wheel bolt torque FORD MUSTANG 1969 Volume One Chassis

03-05-02
Steering Columns
And
Linkage

03-05-02

which also will shear away during
im-

pact.

TILT STEERING COLUMNS

The steering column
is of the col-

lapsible type
to
lessen
the
possibility

of injury
to the
driver
of the
vehicle

should
he
become involved
in an
acci-

dent.
The
lower
end of the
steering

column tube
at the
bellows area will

collapse approximately
six
inches

upon
a
hard impact.

The shift tube
and the
steering shaft

are provided with plastic dowels
and

will shear
and
allow them
to
collapse

in proportion
to the
outer tube upon

impact.

Once
the
steering column
has
been

collapsed,
a
complete
new
column
must
be
installed.

The tilt column features nine driv-

ing positions (four
up and
four down

from
a
center position).
The
.column

also features
a
turn signal switch with

a lane-changer position turn indicating

position
and
emergency warning flash-

er control.

TILT-AWAY STEERING COLUMNS

The tilt-away steering column
fea-

tures nine driving positions (four
up

and four down from
a
center position)

and
a
tilt-away position that
is
auto-

matically accomplished
on
Mustang

and Cougar models when
the
ignition

key
is
turned
to the
OFF
position
and

the left door
is
opened.
On
Thunder-

bird models,
the
tilt-away occurs when
the shift lever
is
placed
in
PARK
and

the driverns door
is
opened.

The steering column
is of the col-

lapsible type
to
lessen
the
possibility

of injury
to the
driver
of the
vehicle

should
he
become involved
in an
acci-

dent.
The
lower
end of the
steering

column tube
at the
bellows area will

collapse approximately
six
inches

upon
a
hard impact.

The shift tube
and the
steering shaft

are provided with plastic dowels
and

will shear
and
allow them
to
collapse

in proportion
to the
outer tube upon

impact.

Once
the
steering column
has
been

collapsed,
a
complete
new
column

must
be
installed along with mounting

brackets which will also shear away

during impact.

IN-VEHICLE ADJUSTMENTS
AND
REPAIRS

STEERING WHEEL SPOKE

POSITION ADJUSTMENT

When
the
steering gear
is on the

high point,
the
front wheels should
be

in
the
straight-ahead position
and the

steering wheel spokes should
be in

their normal position with
the
Pitman

arm pointing directly forward.
If the

spokes
are not in
their normal posi-

tion, they
can be
adjusted without
dis-

turbing
the
toe-in adjustment (Part

3-1).

STEERING WHEEL

REPLACEMENT

1.
Disconnect
the
negative cable

from
the
battery.

2.
Working from
the
underside
of

the steering wheel spoke, remove
the

crash
pad
attaching screws. Lift
the

crash
pad
from
the
wheel.
(On
Conti-

nental Mark
III
models,
pry out the

crash
pad
insert
and
remove
the two

screws that secure
the
crash
pad. Re-

move
the
crash
pad. On
models

equipped with steering wheel mounted

speed controls, refer
to
Group
16 for

removal instructions). Remove
the

horn ring
(if so
equipped)
by
turning

it counterclockwise.

3.
Remove
the
steering wheel
nut,

and then remove
the
steering wheel

with tool T67L-3600-A
(Fig. 1). Do

not
use a
knock-off type steering

wheel puller
or
strike
the end of the

steering shaft with
a
hammer. Striking

the puller
or
shaft will damage
the

bearing
or the
collapsible column.

4.
Transfer
all
serviceable parts
to

the
new
steering wheel.

5.
Position
the
steering wheel
on

the shaft
so
that
the
alignment mark
on
the hub of the
wheel
is
adjacent
to

the
one on the
shaft. Install
a new

locknut
and
torque
it to
specifications.

6. Install
the
horn ring
(if so

equipped)
and
crash
pad.

STEERING COLUMN UPPER

BEARING REPLACEMENT

STATIONARY COLUMNS

Removal

1. Disconnect
the
horn wire
and the

turn indicator wires
at the
connector.

