FORD MUSTANG 1969 Volume One Chassis

03-02-25
Suspension

03-02-25

pivot bolts and nuts to specification

(Part 3-13).

5.
Connect the track bar to the

frame bracket with a new nut and

bolt. Torque the nut to specification

(Part 3-13).

6. Remove the alignment spacers

and jack stands and lower the vehicle.

REAR SUSPENSION-

UPPER ARM

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK HI

Removal

1.
Raise the vehicle and support the

frame side rails with jack stands.

2.
Support the rear axle, then dis

connect the track bar from the frame

bracket.

3.
Lower the axle and support axle

under differential pinion nose, as well

as under axle.

4.
Remove the nut, bolt and two

washers that attach the upper arm to

the axle housing. Disconnect the arm

from the housing.

5.
Remove the nut and bolt that se-

cures the upper arm to the crossmem-

ber and remove the arm.

Installation

1.
Hold the upper arm in place on

the crossmember and install a new at-

taching bolt, a new lockwasher and a

new nut. Do not tighten the nut at this

time.

2.
Secure the upper arm to the axle

housing with a new attaching bolt,

two washers and a new nut. Do not

tighten the nut at this time.

3.
Install alignment spacers be-

tween the rear axle housing and

frame.

4.
Connect the track bar to the

frame bracket with a new nut and

bolt. Torque the nut to specifications.

5.
Torque the upper arm front nut

to specification. Remove the align-

ment spacers and the jack stands.

6. Adjust the pinion angle and tor-

que the rear nut to specification.

7.
Lower the vehicle.

TRACK BAR

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK HI

1.
Raise the vehicle on an axle con-

tact hoist.
FRONT PIVOT BOLT
LOWER ARM
REAR PIVOT BOLT NUT

F1439-A

FIG. 33—Rear Suspension Lower Arm Installed

Tool-T64K-5781-B4 (Thrust
Washer)

FIG. 34—Rear Spring Front Bushing Removal—Typical
F 1485. A

2.
Remove rubber cover at axle at-

tachment on track bar.

3.
Remove the nut and washer at-

taching the track bar to the upper arm

bracket and disengage the track bar

from the mounting stud (Fig. 33).

4.
Remove the nut and bolt attach-

ing the track bar to the frame side rail

and remove the track bar.

5.
Position the track bar to the

frame side rail and install a new at-

taching bolt and new nut.

6. Position the track bar on the

upper arm bracket mounting stud and

install a new washer and a new at-

taching nut. Torque the track bar at-

taching bolt and nuts to specification

(Part 3-13). Lubricate rubber cover

with synthetic rubber lubricant and in-

sert over end of stud onto washer.

Then, lower the vehicle.
REAR SPRING AND/OR BUSHING

COUGAR, FAIRLANE,

FALCON, MONTEGO,

MUSTANG

Removal

1.
Raise the vehicle on a hoist and

place supports beneath the underbody

and under the axle.

2.
Disconnect the lower end of the

shock absorber from the spring clip

plate and push the shock out of the

way. Remove the supports from under

the axle.

3.
Remove the spring clip plate

nuts from the U-bolts; then, remove

the plate (Fig. 31). Raise the rear axle

just enough to remove the weight from

the spring.

4.
Remove the two attaching nuts,

and rear shackle bar, and the two

shackle inner bushings.procarmanuals.com

03-02-26
Suspension

03-02-26

T64K-578 7-B2 (Adapter)

-83 (Nut)

(Bolt)

SPRING FRONT
EYE

Tool-T64K-5781-B2 (Adapter)
BUSHING

F 1484-A

FIG. 35—Rear Spring Front Bushing Installation—Typical

5.
Remove
the
rear shackle assem-

bly
and the two
outer bushings.

6. Remove
the
front hanger bolt,

nut,
and
washer from
the eye at the

forward
end of the
spring. Lift
out the

spring assembly.

7.
If the
front bushing
is
being
re-

placed, assemble
the
special tool
com-

bination
to the
bushing
in the
spring

front
eye as
shown
in
Fig.
34.

8. While holding
the
tool
nut,
tight-

en
the
tool bolt against
the
tool thrust

washer,
the
adapter,
and
detail
Al.

This operation will force
the
bushing

out
of the
spring
eye
into detail
A4 of

the tool
as
shown.

