brake FORD MUSTANG 1969 Volume One Chassis

04-04-07
Rear Axle — Ford Light-Duty (WER)
04-04-07

RUNOUT CHECK

E 1573-A

FIG. 70—Checking Backlash and Runout—Light-Duty (WER) Axle

All service operations on the differ-

ential case assembly can be performed

with the axle housing in the vehicle.

1.
Raise the vehicle on a hoist.

2.
Position the drain pan under the

axle housing. Loosen the housing

cover attaching bolts. Drain the lubri-

cant from the housing.

3.
Make scribe marks on the drive

shaft end yoke and the rear axle shaft

companion flange to insure proper po-

sition of the drive shaft at assembly.

Disconnect the driveshaft from the

rear axle companion flange. Be care-

ful to avoid dropping the loose univer-

sal joint bearing cups. Hold the cups

on the spider with tape. Mark the

cups so that they will be in their origi-

nal position in relation to the flange

when they are reassembled. Remove

the drive shaft from the transmission

extension housing. Install an oil seal

replacer tool in the transmission ex-

tension housing to prevent transmis-

sion leakage. Refer to the transmis-

sion group for the appropriate tool.

4.
Raise the vehicle and place

jack-type stands under the rear frame

crossmember. Lower the vehicle on a

hoist and allow the axle to lower as

far as possible.

5.
Remove the axle housing cover

and gasket. Discard the gasket.

6. Perform the Inspection Before

Disassembly of Carrier procedure.

Refer to Part 4-1, Section 3 of this

Shop Manual.

7.
Remove the attaching (Tinner-

man) nuts that secure the rear brake

drums to the axle shaft flanges, and

then remove the drums.

8. Working through the differential

case opening, remove the pinion shaft

lock bolt and pinion shaft (Fig. 2).

9. Push the axle shafts inward

toward the center of the axle housing.

Remove the C-locks (Fig. 3) from the

inner ends of the rear axles. Remove

the axle shafts from the housing. Ex-

treme care must be used to avoid con-

tacting the axle shaft seal lip with any
portion of the axle shaft except the

seal journal.

10.
Remove the bearings and oil

seals from the axle housing as shown

in Fig. 4.

11.
Remove the pinion side gears

and the side gear thrust washers.

12.
Remove both side bearing ad-

justing nut locks (bolts).

13.
Install a dial indicator (Fig. 10),

and check and record the backlash

and ring gear runout.

14.
Mark one differential bearing

cap and the case to help in positioning

the parts properly during assembly.

15.
Remove the bearing cap retain-

ing bolts. Remove the bearing caps,

cups,
adjusting nuts and case assem-

bly.

16.
Hold the drive pinion flange

and remove the pinion nut (Fig. 11).

Discard the nut.

17.
Remove the pinion flange (Fig.

12).

18.
Drive the pinion out of the

front bearing cone and remove it from

the carrier housing. Remove and dis-

card the bearing spacer.

19.
With a hammer and drift re-

move the pinion shaft oil seal out

through the front of the carrier hous-

ing.

20.
Remove the pinion rear bearing

from the drive pinion shaft (Fig. 13).

21.
Measure the shim which is

found under the bearing cone with a

Tool-T57L-485T-A

or 4851-K

El 906A
Tool
-
T6SL-485UA
\

E 1574-A

FIG. 12—Drive Pinion Flange

Removal

1575-A

FIG. 13—Pinion Rear Bearing

Removal

00/
- T57L-4220-A

FIG. 11—Typical Drive Pinion

Shaft Nut Removal
E 1576-A

FIG. 14—Differential Bearing

Removal

micrometer. Record the thickness of

the shim.

DISASSEMBLY OF

DIFFERENTIAL CASE

1.
If the 2 differential side bearings

are to be removed from the differen-

tial case, use the tool shown in Fig.

14.procarmanuals.com

04-05-04
Specifications

04-05-04

ATTACHING TORQUE SPECIFICATIONS -(By Axle Ring Gear Diameter)

Description

Differential Bearing Cap Bolt- 7 1/4"

8"

All Others

Differential Bearing Adjusting

Nut Lock Bolts

Carrier
to
Housing Stud Nuts-

8", 8 3/4", 9" 8 3/8"

Pinion Retainer
to
Carrier Bolts-

8", 8 3/4", 9" 9 3/8"

Ring Gear Attaching Bolts-

7 1/4"

All Others

Differential Pinion Shaft

Lock Pin
•
8 1/2" Only
Torque Lbs.
Ft.

40-55

55-70

70-85

12-25

25-40

30-45

40-55

65-80

15-22
Description

Rear Cover Screw and Washer

Assemblies
-8
1/4" &
8
1/2

Only

Oil Filler Plug

Rear Axle Shaft Bearing Retainer

Bolt Nuts:

Falcon,
Fairlane, Montego,

Mustang and Cougar (All)

Ford & Meteor (Exc.
8 1/2" R.G.)

Mercury,
T
Bird

Lincoln Continental (All)

Brake Backing Plate Bolt Nuts-

Ford & Meteor
8
1/2" Only
Torque Lbs.
Ft.

