air suspension 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

03-01-04

Suspension — Steering, Wheels And Tires — General Service

03-01-04

Tool
- T 65 P -
3000
B or C

1266-B

FIG. 5—Typical Rear Alignment

Spacer Installation—Cougar,

Fairlane, Falcon, Montego,

Mustang

ment. In the absence of such equip-

ment, portable equipment may be

used and the work may be performed

on a level floor. The floor area should

be level within 1/4 inch from front to

rear of the vehicle and within 1/8 inch

from side to side. Alignment height

spacers (Figs. 4, 8 and 9) are used to

check caster and camber. The spacers

should be omitted when checking toe-

in.

1.
Check the runout of each front

wheel and tire using a dial indicator

against the rim outer band. If the ru-

nout exceeds 1/8 inch, correction may

be made by rotating the wheel on the

drum. When the minimum runout has

been obtained, mark the point of

greatest runout so the wheels can be

positioned as shown in Fig. 10 when

checking the front end alignment.

Hold a piece of chalk against the

wheel rim or the tire sidewall while

spinning the wheels. The chalk will

mark the rim or tire at the point of

greatest runout.

2.
Drive the vehicle in a straight

line far enough to establish the

straight ahead position of the front

wheels, and then mark the steering

wheel hub and the steering column

collar (Fig. ll).Do not adjust the

steering wheel spoke position at this

time. If the front wheels are turned at

any time during the inspection, align

the marks to bring the wheels back to

the straight-ahead position.

3.
With the vehicle in position for

the front end alignment inspection and

adjustment, install the suspension

alignment spacers as follows to esta-

blish the curb height.
F1432-A

FIG. 6—Alignment Spacer

Installation—Rear—Ford,

Mercury, Meteor, Thunderbird,

Continental Mark III

|F1258-Af

FIG. 7— Alignment Spacer

Installation — Rear Lincoln Continental

Tool-T65P-3000-B or -C

F1431-A

FIG. 8—Alignment Spacer

Installation—Front—Ford,

Mercury, Meteor, Thunderbird,

Continental Mark III
F 1499-A

FIG. 9—Alignment Spacer

Installation—Front—Lincoln

Continental

CHALK MARK IN THIS POSITION

WHEN CHECKING TOE-IN AND TOE-OUT

ON TURNS

CHALK MARK IN THIS POSITION

WHEN CHECKING CASTER AND CAMBER

LOCATION OF POINT OF GREATEST

LATERAL RUN-OUT ON FRONT

WHEaS WHEN CHECKING

ALIGNMENT FACTORS

F1215-A

FIG. 70—Front Wheel Position

For Checking Alignment

Lift the front of the vehicle and

position the alignment spacers be-

tween the suspension lower arm and

the frame spring pocket as shown in

Figs.
4, 8 and 9. Be sure the spacer

pin is placed in the correct hole for

the vehicle being checked. The lower

end of the alignment spacers should

be placed over the head of the strut

front attaching bolt. Remove the

bumpers from the right and left rear

side rails. Position the rear alignment

spacers between the rear axle and the

rear side rails as shown in Figs. 5, 6

and 7.

4.
Install the wheel alignment

equipment on the vehicle. Whicheverprocarmanuals.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

03-01-06
Suspension — Steering, Wheels And Tires — General Service

03-01-06

SUSPENSION UPPER

ARM MOVEMENT

Front Bolt Outboard

Rear Bolt Outboard

Front Bolt Inboard

Rear Bolt Inboard
CASTER CHANGE

Tilt Backward

Increase Positive Caster

or

Decrease Negative Caster

Tilt Forward

Decrease Positive Caster

or

Increase Negative Caster

Tilt Forward

Decrease Positive Caster

or

Increase Negative Caster

Tilt Backward

Increase Positive Caster

or

Decrease Negative Caster
CAMBER CHANGE

Tilt Outward

Increase Positive Camber

or

Decrease Negative Camber

Tilt Inward

Decrease Positive Camber

or

Increase Negative Camber

FIG. 14—Caster and Camber Adjustments

sary. Then, tighten the upper arm

inner shaft attaching bolts to specifi-

cation. Remove the adjusting bar

(Tool T65P-3OOO-D) and the align-

ment spacers (Tool T65P-3O00-E or

F).

Camber

To adjust the camber angle, install

the tool as outlined above (Fig. 13).

Loosen both inner shaft attaching

bolts and tighten or loosen the hook

nuts to move the inner shaft inboard

or outboard as necessary with Tool

T65P-3OOO-D to increase or decrease

camber (Fig. 13). The camber angle

can be checked without tightening the

inner shaft attaching bolts.