2.
Working from
the
underside
of

the steering wheel spoke, remove
the

two crash
pad
attaching screws. Lift

the crash
pad
from
the
wheel.
(On

Continental Mark
III
models,
pry out

the crash
pad
insert
and
remove
the

two screws that secure
the
crash
pad.

Remove
the
crash
pad. On
models

equipped with steering wheel mounted

speed controls, refer
to
Group
16 for

7oo/-T67L-3600-A
removal instructions). Remove
the

horn ring
(if so
equipped)
by
turning

it counterclockwise.

3.
Remove
the
steering wheel
at-

taching
nut.
Remove
the
steering

wheel using tool T67L-3600-A
(Fig.

1).
Do not use a
knock-off type steer-

ing wheel puller
or
strike
the end of

the steering shaft with
a
hammer.

Striking
the
puller
or
shaft will
dam-

age
the
bearing
or the
collapsible
col-

umn.

4.
Remove
the
turn indicator lever.

5.
Remove
the
turn signal switch

attaching screws. Lift
the
switch over

the
end of the
steering shaft
and
place

it
to one
side.

6. Remove
the
snap ring from
the

top
of the
steering shaft.

7.
Loosen
the two
flange-to-steering

column tube attaching bolts
to
disen-

gage them from
the
tube.

8. Raise
the
flange upward while

BEARING
AND

INSULATOR

Spacer

G 1502 -B

FIG.
1—Removing
Steering Wheel
G 1497-A

FIG. 2—Installing Upper Bearingprocarmanuals.com

03-05-03
Steering Columns And Linkage

03-05-03

tapping the steering shaft lightly with

a plastic hammer to free the bearing

and flange from the shaft.

9. Remove the bearing and insula-

tor from the flange.

Installation

1.
Install flange bolts (square head)

in flange if they were removed. Turn

the nuts onto the bolts one complete

turn only.

2.
Position the flange onto the

steering column tube.

3.
Engage the two flange bolt heads

with the square holes in the column

tube,
then tighten the two attaching

nuts to specification.

4.
Position the bearing and insula-

tor on the shaft. Work it down onto

the shaft as far as possible, then place

a piece of 3/4 ID x 2 1/8 inch pipe

over the end of the shaft and install

the steering wheel attaching nut (Fig.

2).

5.
Tighten the nut until the bearing

is seated in the flange, then remove

the nut and pipe from the shaft.

6. Position the turn signal switch

on the flange and install the three at-

taching screws.

7.
Make certain that the wheels are

in the straight ahead position. Place

the steering wheel on the steering

shaft with the spokes in the horizontal
position. Install and torque the attach-

ing nut to specification.

8. Secure the crash pad to the

steering wheel with the two attaching

screws.

9. Connect the horn and turn signal

wires.

10.
Install the turn signal lever.

TILT WHEEL COLUMNS

Removal

1.
Disconnect the negative cable

from the battery.

2.
Remove the steering wheel with

tool T67L-3600-A (Fig. 1). Install the

spring, shipping spacer (3/4 x 1 1/8-

inch pipe) and a steering wheel attach-

ing nut on the shaft. Do not use a

knock-off type steering wheel puller or

strike the end of the steering shaft

with a hammer. Striking the puller or

shaft will damage the bearing or the

collapsible column.

3.
Remove the turn indicator lever

(Fig. 3).

4.
Remove the three screws that at-

tach the upper cover to the column

and remove the cover. It may be nec-

essary to rotate the cover approxi-

mately
1/4—1/2
inch to engage the

cover lip in the slot of turn signal

switch to permit clearance.
5.
Loosen the screw on the bottom

side and slide the lower cover down-

ward on the column (on Ford and

Mercury models, remove the shroud.)

6. Remove the screw that secures

the turn signal wire retaining clip to

the column and remove the clip.

7.
Remove the two screws that at-

tach the turn signal switch to the

steering column. Move the switch

wires upward enough to permit lifting

the switch over the end of the steering

shaft and lay the switch to one side.

Be careful not to lose the turn signal

lever pivot from the switch.

8. Compress the steering column

locking clamp with vise grip pliers

(Fig. 4) and move the steering shaft to

the full up position.

