Specifications part 3-13 FORD MUSTANG 1969 Volume One Chassis

03-01-01

PART
3-1
PAGE

Suspension,
Steering, Wheels and

Tires,
General Service 03-01-01

PART
3-2

Suspension 03-02-01

PART
3-3

Automatic
Air
Leveling System ....03-03-01

PART
3-4

Automatic
Air
Leveling System

Lincoln Continental 03-04-01

PART
3-5

Steering Columns and Linkage ... 03-05-01

PART
3-6

Manual Steering 03-06-01

PART
3-7

Ford Design Non-Integral Power

Steering System
03-07-01
PART
3-8
PAGE

Ford Design Integral Power

Steering Gear 03-08-01

PART
3-9

Saginaw Design Integral Power

Steering Gear 03-09-01

PART
3-10

Ford-Thompson Power Steering

Pump 03-10-01

PART
3-11

Eaton Power Steering Pump 03-1
1-01

PART 3-12

Wheels and Tires 03-1 2-01

PART
3-13

Specifications
03-13-01

PART
3-1
Suspension,Steering, Wheels
and

Tires—General Service

COMPONENT INDEX

CASTER AND CAMBER ADJUSTMENTS

FRONT
END
INSPECTION

FRONT WHEEL ALIGNMENT CHECKS

LUBRICANT CHECKING PROCEDURE

POWER STEERING GEAR CLEANING

AND INSPECTION

POWER STEERING PRELIMINARY TESTS

POWER STEERING PUMP

Cleaning
and
Inspection

Flow
and
Pressure Tests

POWER STEERING SYSTEM FLUSHING

SHOCK ABSORBER CHECKS

STEERING WHEEL SPOKE POSITION

Adjustment

TOE-IN ADJUSTMENT

WHEEL BALANCING
MODEL APPLICATION
All
Models

01-08

01-03

01-07

01-09

01-02

01-11

01-07

01-07

01-07
Ford
01-05

01-09

01-02

01-09
Mercury
01-05

01-09

01-02

01-09
Meteor
01-05

01-09

01-02

01-09
Cougar
01-06

01-09

01-02

01-09
Fairlane
01-06

01-09

01-02

01-09
Falcon
01-06

01-09

01-02

01-09
Montego
01-06

01-09

01-02

Gl-09
Mustang
01-06

01-09

01-02

01-09
Lincoln-
Continental
01-06

01-09

01-03

N/A
Thunderbird
01-05

01-09

01-02

01-09
Continental-
Mark
III
01-05

01-10

01-03

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.
procarmanuals.com

03-01-02
Suspension — Steering, Wheels And Tires — General Service

03-01-02

1 TESTING

POWER STEERING-

PRELIMINARY TESTS

The following preliminary checks

should always be made before per-

forming any operations.

AIR BLEEDING

Air in the power steering system

(shown by bubbles in the fluid) should

be bled. After making sure that the

reservoir is filled to specification (the

fluid must be at normal operating

temperature when the check is made),

turn the steering wheel through its full

travel three or four times. Do not hold

the wheels against their stops. Re-

check the fluid level.

CHECK FLUID LEVEL

Run the engine until the fluid is at

normal operating temperature. Then

turn the steering wheel all the way to

the left and right several times, and

shut off the engine.

Check the fluid level in the power

steering reservoir. The level must show

on the cross hatching between the bot-

tom of the dipstick and the full mark

(Fig. 1). If the level is low, add

enough automatic transmission fluid

C1AZ-19582-A to raise the level to

the F mark on the dipstick. Do not

overfill the reservoir.

CHECK PUMP BELT

If the pump belt is broken, glazed,

or worn, replace it with a new belt.

Use only the specified type of belt.

Refer to Part 3-13 for belt adjustment

procedure.

CHECK FOR FLUID

LEAKS

With the engine idling, turn the

steering wheel from stop to stop sever-

al times. Check all possible leakage

points. Tighten all loose fittings, and

replace any damaged lines or defective

seats.

CHECK TURNING EFFORT

With the front wheels properly al-

igned and tire pressures correct, check

the effort required to turn the steering

wheel.
G 1508- A

FIG.
1—Power
Steering Pump

Dipstick

1.
With the vehicle on dry concrete,

set the parking brakes.

2.
With the engine warmed up and

running at idle speed, turn the steering

wheel to the left and right several

times to warm the fluid.

3.
Attach a pull scale to the rim of

the steering wheel. Measure the pull

required to turn the wheel one com-

plete revolution in each direction. The

effort required to rotate the steering

wheel should not exceed specifications

given in Part 3-13.

POWER STEERING PUMP FLOW

AND PRESSURE TESTS—

EXCEPT LINCOLN CONTINENTAL

AND CONTINENTAL MARK III

The power steering flow and pres-

sure tests will show whether the pump,

steering gear or power assist control

RETURN LINE

POWER

STEERING PUMP

Sr
valve is causing the trouble. Steps out-

lined below should be followed to de-

termine the cause of the trouble.