25-35

25-50

20-40

50-75

30-55

20-40

LUBRICANT
CAPACITIES
AND CHECKING PROCEDURES®

Vehicle

Falcon,
Mustang

Cougar, Fairlane, Falcon

Montego, Mustang

Ford,
Meteor

Ford,
Meteor

Cougar, Fairlane, Falcon, Ford,

Mercury, Meteor, Montego, Mustang

Lincoln,
Thunderbird
Engine

(C.I.D.)

170,
200

250,
302

240,
302

240,
302

351,
390,

428,
429

429,
460
Axle

Ratio

All

All

2.80:1,
3.10:1

All Except

2.80:1,
3.10:1

All

All
U.S. Measure

Capacity® (Pints)

2.5

4.0

4.0

5.0

5.0

5.0©
Imperial

Capacity
CD
(Pints)

2

31/5

3 1/5

4.0

4.0

4.0©

©All limited slip and Traction-Lok axles use ESW-M2C-104-A lubricant (C6AZ-19580-C).

All conventional axles use ESW-M2C-105-A lubricant (C6AZ-19580-B).

©Approximate refill capacity-Actual lubricant capacities are determined
by
filling
to
bottom
of
filler hole.

©To check these axles, the plug should be backed
out
slowly.
If
seepage occurs around the threads, the plug should
be
turned back
in

immediately to avoid any drainage. This indicates that the specified amount
of
lubricant
is
present
in
the axle.

SPECIAL TOOLS

FORD,
MERCURY, METEOR

Ford Tool No.

T66L-4204-L

T57L-500-A

T50T-100-A

TOOL-4235-C

T00L-4621-A

TOOL-1225-D

T00L42344

TOOL-1177

TOOL-U75-AB

T57L4220-A

T00L4221-AE

T00L-4221-AF

T66P-4220-P

TOOL-4851-K
Former No.

42211 or

42211-A

6005-M

6005-MS

B-160

4235C

—

—

4234-A

4245-B

1175-AB

—

4221-AF

T57L-4851-A

4851-K
Description

Limited-Slip Differential Check

Bench Fixture

Impact Hammer

Axle Shaft Remover

Drive Pinion Bearing and

Rear Wheel Bear Replacer

Rear Wheel Bearing Remover

Rear Wheel Bearing Installer

Rear Wheel Bearing Oil Seal Installer

Rear Wheel Bearing Oil Seal Remover

Differential Bearing Remover

Differential Bearing Remover

U-Joint
Flange Holder
Ford Tool No.

T53T4851-A

T00L4858-D

T57L4614-A

T00L4621-K

T53L-200-A

T57L-4625-A or

T00L4625-K

T57L4616-A or

T00L4615-D

T58L-101-A

T55P4616-A2

T57L4621-B or

T00L4621-L

T58L4676-A

T00L4858-E
Former No.

4851-A, D

—

4614

4621-K

—

4625-K

—

—

—

—

4676-F

4858-E
Description

U-Joint
Flange Remover

U-Joint
Flange Remover

Drive Pinion Retainer Support

Pinion Rear Bearing Cone Remover

Handle Adapter

Pinion Pilot Bearing Remover and

Installer

Pinion Front Bearing Cup Remover

and Replacer

Puller Attachment—For Bearing

Cup Removal

Pinion Rear Bearing Cup Remover

and Replacer

Pinion Rear Bearing Cone Installer

Drive Pinion Oil Seal Replacer

U-Joint
Flange and Pinion Bearing

Replacerprocarmanuals.com

05-01-01
05-01-01

Clutch
GROUP

5

PART
5-1
PAGE

Drive Shaft 05-01-01

PART
5-2

General Clutch Service 05-02-01
PART
5-3

Clutch

PART
5-4

Specifications
PAGE

05-03-01

05-04-01

PART
5-1
Drive Shaft

COMPONENT INDEX

DESCRIPTION

DRIVE SHAFT ANGLE CHECK

DRIVE SHAFT BALANCE CHECK

DRIVE SHAFT BALANCING

(Single Universal Joint)

DRIVE SHAFT DISASSEMBLY
AND

OVERHAUL

Single Universal Joint — Ford Design

Double Cardan Joint — Dana Design

Double Cardan Joint — Saginaw Design

DRIVE SHAFT REMOVAL
AND

INSTALLATION

DRIVE SHAFT RUNOUT CHECK
MODEL APPLICATION
All
Models

01-01

01-01

01-01

01-02

01-01
Ford
01-04

01-04

N/A

N/A
Mercury
01-04

01-04

N/A

N/A
Meteor
01-04

01-04

N/A

N/A
Cougar
01-04

01-04

N/A

N/A
Fairlane
01-04

01-04

N/A

N/A
Falcon
01-04

01-04

N/A

N/A
Montego
01-04

01-04

N/A

N/A
Mustang
01-04

01-04

N/A

N/A
Lincoln-
Continental
N/A

N/A

01-04

N/A
Thunderbird
N/A

N/A

N/A

01-05
Continental-
Mark
III
N/A

N/A

N/A

01-05

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.

