service FORD MUSTANG 1969 Volume One Chassis

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

03-02-22
Suspension

03-02-22

washer and the nut on the upper stud

from the upper side of the spring

upper seat. Torque the nut to specifi-

cations.

6. Extend the shock absorber and

locate the lower stud in the hole in

mounting bracket on the rear axle

housing. Install a new self-locking at-

taching nut and torque to specifica-

tion.

MUSTANG AND COUGAR

Removal

1.
Disconnect the shock absorber

from the spring clip plate (Fig. 30).

2.
Remove the shock absorber ac-

cess cover from the luggage compart-

ment (Fig. 28).-(On convertible mod-

els,
remove the rear seat and seat

back to reach the access cover.)

SHOCK ABSORBER ACCESS COVER
SHOCK ABSORBER UPPER ATTACHING NUT

LUGGAGE COMPARTMENT

FLOOR PANEL

F 1489-A

FIG. 28—Rear Shock Absorber

Access Cover

3.
Remove the shock absorber

upper attaching nut.

4.
Compress the shock absorber

and remove it from the vehicle. Re-

move the bushings and washers from

the shock absorber studs.

Installation

1.
Place the bushing and inner

washer on the shock absorber stud.

2.
Connect the upper stud to the

mounting, and install the bushing,
ACCESS COVER

F 1488-A

FIG. 29—Rear Shock Absorber

Upper Mounting

outer washer, and new nut on the

stud. Torque the nut to specification,

and install the cover.

3.
Connect the lower stud to the

spring clip plate, and install the bush-

ing, outer washer, and new nut on the

stud. Be sure that spring clip plate is

free of burrs. Tighten the nut to speci-

fication.

MONTEGO, FALCON, AND

FAIRLANE (EXCEPT

CONVERTIBLE)

Removal

1.
Open the luggage compartment

door, and remove the spare wheel and

tire.

On the Ranchero, remove the at-

taching screws, and lift the forward

half of the floor panel from the body;

then, remove the access cover from

the opening in the floor pan over the

shock absorber.

On station wagons, remove the ac-

cess cover from the opening in the

seat riser over the shock absorber.

2.
Fold back the floor mat and re-

move the shock absorber access cover

from the floor pan. Remove the nut,

outer washer, and rubber bushing that

attach the shock absorber to the upper

mounting in the floor pan (Fig. 29).

3.
Raise the vehicle and remove the

attaching nut, outer washer and bush-

ing from the shock absorber at the

spring clip plate (Fig. 30). Compress

the shock absorber and remove it

from the vehicle.

4.
If the shock absorber is service-

able and requires new bushings, remove

the inner bushings and washers from

the shock absorber studs.

Installation

1.
Place the inner washer and bush-

ing on each shock absorber stud.
2.
Expand the shock absorber and

position it to the spring clip plate and

to the mounting in the floor pan.

3.
Connect the lower stud to the

spring clip plate, and install the bush-

ing, outer washer, and new nut on the

stud (Fig. 30). Be sure the spring clip

plate is free of burrs.

On the Ranchero, after tightening

the nut to specification, install the for-

ward half of the floor panel.

4.
From the luggage compartment,

install the bushing outer washer and

new attaching nut to the upper mount-

ing stud (Fig. 29). Torque to specifica-

tion. On a station wagon, replace the

floor bed panel (14 screws).

5.
Place the spare wheel and tire in

the luggage compartment, and secure

it in the storage position.

MONTEGO AND FAIRLANE

CONVERTIBLE

Removal

1.
Remove the rear seat cushion

and seat back.

2.
Partially raise the vehicle on a

hoist. With an assistant under the ve-

hicle holding the shock absorber, re-

move the nut from the top of the

shock absorber.

3.
Remove the lower shock absor-

ber attaching nut and remove the

shock absorber.

Installation

1.
Position the washers and bush-

ings on the shock absorber and posi-

tion the shock absorber to the lower

attachment. Install the bushing, outer

washer, and new attaching nut and

torque the nut to specification (Part

3-13).

2.
Lower the vehicle and install the

bushing, outer washer, and new at-

taching nut on the top of the shock

absorber. Torque the nut to specifica-

tion.

3.
Install the rear seat back and

seat cushion.

LINCOLN CONTINENTAL

Removal

1.
Lift the vehicle and place support

stands under the axle housing. Posi-

tion the vehicle with a hoist to relieve

tension on the shock absorbers.