9. Hold the column position spring

rod with vise grip pliers to prevent flo-

tation then compress the spring and

remove the retainer. Remove the plas-

tic cover and spring.

10.
Install tool T67P-3D739-B as

shown in Fig. 4. Thread the bolt in-

ward finger tight until it bottoms, then

back it out one full turn. Make sure

that the handle is centered over the

pivot pin to prevent bolt breakage.

Hold the 3/8 inch bolt head station-

ary, then tighten the nut to extract the

pin. Repeat this operation on the op-

posite pin.

11.
Remove the nut, shipping spa-

UPPER

COVER

J

G 1498-B

FIG. 3—Typical Steering Column—Disassembledprocarmanuals.com

03-05-07

Steering Columns And Linkage
03-05-07

the steering column
(F in Fig. 8).

7.
Disconnect
the
transmission shift

rod
at the
shift tube.

8. Working under
the
hood, install

the aligning spacer (Fig.
9)
around
the

visible portion
of the
steering shaft

and slide
it up the
shaft into
the
steer-

ing column.
It may be
necessary
to

move
the
shaft back
and
forth
to
com-

pletely install
the
spacer.

9.
At
this point
the
steering column

assembly, being loose,
may
have

dropped toward
the
steering gear

grounding
the
steering shaft
on the

steering gear input shaft.
To
properly

establish
the
steering shaft
to
steering

gear clearance, insert
a 1/8
diameter

rod
or
drill through
the
opening
in the

upper half
of the
flex coupling.

10.
Tighten
to a
snug
fit
(approxi-

mately
2-3
ft-lb)
the
nuts retaining
the

toe plates
to the
dash panel
(B in Fig.

8).

11.
If the
aligning spacer cannot
be

rotated freely,
the
dash panel holes

must
be
filed
or
reamed
for
greater

travel
(as
mentioned
in the
second

paragraph
at the
beginning
of
this

procedure).

12.
Tighten
all
nuts
and
bolts

(noted
as C, D and E in
Fig.
8) in the

passenger compartment
to a
snug
fit

(approximately 2-3 ft-lb). Again check

aligning spacer
for
looseness. Perform

these tightening operations
in
alpha-

betical order.

13.
Tighten
the
lateral adjustment

bolt
(F in Fig. 8) to
snug
fit.
Again

check
the
aligning spacer
for
loose-

ness.

14.
Tighten
all
bolts and nuts
to the

proper torque value (listed
in Fig. 8)

in alphabetical order.

15.
Remove
the
steering shaft
al-

igning spacer.

16.
Remove
the 1/8
diameter
rod or

drill previously inserted
in the
flex

coupling.

17.
Reinstall
the
trim
at the
instru-

ment panel
to
steering column mount-

ing.

LINCOLN CONTINENTAL

If
a
condition
of
high shift
or
steer-

ing effort
is
experienced
it may be

caused
by
improper alignment
of the

energy absorbing steering column.
The

following procedures outline
the
steps

necessary
to
correctly realign either

fixed
or
tilt columns:

1.
Disconnect
the
battery.

2.
Loosen four
toe
plate attaching

nuts (Fig.
10).

3.
Loosen
one toe
plate
to
steering

column clamp bolt
and nut.
Check

alignment
of
steering shaft
to
shift
-HANDLE PORTION

2-3/4"
-*- 3/4"

BEND AROUND

STEERING SHAFT
DIMENSION
A:

STANDARD COLUMN 7/16"

TILT WHEEL COLUMN
1-1/8"

•2-3/4

FABRICATE ALIGNING SPACER OUT OF

PLASTIC SHIPPING COLLAR PROVIDED

ON SERVICE DRIVESHAFTS, OR OUT
OF

1/32"—1/16" CARDBOARD
STEERING SHAFT

ALIGNMENT SPACER-BEND AROUND

STEERING SHAFT (DIMENSION
A)
AND

SLIDE UP THE SHAFT INTO COLUMN

G1537-A

FIG. 9—Aligning Spacer Fabrication
and
Insertion

BRAKE PEDAL

SUPPORT BRACKET

PART

A-TOE PLATE

B-CLAMP

C-C0LUMN BRACKET

D-BRAKE PEDAL

SUPPORT BRACKET
TORQUE VALUE

8-12 FT. LB.