Installation

During rear suspension leaf spring

assembly replacement
in
service,
all

used attaching components must
be

discarded
and
replaced with
new com-

ponents.

1.
Assemble
the
bushing
and the

special tool combination
to the
spring

front
eye as
shown
in Fig. 35.

2.
While holding
the
tool
nut,
tight-

en
the
tool bolt against
the
tool thrust

washer, adapter,
and
detail
A4 to

force
the
bushing into
the
spring
eye

as shown.

3.
Position
the
spring under
the

rear axle
and
insert
the
shackle
as-

sembly into
the
rear hanger bracket

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

ings,
the
shackle plate,
and the
lock-

nuts.
Tighten
the
locknuts finger-tight.

5.
Position
the
spring front
eye in

the front hanger, slip
the
washer
on

the front hanger bolt,
and
(from
the

inboard side) insert
the
bolt through

the hanger
and
eye. Install
the
locknut

on
the
hanger bolt
and
tighten finger-

tight.

6. Lower
the
rear axle until
it
rests

on
the
spring. Position
the
spring clip

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

U-bolt nuts
and
torque
to
specifica-

tion.

7.
Connect
the
lower
end of the

shock absorber
to the
spring clip plate

using
a new nut if
working
on a sta-

tion wagon
or
Ranchero.

8. Place safety stands under
the

rear axle, lower
the
vehicle until
the

spring
is in the
approximate curb load

position,
and
then torque
the
front

hanger stud locknut
to
specification.

9. Torque
the
rear shackle locknuts

to specification.

10.
Remove
the
safety stands
and

lower
the
vehicle.

REAR SPRING

LINCOLN CONTINENTAL

Removal

1.
Raise
the
vehicle
and
place
sup-

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

2.
Lower
the
rear axle slightly
to

reduce some
of the
spring load; then,

remove
the
spring U-bolts.

3.
Remove
the
nuts, lock washers

and front mounting stud. Refer
to

Fig.
6.

4.
Remove
the
rear shackle nuts

and mounting plate. Remove
the

lower inner insulator. Remove
the

spring.
If the
rear shackle insulators

are
to be
replaced,
it
will
be
necessary

to remove
the
rear hanger assembly.

(Hanger attaching bolts must
be tor-

qued
to
specification when rein-

stalled.)

5.
Remove
the
insulators from
the

spring.

6. Examine
all
parts
for
wear
or

damage. Note
the
condition
of the

spring center bolt.

7.
The
spring center bolt
can be re-

placed
by
clamping
the
spring
in a

vise,
thus keeping
the
spring
com-

pressed during bolt removal
and in-

stallation.

Installation

1.
Attach
the
spring
and
bushing
to

the front hanger. Torque
the
outboard

nut
to
specifications.
Do not
tighten

the inboard
nut at
this time.

2.
Install
the
spring
to the
rear

shackle assembly with
the
insulators

in position.
Do not
tighten
the
nuts
at

this time. Refer
to Fig. 6.

3.
Place
the
insulator
and
retainers

in position
on the
spring.

4.
Lower
the
axle housing onto
the

insulator
and
retainer assembly.

If
a
wedge
was
located between
the

upper retainer
and
mounting
pad,

reinstall
the
same thickness wedge

with
the
taper
in the
original direc-

tion. Raise
the
axle until
the
spring
is

approximately horizontal with
the

floor.

5.
Install
the
lower insulator retain-

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

bolt nuts
at
this time. Torque
the
rear

shackle nuts
to
specifications.

6. Torque
the
inboard
nut at the

front
eye to
specification.

7.
Tighten
the
U-bolt nuts evenly
to

the specified torque.

8. Make sure
the
lower insulator

retainer contacts
the
upper retainer.procarmanuals.com

03-02-27

Suspension

03-02-27

MAJOR
REPAIR OPERATIONS

FRONT
SUSPENSION UPPER

ARM
BUSHINGS—ARM

REMOVED

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK III

1.
Remove the nuts and washers

from both ends of the upper arm inner

shaft.

2.
Install Tool T65P-3044-A1 on

the inner shaft and place Tool T65P-

3044-A3 inside the upper arm around

the inner shaft (Fig. 36).

F1440-A

FIG.
36—Removing Upper Arm

Bushings

3.
Position the upper arm in an

arbor press on Tool T65P-3044-A4

(Fig. 36), and press the lower bushing

out of the upper arm.

