check transmission fluid FORD MUSTANG 1969 Volume One Chassis

02-01-02
Brakes

02*01-02

STEERING
WHEEL RIW

TOEBOARD
OR

DASH
METAL
CHECKING
POINTS

STEERING
COLUMN-

STEEL
MEASURING TAPE

VEHICLE

FORD,
MERCURY AND METEOR

FORD,
MERCURY AND METEOR

FORD,
MERCURY AND METEOR

FORD,
MERCURY AND METEOR

FAIRLANE,
MONTEGO AND FALCON

FAIRLANE,
MONTEGO AND FALCON

MUSTANG
AND COUGAR

MUSTANG
AND COUGAR

THUNDERBIRD

CONTINENTAL
MARK III

LINCOLN
CONTINENTAL
TYPE

NON-POWER
DRUM

POWER
DRUM & DISC

NON-POWER
DISC

POLICE
POWER DISC

NON-POWER
DRUM

POWER
DISC

NON-POWER
DRUM

POWER
DISC

POWER
DISC

POWER
DISC

POWER
DISC
PEDAL
FREE

HEIGHT-A

8.09-7.17

6.18-5.99

8.65-7.82

7.58-6.72

8.13-6.91

7.25-5.71

7.49-6.43

6.25-5.56
PEDAL
FREE

HEIGHT-B"

5.96-5.04

5.96-5.04

6.50-5.50
PEDAL

TRAVEL-C

3.10

3.27

2.18

3.27

2.90

2.35

2.58

1.75

3.00

3.00

2.25

NOTE:AgB
DIMENSION TO BE MEASURED TO SHEET METAL

C
DIMENSION TO BE MEASURED PARALLEL TO THE VERTICAL CENTERLINE OF THE

STEERING
COLUMN WITH A 50 POUND LOAD APPLIED TO THE CENTERLINE OF THE

BRAKE
PEDAL PAD. (CHECKS ON POWER BRAKE VEHICLES MADE WITH ENGINE RUNNING

H1630-A

FIG. 1 — Brake Pedal Height and Travel Measurements

Tool-WRE-l

HI525-A

FIG.
2—Brake Pedal Effort Gauge Installed
o'clock position on the steering wheel

rim.

3.
With the steel tape still hooked

to the brake pedal depress the brake

pedal by pressing downward on the

brake pedal effort gauge. Apply a 50

pound load to the center of the pedal

by observing the pressure gauge, and

measure the distance from the brake

pedal to the fixed reference point on

the steering wheel rim parallel to the

centerline of the steering column.

4.
The difference between the brake

pedal free height and the depressed

pedal measurement under a 50 pound

load should be within the specified

maximum pedal travel service specifi-

cation B in Fig. I.

5.
If the pedal travel is more than

the specified maximum shown in Fig.

1,
dimension C, make several sharp

reverse stops (equivalent to 50 pounds

pedal pressure) with a forward stop

before each. Move the vehicle in rev-

erse and forward for a distance of ap-

proximately ten feet; then, apply the

brakes sharply and hold the brake

pedal down until the vehicle is com-

pletely stopped. This will actuate the

brake self-adjusters. If these stops do

not bring the brake pedal travel within

specification, make several additional

forward and reverse stops as outlined

above.

6. If the second series of stops do

not bring the brake pedal travel within

specification, remove the brake drums

and check the brake adjusters to make

sure they are functioning. Check the

brake linings for wear or damage. Re-

pair or replace all worn or damaged

parts and non-functioning adjusters.

Adjust the brake lining outside diame-

ter to the approximate inside diameter

of the brake drum with Rotunda Tool

HRE-8650 (Fig. 12, Part 2-2).

7.
If all the brake adjusters, brake

drums and linings are functional and

the brake travel is not within specifi-

cations, check the pedal linkage for

missing or worn bushings, or loose at-

tachments. Bleed the brakes and cen-

tralize the differential valve.

POWER BRAKE

FUNCTIONAL TEST

1.
Check the hydraulic brake sys-

tem for leaks or insufficient fluid.

2.
With the transmission in neutral,

stop the engine and apply the parking

brake. Depress the brake pedal several

times to exhaust all vacuum in the

system.

3.
With the engine shut off and all

vacuum in the system exhausted, dep-

ress the pedal, and hold it in the ap-

plied position. Start the engine If theprocarmanuals.com

02-02-20
Brake System

02-02-20

1.
Disconnect the stoplight switch

wires at the connector. Remove the

spring retainer. Slide the stop light

switch off the brake pedal pin just far

enough to clear the end of the pin,

then liftfthe switch straight upward

from the pin. Use care to avoid switch

damage during removal.

