wheel FORD MUSTANG 1969 Volume One Chassis
Page 140 of 413
03-07-02
Ford Design Non-Integral Power Steering System
03-07-02
PUMP AND RESERVOIR
CONTROL VALVE
POWER CYLINDER
FIG. 7—Non-Integral Power Steering System
G 1651-A
IN-VEHICLE ADJUSTMENTS
AND
REPAIRS
HOISTING INSTRUCTIONS
Damage
to
suspension and/or steer-
ing linkage components
may
occur
if
care
is not
exercised when positioning
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
front suspension lower arms.
Do not
allow
the
adapters
to
contact
the
steering linkage.
CONTROL VALVE CENTERING
SPRING ADJUSTMENT
1.
Raise
the
vehicle
and
remove
2
spring
cap
attaching screws
and
lock
washers
and
remove
the
spring
cap.
2.
Tighten
the
adjusting
nut
snug
(90-100 in-lbs); then, loosen
the nut
1/4 turn. Make sure that
the nut ro-
tates
1/4
turn
(90
degrees)
on the
threads
of the
bolt.
Do not
tighten
the
adjusting
nut too
tight.
3.
Position
the
spring
cap to the
valve housing. Lubricate
and
install
the
two
attaching screws
and
washers.
Torque
the
screws
to
72-100 in-lbs.
4.
Lower
the
vehicle.
5.
Start
the
engine
and
check
the
turning effort with
a
spring scale.
With
the
spring scale attached
to the
rim
of the
steering wheel,
the
effort
to
turn
the
wheel
in
both directions
should
not
exceed
12
pounds.
CONTROL VALVE
TO
POWER
STEERING CYLINDER HOSE
1.
Raise
the
vehicle
on a
hoist
and
place
a
drain
pan
under
the
power
cylinder.
2.
Disconnect
the
hose from
the
power cylinder
and
allow
the
fluid
to
drain from
the
hose. Then, disconnect
the hose from
the
control valve.
3.
Connect
the
unmarked
end of
the shorter tube
(9 7/16 in
long)
to
valve port
C
(Fig. 2). Hold
the
tube
so
that
the
bend parallels
the
surface
of
valve shown
in Fig. 2,
tighten
the nut.
PLANE
OF
TUBE BEND
IN
3A717 HOSE
TO BE
PARALLEL
WITH THIS SURFACE ON VALVE.
CLEARANCE BETWEEN
COUPLING TO
BE 1/16-
1/8 INCH
IN
THIS AREA
G 1503-A
FIG. 2—Power Steering Hose
Installation
Connect
the
opposite
end to the
lower
port
in the
cylinder. Hold
the
tube
se-
curely while tightening
the nut to pre-
vent twisting
the
tube. Connect
the
other tube
(9 5/8 in
long)
to
port
A,
making sure that tube
is
parallel with
the other tube.
4.
Remove
the
drain
pan and
lower
the vehicle.
5.
Fill
the
power steering pump res-
ervoir with fluid
to the
proper level
(Part
3-1).
6. Start
the
engine
and
turn
the
steering wheel
to
each
end of its
travel
several times
to
cycle
the
system.
Then, check
for
leaks.
7.
Stop
the
engine
and
again check
the power steering fluid level.
Add
fluid
as
required.
POWER STEERING PUMP
TO CONTROL VALVE HOSE
REMOVAL
1.
Remove
the
fluid from
the
pump
reservoir with
a
suction
gun.
2.
Raise
the
vehicle
on a
hoist.
3.
Remove
the
clamp retaining
the
hose tubes
to the
control valve.
4.
Disconnect
the
fluid return
and
pressure hoses from
the
control valve
and allow
the
fluid
to
drain into
a
pan.procarmanuals.com
Page 141 of 413
03-07-03
Ford Design Non-Integral Power Steering System
03-07-03
5.
Lower the vehicle and disconnect
the fluid return hose from the reser-
voir.
6. Disconnect the fluid pressure
hose from the pump outlet fitting.
7.
Remove 1 bolt attaching the
hoses,
insulator, and the retainer to
the frame side rail and remove the
hoses,
and the insulator and retainer
as an assembly from the vehicle.
8. Remove the pressure and return
hoses from the retainer and insulator.
INSTALLATION
1.
Install the pressure and return
hoses in the insulator and retainer.
