Ford Mercury Colony 1968 Shop Manual page 32

2-24
GROUP 2 - Brakes
damage during removal.
3. Slide the master cylinder push
rod and the nylon washers and bush-
ings off the brake pedal pin.
4. Remove the brake tube from
the primary and secondary outlet
ports of the master cylinder.
5. Remove the lock nuts that se-
cure the master cylinder to the dash
panel and lift the cylinder forward
and upward from the vehicle.
INSTALLATION
1. Position the boot on the push
rod and secure the boot to the master
cylinder. Carefully insert the master
cylinder push rod and boot through
the dash panel opening and position
the master cylinder on the mounting
studs on the dash panel (Fig. 22).
2. Install the lock nuts on the studs
at the dash panel and torque them to
specification.
3. Coat the nylon bushings with
SAE 10W oil. Install the nylon washer
and bushing on the brake pedal pin.
4. Position the stop light switch 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. Connect the brake lines to the
master cylinder leaving the brake line
fittings loose.
7. Fill the master cylinder with
the specified brake fluid to within 1/4
inch of the top of the dual reservoirs.
Use Rotunda Brake Fluid—Extra
Heavy Duty—Part Number C6AZ-
19542-A (ESA-M6C25-A) for disc
brake applications, and Rotunda
Brake Fluid—Part Number B7AZ-
19542-A, R103-A or equivalent for
drum brake applications. The disc
brake system fluid is colored blue for
identification. Do not mix low tem-
perature brake fluids with the speci-
fied fluid for the power disc brake
system.
8. Bleed the dual-master cylinder
and the primary and secondary brake
systems. Centralize the pressure dif-
ferential valve. Refer to Hydraulic
System Bleeding and Centralizing of
the Differential Valve, Part 2-1, Sec-
tion 2 for proper procedure.
9. Operate the brakes several
times, then check for external hy-
draulic leaks.
DUAL MASTER C Y L I N D E R -
POWER BRAKES
REMOVAL
1. Remove the brake tubes from
DISC BRAKE
SHAFT CLUTCH
(AUTOMATIC PEDAL
TRANSMISSION) ASSEMBLY
OUTLET TUBE
REAR BRAKES
ALL STANDARD TRANSMISSIONS
AND 390, AND 428
ENGINES WITH AUTOMATIC
TRANSMISSION
FORD MODELS ONLY
240 AND 302
ENGINES-AUTOMATIC
TRANSMISSION
H 1495-C
FIG. 23—Master Cylinder Installation— Power Brakes
the primary and secondary outlet
ports of the master cylinder (Fig.
23).
2. Remove the two nuts and two
lock washers attaching the master cyl-
inder to the brake booster assembly.
3. Slide the master cylinder for-
ward and upward from the vehicle.
INSTALLATION
1. Before installing the master cyl-
inder, check the distance from the
outer end of the booster assembly
push rod to the master cylinder
mounting surface. Turn the push rod
adjusting screw in or out as required
to obtain the specified length. Refer
to Part 2-1, Section 2, Power Brake
Master Cylinder Push Rod Adjust-
ment for the proper procedure.
2. Position the master cylinder as-
sembly over the booster push rod and
onto the two studs on the booster as-
sembly (Fig. 23).
3. Install the attaching nuts and
lock washers and torque them to spec-
ifications.
4. Install the front and rear brake
tubes to the master cylinder outlet
fittings.
5. Fill the master cylinder with the
spicified brake fluid to within 1/4
inch of the top of the dual reser-
voirs. Use Rotunda Brake Fluid
Extra Heavy Duty Part Number
C6AZ-19542-A (ESA-M6C25-A) for
all brake applications. The brake
system fluid is colored blue for identi-
fication. Do not mix low temperature
brake fluids with the specified fluis
for the disc brake system.
6. Bleed the dual-master cylinder
and the primary and secondary brake
systems. Centralize the pressure dif-
ferentical valve. Refer to Hydraulic
System Bleeding and Centralizing of
the Differential Valve, Part 2-1, Sec-
tion 2 for the proper procedure.
7. Operate the brakes several
times, then check for external hydrau-
lic leaks.
PRESSURE DIFFERENTIAL
VALVE ASSEMBLY
REMOVAL
1. Disconnect the brake warning
light wire from the pressure differen-
tial valve assembly switch (Figs. 19
and 21). To prevent damage to the
brake warning switch wire connector,
expand the plastic lugs to allow re-
moval of the shellwire connector