torque FORD MUSTANG 1969 Volume One Chassis

02-02-26
Brake System

02-02-26

14.
Remove the clutch pedal assist

spring.

15.
On non-power brakes, remove

the retainer clip 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.

On power brakes, remove the retainer

nut from the brake pedal shaft then

remove the pedal shaft, the brake

pedal assembly and the bushings from

the pedal support bracket.

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

bushings in their proper places on the

clutch and brake pedal assemblies.

2.
On non-power brakes, position

the brake pedal to the pedal support

bracket, then install the clutch pedal

and shaft assembly through the sup-

port bracket and brake pedal assem-

bly. On power brakes position the

brake pedal to the pedal support

bracket, then install the pedal shaft

and nut.

3.
Install the clutch pedal assist

spring and pivot the clutch pedal

against its bumper stop. Secure the

pedal to the stop with a small C-

clamp as shown in Figs. 28 and 31.

4.
Position the pedal support

bracket assembly to the dash panel,

and to the steering column retainer

studs.

5.
Align the pedal support bracket

holes with the holes in the dash panel

and install the two attaching sheet

metal screws. On power brakes install

the nuts on the brake booster studs.

6. Install the two cap screws at-

taching the pedal support bracket to

the upper cowl bracket.

7. Install the cap screw attaching

the pedal support bracket to the top

inner cowl bracket (Figs. 28 and 31).

8. Install the inner nylon washer,

the master cylinder push rod, and the

bushing on the brake pedal pin. Posi-

tion the stop light 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 outer nylon washer as

shown in Figs. 28 and 31. Secure

these parts to the pin with the
self-

locking retainer.

9. Connect the stop light switch

wires to the connector.

10.
Connect the clutch pedal-

to-equalizer rod to the clutch pedal

assembly with the bushing and the

spring clip retainer. Apply SAE 10
engine oil to the bushing. Remove the

C-clamp from the clutch pedal.

11.
Working from the engine side

of the dash panel, on non-power

brakes, install the two cap screws at-

taching the pedal support bracket to

the dash panel. Then install the two

screws attaching the master cylinder

to the dash panel. On power brakes

install the cap screws retaining the

brake booster to the dash panel.

12.
Install the steering column.

Refer to Part 3-4, Section 2 for pro-

cedure.

13.
Adjust the clutch pedal free

play (Group 5) to specification, if re-

quired.

14.
Check the Brake Pedal Free

Height and Travel Measurements

(Part 2-1, Section 1).

15.
Connect the ground cable to the

battery.

FAIRLANE, MONTEGO,

FALCON, MUSTANG

AND COUGAR-

AUTOMATIC TRANSMISSION

Removal

1. Disconnect the stop light switch

wires at the connector.

2.
Remove the self-locking pin 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. Slide the master cylinder or

booster push rod and the nylon wash-

ers and bushing off from the brake

pedal pin (Figs. 27, 28, 30 and 31).

3.
On all vehicles except Mustang

and Cougar with power brakes, re-

move the self-locking pin and washer

from the brake pedal shaft, then re-

move the shaft, the brake pedal as-

sembly and the bushings from the

pedal support bracket. On Mustang

and Cougar vehicles with power

brakes, remove the locknut and bolt

from the pedal. Remove the pedal as-

sembly from the support bracket (Fig.

3).

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

the bushings in their proper places on

the pedal assembly and pedal support

bracket (Figs. 27, 28, 30 and 31).

2.
Position the brake pedal assem-

bly to the support bracket, then install

the pedal shaft or bolt through the

support bracket and brake pedal as-

sembly. Install the retainer or locknut.
3.
Install the inner nylon washer,

the master cylinder or booster 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 outer nylon washer

as shown in Figs. 27, 28, 30 and 31.

Secure these parts to the pin with the

self-locking pin.

4.
Connect the stop light switch

wires to the connector, and install the

wires in the retaining clip.

Check the Brake Pedal Free Height

and Travel Measurements, Part 2,

Section 1.

THUNDERBIRD
AND

CONTINENTAL MARK
III

Removal

1.
Loosen the booster mounting

nuts.

2.
Disconnect the stop light switch

wires at the connector.

3.
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. Slide the master

cylinder push rod and the nylon wash-

ers and bushing off from the brake

pedal pin (Fig. 32).

4.
Remove the pivot bolt and nut

that holds the pedal to the pedal sup-

port bracket. Remove the brake pedal

assembly from the pedal support

bracket, and remove the bushings.

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

the bushings in their proper places on

the pedal assembly (Fig. 32).

2.
Install the brake pedal assembly

and bushings to the support bracket,

and then install the pivot bolt through

the support bracket and brake pedal

assembly. Install the pivot bolt nut

and torque to specifications.

3.
Install the inner nylon washer,

the master cylinder push rod, and the

bushing on the brake pedal pin. Posi-

tion 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, install the

outer nylon washer as shown in Fig.