3-5 FT. LB.

10-15
FT.
LB.

8-12 FT. LB.

G1541-A

FIG. 10—Steering Column Alignment Locations
and
Torque

Specifications—Lincoln Continentalprocarmanuals.com

03-05-08
Steering Columns And Linkage

03-05-08

tube.
In some instances the column

will shift into proper alignment when

the toe plate attaching nuts are loos-

ened. (Alignment is acceptable if a

.010 inch feeler blade can be passed

freely, completely around the area be-

tween the outer diameter of the steer-

ing shaft and the shift tube.) if the

misalignment condition can be attrib-

uted to this area, file or ream the dash

panel holes for greater clearance. If

the alignment is maintained after the

toe plate nuts and toe plate to column

clamp bolt and nut are torqued to the

8-12 ft-lb specification, no further ad-

justment is necessary.

4.
Remove instrument panel lower

trim panel. Vehicles equipped with a

combination radio stereo tape player

will require removal of the radio and

tape player assembly in order to gain

access to the upper R.H. steering col-

umn support bracket bolt.

5.
Loosen the seven bolts at the

steering column support bracket and

brake pedal support bracket.
6. Install a 3/16 inch diameter rod

spacer in the flex coupling to assure

proper clearance between upper and

lower steering shaft.

7.
Raise the vehicle, remove the

transmission splash shield, and visual-

ly align the column to center the

steering shaft in the column. Tighten

two toe plate attaching nuts sufficient-

ly to hold the column alignment (two

persons may be required for this oper-

ation).

8. Lower the vehicle.

9. Check the clearance between the

steering column support bracket and

the instrument panel bracket. It may

be necessary to add shims (Part Num-

ber MK-3054-A .060 inch thick, or

C3AZ-3054-A, .113 inch thick) be-

tween the support bracket and the in-

strument panel bracket to prevent

movement of the column when the

support bracket bolts are tightened.

10.
Loosen the two toe plate at-

taching nuts previously tightened. Re-

check steering column alignment. In
some instances it may be necessary to

enlarge the holes in the dash panel in

order to obtain proper column align-

ment.

11.
With the column properly al-

igned, torque the four toe plate at-

taching nuts to 4-9 ft-lbs.

12.
Torque the toe plate to steering

column clamp bolt to 3-5 ft-lbs.

13.
Recheck steering shaft to shift

tube alignment. A 0.10 inch feeler

blade should pass freely, completely

around the area between the outer di-

ameter of the steering shaft and shift-

er tube.

14.
Raise the vehicle.

15.
Adjust transmission shift link-

age.

16.
Install transmission splash

shield.

17.
Lower the vehicle.

18.
Install the radio stereo tape

player if so equipped.

19.
Install instrument panel lower

trim panel.

20.
Connect the battery.

REMOVAL AND INSTALLATION

STEERING COLUMN

FORD, MERCURY, METEOR

Removal

1.
Disconnect the battery cable

from the negative post.

2.
Disconnect the turn signal switch

wires at the connector.

3.
Disconnect the neutral start

switch and back-up light switch wires

from the switches.

4.
Disconnect the transmission con-

trol rod(s) from the lever(s) at the

lower end of the column.

5.
Remove the bolt that secures the

flex coupling to the steering gear.

6. Remove the nuts that secure the

column retainer and seal at the toe

plate (Fig. 11).

7.
Ford, Meteor: Remove the two

screws that secure the lower trim

shroud to the upper trim shroud. Re-

move the two shrouds.

Mercury: Remove the two screws

that secure the lower trim shroud to

the upper trim shroud. Remove the

top shroud Disconnect the ignition

switch light bulb. Remove the ignition

and light switch bezels and spring clip

and remove the lower shroud. Discon-
nect the light switch electrical connec-

tor block.

8. Remove the two screws that se-

cure the intermediate bracket to the

column lower bracket.