DRIVE SHAFT TESTS

DRIVE LINE BALANCE CHECK

If detailed parts
of the
drive shaft

are replaced
and
shaft vibration
is en-

countered after installation, disconnect

the shaft
at the
slip yoke. Rotate
the

slip yoke
180
degrees; then, reconnect

the shaft
to the
slip yoke.
If the
vibra-

tion persists, disconnect
the
shaft
at

the rear axle companion flange.
Ro-

tate
the
companion flange
180
degrees

and reconnect
the
shaft
to the
flange.
DRIVE LINE ANGLE CHECK

Vibration
or
"shudder" which
is no-

ticeable either
on
fast acceleration
or

when coasting, using
the
engine
for a

brake,
may be
caused
by the
rear axle

housing being loose
on the
rear

springs
or by
improper pinion angle.

Refer
to
Group
3,
Part
2 for
pinion

angle checking procedures.
If the
rear

axle U-bolts (Fairlane, Montego,

Mustang, Cougar, Falcon models
only)
are
loose, torque
the
nuts
to

specification.

DRIVE SHAFT RUNOUT CHECK

Using
a
dial indicator, check
the

runout
at
each
end and in the
middle

of
the
driveshaft.
The
rear check

should
be
made
on the
small tube
sec-

tion
of the
shaft between
the
balance

weights
and the
yoke welds. Drive-

shaft runout should
not
exceed 0.035

inch
at any one
point.

DESCRIPTION

The drive shaft
is the
means
of

transferring power from
the
engine,

through
the
transmission,
to the dif-
ferential
in the
rear axle,
and
then
to

the rear wheels.
The
drive shaft incor-

porates
two
universal joints
and a
slip
yoke
(Fig. 1) or two
double cardan

universal joints,
one at
each
end of the

shaft (Figs.
2 and 3).
Each double
procarmanuals.com

05-03-03
Clutch
05-03-03

CLUTCH PEDAL

ADJUSTMENTS

Adjust
the
clutch pedal free travel

whenever
the
clutch does
not
disen-

gage properly,
or
when
new
clutch

parts
are
installed. Improper adjust-

ment
of the
clutch pedal
is one of the

most frequent causes
of
clutch failure

and
can be a
contributing factor
in

some transmission failures.

FREE TRAVEL

1.
Disconnect
the
clutch return

spring from
the
release lever.

2.
Loosen
the
release lever
rod

locknut
and
adjusting
nut
(Figs.
1, 2

and
3).

3.
Move
the
clutch release lever

rearward until
the
release bearing

lightly contacts
the
clutch pressure

plate release fingers.

4.
Adjust
the rod
length until
the

rod seats
in the
release lever pocket.

5.
Insert
the
specified feeler gauge

between
the
adjusting
nut and the

swivel sleeve. Then tighten
the
adjust-

ing
nut
against
the
gauge finger tight.

6. Tighten
the
locknut against
the

adjusting
nut,
being careful
not to di-

sturb
the
adjustment. Torque
the
lock-

nut
to
specification
and
remove
the

feeler gauge.

7.
Install
the
clutch return spring.

8. Check
the
free travel
at the
pedal

for conformance
to
specification.
Re-
adjust
if
necessary.

9.
As a
final check, measure
the

pedal free travel with
the
transmission

in neutral
and the
engine running
at

about 3000
rpm. If the
pedal free

travel
at
this speed
is not a
minimum

of
1/2
inch, readjust
the
clutch pedal

free travel. Otherwise,
the
release
fin-

gers
may
contact
the
release bearing

continuously, resulting
in
premature

bearing
and
clutch failure. Free travel

must
be
exactly
to
specification.

CLUTCH ASSIST

SPRING REPLACEMENT

(FAIRLANE, FALCON,

MONTEGO)

1.
Remove
the
cotter
pin
from
the

clutch
rod at the
clutch pedal lever
as-

sembly inside
the
passenger compart-

ment.

2.
Grasp
the
clutch pedal lever

firmly
to
prevent slipping
and
remove

the clutch
rod
from
the
lever. Allow

the clutch pedal lever
to
rest
on the

floor panel.

3.
Remove
the
forward bolt secur-

ing
the
assist spring bracket
to the

brake pedal bracket
and
loosen
the

rear bolt
two or
three turns.
Do not

remove
the
rear bolt.

4.
Grasp
the
assist spring bracket

with pliers
and
rotate upward until
the

spring
can be
separated from
the

bracket.

BRAKE PEDAL

BRACKET

CLUTCH ASSIST SPRING

BRACKET
-
7535

CLUTCH PEDAL

7519
5.
Position
the
assist spring
in the

clutch pedal spring bracket
and the

assist spring bracket. Rotate
the

spring bracket downward until
the

forward bolt holes
in the
assist spring

bracket line
up
with
the
holes
in the

brake pedal bracket
(Fig. 4).