32.
Secure these parts to the pin with

the hairpin retainer.procarmanuals.com

02-02-27
Brake System

02-02-27

4.
Connect the stop light switch

wires to the connector, and install the

wires in the retaining clip.

5.
Torque the booster mounting

nuts to specifications.

LINCOLN CONTINENTAL

Removal

1.
Disconnect the battery ground

cable from the battery.

2.
It is necessary to obtain clear-

ance to remove vacuum hoses and the

electrical connector to the temperature

heat control box. Remove the two

screws retaining the relay to the fend-

er and push the relay aside. Discon-

nect the vacuum hoses and connector

at the heat control box.

3.
Working under the instrument

panel, disconnect the vacuum hoses,

wires and retaining clip from the tem-

perature heat control box. Remove the

two screws securing the temperature

control box to the dash panel.

4.
Remove the lower control hous-

ing retaining screws (6). Disconnect

the wire harnesses at the lower control

panel and place the panel aside. Re-

move the wire harness shield. Remove

the wire harness clip. Position the

wire harness aside. Remove the tem-

perature control box and position it

aside.

5.
Remove the hair-pin type retain-

er. Slide the stop light switch off the

brake pedal pin just far enough for

the switch outer hole to clear the pin.

Lift the switch upward from the pin.

Slide the master cylinder push rod,

nylon washers and bushing off the

brake pedal pin.

6. Remove the pivot bolt and nut

that holds the pedal to the pedal sup-

port bracket. Remove the brake pedal

assembly from the support bracket

and remove the bushings.

7.
If required, remove the brake

pedal pad retaining nuts and remove

the brake pedal pad.

Installation

1.
If the brake pedal pad was re-

moved, position the pad on the pedal.

Install the pad retaining nuts and tor-

que them to specification.

2.
Apply SAE 10 engine oil to the

bushings and locate all the bushings in

their proper places on the pedal as-

sembly.

3.
Install the brake pedal assembly

and bushings to the support bracket,

and then install the pivot bolt through
the support bracket and pedal assem-

bly. Install the pivot bolt nut and tor-

que it to specification.

4.
Install the inner nylon washer,the

master cylinder push rod link, and the

bushing on the brake pedal pin. Posi-

tion the switch so that it straddles the

push rod link with the switch slot on

the pedal and the switch outer hole

just clearing the pin. Install the outer

nylon washer as shown in Fig. 33. In-

stall the hair-pin type retainer on the

brake pedal pin.

5.
Connect the stop light switch

wires to the connector, and install the

wires in the retaining clip.

6. Position the wire harness and

clip on the temperature control box

and install the retaining screw. Posi-

tion the temperature control box to

the dash panel and install the two re-

taining bolts.

7.
Connect the vacuum lines and

the electrical connector to the control

box. Position the wire harness to the

control box and install the retaining

clip.

8. Position the wire harness shield

and install two retaining bolts.

9. Connect the wire harnesses to

the lower control panel and install the

retaining screws.

10.
Working within the engine

compartment, connect the wire con-

nector to the temperature heat control

box.

11.
Position the relay to the fender

apron and install the retaining bolts.

12.
Connect the ground cable to the

battery.

13.
Check the brakes and light

switch for proper operation. Close the

hood.

PARKING BRAKE CONTROL

ASSEMBLY

FORD, MERCURY

AND METEOR

Removal

Refer to Fig. 34.

1.
Make sure the parking brake is

fully released.

2.
Remove all tension from the rear

cables by backing off the adjusting nut

from the equalizer.

3.
Remove the roll pin that secures

the release knob to the cable and re-

move the knob.

4.
Remove the nut that secures the

release cable to the instrument panel
and remove the cable from the rear of

the instrument panel.

5.
Remove the two nuts attaching

the control assembly to the dash

panel.

6. Remove the cap screw attaching

the control assembly to the cowl side

bracket.

7.
Disconnect the hose to the park-

ing brake vacuum unit, if so equipped.

8. Remove the front cable assembly

retainer clip from the cable assembly

and disconnect the cable ball from the

control clevis.

9. Remove the control assembly

from the vehicle.

Installation

1.
Position the control assembly in

the vehicle.

2.
Fit the cable assembly through

its mounting hole and install the re-

taining clip. Connect the cable ball to

the control clevis.

3.
Connect the vacuum hose to the

parking brake unit, if so equipped.

4.
Install the attaching cap screw to

the cowl side bracket. Do not tighten.

5.
Install the two control assemb-

ly-to-dash panel nuts. Tighten the nuts

and the cap screw to specifications.

6. Insert the release cable into the

instrument panel and install the re-

taining nut.

7.
Install the release knob on the

cable with the roll pin.

8. Check the operation of the park-

ing brake. Adjust the parking brake

as required.

FAIRLANE, MONTEGO

AND FALCON

Removal

Refer to Fig. 35.