COUGAR, FAIRLANE, FALCON,

MONTEGO, MUSTANG

Be sure all the equipment listed in

Equipment Installation is installed be-

fore adjusting the caster and camber.

Caster is controlled by the front

suspension strut (Fig. 15). To obtain

positive caster, loosen the strut rear

nut and tighten the strut front nut

against the bushing. To obtain nega-

tive caster, loosen the strut front nut

and tighten the strut rear nut against

the bushing.

Camber is controlled by the eccen-

tric cam located at the lower arm at-

tachment to the side rail (Fig. 13).

To adjust the camber, loosen the

camber adjustment bolt nut at the

rear of the body bracket. Spread the

body bracket at the camber adjust-
TER ADJUSTMENT NUTS

EAR INSULATOR

WASHER
FRONT ADJUSTMENT NUT

INNER SLEEVE

TURN NUTS

REARWARD

TO OBTAIN

POSITIVE

CASTER
OUTER SLEEVE

RONT INSULATOR

WASHER

CASTELLATED

NUT

TURN NUTS

FORWARD

TO OBTAIN

NEGATIVE

CASTER

NEGATIVE

CAMBER

SPREAD THIS MEMBER AT

LOWER ARM PIVOT

BUSHING

PRY AT THESE POINTS'

F1371-A

FIG. J5—Caster and Camber Adjustments

ment bolt area just enough to permit

lateral travel of the arm when the ad-

justment bolt is turned. Rotate the

bolt and eccentric clockwise from the

high position to increase camber or

counterclockwise to decrease camber.

After the caster and camber has

been adjusted to specification, torque

the lower arm eccentric bolt nut and

the strut front nut to specification.
LINCOLN CONTINENTAL

Preliminary Steps

1.
With the car properly positioned

and wheel alignment measuring equip-

ment properly installed, raise the hood

and scribe chalk marks around the

bolts and lock washers that secure theprocarmanuals.com

03-01-08
Suspension
—
Steering,
Wheels
And
Tires
—
General Service

03-01-08

3.
Remove the lower (upper on

Mustang and Cougar) cover- to-

housing attaching bolt.

4.
With a clean punch or like in-

strument, clean out or push inward

the loose lubricant in the filler plug

hole and cover to housing attaching

bolt hole.
5.
Slowly turn the steering wheel to

the left stop, lubricant should rise

within the lower cover bolt hole; then

slowly turn the steering wheel to the

right stop, lubricant should rise within

the filler plug hole. If lubricant does

not rise in both the cover bolt hole
and the filler plug hole, add lubricant

until it comes out both holes during

this check.

6. Install the lower (upper on

Mustang and Cougar) cover- to-

housing attaching bolt and the filler

plug.

CLEANING
AND
INSPECTION

FRONT
END
GENERAL

INSPECTION

Do not check and adjust front

wheel alignment without first making

the following inspection for front-end

damage, or wear.

1.
Check for specified air pressures

in all four tires.

2.
Raise the front of the vehicle off

the floor. Shake each front wheel

grasping the upper and lower surfaces

of the tire. Check the front suspension

ball joints and mountings for loose-

ness,
wear, and damage. Check the

brake backing plate mountings. Tor-

que all loose nuts and bolts to specifi-

cation. Replace all worn parts as out-

lined in Part 3-2.

3.
Check the steering gear mount-

ings and all steering linkage connec-

tions for looseness. Torque all mount-

ings to specifications. If any of the

linkage is worn or bent, replace the

parts as outlined in Part 3-5.

4.
Check the front wheel bearings.

If any in-and-out free play is noticed,

adjust the bearings to specifications.

Replace worn or damaged bearings as

outlined in Part 3-12.

5.
Spin each front wheel with a

wheel spinner, and check and balance

each wheel as required.

6. Check the action of the shock

absorbers. If the shock absorbers are

not in good condition, the vehicle may

not settle in a normal, level position,

and front wheel alignment may be af-

fected.

WHEEL INSPECTION

Wheel hub nuts should be inspected

and tightened to specification at pre-

delivery. Loose wheel hub nuts may

cause shimmy and vibration. Elongat-

ed stud holes in the wheels may also

result from loose hub nuts.

Keep the wheels and hubs clean.

Stones wedged between the wheel and

drum and lumps of mud or grease can

unbalance a wheel and tire.
Check for damage that would affect

the runout of the wheels. Wobble or

shimmy caused by a damaged wheel

will eventually damage the wheel bear-

ings.
Inspect the wheel rims for dents

that could permit air to leak from the

tires.

