Specifications

PART 2-2-Bra ke System
6. Disconnect the secondary system
rear brake outlet tube from the lower
side pressure differential valve assem-
bly.
7. Remove the screw retaining the
pressure differential valve assembly
to the vehicle and remove the differ-
ential valve assembly.
8. If the differential valve is to
be replaced, remove the brake warn-
ing lamp switch and install the switch
in the new differential valve.
The pres-
sure differential valve assembly and
the brake warning lamp switch are
separate units and each is serviced
as a separate assembly only.
9. On disc brake equipped ve-
hicles, remove front wheel covers. Re-
move front wheel and tire assemblies.
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INSTALLATION
I. Mount the pressure differential
valve assembly on the vehicle and
tighten the attaching screw.
2. Connect the rear brake system
inlet tube to the pressure differential
valve assembly and tighten the tube
nut to the specified torque (Refer to
Part 2-3).
3. Connect the rear brake system
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outlet tube to the pressure differential
valve assembly. Tighten the tube
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nut to the specified torque.
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4. Connect the front brake system
inlet tube to the pressure differential
valve assembly and tighten the tube
nut to the specified torque.
5. Connect the right front brake
outlet tube to the pressure differential
valve assembly. Tighten the tube
nut to the specified torque.
6. Connect the left front brake out-
let tube to the pressure differential
valve assembly. Tighten the tube nut
to the specified torque.
7. Connect the shell-wire connector
to the brake warning lamp switch.
Make sure the plastic lugs on the
connector hold the connector securely
to the switch.
8. Bleed the brakes and centralize
the pressure differential valve (Part
2-1, Section 2).
9. On disc brake equipped cars,
install front wheel and tire assemblies,
and torque the retaining nuts to
specification. Install wheel covers.
BRAKE BOOSTER
Refer to Figs. 24 and 25.
REMOVAL
1. Working from inside the vehicle
below the instrument panel, discon-
nect the booster push rod link from
the brake pedal assembly. To do
this, proceed as follows:
Disconnect the stop light switch
wires at the connector. Remove the
hairpin retainer. Slide the stop light
switch off from the brake pedal pin
just far enough for the switch outer
hole to clear the pin,
and then lift the
switch straight
upward from the pin.
Be careful not to damage the switch
during removal. Slide the master cyl-
inder push rod and the nylon washers
and bushing off the brake pedal
pin.
2. Open the hood. Disconnect the
master cylinder outlet front and rear
tubes from the master cylinder and
the differential valve. Remove the mas-
ter cylinder from the booster. Secure
it to one side without disturbing the
hydraulic lines.
3. Disconnect the manifold vacuum
hose from the booster unit. If the
vehicle is equipped with an automatic
transmission disconnect the transmis-
sion vacuum unit hose.
4. Remove the four bracket-to-
dash panel attaching nuts or bolts.
Remove the booster and bracket as-
sembly from the dash panel, sliding
the push rod link out from the engine
side of the dash panel.
5. Remove the push rod link boot
from the dash panel.
Refer to Figs. 24 and 25.
1. Install the push rod link boot
in the hole in the dash panel.
2. On Falcon, Comet, Fairlane
vehicles, mount the booster and brack-
et assembly to the dash panel by
sliding the bracket onto the mount-
ing studs and the push rod link in
through the hole and boot in the dash
panel. Install the bracket-to-dash
panel attaching locknuts and torque
them to specification.
3. On Mustang and Couger ve-
hicles, mount the booster and bracket
assembly to the dash panel by slid-
ing the push rod link in through the
hole and boot in the dash panel. In-
stall the bracket to dash panel at-
taching bolts and torque them to
specification. Connect the manifold
vacuum hose to the booster. If the
vehicle is equipped with an automatic
transmission, connect the transmission
vacuum unit hose.
4. Before installing the master
cylinder, check the distance from the
outer end of the booster assembly
push rod to master cylinder surface.
Turn the screw in or out to obtain
the specified length. Refer to Part 2-1,
Section 2, Power Brake Master Cylin-
der Push Rod Adjustment. Install the
master cylinder and torque the re-
taining nuts to specifications.
5. Working from inside the vehicle
below the instrument panel, connect
the booster push rod link to the brake
pedal assembly. To do this, proceed
as follows:
Apply a coating of SAE 10 engine
oil to the bushings. Install the inner
nylon washer, the master cylinder
push rod, and the bushing on the
brake pedal pin. Position the switch
so that it straddles the push rod with
the switch slot on the pedal pin and the
switch outer hole just clearing the
pin. Slide the switch completely onto
the pin, and install the nylon washer.
Be careful not to bend or deform the
switch.
Secure these parts to the pin
with the hairpin retainer. Connect the
stop light switch wires to the connector,
and install the wires in the retaining
clip.
6. Connect the master cylinder
outlet front and rear tubes to the
master cylinder and the differential
valve. Torque the brake tube fittings
to specification (Figs. 20 and 21).
Bleed the brake system and centralize
the pressure differential valve.
7. Check the brake booster for
proper operation. Check the vacuum
lines for leakage.
BRAKE PEDAL
REMOVAL-MANUAL
SHIFT TRANSMISSION
1. On a Falcon, Comet or Fair-
lane, remove the clutch pedal assist
spring.
On a Mustang, remove the pedal
bumper and bracket assembly from
the pedal support bracket to relieve
the tension on the assist spring, and
then remove the spring.
2. Disconnect the clutch pedal-to-
equalizer rod at the clutch pedal by
removing the hairpin type retainer
and bushing.
3. Disconnect the stop light switch
wires at the connector.
4. Remove the switch retainer, and
slide the stop light switch off the brake
pedal pin just far enough for the
switch outer hole to clear the pin. Then
lower the switch away from the pin.
5. Slide the master cylinder push
rod and the nylon washers and bush-
ing off from the brake pedal pin
(Figs. 22 and 23).
6. Remove the self-locking pin
and washer from the clutch and
brake pedal shaft, then remove the
clutch pedal and shaft assembly, the
brake pedal assembly, and the bush-
ings from the pedal support bracket
(Figs. 22 and 23).
INSTALLATION
1. Apply a coating of SAE 10 en-