lock FORD MUSTANG 1969 Volume One Chassis

03-09-04
Saginaw Design Integral Power Steering Gear

03-09-04

CLAMP

BALL
RETURN GUIDE
TEFLON
RINGS (3)

VALVE
SPOOL

0-RING SPOOL

SEAL

INLET
PORT SEAT

CHECK
VALVE

RETURN
PORT

SEAT

SPRING
STUB
SHAFT

ASSEMBLY

TEFLON
RING

RACK-PISTON
END PLUG

O-RING

HOUSING
END PLUG

RETAINING
RING
FLEXIBLE

COUPLING

'BEARING
LOCK

NUT

GROUND
STRAP

RETAINING
RING

DUST
SEAL

OIL
SEAL

ADJUSTER
PLUG

O-RING SEAL

THRUST
BEARING

SPACER

BEARING
RETAINER

SPOOL
SPRING

RETAINING
RING

FIG. 4—Steering Gear Disassembled

SPANNER
WRENCH

Tool - T65P-

lG
1646-A

FIG. 5—Removing Adjuster Plug
14.
Pull the stub shaft and valve as-

sembly from the housing.

15.
Lift the worm, lower thrust

bearing and the races from the hous-

ing.

REPAIR
OF SUB-

ASSEMBLIES

Do not clean, wash, or soak seals in

cleaning solvent.

STEERING GEAR HOUSING

1.
Remove the snap ring (Fig. 7)
G
1647-A

that secures the sector shaft seals in

the lower end of the housing. Remove

the lower spacer washer.

2.
Remove the lower seal (double

lip),
spacer washer, upper seal (single

lip) with Tools T85L-1O1-A and

T59L-100-B (Fig. 8).

3.
Check the housing bearing for

wear and remove the bearing only if

worn or damaged. Working from the

lower end of the housing (Fig. 9) press

the bearing out of the housing. Dis-

card the bearing.

.HOUSING
LOWER
SEAL (DOUBLE LIP)

Tool
- T 65P-3D517-A

G
1645-A

FIG. 6—Removing Rack Piston

into the end of the rack-piston until it

contacts the worm shaft. Rotate the

stub shaft in a counterclockwise direc-

tion until the worm is free of the

rack-piston. Withdraw the rack-piston

from the housing making sure that the

tool is held all the way in the piston

to prevent dropping the balls. Do not

disassemble the rack-piston at this

time.
SNAP

RING

INLET
PORT

SEAT

RETUkN
PORT

SEAT

G
1643-A

FIG. 7—Steering Gear Housing Disassembledprocarmanuals.com

03-09-07

Saginaw Design Integral Power Steering Gear

03-09-07

VALVE SPOOL

DAMP EN
ERO-RING

TORSION BAR

G 1633-A

FIG. 18 —Removing Spool

from Valve Body

7.
Dip three new valve body O-

rings and teflon rings in C1AZ-

19582-A lubricant. Install the O-rings

on the valve body being careful not to

twist them. Slide the three teflon rings

into place over the O-rings being care-

ful not to stretch them any more than

necessary.

8. Lubricate a new dampener O-

ring and install it in the spool groove.

9. Assemble the stub shaft in the

valve body making sure that the

groove in the cap engages the pin in

the body. Tap the cap lightly with a

soft-faced hammer to seat it in the

valve body.

10.
Dip the valve spool in C1AZ-

19582-A. With the notch of the spool

toward the valve body, carefully slide

the spooi over the shaft and into the

body rotating it slightly to permit easy

entry. Make sure that the dampener

O-ring is distributed evenly to prevent

TEFLON RING
damage. Guide the spool to engage

the notch with the dowel in the body.

11.
Place the spool spring on the

stub shaft with the larger diameter

toward the spool. Work the small end

of the spring down over the shaft until

the small end is seated in the groove

of the stub shaft.

12.
If, during the assembly of the

valve, the stub shaft and end cap as-

sembly is allowed to slip out of en-

gagement with the valve body pin, the

spool will be permitted to enter the

valve body too far. The dampener O-

ring seal will expand into the valve

body fluid grooves preventing with-

drawal of the spool. Attempt to with-

draw the spool with a slight pull and

much rotary motion. If this does not

free the spool after several tries, make

sure that the spool is free to rotate;

place the valve body on a flat surface

with the notched end up, and tap the

spool with a wooden or plastic rod

until the O-ring seal is cut and the

spool can be removed. Replace the

dampener O-ring seal and proceed

with the assembly procedure as be-

fore.

