steering FORD MUSTANG 1969 Volume One Chassis

03-09-05
Saginaw Design Integral Power Steering Gear

03-09-05

Tool . T59L -100S

FIG. 8—Removing Sector

Shaft Seals

Too/
-
T65P -3576-C

G 1641-A

FIG. 9—Removing Sector

Shaft Bearings

4.
Working from
the
upper
end of

the housing, press
in a new
bearing

until
the
upper
end
is
0.030 inch below

the housing bore. When installing
the

bearing, make sure
it is
pressed
in

from
the
identification
end
(stamped

end).

5.
Lubricate
new
sector shaft seals

(Fig.
7) in
C1AZ-19582-A hydraulic

fluid. Install
the
single
lip
seal first,

then
a
back-up washer. Using special

tool
(Fig. 10),
drive
the
seal
and
wash-

er
in far
enough
to
provide clearance

for
the
other seal
and
back-up washer

and
the
retaining ring.
The
seal must

not bottom
on the end of
the
counter-

bore.
Install
the
double
lip
seal
and

the second back-up washer. Again using
the special tool, drive
the
seal
and

back-up washer
in
only
far
enough
to

provide clearance
for the
retaining

ring. Install
the
sector shaft seal
re-

taining ring with snap ring pliers,

making certian that
the
ring
is
seated

properly.

6.
To
remove
a
damaged port seat,

use
a
5/16-18 inch
U.S.
thread

(coarse)
tap and
turn
it
two
turns into

the seat.

7.
Thread
a
bolt
and nut
with
a
flat

washer into
the
tapped hole
(Fig.
11).

8. Hold
the
bolt from turning
and

tighten
the nut to
extract
the
seat.

Discard
the
seat.

9. Remove
the
check valve
and

spring from
the
inlet port.

10.
Blow
all
chips from
the
hous-

ing.

11.
Position
the
spring, check valve

and
new
seat
in the
inlet port.

12.
Use the
tool shown
in Fig. 12

and drive
the
seat into place.

.
T65P-3D642-A

G1287-
A

FIG.
10
— Installing Sector

Shaft Seal

5/16
•
16x2"

BOLT
13.
Install
the
outlet port seat
in

the same manner.

ADJUSTER PLUG

1.
Lift
the
adjuster plug
off
the
stub

shaft
(Fig.
4).

2.
Pry the
thrust bearing retainer

off
the
adjuster plug
as
shown
in Fig.

13.
Be
careful
not to
score
the
needle

bearing bore. Discard
the
retainer.

3.
Lift
the
spacer, thrust bearing,

races
and the
O-ring, from
the
plug

(Fig.
14).
Discard
the
O-ring.

4.
If
necessary
to
replace
the
roller

bearing, remove
the
dust seal retaining

ring. Working from
the
spacer
end of

the adjuster plug, remove
the
roller

bearing,
oil
seal
and the
dust seal
as

shown
in Fig. 15.

G1639-A

FIG.
12
-Installing Inlet Port

BEARING RETAINER

G1640-A

FIG. 11 —Removing Port Seat
C1638-A

FIG. 73—Removing Thrust

Bearing Retainer

If
the
roller bearing does
not
need

replacing
do not
remove
it. Pry the

dust seal
and the oil
seal from
the ad-

juster plug with
a
screwdriver.

5.
Place
a new
roller bearing
on the

tool shown
in Fig.
15
with
the
bearing

manufacturer's identification facing

toward
the
tool.

6. Position
the
bearing
and
tool
in

the bore. Drive
the
bearing into
the

plug until
it is
flush with
the
bottom

surface
of the
stub shaft seal bore.

7.
Lubricate
a new oil
seal with

C1AZ-19582-A. Install
the
seal with

Tool T65P-3D536-A pressing
it
intoprocarmanuals.com

03-09-06
Saginaw Design Integral Power Steering Gear

03-09-06

ADJUSTER
PLUG

DUST
SEAL

FIG. 14 —Adjuster Plug Disassembled

the plug far enough to provide clear-

ance for the dust seal and the snap

ring.

8. Lubricate a new dust seal

C1AZ-19582-A and install it with

smooth rubber surface facing outward.

9. Secure the dust seal with the

ring, making sure that the ring is

properly seated.

10.
Lubricate a new O-ring seal

with vaseline and install it on the ad-

juster plug.

