air condition FORD MUSTANG 1969 Volume One Chassis

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

03-07-01
Ford Design Non-Integral Power Steering System

03-07-01

PART
3-7
Ford Design Non-Integral Power

Steering System

COMPONENT INDEX

CONTROL VALVE

Disassembly
and
Overhaul

Removal
and
Installation

CONTROL VALVE CENTERING SPRING

Adjustment

CONTROL VALVE
TO
POWER STEERING

CYLINDER HOSE

Removal
and
Installation

HOISTING INSTRUCTIONS

POWER CYLINDER

Removal
and
Installation

POWER CYLINDER SEAL

Removal
and
Installation

POWER STEERING PUMP CLEANING

AND INSPECTION
(See
Part 03-01)

Removal
and
Installation

POWER STEERING PUMP
TO
CONTROL

VALVE HOSE

Removal
and
Installation

STEERING GEAR

Cleaning
and
Inspection

(See Part 03-01)
MODEL APPLICATION
All
Models
Ford

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Mercury
N/A

N/A

N/A

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

N/A

N/A

N/A
Cougar
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Fairlane
07-04

07-03

07-02

07-02

07-02

07-04

07-06

07-03

07-02
Falcon
07-04

07-03

07-02

07-02

07-02

07-04

07-06

07-03

07-02
Montego
07-04

07-03

07-02

07-02

07-02

07-04

07-06

07-03

07-02
Mustang
07-04

07-03

07-02

07-02

07-02

07-04

07-06

07-03

07-02
Lincoln-
Continental
07-04

07-03

07-02

07-02

07-02

07-04

07-06

07-03

07-02
Thunderbird
N/A

N/A

N/A

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

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 Ford Non-Integral Power

Steering System
(Fig. 1) is a
hydrauli-

cally controlled linkage-type steering

system which includes
an
integral

pump
and
fluid reservoir,
a
control

valve,
a
power cylinder,
the
connecting
fluid lines,
and the
steering linkage.

The hydraulic pump
and
belt, driven

from
the
engine crankshaft, draws

fluid from
the
reservoir
and
provides

fluid pressure
for the
system. Within

the pump itself
is a
pressure-relief
valve which governs
the
pressures

within
the
steering system according

to
the
varying conditions
of
operation.

After fluid
has
passed from
the
pump

to
the
control valve
and the
power
cyl-

inder,
it
returns
to the
reservoir.
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

03-11-02
Eaton Power Steering Pump

03-11-02

gasket. Withdraw the fluid with a suc-

tion gun.

2.
Remove the reservoir bracket-

to-cylinder block upper cap screw and

the lower cap screw and spacer.

3.
Disconnect the reservoir infet line

and the outlet line at the reservoir,

and remove the reservoir.

Installation

1.
Connect the reservoir-to-pump

line (outlet line) at the reservoir, but

do not tighten the clamp.

2.
Attach the reservoir and bracket

to the cylinder block with the upper

cap screw and the lower cap screw

and spacer. Tighten the cap screws.

3.
Tighten the outlet line clamp at

the reservoir. Connect the reservoir

inlet line to the reservoir.

4.
Fill the reservoir with the speci-

fied automatic transmission fluid. Run

the engine, and bleed the system by

cycling the steering gear with the

windshield wipers turned on. Check

for leaks, and recheck the fluid level.
WITH AIR CONDITIONING

Removal

1. Raise the front of the vehicle.

Remove the reservoir-to-pump line

(outlet line) clamp at the reservoir,

but do not disconnect the line at this

time.

2.
Disconnect the reservoir inlet line

at the reservoir.

3.
Remove the reservoir bracket to

the cylinder block upper cap screw.

Support the reservoir and remove the

lower cap screw and spacer.

4.
With a drain pan under the res-

ervoir, disconnect the outlet line hose

from the reservoir tube and allow the

fluid to drain.

5.
Remove the reservoir cover re-

taining nut and the cover. Position the

cover and the reservoir out of the way

and allow them to rest in the engine

compartment.

6. Lower the front of the vehicle.

Remove the fan shroud.

7.
Remove the reservoir and the
cover by manipulating them through

the opening between the radiator and

the compressor drive belt.

Installation

1.
Position the reservoir in the en-

gine compartment. Loosely attach the

reservoir and bracket to the cylinder

block with the upper cap screw.

2.
Install the fan shroud, then raise

the front of the vehicle.

3.
Connect the reservoir-to-pump

line (outlet line) at the reservoir.