PUMP FLOW TEST

1.
Depending on the equipment

present on the vehicle (air condition-

ing, power brakes, standard transmis-

sion),
one of the following options

may be used to connect the pump

pressure and return hoses to the test

tool (T56L-3361O-D and T68L-

33610-A):

a. Disconnect the pressure and re-

turn lines at the power steering pump

(Fig. 2). Obtain a power steering re-

turn hose from stock and connect the

end with the fitting to the output fit-

ting of the tool using the
5/8-18
SAE

female, 1/4 N.P. thread male fitting

provided. The end of the stock hose

(without the fitting) should be con-

nected to the return tube of the pump.

Connect the pressure hose from the

tool to the outlet fitting of the pump.

b.
Disconnect the pressure line at

the pump and connect the pressure

line from the test tool to the outlet fit-

ting of the pump. Disconnect the re-

turn line at the gear and connect it to

the output fitting of the tool, using the

5/8-18
SAE female, 1/4 N.P. thread

male fitting provided.

2.
After installing the lines by the

most advantageous method, proceed

as follows:

3.
Open the manual valves A and B

fully (Fig. 2).

CALIBRATED FLOW

DETERMINING ORIFICE

PRESSURE LINE

FIG. 2—Power Steering Pump Test Circuit Diagram
PRESSURE GAGE

G1611-Aprocarmanuals.com

03-01-03
Suspension — Steering, Wheels And Tires — General Service

03-01-03

4.
Connect a tachometer, start the

engine and operate it at idle speed

until the reservoir fluid temperature

reaches 165 to 175. This temperature

must be maintained throughout the

test. Valve B may be partially closed

to create a back pressure up to 350

psi to hasten the temperature rise. The

reservoir fluid must be at the proper

level.

5.
With the engine operating at rec-

ommended idle rpm and fluid temper-

ature noted in Step 4, close the manu-

al valve B. The minimum acceptable

pressure reading is 620 psi.

6. If the pressure gauge reading is

below the minimum specification, the

pump is at fault and should be re-

paired with necessary parts.

7.
If the reading is at or above the

minimum specification, the pump flow

is normal. Open manual valve B and

proceed to the Pump Fluid Pressure

Test.

PUMP FLUID

PRESSURE TEST

1.
Keep the lines and tools con-

nected as in the Pump Flow Test.

2.
With manual valves A and B

opened fully, operate the engine at

recommended idle speed (Fig. 2).

Close manual valve A, then manual

valve B. Do not keep both valves

closed for more than 5 seconds as this

would abnormally increase the fluid

temperature and cause undue pump

and/or gear wear.

3.
With the valves fully closed, the

pressure gauge should read 1000 psi

minimum for Ford, Mercury, Meteor

or Thunderbird and 750 psi minimum

for Cougar, Fairlane, Falcon, Monte-

go or Mustang.

4.
If the pressure gauge reading is

below the minimum specification, the

pump is at fault and should be re-

paired with necessary parts.

5.
If the pressure gauge reading is

at or above the minimum specifica-

tions,
the pump is normal and the

power steering gear or power assist

control valve is at fault.

FLUID PRESSURE TEST-

LINCOLN CONTINENTAL AND

CONTINENTAL MARK III

The pressure testing gauge set, tool

T56L-33610-D, requires modification

to make it adaptable for installation

in the power steering hydraulic sys-

tem. The parts required and the modi-

fication procedure are as follows:
OWER STEERING

PRESSURE LINE

INVERTED FLARE

CONNECTOR

%* TUBE x VA" PIPE

FLARED FEMALE COUPW

%' TUBE x VA" PIPE

G1544.A

FIG. 3—Modified Pressure Gauge

Assembly

a. Power Steering Pressure Line

(refer to the appropriate Parts Catal-

og).

b.
Inverted Flare Connector (3/8

inch OD Tube x 1/4 inch Pipe

Thread).

c. Inverted Flare Connector (5/16

inch OD Tube x 1/4 inch Pipe

Thread).

d. Flared Tube Female Coupling

(3/8 inch OD Tube x 1/4 inch Pipe

Thread).

The connectors and the coupling are

standard-type fittings and can be pur-

chased locally.

e. To modify tool T56L-33610-D,

remove the hose from the hand shut-

off valve block. Install the 3/8 inch x

1/4 inch inverted flare connector in

the valve block, and assemble the

pressure line to the connector (Fig. 3).

Assemble the 3/8 x 1/4 inch coupling

and the 5/16-inch connector to the

free end of the hose leading to the.

pressure gauge.

1.
To check the pump pressure, dis-

connect the front and rear sections of

the pressure line over the number 6

cylinder. Connect the modified pres-

sure-testing gauge assembly, tool

T56L-3361O-D, between the two sec-

tions.

2.
Make sure the hand-valve at the

gauge is fully opened. Start the engine

and cycle the steering gear from stop

to stop to warm up the fluid. Check

the fluid level in the reservoir and add

fluid, if necessary.

3.
Turn the steering wheel to the

full right and full left turn positions

and observe the gauge readings.

Hold the wheels in this position

only long enough to obtain an accu-

rate reading. Do not exceed 5 seconds.