6. Install
the
forward bolt retaining

the assist spring bracket
to the
brake

pedal bracket
and
torque
the
forward

and rear bolts
to
specification.

7.
Install
the
clutch
rod to the

clutch pedal lever
and
insert
the
cotter

pin.

CLUTCH PEDAL, PEDAL

ASSIST SPRING AND/OR

BUSHING REMOVAL

AND INSTALLATION

FORD, MERCURY,

METEOR

1.
Remove
the pin
that secures
the

clutch pedal-to-equalizer
rod to the

clutch pedal.

2.
Grasp
the
clutch pecal lever

firmly
to
prevent slipping
and
remove

the clutch
rod
from
the
lever. Allow

the clutch pedal lever
to
rest
on the

floor.

3.
Loosen
the
lower bolt securing

the assist spring bracket
to the
pedal

support bracket
two or
three turns.

Then, remove
the
upper bolt from
the

bracket.
Do not
remove
the
lower

bolt.

4.
Grasp
the
assist spring bracket

with pliers
and
rotate
it
counterclock-

wise until
the
spring
is
free
(Fig 5).

5.
Remove
the
retaining ring from

the
end of the
clutch pedal shaft. Then

remove
the
shaft, bushings
and
clutch

pedal from
the
support.

6. Remove
the
bushings from
the

pedal shaft
and
pedal support
and

transfer
the
rubber pedal
pad.

7.
After lubricating
the
pedal shaft

ASSIST SPRING

LOWER BOLT

ASSIST SPRING BRACKET-

UPPER
BOL"

C 1769-B

FIG. 4—Clutch Pedal Assembly
—
Fairlane, Montego, Falcon
C2058-A

;. 5—Removing Clutch Assist

Spring
—
Ford,
Mercury and Meteorprocarmanuals.com

05-03-04
Clutch

05-03-04

bushings, position the clutch pedal and

bushings in the pedal support.

8. Install the retaining ring on the

clutch pedal shaft.

9. Position the assist spring in the

pedal support bracket and the assist

spring bracket. Rotate the assist

spring bracket clockwise until the

upper bolt holes line up and install the

bolt. Torque both the upper and lower

bolts to specification.

10.
Check the clutch pedal free

travel and adjust as required.

MUSTANG, COUGAR

1.
Disconnect the battery ground

cable.

2.
Remove the steering column.

Refer to Group 3 of this manual for

the procedure.

3.
Remove the two capscrews re-

taining the master cylinder or booster

to the dash panel. Then remove the

two capscrews retaining the pedal sup-

port bracket to the dash panel.

4.
Working inside the vehicle, dis-

connect the clutch pedal-to-equalizer

rod at the clutch pedal by removing

the retainer and bushing.

5.
Secure the clutch pedal against

the bumper stop with a small C-clamp

as shown in Fig. 6.

6. Disconnect the stop light switch

wires at the connector.

7.
Remove the switch retainer and

slide the stop light switch off the

brake pedal pin just far enough for

the switch outer hole to clear the pin.

Then lower the switch away from the

pin.
Remove the master cylinder push

CLUTCH PEDAL ASSIST SPRING
rod, bushing and nylon washer from

the brake pedal pin.

8. Remove the screw retaining the

pedal support bracket to the top inner

cowl bracket (Fig. 6).

9. Remove the two sheet metal

screws retaining the pedal support

bracket to the dash panel.

10.
Remove the two screws retain-

ing the pedal support bracket to the

upper cowl brace and lower the pedal

support bracket away from the steer-

ing column studs.

11.
Remove the pedal support

bracket assembly from the vehicle.

12.
Mount the bracket in a vise.

13.
Remove the small C-clamp se-

curing the clutch pedal to the bumper.

Slowly pivot the pedal away from the

bumper until the assist spring can be

lifted from its seat.

14.
Remove the retainer clip from

the clutch and brake pedal shaft.

Then, remove the clutch pedal and

shaft assembly, brake pedal assembly,

and bushings from the pedal support

bracket.

15.
Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

bushings in their proper places on the

brake and clutch pedal assemblies.

16.
Position the brake pedal to the

pedal support bracket. Install the

clutch and brake pedal shaft through

the pedal support and brake pedal as-

sembly. Install the retainer.

17.
Install the clutch pedal assist

spring and pivot the pedal against its

bumper stop. Secure the pedal against

the bumper with a small C-clamp as

TOP INNER COWL-TO-BRACKET

RETAINING SCREW

C2057-A

FIG.
6—Clutch
Pedal —Mustang and Couga?
shown in Fig. 6.

18.
Position the pedal support

bracket assembly to the dash panel

and to the steering column retainer

studs.

19.
Align the pedal support bracket

holes with the holes in the dash panel

and install the two sheet metal screws.

20.
Install the two capscrews at-

taching the pedal support bracket to

the upper cowl bracket.

21.
Install the screw attaching the

support bracket to the top inner cowl

bracket (Fig. 6).