2.
Slide the master cylinder push

rod and the nylon washers and bush-

ings off the brake pedal pin.

3.
Remove the brake tube from the

primary and secondary outlet ports of

the master cylinder.

4.
Remove the cap screws and lock-

washers that secure the master cylin-

der to the dirSh panel and lift the cyl-

inder forward and upward from the

vehicle.

Installation

1.
Position the boot on the push

rod and secure the boot to the master

cylinder. Carefully insert the master

cylinder push rod and boot through

the dash panel opening and position

the master cylinder on the panel.

2.
Install the cap screws at the dash

panel and torque them to specifica-

tion.

3.
Coat the nylon bushings with

SAE 10W oil. Install the nylon wash-

er and bushing on the brake pedal pin.

4.
Position the stop light switch on

the brake pedal pin, install the nylon

bushing and washer and secure them

in position with the spring retainer.

5.
Connect the wires at the stop

light switch connector.

6. Connect the brake lines to the

master cylinder leaving the brake line

fittings loose.

7.
Fill the master cylinder with the

specified brake fluid to within 1/4

inch of the top of the dual reservoirs.

Use Ford Brake Fluid— Extra Heavy

Duty-Part Number C6AZ-19542-A

(ESA-M6C25-A) or equivalent for all

drum brake applications. The extra

heavy duty brake system fluid is col-

ored blue for identification. Do not

mix low temperature brake fluids with

the specified fluid for the power disc

brake system.

8. Bleed the dual-master cylinder

and the primary and secondary brake

systems. Centralize the pressure dif-

ferential valve. Refer to Hydraulic

System Bleeding and Centralizing of

the Differential Valve, Part 2-1, Sec-

tion 2 for proper procedure.

9. Operate the brakes several times,

then check for external hydraulic

leaks.
FAIRLANE, MONTEGO,

FALCON, MUSTANG AND

COUGAR

Removal

Refer to Figs. 27 and 28.

1.
Working from inside the vehicle

below the instrument panel, disconnect

the master cylinder push rod from the

brake pedal assembly. The push rod

cannot be removed from the master

cylinder.

2.
Disconnect the stoplight switch

wires at the connector. Remove the

hairpin retainer. Slide the stop light

switch off the brake pedal pin just far

enough to clear the end of the pin,

then lift the switch straight upward

from the pin. Use care to avoid switch

damage during removal.

3.
Slide the master cylinder push

rod and the nylon washers and bush-

ings off the brake pedal pin.

4.
Remove the brake tubes from

the primary and secondary outlet

ports of the master cylinder.

5.
Remove the lock nuts or cap

screw and lockwashers that secure the

master cylinder to the dash panel and

lift the cylinder forward and upward

from the car.
Installation

Refer to Figs. 27 and 28.

1.
Position the boot on tie push

rod and secure the boot to the master

cylinder. Carefully insert the master

cylinder push rod and boot through

the dash panel opening.

2.
On Fairlane, Falcon or Montego

models, position the gasket and mas-

ter cylinder on the mounting studs on

the dash panel. Install the lock nuts

on the studs at the dash panel and

torque them to specification.

3.
On Mustang or Cougar models,

position the gasket and master cylin-

der on the dash panel. Install the re-

taining screws and torque them to

specification. Coat the nylon bushings

with SAE 10W oil. Install the nylon

washer and bushing on the brake

pedal pin.

4.
Position the stop light switch on

the brake pedal pin, install the nylon

bushing and washer and secure them

in position with the spring retainer.

5.
Connect the wires at the stop

light switch connector.

6. Connect the brake lines to the

master cylinder and tighten to speci-

fied torque.

7.
Fill the master cylinder with the

specified brake fluid to within 1/4

MASTER CYLINDER

IDENTIFICATION
UPPER STUD

SHAFT (AUTOf/lATIC

TRANSMISSION)

CLIP

BRAKE PEDAL

BUSHING SUPPORT

TUBE-2B253

TUBE-2A040
CLUTCH

PEDA_

LOWER STUD
STOP LITE

SWITCH

/ 13480

MASTER CYLINDER

PUSH ROD
BRAKE PEDAL

H 1556-C

FIG. 27—Dual Master Cylinder Installation—Non Power Brake

Fairlane, Montego, and Falconprocarmanuals.com

02-02-21
Brake System

02-02-21

INSTALLATION

CLUTCH ASSIST

SPRING

MASTER CYLINDER

2140

FIG. 28 —Dual Master Cylinder Installation—

Non Power Brake—Mustang and Cougar

inch of the top of the dual reservoirs.