The gauge should read between

1120 and 1250 psi. If the pressure is
less than 1120 psi, close the valve at

the gauge and note the pump pressure.

If it is low with the valve closed, it in-

dicates that the pump is not operating

properly. If the pressure goes up with

the valve closed, it indicates that the

low pressure in the system must be

due to internal leakage in the power

unit, providing all connections are

tight.

4.
Remove the pressure testing

gauge set, and connect the pressure

line at the steering gear. Fill and bleed

the system.

FRONT WHEEL ALIGNMENT

CHECKS

Do not attempt to check and adjust

front wheel alignment without first

making a preliminary inspection of

the front-end parts. Refer to Section

3.

Check all the factors of front wheel

alignment except the turning angle

before making any adjustments. The

turning angle should be checked only

after caster, camber, and toe-in have

been adjusted to specifications.

The front wheel alignment specifica-

tions given in Part 3-13, are correct

only when the vehicle is at curb load.

Before checking or adjusting the

alignment factors, the suspension

alignment spacers must be installed to

obtain the curb Height.

EQUIPMENT INSTALLATION

Equipment used for front wheel

alignment inspection must be accu-

rate.
Whenever possible, front wheel

alignment checks should be performed

on stationary wheel aligning equip-

Too/
- T65P3000-A or S

FIG. 4—Typical Front Alignment

Spacer Installation—Cougar,

Fairlane, Falcon,
Montego,
Mustangprocarmanuals.com

03-01-05
Suspension — Steering, Wheels And Tires — General Service

03-01-05

type of equipment is used, follow the

installation and inspection instructions

provided by the equipment manufactu-

rer.

CASTER

Check the caster angle at each front

wheel.

The caster is the forward or rear-

ward tilt of the top of the wheel

spindle (Fig. 12). If the spindle tilts to

the rear, caster is positive. If the

spindle tilts to the front, caster is neg-

ative. The correct caster angle, or tilt,

is specified in Part 3-13.

On Mustang, Cougar, Fairlane,

Falcon and Montego vehicles, the

maximum caster difference for check-

ing purposes must not exceed one de-

gree.
If setting is necessary, then the

maximum difference must not exceed

1/2 degree. On all other vehicles, the

maximum caster difference must never

exceed 1/2 degree.

CAMBER

Check the camber angle at each

front wheel.

Camber is the amount the front

wheels are tilted at the top (Fig. 12).

If a wheel tilts outward, camber is

positive. If a wheel tilts inward, cam-

ber is negative. The correct camber

angle, or outward (positive) tilt is

specified in Part 3-13.

On Mustang, Cougar, Fairlane,

Falcon and Montego vehicles, the

maximum camber difference for

checking purposes must not exceed

one degree. If setting is necessary,
then the maximum difference must

not exceed 1/2 degree. On all other

vehicles, the maximum camber differ-

ence must never exceed 1/2 degree.

TOE-IN

Alignment height spacers should not

be used to check and adjust toe-in.

Toe-in should only be checked and ad-

justed after the caster and camber

have been adjusted to specifications.

Check the toe-in with the front

wheels in the straight-ahead position.

Run the engine so that the power

steering control valve will be in the

center (neutral) position (if so

equipped). Measure the distance be-

tween the extreme front and also be-

tween the extreme rear of both front

wheels. The difference between these

two distances is the toe-in or toe-out.

Correct toe-in, or inward pointing

of both front wheels at the front is

specified in Part 3-13.

FRONT WHEEL

TURNING ANGLE

When the inside wheel is turned 20

degrees, the turning angle of the out-

side wheel should be as specified in

Part 3-13. The turning angle cannot

be adjusted directly, because it is a re-

sult of the combination of caster,

camber, and toe-in adjustments and

should, therefore, be measured only

after these adjustments have been

made. If the turning angle does not

measure to specifications, check the

spindle or other suspension parts for a

bent condition.
ALIGNMENT
MARKS

G-1496-A

FIG. I?—Straight Ahead Position

Marks—Typical

POSITIVE

CAMBER

• •
NEGATIVE-*!
| ^*—

CASTER

ICL
OF TIRE
POSITIVE

CASTER

5r\

CA&U

ANGlE
F1216-A

FIG. 72—Caster and Camber

Angles

COMMON ADJUSTMENTS AND REPAIRS

After front wheel alignment factors

have been checked, make the neces-

sary adjustments. Do not attempt to

adjust front wheel alignment by bend-

ing the suspension or steering parts.

CASTER AND CAMBER

ADJUSTMENTS

FORD, MERCURY, METEOR,

THUNDERBIRDAND

CONTINENTAL MARK III

Caster and camber is adjusted by

loosening the bolts that attach the

upper suspension arm inner shaft to

the frame side rail, and moving the

inner shaft in or out in the elongated

bolt holes with the tool shown in Fig.
13.
The tool should be installed with

the tool pins in the frame holes and

the hooks over the upper arm inner

shaft. Then, tighten the tool hook nuts

snug before loosening the upper arm

inner shaft attaching bolts.