Paint stripe on pressure hose must be
aligned with slot in insulator. Paint or
tape band on return hose must be cen-
tered in insulator. Position the assem-
bly to the frame side rail and install
the attaching bolt.
2.
Place a hose clamp on the fluid
return hose and install the hose on the
power steering pump reservoir return
fitting.
3.
Torque the pump outlet fitting to
specification (Part 3-13). Then, con-
nect the pressure hose to the outlet fit-
ting and torque the fitting to specifica-
tion.
4.
Raise the vehicle and connect the
pressure and return lines to the con-
trol valve.
5.
Install the clamp to retain the
hose tubes to the control valve.
6. Lower the vehicle and fill the
power steering pump reservoir with
fluid, C1AZ-19582-A, to the proper
level (Part 3-1).
7.
Start the engine and turn the
steering wheel to each end of its travel
several times to cycle the system.
Then, check for fluid leaks.
8. Stop the engine and again check
the power steering fluid level (Part
3-1). Add fluid as required.
REMOVAL AND INSTALLATION
HOISTING INSTRUCTIONS
Damage to suspension and/or steer-
ing linkage components may occur if
care is not exercised when positioning
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
front suspension lower arms. Do not
allow the adapters to contact the
steering linkage.
STEERING GEAR
Refer to Group 3-6, Section 3 for
detailed instructions.
POWER STEERING PUMP
Refer to Group 3-10, Section 3 for
detailed instructions.
POWER STEERING CONTROL
VALVE
REMOVAL
1.
Disconnect the 4 fluid line fit-
tings at the control valve, and drain
the fluid from the lines. Turn the front
wheels to the left and right several
times to force all the fluid from the
system.
2.
Loosen the clamping nut and
bolt at the right end of the sleeve.
3.
Remove the roll pin from the
steering arm-to-idler arm rod -through
the slot in the sleeve.
4.
Remove the control valve ball
stud nut.
5.
Using the tool shown in Fig. 3,
remove the ball stud from the sector
shaft arm.
VALVE
Too/-3290-C BALL STUD PITMAN ARM
FIG. 3—Removing Control Valve
Ball Stud
6. After turning the front wheels
fully to the left, unthread the control
valve from the center link steering
arm-to-idler arm rod.
INSTALLATION
1.
Thread the valve onto the center
link until about four threads are still
visible on the link.
2.
Position the ball stud in the sec-
tor shaft arm.
3.
Measure the distance between
the center of the grease plug in the
sleeve and the center of the stud at the
inner end of the left spindle connect-
ing rod (Fig. 4). The distance should
be 5 5/8 inches for Montego, Falcon
and Fairlane vehicles. The distance
should be 4 7/8 inches for Mustang
and Cougar models. If the distance is
not correct, disconnect the ball stud
from the sector shaft arm and turn the
valve on the center link to increase or
decrease the distance.
4.
When the correct distance is ob-
tained and the ball stud is positioned
in the sector shaft arm, align the hole
in the steering arm-to-idler arm rod
with the slot near the end of the valve
sleeve. Install the roll pin in the rod
hole to lock the valve in position on
the rod.
5.
Torque the valve sleeve clamp
bolt to specification.
6. Install the nut on the ball stud,
and torque the nut to specification.
Install a new cotter pin.
7.
Connect the fluid lines to the
control valve, and tighten all fittings
securely. Do not over-tighten.
8. Fill the fluid reservoir with the
specified fluid to the cross hatched
area on the dip stick.
9. Start the engine and run it at
idle speed for about two minutes to
warm the fluid in the power steering
system.
10.
Turn the steering wheel all the
way to the left and right several times,
and check the system for fluid leaks.
11.
Increase the engine speed to
about 1000 rpm, and turn the steering
wheel all the way to the left and right
several times.
CONTROL VALVE CONNECTING ROD STUD
LUBRICATION PLUG
G1653-A
FIG. 4—Control Valve Installation
Measurements—All Modelsprocarmanuals.com
Page 142 of 413
03-07-04
Ford Design Non-Integral Power Steering System
03-07-04
12.
Stop the engine, and check the
control valve and hose connections for
fluid leaks. Correct the cause of any
leaks.
13.
Check the fluid level, and refill
the reservoir if necessary.
14.
With the engine running check
the position of the steering wheel
when the front wheels are in the
straight-ahead position.Do not make
any adjustments until toe-in is
checked.
15.
Keep the engine running, and
check toe-in. If either toe-in or steer-
ing wheel position is not correct make
all necessary adjustments (Part 3-1) at
the spindle connecting rod sleeves.