Use Ford Brake Fluid- Extra Heavy

Duty-Part Number C6AZ-19542-A

for all brake applications. The brake

fluid is colored blue for identification.

Do not mix low temperature brake

fluids with the specified fluid for the

brake system.

8. Bleed the dual-master cylinder

and the primary and secondary brake

systems. Centralize the pressure dif-

ferential valve. Refer to Hydraulic

System Bleeding and Centralizing of

the Differential Valve, Part 2-1, Sec-

tion 2 for the proper procedure.

9. Operate the brakes several times,

then check for external hydraulic

leaks.

DUAL MASTER CYLINDER-

POWER BRAKES

REMOVAL

1.
Remove the brake tubes from

the primary and secondary outlet

ports of the master cylinder (Figs. 29

thru 33).

2.
Remove the two nuts and two

lock washers attaching the master cyl-

inder to the brake booster assembly.

3.
Slide the master cylinder forward

and upward from the vehicle.
SHAFT

AUTOMATIC

TRANSMISSION

CLUTCH PEDAL

BUMPER STOP
H1638-A
1.
Before installing the mater cyl-

inder, check the distance t; m the

outer end of the booster ass;. ,ihi\

push rod to the master .>',nder

mounting surface. Turn the nu->h rod

adjusting screw in or out as required

to obtain the specified length. Refer to

Part 2-1, Section 2. Power Brake

Master Cylinder Push Rod Adjust-

ment for the proper procedure.

2.
Position the master cylinder as-

sembly over the booster push rod and

onto the two studs on the booster as-

sembly (Figs. 29 thru 37).

3.
Install the attaching nuts and

lock washers and torque them to spec-

ifications.

4.
Install the front and rear brake

tubes to the master cylinder outlet fit-

tings.

5.
Fill the master cylinder with the

specified brake fluid to within 1/4

inch of the top o\ the dual reservoirs.

Use Ford Brake Fluid Fxtra Heavy

Duty Part Number C6AZ-19542-A

(ESA-M6C25-A) for all brake appli-

cations. The extra htaw duty brake

fluid is colored blue for identification.

Do not mix low temperature brake

fluids with the specified fluids for the

disc brake svstem.

CLIP

W
'0 AIR CONDITIONING

BUSHING

SHAFT

BUSHING

BRAKE PEDAL

SPACER

H 1642-A

FIG. 29—Master Cylinder Installation-

Ford,
Mercury and Meteor
-Power Brake-procarmanuals.com

03-01-02
Suspension — Steering, Wheels And Tires — General Service

03-01-02

1 TESTING

POWER STEERING-

PRELIMINARY TESTS

The following preliminary checks

should always be made before per-

forming any operations.

AIR BLEEDING

Air in the power steering system

(shown by bubbles in the fluid) should

be bled. After making sure that the

reservoir is filled to specification (the

fluid must be at normal operating

temperature when the check is made),

turn the steering wheel through its full

travel three or four times. Do not hold

the wheels against their stops. Re-

check the fluid level.

CHECK FLUID LEVEL

Run the engine until the fluid is at

normal operating temperature. Then

turn the steering wheel all the way to

the left and right several times, and

shut off the engine.

Check the fluid level in the power

steering reservoir. The level must show

on the cross hatching between the bot-

tom of the dipstick and the full mark

(Fig. 1). If the level is low, add

enough automatic transmission fluid

C1AZ-19582-A to raise the level to

the F mark on the dipstick. Do not

overfill the reservoir.

CHECK PUMP BELT

If the pump belt is broken, glazed,

or worn, replace it with a new belt.

Use only the specified type of belt.

Refer to Part 3-13 for belt adjustment

procedure.

CHECK FOR FLUID

LEAKS

With the engine idling, turn the

steering wheel from stop to stop sever-

al times. Check all possible leakage

points. Tighten all loose fittings, and

replace any damaged lines or defective

seats.

CHECK TURNING EFFORT

With the front wheels properly al-

igned and tire pressures correct, check

the effort required to turn the steering

wheel.
G 1508- A

FIG.
1—Power
Steering Pump

Dipstick

1.
With the vehicle on dry concrete,

set the parking brakes.

2.
With the engine warmed up and

running at idle speed, turn the steering

wheel to the left and right several

times to warm the fluid.

3.
Attach a pull scale to the rim of

the steering wheel. Measure the pull

required to turn the wheel one com-

plete revolution in each direction. The

effort required to rotate the steering

wheel should not exceed specifications

given in Part 3-13.

POWER STEERING PUMP FLOW

AND PRESSURE TESTS—

EXCEPT LINCOLN CONTINENTAL

AND CONTINENTAL MARK III

The power steering flow and pres-

sure tests will show whether the pump,

steering gear or power assist control

RETURN LINE

POWER

STEERING PUMP

Sr
valve is causing the trouble. Steps out-

lined below should be followed to de-

termine the cause of the trouble.