22.
Install the inner nylon washer,

bushing master cylinder push rod on

the brake pedal pin. Position the stop

light switch so that it straddles the

push rod with the switch slot on the

pedal pin and the switch outer hole

just clearing the pin. Slide the switch

completely onto the pin, and install

the outer nylon washer. Secure with

the self-locking pin.

23.
Connect the stop light switch

wires to the connector and install the

wires to the retaining clip.

24.
Connect the clutch pedal-

to-equalizer rod to the clutch pedal

assembly with the bushing and retain-

er and remove the C-clamp from the

bracket.

25.
Working from the engine side

of the dash panel, install the two cap-

screws attaching the pedal support

bracket to the dash panel. Then install

the two screws attaching the master

cylinder to the dash panel.

26.
Install the steering column.

Refer to Group 3 of this manual for

the procedure.

27.
Adjust the clutch pedal free

travel.

28.
Check the brake pedal free

height and travel measurements

(Group 2).

29.
Connect the battery ground

cable.

CLUTCH PEDAL AND/OR

BUSHING REMOVAL

AND INSTALLATION

MOM EGO, FALCON

FAIRLANF

1.
Remove the retaining clip (Fig.

2) that secures the equalizer rod to the

clutch pedal. Disconnect the rod from

the pedal.

2.
Remove the lower bolt retaining

the assist spring bracket to the pedal

support. Then, loosen the upper

bracket retaining bolt (approximately

4 turns) and disconnect the spring

from the clutch pedal and bracket.

3.
Disconnect the brake pedal push

rod from the brake pedal.procarmanuals.com

05-03-05
Clutch

05-03-05

4.
Remove the bolt that secures the

left air vent control cable bracket to

the instrument panel. Position the

control cable to one side.

5.
Remove the retaining clip and

flat washer from the clutch pedal

shaft. Then, remove the shaft, bush-

ing, clutch pedal and brake pedal

from the support.

6. Remove the bushings from the

pedal shaft, and transfer the pedal

pad.

7.
Lubricate the clutch pedal shaft

bushings and position them on the

shaft. Then, position the brake pedal

and clutch pedal in the pedal support.

8. Install the flat washer and re-

taining clip on the pedal shaft.

9. Position the assist spring to the

pedal and bracket. Pry the bracket

forward and install the lower bolt.

Torque the bolts to specifications.

10.
Position the master cylinder

push rod, bushing, and washers on the

brake pedal and secure with a retain-

ing clip.

11.
Connect the equalizer rod to

the clutch pedal and secure it in place

with a retaining clip.

12.
Position the air vent control

cable bracket to the instrument panel

and secure with the attaching bolt.

13.
Adjust the clutch pedal free

travel.

EQUALIZER BAR AND/OR

BUSHING REMOVAL AND

INSTALLATION

FORD, MERCURY

AND METEOR

1.
Raise the vehicle and disconnect

the clutch pedal-to-equalizer rod at

the equalizer bar (Fig. 1).

2.
Disconnect the return spring and

retaining spring at the release lever.

Separate the release lever rod from

the release lever.

3.
Remove the equalizer bar frame

bracket from the frame.

4.
Remove the equalizer bar from

the pivot on the flywheel housing.

5.
Remove the wire clip to replace

the outer bushing and the snap ring
from the inner pivot stud to replace

the inner bushing.

6. Position the flat washer, felt

washer and bushing on the inner and

outer pivots. Secure these parts with

the snap ring.

7.
Position the equalizer bar on the

inner pivot and bolt the equalizer bar

frame bracket to the frame. Torque

the attaching bolts to specification.

8. Install the clutch release rod, re-

turn spring and retaining spring.

9. Connect the clutch pedal rod to

the equalizer bar.

10.
Adjust the clutch pedal free

travel.

MUSTANG, COUGAR,

MONTEGO, FALCON,

FAIRLANE (EXCEPT

MONTEGO AND FAIRLANE

WITH 390 V-8)

1.
Disconnect the clutch pedal

equalizer rod at the equalizer bar

(Figs.
2 and 3).

2.
Raise the vehicle and disconnect

the release lever, return spring at the

lever.

3.
Remove the equalizer bar outer

bracket and bushing assembly.

4.
Remove the release rod from the

equalizer bar, and then remove the

equalizer bar. Remove the bushing

and washers from the inner mounting

stud.

5.
Position the equalizer bar, wash-

ers,
inner bushing, and retainer on the

inner stud.

6. After positioning the outer bush-

ing, install the outer bracket (with the

equalizer bar in place).

7.
Connect the release rod and the

release lever return spring.

8. Lower the vehicle. Connect the

clutch pedal equalizer rod to the

equalizer baY and secure with the re-

taining pin.

9. Adjust the clutch pedal free trav-

el as required.

MONTEGO AND

FAIRLANE—390 V-8

1.
Disconnect the clutch pedal
equalizer rod at the equalizer bar (Fig.

2).

2.
Raise the vehicle and disconnect

the return spring at the release lever.

Disconnect the release lever rod from

the equalizer lever.

3.
Remove the equalizer bar center

bolt.

4.
Separate the equalizer bar and

remove both sections from the vehicle.