4.
Install the reservoir bracket-

to-cylinder block lower cap screw and

spacer. Tighten both the upper and

the lower cap screws.

5.
Connect the reservoir inlet line at

the reservoir. Install the clamps on

both lines. Lower the car, and install

the reservoir cover and attaching nut.

6. Fill the reservoir with the speci-

fied automatic transmission fluid. Run

the engine, and bleed the system by

cycling the steering gear with the

windshield wipers turned on. Check

for leaks, and recheck the fluid level.

3 MAJOR REPAIR OPERATIONS

INSULATOR (2)

WASHER (2)

MOUNTING BOLT (2)

COVER

BOLT (7)
DOWEL
PIN (2)

ROTOR

ROTOR
SHAFT

COVER
SEAL
PLUG

O RING

VALVE
ASSEMBLY

VALVE
SPRING

INSULATOR

HOUSING

CAM RING

PRESSURE
PLATE
,
PUMP

i
HOUSING

SEAL

ROLL

PIN

INSULATOR

RETAINER
RING
TUBE SEAT

O RING

SCREW
(2)

G12O8-B

FIG.
1
— Power Steering Pumpprocarmanuals.com

03-12-03

Wheels And Tires

03-12-03

DISC BRAKES

1.
Raise the vehicle until the wheel

and tire clear the floor.

2.
Pry off the wheel cover and re-

move the grease cap (Fig. 2) from the

hub.

3.
Wipe the excess grease from the

end of the spindle, and remove the ad-

justing nut cotter pin and nut lock.

4.
Loosen the bearing adjusting nut

three turns. Then, rock the wheel,

hub,
and rotor assembly in and out

several times to push the shoe and lin-

ings away from the rotor.

5.
While rotating the wheel, hub,

and rotor assembly, torque the adjust-

ing nut to 17-25 ft-lbs to seat the

bearings (Fig. 4).

6. Back the adjusting nut off one

half turn. Then, retighten the adjust-

ing nut to 10-15 in-lbs with a torque

wrench or finger tight.

7.
Locate the nut lock on the ad-

justing nut so that the castellations on

the lock are aligned with the cotter

pin hole in the spindle.

8. Install a new cotter pin, and

bend the ends of the cotter pin around

the castellated flange of the nut lock.

9. Check the front wheel rotation.

If the wheel rotates properly, install

the grease cap and the hub cap or

wheel cover. If the wheel still rotates

roughly or noisily, clean or replace the

bearings and cups as required.

10.
Before driving the vehicle,
pump the brake pedal several times to

obtain normal brake lining to rotor

clearance and restore normal brake

pedal travel.

BALANCING LIFE

GUARD TIRE

Tires fitted with the Life Guard

Safety Spare are balanced in the same

manner as conventional tires. If an ex-

cessive out of balance condition exists

the following procedure can be used to

correct the condition:

1.
Remove the core housing and de-

flate both air chambers.

2.
Install the core housing.

3.
Unseat the beads of tire with the

bead breakers away from the valve

stem as shown in Fig. 5.

F 1383

FIG. 5—Breaking Top Bead of

Tire From Wheel Rim
4.
Rotate tire casing 90 degrees on

the wheel rim.

5.
Rotate the tire casing back and

forth on the rim to center the valve.

6. Inflate both chambers of the tire

following steps 13 through 15 of the

Tire Installation procedure.

7.
Balance the tire in the normal

manner.

CORRECTING VIBRATION

AND SHAKE-

LIFE GUARD TIRE

The condition of excessive vibration

and shake is generally the result of an

incorrect pressure relationship between

the inner and outer air chambers that

may cause the life guard to shift posi-

tion within the tire. The following

procedure should be used to correct

vibration and shake conditions:

1.
Check pressure of the inner and

outer air chambers on all four tires.

2.
If the inner chamber has at least

five psi more pressure than the outer

chamber the pressures should be ad-

justed and the tires rebalanced if nec-

essary.

3.
If the pressures of the inner and

outer air chambers are equal the Air

Container is leaking. To repair the

leaking air container the recommend-

ed procedures for the removal, repair

of air container, mounting, and bal-

ancing should be followed.

REMOVAL AND INSTALLATION

HOISTING INSTRUCTIONS

Damage to steering linkage compo-

nents and front suspension struts may

occur if care is not exercised when po-

sitioning 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

lower arms or the No. 1 crossmember.