2.
Remove the screws that attach

the shock absorber mounting plate to

the crossmember (Fig. 31).procarmanuals.com

03-02-23
Suspension

03-02-23

SEDAN MODELS ONLY-

SPRING CLIPS
5705
,^-::^^^^SSSS^

^CS^.-''' .--'""-.'.'""'"* D D
A
f~
V
C
T

BRACKET

(STATION WAGON-

AND RANCHERO

ONLY) 5610

INSULATOR RETAINER

5736

INBOARD

SHACKLE

BUSHING

5791

... ».IA-

vae.

FRONT HANGER

INBOARD BUSHING

FRONT HANGER

OUTBOARD BUSHING
REAR

SHACKLE

ASSEMBLY

5776

OUTBOARD SHACKLE

BUSHING

5791

LOWER INSULATOR 5732

INSULATOR PLATES

(H.D.
STATION WAGON

AND RANCHERO) 5A584

SPRING CLIP PLATE

(STATION WAGON

AND RANCHERO

ONLY) 5798-99

SPRING HANGER

MOUNTING BOLT

HANGER

FIG. 30—Rear Spring and Shock Absorber—Typical

3.
Remove the attaching nut and

washers from the lower end of the

shock absorber.

4.
Remove the shock absorber.

5.
Remove the nut, outer washer,

and insulator that attach the shock

absorber to the mounting plate; then

remove the plate.

6. Inspect the shock absorber for

damage or leaks. If the bushing must

be replaced, the operation may be per-

formed without the use of special

tools.
Wet the rubber bushing with a

soap solution and press it into the

shock absorber eye by hand. Repla-

cethe insulators if they appear worn or

damaged.

Installation

1.
Place the inner washer and insu-

lator on the upper (stud) end of the

shock absorber (Fig. 31).
2.
Install the mounting plate, outer

insulator, washer and nut on the stud.

Torque the nut to specification.

3.
Attach the mounting plate and

shock absorber to the crossmember

with the attaching screws and washers.

Torque the screws to specifications.

4.
Connect the lower end of the

shock absorber to the mounting stud

with the washers and attaching nut.

Torque the nut to specification.

REAR SHOCK ABSORBER

LOWER MOUNTING STUD

REPLACEMENT

LINCOLN CONTINENTAL

If the shock absorber mounting stud

is damaged, replace the stud as fol-

lows:
F 1487-A

1.
Cut off the old stud as close to

the bracket as possible.

2.
Grind off the weld at both ends

of the stud and bracket face.

3.
Drive out the balance of the stud

with a brass drift. Do not enlarge the

hole in the bracket.

4.
Remove any weld remaining on

the sides of the bracket.

5.
Attach the service stud to the

axle housing bracket with a nut. Tor-

que the nut to specification.

6. Stake the nut to prevent loos-

ening.

REAR SPRING

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK III

Removal

1.
Raise the vehicle on a hoist with

the hoist under the rear axle housing.procarmanuals.com

03-02-26
Suspension

03-02-26

T64K-578 7-B2 (Adapter)

-83 (Nut)

(Bolt)

SPRING FRONT
EYE

Tool-T64K-5781-B2 (Adapter)
BUSHING

F 1484-A

FIG. 35—Rear Spring Front Bushing Installation—Typical

5.
Remove
the
rear shackle assem-

bly
and the two
outer bushings.

6. Remove
the
front hanger bolt,

nut,
and
washer from
the eye at the

forward
end of the
spring. Lift
out the

spring assembly.

7.
If the
front bushing
is
being
re-

placed, assemble
the
special tool
com-

bination
to the
bushing
in the
spring

front
eye as
shown
in
Fig.
34.

8. While holding
the
tool
nut,
tight-

en
the
tool bolt against
the
tool thrust

washer,
the
adapter,
and
detail
Al.

This operation will force
the
bushing

out
of the
spring
eye
into detail
A4 of

the tool
as
shown.

Installation

During rear suspension leaf spring

assembly replacement
in
service,
all

used attaching components must
be

discarded
and
replaced with
new com-

ponents.

1.
Assemble
the
bushing
and the

special tool combination
to the
spring

front
eye as
shown
in Fig. 35.

2.
While holding
the
tool
nut,
tight-

en
the
tool bolt against
the
tool thrust

washer, adapter,
and
detail
A4 to

force
the
bushing into
the
spring
eye

as shown.

3.
Position
the
spring under
the

rear axle
and
insert
the
shackle
as-

sembly into
the
rear hanger bracket

and
the
rear
eye of the
spring.
4.
Install
the
shackle inner bush-

ings,
the
shackle plate,
and the
lock-

nuts.
Tighten
the
locknuts finger-tight.