Caster

To adjust the caster angle, tighten

the tool front hook nut or loosen the

rear hook nut (Fig. 14) as required to

increase caster to the desired angle.

To decrease caster, tighten the tool

rear hook nut or loosen the front

hook nut as required (Fig. 14). The

caster angle can be checked without

tightening the inner shaft attaching

bolts.
Check the camber adjustment to

be sure it did not change during the

caster adjustment and adjust if neces-
FIG. 73—Camber and Caster

Adjusting Toolprocarmanuals.com

03-01-07
Suspension — Steering, Wheels And Tires — General Service

03-01-07

upper arm shaft to the frame member

(Fig. 3, Part 3-2).

2.
Loosen the arm shaft attaching

bolts,
raise the front end of the vehicle

and lower it again. This will break the

arm shaft loose from the frame mem-

ber.

3.
With a pry bar, move the arm

shaft back into alignment with the

chalk marks made in Step 1, and

tighten the shaft attaching bolts. The

bolts should be tightened just enough

to hold the shaft in position without

preventing its being moved with the

pry bar.

Caster

1.
With the aid of a pry bar, move

the shaft in or out, as required, to

meet specifications. A movement of

approximately 3 /32 inch at either the

front or rear bolt location will change

the caster 1/2 degree. Inboard move-

ment of the front bolt, or outboard

movement of the rear bolt, will change

caster in the negative direction. Out-

board movement of the front bolt, or

inboard movement of the rear bolt,

will change caster in the positive di-

rection.

2.
When the caster is correct, tor-

que the shaft attaching bolts to speci-

fication and recheck the caster and

camber to insure that the readings

have not changed.

Camber
TURN DOWNWARD TO

INCREASE ROD LENGTH

TURN UPWARD

TO DECREASE

ROD LENGTH
TURN

DOWNWARD

TO DECREASE

ROD LENGTH
TURN UPWARD TO

INCREASE ROD LENGTH

LEFT-HAND SLEEVE
RIGHT-HAND SLEEVE

FIG. 16—Spindle Connecting Rod Adjustment

WHEN TOE-IN IS CORRECT

TURN BOTH CONNECTING ROD

SLEEVES UPWARD TO ADJUST

SPOKE POSITION
F1433-A

i URN BOTH CONNECTING ROD

SLEEVES DOWNWARD TO

ADJUST SPOKE POSITION

WHEN TOE-IN IS

NOT CORRECT

LENGTHEN LEFT ROD TO

INCREASE TOE-IN

SHORTEN RIGHT ROD

TO DECREASE TOE-IN
SHORTEN LEFT ROD

TO DECREASE TOE-IN

LENGHTEN RIGHT ROD

TO INCREASE TOE-IN

ADJUST BOTH RODS EQUALLY TO MAINTAIN NORMAL SPOKE POSITION

1.
With the aid of a pry bar, move

the shaft in or out, as required, to

meet specifications. A movement of

approximately 3/64 inch of the entire

shaft will change the camber 1/4 de-

gree.
Inboard movement will change

the camber in the negative direction.

Outboard movement will change the

camber in the positive direction.

2.
When the camber is correct, tor-

que the shaft attaching bolts to speci-

fication and recheck the camber and

caster to insure that the readings have

not changed. Remove all alignment

equipment and alignment spacers and

install the right and left side rail

bumpers.

TOE-IN AND STEERING

WHEEL SPOKE

POSITION ADJUSTMENTS

Check the steering wheel spoke po-

sition when the front wheels are in the

straight-ahead position. If the spokes

are not in their normal position, they

can be properly adjusted while toe-in

is being adjusted.
F1434-
A

f/G.77—Toe-in and Steering Wheel Spoke Alignment Adjustment—Typical

1.
Loosen the two ciamp bolts or

each spindle connecting rod sleeve

(Fig. 16).

2.
Adjust toe-in. If the steering

wheel spokes are in their normal posi-

tion, lengthen or shorten both rods

equally to obtain correct toe-in (Fig.

16).
If the steering wheel spokes are

not in their normal position, make the

necessary rod adjustments to obtain

correct toe-in and steering wheel

spoke alignment (Fig. 17).

3.
Recheck toe-in and the steering

wheel spoke position. If toe-in is cor-

rect and the steering wheel spokes are

still not in their normal position, turn

both connecting rod sleeves upward or

downward same number of turns to

move the steering wheel spokes (Fig.

16).

4.
When toe-in and the steering

wheel spoke position are both correct,

torque the clamp bolts on both con-

necting rod sleeves to specification
(Part 3-13). Lubricate clamp, bolts

and nuts prior to torquing to specifi-

cation. The sleeve position should not

be changed when the clamp bolts are

tightened.

WHEEL BALANCING

See the instructions provided with

the Rotunda Wheel Balancer.

Make certain that the brakes are

not dragging before attempting to spin

the wheels. Push the brake shoes into

the caliper to free the rotor.

