wheel FORD MUSTANG 1969 Volume One Chassis

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

03-07-04
Ford Design Non-Integral Power Steering System

03-07-04

12.
Stop the engine, and check the

control valve and hose connections for

fluid leaks. Correct the cause of any

leaks.

13.
Check the fluid level, and refill

the reservoir if necessary.

14.
With the engine running check

the position of the steering wheel

when the front wheels are in the

straight-ahead position.Do not make

any adjustments until toe-in is

checked.

15.
Keep the engine running, and

check toe-in. If either toe-in or steer-

ing wheel position is not correct make

all necessary adjustments (Part 3-1) at

the spindle connecting rod sleeves.

16.
Check the effort to turn the

wheels in both directions. The effort

should be about equal in both direc-

tions.

POWER CYLINDER

REMOVAL

1.
Disconnect the two fluid lines

from the power cylinder and allow

them to drain into a container.
CENTER LINK

POWER CYLINDER

Tool- T64P-3590-F

G 1654-A

FIG. 5—Disconnecting Power

Cylinder Stud

2.
Remove the 'pal nut, attaching

nut, washer and the insulator from the

end of the power cylinder rod.

3.
Remove the cotter pin and cas-

tellated nut that secures the power

cylinder stud to the center link.

4.
Disconnect the power cylinder

stud from the center link as shown in

Fig. 5.

5.
Remove the insulator sleeve and

washer from the end of the power cyl-

inder rod.
6. Inspect the tube fittings and the

seats in the power cylinder for nicks,

burrs or damage. Replace the seats in

the cylinder or the tubes as required.

INSTALLATION

1.
Install the washer, sleeve and the

insulator on the end of the power cyl-

inder rod.

2.
Extend the rod as far as possible.

Insert the rod in the bracket on the

frame and compress the rod as neces-

sary to insert the stud in the -center

link. Secure the stud with a castellat-

ed, nut and a cotter pin.

3.
Secure the power cylinder rod

with an insulator, washer, nut and a

pal nut.

4.
Connect each of the two fluid

lines to its respective port in the cylin-

der.

5.
Fill the reservoir to the correct

level.

6. Start the engine and turn the

steering wheel to each end of its travel

several times to cycle the system. Stop

the engine.

7.
Check the fluid level and fill as

necessary. Install the dipstick and cap.

8. Start the engine and check for

leaks.

MAJOR REPAIR OPERATIONS

CONTROL VALVE

DISASSEMBLY

1.
Wipe all fluid and loose dirt

from the outside of the control valve.

2.
Remove the centering spring cap

from the valve housing (Fig. 6).

When holding the control valve for

disassembly, use a soft-jawed vise, and

clamp the valve only around the sleeve

flange to prevent damage to the hous-

ing, spool, or sleeve.

3.
Remove the nut from the end of

the valve spool bolt. Remove the

washers, spacer, centering spring,

adapter, and bushing from the bolt

and the valve housing.

4.
Remove the two bolts that hold

the valve housing and the sleeve to-

gether, and separate the housing from

the sleeve.

5.
Remove the plug from the valve

sleeve.

6. Push the valve spool out of the

centering spring end of the valve hous-

ing, and remove the seal from the

spool.

7.
Remove the spacer, bushing, and

seal from the sleeve end of the valve

housing.
8. Drive the stop pin out of the

travel regulator stop with a punch and

hammer (Fig. 7). Pull the head of the

valve spool bolt tightly against the

travel regulator stop before driving the

pin out of the stop.

9. Turn the travel regulator stop

counterclockwise in the valve sleeve to

remove the stop from the sleeve.

10.
Remove the valve spool bolt,

spacer, and rubber washer from the

travel regulator stop.

11.
Remove the rubber boot and

clamp from the valve sleeve.

12.
Slide the bumper, spring, and

ball stud seat out of the valve sleeve,

and remove the ball stud socket from

the sleeve.

13.
After removing the return port

hose seat, remove the return port re-

lief valve.

14.
After removing the spring plug

and O-ring, remove the reaction limit-

ing valve (Fig. 8).

Tube Seat Replacement

If a hose seat is worn or damaged it

should be replaced. It can be removed

with an Easy-Out tool, or by using a

bolt of appropriate size as a puller.
1.
Tap the existing hole in the hose

seat, using a starting tap of suitable

size.
Be sure to remove all metal chips

from the hose seat port after tapping.

2.
Place a nut and large flat washer

on a bolt of the same size as the

tapped hole. The washer must be large

enough to cover the hose seat port.