16.
Check the effort to turn the
wheels in both directions. The effort
should be about equal in both direc-
tions.
POWER CYLINDER
REMOVAL
1.
Disconnect the two fluid lines
from the power cylinder and allow
them to drain into a container.
CENTER LINK
POWER CYLINDER
Tool- T64P-3590-F
G 1654-A
FIG. 5—Disconnecting Power
Cylinder Stud
2.
Remove the 'pal nut, attaching
nut, washer and the insulator from the
end of the power cylinder rod.
3.
Remove the cotter pin and cas-
tellated nut that secures the power
cylinder stud to the center link.
4.
Disconnect the power cylinder
stud from the center link as shown in
Fig. 5.
5.
Remove the insulator sleeve and
washer from the end of the power cyl-
inder rod.
6. Inspect the tube fittings and the
seats in the power cylinder for nicks,
burrs or damage. Replace the seats in
the cylinder or the tubes as required.
INSTALLATION
1.
Install the washer, sleeve and the
insulator on the end of the power cyl-
inder rod.
2.
Extend the rod as far as possible.
Insert the rod in the bracket on the
frame and compress the rod as neces-
sary to insert the stud in the -center
link. Secure the stud with a castellat-
ed, nut and a cotter pin.
3.
Secure the power cylinder rod
with an insulator, washer, nut and a
pal nut.
4.
Connect each of the two fluid
lines to its respective port in the cylin-
der.
5.
Fill the reservoir to the correct
level.
6. Start the engine and turn the
steering wheel to each end of its travel
several times to cycle the system. Stop
the engine.
7.
Check the fluid level and fill as
necessary. Install the dipstick and cap.
8. Start the engine and check for
leaks.
MAJOR REPAIR OPERATIONS
CONTROL VALVE
DISASSEMBLY
1.
Wipe all fluid and loose dirt
from the outside of the control valve.
2.
Remove the centering spring cap
from the valve housing (Fig. 6).
When holding the control valve for
disassembly, use a soft-jawed vise, and
clamp the valve only around the sleeve
flange to prevent damage to the hous-
ing, spool, or sleeve.
3.
Remove the nut from the end of
the valve spool bolt. Remove the
washers, spacer, centering spring,
adapter, and bushing from the bolt
and the valve housing.
4.
Remove the two bolts that hold
the valve housing and the sleeve to-
gether, and separate the housing from
the sleeve.
5.
Remove the plug from the valve
sleeve.
6. Push the valve spool out of the
centering spring end of the valve hous-
ing, and remove the seal from the
spool.
7.
Remove the spacer, bushing, and
seal from the sleeve end of the valve
housing.
8. Drive the stop pin out of the
travel regulator stop with a punch and
hammer (Fig. 7). Pull the head of the
valve spool bolt tightly against the
travel regulator stop before driving the
pin out of the stop.
9. Turn the travel regulator stop
counterclockwise in the valve sleeve to
remove the stop from the sleeve.
10.
Remove the valve spool bolt,
spacer, and rubber washer from the
travel regulator stop.
11.
Remove the rubber boot and
clamp from the valve sleeve.
12.
Slide the bumper, spring, and
ball stud seat out of the valve sleeve,
and remove the ball stud socket from
the sleeve.
13.
After removing the return port
hose seat, remove the return port re-
lief valve.
14.
After removing the spring plug
and O-ring, remove the reaction limit-
ing valve (Fig. 8).
Tube Seat Replacement
If a hose seat is worn or damaged it
should be replaced. It can be removed
with an Easy-Out tool, or by using a
bolt of appropriate size as a puller.
1.
Tap the existing hole in the hose
seat, using a starting tap of suitable
size.
Be sure to remove all metal chips
from the hose seat port after tapping.
2.
Place a nut and large flat washer
on a bolt of the same size as the
tapped hole. The washer must be large
enough to cover the hose seat port.
3.
Insert the bolt in the tapped
hole,
and using the nut as a puller, re-
move the hose seat.
4.
Place a new hose seat in the
port, and thread a bolt of suitable size
into the port. Tighten the bolt enough
to bottom the seat in the port.
ASSEMBLY
Before assembling the control valve,
coat all parts except the seals with
Automatic Transmission Fluid. Coat
the seals with lubricant COAZ-
19553-A.
1.
Install the reaction limiting
valve, the spring, and the plug.