4.
Remove the bushing from the

inner shaft; turn the assembly over

and remove the bushing from the

other side of the arm. It may be nec-

essary to remove Tool T65P-3044-A1

from the inner shaft and remove the

shaft from the arm to remove the

bushing from the shaft. Then, install

the tool on the shaft and remove the

other bushing.

5. Position the shaft and bushings

to the upper arm and install the bush-
ings and inner shaft in the upper arm

as shown in Fig. 37.

6. Install a washer and new nut on

each end of the inner shaft.
PRESS
RAM

Tool—3069-AA

Tool
- T65P

3044
- A3
Tool
- T65P

3044
- A2

F1441-A

FIG.
37—Installing Upper Arm

Shaft
Bushings

LOWER
ARM OVERHAUL-

ARM
REMOVED

LINCOLN CONTINENTAL

Inspect the lower arm, bushings and

pivot bolt for cracks, bends, wear or

other damage. Replace the arm if nec-

essary.

1. If the ball joint requires replace-

ment, remove the rivet heads with a

chisel. Punch the remaining portion of

the rivets from the holes.

Do not wash the ball joint with sol-

vent. The solvent may attack parts

within the joint.

2.
If the bushing requires replace-

ment, press it out of the arm with

Tool 3069—details H, AA, and AA2

(Fig. 38).

3.
Apply silicone or liquid soap to

the shell of the new bushing. Place the

bushing in the arm with the flange end

(large end) of the bushing at the front

of the arm.

4.
Press the bushing into the arm

until the shoulder on the bushing shell

seats against the arm. Use tool

3069—details H, AA2, and M5 (Fig.

39).
F
1483-A

FIG.
38—Removing Lower Arm

Bushing

PRESS

RAM

1482-A

FIG.
39—Installing Lower Arm

Bushing

5.
If the ball joint was removed, in-

stall the new joint using the parts sup-

plied in the ball joint kit. Torque the

nuts to specification. Make sure the

joint is completely filled with the spec-

ified lubricant.

UPPER
ARM OVERHAUL-

ARM
REMOVED

LINCOLN CONTINENTAL

Inspect the upper arm and the inner

shaft for cracks, bends or other dam-

age.
Replace the parts as required.

Replacement arms come with the

bushings, inner shaft, and ball joint

installed. If the original arm is to beprocarmanuals.com

03-02-28
Suspension

03-02-28

used, these components should
be re-

placed
on the
bench.

Do not wash the ball joint with sol-

vent.
The
solvent
may
attack parts

within the joint.

BUSHING AND INNER

SHAFT REPLACEMENT

LINCOLN CONTINENTAL

Always replace both upper
arm

bushings,
if
either bushing
is
worn
or

damaged. Install only
new
bushings

when replacing
the
inner shaft. Refer

to Section
3 for
the upper arm remov-

al procedure.

1.
Remove
the
bolts, lock washers,

and flat washers from the ends
of
the

upper arm shaft.

2.
Assemble
the
remover, tool

3044-LA,
to the
shaft
at the
front

bushing. Press
the
bushing
out of the

arm using
the
support cup, tool 6069-

H,
and the
remover tool 3044-AB3

(Fig. 40).

PRESS RAM

FIG.
40
—Removing Upper
Arm

Front Bushing

3.
Remove
the
shaft.

4.
Remove
the
upper
arm
rear

bushing using
the
support
cup,
tool

3069-H, and
the
remover, tool 3069-L

(Fig. 41).

5.
Both upper
arm
bushings
are

pressed into the arm from the outside

toward the inside
of
the arm. To facil-

itate installation, use silicone
or
liquid

oap
as a
lubricant.
See
Fig.
41 for
PRESS RAM

Tool-3069-H

F 1480-A

FIG. 41—Removing Upper
Arm

Rear Bushing

proper assembly
of the
shaft
and

bushings.

6. Press the upper arm rear bushing

into
the arm
using
the
support cup,

tool 3069-H,
and the
replacer, tool

3068 (Fig. 43). Press
the
bushing
in

until
the
shoulder stop
is
reached.

7.
Insert
the end of the
shaft into

the rear bushing. Press the front bush-

ing onto
the
shaft
and
into
the arm

using the replacer, tool 3068 (Fig. 44).