1.
Make sure the parking brake is

completely released.

2.
Remove all tension from the rear

cables by backing off the jam nut and

adjusting nut from the equalizer.

3.
Working inside the vehicle, re-

move the four bolts and one nut re-

taining the left air vent and cable as-

sembly to the dash and instrument

panels. Remove the vent assembly.

4.
Remove the parking brake front

cable ball retaining clip from the clev-

is.

5.
Disconnect the cable ball from

the notch in the brake clevis.

6. Remove the three screws that at-

tach the control assembly to the left

cowl inner side panel.procarmanuals.com

02-03-02
Specifications

02-03-02

BORE DIAMETERS-BRAKE DRUM, WHEEL CYLINDER AND MASTER

Models

Ford,

Mercury

and

Meteor

Mont ego

and

Fairlane

Falcon

Mustang

and Cougar

Thunderbird

Continental Mark
III

Lincoln Continental
Taxi and Station Wagon

Other

Pass, except Conv. 250, 302 CID Engines

Pass, and Conv. 351, 390, 428 CID Eng.

Convertible 250, 302 CID Engines

Station and Ranchero

9 Inch Brake
-
Passenger Car

10 Inch Brake
•
Station Wagon

10 Inch Brake
•
Passenger Car

200 CID Engine

351,
390, 428 CID Engine

250,
302, CID Engine
CYLINDER

Brake Drum

Inside

Diameter

11.030

11.030

10.000

10.000

10.000

10.000

9.000

10.000

10.000

9.000

10.000

10.000

11.030

11.030

11.090
Boring Umit

(Max.)
®

11.090

11.090

10.060

10.060

10.060

10.060

9.060

10.060

10.060

9.060

10.060

10.060

11.090

11.090

11.130
Wheel Cylinder Bore Dia.

Front
0

1.094

L_ U25

1.125

1.094

1.094

1.094

1.062
0

1.094

1.125

1.062
®

1.094

1.125

N/A

N/A

N/A
Rear
®

0.938

0.938

0.875

0.875

0.875

0.938

0.844®

0.938

0.875

0.844®

0.875

0.875

0.938

0.938

0.938
Master Cylinder Bore Dia.

With Power

Brake
®

1.000

1.000

0.9375

0.9375

0.9375

0.9375

0.9375

0.9375

0.9375

1.000

1.000

1.000

1.000

1.000

1.000
Less Power

Brake
®

1.000

1.000

1.000

1.000

1.000

1.000

1.000

1.000

1.000

1.000

1.000

1.000

N/A

N/A

N/A

©Max. Runout
0.007

(DMax. Allowable Hone
0.003

CD2.755 For
Ford,
Mercury, Meteor with Disc Brakes.

2.381 For Fairlane, Montego, Falcon, Mustang, Cougar with Disc Brakes.

SHOE AND LINING DIMENSIONS-

DISC BRAKES-INCHES
® Front Wheel Cylinder cannot be honed on Falcon or Mustang with
9
inch Brakes.

Lining Material

Lining Size

Lining Area
-
Square Inches

per Segment

Lining Thickness • Nominal

Lining Wear Limit (Front

Surface
of
Shoe)
•
Max.

Lining Taper -Max.

Lining to Rotor Clearance

(Brakes Released)
Ford,
Mercury, Meteor

Thunderbird, Continen-

tal Mark
III

Bonded

7.38x2.27
Outer

5.36x2.03
Inner

12.25 Outer

8.44 Inner

0.394

0.030

0.125

0.000-0.010
Fairlane, Montego

Falcon,
Mustang,

Cougar

Bonded

6.82 x 1.80 Outer

4.90x1.84 Inner

11.30 Outer

8.80 Inner

0.333
Outer

0.362
Inner

0.030

0.125

0.000
• 0.010
Lining Material

Lining Size

Lining Area

Shoe and Lining Thickness

Lining Thickness

Shoe and Lining Maximum

Wear Limit

Lining Maximum Wear Limit

(from front surface
of
shoe)

Lining to Rotor Clearance

(brakes released)
Lincoln Continental

Riveted Fomoco

5.36x1.90

10.03 Sq. In/segment

0.600
nominal

0.436
nominal

0.231

0.066

0.000-0.010

CALIPER CYLINDER BORE DIAMETER -INCHES

TORQUE LIMITS-HUB TO SPINDLE

Ford,
Mercury, Meteor, Thunderbird, Continental Mark

2.755

Mustang, Cougar, Falcon, Fairlane and Montego

2.381

Lincoln Continental

1.938

ROTOR DIMENSIONS

Car Line

Ford,
Mercury, Meteor

Thunderbird, Continental Mark
III

Fairlane, Falcon, Montego, Mustang

and Cougar

Lincoln Continental
Norn.