RACK-PISTON

1.
Cut the teflon ring and the O-

ring from the piston.

2.
Place the assembly on a clean

lint-free cloth and remove the screws

that attach the ball return guide clamp

to the rack piston and remove the

clamp (Fig. 19).

3.
Lift the ball return guides from

the rack-piston.

4.
Remove Tool T65P-3D517-A

from the piston and remove the re-

maining balls.

5.
Thoroughly clean all parts.

END PLUG

RACK PI STON

DARK COLORED BALLS

(11 REQUIRED)

V

0-RING

POLISHED BALLS

(II REQUIRED)

BALL RETURN GUIDE

CLAMP

B

G1296. A
6. Lubricate a new O-ring and tef-

lon ring. Install the O-ring on the pis-

ton being qareful not to twist it. Slide

the teflon ring into place being careful

not to stretch it any more than neces-

sary.

7.
Slide worm (Fig. 20) fully into

the rack-piston. Load 16 balls into the

guide hole nearest the teflon ring

while slowly rotating the worm count-

erclockwise to feed the balls through

circuit. Alternate the dark colored

balls with the polished balls through

the circuit.

TEFLON RING

FIG. 19—Rack-Piston Disassembled
G 1632-A

FIG. 20—Assembling Rack Piston

Apply Lubriplate liberally to one of

the ball return guides and install the

six remaining balls in the guide. Place

the other half of the guide in position

and insert them into holes in the

rack-piston. Be sure that the dark ball

in the guide is installed next to the

polished ball in the rack-piston. Install

the ball return guide clamp with

screws and lock washers. Tighten the

screws to 8-12 ft-lbs.

8. The worm groove is ground with

a high point in the center. V/hen the

rack-piston passes over this high point

there should be a preload of 1-4 in-

lbs.
Clamp the rack-piston in a vise

with soft jaws with the worm shaft

pointing up. To avoid distortion, do

not tighten the vise too tight.

9. Place the valve assembly on the

worm, engaging the worm drive pins.

Rotate the worm until it extends 1

1/4 inch from the rack-piston to the

thrust bearing face. This is the center

position.

10.
Place an in-lb torque wrench

with a 3/4-inch-deep wall 12-point

socket on the stub shaft, and rotate

the wrench through an arc of approxi-

mately 60 degrees in both directions

several times, then take a torque read-

ing. The highest average reading ob-

tained with the worm rotating should

be between 1-4 in-lbs.

11.
If this reading is too high or

too low a new set of balls should beprocarmanuals.com

03-09-08
Saginaw Design Integral Power Steering Gear

03-09-08

Code

Size

6

7

8

9

10

11
Diameter

Mean

0.28117

0.28125

0.28133

0.28141

0.28149

0.28157
Size Range of Ball

(Inch)

0.28112-0.28122

0.28120-0.28130

0.28128-0.28138

0.28136-0.28146

0.28144-0.28154

0.28152-0.28162

FIG. 21 —Worm Ball Sizes

installed. Service replacement balls are

available in the sizes shown in (Fig.

21).

12.
Note the ball size stamped on

the rack-piston and install the next

size larger balls to increase the pre-

load. If no number is stamped on the

rack-piston, the original ball code size

was No. 7.

A change of one ball size larger will

increase the preload approximately

one in-lb. Final preload on replace-

ment balls should be 2-3 in-lbs.

Remove the valve assembly from

the worm and the rack-piston from

the vise.

13.
Insert Tool T65P-3D517-A into

the plug end of the rack and piston to

contact the worm shaft (Fig. 22).

Apply pressure on the tool while ro-

tating the worm shaft out of the pis-

ton and rack. Leave the tool in place

until the piston is installed in the

housing.

END OF TOOL MUST BE IN

CONTACT WITH WORM

SHAFT

Tool * T65P-3D517-A

FIG. 22—Installing Tool

in Raek-Piston
G 1631-A
ASSEMBLY OF

STEERING GEAR

1.
Secure the steering gear housing

in a vise.

2.
Lubricate the worm shaft, lower

thrust bearing, and races; then posi-

tion the thrust bearing and races on

the worm.

Align the valve body drive pin on

the worm, with the narrow pin slot in

the valve body. Be sure O-Ring seal

between the valve body and the worm

head is installed.