Do not allow the adapters to contact

the steering linkage. If the adapters

are placed under the crossmember, a

piece of wood (2x4x16 inches) should

be placed on the hoist channel be-

tween the adapters. This will prevent

the adapters from damaging the front

suspension struts.

WHEELS AND TIRES

WHEEL AND TIRE

REMOVAL

1.
Pry off the wheel hub cap or
wheel cover. Loosen but do not re-

move the wheel hub nuts.

2.
Raise the vehicle until the

wheel and tire clear the floor.

3.
Remove the wheel hub nuts

from the bolts, and pull the wheel

and tire from hub and drum.

F1424-
A

FIG.
6—Bead
Loosening Tool
REMOVING CONVENTIONAL

TIRE FROM WHEEL

The tire can be demounted on a

mounting machine. Be sure that the

outer side of the wheel is positioned

downward. If tire irons are used, fol-

low the procedure given here.

1.
Remove the valve cap and core,

and deflate the tire completely.

2.
With a bead loosening tool,

break loose the tire side walls from

the wheel (Fig. 6).

3.
Position the outer side of the

wheel downward, and insert two tire

irons about eight inches apart between

the tire inner bead and the back side

of the wheel rim. Use only tire irons

with rounded edges or irons designed

for removing tubeless tires.

4.
Leave one tire iron in position,

and pry the rest of the bead over the

rim with the other iron. Take small

bites with the iron around the tire inprocarmanuals.com

04-04-08
Rear Axle — Ford Light-Duty (WER)

04-04-08

E 1577-A

75—Pinion Bearing
Cup
Installation—Typical

2.
Remove
the
bolts that attach
the

ring gear
to the
differential case. Press

the ring gear from
the
case
or tap it

off with
a
soft-faced hammer.

PARTS REPAIR
OR

REPLACEMENT

Clean
and
inspect
all the
parts
as

outlined
in
Cleaning
and
Inspection,

Part 4-1, Section
3 of
this Shop
Man-

ual.
Before assembling
the
carrier,
re-

pair
or
replace
all
parts
as
indicated

by
the
inspection.
The
principle
re-

placement operations
are
covered
in

the following procedures.
All
other
re-

pair
or
replacement operations
are

performed during
the
Cleaning
and

Inspection, Part 4-1, Section
3
opera-

tions noted above,
or
during
the as-

sembly
in
this section.

PINION BEARING CUPS

Do
not
remove
the
pinion bearing

cups from
the
carrier casting unless

the cups
are
worn
or
damaged.

If
the
pinion bearing cups
are to be

replaced, drive them
out of the
carrier

casting with
a
drift.
Tap on the
side

opposite
the cup. Use
care
to
prevent

the cups from cocking
in the
carrier.

Install
the new
cups with
the
tool

shown
in Fig. 15.
Make sure
the
cups

are properly seated
in
their bores.
If a

0.0015-inch feeler gauge
can be
insert-

ed between
a cup and the
bottom
of

its bore
at any
point around
the cup,

the
cup is not
properly seated.

Whenever
the
cups
are
replaced,
the

cone
and
roller assemblies should also

be replaced.
DRIVE PINION
AND

GEAR
SET

Individual differences
in
machining

the carrier casting
and the
gear
set re-

quire
a
shim between
the
pinion rear

bearing cone
and the
pinion gear
to

locate
the
pinion
for
correct tooth

contact with
the
ring gear.

When replacing
a
ring gear
and pin-

ion
it
should
be
noted that
the
original

factory installed shim
is of the
correct

thickness
to
adjust
for
individual vari-

ations
in
both
the
carrier casting
di-

mension
and in the
original gear
set

dimension; therefore,
to
select
the cor-

rect shim thickness
for the new
gear

set
to be
installed, follow these steps:

1.
Use a
micrometer
to
measure

the thickness
of the
original shim
re-

moved from
the
axle
and use the
same

thickness upon installation
of the re-

placement carrier assembly
or
drive

pinion.
If
further shim change
is nec-

essary,
it
will
be
indicated
in the
tooth

pattern check.

2.
If the
original shim
is
lost,
sub-

stitute
a
nominal shim
for the
original

and
use the
tooth pattern check
to de-

termine
if
further shim changes
are re-

quired. Nominal shim thicknesses
is

indicated
in
Part
4-3,
Specifications.

A
new
ring gear
and
pinion should

always
be
installed
in an
axle
as a

matched
set
(never separately).
Be

sure
the
same identifying (matching)

number, painted, appears
on the
bolt

hole face
of the
ring gear
and on the

head
of the
drive pinion
(Fig. 16).