3.
Insert the bolt in the tapped

hole,
and using the nut as a puller, re-

move the hose seat.

4.
Place a new hose seat in the

port, and thread a bolt of suitable size

into the port. Tighten the bolt enough

to bottom the seat in the port.

ASSEMBLY

Before assembling the control valve,

coat all parts except the seals with

Automatic Transmission Fluid. Coat

the seals with lubricant COAZ-

19553-A.

1.
Install the reaction limiting

valve, the spring, and the plug.

2.
Install the return port relief valve

and the hose seat.

3.
Insert one of the ball stud seats

(flat end first) into the ball stud sock-

et, and insert the threaded end of the

ball stud into the socket.procarmanuals.com

03-08-01
Ford Design Integral Power Steering Gear

03-08-01

PART
3-8
Ford Design Integral Power

Steering Gear

COMPONENT INDEX

STEERING GEAR

Adjustments

Cleaning
and
Inspection
(See

Part 03-01)

Description

Disassembly
and
Assembly

Overhaul

Removal
and
Installation

VALVE CENTERING SHIM

Removal
and
Installation

VALVE SPOOL CENTERING CHECK
MODEL APPLICATION
All Models
Ford

08-02

08-01

08-05

08-06

08-03

08-03

08-02
Mercury
08-02

08-01

08-05

08-06

08-03

08-03

08-02
Meteor
08-02

08-01

08-05

08-06

08-03

08-03

08-02
Cougar
N/A

N/A

N/A

N/A

N/A

N/A

N/A
Fairlane
N/A

N/A

N/A

N/A

N/A

N/A

N/A
Falcon
N/A

N/A

N/A

N/A

N/A

N/A

N/A
Montego
N/A

N/A

N/A

N/A

N/A

N/A

N/A
Mustang
N/A

N/A

N/A

N/A

N/A

N/A

N/A
Lincoln-
Continental
08-02

08-01

08-05

08-06

08-03

08-03

08-02
Thunderbird
08-02

08-01

08-05

08-06

08-03

08-03

08-02
Continental-
Mark
III
08-02

08-01

08-05

08-06

08-03

08-03

08-02

DESCRIPTION

The Ford integral power steering

unit
(Fig. 1) is a
torsion-bar type
of

hydraulic assisted system. This system

furnishes power
to
reduce
the
amount

of turning effort required
at the
steer-

ing wheel.
It
also reduces road shock

and vibrations.

The torsion
bar
power steering unit

includes
a
worm
and
one-piece rack

piston, which
is
meshed
to the
gear

teeth
on the
steering sector shaft.
The

unit also includes
a
hydraulic valve,

valve actuator, input shaft
and
torsion

bar assembly which
are
mounted
on

the
end of the
worm shaft
and
operat-

ed
by the
twisting action
of the tor-

sion
bar.

The torsion-bar type
of
power steer-

ing gear
is
designed with
the one
piece
rack-piston, worm
and
sector shaft
in

one housing
and the
valve spool
in an

attaching housing
(Fig. 1).
This makes

possible internal fluid passages
bet-

ween
the
valve
and
cylinder, thus
eli-

minating
all
external lines
and
hoses,

except
the
pressure
and
return hoses

between
the
pump
and
gear assembly.

The power cylinder
is an
integral

part
of the
gear housing.
The
piston
is

double acting,
in
that fluid pressure

may
be
applied
to
either side
of the

piston.

A selective metal shim located
in

the valve housing
of the
gear
is for the

purpose
of
tailoring steering gear
ef-

forts.
If
efforts
are not
within specifi-

cations they
can be
changed
by in-
creasing
or
decreasing shim thickness

as follows:

Efforts heavy
to the
left—Increase

shim thickness.

Efforts light
to the
left—Decrease

shim thickness.

A change
of one
shim size will
in-

crease
or
decrease steering efforts
ap-

proximately
1 1/2
in-lbs.

Shims
are
available
in the
following

thicknesses
and are
notched
on the

outside diameter
for
identification:

0.0057-0.0063 inch—0 notch

0.0077-0.0083 inch—1 notch

0.0097-0.0103 inch—2 notches

0.0117-0.0123 inch—3 notches

0.0137-0.0143 inch—4 notches

Do
not use
more than
one
shim.
procarmanuals.com

03-08-02
Ford Design Integral Power Steering Gear

03-08-02

-INPUT SHAFT

OUTLET PORT

INLET PORT

CONTROL VALVE HOUSING

SECTOR SHAFT COVER

SECTOR SHAFT ADJUSTMENT SCREW

LOCK NUT

IDENTIFICATION TAG

SECTOR SHAFT

FIG.
1—Power
Steering Gear
G1545- A

IN-VEH1CLE ADJUSTMENTS AND REPAIRS

VALVE SPOOL

CENTERING CHECK

1.
Install a 0-2000 psi pressure

gauge Tool T56L-33610-D in the pres-

sure line between the power steering

pump outlet port and the integral

steering gear inlet port.