11.
Assemble the thrust bearing

outer race, thrust bearing, inner race,

and the thrust bearing spacer on the

adjuster plug (Fig. 16).
OIL
RETAINING

SEAL
RING

G
1637-A

12.
Press a new bearing retainer

into the bearing bore. The radial loca-

tion of the dimples is not important.

STUB SHAFT AND

VALVE ASSEMBLY

The control valve and spool is a se-

lect fit and cannot be serviced other

BEARING
AND

RACES

1636-A

FIG. 15 —Removing or Installing

Roller Rearing from Adjuster Plug
G
1635-A

FIG.
76
—Installing Thrust

Bearing Retainer

SPOOL
SPRING

DOWEL
BEARING

RACE

G1634-A

FIG. 77—Control Valve Disassembled
than removing the spool to replace the

dampener O-ring or replace the three

teflon seals or O-rings under the teflon

seals.

1.
Remove the cap to worm O-ring

and discard it (Fig. 17).

2.
Work the rear coil of spool

spring onto the stub shaft bearing sur-

face.
Do not pry on the valve body.

Slide the spring off the shaft.

3.
Extreme care must be used when

removing the valve spool. The diame-

tral clearance between the valve body

and the spool may be as low as 0.0004

inch. The slightest cocking of the

spool may jam it in the valve body.

a. To remove the valve spool, hold

the valve assembly in both hands with

the stub shaft pointing downward.

Push lightly on the valve spool with a

small rod by inserting the rod through

the openings in the end cap (Fig. 18)

until the spool is far enough out of the

valve so that it may be grasped by the

hand. Withdraw the spool with a

steady oscillating pull to prevent jam-

ming. If slight sticking occurs, make a

gentle attempt to reverse the with-

drawal procedure. If this does not free

the spool, it has become cocked in the

valve body bore. Do not attempt to

force the spool in or out if it becomes

cocked. In this case, continue to disas-

semble the valve assembly as follows

and return to the spool as described

later. Remove the stub shaft, torsion

bar, and end cap assembly by holding

the thumbs on the valve body as

shown in Fig. 18. Tap the torsion bar

lightly against the workbench. This

will dislodge the cap from the valve

body to cap pin. The stub shaft, tor-

sion bar and end cap assembly can

now be removed from the valve body.

b.
If the valve spool has become

cocked as described in step 3 above, it

can now be freed. By visual inspection

on a flat surface it can be determined

in which direction the spool is cocked.

A few very light taps with a light soft

plastic or raw-hide mallet should align

the spool in the bore and free it. Do

not tap with anything metallic. If

spool can be rotated, it can be re-

moved.

4.
Remove O-ring dampener seal

from the spool and discard it.

5.
Carefully cut the valve rings and

the ring back-up seals, remove and

discard them, providing the rings show

evidence of excessive wear. The valve

rings are made of filled teflon and it is

very unusual that replacement is re-

quired.

6. Remove the dampener O-ring

from the valve spool and discard it.procarmanuals.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

03-10-01

Ford-Thompson Power Steering Pump*

03-10-01

PART 3-10 Ford-Thompsonr Power Steering Pump

COMPONENT INDEX

PUMP BELT TENSION ADJUSTMENT

PUMP DRIVE BELT

Removal and Installation

POWER STEERING PUMP

Cleaning and Inspection (See Part 03-01)

Description

Disassembly and Assembly

Removal and Installation

POWER STEERING PUMP PULLEY

Removal and Installation

POWER STEERING PUMP RESERVOIR

Removal and Installation

ROTOR SHAFT SEAL

Removal and Installation
MODEL APPLICATION
All
Models
Ford

10-01

l5-O2

10-01

10-04

10-02

10-03

10-03

10-04
Mercury
10-01

10-02

10-01

10-04

10-02

10-03

10-03

10-04
Meteor
10-01

10-02

10-01

10-04

10-02

10-03

10-03

10-04
Cougar
10-01

10-02

10-01

10-04

10-02

10-03

10-03

10-04
Fairlane
10-01

10-02

10-01

10-04

10-02

10-03

10-03

10-04
Falcon
10-01

10-02

10-01

10-04

10-02

10-03

10-03

10-04
Montego
10-01

10-02

10-01

10-04

10-02

10-03

10-03

10-04
Mustang
10-01

10-02

10-01

10-04

10-02

10-03

10-03

10-04
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A
Thunderbird
10-01

10-02

10-01

10-04

10-02

10-03

10-03

10-04
Continental-
Mark
III
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.

