drain bolt FORD MUSTANG 1969 Volume One Chassis

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

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

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

03-08-05

Ford Design Integral Power Steering Gear

03-08-05

rque Wrench

Tool-T66P-3553-C

G1366-A

FIG.
5—Installing Valve Housing Attaching
Nut
24.
Align
the
lube passage
in the

valve housing with
the
one
in
the gear

housing,
and
install but
do
not tighten

the attaching bolts.

25.
Rotate
the
ball
nut so
that
the

teeth
are in the
same place
as
the sec-

tor teeth. Tighten
the
four valve hous-

ing attaching bolts
to
specification.

26.
Position
the
sector shaft cover

O-ring
in the
steering gear housing.

Turn
the
input shaft
as
required
to

center
the
piston.

27.
Apply vaseline
to the
sector

shaft journal; then, position
the
sector

shaft
and
cover assembly
in
the
gear

housing. Install
the
steering gear iden-

tification
tag and the
two sector shaft

cover attaching bolts.

28.
Position
an
in-lb torque wrench

on
the
gear input shaft
and
adjust
the

meshload
to
approximately
4
in-lbs.

Then, torque the sector shaft cover
at-

taching bolts
to
specification (Part

3-13).

29.
After
the
cover attaching bolts

have been tightened
to
specification,

adjust
the
meshload
to
specification

with
an
in-lb torque wrench.

STEERING GEAR

DISASSEMBLY

1.
Hold
the
steering gear over
a

drain
pan
in an
inverted position
and

cycle
the
input shaft several times
to

CENTERING SHIM

WORM AND VALVE ASSEMBLY

LOCK NUT

PISTON AND BALL NUT
VALVE HOUSING

TEFLON RING

•BALL GUIDE CLAMP

0-RING
BALL GUIDES

G1548-A

FIG.
6 —
Ball
Nut and
Valve Housing Disassembledprocarmanuals.com

03-08-06

Ford Design Integral Power Steering Gear

03-08-06

VALVE HOUSING

7W-T65P

C1239 -A

FIG. 7—Removing or Installing Lock

Nut

drain the remaining fluid from the

gear.

2.
Mount the gear in a soft-jawed

vise.

3.
Remove the lock nut and the

brass washer from the adjusting screw.

4.
Turn the input shaft to either

stop then, turn it back approximately

1 3/4 turns to center the gear.

5.
Remove the two sector shaft

cover attaching screws and the
identif-

ication tag.

6. Tap the lower end of the sector

shaft with a soft-hammer to loosen it,

then lift the cover and shaft from the

housing as an assembly. Discard the

O-ring.

7.
Turn the sector shaft cover coun-

terclockwise off the adjuster screw.

8. Remove the four valve housing

attaching bolts. Lift the valve housing

from the steering gear housing while

holding the piston to prevent it from

rotating off the worm shaft. Remove

the valve housing and the lube passage

O-rings and discard them.

9. Stand the valve body and piston

on end with the piston end down. Ro-

tate the input shaft counterclockwise

out of the piston allowing the ball

bearings to drop into the piston.

10.
Place a cloth over the open end

of the piston and turn it upside down

to remove the balls.

11.
Remove the two screws that at-

tach the ball guide clamp (Fig. 6) to

the ball nut and remove the clamp and

the guides.

12.
Install the valve body assembly

in the holding fixture (do not clamp

in a vise) and remove the lock nut and

the attaching nut as shown in Fig. 7.

13.
Carefully slide the input shaft,

worm and valve assembly out of the

valve housing. Due to the close diame-

trical clearance between the spool and

housing, the slightest cocking of the

spool may cause it to jam in the hous-

ing.

14.
Remove the shim from the

valve housing bore.
OIL SEAL

INLET TUBE SEAT

OUTLET TUBE SEAT
DUST SEAL

G1549-A

FIG.
8—Valve Housing Disassembled

Too/-T<

Tool-

T57L-500-A ,^^^

G1364-A

FIG. 9—Removing Bearing and Oil

Seal

PARTS REPAIR

OR REPLACEMENT

Valve Housing

1.
Remove the dust seal (Fig. 8)

from the rear of the valve housing

with Tools T59L-100-B and T58L-

101-A and discard the seal.