9. While supporting the steering

column, remove the two nuts that se-

cure the column lower bracket to the

instrument panel. Remove the brack-

ets.

10.
Lift the steering column and

wheel from the vehicle.

Installation

1.
Position the steering column in

the vehicle. Index the block tooth on

the steering gear shaft with the corre-

sponding slot on the flex coupling. In-

stall and tighten the flex coupling-

to-steering gear attaching bolt.

2.
Place the column upper bracket

and column lower bracket in position

on the column and install but do not

tighten the four attaching nuts.

3.
Install and tighten the two nuts

that secure the column lower bracket

to the instrument panel. Make certain

the column is properly positioned rela-

tive to the flex coupling input shaft

connection.

4.
Install and tighten the screws

that secure the intermediate bracket to

the column lower bracket.
5.
Tighten the four attaching nuts

at the upper and lower brackets and

the two nuts at the upper bracket to

instrument panel. The dial pointer (if

so equipped) should be adjusted to

coincide with the selector lever.

6. Install and tighten the nuts and

bolts that secure the column retainer

and seal at the toe plate. Make sure

the steering shaft is centered in the

column before tightening the nuts.

7.
Ford, Meteor: Install and tighten

the two screws that secure the lower

trim shroud to the upper trim shroud.

Mercury: Connect the light switch

harness block. Install the ignition and

light switch bezels. Connect the igni-

tion switch light bulb. Install the top

shroud and the two screws that secure

the lower trim shroud to the upper

shroud.

8. Connect the transmission control

rod(s) to the lever(s) at the lower end

of the column.

9. Connect the neutral start switch

and back-up light switch to their re-

spective terminals.

10.
Connect the turn signal switch

wires.

11.
Connect the negative battery

cable to the battery.

12.
Check the operation of the

steering tilt mechanism if so equipped

and the switches.procarmanuals.com

03-05-20
Steering Columns And Linkage

03-05-20

placed if it becomes worn or damaged

(Figs.
18 through 21). Do not attempt

to straighten the sleeve if damaged.

1.
Remove the spindle connecting

rod end assemblies as described in the

previous sub-section.

2.
Screw the spindle rod end assem-

blies into the new sleeve the same

number of turns as the ends that were

removed. Do not tighten the clamp

bolts at this time.

3.
Position the sleeve and end as-

sembly on the center link and the

spindle arm. Install the attaching nut,

torque it to specification, and install

the cotter pin.

4.
Check and, if necessary, adjust

toe-in (Part 3-1). After toe-in is

checked and adjusted, oil the sleeve

clamp bolts then torque them to speci-

fication. The sleeve clamp must be in-

stalled as shown in Figs. 18 through

21.

CENTER LINK

REPLACEMENT

The center link connecting the Pit-

man arm and the idler arm is non-

adjustable and is provided with ta-

pered holes to accommodate the ball

studs (Figs. 18 through 21). The link

should be replaced when damaged or

when worn at the ball studs. On Lin-

coln Continental models, the link

should be replaced if excessive loose-

ness is noticed in either ball stud sock-

et.

REMOVAL

1.
Raise the vehicle on a hoist and

position safety stands.

2.
Remove the cotter pins and nuts

that attach both inner connecting rod

ends to the center link (Figs. 18

through 21).

3.
Disconnect the inner connecting

rod ends from the center link using

Tool 3290-C (Fig. 22).

4.
Remove the cotter pin and nut

attaching the idler arm to the center

link. Disconnect the idler arm from

the center link using Tool 3290-C for

Lincoln Continental models only.

5.
Remove the cotter pin and nut

attaching the Pitman arm to the cen-

ter link. Disconnect the Pitman arm

from the center link (use Tool 3290-C)

and remove the center link. On ve-

hicles equipped with the non-integral

power steering system, remove the

center link from the control valve as

detailed in Part 3-7.

INSTALLATION

1.
Replace the rubber seals on the
spindle connecting rod ends, if re-

quired.

