automatic transmission FORD MUSTANG 1969 Volume One Chassis

01-01-02
Vehicle Identification
01-01-02

VEHICLE WARRANTY NUMBER

The vehicle warranty number is the first line of numbers and

letters appearing on the Warranty Plates (Fig. 1). The Warranty

Plate is riveted to the left front door lock face panel. The first

number indicates the model year. The letter following the model

year number indicates the manufacturing assembly plant. The next

two numbers designate the Body Serial Code followed by a letter

expressing the Engine Code. The group of six digits remaining on

the first line indicate the Consecutive Unit Number.

VEHICLE DATA

The vehicle data appears on the second or lower line on the

Warranty Plate. The first two numbers and a letter identify the

Body Style. A letter or a number appears next indicating the

Exterior Paint Color followed by a number-letter combination

designating the Interior Trim. To the right of this code appears the

Date Code indicating the date the car was manufactured. A two-

digit number next designates the district in which the car was

ordered and may appear in conjunction with a Domestic Special

Order or Foreign Special Order number when applicable. The final

two spaces indicate the Rear Axle Ratio (numbers for regular axles,

letters for locking-types) and the Transmission type (numbers for

manual,
letters for automatic).

OFFICIAL VEHICLE IDENTIFICATION NUMBER

The official Vehicle Identification Number (VIN) for title and

registration purposes is stamped on an aluminum tab that is riveted

to the instrument panel close to the windshield on the driver's side

of the car and is visible from outside (Fig. 2).

MODEL YEAR CODE

The number 9 designates 1969.

ASSEMBLY PLANT CODES
COUGAR

Code

Letter
Code

Letter

A

B

C

D

E

F

G

H

J

K
Atlanta
L

Oakville (Canada)
N

Ontario Truck
P

Dallas
R

.,
Mahwah
S

Dearborn
T

Chicago
U

Lorain
W

Los Angeles
X

Kansas City
Y

Z
Michigan Truck

Norfolk

Twin Cities

San Jose

.
(Pilot). ...Allen Park

Metuchen

Louisville

Wayne

St. Thomas

Wixom

St. Louis

BODY SERIAL AND STYLE CODES

The two-digit numeral which follows the assembly plant code

identifies the body series. This two-digit number is used in con-

junction with the Body Style Code, in the Vehicle Data, which

consists of a two-digit number with a letter suffix. The following

chart lists the Body Serial Codes, Body Style Codes and the model.

LINCOLN CONTINENTAL

Body Body

Serial Style

Code Code Body Type

82
53A
4-Door Sedan

80
65A
2-Door
Hardtop

CONTINENTAL MARK
III

Body Body

Serial Style

Code Code Body Type

89
65A
2-Door
Hardtop
Body

Serial

Code

91

92

93

94

91
Body

Style

Code

65A

76A

65B

76B

65C

® Bench Seat

MERCURY

Body

Serial

Code

44

46

48

45

40

41

42

54

56

58

63

66

68

65

63

66

68

60

61

72

72

74

74

76

76
Body

Style

Code

54A

65A

57A

76A

53M

65M

57M

54C

65B

57B

53F

65F

57 F

76F

53C

65C

57C

63G

63H

71B

71C

71F

71G

71E

71A

©Bench Seat
Body
Type

2-Door
Hardtop©

Convertible©

2-Door
Hardtop©

Convertible®

2-Door
Hardtop®
Model

Standard

XR-7 Luxury

Standard

©Split Bench ©Bucket Seats

Body Type

4-Door Sedan©

2-Door
Hardtop-Formal®

4-Door Hardtop®

Convertible®

CANADA ONLY

4-Door Hardtop Sedan®

2-Door
Hardtop-Formal®

4-Door Hardtop®

4-Door Sedan®

2-Door
Hardtop-Formal®

4-Door Hardtop®

4-Door Hardtop Sedan®©

2-Door
Hardtop-Formal®©

4-Door Hardtop®®

Convertible®®

4-Door Hardtop Sedan©

2-Door
Hardtop-Formal©

4-Door Hardtop©
Model

Monterey

Marquis

Monterey-Custom

Marquis

Brougham (Option)