REAR BUSHING
FRONT BUSHING

F 1479-A

FIG. 42— Upper Arm, Shaft,
and

Bushing Assembly

PRESS RAM

Tool— 3068

JF 1478-A
Bottom the bushing flange against the

flange
in the
arm.

8. Install
the
flat washers, lock-

washers,
and
bolts
at
the ends
of
the

upper
arm
shaft.
Do not
tighten
the

bolts
at
this time. These must
be

tightened after
the
arm assembly
has

been installed, and when the front end

weight
of
the vehicle
is
on the wheels.

These bolts
are
made
of a
special

material. Use only the specified bolt
if

replacement
is
necessary.

PRESS
RAM

FIG. 43—Installing Upper
Arm

Rear Bushing
FIG. 44—Installing Upper
Arm

Front Bushing

REAR SPRING OVERHAUL-

SPRING REMOVED

LINCOLN CONTINENTAL

Front Hanger Assembly

If
the
front hanger
or
bushings
are

to
be
replaced, proceed
as
follows:

1.
Remove
the
nuts and lock wash-

ers from
the
spring front mounting

bolt (Fig.
6).

2.
Tap the
spring mounting stud

out
of the
bushing
and
hanger, then

separate
the
hanger from
the
spring.

3.
Remove
the
front bushing from

the spring with tool T64N-5781-A.

4.
Install
the
bushing
in the
spring

with tool T64N-5781-A.

5.
Assemble the front hanger
to
the

spring
eye and
install
the
spring

mounting stud through
the
hanger,

bushings,
and
spring eye
as
shown
in

Fig.
6.

6. Install the lock washers and nuts

on
the
mounting stud
and
tighten
the

outboard
nut to
specification. Tighten

the inboard
nut to
specification with

the vehicle
at
curb riding height.procarmanuals.com

03-02-29

Suspension

03-02-29

SPRING LEAVES

AND TIE-BOLT

LINCOLN CONTINENTAL

Check for broken spring leaves. In-

spect the anti-squeak inserts between

the leaves, and replace them if they

are worn. The spring leaves must be

dry and free of oil and dirt before new

inserts are installed.
If the spring center tie-bolt requires

replacement, clamp the spring in a

vise to keep the spring compressed

during bolt removal and installation.

REAR SHACKLE AND

HANGER ASSEMBLY

LINCOLN CONTINENTAL

Inspect the rear shackle, bushings,

and studs for wear or damage. Re-

place parts where necessary (Fig. 6).
If the rear shackle bushings are to

be replaced, it will be necessary to re-

move the rear hanger assembly. Tor-

que the hanger attaching bolts to

specification when installed.procarmanuals.com

03-03-01
Automatic
Air
Leveling System

03-03-01

PART
3-3
Automatic
Air
Leveling System

COMPONENT INDEX

AIR COMPRESSOR

Disassembly
and
Overhaul

Removal
and
Installation

AIR CYLINDER

Removal
and
Installation

DESCRIPTION

HEIGHT CONTROL VALVE

Disassembly
and
Overhaul

Removal
and
Installation
MODEL APPLICATION
All
Models
Ford

03-03

03-02

03-02

03-01

03-03

03-02
Mercury
03-03

03-02

03-02

03-01

03-03

03-02
Meteor
03-03

03-02

03-02

03-01

03-03

03-02
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

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.
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/A

N/A
Continental-
Mark III
N/A

N/A

N/A

N/A

N/A

N/A

DESCRIPTION

The automatic level control
is an

accessory item
on the
Ford, Mercury

and Meteor vehicles
(Fig. 1).
This
de-

vice
is a
supplement
to the
rear coil

spring suspension,
and
will automati-
cally maintain
the
rear standing height

of
the
vehicle
at an
approximate
con-

stant position compensating
for
vary-

ing loaded conditions.
The
system

consists
of a
vacuum operated
com-
pressor, control valve,
air
cylinders

and
the
connecting lines
and
fittings.

In
the
event
of
accidental
air
loss,
the

conventional coil springs will support

the vehicle.