2.
Install the return port relief valve
and the hose seat.
3.
Insert one of the ball stud seats
(flat end first) into the ball stud sock-
et, and insert the threaded end of the
ball stud into the socket.procarmanuals.com
Page 145 of 413
03-08-01
Ford Design Integral Power Steering Gear
03-08-01
PART
3-8
Ford Design Integral Power
Steering Gear
COMPONENT INDEX
STEERING GEAR
Adjustments
Cleaning
and
Inspection
(See
Part 03-01)
Description
Disassembly
and
Assembly
Overhaul
Removal
and
Installation
VALVE CENTERING SHIM
Removal
and
Installation
VALVE SPOOL CENTERING CHECK
MODEL APPLICATION
All Models
Ford
08-02
08-01
08-05
08-06
08-03
08-03
08-02
Mercury
08-02
08-01
08-05
08-06
08-03
08-03
08-02
Meteor
08-02
08-01
08-05
08-06
08-03
08-03
08-02
Cougar
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Fairlane
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Falcon
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Montego
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Mustang
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Lincoln-
Continental
08-02
08-01
08-05
08-06
08-03
08-03
08-02
Thunderbird
08-02
08-01
08-05
08-06
08-03
08-03
08-02
Continental-
Mark
III
08-02
08-01
08-05
08-06
08-03
08-03
08-02
DESCRIPTION
The Ford integral power steering
unit
(Fig. 1) is a
torsion-bar type
of
hydraulic assisted system. This system
furnishes power
to
reduce
the
amount
of turning effort required
at the
steer-
ing wheel.
It
also reduces road shock
and vibrations.
The torsion
bar
power steering unit
includes
a
worm
and
one-piece rack
piston, which
is
meshed
to the
gear
teeth
on the
steering sector shaft.
The
unit also includes
a
hydraulic valve,
valve actuator, input shaft
and
torsion
bar assembly which
are
mounted
on
the
end of the
worm shaft
and
operat-
ed
by the
twisting action
of the tor-
sion
bar.
The torsion-bar type
of
power steer-
ing gear
is
designed with
the one
piece
rack-piston, worm
and
sector shaft
in
one housing
and the
valve spool
in an
attaching housing
(Fig. 1).
This makes
possible internal fluid passages
bet-
ween
the
valve
and
cylinder, thus
eli-
minating
all
external lines
and
hoses,
except
the
pressure
and
return hoses
between
the
pump
and
gear assembly.
The power cylinder
is an
integral
part
of the
gear housing.
The
piston
is
double acting,
in
that fluid pressure
may
be
applied
to
either side
of the
piston.
A selective metal shim located
in
the valve housing
of the
gear
is for the
purpose
of
tailoring steering gear
ef-
forts.
If
efforts
are not
within specifi-
cations they
can be
changed
by in-
creasing
or
decreasing shim thickness
as follows:
Efforts heavy
to the
left—Increase
shim thickness.
Efforts light
to the
left—Decrease
shim thickness.
A change
of one
shim size will
in-
crease
or
decrease steering efforts
ap-
proximately
1 1/2
in-lbs.
Shims
are
available
in the
following
thicknesses
and are
notched
on the
outside diameter
for
identification:
0.0057-0.0063 inch—0 notch
0.0077-0.0083 inch—1 notch
0.0097-0.0103 inch—2 notches
0.0117-0.0123 inch—3 notches
0.0137-0.0143 inch—4 notches
Do
not use
more than
one
shim.
procarmanuals.com
Page 146 of 413
03-08-02
Ford Design Integral Power Steering Gear
03-08-02
-INPUT SHAFT
OUTLET PORT
INLET PORT
CONTROL VALVE HOUSING
SECTOR SHAFT COVER
SECTOR SHAFT ADJUSTMENT SCREW
LOCK NUT
IDENTIFICATION TAG
SECTOR SHAFT
FIG.
1—Power
Steering Gear
G1545- A
IN-VEH1CLE ADJUSTMENTS AND REPAIRS
VALVE SPOOL
CENTERING CHECK
1.
Install a 0-2000 psi pressure
gauge Tool T56L-33610-D in the pres-
sure line between the power steering
pump outlet port and the integral
steering gear inlet port.
2.
Make sure that the valve on the
gauge is in the fully open position.
3.
Check the fluid level in the reser-
voir and fill it to proper level with the
specified fluid.
4.