3.
Position the valve assembly and

the worm shaft in the housing as a

unit (Fig. 23). Do not push against the

stub shaft as this could cause the stub

shaft and cap to pull out of the valve

body, allowing the spool seal to slip

into valve body fluid grooves. Install

the valve assembly by pushing on the

outer diameter of the valve body hous-

ing with the finger tips. Be sure that

the teflon rings are not binding inside

the housing. The valve assembly is

correctly seated when the fluid return

hole in the gear housing is fully vis-

ible.

4.
Place the tool shown in Fig. 24

over the end of the stub shaft.

5.
Lubricate a new adjuster plug

O-ring and install it in the adjuster

plug groove.

6. Install the adjuster plug over the

end of the stub shaft and tighten it

DRIVE PIN
just enough to be sure all parts are

properly seated. Remove Tool T65P-

3A537-B.

7.
Install the adjuster plug locknut

loosely on the plug.

8. Tighten the adjuster plug with

wrench J7624 while rotating the input

shaft. As soon as additional drag is

noted, back the adjuster plug off 1/8

turn. Measure the input shaft drag

with an in-lb torque wrench.

9. Tighten the adjuster plug (Fig.

25) to obtain a 1-3 in-lb preload in ex-

cess of the drag that was measured

previously. Tighten the adjuster plug

lock nut and recheck the thrust bear-

ing preload. Total preload must not

exceed 8 in-lbs.

10.
Install Tool T65P-3805-A in

the steering gear housing. Position the

rack-piston as shown in Fig. 26. Be

sure that Tool T65P-3D517-A is con-

tacting the worm shaft. Push the

rack-piston inward until it contacts

the worm shaft while keeping pressure

applied to Tool T65P-3D517-A. Turn

the stub shaft clockwise until the

middle rack groove in the rack-piston

is aligned with the center of sector

shaft roller bearing. Remove the tool

from the housing.

11.
Lubricate a new O-ring with

C1AZ-19582-A and position it in the

sector shaft cover.

12.
Thread the sector shaft cover

on the adjusting screw until it bottoms

then back it off 1 1/2 turns.

13.
Install the sector shaft so that

the center gear tooth meshes with the

center groove in the rack-piston. Be

sure that the cover O-ring is in place

before pushing the cover down on the

housing.

14.
Install the cover screws and

lock washers. Tighten to 30-35 ft-lbs.

15.
Install a new adjuster lock nut

halfway on the adjuster screw.

16.
Install the end plug in the

rack-piston. Tighten the plug to 50-

100 ft-lbs torque.

17.
Lubricate a new housing end

plug O-ring and install it in the hous-

ing.

18.
Place the end plug in the gear

housing and seat it against the O-ring

seal. It may be necessary to tap the

Tool
T65P-3A537-B

STUB SHAFT

ADJUSTER

PLUG

G 1630-A

FIG. 23—Installing Valve and Worm Shaft in Housing
G 1629-A

FIG. 24 —Installing Adjuster Plugprocarmanuals.com

03-09-09
Saginaw Design Integral Power Steering Gear

03-09-09

Tool • T65P-3D517-A

LOCK NUT

ADJUSTER PLUG

G1628-A

FIG. 25
—
Adjusting Thrust Preload

end plug lightly with
a
soft-faced mal-

let
to
seat
it
properly.

19.
Snap
the
retainer ring
in
place

with
the
fingers.
Tap
lightly
on the

ring
to be
sure
the
ring
is
bottomed

securely
in the
housing.

20.
Turn
the
input shaft
to the
full

left
or
right position then turn
it
back

approximately
1 3/4
turns
to
center

the worm.
RACK PISTON

Tool - T65P.3805-A

FIG. 26—Installing Rack-Piston

21.
Place
an
in-lb torque wrench
on

the input shaft
as
shown
in Fig. 27.

22.
With
the
gear
on
center
and the

sector shaft adjuster backed
off,
meas-

ure
the
total drag. With
the
gear
on

center, adjust
the
sector shaft thrust

screw
so
that preload
is 4-8
in-lbs
in

excess
of
total preload
and
drag.

Readings
are to be
made through
an

arc
not
exceeding
20
degrees with
the

gear
on
center. Tighten
the
lock
nut.