5.
Position
the
spring front
eye in

the front hanger, slip
the
washer
on

the front hanger bolt,
and
(from
the

inboard side) insert
the
bolt through

the hanger
and
eye. Install
the
locknut

on
the
hanger bolt
and
tighten finger-

tight.

6. Lower
the
rear axle until
it
rests

on
the
spring. Position
the
spring clip

plate
on the
clips (U-bolts). Install
the

U-bolt nuts
and
torque
to
specifica-

tion.

7.
Connect
the
lower
end of the

shock absorber
to the
spring clip plate

using
a new nut if
working
on a sta-

tion wagon
or
Ranchero.

8. Place safety stands under
the

rear axle, lower
the
vehicle until
the

spring
is in the
approximate curb load

position,
and
then torque
the
front

hanger stud locknut
to
specification.

9. Torque
the
rear shackle locknuts

to specification.

10.
Remove
the
safety stands
and

lower
the
vehicle.

REAR SPRING

LINCOLN CONTINENTAL

Removal

1.
Raise
the
vehicle
and
place
sup-

port stands under
the
sidemembers
on
the rear
of
each rear spring hanger.

2.
Lower
the
rear axle slightly
to

reduce some
of the
spring load; then,

remove
the
spring U-bolts.

3.
Remove
the
nuts, lock washers

and front mounting stud. Refer
to

Fig.
6.

4.
Remove
the
rear shackle nuts

and mounting plate. Remove
the

lower inner insulator. Remove
the

spring.
If the
rear shackle insulators

are
to be
replaced,
it
will
be
necessary

to remove
the
rear hanger assembly.

(Hanger attaching bolts must
be tor-

qued
to
specification when rein-

stalled.)

5.
Remove
the
insulators from
the

spring.

6. Examine
all
parts
for
wear
or

damage. Note
the
condition
of the

spring center bolt.

7.
The
spring center bolt
can be re-

placed
by
clamping
the
spring
in a

vise,
thus keeping
the
spring
com-

pressed during bolt removal
and in-

stallation.

Installation

1.
Attach
the
spring
and
bushing
to

the front hanger. Torque
the
outboard

nut
to
specifications.
Do not
tighten

the inboard
nut at
this time.

2.
Install
the
spring
to the
rear

shackle assembly with
the
insulators

in position.
Do not
tighten
the
nuts
at

this time. Refer
to Fig. 6.

3.
Place
the
insulator
and
retainers

in position
on the
spring.

4.
Lower
the
axle housing onto
the

insulator
and
retainer assembly.

If
a
wedge
was
located between
the

upper retainer
and
mounting
pad,

reinstall
the
same thickness wedge

with
the
taper
in the
original direc-

tion. Raise
the
axle until
the
spring
is

approximately horizontal with
the

floor.

5.
Install
the
lower insulator retain-

er
and
U-bolts.
Do not
tighten
the U-

bolt nuts
at
this time. Torque
the
rear

shackle nuts
to
specifications.

6. Torque
the
inboard
nut at the

front
eye to
specification.

7.
Tighten
the
U-bolt nuts evenly
to

the specified torque.

8. Make sure
the
lower insulator

retainer contacts
the
upper retainer.procarmanuals.com

03-05-02
Steering Columns
And
Linkage

03-05-02

which also will shear away during
im-

pact.

TILT STEERING COLUMNS

The steering column
is of the col-

lapsible type
to
lessen
the
possibility

of injury
to the
driver
of the
vehicle

should
he
become involved
in an
acci-

dent.
The
lower
end of the
steering

column tube
at the
bellows area will

collapse approximately
six
inches

upon
a
hard impact.

The shift tube
and the
steering shaft

are provided with plastic dowels
and

will shear
and
allow them
to
collapse

in proportion
to the
outer tube upon

impact.

Once
the
steering column
has
been

collapsed,
a
complete
new
column
must
be
installed.

The tilt column features nine driv-

ing positions (four
up and
four down

from
a
center position).
The
.column

also features
a
turn signal switch with

a lane-changer position turn indicating

position
and
emergency warning flash-

er control.

TILT-AWAY STEERING COLUMNS

The tilt-away steering column
fea-

tures nine driving positions (four
up

and four down from
a
center position)

and
a
tilt-away position that
is
auto-

matically accomplished
on
Mustang

and Cougar models when
the
ignition

key
is
turned
to the
OFF
position
and

the left door
is
opened.
On
Thunder-

bird models,
the
tilt-away occurs when
the shift lever
is
placed
in
PARK
and

the driverns door
is
opened.