PUMP FLOW TEST

1.
Depending on the equipment

present on the vehicle (air condition-

ing, power brakes, standard transmis-

sion),
one of the following options

may be used to connect the pump

pressure and return hoses to the test

tool (T56L-3361O-D and T68L-

33610-A):

a. Disconnect the pressure and re-

turn lines at the power steering pump

(Fig. 2). Obtain a power steering re-

turn hose from stock and connect the

end with the fitting to the output fit-

ting of the tool using the
5/8-18
SAE

female, 1/4 N.P. thread male fitting

provided. The end of the stock hose

(without the fitting) should be con-

nected to the return tube of the pump.

Connect the pressure hose from the

tool to the outlet fitting of the pump.

b.
Disconnect the pressure line at

the pump and connect the pressure

line from the test tool to the outlet fit-

ting of the pump. Disconnect the re-

turn line at the gear and connect it to

the output fitting of the tool, using the

5/8-18
SAE female, 1/4 N.P. thread

male fitting provided.

2.
After installing the lines by the

most advantageous method, proceed

as follows:

3.
Open the manual valves A and B

fully (Fig. 2).

CALIBRATED FLOW

DETERMINING ORIFICE

PRESSURE LINE

FIG. 2—Power Steering Pump Test Circuit Diagram
PRESSURE GAGE

G1611-Aprocarmanuals.com

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

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

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

03-10-02

Ford-Thompson Power Steering Pump

03-10-02

LOWER PRESSURE

PLATE 3D590

SPRING-3D601

UPPER PRESSURE

PLATE -3A645

RETAINER END

PLATE-3D589

CAM AND ROTOR

ASSEMBLY-
-3D607

SCREW AND WASHER

ASSEMBLY-379376-S
PULLEY-3D673

PUMP SHAFT

SEAL 3B592

PLATE AND BUSHING

ASSEMBLY-3D643

0-RING

382744-S

HOUSING GASKET

3A760

G1343-B

FIG. 2—Power Steering Pump Disassembled

To adjust the belt on 8 cyl. engines

loosen the mounting bolt in the ad-

justing slot and the nut directly above

the adjusting slot. Place a suitable pry

bar between the cast boss on the

pump mounting bracket and the cast

boss on the pump cover plate and pry

upward to correct tension.

Do not pry against the reservoir to

obtain proper belt load as it can be

deformed and cause a leak.

3.
Recheck the belt tension. When

the tension has been correctly adjusted,
tighten the bolts and the fiut to speci-

fication (Part 3-13).

POWER STEERING

PUMP DRIVE BELT

REPLACEMENT

1.
Loosen the idler pulley attaching

bolts and remove the compressor drive

belt if equipped with an air condition-

er.

2.
Loosen 3 bolts and one nut at-
taching the power steering pump to

the pump bracket, and remove the

pump drive belt.

3.
Position the power steering

pump drive belt on the pulleys.

4.
Adjust the drive belt tension as

outlined in Section 2 to specification

(Part 3-13) and tighten the pump at-

taching bolts and one nut to specifica-

tion.

5.
Install the compressor drive belt

if equipped with an air conditioner

and adjust to specification (Part 16).

REMOVAL AND INSTALLATION

POWER STEERING

PUMP REPLACEMENT

EIGHT CYLINDER

WITHOUT AIR

CONDITIONER AND

ALL SIX CYLINDER

1.
Remove the power steering fluid

from the pump reservoir by discon-

necting the fluid return hose at the

reservoir, and allow the fluid to drain

into 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

(rear nut on 8 cyl. engines only) that

attach the pump to the mounting

bracket; disconnect the belt from the

pulley and remove the pump from the

vehicle.

4.
Position the pump to the mount-

ing bracket and install the 3 bolts at

the front of pump and (rear nut on 8

cyl.
engines only) the 1 nut at the

rear. Torque to specification.

5.
Place the belt on the pulley and

adjust the belt tension (Section 2) with
Tool T63L-8620-A and tighten the

bolts and nut to specifications.

6. Torque the pressure hose fitting

hex nut to specification. Then, connect

the pressure hose to the fitting and

torque the hose nut to specification.

7.
Connect the hose to the pump.

Then, tighten the clamp.

8. Fill the power steering pump res-

ervoir with transmission fluid C1AZ-

19582-A and cycle the system to re-

move air from the steering gear sys-

tem.

9. Check for leaks and again check

the fluid level. Add fluid as necessary.procarmanuals.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

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