Thickness

1.180

1.180

0.935

1.240
Diameter

Outside

11.72

11.72

11.29

11.960
Inside

7.785

7.785

7.355

7.785
Description

Hub and Drum or Rotor Assembly to

Front Wheel Spindle
Ft-Lbs

Rotate
hub
while torquing

to 17-25 ft-lbs. Backoff

the adjusting nut 1/2 turn

and retighten to 10-15

inch pounds while rotat-

ing wheel Selectively
posi-

tion
nut
retainer
on ad-

justing nut
so
that a set

of slots are in line with

cotter pin hole. Adjusting

nut should not be rotated

in this operation. Lock
ad-

justing nut and nut retain-

er with cotter pin so that

the cotter
pin end
does

not interfere with seating

of wheel static collector

in spindle hole.procarmanuals.com

02-03-03
Specifications

02-03-03

ROTOR REFINISH

The following requirements must be met when resurfacing disc

brake rotors:

Rotunda Disc Brake Attachment FRE-2249-2 is the only approv-

ed tool to be used to ref inish the disc brake rotors. The step-by-

step resurfacing procedure provided with the tool must be adhered

t0" The finished braking surfaces of the rotor must be flat and

parallel within 0.0007
inch;
lateral runout must not exceed 0.003

inch total indicator reading, and the surface finish of the braking

surfaces are to be 15-80 micro inches.
On all models except Lincoln Continental the limiting dimen-

sion from the inner bearing cup to the inner rotor face must be

measured with a ball and gage bar (Rotunda FRE-70160).

On Lincoln Continental models the limiting dimension from the

inboard bearing cup to the inboard rotor face of 0.755 inch
mini-

mum and from the inboard bearing cup to the outboard rotor face

of 0.395 inch minimum must be observed.

TORQUE LIMITS -GENERAL -FT-LBS.

Parking Brake Control Assembly

Mounting Nuts and Bolts

Master Cylinder to Dash Panel Screw

Master Cylinder to Booster

Booster to Dash Panel

Disc Brake Caliper to Spindle Bolts

Disc Brake Rotor Splash Shield

to Spindle

Brake Hose to Caliper Connection Bolt

Caliper Locating Pins

Caliper Stabilizer to Anchor Plate

Bolt

Caliper Brake Shoe Clips

Caliper Bleeder Screws

Wheel Cylinder to Backing Plate Screws

Wheel Cylinder & Backing Plate

Anchor Pin Nut

Rear Brake Backing Plate to Axle

Housing:
Removable Carrier

Integral Type

Front Brake Backing Plate to Spindle

Wheel Cylinder Bleeder Screw

Brake Hose Connection to Front

Wheel Cylinder

Brake Line Connection to Rear Axle

Housing:
Removable Carrier

Integral Type

Hydraulic Tube Connections ®

3/8 x 24

7/16 x 24

1/2 x 20

9/16 x 18

Wheel to Hub and Drum or Hub and

Rotor Nuts
Ford-Mercury

Meteor

Cap Screw

12-19

Nuts 7-11

13-20

13-?0

13-20

Upper ©

110-140

Lower

90-120

9-14

17-25

25-35

8-11

6-10

6-15

10-20

20-30

50-70

IPo

25-40

6-15

12-20

30-40

25-35

10-15

10-15

10-17

10-17

70-115
Fair
lane-

Montego

Falcon

12-25

13-20

13-20

13-20

Upper CD

100-140

Lower

55-75

9-14

17-25

25-35

8-11

6-10

6-15

10 in. Brake

10-20

9 in. Brake

5-7

50-70

20-40

28-35

32-65 ®

Inch-lb.

12-20

12-19

12-19

10-15

10-15

10-17

10-17

4 lug

55-85

5 lug

70-115
Mustang-

Cougar

12-25

13-20

13-20

13-20

Upper ©

100-140

Lower

55-75

9-14

17-25

25-35

8-11

6-10

6-15

10 in. Brake

10-20

9 in. Brake

5-7

50-70

20-40

28-35

32-65 ®

Inch-lb.

12-20

12-19

12-19

10-15

10-15

10-17

10-17

4 lug

55-85

5 lug

70-115
Thunderbird

Continental

Mark III

1218

13-20

13-20

Upper ©

110-140

Lower

90-120

9-14

17-25

25-35

8-11

6-10

6-15

10-20

50-70

6-15

30-40

10-15

10-15

10-17

10-17

70-115
Lincoln

Continental

Dash Panel

10-20

Inst. Panel

712

13-20

13-20

100-140

9-14

7-9

6-15

10-20

30-35

6-15

10-15

10-15

10-17

10-17

70-115

® The upper bolt must be tightened first.

® On front disc brake calipers 6-15 ft-lbs.

® All hydraulic lines must be tightened to the specified torque value and be free of fluid leakage.procarmanuals.com

02-03-04
Specifications

02-03-04

SERVICE TOOLS

Ford Tool
No.

Rotunda
HRE
8650

Tool
7000-00

Rotunda
70160

Tool 33621

Tool 4235-C

Rotunda
FRE 1431

Rotunda
FRE
22492
Former
No.