3.
After determining
the
correct

shim thickness
as
explained
in the

foregoing steps, install
the new
pinion

and ring gear
as
outlined under
As-

sembly which follows
in
this section.
MATCHED

GEAR
SET

IDENTIFICATION

E 1628-A

. ?6—Pinion
and
Ring Gear

Markings

3ress
Ro-

Tool

T57L-4221-A-1

DIFFERENTIAL

BEARING CONE

ANC ROLLER

|E 1579-A

PIG. 77—Differential Bearing

Installation

DIFFERENTIAL CASE,

BEARINGS,
AND
DRIVEN

GEAR

If
the
ring gear runout check
(be-

fore disassembly) exceeded specifica-

tions,
the
condition
may be
caused
by

a warped gear,
a
defective case,
or ex-

cessively worn differential bearings.

To determine
the
cause
of
excessive

runout, proceed
as
follows:

1.
Press
the
original bearings
on

the one-piece differential case hubs

without
the
ring gear installed.

2.
Place
the
differential bearing

cups
on the
bearing cone
and
roller

and
set the
differential case
in the car-

rier.

3.
Install
the
matched (marked)

bearing caps
and
adjusting nuts
as

outlined
in
steps
11
thru
14
under
In-

stallation
of
Drive Pinion
and
Differ-

ential Case which follows
in
this
sec-

tion.

4.
Tighten
the
left adjuster
nut
until

it just touches
the
bearing
cup
then

tighten
the nut two
notches beyond

the point where
it
first contacts
the

bearing
cup.
Rotate
the
differentialprocarmanuals.com

06-01-02
General Transmission Service

06-01-02

REAR SEAL REPLACEMENT

1.
Remove the drive shaft.

2.
Remove the seal from the exten-

sion housing with the tool shown in

Fig. 2.

3.
Install the new seal in the exten-

sion housing with the tool shown in

Fig. 3.

4.
Install the drive shaft.

.REAR OIL SEAL

Tool-T61L-7657-A

EXTENSION HOUSING

C 1830.A

FIG. 3—Installing Extension

Housing Seal
Too/-7J75-AB

Tool-TSOT-lOO-A

FIG. 2—Removing Extension Housing Seal

EXTENSION HOUSING

Tool-T52L-7000-GAE

or 7000-G

C1O28-D

FIG. 4—Removing Extension

Housing Bushing and Seal
EXTENSION HOUSING
D
1927. A

Tool—T57P-7697-B

57-G

BUSHING

C 1832.A

FIG. 5—Installing Extension

Housing Bushing

REAR BUSHING AND SEAL

REMOVAL AND INSTALLATION

1.
Remove the drive shaft from the

vehicle.

2.
Insert the tool shown in Fig. 4

into the extension housing until it

grips on ihe front side of the bushing.
3.
Turn the screw clockwise until

the seal and the bushing are free of

the housing.

4.
Drive a new bushing into the ex-

tension housing with the tool shown in

Fig. 5.

5.
Install a new seal in the housing

as shown in Fig. 3.

6. Install the drive shaft.
LUBRICATION

Lubricant level should be even with

the bottom of the filler hole at the

right side of the transmission case.

CLEANING AND INSPECTION

CLEANING

1.
Wash all parts, except the ball

bearings and seals in a suitable clean-

ing solvent. Brush or scrape all foreign

matter from the parts. Be careful not

to damage any parts with the scraper.

Do not clean, wash or soak transmis-

sion seals in cleaning solvents. Dry all

parts with compressed air.

2.
Rotate the ball bearings in a

cleaning solvent until all lubricant is

removed. Hold the bearing assembly

to prevent it from rotating and dry it

with compressed air.

3.
Lubricate the bearings with ap-

proved transmission lubricant and

wrap them in a clean, lint-free cloth

or paper until ready for use.

4.
Clean the magnet welded to the

bottom of the case with kerosene or

mineral spirits.
INSPECTION

1.
Inspect the transmission case for

cracks, worn or damaged bearings

bores,
damaged threads or any other

damage that could affect the opera-

tion of the transmission.

2.
Inspect the front face of the case

for small nicks or burrs that could

cause misalignment of the transmis-

sion with the flywheel housing. Re-

move all small nicks or burrs with a

fine stone.

3.
Replace a cover that is bent or

distorted. Make sure that the vent

hole in the cover is open.

4.
Check the condition of the shift

levers, forks, shift rails and the lever

and shafts.

