page
Brake Tube Replacement
...................... 2-20
Brake Hose Replacement
...................... 2-20
3 Removal and Installation ............................ 2-23
Dual Master Cylinder
- Standard Brakes ...... 2-23
Dual-Master
Cylinder-Power Brakes ......... 2-24
Pressure Differential Valve Assembly
.......... 2-24
Brake Booster
........................................ 2-25
Brake Pedal
........................................... 2-25
Parking Brake Control Assembly
............... 2-26
Parking Brake Equalizer to Control
Cable
.................................................... .2-26
Parking Brake Equalizer to Rear Wheel
Cable
................................................ 2-27
............................
4 Major Repair Operations 2-28
Brake Drum Refinishing
.......................... 2-28
Rotor Refinishing
................................... 2-28
Brake Shoe Relining
............................... 2-29
Dual-Master Cylinder
.............................. 2-29
Disc Brake Caliper
................................ .2-30
DESCRIPTION AND
Disc brakes are available as op-
tional equipment for the front wheels
on the various vehicle models listed
in (Fig. I).
The dual-master cylinder equipped
hydraulic brake system employes
sin-
gle-anchor, internal expanding and
self-adjusting drum brake assemblies
on the rear wheels of vehicles with
disc brakes, and on the front and rear
wheels of all others (Fig.
1).
DUAL-MASTER CYLINDER
BRAKE SYSTEM
The dual-master cylinder brake sys-
tem has been incorporated in all car
models to provide increased vehicle
safety. The system consists of a dual-
master cylinder, pressure differential
valve assembly and a switch. The
switch on the differential valve acti-
vates a dual-brake system warning
light, located on the instrument panel.
The dual-master cylinder brake sys-
tem is similar to a conventional
(single) brake master cylinder sys-
tem. In the dual-system, two master
cylinders are combined in a single
cast iron casting (Fig. 2). One por-
tion actuates the front brake system
and the other actuates the rear brake
system (Figs. 20 and 21). Hydraulic
fluid leakage or failure of one of
the systems does not impair the oper-
ation of the other portion of the dual-
brake system. A dual-brake warning
light signals a failure of either the
front or rear brake system.
OPERATION
The dual-master cylinder used on
Fairlane, Falcon and Comet vehicles
equipped with power brakes have the
master cylinder outlet ports for the
rear brake system located on the bot-
tom of the master cylinder body.
Master cylinder hydraulic system
bleed screws are located in the out-
board side of those master cylinders
having secondary (rear brake) system
outlet ports in the bottom of the mas-
ter cylinder castings (Fig. 29).
All Fairlane, Falcon and Comet ve-
hicles equipped with standard drum
brakes and all Mustang and Cougar
vehicles equipped with power disc,
power drum and standard drum
brakes have both the primary (front)
and secondary (rear) brake system
outlet ports located on the outboard
side of the dual-master cylinder body
castings. These master cylinders do
not require master cylinder bleed
screws (Figs. 27, 28 and 30).
The external appearance of the dual
master cylinders for the various ve-
hicles also differ in configuration
of the covers. All vehicles having
standard drum brake systems and
Mustang, Cougar vehicles equipped
with power drum brakes have primary
and secondary master cylinder cover
domes of equal size. Dual master cyl-
inders for all other vehicles equipped
with power disc and power drum
brake systems have large primary
(front brake) and smaller secondary
(rear brake) cover domes.
A code letter is stamped on the
side or outer end of each master cyl-
inder body casting for easy service
identification. The vehicle application,
type of brakes and the identification
code are shown in Fig. 3.
A brake pressure differential valve
assembly (Fig.
4) incorporating an hy-
draulically operated mechanical
switch is utilized to operate a dual-
brake warning light, located on the
instrument panel.
Hydraulic pressure for both front
wheel brakes is provided from the pri-
mary system (front) brake outlet port
and line, located opposite the primary
system inlet port of the differential
valve.
Hydraulic pressure for both rear
wheel brakes is provided from the sin-
gle secondary (rear brake) outlet
line, located opposite the secondary
system inlet port of the differential
valve. On disc brake equipped ve-
hicles, a proportioning valve is located
in the secondary (rear brake) system
line that leads to the brake hose
bracket on the rear axle housing. The
brake hose bracket serves as a junc-
tion point for the individual brake
lines that lead to the wheel cylinders
of right and left rear brake com-
ponents.
When the brake pedal is depressed,
both the primary (front brake) and