LM 119

2018-A

2162

2035N

33621

Milbar

1112-144

4235-C

J
22742 (Kent Moore)
Description

Brake
Adjusting
Gage

Brake
Cylinder
Retaining

Clamp

Brake
Adjusting
Tool

Adapter
Cap

Brake Shoe
R
&
R
Spring

Rubber
Tipped
Air
Nozzle

Ball
and
Gage
Bar

Internal
Snap Ring PMers

Inch Pound Torque
Wrench

Axle Shaft
Remover

Brake Drum
Micrometer

Bleeder
Valve Clip Spring

Disc Brake Rotor
Attachmentprocarmanuals.com

03-01-06
Suspension — Steering, Wheels And Tires — General Service

03-01-06

SUSPENSION UPPER

ARM MOVEMENT

Front Bolt Outboard

Rear Bolt Outboard

Front Bolt Inboard

Rear Bolt Inboard
CASTER CHANGE

Tilt Backward

Increase Positive Caster

or

Decrease Negative Caster

Tilt Forward

Decrease Positive Caster

or

Increase Negative Caster

Tilt Forward

Decrease Positive Caster

or

Increase Negative Caster

Tilt Backward

Increase Positive Caster

or

Decrease Negative Caster
CAMBER CHANGE

Tilt Outward

Increase Positive Camber

or

Decrease Negative Camber

Tilt Inward

Decrease Positive Camber

or

Increase Negative Camber

FIG. 14—Caster and Camber Adjustments

sary. Then, tighten the upper arm

inner shaft attaching bolts to specifi-

cation. Remove the adjusting bar

(Tool T65P-3OOO-D) and the align-

ment spacers (Tool T65P-3O00-E or

F).

Camber

To adjust the camber angle, install

the tool as outlined above (Fig. 13).

Loosen both inner shaft attaching

bolts and tighten or loosen the hook

nuts to move the inner shaft inboard

or outboard as necessary with Tool

T65P-3OOO-D to increase or decrease

camber (Fig. 13). The camber angle

can be checked without tightening the

inner shaft attaching bolts.

COUGAR, FAIRLANE, FALCON,

MONTEGO, MUSTANG

Be sure all the equipment listed in

Equipment Installation is installed be-

fore adjusting the caster and camber.

Caster is controlled by the front

suspension strut (Fig. 15). To obtain

positive caster, loosen the strut rear

nut and tighten the strut front nut

against the bushing. To obtain nega-

tive caster, loosen the strut front nut

and tighten the strut rear nut against

the bushing.

Camber is controlled by the eccen-

tric cam located at the lower arm at-

tachment to the side rail (Fig. 13).

To adjust the camber, loosen the

camber adjustment bolt nut at the

rear of the body bracket. Spread the

body bracket at the camber adjust-
TER ADJUSTMENT NUTS

EAR INSULATOR

WASHER
FRONT ADJUSTMENT NUT

INNER SLEEVE

TURN NUTS

REARWARD

TO OBTAIN

POSITIVE

CASTER
OUTER SLEEVE

RONT INSULATOR

WASHER

CASTELLATED

NUT

TURN NUTS

FORWARD

TO OBTAIN

NEGATIVE

CASTER

NEGATIVE

CAMBER

SPREAD THIS MEMBER AT

LOWER ARM PIVOT

BUSHING

PRY AT THESE POINTS'

F1371-A

FIG. J5—Caster and Camber Adjustments

ment bolt area just enough to permit

lateral travel of the arm when the ad-

justment bolt is turned. Rotate the

bolt and eccentric clockwise from the

high position to increase camber or

counterclockwise to decrease camber.

After the caster and camber has

been adjusted to specification, torque

the lower arm eccentric bolt nut and

the strut front nut to specification.
LINCOLN CONTINENTAL

Preliminary Steps

1.
With the car properly positioned

and wheel alignment measuring equip-

ment properly installed, raise the hood

and scribe chalk marks around the

bolts and lock washers that secure theprocarmanuals.com

03-01-07
Suspension — Steering, Wheels And Tires — General Service

03-01-07

upper arm shaft to the frame member

(Fig. 3, Part 3-2).

2.
Loosen the arm shaft attaching

bolts,
raise the front end of the vehicle

and lower it again. This will break the

arm shaft loose from the frame mem-

ber.

3.
With a pry bar, move the arm

shaft back into alignment with the

chalk marks made in Step 1, and

tighten the shaft attaching bolts. The

bolts should be tightened just enough

to hold the shaft in position without

preventing its being moved with the

pry bar.

Caster

1.
With the aid of a pry bar, move

the shaft in or out, as required, to

meet specifications. A movement of

approximately 3 /32 inch at either the

front or rear bolt location will change

the caster 1/2 degree. Inboard move-

ment of the front bolt, or outboard

movement of the rear bolt, will change

caster in the negative direction. Out-

board movement of the front bolt, or

inboard movement of the rear bolt,

will change caster in the positive di-

rection.