The steering column
is of the col-

lapsible type
to
lessen
the
possibility

of injury
to the
driver
of the
vehicle

should
he
become involved
in an
acci-

dent.
The
lower
end of the
steering

column tube
at the
bellows area will

collapse approximately
six
inches

upon
a
hard impact.

The shift tube
and the
steering shaft

are provided with plastic dowels
and

will shear
and
allow them
to
collapse

in proportion
to the
outer tube upon

impact.

Once
the
steering column
has
been

collapsed,
a
complete
new
column

must
be
installed along with mounting

brackets which will also shear away

during impact.

IN-VEHICLE ADJUSTMENTS
AND
REPAIRS

STEERING WHEEL SPOKE

POSITION ADJUSTMENT

When
the
steering gear
is on the

high point,
the
front wheels should
be

in
the
straight-ahead position
and the

steering wheel spokes should
be in

their normal position with
the
Pitman

arm pointing directly forward.
If the

spokes
are not in
their normal posi-

tion, they
can be
adjusted without
dis-

turbing
the
toe-in adjustment (Part

3-1).

STEERING WHEEL

REPLACEMENT

1.
Disconnect
the
negative cable

from
the
battery.

2.
Working from
the
underside
of

the steering wheel spoke, remove
the

crash
pad
attaching screws. Lift
the

crash
pad
from
the
wheel.
(On
Conti-

nental Mark
III
models,
pry out the

crash
pad
insert
and
remove
the two

screws that secure
the
crash
pad. Re-

move
the
crash
pad. On
models

equipped with steering wheel mounted

speed controls, refer
to
Group
16 for

removal instructions). Remove
the

horn ring
(if so
equipped)
by
turning

it counterclockwise.

3.
Remove
the
steering wheel
nut,

and then remove
the
steering wheel

with tool T67L-3600-A
(Fig. 1). Do

not
use a
knock-off type steering

wheel puller
or
strike
the end of the

steering shaft with
a
hammer. Striking

the puller
or
shaft will damage
the

bearing
or the
collapsible column.

4.
Transfer
all
serviceable parts
to

the
new
steering wheel.

5.
Position
the
steering wheel
on

the shaft
so
that
the
alignment mark
on
the hub of the
wheel
is
adjacent
to

the
one on the
shaft. Install
a new

locknut
and
torque
it to
specifications.

6. Install
the
horn ring
(if so

equipped)
and
crash
pad.

STEERING COLUMN UPPER

BEARING REPLACEMENT

STATIONARY COLUMNS

Removal

1. Disconnect
the
horn wire
and the

turn indicator wires
at the
connector.

2.
Working from
the
underside
of

the steering wheel spoke, remove
the

two crash
pad
attaching screws. Lift

the crash
pad
from
the
wheel.
(On

Continental Mark
III
models,
pry out

the crash
pad
insert
and
remove
the

two screws that secure
the
crash
pad.

Remove
the
crash
pad. On
models

equipped with steering wheel mounted

speed controls, refer
to
Group
16 for

7oo/-T67L-3600-A
removal instructions). Remove
the

horn ring
(if so
equipped)
by
turning

it counterclockwise.

3.
Remove
the
steering wheel
at-

taching
nut.
Remove
the
steering

wheel using tool T67L-3600-A
(Fig.

1).
Do not use a
knock-off type steer-

ing wheel puller
or
strike
the end of

the steering shaft with
a
hammer.

Striking
the
puller
or
shaft will
dam-

age
the
bearing
or the
collapsible
col-

umn.

4.
Remove
the
turn indicator lever.

5.
Remove
the
turn signal switch

attaching screws. Lift
the
switch over

the
end of the
steering shaft
and
place

it
to one
side.

6. Remove
the
snap ring from
the

top
of the
steering shaft.

7.
Loosen
the two
flange-to-steering

column tube attaching bolts
to
disen-

gage them from
the
tube.

8. Raise
the
flange upward while

BEARING
AND

INSULATOR

Spacer

G 1502 -B

FIG.
1—Removing
Steering Wheel
G 1497-A

FIG. 2—Installing Upper Bearingprocarmanuals.com

03-05-07

Steering Columns And Linkage
03-05-07

the steering column
(F in Fig. 8).

7.
Disconnect
the
transmission shift

rod
at the
shift tube.