23.
After obtaining
the
proper mesh

load, tighten
the
sector shaft adjust-

ment screw lock
nut to
20-30 ft-lbs.
jG1302
A

G1303-A

FIG. 27—Adjusting Sector

Shaft Mesh Loadprocarmanuals.com

03-10-03
Ford-Thompson Power Steering Pump

03-10-03

EIGHT CYLINDER WITH

AIR CONDITIONER

1.
Remove the power steering fluid

from the pump reservoir by discon-

necting the fluid return hose from the

reservoir and allow the fluid to drain

in a suitable container.

2.
Disconnect the pressure hose

from the pump.

3.
Remove 3 bolts from the front of

the pump and the one nut at the rear

that attach the pump to the mounting

bracket and remove the drive belt

from the pump pulley.

4.
Loosen the upper pump bracket-

to-engine attaching bolt and remove

the bolt in the belt adjusting slot. Re-

move the pump.

5.
Position the pump to the bracket

and install the bracket-to-pump at-

taching bolts and nuts. Tighten to spe-

cifications.

6. Place the belt on the pump pul-

ley. Adjust the belt tension as outlined

in Section 2 and tighten the bolts and

nut to specification.

7.
Torque the pressure hose fitting

hex nut to specification. Then, connect

the pressure hose to the fitting and

torque the hose nut to specification.

8. Connect the return hose to the

power steering pump and tighten the

clamp.

9. Fill the pump with automatic

transmission fluid C1AZ-19582-A.

Bleed the air from the system (Part

3-1) and check for leaks and again
check the fluid level. Add fluid as re-

quired.

POWER STEERING PUMP

PULLEY REPLACEMENT

REMOVAL

1.
Drain as much of the fluid as

possible from the pump through filler

pipe.

2.
Install a 3/8-16 inch capscrew in

the end of the pump shaft to prevent

damage to the shaft end by the tool

screw.

3.
Install the pulley remover, Tool

T63L-1O3OO-B, on pulley hub, and

place the tool and pump in a vise as

shown in Fig. 3.

4.
Hold the pump and rotate the

tool nut counterclockwise to remove

the pulley (Fig. 3). The pulley must be

removed without in and out pressure

on the pump shaft to prevent damage

to internal thrust areas.

INSTALLATION

1.
Position the pulley to the pump

shaft and install Tool T65P-3A733-A

as shown in Fig. 4.

2.
Hold the pump and rotate the

tool nut clockwise to install the pulley

on the shaft. The pulley face will be

flush with end of pump shaft. Install

the pulley without in and out pressure
on the shaft to prevent damage to in-

ternal thrust areas.

3.
Remove the tool.

POWER STEERING PUMP

RESERVOIR REPLACEMENT

Reservoir replacement must be done

on a clean workbench. Cleanliness of

work area and tools is extremely im-

portant when repairing any hydraulic

unit. Thoroughly clean the exterior of

the pump with a suitable cleaning sol-

vent. Do not clean, wash or soak the

shaft oil seal in solvent. Plug the inlet

and outlet openings with plugs or

masking tape before cleaning the

pump exterior or removing the reser-

voir.

REMOVAL

1.
Assemble the adapter plate (Tool

T69P-3A674-A) to the bench mounted

fixture tool (T57L-5OO-A). Position

the pump and pulley on the adapter

plate, pulley facing down.

2.
Remove the outlet fitting hex nut

and the service identification tag.

3.
Invert the pump so the pulley is

facing up and remove the reservoir by

tapping around the flange with a wood

block (Fig. 5).

4.
Remove the reservoir O-ring seal

and the outlet fitting gasket from the

pump.

INSTALLATION

Tool • T 63 L-

10300 -

G 1477 A

FIG. 3—Removing Power

Steering Pump Pulley
1478 A

FIG. 4—Installing Power

Steering Pump Pulley
1.
Install a new gasket on the outlet

fitting and a new reservoir O-ring seal

on the pump housing plate (Fig. 6).

The old gasket and seal should never

be re-used.

Too/
T57L 500-A

G1602-A

FIG. 5—Removing Pump

Reservoirprocarmanuals.com

03-10-04
Ford-Thompson Power Steering Pump

03-10-04

OUTLET FITTING

GASKET
Wood Block

0-RING SEAL

G1345-
-500-
A

G1603- A

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

on Pump—Typical
2.
Apply vaseline to the reservoir

O-ring seal and to the inside edge of

the new reservoir flange. Do not twist

the O-ring seal.

3.
Position the reservoir over the

pump and align the notch in the reser-

voir flange with the notch in the outer

diameter of the plate and bushing as-

sembly.