Start the engine and cycle the
steering wheel from stop-to-stop, to
bring the steering lubricant up to nor-
mal operating temperature. Stop the
engine and recheck the reservoir. Add
fluid if necessary.
5.
With the engine running at ap-
proximately 1000 rpm and the steer-
ing wheel centered, attach an inch-
pound torque wrench to the steering
wheel retaining nut. Apply sufficient
torque to the torque wrench in each
direction, either side of center, to get
a gauge reading of 250 psi.
6. The torque reading should be the
same in both directions when 250 psi
is reached. If the difference between
the readings exceeds 4 in-lbs, the
steering gear must be removed and the
valve centering shim removed from the
valve housing and a thicker or thinner
shim installed. Only one shim is to be
used. If the steering effort is heavy,
the shim thickness should be in-
creased. Shim thickness should be de-
creased if the steering effort is light to
the left.
The out of vehicle procedure for
valve centering check is the same as
for the in vehicle except the torque
and simultaneous pressure reading
must be made at the right and left
stops instead of either side of center.
STEERING GEAR
ADJUSTMENTS
During the vehicle breaking-in peri-
od, it is probable that some of theprocarmanuals.com
Page 147 of 413
03-08-03
Ford Design Integral Power Steering Gear
03-08-03
factory adjustments will change. These
changes in adjustment do not neces-
sarily affect the satisfactory operation
of the steering gear assembly, and
therefore ordinarily do not require
readjustment unless there is excessive
lash or other malfunctioning.
ADJUSTMENT IN
VEHICLE
The only adjustment which can be
performed is the total over center
position load, to eliminate excessive
lash between the sector and rack
teeth.
1.
Disconnect the pitman arm from
the sector shaft.
2.
Disconnect the fluid return line
at the reservoir, at the same time cap
the reservoir return line pipe.
3.
Place the end of the return line
in a clean container and cycle the
INPUT SHAFT
SECTOR SHAFT
ADJUSTMENT SCREW
C1547- A
FIG.
2—Adjusting Mesh Load
steering wheel in both directions as re-
quired, to discharge the fluid from the
gear.
4.
Remove the ornamental cover
from the steering wheel hub and turn
the steering wheel to 45 degrees from
the left stop.
5.
Using an in-lb torque wrench on
the steering wheel nut, determine the
torque required to rotate the shaft
slowly through an approximately 1/8
turn from the 45 degree position.
6. Turn the steering gear back to
center, then determine the torque re-
quired to rotate the shaft back and
forth across the center position. Loos-
en the adjuster nut, and turn the ad-
juster screw in (Fig. 2) until the read-
ing is 8-9 in-lb greater than the torque
45 degrees from the stop.
Tighten the lock nut while holding
the screw in place.
7.
Recheck the readings and replace
pitman arm and steering wheel hub
cover.
8. Connect the fluid return line to
the reservoir and fill the reservoir with
specified lubricant to the proper level.
REMOVAL AND INSTALLATION
REMOVAL
1.
Disconnect the pressure and the
return lines from the steering gear.
Plug the lines and the ports in the
gear to prevent entry of dirt.
2.
Remove the two bolts that secure
the flex coupling to the steering gear
and to the column.
3.
Raise the vehicle and remove the
sector shaft attaching nut.
4.
Remove the Pitman arm from
the sector shaft with Tool T64P-
3590-F.
Remove the tool from the
Pitman arm. Do not damage the
seals.
5.
If working on a vehicle equipped
with a standard transmission, remove
the clutch release lever retracting
spring to provide clearance for remov-
ing the steering gear.
6. Support the steering gear then
remove the three steering gear attach-
ing bolts.
7.
Work steering gear free of the
flex coupling and remove it from the
vehicle.
8. If the flex coupling stayed on the
input shaft, lift if off the shaft at this
time.
INSTALLATION
1.
Slide the flex coupling into place
on the steering shaft. Turn the steer-
ing wheel so that the spokes are in the
horizontal position.
2.
Center the steering gear input
shaft.
3.
Slide the steering gear input
shaft into the flex coupling and into
place on the frame side rail. Install
the three attaching bolts and torque
them to specification.
4.
Make sure that the wheels are in
the straight ahead position, then in-
stall the Pitman arm on the sector
shaft. Install and tighten the sector
shaft and install and tighten the at-
taching bolts to specification.
5.
Move the flex coupling into
place on the input and steering co-
lumn shaft and install and tighten the
attaching bolts to specification.