2.
Remove the snap ring from the

valve housing.

3.
Turn the fixture to place the

valve housing in an inverted position.

4.
Insert special tool in the valve

body assembly opposite the seal end

and gently tap the bearing and seal

out of the housing as shown in Fig.

9. Discard the seal. Caution must be

exercised when inserting and removing

the tool to prevent damage to the

valve bore in the housing.

5.
Remove the fluid inlet and outlet

tube seats with an EZ-out if they are

damaged.
Press Ra
Tool-

T65P-3524-A7

G1363-A

FIG. 10—Installing Valve Housing

Bearing

6. Coat the fluid inlet and outlet

tube seats with vaseline and position

them in the housing. Install and tight-

en the tube nuts to press the seats to

the proper location.

7.
Coat the bearing and seal surface

of the housing with a film of vaseline.

8. Position the bearing in the valve

housing. Seat the bearing in the valve

housing with the tool shown in Fig.

10.
Make sure that the bearing is

free to rotate.

9. Dip the new oil seal in gear lu-

bricant; then, place it in the housing

with the metal side of the seal facing

outward. Drive the seal into the hous-

ing until the outer edge of seal does

not quite clear the snap ring groove

(Fig. 11).

10.
Place the snap ring in the hous-

ing; then, drive on the ring with the

tool shown in Fig. 11 until the snap

ring seats in its groove to properly lo-

cate the seal.procarmanuals.com

03-09-03
Saginaw Design Integral Power Steering Gear

03-09-03

shaft and install and tighten the attach-

ing 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.
Check the reservoir fluid level

again and add as required.

MAJOR REPAIR OPERATIONS

Disassembly and reassembly of the

unit and the subassemblies must be

made on a clean workbench. As in re-

pairing any hyldraulically operated

unit, cleanliness is of tftfiiost impor-

tance. Therefore, the bench, tools, and

parts must be kept clean at all times.

Thoroughly clean the exterior of the

gear with a suitable solvent and, when

necessary, drain as much of the hy-

draulic fluid from the gear as possible.

DISASSEMBLY INTO

SUB-ASSEMBLIES

1,
Mount the steering gear in a

vise.
(Fig..
2\

2.
Rotate the end plug retaining

ring to place one end of the ring

opposite the hole in the housing.
3.
Working through the hole in the

housing (Fig. 3), unseat the retaining

ring then work it out of the groove

with a screwdriver.

4.
Rotate the input shaft in a coun-

terclockwise direction using a 3/4

inch, 12-point socket wrench to force

the end plug out of the housing. Do

not rotate the shaft any more than

necessary to remove the plug. Further

rotation will allow the balls to fall

from their circuit and allow the rack-

piston to become disengaged from the

sector shaft. Remove the O-ring from

the housing and discard it.

5.
Rotate the input shaft 1/2 turn

in a clockwise direction to draw the

piston inward.

6. Turn the end plug (Fig. 4) count-

erclockwise out of the piston with a

1/2 inch drive extension.
7.
Remove the lock nut from the

sector shaft adjustment screw. Discard

the nut.

8. Remove the four cover attaching

screws. Rotate the sector shaft adjust-

ment screw with an Allen wrench until

the cover is free of the housing. Re-

move the cover and the O-ring. Dis-

card the O-ring.

9. Turn the input shaft as required

to center the sector shaft teeth in the

housing.

10.
Tap the end of the sector shaft

with a soft-faced hammer to free it

from the housing.

11.
Remove the adjuster plug lock

nut.

12.
Remove the adjuster p>ug with

spanner wrench T65P-3A537-A (Fig.

15).