UPPER BALL JOINT

INSPECTION

Ford,
Mercury,
Meteor,

Thunderbird,

Lincoln Continental
and

Continental Mark
III

1.
Raise the vehicle and place floor

jacks beneath the lower arms.

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 upper end of the

spindle and the upper arm.

4.
Any movement between the

upper end of the spindle and the upper

arm indicates ball joint wear and loss

of preload. If any such movement is

observed, replace the upper ball joint.

During
the
foregoing
check,
the

lower ball joint will
be
unloaded
and

may
move.
Disregard
all
such
move-

ment
of the
lower ball
joint.
Also,
do

not mistake loose wheel bearings
for a

worn ball
joint.

Cougar,
Fairlane,
Falcon,

Montego
and
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 as

shown in Fig. 18. This will unload the

upper ball joint.

2.
Adjust the wheel bearings as de-

scribed in Part 3-12.

3.
Attach a dial indicator to the

upper arm and position the indicator
so that the plunger rests against the

inner side of the wheel rim adjacent to

the upper arm ball joint.

4.
Grasp the tire at the top and

bottom, and slowly move the tire in

and out (Fig. 18). Note the reading

(radial play) on the dial indicator. If

MAXIMUM TOLERANCE

F
1500-A

FIG.
T8—Measuring Upper Ball

Joint Radial Play

MAXIMUM TOLERANCE

F14
35-A

FIG.
79—Measuring Lower Ball

Joint Radial Playprocarmanuals.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

03-01-10
Suspension — Steering, Wheels And Tires — General Service

03-01-10

The following procedure should be

followed when cleaning the relief valve

which is a part of the pump valve as-

sembly.

1.
Using a punch or rod of suitable

diameter, apply an even pressure in a

straight line to the tip of the relief

valve pin (Fig. 20). Depress the valve

two or three times to exhaust the oil

which is trapped in the assembly. Do

not hammer on the valve pin or hous-

ing.

2.
Submerge the assembly in a con-

tainer of clean solvent. Again applying

an even pressure to the tip of the relief

valve pin, (a sudden strong force could

push the pin through the relief valve

spool) move the valve in and out sev-

eral times, thereby thoroughly flushing

the assembly. Pressure created within

the valve bore when the valve is moved

inward should force the cleaning fluid

out through the sensing orifice. If this

does not occur, the sensing orifice

should be cleaned with a piece of wire.

The valve must move freely and even-

ly. If the pin is bent or damaged, or if

the valve binds, the pump valve must

be replaced.

INSPECTION

The following describes the compo-

nents of the power steering pump

which must be replaced regardless of

condition and how to determine when

other components should be replaced.

The outlet fitting hex nut may be

reused if the corners of the hex are

not rounded. The housing bolts may

be reused if the threads are not dam-

aged.

All gaskets and seals must be re-

placed with new components except

the rotor shaft seal which should be

reused unless it was leaking.

The reservoir assembly may be

reused if the reservoir seal and gasket

areas are not damaged (dents, scratch-

es,
etc.). The soldered joints of the re-

turn and fill tubes must not be loose

or bent. Be sure to check for a broken

baffle.

The housing or housing assembly

may be reused if there is no damage

(scratches, etc.) at reservoir gasket,

outlet fitting or cover seal areas.

If the outlet fitting is damaged, the

pump housing must be replaced. The

pressure plate springs may be reused

providing they are not bent, broken or

have not taken a set.

Do not reuse the retainer end plate

if it is burred or damaged. The upper

pressure plate may be reused if there

is no scoring on the wear surface. It is

acceptable to polish the phosphate

coating.
The rotor and cam assembly can be

reused if there is no wear other than

the removal of the phosphate coating

on the cam contour. Do not disas-

semble the rotor and cam assembly.

Push the rotor part way out the cam

insert taking care not to let the slip-

pers and springs fall out. Check the

cam ID for scoring and burning.

Check the rotor faces and OD for

scoring and chipping. Do not attempt

to repair or refinish the lower and

upper pressure plates, cam or rotor

assembly. When wear or burning is

encountered, replace, them with new

components.

Install a new rotor and cam assem-

bly if the slippers are worn. Replace

the springs if they are bent or broken.

Polishing the phosphate coating of the

slipper sealing surface is permissable.

The rotor shaft can be reused if the

front and rear thrust faces, the bush-

ing diameter and the shaft seal diame-

ter are not excessively worn or scored.

The housing plate and bushing as-

sembly may be reused if all of the

threaded holes are not damaged

beyond repair and the bushing diame-

ter is not scored or worn .0005 inch

over the maximum dimension of .6897

inch. Threaded holes can be repaired

by drilling out the damaged threads

and installing a helicoil insert. If the

bushing is scored or excessively worn,

a new plate and bushing assembly

must be installed.