6. Connect and tighten the fluid
pressure and the return line to the
steering gear.
7.
Fill the power steering pump and
cycle the steering gear. Check for
leaks and again check the fluid level.
Add fluid as required.
MAJOR REPAIR OPERATIONS
In most cases, complete disassembly
of the power steering gear will not be
necessary. It is suggested that only
those assemblies that are faulty be dis-
assembled. Disassembly and reassem-
bly of the unit and the subassemblies
must be made on a clean workbench.
As in repairing any hydraulically op-
erated unit, cleanliness is of utmost
importance. Therefore, the bench,
tools,
and parts must be kept clean at
all times. Thoroughly clean the exter-
ior of the unit with a suitable solvent
and when necessary, drain as much of
the hydraulic oil as possible. Handle
all parts very carefully to avoid nicks,
burrs,
scratches and dirt, which could
make the parts unfit for use. Do not
clean, wash or soak seals in cleaning
solvent.
VALVE CENTERING
SHIM REPLACEMENT
1.
Hold the steering gear over a
drain pan in an inverted position and
cycle the input shaft several times to
drain the remaining fluid from the
gear.
2.
Mount the gear in a soft-jawed
vise.procarmanuals.com
Page 153 of 413
03-09-01
Saginaw Design Integral Power Steering Gear
03-09-01
PART 3-9 Saginaw Design
Integral Power Steering Gear
COMPONENT INDEX
STEERING GEAR
Cleaning and Inspection (See Page 03-01)
Description
Disassembly and Assembly
Mesh Load Adjustment
Removal and Installation
Overhaul
MODEL APPLICATION
All
Models
Ford
09-01
09-03
09-01
09-02
09-04
Mercury
N/A
N/A
N/A
N/A
N/A
N/A
Meteor
N/A
N/A
N/A
N/A
N/A
N/A
Cougar
N/A
N/A
N/A
N/A
N/A
N/A
Fairlane
N/A
N/A
N/A
N/A
N/A
N/A
Falcon
N/A
N/A
N/A
N/A
N/A
N/A
Montego
N/A
N/A
N/A
N/A
N/A
N/A
Mustang
N/A
N/A
N/A
N/A
N/A
N/A
Lincoln-
Continental
N/A
N/A
N/A
N/A
N/A
N/A
Thunderbird
N/A
N/A
N/A
N/A
N/\
N/A
Continental-
Mark III
N/A
N/A
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
The Rotary Valve Safety power
steering gear operates entirely on dis-
placing fluid to provide hydraulic fluid
pressure assists only when turning. As
the entire gear assembly is always full
of fluid, all internal components of the
gear are immersed in fluid making
periodic lubrication unnecessary. In
addition, this fluid acts as a cushion
to absorb road shocks that may be
transmitted to the driver. All fluid
passages are internal except the pres-
sure and return hoses between the
gear and pump.
The rotary valve provides a smooth
transmission through the driving range
of steering wheel effort. A torsion bar
transmits the road feel to the driver.
Response of the steering gear to effort
applied to the steering wheel has been
greatly increased.
The rack-piston nut is one piece and
is geared to the sector shaft. Lash be-
tween the sector shaft and rack-piston
nut is maintained by an adjusting
screw which is retained in the end o\'
the shaft uear (Eiiz.l).
IN-VEHICLE ADJUSTMENTS AND REPAIRS
During the breaking in period of
the vehicle, it is probable that some
of the factory adjustments will change.
These changes in adjustment do not
necessarily affect the satisfactory op-
eration of the steering gear assembly
and ordinarily do not require re-ad-
justment unless there is excessive lash
or other malfunctioning. The only ad-
justment that should be performed in
the vehicle is the total over center
position load (mesh load) to eliminate
excessive lash between the sector shaft
and rack teeth.
MESH LOAD ADJUSTMENT
1.
Disconnect the Pitman arm from
the sector shaft and remove the steer-
ing wheel hub.
2.
Disconnect the fluid return line
at the reservoir; at the same time cap
the reservoir return line pipe.
3.
Place the end of the return line
in a clean container and cycle the
steering wheel in both directions as
required, to discharge the fluid from
the gear.
4.
Turn the gear 1/2 turn off cen-
ter (either direction). Using a 24 in-
lb torque wrench on the steering wheel
nut, determine the torque required to
rotate the shaft slowly through a 20
degree arc.
5.
