Ford COUGAR 1968 Shop Manual page 27

PART 2-2-Bra
ke System
CYLINDER
;----BLEEDER SCREW
BOOT CUP
\
I
BOOT
I
PISTON
RETURN' SPRING
I
PISTON
FRONT
B L E E D E R
_ _ _ - - -
SCREW
Cdp6
PISTON
RETURN SPRING cup BOOT
r"
REAR H I 197-B
FIG.
17-Front a n d R e a r W h e e l C y l i n d e r s
P R O P O R T I O N I N G V A L V E
assembled unless they are leaking o r
unless new cups and boots ;ire t o be
installed.
T h e proportioning valte is s'r-
I t is not necessary t o remove the
viced as a n a s s e m h l ~ and i s n e t e r ad-
wheel cylinder f r o m the hacking plate
justed o r orcrhauled.
t o disassc~nhle, inspect and overhaul
Refer
lo
View
oI'
Fig. l 8
for
Ihe
it, RemuVal is necess;lry only when
Fairlane, Falcon and M o n t e g o disc
the cylinder is damaged or scored
brake pressure control valve installa-
beyond repair.
lion. V i e w R o f Fig. 19 shows the in-
stallation o f the ~ " s t a n g and Cougar
D I S A S S E M BI,E
disc brake pressure control valve.
R E M O V A L
I. Disconnect the brake tubes at
the proportioning valve. O n a M u s t a n g
and Cougar vehicle. remove the con-
trol valve.
2. O n
a
Fairlane, Falcon o r M o n -
tego vehicle. remove the attaching bolt
and c l i p and remove the proportion-
ing valve.
I. O n a Fairlane. Falcon o r M o n -
tego vehicle, position the disc brake
pressure control valve. c l i p and i ~ t t a c h -
ing b o l t as shown i n Fig. 19. V i e w P.
and tighten the attaching bolt.
2. Connect the brake lines t o the
proportioning valve. and torque !he
conr~ector nuts t o specification (Fips.
18 and 19).
3. Bleed the brake system and cen-
tralize the differential pressure valve.
Refer t o Part 2-1, Section Z for the
correct procedure.
WHEEL CYLINDER REPAIR
Wheel cylinders should not be dih-
I. W i t h the wheel i n
a
raised po-
sition. remove the wheel and the drum.
2. Place a c l a m p over the ends
o f the hrake cylinder as shown i n
Fis. 13.
3. Remove the hrake shoe assem-
hlics I'ollowing procedure outlined i n
this section.
4.
The 6-cylinder Falcon and M u s -
tang models are not provided w i t h
links. Reniove the rubber boots f r o m
the ends of the piston.
O n 8-cylinder models and on a11
M o n t e g o and Fairlanes, remove the
links and rubber boots f r o m the ends
o f the piston. Remove the pistons,
cups, and return spring f r o m the cyl-
inder bore (Fig. 17).
5. Remove the bleeder screw f r o m
the cylinder.
I. Wash
;!I1
parts i n clean speci-
fied hrake fluid. D r y w i t h compressed
LIlr.
2. Check a l l the internal parts for
excessive wear o r damagc. Replace
scored pistons. Always replace the
rubher cups and dust hoots. I f anv of
the internal parts rcquirc replacing,
a l l should he replaced.
3. Inspect the cylinder hore for
score marks o r rust. I f either condi-
tion is present. the cylinder bore must
be honed. However. the cylinder
should not he honed more than 0.003
inch hcyond i t s original diameter. A
baffle i n the front wheel cylinder o f
the 6-cylinder Falcon and M u s t ; t n ~
models prevents honiny. :!!ciefore,
the cylinder must be replaceti.
4. Check the bleeder liole t o be
sure that i t is open.
I. A p p l y a light coating o f heavy-
duty brake fluid t o a l l internal parts.
2. Thread the bleeder screw i n t o
the cylinder and tighten securely.
3. Insert the return spring. cups.
and pistons i n t o their respective posi-
tions i n the cylinder bore (Fig. 17).
Place a boot over each end o f the cy-
linder. O n &cylinder model Mustangs,
Cougars, Falcons and a l l M o n t e g o
and Fairlanes. install the links i n the
ends o f the brake cylinders.
4. Install the shoe and adjuster
a h -
semblies, then adjust the shoes as out-
lined i n t his section.
5. Install the brake d r u m and
wheel. then bleed the brakes and cen-
t r a l i ~ e the differential valve ( P a r t 2-1,
Section 2).
WHEEL CYLINDER
REPLACEMENT
R E M O V A L
I. W i t h the wheel i n a raised po-
sition. remove the wheel and the d r u m .
2. Place
a
c l a m p over the ends o f
the wheel cylinder as shown i n I'ig.
13).
3. Reniove the brake shoe assem-
blies following procedures outlined i n
this section.
4. Disconnect the brake line From
the b r a k e cylinder.
T o disconnect the hose ;it a I'ront
cylinder. remove the tube f i t t i n g that
connects the opposite end o f the hose
t o the brake tube at
a
bracket on the
side rail. Remove the horse-shoe-type
retaining c l i p f r o m the hose and
bracket, disengage the hose f r o m the
bracket, then unscrew the entire hose
assembly f r o m the I'ront wheel cyl-
inder.
A t a rear cylinder, unscrew the tube
f i t t i n g that connects the tuhe t o the
cylinder. Do not p u l l the metal tuhe
away f r o m the cylinder. Pulling the
tuhe out of the cylinder connection
will hcnd the metal tuhe and make in-
stallation difficult. The tube w i l l sep-
arate f r o m the cylinder when the cyl-
inder is removed froni the hacking
plate.