2.
When the caster is correct, tor-

que the shaft attaching bolts to speci-

fication and recheck the caster and

camber to insure that the readings

have not changed.

Camber
TURN DOWNWARD TO

INCREASE ROD LENGTH

TURN UPWARD

TO DECREASE

ROD LENGTH
TURN

DOWNWARD

TO DECREASE

ROD LENGTH
TURN UPWARD TO

INCREASE ROD LENGTH

LEFT-HAND SLEEVE
RIGHT-HAND SLEEVE

FIG. 16—Spindle Connecting Rod Adjustment

WHEN TOE-IN IS CORRECT

TURN BOTH CONNECTING ROD

SLEEVES UPWARD TO ADJUST

SPOKE POSITION
F1433-A

i URN BOTH CONNECTING ROD

SLEEVES DOWNWARD TO

ADJUST SPOKE POSITION

WHEN TOE-IN IS

NOT CORRECT

LENGTHEN LEFT ROD TO

INCREASE TOE-IN

SHORTEN RIGHT ROD

TO DECREASE TOE-IN
SHORTEN LEFT ROD

TO DECREASE TOE-IN

LENGHTEN RIGHT ROD

TO INCREASE TOE-IN

ADJUST BOTH RODS EQUALLY TO MAINTAIN NORMAL SPOKE POSITION

1.
With the aid of a pry bar, move

the shaft in or out, as required, to

meet specifications. A movement of

approximately 3/64 inch of the entire

shaft will change the camber 1/4 de-

gree.
Inboard movement will change

the camber in the negative direction.

Outboard movement will change the

camber in the positive direction.

2.
When the camber is correct, tor-

que the shaft attaching bolts to speci-

fication and recheck the camber and

caster to insure that the readings have

not changed. Remove all alignment

equipment and alignment spacers and

install the right and left side rail

bumpers.

TOE-IN AND STEERING

WHEEL SPOKE

POSITION ADJUSTMENTS

Check the steering wheel spoke po-

sition when the front wheels are in the

straight-ahead position. If the spokes

are not in their normal position, they

can be properly adjusted while toe-in

is being adjusted.
F1434-
A

f/G.77—Toe-in and Steering Wheel Spoke Alignment Adjustment—Typical

1.
Loosen the two ciamp bolts or

each spindle connecting rod sleeve

(Fig. 16).

2.
Adjust toe-in. If the steering

wheel spokes are in their normal posi-

tion, lengthen or shorten both rods

equally to obtain correct toe-in (Fig.

16).
If the steering wheel spokes are

not in their normal position, make the

necessary rod adjustments to obtain

correct toe-in and steering wheel

spoke alignment (Fig. 17).

3.
Recheck toe-in and the steering

wheel spoke position. If toe-in is cor-

rect and the steering wheel spokes are

still not in their normal position, turn

both connecting rod sleeves upward or

downward same number of turns to

move the steering wheel spokes (Fig.

16).

4.
When toe-in and the steering

wheel spoke position are both correct,

torque the clamp bolts on both con-

necting rod sleeves to specification
(Part 3-13). Lubricate clamp, bolts

and nuts prior to torquing to specifi-

cation. The sleeve position should not

be changed when the clamp bolts are

tightened.

WHEEL BALANCING

See the instructions provided with

the Rotunda Wheel Balancer.

Make certain that the brakes are

not dragging before attempting to spin

the wheels. Push the brake shoes into

the caliper to free the rotor.

LUBRICANT CHECKING

PROCEDURE

MANUAL STEERING GEAR

1.
Center the steering wheel.

2.
Remove the steering gear hous-

ing filler plug.procarmanuals.com

03-01-08
Suspension
—
Steering,
Wheels
And
Tires
—
General Service

03-01-08

3.
Remove the lower (upper on

Mustang and Cougar) cover- to-

housing attaching bolt.

4.
With a clean punch or like in-

strument, clean out or push inward

the loose lubricant in the filler plug

hole and cover to housing attaching

bolt hole.
5.
Slowly turn the steering wheel to

the left stop, lubricant should rise

within the lower cover bolt hole; then

slowly turn the steering wheel to the

right stop, lubricant should rise within

the filler plug hole. If lubricant does

not rise in both the cover bolt hole
and the filler plug hole, add lubricant

until it comes out both holes during

this check.

6. Install the lower (upper on

Mustang and Cougar) cover- to-

housing attaching bolt and the filler

plug.

CLEANING
AND
INSPECTION

FRONT
END
GENERAL

INSPECTION

Do not check and adjust front

wheel alignment without first making

the following inspection for front-end

damage, or wear.

1.
Check for specified air pressures

in all four tires.