2.
Make sure that the valve on the

gauge is in the fully open position.

3.
Check the fluid level in the reser-

voir and fill it to proper level with the

specified fluid.

4.
Start the engine and cycle the

steering wheel from stop-to-stop, to

bring the steering lubricant up to nor-

mal operating temperature. Stop the
engine and recheck the reservoir. Add

fluid if necessary.

5.
With the engine running at ap-

proximately 1000 rpm and the steer-

ing wheel centered, attach an inch-

pound torque wrench to the steering

wheel retaining nut. Apply sufficient

torque to the torque wrench in each

direction, either side of center, to get

a gauge reading of 250 psi.

6. The torque reading should be the

same in both directions when 250 psi

is reached. If the difference between

the readings exceeds 4 in-lbs, the

steering gear must be removed and the

valve centering shim removed from the

valve housing and a thicker or thinner
shim installed. Only one shim is to be

used. If the steering effort is heavy,

the shim thickness should be in-

creased. Shim thickness should be de-

creased if the steering effort is light to

the left.

The out of vehicle procedure for

valve centering check is the same as

for the in vehicle except the torque

and simultaneous pressure reading

must be made at the right and left

stops instead of either side of center.

STEERING GEAR

ADJUSTMENTS

During the vehicle breaking-in peri-

od, it is probable that some of theprocarmanuals.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

03-09-01
Saginaw Design Integral Power Steering Gear

03-09-01

PART 3-9 Saginaw Design

Integral Power Steering Gear

COMPONENT INDEX

STEERING GEAR

Cleaning and Inspection (See Page 03-01)

Description

Disassembly and Assembly

Mesh Load Adjustment

Removal and Installation

Overhaul
MODEL APPLICATION
All
Models
Ford

09-01

09-03

09-01

09-02

09-04
Mercury
N/A

N/A

N/A

N/A

N/A

N/A
Meteor
N/A

N/A

N/A

N/A

N/A

N/A
Cougar
N/A

N/A

N/A

N/A

N/A

N/A
Fairlane
N/A

N/A

N/A

N/A

N/A

N/A
Falcon
N/A

N/A

N/A

N/A

N/A

N/A
Montego
N/A

N/A

N/A

N/A

N/A

N/A
Mustang
N/A

N/A

N/A

N/A

N/A

N/A
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A

N/A
Thunderbird
N/A

N/A

N/A

N/A

N/\

N/A
Continental-
Mark III
N/A

N/A

N/A

N/A

N/A

N/A

A page number indicates that the item is for the vehicle listed at the head of the column.

N/A indicates that the item is not applicable to the vehicle listed.

DESCRIPTION

The Rotary Valve Safety power

steering gear operates entirely on dis-

placing fluid to provide hydraulic fluid

pressure assists only when turning. As

the entire gear assembly is always full

of fluid, all internal components of the

gear are immersed in fluid making

periodic lubrication unnecessary. In

addition, this fluid acts as a cushion
to absorb road shocks that may be

transmitted to the driver. All fluid

passages are internal except the pres-

sure and return hoses between the

gear and pump.

The rotary valve provides a smooth

transmission through the driving range

of steering wheel effort. A torsion bar

transmits the road feel to the driver.
Response of the steering gear to effort

applied to the steering wheel has been

greatly increased.

The rack-piston nut is one piece and

is geared to the sector shaft. Lash be-

tween the sector shaft and rack-piston

nut is maintained by an adjusting

screw which is retained in the end o\'

the shaft uear (Eiiz.l).

IN-VEHICLE ADJUSTMENTS AND REPAIRS

During the breaking in period of

the vehicle, it is probable that some

of the factory adjustments will change.

These changes in adjustment do not

necessarily affect the satisfactory op-

eration of the steering gear assembly

and ordinarily do not require re-ad-

justment unless there is excessive lash

or other malfunctioning. The only ad-

justment that should be performed in

the vehicle is the total over center

position load (mesh load) to eliminate

excessive lash between the sector shaft

and rack teeth.

