key FORD MUSTANG 1969 Volume One Chassis
[x] Cancel search | Manufacturer: FORD, Model Year: 1969, Model line: MUSTANG, Model: FORD MUSTANG 1969Pages: 413, PDF Size: 75.81 MB
Page 74 of 413
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
Page 75 of 413
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
Page 94 of 413
03-02-18
Suspension
03-02-18
5.
Remove the cotter pin from the
upper ball joint stud nut.
6. Loosen the upper ball joint stud
nut one or two turns. Do not remove
the nut from the stud at this time.
7.
Install tool T57P-3006-A be-
tween the upper and lower ball joint
studs with the adapter screw on top
(Fig. 13). The tool should be seated
firmly against the ends of both studs
and not against the nuts or lower stud
cotter pin.
8. With a wrench, turn the adapter
screw until the tool places the stua
under tension. Tap the spindle near
the upper stud with a hammer to loos-
en the stud in the spindle. Do not
loosen the stud from the spindle with
tool pressure only.
9. Remove the tool from between
the ball joint studs and place a floor
jack under the lower arm.
10.
Raise the floor jack to relieve
the pressure from the upper ball joint
stud nut and remove the nut.
11.
Remove the upper arm inner
shaft attaching bolts. Remove the
upper arm and inner shaft as an as-
sembly (Fig. 1).
12.
Remove the bumpei from the
upper arm.
Installation
1.
Position the bumper to the upper
arm and install the nut and washer.
Torque the nut to specifications.
2.
Position the upper arm inner
shaft to the frame side rail and install
the 2 attaching bolts and washers
snug.
3.
Connect the upper ball joint stud
to the spindle and install the attaching
nut. Torque the nut to specification
and continue to tighten the nut until
the cotter pin hole in the stud is in
line with the nut slots. Then, install
the cotter pin.
4.
If equipped with drum type bra-
kes—Adjust the brakes as outlined in
Part 2-2. Install the wheel, tire, and
drum to the spindle and adjust the
wheel bearings as outlined in Part
3-12.
5.
If equipped with disc brak-
es—Install the wheel and tire on the
hub and adjust the wheel bearings as
outlined in Part 3-12.
6. Install the hub cap or wheel
cover.
7.
Remove the safety stands and
lower the front of the vehicle.
8. Check caster, camber, and toe-in
and adjust as required (Section 2, Part
3-D.
COUGAR, FAIRLANE,
FALCON, MONTEGO,
MUSTANG
Removal
1.
Raise the front of the vehicle,
position safety stands under the
frame, and lower the vehicle slightly.
2.
Remove the wheel and tire.
3.
Remove the shock absorber
lower attaching nuts and washers.
4.
Remove the shock absorber
upper mounting bracket attaching
nuts,
and remove the shock absorber
and bracket as an assembly (Fig. 26).
On all 8-cylinder vehicles, remove
the air cleaner to obtain access for
tool installation.
5.
Install the spring compressor
tool and compress the spring (Figs.
19,
20 and 21).
6. Position a safety stand under the
lower arm.
7.
Remove the cotter pin from the
nut on the upper ball joint stud, and
loosen the nut one or two turns. Do
not remove the nut from the stud at
this time.
8. Position the ball joint remover
tool between the upper and lower ball
joint studs as shown in 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; then, hit the spindle
smartly near the upper stud with a
hammer to break the stud loose in the
spindle. Do not loosen the stud in the
spindle with tool pressure only. If
both arms are being removed, loosen
the lower stud in the same manner as
the upper stud.
10.
Remove the nut from the upper
stud and lift the stud out of the
spindle.
11.
Remove the upper arm inner
shaft attaching nuts from the engine
compartment, and remove the upper
arm.
12.
Wipe off all loose dirt from the
upper arm parts. Do not wash the ball
joint with a solvent.
Installation
1.
Position the upper arm on the
underbody mounting bracket, and in-
stall the nuts and lock washers on the
two inner shaft attaching bolts. The
specified keystone-type lock washers
must be used. Torque the nuts to
soecification.
2.
Position the upper ball joint stud
in the top of the wheel spindle, and in-
stall the stud nut. Torque the nut to
specification, and continue to tighten
it until the cotter pin hole and slots
line up. Install a new cotter pin.
3.
Release the coil spring, remove
the tool, and install the front shock
absorber and the wheel and tire.
LINCOLN CONTINENTAL
Removal
1.
Place a jack under the outer end
of the suspension lower arm and raise
the arm. Refer to Fig. 22.
2.
Remove the wheel and tire.
3.
Remove the cotter pin from the
upper ball joint stud. Loosen the nut
one or two turns.
4.
Place a box wrench over the
lower end of the ball joint remover
tool, and position the tool as in Fig.
13.
The tool should seat firmly against
the ends of both studs, and not
against the upper stud nut.
5.
Turn the wrench until both studs
are under tension, and then, tap the
spindle with a hammer near the upper
stud to loosen it from the spindle. Do
not loosen the stud with tool pressure
alone. Remove the nut.
UPPER MOUNTING BRACKET
LOWER RETAINING BOLTS F 1490-A
FIG. 26—Removing or Installing
Front Shock Absorber—Typicalprocarmanuals.com
Page 115 of 413
03-05-02
Steering Columns
And
Linkage
03-05-02
which also will shear away during
im-
pact.
TILT STEERING COLUMNS
The steering column
is of the col-
lapsible type
to
lessen
the
possibility
of injury
to the
driver
of the
vehicle
should
he
become involved
in an
acci-
dent.
The
lower
end of the
steering
column tube
at the
bellows area will
collapse approximately
six
inches
upon
a
hard impact.