Turn the sear back to center and
repeating the method of reading tor-
que as in Step 4, above, loosen the
adjuster lock nut, turn the screw in-
ward with a 7/32-inch Allen wrench
until the reading is equal to 6 in-lbs
in excess of Step 4 above, and retigh-
ten the lock nut while holding the
screw in place.
6. Recheck the readings and re-
place the Pitman arm and the steering
wheel hub.
7.
Connect the fluid return line to
the reservoir and fill the reservoir
with C1AZ-I9582-A Fluid to the
proper level.
procarmanuals.com
Page 154 of 413
03-09-02
Saginaw Design Integral Power Steering Gear
03-09-02
WORM
ADJUSTER PLUG
TORSION BAR
STUB SHAFT
SEAL
NEEDLE BEARINGS
TEFLON RING
TEFLON SEALS
SECTOR SHAFT
FIG.l —
Power
Steering Gear—Sectional View
G 1650-A
REMOVAL
AND
INSTALLATION
REMOVAL
1.
Disconnect
the
pressure
and the
return line from
the
steering gear.
Plug
the
lines
and the
ports
in the
gear to prevent entry of dirt.
2.
Remove the two bolts that secure
the flex coupling
to the
steering gear
and
to
the column.
3.
Raise
the
vehicle
and
remove
the
Pitman arm attaching nut.
4.
Remove
the
Pitman arni from
the sector shaft with Tool T64P-3590-
F.
Remove
the
tool from
the
Pitman
arm.
5.
If
working
on a
vehicle equipped
with
a
standard transmission, remove
the clutch release lever retracting spring
to provide clearance
for
removing
the
steering gear.
6. Support
the
steering gear then
remove
the
three steering gear attach-
ing bolts.
7.
Work
the
steering gear free
of
the flex coupling
and
remove
it
from
the vehicle.
8.
If
the flex coupling stayed
on the
input shaft, lift
it off the
shaft
at
this time.
INSTALLATION
1.
Slide
the
flex coupling into place
on
the
steering shaft. Turn
the
steer-
ing wheel
so
that
the
spokes
are in
the horizontal position.
2.
Center
the
steering gear input
shaft.
3.
Slide the steering gear input shaft
into
the
flex coupling
and
into place
on
the
frame side rail. Install the three
attaching bolts
and
torque them
to
specification.
4.
Make sure that
ihe
wheels
are
in
the
straight-ahead position, then
install
the
Pitman
arm on the
sector
shaft. Install
and
tighten
the
sector
shaft attaching nut to specification.
5.
Move the flex coupling into place
on
the
input shaft
and
steering columnprocarmanuals.com
Page 169 of 413
03-11-01
Eaton Power Steering Pump
03-11-01
PART 3-11 Eaton Power Steering Pump
COMPONENT INDEX
MODEL APPLICATION
3
§>
"o
4
POWER STEERING PUMP
Cleaning and Inspection (See Part 03-01)
Description
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
11-01
N/A
11-01
Disassembly and Overhaul
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
11-03
N/A
11-03
Removal and Installation
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
11-01
N/A
11-01
POWER STEERING PUMP RESERVOIR
Removal and Installation
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
11-01
N/A
11-01
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.
l
DESCRIPTION
The roller-type hydraulic pump,
driven by the crankshaft, draws auto-
matic transmission fluid down the res-
ervoir and provides fluid pressure for
the system. Steering gear lubrication
is also provided by the same fluid
from the reservoir. Within the pump
itself is a flow-control and pressure-
relief valve which governs the pres-
sures within the steering system ac-
cording to the varying conditions of
operation. After fluid has passed from
the gear, it returns to the reservoir.
REMOVAL AND INSTALLATION
POWER STEERING PUMP
REMOVAL
1.
Open the hood, and install fend-
er covers.
2.
If the vehicle is equipped with air
conditioning, loosen the compressor
adjusting and support bracket bolts
and remove the drive belt.
3.
Loosen the generator adjusting
and support bracket bolts, and remove
the drive belts.
4.
Remove the fan, pulley, and spa-
cer.
5.
Raise the vehicle.
6. Remove the crankshaft damper
bolt and washer. Remove the damper
with Tool 6306-AG. Remove the drive
key.
7.
Disconnect the pump inlet line at
the pump, and plug the end of the line
to prevent the loss of fluid. Disconnect
the pump pressure line at the pump.