4.
Install the reservoir on the pump

and O-ring seal with a plastic or rub-

ber hammer and a block of wood as

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

reservoir and on the outer edges only.

5.
Inspect the assembly to be sure

the reservoir is evenly seated on the

pump housing plate.

6. Position the service identification

tag on the outlet fitting and install the

outlet fitting hex nut. Torque the nut

to specification (Part 3-13). Do not

exceed specification.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

Disassembly of the pump and its

subassemblies must be made on a

clean work bench. In repairing any

hydraulically operated unit, cleanliness

is of utmost importance. Clean the ex-

terior of the unit with a suitable sol-

vent and drain as much of the fluid as

possible.

If only the reservoir is to be re-

moved, plug the inlet and outlet open-

ings with masking tape or plugs. Do

not immerse the shaft oil seal in sol-

vent. If only the rotor shaft seal is to

be replace, see Rotor Shaft Seal Re-

placement outlined in this section.

1.
Assemble the adapter plate (Tool

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

ed holding fixture Tool T57L-5OO-A

(Fig. 8).

2.
Position the pump assembly,

with pulley assembled, on the adapter

plate, pulley facing down.

3.
Remove the outlet fitting nut and

the service identification tag.

4.
Invert the pump assembly and,

using a block of wood and a rubber or

plastic hammer, remove the pump res-

ervoir and seal by tapping around the

flange of the reservoir and on the und-

erside of the filler neck.

5.
Again invert the pump assembly,

loosen and remove the pump housing

retention bolts and remove the pump

housing.
6. If necessary, remove the fol-

lowing components from the pump

housing: the housing cover, the O-ring

seal and the pressure springs. These

components normally will remain in

the pump housing when it is removed.

7.
Remove and discard the pump

cover gasket.

8. Remove the retainer end plate

and upper pressure plate (in some

pumps, the end plate and upper pres-

sure plate are integral).

9. Remove the loose fitting dowel

pin. Be careful not to bend the fixed

dowel pin which remains in the hous-

ing plate assembly.

10.
Remove the rotor assembly

being careful to prevent the springs

and slippers from falling out and be-

coming lost. Do not disassemble fur-

ther unless the lower pressure plate,

housing plate, rotor shaft and/or seal

is to be replaced.

11.
Invert the pump assembly and,

using Tool T63L-1O3OO-B, remove the

pulley.

12.
Clean any rust, road dirt, burrs,

scoring, etc. from the pulley end of

the rotor shaft prior to removal of the

shaft from the housing plate. The

shaft must come out without restric-

tions to prevent scoring or damage to

the bushing. Remove the pump rotor

shaft.

13.
Remove the lower pressure

plate.
PARTS REPAIR OR

REPLACEMENT

ROTOR SHAFT

SEAL REPLACEMENT

Removal

1.
Remove the pulley from the

rotor shaft as described under Power

Steering Pump Pulley Removal.

2.
Position the pump assembly in

T57L-500-A

T69P-3A674-A

•
G1604-A

FIG. 8—Adapter Plate Installationprocarmanuals.com

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

03-11-03

Eaton Power Steering Pump

03-11-03

POWER STEERING PUMP

DISASSEMBLY

A clean working area should be

used when overhauling the power

steering pump. Foreign matter picked

up on working parts may cause dam-

age or failure of the unit. Clean con-

tainers should be used for parts.

1.
Drain the fluid from the pump.

Remove the pump cover-to-housing

cap screws (Fig. 1). Place the pump

on the bench, cover side down. Lift

the housing from the cover.

2.
Remove the large and the small

O-rings from the pump cover. Remove

the O-ring from the pressure plate

hub.

3.
Remove the pressure plate-

to-cover screws, and remove the plate.

Lift the cam ring off the dowel pins.

4.
Remove the rollers. Lift the

rotor off the shaft, and remove the

drive key from the shaft. Remove the

dowel pins from the cover.

5.
Remove the rotor shaft from the

cover. Do not remove the snap ring

from the shaft unless it, or the shaft,

is damaged.

6. Pry the rotor shaft seals out of

the cover and the housing.

7. Do not disturb the control valve

unless diagnosis indicated a control

valve problem or foreign matter in the

valve. To remove the valve, drive the

roll pin out of the housing. Remove

the plug and O-ring, control valve,

and the spring. If the plug or valve is

stuck, tap the end of the housing on a

piece of wood or tap it with a soft-

faced hammer. Remove the O-ring

from the plug.