8. Working under
the
hood, install

the aligning spacer (Fig.
9)
around
the

visible portion
of the
steering shaft

and slide
it up the
shaft into
the
steer-

ing column.
It may be
necessary
to

move
the
shaft back
and
forth
to
com-

pletely install
the
spacer.

9.
At
this point
the
steering column

assembly, being loose,
may
have

dropped toward
the
steering gear

grounding
the
steering shaft
on the

steering gear input shaft.
To
properly

establish
the
steering shaft
to
steering

gear clearance, insert
a 1/8
diameter

rod
or
drill through
the
opening
in the

upper half
of the
flex coupling.

10.
Tighten
to a
snug
fit
(approxi-

mately
2-3
ft-lb)
the
nuts retaining
the

toe plates
to the
dash panel
(B in Fig.

8).

11.
If the
aligning spacer cannot
be

rotated freely,
the
dash panel holes

must
be
filed
or
reamed
for
greater

travel
(as
mentioned
in the
second

paragraph
at the
beginning
of
this

procedure).

12.
Tighten
all
nuts
and
bolts

(noted
as C, D and E in
Fig.
8) in the

passenger compartment
to a
snug
fit

(approximately 2-3 ft-lb). Again check

aligning spacer
for
looseness. Perform

these tightening operations
in
alpha-

betical order.

13.
Tighten
the
lateral adjustment

bolt
(F in Fig. 8) to
snug
fit.
Again

check
the
aligning spacer
for
loose-

ness.

14.
Tighten
all
bolts and nuts
to the

proper torque value (listed
in Fig. 8)

in alphabetical order.

15.
Remove
the
steering shaft
al-

igning spacer.

16.
Remove
the 1/8
diameter
rod or

drill previously inserted
in the
flex

coupling.

17.
Reinstall
the
trim
at the
instru-

ment panel
to
steering column mount-

ing.

LINCOLN CONTINENTAL

If
a
condition
of
high shift
or
steer-

ing effort
is
experienced
it may be

caused
by
improper alignment
of the

energy absorbing steering column.
The

following procedures outline
the
steps

necessary
to
correctly realign either

fixed
or
tilt columns:

1.
Disconnect
the
battery.

2.
Loosen four
toe
plate attaching

nuts (Fig.
10).

3.
Loosen
one toe
plate
to
steering

column clamp bolt
and nut.
Check

alignment
of
steering shaft
to
shift
-HANDLE PORTION

2-3/4"
-*- 3/4"

BEND AROUND

STEERING SHAFT
DIMENSION
A:

STANDARD COLUMN 7/16"

TILT WHEEL COLUMN
1-1/8"

•2-3/4

FABRICATE ALIGNING SPACER OUT OF

PLASTIC SHIPPING COLLAR PROVIDED

ON SERVICE DRIVESHAFTS, OR OUT
OF

1/32"—1/16" CARDBOARD
STEERING SHAFT

ALIGNMENT SPACER-BEND AROUND

STEERING SHAFT (DIMENSION
A)
AND

SLIDE UP THE SHAFT INTO COLUMN

G1537-A

FIG. 9—Aligning Spacer Fabrication
and
Insertion

BRAKE PEDAL

SUPPORT BRACKET

PART

A-TOE PLATE

B-CLAMP

C-C0LUMN BRACKET

D-BRAKE PEDAL

SUPPORT BRACKET
TORQUE VALUE

8-12 FT. LB.

3-5 FT. LB.

10-15
FT.
LB.

8-12 FT. LB.

G1541-A

FIG. 10—Steering Column Alignment Locations
and
Torque

Specifications—Lincoln Continentalprocarmanuals.com

03-06-01
Manual Steering

03 06-01

PART
3-6
Manual Steering

COMPONENT INDEX

STEERING GEAR

Cleaning
and
Inspection

(See Part 03-01)

Description

Disassembly
and
Overhaul

Removal
and
Installation

STEERING WORM
AND
SECTOR

Adjustment
and
Repair
MODEL APPLICATION
All
Models
Ford

06-01

06-03

06-02

06-02
Mercury
06-01

06-03

06-02

06-02
Meteor
06-01

06-03

06-02

06-02
Cougar
06-01

06-03

06-02

06-02
Fairlane
06-01

06-03

06-02

06-02
Falcon
06-01

06-03

06-02

06-02
Montego
06-01

06-03

06-02

06-02
Mustang
06-01

06-03

06-02

06-02
Lincoln-
Continental
N/A

N/A

N/A

N/A
Thunderbird
N/A

N/A

N/A

N/A
Continental-
Mark
III
N/A

N/A

N/A

N/A

A page number indicates that the item
is for
the vehicle listed
at
the head
of
the column.