LUBRICANT CHECKING

PROCEDURE

MANUAL STEERING GEAR

1.
Center the steering wheel.

2.
Remove the steering gear hous-

ing filler plug.procarmanuals.com

03-01-09
Suspension — Steering, Wheels And Tires — General Service

03-01-09

the reading exceeds specifications

(Part 3-13), replace the upper ball

joint.

LOWER BALL JOINT

INSPECTION

Ford,
Mercury, Meteor,

Thunderbird, Lincoln Continental

and Continental Mark III

1.
Raise the vehicle and place

jacks under the lower arms as shown

in Fig. 12. This will unload the lower

ball joints.

2.
Adjust the wheel bearings as des-

cribed in Part 3-12.

3.
Attach a dial indicator to the

lower arm and position the indicator

so that the plunger rests against the

inner side of the wheel rim adjacent to

the lower ball joint.

4.
Grasp the tire at the top and

bottom and slowly move the tire in

and out (Fig. 19). Note the reading

(radial play) on the dial indicator. If

the reading exceeds specifications

(Part 3-13), replace the lower ball

joint.

Cougar, Fairlane, Falcon,

Montego, Mustang

1.
Raise the vehicle on a frame

contact hoist or by floor jacks placed

beneath the underbody until the wheel

falls to the full down position.

2.
Ask an assistant to grasp the

lower edge of the tire and move the

wheel in and out.

3.
As the wheel is being moved in

and out, observe the lower end of the

spindle and the lower arm.

4.
Any movement between the

lower end of the spindle and the lower

arm indicates ball joint wear and loss

of preload. If any such movement is

observed, replace the lower arm.

During the foregoing check, the

upper ball joint will be unloaded and

may move. Disregard all such move-

ment of the upper ball joint. Also, do

not mistake loose wheel bearings for a

worn ball joint.

POWER STEERING GEAR

CLEANING

Disassembly and assembly of the

steering gear and. the sub-assemblies

must be made on a clean workbench.

As in repairing any hydraulically op-

erated unit, cleanliness is of utmost
importance. The bench, tools, and

parts must be kept clean at all times.

Thoroughly clean the exterior of the

unit with a suitable solvent and, when

necessary drain as much of the hy-

draulic fluid 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.

INSPECTION

1.
Check the sector shaft contact

surface in the cover for wear. If worn,

replace the cover.

2.
Inspect the input shaft bearing

for cracked races and the balls for

looseness, wear, pitting, end play or

other damage. Check the fit of the

bearing on the input shaft. Replace

the bearing, if required.

3.
Inspect the valve housing for

wear, scoring or burrs.

4.
Inspect the tube seats in the

pressure and return ports in the valve

body for nicks, etc. If necessary, re-

move and replace.

5.
Check the sector shaft contact

surface in the housing for wear. If

worn, replace the bushing or the hous-

ing.

6. Check all fluid passages for ob-

struction or leakage.

7.
Inspect the steering gear housing

for cracks, stripped threads, and mat-

ing surfaces for burrs. Inspect the pis-

ton bore of the housing for scoring or

wear. If necessary, replace the hous-

ing.

8. Check the input shaft bearing

after installation to be sure that it ro-

tates freely.

9. If the valve spool is not free in

the valve housing, check for burrs at

the outward edges of the working

lands in the housing and remove with

a hard stone. Check the valve spool

for burrs and if burrs are found, stone

the valve in a radial direction only.

Check for freedom of the valve again.

10.
Check the piston rack teeth and

sector shaft teeth for nicks and burrs.

FLUSHING THE POWER

STEERING SYSTEM—ALL EXCEPT

LINCOLN CONTINENTAL AND

CONTINENTAL MARK III

Should it be necessary to replace an

inoperative power steering pump, the

need for flushing the steering system

is required when installing the new

pump.
1.
Remove the power steering pump

and remove the pulley as outlined in

Part 3-10.

2.
Install the pulley on a new

pump. Install the pump and connect

only the pressure hose to the pump

(Part 3-10).

3.
Place the fluid return line in a

suitable container and plug the reser-

voir return pipe.

4.
Fill the reservoir with lubricant

(C1AZ-19582-A).

5.
Disconnect the coil wire to pre-

vent the engine from starting and raise

the front wheels off the ground.

6. While approximately two quarts

of steering gear fluid are being poured

into the reservoir, turn the engine over

using the ignition key, at the same

time cycle the steering wheel from

stop to stop.

7.
As soon as all of the lubricant

has been poured in, turn off the igni-

tion key, and attach the coil wire.

8. Remove the plug from the reser-

voir return pipe, and attach the return

hose to the reservoir.

9. Check the reservoir fluid level; if

low, add fluid to the proper level. Do

not overfill.

10.
Lower the vehicle.

11.
Start the engine and cycle the

steering from stop to stop to expel

any trapped air from the system.

POWER STEERING PUMP—ALL

EXCEPT LINCOLN

CONTINENTAL AND

CONTINENTAL MARK III

CLEANING

Wash all parts (except seals) in a

Naptha or Chlorinated-type solvent

and dry with compressed air.