ASSEMBLY

Apply automatic transmission fluid

to all parts as they are assembled. Al-

ways use new seals and O-rings.

1.
Install the control valve spring in

the housing. Install the valve with the

small sensing hole in the end of the

valve toward the spring. Install a new

O-ring on the plug. The plug O-ring is

1/8 inch smaller in diameter than the

bypass O-ring. Make sure the proper

O-ring is used. Install the plug and a

new roll pin (Fig. 1).

2.
The rotor shaft oil seals are in-

stalled in the cover and the housing

with Tool 3583-J, which consists of a

driver and an adapter. The procedure

is as follows:

a. Support the cover on wood

blocks (Fig. 2) to provide tool clear-

ance.
Use clean blocks that will not

nick or damage the inner face of the

cover.
b.
Start the seal (metal shell up-

ward) square!y into the bore with fin-

ger pressure. Place the adapter on the

driver with the square corner of the

FIG. 2—Preparation for Installing

Rotor Shaft Seals

adapter toward the seal (Fig. 2). Drive

the seal into the cover, as shown in

Fig. 3, until it bottoms.

Driving the seal beyond this point

can damage it. Install the seal in the

pump housing in the same manner.

3.
Install the rotor shaft in the

FIG. 3—Installing Rotor

Shaft Seals
cover as shown in Fig. 4 to prevent

damage to the seal.

4.
Install the dowel pins in the

cover. Place the rotor drive key in the

shaft. Install the rotor on the shaft

with the drive key groove aligned with

the key and the counterbored side of

the rotor toward the cover so that it

goes over the snap ring.

5.
Place the cam ring on the dowel

pins with the chamfered edge upward

(Fig. 5). Place the rollers in the rotor.

6. Place the pressure plate on the

dowel pins. Install and tighten the

screws to 20 in-lbs torque. Install the

O-ring on the pressure plate hub. In-

stall O-rings in the groove at the fluid

bypass hole and around the cam ring

(Fig. 6).

7.
Place the tool shown in Fig. 6 in

the rotor shaft to prevent damage to

the oil seal, then install the housing on

the cover. Install and torque the cap

screws to 15-20 ft-lbs.

FIG. 5—Cam Ring Installation

FIG. 4—Installing Rotor Shaft

in Cover

FIG. 6—O-Ring Installationprocarmanuals.com

03-12-01

Wheels
And
Tires

03-12-01

PART
3-12
Wheels
And
Tires

COMPONENT INDEX

FRONT
HUB AND
DRUM ASSEMBLY

Removal
and
Installation

FRONT
HUB AND
ROTOR ASSEMBLY

Removal
and
Installation

FRONT WHEEL ASSEMBLY DESCRIPTION

FRONT WHEEL BEARING ADJUSTMENT

FRONT WHEEL GREASE SEAL
AND

BEARING

Removal, Installation, Repacking

HOISTING INSTRUCTIONS

LIFE GUARD TIRE

Balancing

Correcting Vibration
and
Shake

Description

Repairs

REAR WHEEL ASSEMBLY DESCRIPTION

WHEELS AND TIRES (Conventional)

Removal
and
Installation
MODEL APPLICATION
All
Models

12-07

12-07

12-01

12-02

12-05

12-02

12-01

12-03
Ford
N/A

N/A

N/A

N/A
Mercury
N/A

N/A

N/A

N/A
Meteor
N/A

N/A

N/A

N/A
Cougar
N/A

N/A

N/A

N/A
Fairlane
N/A

N/A

N/A

N/A
Falcon
N/A

N/A

N/A

N/A
Montego
N/A

N/A

N/A

N/A
Mustang
N/A

N/A

N/A

N/A
Lincoln-
Continental
12-03

12-03

12-02

12-08
Thunderbird
12-03

12-03

12-02

12-08
Continental-
Mark
III
12-03

12-03

12-02

12-08

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

FRONT WHEEL ASSEMBLY

Each front wheel
and
tire
is
bolted

to
its
respective front
hub and
brake

drum
or
rotor assembly.
Two
opposed

tapered roller bearings
are
installed
in

each
hub. A
grease retainer
is in-

stalled
at the
inner
end of the hub to

prevent lubricant from leaking into

the drum
or on the
rotor.
The
entire

assembly
is
retained
to its
spindle
by

the adjusting
nut, nut
lock
and
cotter

pin (Figs.
1 and 2).