N/A indicates that the item
is not
applicable
to
the vehicle listed.

DESCRIPTION

STEERING GEAR

The steering gear
(Fig.
1) is of the

worm
and
recirculating ball type.
The

sector shaft
is
straddle mounted
hav-

INPUT SHAFT
ing
a
bushing located
in the
cover

above
the
gear
and a
roller bearing
in

the housing below
the
gear.

SECTOR SHAFT ADJUSTMENT SCREW

LOCK
NUT

IDENTIFICATION
TAG

SECTOR SHAFT COVER
The worm bearing preload
is con-

trolled
by the
large adjusting
nut

which
is
threaded into
the
housing.

The sector shaft mesh load
is con-

trolled
by an
adjusting screw located

in
the
housing cover.

The steering linkage consists
of the

Pitman
arm,
steering-arm-to-idler
arm

rod, idler
arm and the
spindle
con-

necting rods
(tie
rods).

A steering gear identification
tag is

provided under
one of the
cover
at-

taching bolts
(Fig.
2).

STEERING GEAR

MODEL
SERVICE IDENTIFICATION

CODE NUMBER

FIG.
1—Manual
Steering Gear
SERIAL NUMBER
OR
DATE CODE

G 1625-A
G
1626-A

FIG. 2—Steering Gear Identification
procarmanuals.com

03-09-06
Saginaw Design Integral Power Steering Gear

03-09-06

ADJUSTER
PLUG

DUST
SEAL

FIG. 14 —Adjuster Plug Disassembled

the plug far enough to provide clear-

ance for the dust seal and the snap

ring.

8. Lubricate a new dust seal

C1AZ-19582-A and install it with

smooth rubber surface facing outward.

9. Secure the dust seal with the

ring, making sure that the ring is

properly seated.

10.
Lubricate a new O-ring seal

with vaseline and install it on the ad-

juster plug.

11.
Assemble the thrust bearing

outer race, thrust bearing, inner race,

and the thrust bearing spacer on the

adjuster plug (Fig. 16).
OIL
RETAINING

SEAL
RING

G
1637-A

12.
Press a new bearing retainer

into the bearing bore. The radial loca-

tion of the dimples is not important.

STUB SHAFT AND

VALVE ASSEMBLY

The control valve and spool is a se-

lect fit and cannot be serviced other

BEARING
AND

RACES

1636-A

FIG. 15 —Removing or Installing

Roller Rearing from Adjuster Plug
G
1635-A

FIG.
76
—Installing Thrust

Bearing Retainer

SPOOL
SPRING

DOWEL
BEARING

RACE

G1634-A

FIG. 77—Control Valve Disassembled
than removing the spool to replace the

dampener O-ring or replace the three

teflon seals or O-rings under the teflon

seals.

1.
Remove the cap to worm O-ring

and discard it (Fig. 17).

2.
Work the rear coil of spool

spring onto the stub shaft bearing sur-

face.
Do not pry on the valve body.

Slide the spring off the shaft.

3.
Extreme care must be used when

removing the valve spool. The diame-

tral clearance between the valve body

and the spool may be as low as 0.0004

inch. The slightest cocking of the

spool may jam it in the valve body.

a. To remove the valve spool, hold

the valve assembly in both hands with

the stub shaft pointing downward.

Push lightly on the valve spool with a

small rod by inserting the rod through

the openings in the end cap (Fig. 18)

until the spool is far enough out of the

valve so that it may be grasped by the

hand. Withdraw the spool with a

steady oscillating pull to prevent jam-

ming. If slight sticking occurs, make a

gentle attempt to reverse the with-

drawal procedure. If this does not free

the spool, it has become cocked in the

valve body bore. Do not attempt to

force the spool in or out if it becomes

cocked. In this case, continue to disas-

semble the valve assembly as follows

and return to the spool as described

later. Remove the stub shaft, torsion

bar, and end cap assembly by holding

the thumbs on the valve body as

shown in Fig. 18. Tap the torsion bar

lightly against the workbench. This

will dislodge the cap from the valve

body to cap pin. The stub shaft, tor-

sion bar and end cap assembly can

now be removed from the valve body.

b.
If the valve spool has become

cocked as described in step 3 above, it

can now be freed. By visual inspection

on a flat surface it can be determined

in which direction the spool is cocked.

A few very light taps with a light soft

plastic or raw-hide mallet should align

the spool in the bore and free it. Do

not tap with anything metallic. If

spool can be rotated, it can be re-

moved.