2-Door
Hardtop (Tunnel Roof)®© Marauder

2-Door
Hardtop (Tunnel Roof)®®©

4-Door 2 Seat®

4-Door 3 Seat (Side Facing)®

4-Door
2
Seat®

4-Door 3 Seat (Side Facing)®

4-Door 2 Seat®©

4-Door 3 Seat (Side Facing)®©
Monterey Wagoi

Monterey-Custom Wagon

Marquis Colony Park

©Split Bench ©Bucket Seats

METEOR (CANADA)

Body

Serial

Code

20

21

23
Body

Style

Code

54A

54B

65B
Body Type

4-Door Sedan®

4-Door Sedan®

2-Door
Hardtop-Formal®
Model

Rideau

Rideau 500

30
54C
4-Door Sedan®

35
65C
2-Door
Hardtop-Formal®

35
65E
2-Door
Hardtop-Formal{5-33)®®

33
57C
4-Door Hardtop®

34
76C
Convertible®

34
76E
Convertible (S-33)®®
Montcalm

24
65F
2-Door
Hardtop-Formal®©

27
57F
4-Door Hardtop®®
LeMoyne

28
71B
Rideau 500-6 Passenger®

29
71C
Rideau 500-Dual Face Rear®

38
71E
Mo ntcalm-6 Passenger®

39
71A
Montcalm-Dual Face Rear®
Station Wagons.

©Bench Seat ©Splite Bench ©Bucket Seatsprocarmanuals.com

01-01-04

Vehicle Identification
01-01-04

BODY SERIAL AND STYLE CODES-(continued)

FAIRLANE

Body

Serial

Code

30

31

34

35

33

36

35

33

36

40

41

42

44

43

42

44

43

46

46

45

45

32

37

38

47

48

48

49

49
Body

Style

Code

65A

54A

54B

63B

65B

76B

63E

65E

76E

65C

54C

63F

65F

76F

63D

65D

76D

63B

63E

65A

65E

71D

71B

71E

66A

66B

66B

(Opt.)

66C

66D

©Bench Seat
Body Type

2-Door
Hardtop-formal®

4-Door
Sedan®

4-Door
Sedan®

2-Door
Hardtop—Fastback®

2-Door
Hardtop-formal®

Convertible®

2-Door
Hardtop—Fastback©

2-Door
Hardtop-Formal©

Convertible®

2-Door
Hardtop-Formal®

4-Door
Sedan®

r t

2-Door
Hardtop—FastbackCD

2-Door
Hardtop-Formal®

Convertible®

2-Door
Hardtop—Fastback®

2-Door
Hardtop-Formal®

Convertible®

2-Door
Hardtop-Fastback®

2-Door
Hardtop-Fastback®

2-Door
Hardtop-Formal®

2-Door
Hardtop-formal®

Fairlane®

Fairlane 500®

Fairlane Torino Squire®

Ranchero®

Ranchero 500®

Ranchero 500®

Ranchero®

Ranchero®
Model

Fairlane

Fairlane 500

Fairlane 500

Torino

Torino GT

Torino GT

Cobra

Station Wagons-4 Door

Ranchero

Ranchero

Ranchero GT

©Split Bench ©Bucket Seats

REAR AXLE RATIO CODES

Conventional
Limited-Slip

Ratio

1
J
2.50:1

2
K
2.75:1

3
L
2.79:1

4
M 2.801

5
N
2.83:1

6
0
3.00:1

7
P
3.10:1

8
Q
3.20:1

9
R
3.25:1

A
S
3.50:1

B
T
3.07:1

C
U
3.08:1

D
V
3.91:1

E
W
4.30:1

TRANSMISSION CODES

Code Type

1
3-Speed
Manual

5 4-Speed Manual-wide ratio (2.78 1st Gear)

6 4-Speed Manual-close ratio (2.32 1st Gear)

W Automatic (C4) (XP-3)

U Automatic (C6) (XPL)

Y Automatic (MX)

X Automatic (FMX)

Z Automatic (C6 Special) (XPL, Special)®

©For Police & trailer towing
-
Not available with bucket seats
ENGINE CODES

Code

U
6Cyl.

T
6Cyl.

2
6 Cyl.®

L 6 Cyl.

3
6 Cyl CD

V
6
Cyl."

5
.
6 Cyl CD

B .6
Cyl.

E
6
Cyl.

F
8
Cyl.

6 8 Cyl.®

D 8
Cyl.

H 8 Cyl.

M 8 Cyl.

Y 8
Cyl.

X 8 Cyl.©

S 8 Cyl.©

P 8 Cyl.®

8 Cyl.

8 Cyl.®

K 8
Cyl.