2.
Raise the front of the vehicle off

the floor. Shake each front wheel

grasping the upper and lower surfaces

of the tire. Check the front suspension

ball joints and mountings for loose-

ness,
wear, and damage. Check the

brake backing plate mountings. Tor-

que all loose nuts and bolts to specifi-

cation. Replace all worn parts as out-

lined in Part 3-2.

3.
Check the steering gear mount-

ings and all steering linkage connec-

tions for looseness. Torque all mount-

ings to specifications. If any of the

linkage is worn or bent, replace the

parts as outlined in Part 3-5.

4.
Check the front wheel bearings.

If any in-and-out free play is noticed,

adjust the bearings to specifications.

Replace worn or damaged bearings as

outlined in Part 3-12.

5.
Spin each front wheel with a

wheel spinner, and check and balance

each wheel as required.

6. Check the action of the shock

absorbers. If the shock absorbers are

not in good condition, the vehicle may

not settle in a normal, level position,

and front wheel alignment may be af-

fected.

WHEEL INSPECTION

Wheel hub nuts should be inspected

and tightened to specification at pre-

delivery. Loose wheel hub nuts may

cause shimmy and vibration. Elongat-

ed stud holes in the wheels may also

result from loose hub nuts.

Keep the wheels and hubs clean.

Stones wedged between the wheel and

drum and lumps of mud or grease can

unbalance a wheel and tire.
Check for damage that would affect

the runout of the wheels. Wobble or

shimmy caused by a damaged wheel

will eventually damage the wheel bear-

ings.
Inspect the wheel rims for dents

that could permit air to leak from the

tires.

UPPER BALL JOINT

INSPECTION

Ford,
Mercury,
Meteor,

Thunderbird,

Lincoln Continental
and

Continental Mark
III

1.
Raise the vehicle and place floor

jacks beneath the lower arms.

2.
Ask an assistant to grasp the

lower edge of the tire and move the

wheel in and out.

3.
As the wheel is being moved in

and out, observe the upper end of the

spindle and the upper arm.

4.
Any movement between the

upper end of the spindle and the upper

arm indicates ball joint wear and loss

of preload. If any such movement is

observed, replace the upper ball joint.

During
the
foregoing
check,
the

lower ball joint will
be
unloaded
and

may
move.
Disregard
all
such
move-

ment
of the
lower ball
joint.
Also,
do

not mistake loose wheel bearings
for a

worn ball
joint.

Cougar,
Fairlane,
Falcon,

Montego
and
Mustang

1.
Raise the vehicle on a frame

contact hoist or by floor jacks placed

beneath the underbody until the wheel

falls to the full down position as

shown in Fig. 18. This will unload the

upper ball joint.

2.
Adjust the wheel bearings as de-

scribed in Part 3-12.

3.
Attach a dial indicator to the

upper arm and position the indicator
so that the plunger rests against the

inner side of the wheel rim adjacent to

the upper arm ball joint.

4.
Grasp the tire at the top and

bottom, and slowly move the tire in

and out (Fig. 18). Note the reading

(radial play) on the dial indicator. If

MAXIMUM TOLERANCE

F
1500-A

FIG.
T8—Measuring Upper Ball

Joint Radial Play

MAXIMUM TOLERANCE

F14
35-A

FIG.
79—Measuring Lower Ball

Joint Radial Playprocarmanuals.com

03-01-11
Suspension — Steering, Wheels And Tires — General Service

03-01-11

3.
Inspect the rotor, rollers, cam

ring, pressure plate, cover, and bush-

ing in the pressure plate for wear or

scoring. If damaged, replacement of

the pump (less housing) is required.

4.
Make sure the inner faces of the

cover and the housing are free of

paint, nicks, or burrs. Check all fluid

passages for restrictions.

5.
Inspect the valving surfaces

(areas where the rotor and rollers con-

tact) for wear or scoring. Replace the

pressure plate or the cover if worn or

scored. Inspect the bushing in the

pressure plate for wear or scoring, and

replace the plate if necessary.

6. Inspect the control valve for

scores, nicks, or burred edges. Re-

place the valve if damaged. Do not dis-

assemble the valve. Check the valve

for free movement in the housing

bore.

7.
Inspect the tube seat in the hous-

ing. If damaged, remove it with an

E-Z-Out and install a new seat.

SHOCK ABSORBER CHECKS

All vehicles are equipped with hy-

draulic shock absorbers of the direct-

acting type and are nonadjustable and

nonrefillable. They cannot be repaired.
Before replacing a shock absorber,

check the action of the shock absor-

bers as follows:

ON VEHICLE TESTS

1.
Check the shock absorber to be

sure it is securely and properly in-

stalled. Check the shock absorber in-

sulators for damage and wear.

Replace any defective insulators and

tighten attachments to the specified

torque (on a shock absorber which in-

corporates integral insulators, replace

the shock absorbers).

2.
Inspect the shock absorber for

evidence of fluid leakage. A light film

of fluid is permissible. Be sure any

fluid observed is not from sources

other than the shock absorber.