With Tool T69P-3D608-A (using a

dial indicator) check the squareness of

the fixed dowel pin in the plate (Fig.

21).
The pin must be square with the

adjacent surface within .001 inch per

inch through a 180 degree arch.

A bent or broken dowel pin can be

replaced as follows:
1.
Hold the plate assembly in a

horizontal position and grip at least

an inch of the dowel pin in a vise. Tap

the plate with a plastic or a rubber

hammer to pull the pin from the

plate.

2.
Insert the support guide (Tool

T69P-3D608-B) over a dowel pin (Fig.

22) and press the pin into the plate to

a height of 1.68 inch (See Fig. 23).

The support guide tool will serve as a

stop guide. Be careful not to bend the

new dowel pin during installation.

3.
Again use Tool T69P-3D608-A

(with a dial indicaator) to check the

dowel pin squareness as outlined

above.

POWER STEERING PUMP

INSPECTION—LINCOLN

CONTINENTAL AND

CONTINENTAL MARK III

1.
Wash all parts in clean solvent

and dry them with clean cloths or

compressed air.

2.
Inspect the rotor shaft for wear,

scoring, nicks, or burrs. Replace the

shaft if it is damaged or if the inner

keyway is damaged.

Tool
T69P-3D608-B

G1609-A

FIG. 22—Dowel Pin Insertion

Tool
T69P-3D608-A

G1608-A

FIG. 21—Dowel Pin Squareness

Check
FIG. 23 — Replacing Dowel Pinprocarmanuals.com

03-01-11
Suspension — Steering, Wheels And Tires — General Service

03-01-11

3.
Inspect the rotor, rollers, cam

ring, pressure plate, cover, and bush-

ing in the pressure plate for wear or

scoring. If damaged, replacement of

the pump (less housing) is required.

4.
Make sure the inner faces of the

cover and the housing are free of

paint, nicks, or burrs. Check all fluid

passages for restrictions.

5.
Inspect the valving surfaces

(areas where the rotor and rollers con-

tact) for wear or scoring. Replace the

pressure plate or the cover if worn or

scored. Inspect the bushing in the

pressure plate for wear or scoring, and

replace the plate if necessary.

6. Inspect the control valve for

scores, nicks, or burred edges. Re-

place the valve if damaged. Do not dis-

assemble the valve. Check the valve

for free movement in the housing

bore.

7.
Inspect the tube seat in the hous-

ing. If damaged, remove it with an

E-Z-Out and install a new seat.

SHOCK ABSORBER CHECKS

All vehicles are equipped with hy-

draulic shock absorbers of the direct-

acting type and are nonadjustable and

nonrefillable. They cannot be repaired.
Before replacing a shock absorber,

check the action of the shock absor-

bers as follows:

ON VEHICLE TESTS

1.
Check the shock absorber to be

sure it is securely and properly in-

stalled. Check the shock absorber in-

sulators for damage and wear.

Replace any defective insulators and

tighten attachments to the specified

torque (on a shock absorber which in-

corporates integral insulators, replace

the shock absorbers).

2.
Inspect the shock absorber for

evidence of fluid leakage. A light film

of fluid is permissible. Be sure any

fluid observed is not from sources

other than the shock absorber.

Replace the shock absorber if leak-

age is severe.

3.
Disconnect the lower end of the

shock absorber. Extend and compress

the shock absorber as fast as possible,

using as much travel as possible.

Action should become smooth and

uniform throughout each stroke.

Higher resistance on extension than

on compression is a normal condition.

Faint swish noises are also normal.

Remove the shock absorber for a

bench test if action is erratic. If the
action is smooth, but the shock absor-

bers are suspected of being weak fol-

low step 4:

4.
Repeat step 3 on the mating

shock absorber installed on the oppo-

site side of the vehicle, and compare

results of both tests. If the action is

similar, it is unlikely that either shock

absorber is defective. Reconnect both

shock absorbers.

Replace the shock absorber having

the lower resistance. Ensure that the

part number of the replacement is the

same as that of the original shock ab-

sorber. The replacement shock absor-

ber resistance will appear to be higher

than either original due to initial fric-

tion of the rod seal.

BENCH TEST

With the shock absorber right side

up (as installed in vehicle), extend it

fully. Then turn the shock absorber

upside down and fully compress it.

Repeat this procedure at least three

times to ensure that any entrapped air

has been expelled. Now place the

shock absorber right side up in a vise,

and hand stroke the shock absorber as

described in On Vehicle Tests, step 3.

If action is not now smooth and uni-

form, install a new shock absorber.procarmanuals.com