2.
Position the center link to the

Pitman arm and idler arm and install

the attaching nuts loosely. On all ve-

hicles except Lincoln Continental

models, place the idler arm and the

front wheels in the straight ahead po-

sition to insure keeping the steering

wheel aligned and to prevent bushing

damage after the attaching nuts have

been torqued. On Lincoln Continental

models, insure that the seal is properly

installed on the center link. Torque

the nuts to the low end of the specifi-

cation. Continue to tighten each nut

until the slots in the nut align with the

hole in the stud. Then install a new

cotter pin.

3.
Position the spindle connecting

rod ends to the center link and install

the attaching nuts. Torque the nuts to

the low end of the specification. Con-

tinue to tighten each nut until the

slots in the nut align with the hole in

the stud. Then, install a new cotter

pin.

4.
Remove the safety stands, lower

the vehicle, check and adjust toe-in to

specification (Part 3-1).

STEERING IDLER ARM

AND BRACKET ASSEMBLY

REPLACEMENT

REMOVAL

If the idler arm bushings are worn

the complete idler arm assembly must

be replaced. In Lincoln Continental

models, if the socket at the idler

bracket is excessively loose, replace

the complet assembly.

1.
Remove the cotter pin and nut

attaching the steering center link at

the idler arm (Figs. 18 through 21).

2.
Disconnect the center link from

the idler arm (on Lincoln Continental

models, use Tool 3290-C).

3.
Remove the two bolts that attach

the idler arm and bracket assembly to

the frame.

INSTALLATION

1.
Secure the new idler arm and

bracket assembly to the frame with

the two attaching bolts (nuts and flat

washers as shown in Figs. 18, 19 and

21).

2.
On all vehicles except Lincoln

Continental models, place the idler

arm and the front wheels in the

straight ahead position to insure keep-

ing the steering wheel aligned and to
prevent bushing damage after the at-

taching nut has been torqued. Insert

the center link stud through the hole

in the end of the idler arm and install

the nut and washer.

On Lincoln Continental models, in-

sert the center link stud through the

hole in the end of the idler arm insur-

ing that the seal is properly installed

on the center link.

3.
Torque the idler arm rod nut to

specification and install a new cotter

pin.

PITMAN ARM

REPLACEMENT

REMOVAL

1.
Remove the cotter pin from the

castellated nut that attaches the steer-

ing center link to the Pitman arm.

Remove the castellated nut.

2.
Disconnect the steering center

link from the Pitman arm with tool

3290-C.

3.
Remove the Pitman arm attaching

nut and lock washer.

4.
Position the front wheels in the

straight ahead position. Remove the

Pitman arm with tool T64P-3590-F

(Fig. 23).

INSTALLATION

1.
With the front wheels in the

straight ahead position, place the Pit-

man arm on the sector shaft making

sure it is pointing forward.

2.
Install the nut and lock washer.

Torque the nut to specification.

G1663-A

FIG. 23— Removing Pitman

Arm—Typicalprocarmanuals.com

03-06-02
Manual Steering

03-06-02

IN-VEHICLE ADJUSTMENTS AND REPAIRS

STEERING WORM AND

SECTOR

GEAR ADJUSTMENTS

The ball nut assembly and the sec-

tor gear must be adjusted properly to

maintain minimum steering shaft end

play (a factor of preload adjustment)

and minimum backlash between sector

gear and ball nut. There are only two

possible adjustments within the recir-

culating ball-type steering gear, and

these should be made in the following

order to avoid damage or gear failure.

1.
Disconnect the Pitman arm from

the steering Pitman-to-idler arm rod.

2.
Loosen the nut which locks the

sector adjusting screw (Fig. 3), and

turn the adjusting screw counterclock-

wise.
(On models equipped with the

Cobra Jet engine, it may be necessary

to use a suitable holding tool with an

extension and a long screwdriver to

make the gear adjustment).

3.
Measure the worm bearing pre-

load by attaching an in-lb torque

wrench to the steering wheel nut (Fig.

4).
With the steering wheel off center,

read the pull required to rotate the

input shaft approximately 1 1/2 turns

either side of center. If the torque or

preload is not within specification

(Part 3-1), adjust as explained in the

next step.
.•ADJUSTER
LOCK
NUT

SECTOR
SHAFT

ADJUSTING
SCREW
G
1627-A

FIG. 3—Steering Gear

Adjustments—Typical

4.
Loosen the steering shaft bearing

adjuster lock nut, and tighten or back

off the bearing adjuster (Fig. 1) to

bring the preload within the specified

limits.