Punch or Rod

RELIEF VALVE PLUNGER

G1607-A

FIG.
20—Cleaning Pump Relief Valveprocarmanuals.com

03-02-20
Suspension

03-02-20

hub and rotor on the spindle. Position

the caliper over the rotor and install

the attaching bolts. Torque the bolts

to specification (Part 3-13). Install the

wheel and tire on the hub and adjust

the wheel bearings as outlined in Part

3-12 .

7.
Install the hub cap or wheel

cover. Then, remove the support stand

and lower the vehicle.

8. Check caster, camber, and toe-in

(Part 3-1) and adjust as necessary.

COUGAR, FAIRLANE,

FALCON, MONTEGO,

MUSTANG

Drum Brakes

Removal

1.
Position a support between the

upper arm and frame as shown in

Figs.
8 and 9; then, raise the vehicle

and position safety stands.

2.
Remove the hub cap or wheel

cover.

3.
Remove the grease cap from the

hub;
then, remove the adjusting nut,

washer, and outer bearing cone and

roller assembly.

4.
Pull the wheel, hub, and drum

assembly off the wheel spindle.

5.
Remove the brake backing plate

from the spindle. Support the plate to

prevent damage to the brake hose.

6. Disconnect the spindle connect-

ing rod end from the spindle arm

using Tool 3290-C.

7.
Remove the cotter pins from

both ball joint stud nuts, and loosen

the nuts one or two turns. Do not re-

move the nuts from the studs at this

time.

8. Position the ball joint remover

tool between the upper and lower ball

joint studs (Fig. 10). The tool should

seat firmly against the ends of both

studs and not against the stud nuts.

9. Turn the tool with a wrench until

the tool places the studs under consid-

erable tension, and, with a hammer,

hit the spindle smartly near the studs

to break them loose in the spindle. Do

not loosen the studs in the spindle

with tool pressure alone.

10.
Remove the stud nuts and re-

move the spindle from both studs.

Installation

1.
Position the spindle on the lower

ball joint stud and install the stud nut

(Fig. 25).
2.
Raise the lower suspension arm

and guide the upper ball joint stud

into the spindle. Install the stud nut.

3.
Torque the upper stud nut and

then the lower stud nut to specifica-

tion. Continue to tighten both nuts

until the cotter pin holes and slots line

up.
Install new cotter pins.

4.
Connect the spindle connecting

rod end to the spindle arm.

5.
Install the brake backing plate

on the spindle, and torque the bolts to

specification.

6. Install the wntel and drum and

adjust the wheel bearing (Part 3-12).

7.
Remove the safety stands, and

lower the vehicle.

8. Remove the support from be-

tween the upper arm and frame.

9. Check and, if necessary, adjust

caster, camber, and toe-in.

Disc Brakes

Removal

1.
Remove the hub cap or wheel

cover, and remove the wheel and tire

from the hub.

2.
Remove two bolts attaching the

caliper to the spindle. Remove the cal-

iper from the rotor and wire it to the

underbody to prevent damage to the

brake hose.

3.
Remove the grease cap from the

hub,
then, remove the adjusting nut,

washer, and outer bearing cone and

roller assembly.

4.
Pull the hub and rotor assembly

off the wheel spindle.

5.
Remove the three caliper shield

attaching bolts and remove the shield.

6. Disconnect the spindle connect-

ing rod end from the spindle arm

using Tool-3290-C.

7.
Remove the cotter pins from

both ball joint stud nuts, and loosen

the nuts one or two turns. Do not re-

move the nuts from the studs at this

time.

8. Position the ball joint remover

tool between the upper and lower ball

joint studs (Fig. 10). The tool should

seat firmly against the ends of both

studs and not against the stud nuts.

9. Turn the tool with a wrench until

the tool places the studs under consid-

erable tension, and, with a hammer,

hit the spindle smartly near the studs

to break them loose in the spindle. Do

not loosen the studs in the spindle

with tool pressure alone.

10.
Position a floor jack under the

lower suspension arm.
11.
Remove the upper and lower

ball joint stud nuts; lower the jack

and remove the spindle.

Installation

1.
Position the spindle on the lower

ball joint stud and install the stud nut

(Fig. 25). Torque the nut to specifica-

tion and install the cotter pin.

2.
Raise the lower suspension arm,

and guide the upper ball joint stud

into the spindle. Install the stud nut.

3.
Torque the nut to specifications

and install the cotter pin. Then, re-

move the floor jack.

4.
Connect the spindle connecting

rod end to the spindle arm and install

the attaching nut. Torque the nut to

specification and install the cotter pin.

5.
Position the caliper splash shield

to the spindle and install the attaching

bolts and nuts. Torque the nuts and

bolts to specification.

6. Install the hub and rotor on the

spindle.

7.
Position the caliper to the rotor

and spindle and install the attaching

bolts.
Torque the bolts to specification

and install the safety wire.

8. Install the wheel and tire on the

hub and adjust the wheel bearing

(Part 3-12).

9. Install the hub cap or wheel

cover.

10.
Before driving the vehicle,

pump the brake pedal several times to

obtain normal brake lining-to-rotor

clearance and restore normal brake

pedal travel.