MESH LOAD ADJUSTMENT

1.
Disconnect the Pitman arm from
the sector shaft and remove the steer-

ing wheel hub.

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

steering wheel in both directions as

required, to discharge the fluid from

the gear.

4.
Turn the gear 1/2 turn off cen-

ter (either direction). Using a 24 in-

lb torque wrench on the steering wheel

nut, determine the torque required to

rotate the shaft slowly through a 20

degree arc.

5.
Turn the sear back to center and
repeating the method of reading tor-

que as in Step 4, above, loosen the

adjuster lock nut, turn the screw in-

ward with a 7/32-inch Allen wrench

until the reading is equal to 6 in-lbs

in excess of Step 4 above, and retigh-

ten the lock nut while holding the

screw in place.

6. Recheck the readings and re-

place the Pitman arm and the steering

wheel hub.

7.
Connect the fluid return line to

the reservoir and fill the reservoir

with C1AZ-I9582-A Fluid to the

proper level.
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

03-11-01
Eaton Power Steering Pump

03-11-01

PART 3-11 Eaton Power Steering Pump

COMPONENT INDEX
MODEL APPLICATION

3
§>
"o

4

POWER STEERING PUMP

Cleaning and Inspection (See Part 03-01)

Description

N/A
N/A
N/A
N/A
N/A
N/A

N/A
N/A
11-01

N/A
11-01

Disassembly and Overhaul

N/A
N/A

N/A
N/A

N/A
N/A

N/A
N/A
11-03

N/A
11-03

Removal and Installation

N/A
N/A
N/A
N/A

N/A
N/A
N/A
N/A
11-01
N/A

11-01

POWER STEERING PUMP RESERVOIR

Removal and Installation

N/A
N/A
N/A

N/A
N/A
N/A

N/A

N/A

11-01
N/A

11-01

A page number indicates that the item is for the vehicle listed at the head of the column.

N/A indicates that the item is not applicable to the vehicle listed.

l
DESCRIPTION

The roller-type hydraulic pump,

driven by the crankshaft, draws auto-

matic transmission fluid down the res-

ervoir and provides fluid pressure for

the system. Steering gear lubrication
is also provided by the same fluid

from the reservoir. Within the pump

itself is a flow-control and pressure-

relief valve which governs the pres-
sures within the steering system ac-

cording to the varying conditions of

operation. After fluid has passed from

the gear, it returns to the reservoir.

REMOVAL AND INSTALLATION

POWER STEERING PUMP

REMOVAL

1.
Open the hood, and install fend-

er covers.

2.
If the vehicle is equipped with air

conditioning, loosen the compressor

adjusting and support bracket bolts

and remove the drive belt.

3.
Loosen the generator adjusting

and support bracket bolts, and remove

the drive belts.

4.
Remove the fan, pulley, and spa-

cer.

5.
Raise the vehicle.

6. Remove the crankshaft damper

bolt and washer. Remove the damper

with Tool 6306-AG. Remove the drive

key.

7.
Disconnect the pump inlet line at

the pump, and plug the end of the line

to prevent the loss of fluid. Disconnect

the pump pressure line at the pump.
8. Remove the pump-to-engine

front cover cap screws, and remove

the pump. Remove the seal from the

front cover.

INSTALLATION

1.
Install a new seal on the engine

front cover.

2.
Align the slot in the pump rotor

shaft with the drive key in the crank-

shaft, and slide the pump onto the

shaft. Install the pump-to-engine front

cover cap screws. Torque the cap

screws to specification.

3.
Connect the pump inlet line and

the pressure line.

4.
Install the damper drive key,

damper, washer and bolt. Torque the

bolt to specification.

5.
Install the fan, pulley, and spa-

cer. Install the generator drive belts.

Adjust the belt tension, and tighten

the adjusting and support bracket

bolts.
6. If the vehicle is equipped with air

conditioning, install the compressor

drive belt. Adjust the belt tension, and

tighten the adjusting and support

bracket bolts.

7.
Run the engine at idle speed,

and check the fluid level in the reser-

voir. If required, add the specified au-

tomatic transmission fluid. Turn on

the windshield wipers. Rotate the

steering wheel from stop to stop sever-

al times to bleed the air from the sys-

tem. Recheck the fluid level.

POWER STEERING PUMP

RESERVOIR

WITHOUT AIR

CONDITIONING

Removal

1.
Remove the reservoir cover andprocarmanuals.com

03-12-01

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