N
8
Cyl.

A 8
Cyl.

©Low Compression

©High Performance
Type

170
Cu.
In.
(IV)

200
Cu.
In.
(IV)

200
Cu.
In.
(IV)

250
Cu.
In.
(IV)

250
Cu.
In.
(IV)

240
Cu.
In.
(IV)

240
Cu.
In.
(IV)

240 Cu. In. (IV) Police

240 Cu. In. (IV) Taxi

302
Cu.
In.
(2V)

302
Cu.
In.
(2V)

302 Cu. In. (2V) Police & Taxi

351
Cu.
In.
(2V)

351
Cu.
In.
(4V)

390
Cu.
In.
(2V)

390Cu.ln.(2V)

390
Cu.
In.
(4V)

428 Cu. In. (4V) Police Interceptor

428
Cu.
In.
(4V)
CJ

428
Cu.
In.
(4V)
CJ

429
Cu.
In.
(2V)

429
Cu.
In.
(4V)

460
Cu.
In.
(4V)

©Premium Fuel ©Improved Performance

©Ram Air Induction

CONSECUTIVE UNIT NUMBER

Starting Serial Numbers—1969 Passenger Cars

100,001—Ford, Fairlane, Falcon, Mustang, Thunderbird

500,001 -Mercury, Montego,
Cougar,
Meteor

848,000—Lincoln Continental & Continental Mark
III

EXTERIOR PAINT COLOR CODES

Code
Reference

Number
Color

A

B

c

D

E

F

G

H

|

J

K

L
. .

M

N

p

Q

R

S.
.. .

T

u

v

W

X

Y

z

2.
..

3

4

6.
. .

7

8
..
1724-A
1

3059-A

3197-A

3303-A

3191-A

3065-A
. .

3203-A

..
,.2067-A

2041-A

3080-A

3204-A

3060-A

1619-A
..

921-A

3064-A

1624-A

3198-A
. .

3199-A

2008-A

1070-A

3201-A

3120-A

3061-A
. . .

3202-A

2044-A

3071-A
. .

1730-A

3230-A

.
3077-A

3193-A

3190-A

..M6J-49B..

....M6J-50B.
Black

Maroon

Dk. Ivy Green Met.

Pastel Gray

Lt. Aqua

Dk. Aqua Met. (Brt.)

Med.
Orchid Met.

Lt. Green

Med.
Lime Met.

Dk. Aqua Met.

Dk. Orchid Met.

Lt. Gray Met.

White

Platinum

Med.
Blue Met.

Med.
Blue Met.

Lt. Gold

Med.
Gold Met.

Red

Med.
Aqua Met.

Lt. Aurora Copper IVIet.

Yellow

Dk. Blue Met.

Burnt Orange Met.

Dk. Grey Met.

Lt. Ivy Yellow

Calypso Coral

Med.
Emerald Met.

Med.
Blue Met. (Brt)

Lt. Emerald Green Met.

Lt. Blue

Red Primer

Grey Primerprocarmanuals.com

02-02-07
Brake System

02-02-07

ANTI-SKID CONTROL SYSTEM

RELEASE PAWL CAM PIN

RELEASE PAWL CAM LEVER

RELEASE CABLE

H
1636-
A

FIG. 10—Parking Brake Control Assembly

With Manual Release—Typical

power unit with mounting bracket is

riveted to the control assembly. The

vacuum actuated piston within the

unit is connected by a rod to the

upper end of the release lever (Fig. 9).

The lower end of the release lever ex-

tends out for alternate manual release
in the event of vacuum power failure

or for optional manual release at any

time.

Hoses connect the power unit and

the engine manifold to a vacuum re-

lease valve in the transmission neutral

safety switch.
The anti-skid control system con-

sists of three major components (Fig.

39).
Mechanically driven electromag-

netic sensors at each rear wheel; an

electronic control module mounted

under the glove box; a vacuum pow-

ered actuator attached to a bracket on

the inside of the right front frame rail

under the toe board.

The sensors consist of steel rings

having teeth on their outer diameters,

pressed on each axle shaft just out-

board of the wheel bearing. The teeth

rotate past corresponding teeth on the

inside diameter of stationary steel

rings mounted in the bearing retain-

ers.
Also mounted in the retainers, are

ring-shaped permanent magnets and

coils of wire. Two wires from each

sensor connect the sensors to the con-

trol module.