LINCOLN CONTINENTAL

Removal

1.
Raise the vehicle. Place a sup-

port under each side rail to the rear of

the lower arm in the lifting pad area.

2.
Remove the wheel and tire from

the hub.

3.
Remove 2 bolts and washers that

attach the caliper to the spindle. Re-

move the caliper from the rotor and

wire it to the underbody to prevent

damage to the brake hose.

4.
Remove the hub and rotor from

the spindle.

5.
Remove the splash shield and

gasket from the spindle.

6. Disconnect the spindle arm con-

necting rod from the spindle arm with

Tool 3290-C. See Fig. 23.

7.
Remove the cotter pins from

both ball joint stud nuts. Loosen the

nuts one to two turns.procarmanuals.com

03-02-25
Suspension

03-02-25

pivot bolts and nuts to specification

(Part 3-13).

5.
Connect the track bar to the

frame bracket with a new nut and

bolt. Torque the nut to specification

(Part 3-13).

6. Remove the alignment spacers

and jack stands and lower the vehicle.

REAR SUSPENSION-

UPPER ARM

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK HI

Removal

1.
Raise the vehicle and support the

frame side rails with jack stands.

2.
Support the rear axle, then dis

connect the track bar from the frame

bracket.

3.
Lower the axle and support axle

under differential pinion nose, as well

as under axle.

4.
Remove the nut, bolt and two

washers that attach the upper arm to

the axle housing. Disconnect the arm

from the housing.

5.
Remove the nut and bolt that se-

cures the upper arm to the crossmem-

ber and remove the arm.

Installation

1.
Hold the upper arm in place on

the crossmember and install a new at-

taching bolt, a new lockwasher and a

new nut. Do not tighten the nut at this

time.

2.
Secure the upper arm to the axle

housing with a new attaching bolt,

two washers and a new nut. Do not

tighten the nut at this time.

3.
Install alignment spacers be-

tween the rear axle housing and

frame.

4.
Connect the track bar to the

frame bracket with a new nut and

bolt. Torque the nut to specifications.

5.
Torque the upper arm front nut

to specification. Remove the align-

ment spacers and the jack stands.

6. Adjust the pinion angle and tor-

que the rear nut to specification.

7.
Lower the vehicle.

TRACK BAR

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK HI

1.
Raise the vehicle on an axle con-

tact hoist.
FRONT PIVOT BOLT
LOWER ARM
REAR PIVOT BOLT NUT

F1439-A

FIG. 33—Rear Suspension Lower Arm Installed

Tool-T64K-5781-B4 (Thrust
Washer)

FIG. 34—Rear Spring Front Bushing Removal—Typical
F 1485. A

2.
Remove rubber cover at axle at-

tachment on track bar.

3.
Remove the nut and washer at-

taching the track bar to the upper arm

bracket and disengage the track bar

from the mounting stud (Fig. 33).

4.
Remove the nut and bolt attach-

ing the track bar to the frame side rail

and remove the track bar.

5.
Position the track bar to the

frame side rail and install a new at-

taching bolt and new nut.

6. Position the track bar on the

upper arm bracket mounting stud and

install a new washer and a new at-

taching nut. Torque the track bar at-

taching bolt and nuts to specification

(Part 3-13). Lubricate rubber cover

with synthetic rubber lubricant and in-

sert over end of stud onto washer.

Then, lower the vehicle.
REAR SPRING AND/OR BUSHING

COUGAR, FAIRLANE,

FALCON, MONTEGO,

MUSTANG

Removal

1.
Raise the vehicle on a hoist and

place supports beneath the underbody

and under the axle.

2.
Disconnect the lower end of the

shock absorber from the spring clip

plate and push the shock out of the

way. Remove the supports from under

the axle.

3.
Remove the spring clip plate

nuts from the U-bolts; then, remove

the plate (Fig. 31). Raise the rear axle

just enough to remove the weight from

the spring.

4.
Remove the two attaching nuts,

and rear shackle bar, and the two

shackle inner bushings.procarmanuals.com

03-07-06
Ford Design Non-Integral Power Steering System

03-07-06

VALVE HOUSING

VALVE SPOOL

G
1659-
A

FIG. 70—Inserting Valve Spool

13.
Pick up the housing, and slide

the spool back and forth in the hous-

ing to check for free movement.

14.
Place the valve sleeve on the

housing so that the ball stud is on the

same side of the housing as the ports

for the two power cylinder lines. In-

stall the two bolts in the sleeve, and

torque them to specifications.

15.
Place the adapter on the cen-

tering spring end of the housing, and

install the bushing, washers, spacers,

and centering spring on the valve

spool bolt.

16.
Compress the centering spring,

and install the nut on the bolt. Tight-

en the nut snug (90-100 in-lbs); then

loosen it not more than 1/4 turn (Fig.

11).
Make sure that the nut turns (90

degrees) on the threads of bolt. Exces-

sive tightening of the nut may break

the stop pin at the travel regulator

stop.