5.
Remove the bolts retaining the

equalizer bar inner bracket to the fly-

wheel housing and remove the bracket

and bushing assembly.

6. Remove the equalizer bar outer

bracket and bushing assembly.

7.
Remove the snap ring, bushing,

and felt washer from each bracket as-

sembly.

8. Position a felt washer, and bush-

ing on each bracket assembly and se-

cure with the snap ring.

9. Install the outer bracket and

bushing assembly to the frame (Fig.

2).
Torque the bracket attaching bolts

to specifications.

10.
Position the outer section of the

equalizer bar on the outer bracket

pivot.

11.
Connect the two sections of the

equalizer bar. Insert the inner bracket

pivot into the equalizer bar and install

the assembly to the flywheel housing.

Torque the attaching bolts to specifi-

cations.

12.
Install the equalizer bar center

bolt and torque to specifications.

Make sure that both ends of the

equalizer bar are against the felt

washers.

13.
Connect the release rod and the

release lever return spring.

14.
Adjust the clutch pedal free

travel.

15.
Lower the vehicle. Connect the

clutch pedal equalizer rod to the

equalizer bar and secure with the re-

taining clip.

16.
Check the free travel at the

pedal for conformance to specifica-

tions.
Readjust if necessary.

REMOVAL AND INSTALLATION

CLUTCH REMOVAL

1.
Raise the vehicle on a hoist.

2.
Disconnect the drive shaft from

the rear U-joint flange. Then, slide the

drive shaft off the transmission output

shaft. Insert the appropriate tool over

the output shaft and into the extension

housing oil seal.
3.
Disconnect the speedometer

cable from the extension housing.

4.
Disconnect the gear shift rods

from the transmission. If the vehicle is

equipped with a four-speed transmis-

sion, remove the bolts that secure the

four-speed transmission, disconnect

the front brake cable from the cross-

member and remove the crossmem-
member from the vehicle.

5.
Remove the bolts that attach the

transmission to the flywheel housing.

6. Move the transmission rearward

until the input shaft clears the fly-

wheel housing, then remove it from

the vehicle.

7.
Disconnect the clutch release

lever retaining spring from the release

lever.procarmanuals.com

05-03-06
Clutch

05-03-06

8. Remove the starter cable then

remove the starter motor from the fly-

wheel housing.

9. Remove the bolts that secure the

engine rear plate to the front lower

part of the flywheel housing.

10.
Remove the flywheel housing

lower cover (390 CID housing only).

11.
Remove the bolts that attach

the housing to the cylinder block.

12.
Move the housing back just far

enough to clear the pressure plate,

then move it to the right to free the

pivot from the clutch equalizer bar. Be

careful not to disturb the linkage and

assist spring.

13.
Loosen the six pressure plate

cover attaching bolts evenly to release

the spring tension. If the same pres-

sure plate and cover is to be installed

after the clutch is overhauled, mark

the cover and flywheel so that the

pressure plate can be installed in the

same position.

14.
Remove the pressure plate and

the clutch disc from the flywheel.

CLUTCH INSTALLATION

1.
Install the clutch release lever if

it was removed.

2.
Place the clutch disc, and pres-

sure plate assembly in position on the

flywheel. Start the cover attaching

bolts to hold the pieces in place, but

do not tighten them. Avoid touching

the clutch disc facing, dropping the

parts or contaminating them with oil

or grease as clutch chatter may result.

3.
Align the clutch disc with the

tool shown in Fig. 7, and alternately

tighten the bolts a few turns at a time

until they are all tight. Then torque

the six pressure plate cover attaching

bolts to specification before removing

the tool.
4.
Apply a light film of grease

(C3VY-19586-A) to the outside diam-

eter of the transmission front bearing

retainer. Apply a light film of grease

(C3VY-19586-A) to both sides of the

release lever fork where it contacts the

release bearing bore spring clips.

Apply a light film of grease to the re-

lease bearing surface that contacts the

pressure plate release fingers. Fill the

grease groove of the release bearing

hub with lithium base grease (C3VY-

19586-A). Clean all excess grease

from inside the bore of bearing hub.

Excess grease will be forced onto the

spline by the transmission input shaft

bearing retainer and will contaminate

the clutch disc. Also, place the release

bearing and hub on the release lever.

5.
Make certain that the flywheel

housing and the cylinder block mount-

ing surfaces are clean. Position the

felt washer on the pivot in the fly-

wheel housing. Slip the pivot into the

clutch equalizer shaft being careful

not to disturb the linkage and at the

same time position the housing on the

dowels in the cylinder block. Install

and torque the attaching bolts to spec-

ification.

6. Install the starting motor and

connect the cable.

7.
The mounting surfaces of the

transmission and the flywheel housing

must be free of dirt, paint, and burrs.

Install two guide pins in the flywheel

housing lower mounting bolt holes.

Move the transmission forward on the

guide pins until it is tightly positioned

against the flywheel housing.

8. Install the two upper mounting

bolts.
Then, remove the guide pins

and install the two lower mounting

bolts.
Torque all the bolts to specifica-

tion.