The control module consists of solid

state electronic components sealed in

a container. It is connected to the sen-

sors and to a solenoid on the actuator.

The actuator is similar to a vacuum

brake booster and consists of three

parts.
A chamber divided by a vacuum

suspended diaphragm; a hydraulic cyl-

inder connected to the diaphragm; and

a solenoid connected electrically to the

control module.

IN-VEHICLE ADJUSTMENTS AND REPAIRS

After any brake service work, ob-

tain a firm brake pedal before moving

the vehicle. Riding the brake pedal

(common on left foot application)

should be avoided when driving the

vehicle.

BRAKE SHOE ADJUSTMENTS—

DRUM BRAKES

The hydraulic drum brakes are

self-adjusting and require a manual

adjustment only after the brake shoes

have been relined, replaced, or when

the length of the adjusting screw has

been changed while performing some

other service operation. The manual

adjustment is performed with the

drums removed, using the tool and the

procedure detailed below.

When adjusting the rear brake

shoes,
check the parking brake cables

for proper adjustment. Make sure that

the equalizer operates freely.
To adjust the brake shoes:

1.
Use Rotunda Tool HRE 8650,

(Fig. 11) to determine the inside diam-

eter of the drum braking surface.

2.
Reverse the tool as shown in Fig.

11 and adjust the brake shoe diameter

to fit the gauge. Hold the automatic

adjusting lever out of engagement

while rotating the adjusting screw, to

prevent burring the screw slots. Make

sure the adjusting screw rotates freely.

If necessary, lubricate the adjusting

screw threads with a thin, uniform

coating of MIC-100-A.

3.
Rotate Tool HRE 8650 around

the brake shoes to be sure of the set-

ting.

4.
Apply a small quantity of high

temperature grease to the points

where the shoes contact the backing

plate, being careful not to get the lu-

bricant on the linings.

5. Install the drums. Install Tinner-

man nuts and tighten securely.

6. Install the wheels on the drums
and tighten the nuts to specification.

7.
Complete the adjustment by

applying the brakes several times with

a minimum of 50 lbs pressure on the

pedal while backing the vehicle. After

each stop the vehicle must be moved

forward.

8. After the brake shoes have been

properly adjusted, check the operation

of the brakes by making several stops

while operating in a forward direction.

WHEEL CYLINDER REPAIR-

DRUM BRAKE

Wheel cylinders should not be di-

sassembled unless they are leaking or

unless new cups and boots are to be

installed. It is not necessary to remove

the brake cylinder from the backing

plate to disassemble, inspect, or hone

and overhaul the cylinder. Removal is

necessary only when the cylinder is

damaged or scored beyond repair.procarmanuals.com

02-02-21
Brake System

02-02-21

INSTALLATION

CLUTCH ASSIST

SPRING

MASTER CYLINDER

2140

FIG. 28 —Dual Master Cylinder Installation—

Non Power Brake—Mustang and Cougar

inch of the top of the dual reservoirs.

Use Ford Brake Fluid- Extra Heavy

Duty-Part Number C6AZ-19542-A

for all brake applications. The brake

fluid is colored blue for identification.

Do not mix low temperature brake

fluids with the specified fluid for the

brake system.

8. Bleed the dual-master cylinder

and the primary and secondary brake

systems. Centralize the pressure dif-

ferential valve. Refer to Hydraulic

System Bleeding and Centralizing of

the Differential Valve, Part 2-1, Sec-

tion 2 for the proper procedure.

9. Operate the brakes several times,

then check for external hydraulic

leaks.

DUAL MASTER CYLINDER-

POWER BRAKES

REMOVAL

1.
Remove the brake tubes from

the primary and secondary outlet

ports of the master cylinder (Figs. 29

thru 33).

2.
Remove the two nuts and two

lock washers attaching the master cyl-

inder to the brake booster assembly.

3.
Slide the master cylinder forward

and upward from the vehicle.
SHAFT

AUTOMATIC

TRANSMISSION

CLUTCH PEDAL

BUMPER STOP
H1638-A
1.
Before installing the mater cyl-

inder, check the distance t; m the

outer end of the booster ass;. ,ihi\

push rod to the master .>',nder

mounting surface. Turn the nu->h rod

adjusting screw in or out as required

to obtain the specified length. Refer to

Part 2-1, Section 2. Power Brake

Master Cylinder Push Rod Adjust-

ment for the proper procedure.