TIGHTEN NUT SNUG

(90-100 IN -LBS) THEN

LOOSEN % TURN ON

THREADS OF BOLT

ADJUSTING

NUT

CENTERING SPRING

ADAPTER

G 1034 -C

FIG. 11—Adjusting Centering

Spring

17.
Move the ball stud back and

forth in the sleeve slot to check the

spool for free movement. See Part

3-13 for the specified travel. Apply
COAZ-19553-A (silicone) grease at

the sealing areas.

18.
Lubricate the two cap attaching

bolts.
Install the centering spring cap

on the valve housing, and torque the

two cap bolts to specification.

19.
Install the nut on the ball stud

so that the valve can be positioned in

a vise as shown in Fig. 12. Then push

forward on the cap end of the valve to

check the valve spool for free move-

ment.

20.
Turn the valve around in the

vise,
and push forward on the sleeve

end to check the spool for free move-

ment.

PUSH FORWARD TO CHECK

VALVE SPOOL MOVEMENT

G 1660-A

FIG. 12—Inspecting Valve Spool

Movement

POWER CYLINDER SEAL

REMOVAL

1.
Clamp the power cylinder in a

vise,
and remove the snap ring from

the end of the cylinder. Be careful not

to distort or crack the cylinder in the

vise.

2.
Pull the piston rod out all the

way to remove the scraper, bushing,

and seals. If the seals cannot be re-
moved in this manner, remove them

from the cylinder with a sharp pick.

Take care, when using a pick, not to

damage the shaft or seal seat.

INSTALLATION

When replacing the power cylinder

seals,
install all of the parts supplied

in the repair kit for the cylinder being

repaired.

1.
Coat the new seals with lubricant

COAZ-19553-A and place the parts

(Fig. 13) on the piston rod which has

been coated with the same grease.

2.
Push the rod in all the way, and

install the parts in the cylinder with a

deep socket slightly smaller than the

cylinder opening (Fig. 14).

15/16"
O.D. X6" STEEL

ELECTRICAL CONDUIT

POWER

CYLINDER

G 1662-A

FIG. 14—Installing Power

Cylinder Seals

POWER STEERING PUMP

RESERVOIR REPLACEMENT

Refer to Group 3-10, Section 3 for

detailed instructions.

INSERT

RUBBER WIPER

SCRAPER

SEATS'

FIG. 73—Power Cylinder
SNAP RING

G 1661-Aprocarmanuals.com

03-08-08
Ford Design Integral Power Steering Gear

03-08-08

LONG END

AWAY FROM

SEAL
Press Ram

G1375-A

FIG. 15— Installing Sector Shaft

Outer Seal

1.
Mount the valve housing in the

holding fixture with the flanged end

up.

2.
Place the required thickness

valve spool centering shim (Fig. 6) in

the housing. Use one shim only.

3.
Carefully install the worm and

valve in the housing.

4.
Install the attaching nut in the

housing and torque it to specification

(Part 3-13).

5.
Install the lock nut (Fig. 7) and

torque it to specification (Part 3-13).

6. Place the piston on the bench

with the ball guide holes facing up.

Insert 44ie worm shaft into the piston

so that the first groove is in alignment

with the hole nearest to the center of

the piston (Fig. 16).

7.
Place the ball guide in the pis-

ton. Place the 27 balls in the ball

guide (Fig. 16) turning the worm in a

clockwise direction as viewed from the

input end of the shaft. If all of the

balls have not been fed into the guide

upon reaching the right stop, rotate

the input shaft in one direction and

then in the other while installing the

balls.
After the balls have been in-

stalled, do not rotate the input shaft
FIRST GROOVE OF WORM SHOULD BE IN

ALIGNMENT WITH THIS HOLE

G1554-A

FIG. 16—Assembling Piston on Worm Shaft

INPUT SHAFT

SECTOR
SHAFT

ADJUSTMENT
SCREW

G1547-A

FIG. 77—Adjusting Mesh

or the piston more than 3 1/2 turns

off the right stop to prevent the balls

from falling out of the circuit.

8. Secure the guides in the ball nut

with the clamp (Fig. 6).

9. Position a new lube passage O-

ring in the counterbore of the gear

housing.
10.
Apply vaseline to the teflon seal

on the piston.

11.
Place a new O-ring on the valve

housing.

12.
Slide the piston and valve into

the gear housing being careful not to

damage the teflon seal.

13.
Align the lube passage in the

valve housing with the one in the gear

housing, and install but do not tighten

the attaching bolts.

14.
Rotate the ball nut so that the

teeth are in the same plane as the sec-

tor teeth. Tighten the four valve hous-

ing attaching bolts to specifications.

15.
Position the sector shaft cover

O-ring in the steering gear housing.

Turn the input shaft as required to

center the piston.

16.
Apply vaseline to me sector

shaft journal then position the sector

shaft and cover assembly in the gear

housing. Install the steering identifica-

tion tag and two sector shaft cover at-

taching bolts. Torque the bolts to spe-

cifications.

17.
Attach an in-lb torque wrench

to the input shaft. Adjust the mesh

load to specifications as shown in Fig.

17.procarmanuals.com