9. Raise the rear of the engine and
install the crossmember. Install and

torque the crossmember attaching

bolts to specifications, then lower the

engine.

10.
Install the extension housing-

to-engine rear support attaching bolts.

Torque the bolts to specification.

11.
Remove the transmission jack

and connect the parking brake cable.

12.
If the vehicle is equipped with a

four-speed transmission, connect the

gear shift linkage control bracket to

the extension housing.

13.
Connect the gear shift rods to

the transmission. Adjust the shift link-

age as required.

14.
Connect the release lever retain-

ing spring. Install the flywheel housing

cover (390 CID housing only).

15.
Remove the tool from the

transmission output shaft and install

the drive shaft.

16.
Check the clutch pedal free

travel.

CLUTCH ARBOR CLUTCH DISC

PRESSURE PLATE

C 1788-A

FIG. 7—Installing Clutch Disc —

Typicalprocarmanuals.com

05-04-02

Specifications

05-04-02

TORQUE LIMITS (FT-LBS)

Description

Lower Access Clutch Cover Pan to Flywheel Housing Bolts (Cast Iron Housing)

Transmission Assembly to Flywheel Housing Bolts

Pressure Plate and Cover Assembly to Flywheel Attaching Bolts

Clutch Release Equalizer Frame Bracket Bolts

Clutch Pedal Free Travel Adjustment Nut

Flywheel Housing to Cylinder Block Bolts
6-Cylinder

8-Cylinder

Clutch Pedal Assist Spring Bracket to Brake Pedal Support Bracket
Meteor

Ford,
Mercury

17-20

37-42

12-20

15-24

15-20

_

12-17
Mustang,
Cougar

Fairlane, Montego, Falcon

-

-

12-20

15-24

15-20

23-33

40-50

12-17

SPECIAL TOOLS

Tool No.

A-37H

T61L-7657-Aor B

T57L-7657-A

T64P-7657-A
Description

Clutch Disc Aligner-Universal

Transmission Extension Housing Oil Seal

Replacer
Tool No.

CJ91B

T64L-6392-A

T49P-7580-A
Description

Universal Joint Bearing Replacer

Dia-L-lgner Gauge

Clutch Release Bearing Replacerprocarmanuals.com

06-02-04

Ford Design Three Speed Transmission

06-02-04

shift selector, remove
the
shift selector

assembly from
the
extension housing.

6.
On
Ford, Mercury
and
Meteor

vehicles disconnect
the
parking brake

cable from the equalizer lever and sep-

arate
the
lever from
the
crossmember.

7.
On
Ford, Mercury
and
Meteor

models, remove
the
bolts that secure

the extension housing
to the
engine

rear support.

8. Raise
the
rear
of
the engine high

enough
to
remove
the
weight from
the

crossmember.

9. Support
the
transmission with
a

transmission jack
and
remove
the

transmission from
the
flvwheel hous-

ing.

10.
Move
the
transmission and jack

rearward until
the
input shaft
is
clear

of
the
flywheel housing.

11.
Remove
the
transmission from

the jack
and
mount
it in a
holding

fixture.

Do
not
depress
the
clutch pedal

while
the
transmission
is
removed.

INSTALLATION

1.
Make certain that
the
machined

surfaces
of the
transmission case
and

the flywheel housing
are
free
of
dirt,

paint,
and
burrs.
2.
Install
a
guide
pin in
each lower

mounting bolt hole.

3.
Start
the
input shaft through
the

release bearing. Align
the
splines
on

the input shaft with
the
splines
in the

clutch disc. Move
the
transmission

forward
on the
guide pins until
the

input shaft pilot enters
the
bearing
or

bushing
in the
crankshaft.
If the

transmission front bearing retainer

binds
up on the
clutch release bearing

hub,
work
the
release bearing lever

until
the hub
slides onto
the
transmis-

sion front bearing retainer. Install
the

two transmission-to-flywheel housing

upper mounting bolts
and
lockwash-

ers.
Remove
the two
guide pins
and

install
the
lower mounting bolts
and

lock washers.

4.
Raise
the
rear
of the
engine high

enough
to
provide clearance
for in-

stalling
the
crossmember. Bolt
the

crossmember assembly
to the
frame

side supports.

5.
On
Ford, Mercury
and
Meteor

models, lower
the
engine until
the ex-

tension housing just contacts
the
rear

support. Align
the
bolt holes
in the

extension housing with those
in the

support. Then lower
the
engine
and

remove the jack. Install the two exten-

sion housing-to-support attaching
bolts
and
lock washers.

6.
On
Ford, Mercury
and
Meteor

models, insert
the
parking brake front

cable
in the
equalizer
and
install
the

equalizer
in the
bracket
on the

crossmember. Secure
the
parking

brake rear cable
to the
equalizer.

7.
On
vehicles equipped with
a

column-mounted gear shift selector,

secure
the
shift rods
to the
shift levers

at
the
transmission.
On
vehicles

equipped with
a
floor-mounted gear

shift selector, attach
the
shift selector

assembly
to the
extension housing.