5.
Examine the ball bearing races

for cracks, wear or roughness. Inspect

the balls for looseness, wear, end play
or other damage. Check the bearings

for looseness in the bores. If any of

these conditions exist, replace the

bearings.

6. Replace roller bearings that are

broken, worn or rough.

7.
Replace the countershaft (clust-

er) gear if the teeth are chipped, brok-

en or worn. Replace the countershaft

if it is bent, scored or worn.

8. Replace the reverse idler gear or

sliding gear if the teeth are chipped,

worn or broken. Replace the idler

gear shaft if bent, worn or scored.

9. Replace the input shaft and gear

if the splines are damaged or if the

teeth are chipped, worn or broken. If

the roller bearing surface in the bore

of the gear is worn or rough, or if the

cone surface is damaged, replace the

gear and the gear rollers.

10.
Replace all other gears that areprocarmanuals.com

07-01-06
General Transmission Service

07-01-06

MAKE MARK HERE

BELLOWS INTACT
BELLOWS FAILED

FIG. 9—Checking Vacuum Unit Bellows

tester equipped with a vacuum pump

(Fig. 8). Set the regulator knob so

that the vacuum gauge reads 18 inches

with the end of the vacuum hose

blocked off.

Then connect the vacuum hose to

the transmission vacuum unit. If the

gauge still reads 18 inches, the vacuT

urn unit diaphragm is not leaking. As

the hose is removed from the trans-

mission vacuum unit, hold a finger

over the end of the control rod. When

the hose is removed, the internal

spring of the vacuum unit should push

the control rod outward.

ALTITUDE

COMPENSATING-TYPE

The vacuum diaphragm should be

checked for ruptured or damaged bel-

lows.
Check the diaphragm assembly

as follows:

1.
Remove the diaphragm and

throttle valve rod from the transmis-

sion.

2.
Insert a rod into the diaphragm,

making sure that the rod is buttonec

in the hole. Make a reference mark on

the rod where it enters the diaphragm

hole.

3.
Hold the assembly in such a way

that the end of the rod is resting on

the weighing surface of a scale (Fig.

9).

4.
Gradually press down on the dia-

phragm assembly until the rod is

pressed into the diaphragm body. If

the reference mark on the rod is still
visible with 12 pounds of force regis-

tered on the scale, the bellows are in-

tact. If the mark disappears before 4

pounds of force is exerted, the bellows

have failed and the diaphragm must

be replaced. If the bellows are intact,

then perform various pressure checks.

SHIFT POINT CHECKS

Check the minimum throttle up-

shifts in D. The transmission should

start in first gear, shift to second, and

then shift to third, within the shift

points specified in the specification

section.

While the transmission is in third

gear, depress the accelerator pedal

through the detent (to the floor). The

transmission should shift from third to

second or third to first, depending on

the vehicle speed.

Check the closed throttle downshift

from third to first by coasting down

from about 30 mph in third gear. The

shift should occur within the limits

specified in the specification section.

When the selector lever is at 2, the

transmission can operate only in sec-

ond gear.

With the transmission in third gear

and road speed over 30 mph, the

transmission should shift to second

gear when the selector lever is moved

from D to 2 to 1. The transmission

will downshift from second or third to

first gear when this same manual shift

is made below approximately 25 mph

with a C4 transmission, 30 mph with
D 1791.A

a C6 transmission or 35 mph with an

FMX transmission. This check will

determine if the governor pressure and

shift control valves are functioning

properly.

During the shift point check opera-

tion, if the transmission does not shift

within specifications or certain gear

ratios cannot be obtained, refer to the

Ford Car and Truck Diagnosis Manu-

al to resolve the problem.

AIR PRESSURE CHECKS

A NO DRIVE condition can exist,

even with correct transmission fluid

pressure, because of inoperative

clutches or bands. Erratic shifts could

be caused by a stuck governor valve.

The inoperative units can be located

through a series of checks by subst-

ituting air pressure for the fluid pres-

sure to determine the location of the

malfunction.

To make the air pressure checks,

drain the transmission fluid and re-

move the oil pan and the control valve

body assembly. The inoperative units

can be located by introducing air pres-

sure into the transmission case passa-

ges leading to the clutches, servos, and

governor (Figs. 10, 11 or 12).

HYDRAULIC SYSTEM BENCH

TESTS (FMX TRANSMISSION)

After the transmission has been as-

sembled and is ready for installationprocarmanuals.com