REAR WHEEL ASSEMBLY

The rear wheel
hub and
brake drum

assembly
is
attached
to
studs
on the

rear axle shaft flange
by
three speed

nuts.
The
wheel
and
tire mounts
on

the same rear axle shaft flange studs

and
is
held against
the hub and
drum

by
the
wheel nuts.
The
rear wheel

bearing
is
pressed onto
the
axle shaft

just inside
the
shaft flange,
and the
entire assembly
is
retained
to the
rear

axle housing
by the
bearing retainer

HUB
AND
BRAKE

DRUM
ASSEMBLY
plate which
is
bolted
to the
housing

flange.

ADJUSTING

NUT

GREASE

CAP
OUTER

BEARING

OUTER
CUP

BEARING

CONE
AND

ROLLER

NUT
INNER BEARING

CONE
AND

ROLLER

WHEEL

ASSEMBLY

HUB
BOLT'
^£=3^
F1422-A

FIG.
1
—
Front
Hub,
Bearing
and
Grease Retainer Drum Brakes
procarmanuals.com

03-12-02
Wheels
And
Tires

03-12-02

LIFE GUARD TIRE

The Goodyear Power Cushion Tire

(available
on
Thunderbird, Lincoln

and Continental Mark
III
models)
fit-

ted with
the
Life Guard Safety Spare
provides
a
tire within
a
tire with
two

separate
air
chambers
(Fig.
3). If the

outer tire casing should
be
punctured

or otherwise damaged causing
it to go

flat,
the
Life Guard Safety Spare will

carry
the
load
of the
vehicle
and
will
allow driving
at
speeds
up to 40 mph

with good control
up to a
distance
of

40 miles.
A
Safety-Signal built into

the Life Guard tread produces
a
lope

or vibration indicating
the
outer tire

has lost pressure.

HUB AND ROTOR

ASSEMBLY
INNER

BEARING

CUP
GREASE

RETAINER

ADJUSTING

NUT

OUTER

BEARING

CONE
AND

ROLLER

INNER BEARING

CONE
AND

ROLLER

WHEEL

ASSEMBLY

F1416-A

F- 1380 •
A

FIG. 2—Front
Hub and
Rotor Bearing
and
Grease

Retainer Disc Brakes—Typical
FIG. 3—Life Guard Safety

Tire—Sectional View

IN-VEHICLE ADJUSTMENTS AND REPAIRS

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

steering linkage.
If the
adapters
are

placed under
the
crossmember,
a
piece

of wood (2x4x16 inches) should
be

placed
on the
hoist channel between

the adapters. This will prevent
the

adapters from damaging
the
front
sus-

pension struts.

FRONT WHEEL BEARING

ADJUSTMENT

The front wheel bearings should
be

adjusted
if the
wheel
is
loose
on the

spindle
or if the
wheel does
not
rotate

freely.
The
following procedures will

bring
the
bearing adjustment
to
speci-

fication.

DRUM BRAKES

1.
Raise
the
vehicle until
the
wheel

and tire clear
the
floor.
2.
Pry off the hub cap or
wheel

cover
and
remove
the
grease
cap (Fig.

1) from
the hu6.

3.
Wipe
the
excess grease from
the

end
of the
spindle,
and
remove
the

cotter
pin and nut
lock.

4.
While rotating
the
wheel,
hub,

and drum assembly, torque
the
adjust-

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

bearings
(Fig.
4).

5.
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.

6. Using
a 1
1/8-inch
box
wrench,

WITH WHEEL ROTATING

TORQUE ADJUSTING
NUT

TO 17-25 FT. LBS.
BACK ADJUSTING

NUT
OFF
1/2
TURN
back
off the
adjusting
nut one
half

turn. Retighten
the
adjusting
nut to

10-15 in-lbs with
a
torque wrench
or

finger tight.

7.
Position
the
lock
on the
adjust-

ing
nut and
install
a new
cotter
pin.

Bend
the
ends
of
the
cotter
pin
around

the castellated flange
of the nut
lock.

8. 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, inspect
or

replace
the
bearings
and
cups
as re-

quired.

TIGHTEN ADJUSTING

NUT
TO
10-15 IN.-LBS.
INSTALL THE LOCK

AND
A
NEW COTTER
PIN

F1417-A

FIG. 4— Front Wheel Bearing Adjustmentprocarmanuals.com