13.
Insert the tool shown ir Fig. 6

LOCK NUT RETUF™ P0RT

INLET PORT

TORSION BAR

STUB SHAFT
SECTOR SHAFT

ADJUSTMENT SCREW

ADJUSTER PLUG

HOUSING

SECTOR SHAFT

G
1649-
A

FIG. 2—Steering Gear
END PLUG

G1648-A

FIG. 3—Removing End Plug

Retaining Rinaprocarmanuals.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

03-10-04
Ford-Thompson Power Steering Pump

03-10-04

OUTLET FITTING

GASKET
Wood Block

0-RING SEAL

G1345-
-500-
A

G1603- A

FIG. 6—Gasket Locations
FIG.
7—Installing
Reservoir

on Pump—Typical
2.
Apply vaseline to the reservoir

O-ring seal and to the inside edge of

the new reservoir flange. Do not twist

the O-ring seal.

3.
Position the reservoir over the

pump and align the notch in the reser-

voir flange with the notch in the outer

diameter of the plate and bushing as-

sembly.

4.
Install the reservoir on the pump

and O-ring seal with a plastic or rub-

ber hammer and a block of wood as

shown in Fig. 7. Tap at the rear of the

reservoir and on the outer edges only.

5.
Inspect the assembly to be sure

the reservoir is evenly seated on the

pump housing plate.

6. Position the service identification

tag on the outlet fitting and install the

outlet fitting hex nut. Torque the nut

to specification (Part 3-13). Do not

exceed specification.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

Disassembly of the pump and its

subassemblies must be made on a

clean work bench. In repairing any

hydraulically operated unit, cleanliness

is of utmost importance. Clean the ex-

terior of the unit with a suitable sol-

vent and drain as much of the fluid as

possible.

If only the reservoir is to be re-

moved, plug the inlet and outlet open-

ings with masking tape or plugs. Do

not immerse the shaft oil seal in sol-

vent. If only the rotor shaft seal is to

be replace, see Rotor Shaft Seal Re-

placement outlined in this section.

1.
Assemble the adapter plate (Tool

T69P-3A674-A) to the bench mount-

ed holding fixture Tool T57L-5OO-A

(Fig. 8).

2.
Position the pump assembly,

with pulley assembled, on the adapter

plate, pulley facing down.

3.
Remove the outlet fitting nut and

the service identification tag.

4.
Invert the pump assembly and,

using a block of wood and a rubber or

plastic hammer, remove the pump res-

ervoir and seal by tapping around the

flange of the reservoir and on the und-

erside of the filler neck.

5.
Again invert the pump assembly,

loosen and remove the pump housing

retention bolts and remove the pump

housing.
6. If necessary, remove the fol-

lowing components from the pump

housing: the housing cover, the O-ring

seal and the pressure springs. These

components normally will remain in

the pump housing when it is removed.

7.
Remove and discard the pump

cover gasket.

8. Remove the retainer end plate

and upper pressure plate (in some

pumps, the end plate and upper pres-

sure plate are integral).

9. Remove the loose fitting dowel

pin. Be careful not to bend the fixed

dowel pin which remains in the hous-

ing plate assembly.

10.
Remove the rotor assembly

being careful to prevent the springs

and slippers from falling out and be-

coming lost. Do not disassemble fur-

ther unless the lower pressure plate,

housing plate, rotor shaft and/or seal

is to be replaced.

11.
Invert the pump assembly and,

using Tool T63L-1O3OO-B, remove the

pulley.

12.
Clean any rust, road dirt, burrs,

scoring, etc. from the pulley end of

the rotor shaft prior to removal of the

shaft from the housing plate. The

shaft must come out without restric-

tions to prevent scoring or damage to

the bushing. Remove the pump rotor

shaft.

13.
Remove the lower pressure

plate.
PARTS REPAIR OR

REPLACEMENT

ROTOR SHAFT

SEAL REPLACEMENT

Removal

1.
Remove the pulley from the

rotor shaft as described under Power

Steering Pump Pulley Removal.

2.
Position the pump assembly in

T57L-500-A

T69P-3A674-A

•
G1604-A

FIG. 8—Adapter Plate Installationprocarmanuals.com