4.
Remove O-ring dampener seal

from the spool and discard it.

5.
Carefully cut the valve rings and

the ring back-up seals, remove and

discard them, providing the rings show

evidence of excessive wear. The valve

rings are made of filled teflon and it is

very unusual that replacement is re-

quired.

6. Remove the dampener O-ring

from the valve spool and discard it.procarmanuals.com

03-09-08
Saginaw Design Integral Power Steering Gear

03-09-08

Code

Size

6

7

8

9

10

11
Diameter

Mean

0.28117

0.28125

0.28133

0.28141

0.28149

0.28157
Size Range of Ball

(Inch)

0.28112-0.28122

0.28120-0.28130

0.28128-0.28138

0.28136-0.28146

0.28144-0.28154

0.28152-0.28162

FIG. 21 —Worm Ball Sizes

installed. Service replacement balls are

available in the sizes shown in (Fig.

21).

12.
Note the ball size stamped on

the rack-piston and install the next

size larger balls to increase the pre-

load. If no number is stamped on the

rack-piston, the original ball code size

was No. 7.

A change of one ball size larger will

increase the preload approximately

one in-lb. Final preload on replace-

ment balls should be 2-3 in-lbs.

Remove the valve assembly from

the worm and the rack-piston from

the vise.

13.
Insert Tool T65P-3D517-A into

the plug end of the rack and piston to

contact the worm shaft (Fig. 22).

Apply pressure on the tool while ro-

tating the worm shaft out of the pis-

ton and rack. Leave the tool in place

until the piston is installed in the

housing.

END OF TOOL MUST BE IN

CONTACT WITH WORM

SHAFT

Tool * T65P-3D517-A

FIG. 22—Installing Tool

in Raek-Piston
G 1631-A
ASSEMBLY OF

STEERING GEAR

1.
Secure the steering gear housing

in a vise.

2.
Lubricate the worm shaft, lower

thrust bearing, and races; then posi-

tion the thrust bearing and races on

the worm.

Align the valve body drive pin on

the worm, with the narrow pin slot in

the valve body. Be sure O-Ring seal

between the valve body and the worm

head is installed.

3.
Position the valve assembly and

the worm shaft in the housing as a

unit (Fig. 23). Do not push against the

stub shaft as this could cause the stub

shaft and cap to pull out of the valve

body, allowing the spool seal to slip

into valve body fluid grooves. Install

the valve assembly by pushing on the

outer diameter of the valve body hous-

ing with the finger tips. Be sure that

the teflon rings are not binding inside

the housing. The valve assembly is

correctly seated when the fluid return

hole in the gear housing is fully vis-

ible.

4.
Place the tool shown in Fig. 24

over the end of the stub shaft.

5.
Lubricate a new adjuster plug

O-ring and install it in the adjuster

plug groove.

6. Install the adjuster plug over the

end of the stub shaft and tighten it

DRIVE PIN
just enough to be sure all parts are

properly seated. Remove Tool T65P-

3A537-B.

7.
Install the adjuster plug locknut

loosely on the plug.

8. Tighten the adjuster plug with

wrench J7624 while rotating the input

shaft. As soon as additional drag is

noted, back the adjuster plug off 1/8

turn. Measure the input shaft drag

with an in-lb torque wrench.

9. Tighten the adjuster plug (Fig.

25) to obtain a 1-3 in-lb preload in ex-

cess of the drag that was measured

previously. Tighten the adjuster plug

lock nut and recheck the thrust bear-

ing preload. Total preload must not

exceed 8 in-lbs.

10.
Install Tool T65P-3805-A in

the steering gear housing. Position the

rack-piston as shown in Fig. 26. Be

sure that Tool T65P-3D517-A is con-

tacting the worm shaft. Push the

rack-piston inward until it contacts

the worm shaft while keeping pressure

applied to Tool T65P-3D517-A. Turn

the stub shaft clockwise until the

middle rack groove in the rack-piston

is aligned with the center of sector

shaft roller bearing. Remove the tool

from the housing.

11.
Lubricate a new O-ring with

C1AZ-19582-A and position it in the

sector shaft cover.

12.
Thread the sector shaft cover

on the adjusting screw until it bottoms

then back it off 1 1/2 turns.

13.
Install the sector shaft so that

the center gear tooth meshes with the

center groove in the rack-piston. Be

sure that the cover O-ring is in place

before pushing the cover down on the

housing.

14.
Install the cover screws and

lock washers. Tighten to 30-35 ft-lbs.