2.
Position the master cylinder as-

sembly over the booster push rod and

onto the two studs on the booster as-

sembly (Figs. 29 thru 37).

3.
Install the attaching nuts and

lock washers and torque them to spec-

ifications.

4.
Install the front and rear brake

tubes to the master cylinder outlet fit-

tings.

5.
Fill the master cylinder with the

specified brake fluid to within 1/4

inch of the top o\ the dual reservoirs.

Use Ford Brake Fluid Fxtra Heavy

Duty Part Number C6AZ-19542-A

(ESA-M6C25-A) for all brake appli-

cations. The extra htaw duty brake

fluid is colored blue for identification.

Do not mix low temperature brake

fluids with the specified fluids for the

disc brake svstem.

CLIP

W
'0 AIR CONDITIONING

BUSHING

SHAFT

BUSHING

BRAKE PEDAL

SPACER

H 1642-A

FIG. 29—Master Cylinder Installation-

Ford,
Mercury and Meteor
-Power Brake-procarmanuals.com

02-02-22
Brake System

02-02-22

BRAKE VACUUM BOOSTER -2005

AUTOMATIC I

TRANSMISSION

HAIR PIN RETAINER

330699-S2

SPACER

STOP LIGHT SWITCH-13480

STANDARD

TRANSMISSION
BUSHING
BUSHING

PUSH ROD

BRAKE PEDAL ASSEMBLY
CLUTCH

PEDAL

ASSEMBLY

H 1557-C

FIG. 30—Master Cylinder Installation—Power Brake-

Fairlane, Montego and Falcon

ASSIST

SPRING BRACKET CLUTCH ASSIST

\ SPRING

BRAKE PEDAL

SHAFT

CLUTCH

PEDAL

CLUTCH PEDAL

TO EQUALIZER ROD

HI643-
A

FIG. 31—Master Cylinder Installation-

Power Brake—Mustang and Cougar
6. Bleed the dual-master cylinder

and the primary and secondary brake

systems. Centralize the pressure dif-

ferential valve. Refer to H>draulic

System Bleeding and Centralizing of

the Differential Valve, Part 2-1, Sec-

tion 2 for the proper procedure.

7.
Operate the brakes several times,

then check for external hydraulic

leaks.

PRESSURE DIFFERENTIAL

VALVE AND PROPORTIONING

VALVE ASSEMBLY

REMOVAL

1.
Disconnect the brake warning

light wire from the pressure differen-

tial valve assembly switch (Figs. 17

thru 21). To prevent damage to the

brake warning switch wire connector,

expand the plastic lugs to allow re-

moval of the shellwire connector from

the switch body.

2.
Loosen the tube nuts connecting

the primary and secondary inlet and

outlet tubes at the pressure differential

valve assembly and remove the tubes.

3.
Remove the screw or screws re-

taining the pressure differential valve

assembly to the chassis and remove

the valve assembly.

4.
On disc brake equipped vehicles,

place the pressure differential valve

assembly and mounting bracket in a

vise.
Loosen the proportioning valve

tube nuts at the differential valve and

at the proportioning valve. Remove

the proportioning valve from the

mounting bracket.

5.
If the differential valve is to be

replaced, remove the brake warning

lamp switch and install the switch in

the new differential valve. The pres-

sure differential valve assembly, the

brake warning lamp switch, and the

proportioning valve are separate units

and each is serviced as a separate as-

sembly only.

INSTALLATION

1.
On disc brake equipped vehicles,

connect the proportioning valve inlet

and outlet tubes to the proportioning

valve and differential valve bodies.

Tighten the tube nuts to specification.

2.
Mount the pressure differential

valve assembly on the chassis and in-

stall the attaching screw or screws.

3.
Connect the primary and second-

ary inlet and outlet tubes to the pres-

sure differential valve assembly and

tighten the tube nuts to specifications.procarmanuals.com

02-02-26
Brake System

02-02-26

14.
Remove the clutch pedal assist

spring.

15.
On non-power brakes, remove

the retainer clip from the clutch and

brake pedal shaft, then remove the

clutch pedal and shaft assembly, the

brake pedal assembly, and the bush-

ings from the pedal support bracket.

On power brakes, remove the retainer

nut from the brake pedal shaft then

remove the pedal shaft, the brake

pedal assembly and the bushings from

the pedal support bracket.