5.
Tighten the steering shaft bear-

ing adjuster lock nut, and recheck the

preload.

6. Turn the steering wheel slowly to

either stop. Turn gently against the

stop to avoid possible damage to the

ball return guides. Then rotate the

wheel 2-3/4 turns to center the ball

nut.
7.
Turn the sector adjusting screw

clockwise until the specified torque

(Part 3-13) is necessary to rotate the

worm past its center (high spot) (Fig.

1).

8. While holding the sector adjust-

ing screw, tighten the sector adjusting

screw locknut to specification, and re-

check the backlash adjustment.

9. Connect the Pitman arm to the

steering arm-to-idler arm rod.

G-1495-A

FIG. 4—Checking Steering Gear

Preload—Typical

REMOVAL AND INSTALLATION

STEERING GEAR

REMOVAL

1.
Remove the bolt(s) that retains

the flex coupling to the steering shaft.

2.
Remove the nut and lock washer

that secures the Pitman arm to the

sector shaft using Tool T64P-3590-F

(Fig. 5).

3.
To obtain clearance on some

models equipped with standard trans-

mission, it may be necessary to dis-

connect the clutch linkage. On some

8-cylinder models, it may be necessary

to lower the exhaust system.

4.
Remove the steering gear-to-side

rail bolts and remove the gear.
Too /-MB
STEERING
GEAR
HOUSING

T64P-3590.F

(PITMAN
"APU'^M
-
.-. •
-"
•.:,.17''i.a—
r.iMI.
A

F'G.
5—Removing Pitman Arm
INSTALLATION

1.
Position the steering gear and

flex coupling in place; then, install

and torque the steering gear-to-side

rail bolts to specification (Part 3-13).

2.
If the clutch linkage has been

disconnected, reposition, install and

adjust it. If the exhaust system has

been lowered, reinstall it to its proper

position.

3.
Position the Pitman arm and the

sector shaft and install the attaching

nut and lock washer. Torque the nut

to specification.

4.
Install and connect the flex cou-

pling attaching nut(s) and torque it to

specification (Part 3-13).procarmanuals.com

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

03-08-03
Ford Design Integral Power Steering Gear

03-08-03

factory adjustments will change. These

changes in adjustment do not neces-

sarily affect the satisfactory operation

of the steering gear assembly, and

therefore ordinarily do not require

readjustment unless there is excessive

lash or other malfunctioning.

ADJUSTMENT IN

VEHICLE

The only adjustment which can be

performed is the total over center

position load, to eliminate excessive

lash between the sector and rack

teeth.

1.
Disconnect the pitman arm from

the sector shaft.

2.
Disconnect the fluid return line

at the reservoir, at the same time cap

the reservoir return line pipe.

3.
Place the end of the return line

in a clean container and cycle the
INPUT SHAFT

SECTOR SHAFT

ADJUSTMENT SCREW

C1547- A

FIG.
2—Adjusting Mesh Load

steering wheel in both directions as re-

quired, to discharge the fluid from the

gear.
4.
Remove the ornamental cover

from the steering wheel hub and turn

the steering wheel to 45 degrees from

the left stop.

5.
Using an in-lb torque wrench on

the steering wheel nut, determine the

torque required to rotate the shaft

slowly through an approximately 1/8

turn from the 45 degree position.

6. Turn the steering gear back to

center, then determine the torque re-

quired to rotate the shaft back and

forth across the center position. Loos-

en the adjuster nut, and turn the ad-

juster screw in (Fig. 2) until the read-

ing is 8-9 in-lb greater than the torque

45 degrees from the stop.

Tighten the lock nut while holding

the screw in place.

7.
Recheck the readings and replace

pitman arm and steering wheel hub

cover.

8. Connect the fluid return line to

the reservoir and fill the reservoir with

specified lubricant to the proper level.