1
DESCRIPTION

The Ford-Thompson power steering

pump is a belt driven slipper type

pump which is integral with the reser-
voir (Fig. 1). It is constructed so that

the reservoir is attached to the rear

side of the pump housing front plate
and the pump body is encased within

the reservoir (Fig. 2).

IN-VEHICLE ADJUSTMENTS AND REPAIRS

PUMP BELT TENSION

ADJUSTMENT

Pump drive belt tension cannot be

checked accurately using the
•
thumb

pressure or belt deflection methods.

Correct belt adjustment is assured

only with the use of a belt tension

gauge.

1.
Check the belt tension with a

belt tension gauge tool T63L-8620-A.

With a new belt, or one that has been

run for less than 15 minutes, the ten-

sion should be within 120-150 lbs.

With a belt that has been run for

more than 15 minutes, the tension

should be within 90-120 lbs.

2.
To adjust the belt, loosen the

mounting bolts incorporated on the

front face of the pump cover plate

(hub side) and one nut at the rear of

the reservoir. Fix a 9/16 inch open

end wrench on the nrojecting 1/2 inch

boss on the cover -'plate a"hd pry up-

ward to correct tension on 6 cyl. en-

gines.
DIPSTICK.

DRIVE

PULLEY

RELIEF VALVE

RESERVOIR

ORIFICE PLUG

G1479-B

FIG.
1—Power
Steering Pump—Sectional View
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

03-10-04
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

03-10-05
Ford-Thompson Power Steering Pump

03-10-05

the bench mounted holding fixture,

T57L-5OO-A or on the assembled

adapter plate, T69P-3A674-A, pulley

end of the shaft up.

3.
Clean any rust or road dirt from

the pulley end of the rotor shaft.

4.
To prevent scoring of the shaft,

wrap .005 shim stock (free of burrs)

around the rotor shaft and push it into

the ID of the seal until it is against

the bushing.
5.
Using a sharp tool such as a

sheet metal punch, carefully pierce the

metal seal body face and pry the old

seal out (Hg. 9). Do not damage the

bushing, the housing or the rotor

shaft.

Installation

1.
Remove the shim stock.

2.
Position the new rotor shaft seal

.* SHARP POINTED TOOL

(PRY OUT SEAL)

FIG. 9—Rotor Shaft Seal Removal

s- •:?

. SHAFT SEAL PROTECTOR

TOOL NO. T68P-3B592-B
on the shaft seal protector, Tool

T68P-3B592-B.

3.
Insert the seal protector tool and

the rotor shaft seal onto the shaft

(Fig. 10).

4.
Using" the seal installation Tool

T68P-3B592-A and a rubber or plastic

hammer, tap gently on the end of the

tool until the seal is completely in-

stalled (flush with the end of the seal

bore).

5.
Remove the tools.

6. Install the pulley on the rotor

shaft as described under Power Steer-

ing Pump Pulley Installation.

ASSEMBLY

1.
Assemble adapter plate (Tool

T69P-3A674-A) to the bench mounted

holding fixture Tool T57L-5OO-A. Po-

sition the pump assembly on ' the

adapter plate, pulley side facing doVn.

JrM" the lower pressure plate and rotor

shaft have not been disassembled,

omit Steps 2 and 3).

2.
Insert the lower pressure plate

on the anchor pin with the wide cham-

fered slots at the center hole facing up

(Fig. 11).

FIXED ROUND NOTCH ON

DOWEL HOLE THIS SIDE WIDE

0NLY CHAMFERED

SLOTS

G1347-A

FIG. 10—Rotor Shaft Seal Installation
FIG. 11—Lower Pressure

Plate Installed

3.
Dip the rotor shaft in specified

steering gear lubricant (C1AZ

19582A); then insert the rotor shaft

into the lower pressure plate and

housing plate.

4.
If the rotor assembly is disas-

sembled, hold the cam insert with the

notch on the OD of the cam at the

top and the arrow on the OD of the

cam pointing downward.

5.
Insert the rotor in the cam with

the double step in the ID of the rotor

facing upward.

6. With the rotor extended upward

approximately one half way out of the

cam, insert a spring into a rotor

spring pocket working in the rotor

cavity directly beneath the cam notch.procarmanuals.com