15.
Install a new adjuster lock nut

halfway on the adjuster screw.

16.
Install the end plug in the

rack-piston. Tighten the plug to 50-

100 ft-lbs torque.

17.
Lubricate a new housing end

plug O-ring and install it in the hous-

ing.

18.
Place the end plug in the gear

housing and seat it against the O-ring

seal. It may be necessary to tap the

Tool
T65P-3A537-B

STUB SHAFT

ADJUSTER

PLUG

G 1630-A

FIG. 23—Installing Valve and Worm Shaft in Housing
G 1629-A

FIG. 24 —Installing Adjuster Plugprocarmanuals.com

03-10-03
Ford-Thompson Power Steering Pump

03-10-03

EIGHT CYLINDER WITH

AIR CONDITIONER

1.
Remove the power steering fluid

from the pump reservoir by discon-

necting the fluid return hose from the

reservoir and allow the fluid to drain

in a suitable container.

2.
Disconnect the pressure hose

from the pump.

3.
Remove 3 bolts from the front of

the pump and the one nut at the rear

that attach the pump to the mounting

bracket and remove the drive belt

from the pump pulley.

4.
Loosen the upper pump bracket-

to-engine attaching bolt and remove

the bolt in the belt adjusting slot. Re-

move the pump.

5.
Position the pump to the bracket

and install the bracket-to-pump at-

taching bolts and nuts. Tighten to spe-

cifications.

6. Place the belt on the pump pul-

ley. Adjust the belt tension as outlined

in Section 2 and tighten the bolts and

nut to specification.

7.
Torque the pressure hose fitting

hex nut to specification. Then, connect

the pressure hose to the fitting and

torque the hose nut to specification.

8. Connect the return hose to the

power steering pump and tighten the

clamp.

9. Fill the pump with automatic

transmission fluid C1AZ-19582-A.

Bleed the air from the system (Part

3-1) and check for leaks and again
check the fluid level. Add fluid as re-

quired.

POWER STEERING PUMP

PULLEY REPLACEMENT

REMOVAL

1.
Drain as much of the fluid as

possible from the pump through filler

pipe.

2.
Install a 3/8-16 inch capscrew in

the end of the pump shaft to prevent

damage to the shaft end by the tool

screw.

3.
Install the pulley remover, Tool

T63L-1O3OO-B, on pulley hub, and

place the tool and pump in a vise as

shown in Fig. 3.

4.
Hold the pump and rotate the

tool nut counterclockwise to remove

the pulley (Fig. 3). The pulley must be

removed without in and out pressure

on the pump shaft to prevent damage

to internal thrust areas.

INSTALLATION

1.
Position the pulley to the pump

shaft and install Tool T65P-3A733-A

as shown in Fig. 4.

2.
Hold the pump and rotate the

tool nut clockwise to install the pulley

on the shaft. The pulley face will be

flush with end of pump shaft. Install

the pulley without in and out pressure
on the shaft to prevent damage to in-

ternal thrust areas.

3.
Remove the tool.

POWER STEERING PUMP

RESERVOIR REPLACEMENT

Reservoir replacement must be done

on a clean workbench. Cleanliness of

work area and tools is extremely im-

portant when repairing any hydraulic

unit. Thoroughly clean the exterior of

the pump with a suitable cleaning sol-

vent. Do not clean, wash or soak the

shaft oil seal in solvent. Plug the inlet

and outlet openings with plugs or

masking tape before cleaning the

pump exterior or removing the reser-

voir.

REMOVAL

1.
Assemble the adapter plate (Tool

T69P-3A674-A) to the bench mounted

fixture tool (T57L-5OO-A). Position

the pump and pulley on the adapter

plate, pulley facing down.

2.
Remove the outlet fitting hex nut

and the service identification tag.

3.
Invert the pump so the pulley is

facing up and remove the reservoir by

tapping around the flange with a wood

block (Fig. 5).

4.
Remove the reservoir O-ring seal

and the outlet fitting gasket from the

pump.

INSTALLATION

Tool • T 63 L-

10300 -

G 1477 A

FIG. 3—Removing Power

Steering Pump Pulley
1478 A

FIG. 4—Installing Power

Steering Pump Pulley
1.
Install a new gasket on the outlet

fitting and a new reservoir O-ring seal

on the pump housing plate (Fig. 6).

The old gasket and seal should never

be re-used.

Too/
T57L 500-A

G1602-A

FIG. 5—Removing Pump

Reservoirprocarmanuals.com