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

bushings in their proper places on the

clutch and brake pedal assemblies.

2.
On non-power brakes, position

the brake pedal to the pedal support

bracket, then install the clutch pedal

and shaft assembly through the sup-

port bracket and brake pedal assem-

bly. On power brakes position the

brake pedal to the pedal support

bracket, then install the pedal shaft

and nut.

3.
Install the clutch pedal assist

spring and pivot the clutch pedal

against its bumper stop. Secure the

pedal to the stop with a small C-

clamp as shown in Figs. 28 and 31.

4.
Position the pedal support

bracket assembly to the dash panel,

and to the steering column retainer

studs.

5.
Align the pedal support bracket

holes with the holes in the dash panel

and install the two attaching sheet

metal screws. On power brakes install

the nuts on the brake booster studs.

6. Install the two cap screws at-

taching the pedal support bracket to

the upper cowl bracket.

7. Install the cap screw attaching

the pedal support bracket to the top

inner cowl bracket (Figs. 28 and 31).

8. Install the inner nylon washer,

the master cylinder push rod, and the

bushing on the brake pedal pin. Posi-

tion the stop light switch so that it

straddles the push rod with the switch

slot on the pedal pin and the switch

outer hole just clearing the pin. Slide

the switch completely onto the pin,

and install the outer nylon washer as

shown in Figs. 28 and 31. Secure

these parts to the pin with the
self-

locking retainer.

9. Connect the stop light switch

wires to the connector.

10.
Connect the clutch pedal-

to-equalizer rod to the clutch pedal

assembly with the bushing and the

spring clip retainer. Apply SAE 10
engine oil to the bushing. Remove the

C-clamp from the clutch pedal.

11.
Working from the engine side

of the dash panel, on non-power

brakes, install the two cap screws at-

taching the pedal support bracket to

the dash panel. Then install the two

screws attaching the master cylinder

to the dash panel. On power brakes

install the cap screws retaining the

brake booster to the dash panel.

12.
Install the steering column.

Refer to Part 3-4, Section 2 for pro-

cedure.

13.
Adjust the clutch pedal free

play (Group 5) to specification, if re-

quired.

14.
Check the Brake Pedal Free

Height and Travel Measurements

(Part 2-1, Section 1).

15.
Connect the ground cable to the

battery.

FAIRLANE, MONTEGO,

FALCON, MUSTANG

AND COUGAR-

AUTOMATIC TRANSMISSION

Removal

1. Disconnect the stop light switch

wires at the connector.

2.
Remove the self-locking pin and

slide the stop light switch off the

brake pedal pin just far enough for

the switch outer hole to clear the pin.

Then lower the switch away from the

pin. Slide the master cylinder or

booster push rod and the nylon wash-

ers and bushing off from the brake

pedal pin (Figs. 27, 28, 30 and 31).

3.
On all vehicles except Mustang

and Cougar with power brakes, re-

move the self-locking pin and washer

from the brake pedal shaft, then re-

move the shaft, the brake pedal as-

sembly and the bushings from the

pedal support bracket. On Mustang

and Cougar vehicles with power

brakes, remove the locknut and bolt

from the pedal. Remove the pedal as-

sembly from the support bracket (Fig.

3).

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

the bushings in their proper places on

the pedal assembly and pedal support

bracket (Figs. 27, 28, 30 and 31).

2.
Position the brake pedal assem-

bly to the support bracket, then install

the pedal shaft or bolt through the

support bracket and brake pedal as-

sembly. Install the retainer or locknut.
3.
Install the inner nylon washer,

the master cylinder or booster push

rod, and the bushing on the brake

pedal pin. Position the switch so that

it straddles the push rod with the

switch slot on the pedal pin, and the

switch outer hole just clearing the pin.

Slide the switch completely onto the

pin, and install the outer nylon washer

as shown in Figs. 27, 28, 30 and 31.

Secure these parts to the pin with the

self-locking pin.

4.
Connect the stop light switch

wires to the connector, and install the

wires in the retaining clip.

Check the Brake Pedal Free Height

and Travel Measurements, Part 2,

Section 1.

THUNDERBIRD
AND

CONTINENTAL MARK
III

Removal

1.
Loosen the booster mounting

nuts.

2.
Disconnect the stop light switch

wires at the connector.