8. Insert
the
speedometer cable
and

driven gear
in the
extension housing

and secure
it
with
a cap
screw
and

lock washer.

9. Remove
the
tool shown
in
Fig.
2,

Part 6-1, from
the
extension housing.

Align
the
reference marks
and
slide

the front universal joint yoke onto
the

output shaft
and
into
the
extension

housing. Connect
the
rear universal

joint
to the
axle pinion flange
and tor-

que
the
nuts
to
specifications.

10.
Fill
the
transmission
to the

proper level with
the
approved lubri-

cant.

11.
Adjust
the
clutch pedal free

travel
and the
shift linkage
as re-

quired.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

1.
Mount
the
transmission
in a

holding fixture and drain
the
lubricant

by removing
the
drain plug,
if so

equipped,
or the
lower extension hous-

ing bolt.

2.
Remove
the cap
screws that
at-

tach
the
cover
to
the case. Remove
the

COVER
cover
and the
gasket (Fig.
5)
from
the

case.

3.
Remove
a
long spring that
re-

tains
the
detent plug
in the
case (Fig.

9).
Remove
the
detent plug with
a

small magnet.

4.
Remove
the cap
screws
and
lock

washers that attach
the
extension

housing
to
the case. Remove extension

FRONT

BEARING RETAINER

C2069-A
and gasket from
the
case.

5.
Remove
the cap
screws
and
lock

washers that attach
the
front bearing

retainer
to the
case. Remove
the
front

bearing retainer
and
gasket from
the

case.

6. Remove
the
lubricant filler plug

from
the
right side
of the
case. Work-

ing through
the
plug opening, drive

the roll
pin out of the
case
and
coun-

tershaft with
a
1/4-inch
punch
(Fig.

6).

TERSHAFT'
#

PIN

C 1841-A

FIG. 5—Transmission Case
and
Related Parts—Typical
FIG. 6—Removing Countershaft

Roll
Pinprocarmanuals.com

06-03-02
Ford Design Four-Speed Transmission

06-03-02

1 DESCRIPTION

DESCRIPTION

The Ford designed 4-speed trans-

mission
(Fig. 1) is of the
fully
syn-

chronized type with
all
gears except

the reverse sliding gear being
in con-

stant mesh.
All
forward-speed changes

are accomplished with synchronizer

sleeves.
All forward-speed gears
in the

transmission
are
helical-type, however,

the reverse sliding gear
and the
exter-

ior
of the
first-and second-speed
syn-

chronizer sleeve
are
spur-type gears.

The specifications
of
this section Part

6-4 lists
the
transmission model
num-

bers
and
vehicles
in
which they
are

used.

C 1765-B

FIG. 7—Four-Speed Transmission—Typical
A transmission service identification

tag
is
located
on the
right side
of the

case
at the
front
(Fig. 2). The
first

line
on the tag
will show
the
transmis-

sion model
and
service identification

code when required.
The
second line

will show
the
transmission serial
num-

ber. Additionally,
a
driveline compo-

nent identification
tag is
attached
to

the upper right side
of the
transmis-

sion case.

TRANS.
MODEL

O
RUG-C-2

10001
O

SERIAL NO.

C 2088-A

FIG. 2—Transmission

Identification
Tag

IN-VEHICLE ADJUSTMENTS
AND
REPAIRS

SHIFT LINKAGE ADJUSTMENT

1.
Loosen
the
three shift linkage

adjustment nuts. Install
a 1/4
inch
di-

ameter alignment tool through
the

control bracket
and
lever holes
as

shown
in Fig. 13.

An alignment tool
can be
made

from
1/4
inch diameter drill
rod
bent

to
an "L"
shape.
The
extensions
should
be 2 1/2
inch
and 3 3/4
inch

from
the
elbow. Short
end of
align-

ment
pin
should
be
inserted into
con-

trol bracket
and
linkage holes until
it

bottoms.

2.
Disconnect
the
reverse gear shift

rod from
the
shift lever.

3.
Shift
the
transmission into
re-

verse gear.
4.
Tighten
the 1-2 and 3-4
shift
rod

adjustment nuts.

5.
Connect
the
reverse gear shift

rod
to the
shift lever. Shift
the
reverse

lever
to the
neutral position
and
tight-

en
the
adjustment
nut.

6. Remove
the
alignment
pin.

7.
Check
the
gear shift lever
for a

smooth crossover.

REMOVAL
AND
INSTALLATION

REMOVAL

1.
Raise
the
vehicle
on a
hoist.

2.
Mark
the
driveshaft
so
that
it

may
be
installed
in the
same relative
position. Disconnect
the
drive shaft

from
the
rear U-joint flange. Slide
the

drive shaft
off the
transmission output

shaft
and
install
the
extension housing

seal installation tool into the extension
housing
to
prevent lubricant leakage.

See
Fig. 2,
Part
6-1.

3.
Disconnect
the
speedometer

cable from
the
extension housing.

4.
Disconnect
the
parking brakeprocarmanuals.com