REMOVAL AND INSTALLATION

REMOVAL

1.
Disconnect the pressure and the

return lines from the steering gear.

Plug the lines and the ports in the

gear to prevent entry of dirt.

2.
Remove the two bolts that secure

the flex coupling to the steering gear

and to the column.

3.
Raise the vehicle and remove the

sector shaft attaching nut.

4.
Remove the Pitman arm from

the sector shaft with Tool T64P-

3590-F.
Remove the tool from the

Pitman arm. Do not damage the

seals.

5.
If working on a vehicle equipped

with a standard transmission, remove

the clutch release lever retracting

spring to provide clearance for remov-

ing the steering gear.
6. Support the steering gear then

remove the three steering gear attach-

ing bolts.

7.
Work steering gear free of the

flex coupling and remove it from the

vehicle.

8. If the flex coupling stayed on the

input shaft, lift if off the shaft at this

time.

INSTALLATION

1.
Slide the flex coupling into place

on the steering shaft. Turn the steer-

ing wheel so that the spokes are in the

horizontal position.

2.
Center the steering gear input

shaft.

3.
Slide the steering gear input

shaft into the flex coupling and into
place on the frame side rail. Install

the three attaching bolts and torque

them to specification.

4.
Make sure that the wheels are in

the straight ahead position, then in-

stall the Pitman arm on the sector

shaft. Install and tighten the sector

shaft and install and tighten the at-

taching bolts to specification.

5.
Move the flex coupling into

place on the input and steering co-

lumn shaft and install and tighten the

attaching bolts to specification.

6. Connect and tighten the fluid

pressure and the return line to the

steering gear.

7.
Fill the power steering pump and

cycle the steering gear. Check for

leaks and again check the fluid level.

Add fluid as required.

MAJOR REPAIR OPERATIONS

In most cases, complete disassembly

of the power steering gear will not be

necessary. It is suggested that only

those assemblies that are faulty be dis-

assembled. Disassembly and reassem-

bly of the unit and the subassemblies

must be made on a clean workbench.

As in repairing any hydraulically op-

erated unit, cleanliness is of utmost

importance. Therefore, the bench,
tools,
and parts must be kept clean at

all times. Thoroughly clean the exter-

ior of the unit with a suitable solvent

and when necessary, drain as much of

the hydraulic oil as possible. Handle

all parts very carefully to avoid nicks,

burrs,
scratches and dirt, which could

make the parts unfit for use. Do not

clean, wash or soak seals in cleaning

solvent.
VALVE CENTERING

SHIM REPLACEMENT

1.
Hold the steering gear over a

drain pan in an inverted position and

cycle the input shaft several times to

drain the remaining fluid from the

gear.

2.
Mount the gear in a soft-jawed

vise.procarmanuals.com

03-09-02

Saginaw Design Integral Power Steering Gear

03-09-02

WORM

ADJUSTER PLUG

TORSION BAR

STUB SHAFT

SEAL

NEEDLE BEARINGS

TEFLON RING

TEFLON SEALS

SECTOR SHAFT

FIG.l —
Power
Steering Gear—Sectional View
G 1650-A

REMOVAL
AND
INSTALLATION

REMOVAL

1.
Disconnect
the
pressure
and the

return line 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

Pitman arm attaching nut.

4.
Remove
the
Pitman arni from

the sector shaft with Tool T64P-3590-

F.
Remove
the
tool from
the
Pitman

arm.

5.
If
working
on a
vehicle equipped

with
a
standard transmission, remove
the clutch release lever retracting spring

to provide clearance
for
removing
the

steering gear.

6. Support
the
steering gear then

remove
the
three steering gear attach-

ing bolts.

7.
Work
the
steering gear free
of

the flex coupling
and
remove
it
from

the vehicle.

8.
If
the flex coupling stayed
on the

input shaft, lift
it 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
ihe
wheels
are

in
the
straight-ahead position, then

install
the
Pitman
arm on the
sector

shaft. Install
and
tighten
the
sector

shaft attaching nut to specification.

5.
Move the flex coupling into place

on
the
input shaft
and
steering columnprocarmanuals.com