3.
Remove the hairpin retainer.

Slide the stop light switch off from

the brake pedal pin just far enough

for
the
switch outer hole
to
clear
the

pin,
and then lift the switch straight

upward from the pin. Slide the master

cylinder push rod and the nylon wash-

ers and bushing off from the brake

pedal pin (Fig. 32).

4.
Remove the pivot bolt and nut

that holds the pedal to the pedal sup-

port bracket. Remove the brake pedal

assembly from the pedal support

bracket, and remove the bushings.

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

the bushings in their proper places on

the pedal assembly (Fig. 32).

2.
Install the brake pedal assembly

and bushings to the support bracket,

and then install the pivot bolt through

the support bracket and brake pedal

assembly. Install the pivot bolt nut

and torque to specifications.

3.
Install the inner nylon washer,

the master cylinder push rod, and the

bushing on the brake pedal pin. Posi-

tion the switch so that it straddles the

push rod with the switch slot on the

pedal pin and the switch outer hole

just clearing the pin. Slide the switch

completely onto the pin, install the

outer nylon washer as shown in Fig.

32.
Secure these parts to the pin with

the hairpin retainer.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

03-05-09

Steering Columns And Linkage

03-05-09

FAIRLANE, FALCON

AND MONTEGO

Removal

1.
Disconnect the battery cable

from the negative post.

2.
Disconnect the turn signal switch

wires at the connector.

3.
Disconnect the neutral start

siwtch (with automatic transmission)

and back-up light switch wires from

the switches.

4.
Disconnect the transmission con-

trol rod(s) from the lever(s) at the

lower end of the column.

5.
Remove the bolt that secures the

flex coupling to the steering gear (Fig.

12).
6. Remove the nuts and bolts that

secure the column retainer and seal at

the toe plate.

7.
Disconnect the nuts that secure

the column upper and lower brackets

to the brake pedal support bracket

and the dash panel.

8. Lift the column from the vehicle.

Installation

1.
Position the steering column in

the vehicle. Make sure that the wheels

are in the straight ahead position and

that the steering wheel spokes are in a

horizontal position when the flex cou-

pling engages the input shaft splines.

2.
Install but do not tighten the

nuts that secure the column upper and

lower brackets to the brake pedal sup-
port bracket and the dash panel.

Make certain the column is properly

positioned relative to the flex coupling

inpui shaft connection.

3.
Install and tighten the flex cou-

pling-to-steering gear attaching bolt.

4.
Tighten the nuts at the brake

pedal support bracket and the dash

panel.

5.
Install and tighten the nuts and

bolts that secure the column retainer

and seal at the toe plate.

6. Connect the transmission control

rod(s) to the lever(s) at the lower end

of the column.

7.
Connect the neutral start switch

(if so equipped) and back-up light

switch to their respective terminals.

8. Connect the turn signal switch

wires.

COLUMN UPPER \

BRACKET-3506 V

BRAKE PEDAL

SUPPORT BRACKET

TRIMSHROUD-3530

UPPER CLAMP-3507,

COLUMN LOWER

BRACKET-3R547

•
FLEXCOUPLING-3A525
^INTERMEDIATE

BRACKET-3676

VIEW AA

G1616-A

FIG. 11—Steering Column Installation—Ford, Mercury, Meteorprocarmanuals.com

03-05-15
Steering Columns And Linkage

03-05-15

SHIFT

TUBE
STEERING

COLUMN
TUBE
SELECTOR

I
LEVER
HUB

\
CENTERING

I
WASHER
QUADRANT

BEARING

UPPER

SNAP RING

TURN SIGNAL AND

EMERGENCY FLASHER

SWITCH

PLASTIC

CONDUIT

STEERING

SHAFT

CONNECTOR

FIG. 16—Typical Stationary Steering Column Disassembled—Standard Transmission
G 1494-A

SNAP RING
STEERING WHEEL-3600

SEAL - 7C102

BEARING -3517

SNAP RING

FLANGE -3511

SELECTOR BEZEL-

LEVER- 7210 ZtL

GEAR SHIFT LEVER

(FIRST
&

REVERSE)
/
7303
/ 9

WASHER - 7242

BUSHING - 733

- 7347

UPPER CLAMP-01698
GEARSHIFT LEVER

(SECOND & THIRD) - 7302

SEAL-

LOWER CLAMP - 01699
^^r**——
FLEX JOINT - 3A525

FIG. 17—Typical Stationary Steering Column Disassembled—Automatic Transmission
G1501-Aprocarmanuals.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