Replace the shock absorber if leak-

age is severe.

3.
Disconnect the lower end of the

shock absorber. Extend and compress

the shock absorber as fast as possible,

using as much travel as possible.

Action should become smooth and

uniform throughout each stroke.

Higher resistance on extension than

on compression is a normal condition.

Faint swish noises are also normal.

Remove the shock absorber for a

bench test if action is erratic. If the
action is smooth, but the shock absor-

bers are suspected of being weak fol-

low step 4:

4.
Repeat step 3 on the mating

shock absorber installed on the oppo-

site side of the vehicle, and compare

results of both tests. If the action is

similar, it is unlikely that either shock

absorber is defective. Reconnect both

shock absorbers.

Replace the shock absorber having

the lower resistance. Ensure that the

part number of the replacement is the

same as that of the original shock ab-

sorber. The replacement shock absor-

ber resistance will appear to be higher

than either original due to initial fric-

tion of the rod seal.

BENCH TEST

With the shock absorber right side

up (as installed in vehicle), extend it

fully. Then turn the shock absorber

upside down and fully compress it.

Repeat this procedure at least three

times to ensure that any entrapped air

has been expelled. Now place the

shock absorber right side up in a vise,

and hand stroke the shock absorber as

described in On Vehicle Tests, step 3.

If action is not now smooth and uni-

form, install a new shock absorber.procarmanuals.com

03-02-08
Suspension

03-02-08

IN-VEHICLE ADJUSTMENTS AND REPAIRS

HOISTING INSTRUCTIONS

Damage to steering linkage compo-

nents and front suspension struts may

occur if care is not exercised when po-

sitioning the hoist adapters of 2 post

hoists prior to lifting the vehicle.

If a 2 post hoist is used to lift the

vehicle, place the adapters under the

lower arms or the No. 1 crossmember.

Do not allow the adapters to contact

the steering linkage. If the adapters

are placed under the crossmember, a

piece of wood (2 x 4 x 16 inches)

should be placed on the hoist channel

between the adapters. This will pre-

vent the adapters from damaging the

front suspension struts.

UPPER BALL JOINT

REPLACEMENT

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK III

1.
Raise the vehicle high enough to

provide working space, and place a

support under the lower arm. If a

chain hoist or a jack that has a nar-

row contact pad is to be used on the

bumper to raise the vehicle, distribute

the load along the bumper by using a

steel plate 3 or 4 inches long as a con-

tact pad to prevent damaging the

bumper.

2.
Remove the wheel and tire.

3.
Drill a
1/8-inch
hole through

each upper ball joint retaining rivet.

Using a large chisel, cut off the rivets.

4.
Remove the upper arm suspen-

sion bumper.

5.
Remove the cotter pin and nut

from the upper ball joint stud.

6. Place a box wrench over the

lower end of the ball joint remover

tool, and position the tool as in Fig. 7.

The tools should seat firmly against

the ends of both studs, and not

against the lower stud nut.

7.
Turn the wrench until both studs

are under tension, and then, with a

hammer, tap the spindle near the

upper stud to loosen the stud from the

spindle. Do not loosen the stud with

tool pressure alone. Remove the ball

joint.

8. Clean the end of the arm, and

remove all burrs from the hole edges.

Check for cracks in the metal at the

holes,
and replace the arm if it is

cracked.
F1436-A

FIG. 7—Disconnecting Ball

Joints—Typical

9. Attach the new ball joint to the

upper arm. Use only the specified

bolts,
and nuts. Do not rivet the new

ball joints to the arm. Torque the nuts

to specification.

10 Install the upper arm suspension

bumper. Torque the nut to specifica-

tion.
11.
Position the ball joint stud in

the spindle bore, and torque the at-

taching nut to specification. Install a

new cotter pin.

12.
Install the wheel and tire.

13.
Remove the safety stands, and

lower the vehicle.

14.
Check and, if necessary, adjust

caster, camber, and toe-in. Whenever

any part of the front suspension has

been removed and installed, front

wheel alignment must be checked.

COUGAR, FAIRLANE,

FALCON, MONTEGO,

MUSTANG

1.
Position a support between the

upper arm and frame side rail as

shown in Figs. 8 and 9; then, raise the

vehicle and position safety stands.

2.
Remove the wheel and tire.

3.
Remove the cotter pin and nut

from the upper ball joint stud.

4.
Position the ball joint remover

tool as shown in Fig. 10. The tool

should seat firmly against the ends of

both studs, and not against the lower

stud nut. It may be necessary to re-

move the lower ball joint cotter pin if

it prevents the tool from seating on

the lower stud.

5.
Turn the tool with a wrench until

both studs are under tension, and

then, with a hammer, tap the spindle

near the upper stud to loosen the stud

F 1496-A

FIG. 8—Upper arm Support—Mustangprocarmanuals.com