8. Remove the pump-to-engine
front cover cap screws, and remove
the pump. Remove the seal from the
front cover.
INSTALLATION
1.
Install a new seal on the engine
front cover.
2.
Align the slot in the pump rotor
shaft with the drive key in the crank-
shaft, and slide the pump onto the
shaft. Install the pump-to-engine front
cover cap screws. Torque the cap
screws to specification.
3.
Connect the pump inlet line and
the pressure line.
4.
Install the damper drive key,
damper, washer and bolt. Torque the
bolt to specification.
5.
Install the fan, pulley, and spa-
cer. Install the generator drive belts.
Adjust the belt tension, and tighten
the adjusting and support bracket
bolts.
6. If the vehicle is equipped with air
conditioning, install the compressor
drive belt. Adjust the belt tension, and
tighten the adjusting and support
bracket bolts.
7.
Run the engine at idle speed,
and check the fluid level in the reser-
voir. If required, add the specified au-
tomatic transmission fluid. Turn on
the windshield wipers. Rotate the
steering wheel from stop to stop sever-
al times to bleed the air from the sys-
tem. Recheck the fluid level.
POWER STEERING PUMP
RESERVOIR
WITHOUT AIR
CONDITIONING
Removal
1.
Remove the reservoir cover andprocarmanuals.com
Page 172 of 413
03-12-01
Wheels
And
Tires
03-12-01
PART
3-12
Wheels
And
Tires
COMPONENT INDEX
FRONT
HUB AND
DRUM ASSEMBLY
Removal
and
Installation
FRONT
HUB AND
ROTOR ASSEMBLY
Removal
and
Installation
FRONT WHEEL ASSEMBLY DESCRIPTION
FRONT WHEEL BEARING ADJUSTMENT
FRONT WHEEL GREASE SEAL
AND
BEARING
Removal, Installation, Repacking
HOISTING INSTRUCTIONS
LIFE GUARD TIRE
Balancing
Correcting Vibration
and
Shake
Description
Repairs
REAR WHEEL ASSEMBLY DESCRIPTION
WHEELS AND TIRES (Conventional)
Removal
and
Installation
MODEL APPLICATION
All
Models
12-07
12-07
12-01
12-02
12-05
12-02
12-01
12-03
Ford
N/A
N/A
N/A
N/A
Mercury
N/A
N/A
N/A
N/A
Meteor
N/A
N/A
N/A
N/A
Cougar
N/A
N/A
N/A
N/A
Fairlane
N/A
N/A
N/A
N/A
Falcon
N/A
N/A
N/A
N/A
Montego
N/A
N/A
N/A
N/A
Mustang
N/A
N/A
N/A
N/A
Lincoln-
Continental
12-03
12-03
12-02
12-08
Thunderbird
12-03
12-03
12-02
12-08
Continental-
Mark
III
12-03
12-03
12-02
12-08
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
FRONT WHEEL ASSEMBLY
Each front wheel
and
tire
is
bolted
to
its
respective front
hub and
brake
drum
or
rotor assembly.
Two
opposed
tapered roller bearings
are
installed
in
each
hub. A
grease retainer
is in-
stalled
at the
inner
end of the hub to
prevent lubricant from leaking into
the drum
or on the
rotor.
The
entire
assembly
is
retained
to its
spindle
by
the adjusting
nut, nut
lock
and
cotter
pin (Figs.
1 and 2).
REAR WHEEL ASSEMBLY
The rear wheel
hub and
brake drum
assembly
is
attached
to
studs
on the
rear axle shaft flange
by
three speed
nuts.
The
wheel
and
tire mounts
on
the same rear axle shaft flange studs
and
is
held against
the hub and
drum
by
the
wheel nuts.
The
rear wheel
bearing
is
pressed onto
the
axle shaft
just inside
the
shaft flange,
and the
entire assembly
is
retained
to the
rear
axle housing
by the
bearing retainer
HUB
AND
BRAKE
DRUM
ASSEMBLY
plate which
is
bolted
to the
housing
flange.
ADJUSTING
NUT
GREASE
CAP
OUTER
BEARING
OUTER
CUP
BEARING
CONE
AND
ROLLER
NUT
INNER BEARING
CONE
AND
ROLLER
WHEEL
ASSEMBLY
HUB
BOLT'
^£=3^
F1422-A
FIG.
1
—
Front
Hub,
Bearing
and
Grease Retainer Drum Brakes
procarmanuals.com