RUBBER
AIR
CYLINDER

WITHIN COIL SPRING
HEIGHT CONTROL

VALVE
RUBBER
AIR
CYLINDER

WITHIN COIL SPRING

RUBBER VACUUM LINE
TO
VACUUM

DISTRIBUTION CONNECTOR

RED CLAMP STATION WAGON ONLY

COMPRESSOR

NYLON
AND
STEEL LINES

FROM VALVE
TO
CYLINDERS

FIG.
1
—
Air Leveling System
FT475-A
procarmanuals.com

03-03-02

Automatic Air Leveling System

03-03-02

REMOVAL AND INSTALLATION

AIR COMPRESSOR

REMOVAL

1.
Slip the vacuum line off the in-

take fitting on the side of the com-

pressor (Fig. 2).

2.
Disconnect the output line from

the rear of compressor.

3.
Remove the three compressor at-

taching nuts from the bracket. Lift the

compressor from the mounting brack-

et.

INSTALLATION

1.
Place the star washer on each in-

sulator. Position the compressor on

the mounting bracket and install and

torque the three attaching nuts to

specifications.

2.
Connect the vacuum line to the

intake fitting at the side of the com-

pression.

3.
Start the engine and check the

compressor output.

4.
Connect the output line to the

nylon fitting at the rear of the com-

pressor (Fig. 2).

HEIGHT CONTROL VALVE

REMOVAL

1.
Raise the vehicle on a hoist. It
may be more convenient to support

the rear of the frame with two jack

stands and lower the, axle to provide

greater accessability to the valve.

2.
Disconnect the compressor line

from the intake port of the height

control valve (Fig. 3).

3.
Disconnect the air cylinder line

from the rear of the height control

valve.

4.
Disconnect the link from the

height control valve lever.

5.
Remove the two control valve-

to-mounting bracket attaching screws

and remove the valve.

INSTALLATION

1.
Position the height control valve

to the mounting bracket and install

the two attaching screws. Torque the

screws to specification.

2.
Connect the link to the height

control valve lever.

3.
Connect the compressor line to

the height control valve.

4.
Connect the air cylinder line to

the height control valve.

5.
Set the height control valve lever

as required to obtain the correct trim

height.

6. After obtaining the correct trim
height, check the operation of the air

leveling system.

AIR CYLINDER

REMOVAL

1.
Raise the vehicle on a hoist with

the hoist under the rear axle housing.

Place jack stands under the frame side

rails.

2.
Disconnect the air cylinder line

from the fitting on the lower end of

the cylinder (Fig. 4).

3.
Lower the hoist and axle housing

until the rear shock is fully extended.

4.
Squeeze all air from the bag and

install the valve cap.

5.
Remove the air cylinder from the

rear spring.

INSTALLATION

1.
Make sure all the air is out of

the bag and the valve cap is on.

2.
Position the air cylinder in the

spring with the inlet at the lower end.

3.
Remove the valve cap and con-

nect the air cylinder line to the cylin-

der.

4.
Remove the jack stands and

lower the vehicle.

VACUUM INTAKE LINE

INSULATORS

NYLON FITTING

MOUNTING BRACKET

FIG. 2—Compressor Installed
STAR WASHERS

COMPRESSOR
F 1364-Aprocarmanuals.com

03-03-03
Automatic Air Leveling System

03-03-03

COMPRESSOR LINE
AIR
CYLINDER LINE INTAKE PORT EXHAUSTPORT
ADJUSTMENT SCREW

MOUNTING BRACKET
HEIGHT CONTROL VALVE
REAR SUSPENSION UPPER
ARM

FIG. 3—Height Control Valve Installation

Al R CYLINDER
F 1365-A

FIG. 4—Air Cylinder Installation

3 MAJOR REPAIRS

AIR COMPRESSOR

Compressor repair should
be
limit-

ed
to the
cleaning
of the
micro-bon

filter.

REMOVAL

1.
Remove
the
three cover filter
at-

taching screws.
2.
Remove
the
filter
and
cover

gasket.

3.
Wash
the
filter
in
solvent, blow

it
dry
with compressed
air
working

from
the
inside outward.

INSTALLATION

1.
Position
a new
gasket
and the

cover
on the
compressor.
2.
Install
the
three attaching

screws.

HEIGHT CONTROL VALVE

Other than adjusting
the
trim

height,
no
repairs should
be
made
to

the height control valve.

1.
Thoroughly clean exterior
of the

height control valve.procarmanuals.com

procarmanuals.com

procarmanuals.com