The shift tube
and the
steering shaft
are provided with plastic dowels
and
will shear
and
allow them
to
collapse
in proportion
to the
outer tube upon
impact.
Once
the
steering column
has
been
collapsed,
a
complete
new
column
must
be
installed.
The tilt column features nine driv-
ing positions (four
up and
four down
from
a
center position).
The
.column
also features
a
turn signal switch with
a lane-changer position turn indicating
position
and
emergency warning flash-
er control.
TILT-AWAY STEERING COLUMNS
The tilt-away steering column
fea-
tures nine driving positions (four
up
and four down from
a
center position)
and
a
tilt-away position that
is
auto-
matically accomplished
on
Mustang
and Cougar models when
the
ignition
key
is
turned
to the
OFF
position
and
the left door
is
opened.
On
Thunder-
bird models,
the
tilt-away occurs when
the shift lever
is
placed
in
PARK
and
the driverns door
is
opened.
The steering column
is of the col-
lapsible type
to
lessen
the
possibility
of injury
to the
driver
of the
vehicle
should
he
become involved
in an
acci-
dent.
The
lower
end of the
steering
column tube
at the
bellows area will
collapse approximately
six
inches
upon
a
hard impact.
The shift tube
and the
steering shaft
are provided with plastic dowels
and
will shear
and
allow them
to
collapse
in proportion
to the
outer tube upon
impact.
Once
the
steering column
has
been
collapsed,
a
complete
new
column
must
be
installed along with mounting
brackets which will also shear away
during impact.
IN-VEHICLE ADJUSTMENTS
AND
REPAIRS
STEERING WHEEL SPOKE
POSITION ADJUSTMENT
When
the
steering gear
is on the
high point,
the
front wheels should
be
in
the
straight-ahead position
and the
steering wheel spokes should
be in
their normal position with
the
Pitman
arm pointing directly forward.
If the
spokes
are not in
their normal posi-
tion, they
can be
adjusted without
dis-
turbing
the
toe-in adjustment (Part
3-1).
STEERING WHEEL
REPLACEMENT
1.
Disconnect
the
negative cable
from
the
battery.
2.
Working from
the
underside
of
the steering wheel spoke, remove
the
crash
pad
attaching screws. Lift
the
crash
pad
from
the
wheel.
(On
Conti-
nental Mark
III
models,
pry out the
crash
pad
insert
and
remove
the two
screws that secure
the
crash
pad. Re-
move
the
crash
pad. On
models
equipped with steering wheel mounted
speed controls, refer
to
Group
16 for
removal instructions). Remove
the
horn ring
(if so
equipped)
by
turning
it counterclockwise.
3.
Remove
the
steering wheel
nut,
and then remove
the
steering wheel
with tool T67L-3600-A
(Fig. 1). Do
not
use a
knock-off type steering
wheel puller
or
strike
the end of the
steering shaft with
a
hammer. Striking
the puller
or
shaft will damage
the
bearing
or the
collapsible column.
4.
Transfer
all
serviceable parts
to
the
new
steering wheel.
5.
Position
the
steering wheel
on
the shaft
so
that
the
alignment mark
on
the hub of the
wheel
is
adjacent
to
the
one on the
shaft. Install
a new
locknut
and
torque
it to
specifications.
6. Install
the
horn ring
(if so
equipped)
and
crash
pad.
STEERING COLUMN UPPER
BEARING REPLACEMENT
STATIONARY COLUMNS
Removal
1. Disconnect
the
horn wire
and the
turn indicator wires
at the
connector.
2.
Working from
the
underside
of
the steering wheel spoke, remove
the
two crash
pad
attaching screws. Lift
the crash
pad
from
the
wheel.
(On
Continental Mark
III
models,
pry out
the crash
pad
insert
and
remove
the
two screws that secure
the
crash
pad.
Remove
the
crash
pad. On
models
equipped with steering wheel mounted
speed controls, refer
to
Group
16 for
7oo/-T67L-3600-A
removal instructions). Remove
the
horn ring
(if so
equipped)
by
turning
it counterclockwise.
3.
Remove
the
steering wheel
at-
taching
nut.
Remove
the
steering
wheel using tool T67L-3600-A
(Fig.
1).
Do not use a
knock-off type steer-
ing wheel puller
or
strike
the end of
the steering shaft with
a
hammer.
Striking
the
puller
or
shaft will
dam-
age
the
bearing
or the
collapsible
col-
umn.
4.
Remove
the
turn indicator lever.
5.
Remove
the
turn signal switch
attaching screws. Lift
the
switch over
the
end of the
steering shaft
and
place
it
to one
side.
6. Remove
the
snap ring from
the
top
of the
steering shaft.
7.
Loosen
the two
flange-to-steering
column tube attaching bolts
to
disen-
gage them from
the
tube.
8. Raise
the
flange upward while
BEARING
AND
INSULATOR
Spacer
G 1502 -B
FIG.
1—Removing
Steering Wheel
G 1497-A
FIG. 2—Installing Upper Bearingprocarmanuals.com
Page 169 of 413
03-11-01
Eaton Power Steering Pump
03-11-01
PART 3-11 Eaton Power Steering Pump
COMPONENT INDEX
MODEL APPLICATION
3
§>
"o
4
POWER STEERING PUMP
Cleaning and Inspection (See Part 03-01)
Description
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
11-01
N/A
11-01
Disassembly and Overhaul
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
11-03
N/A
11-03
Removal and Installation
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
11-01
N/A
11-01
POWER STEERING PUMP RESERVOIR
Removal and Installation
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
11-01
N/A
11-01
A page number indicates that the item is for the vehicle listed at the head of the column.
N/A indicates that the item is not applicable to the vehicle listed.
l
DESCRIPTION
The roller-type hydraulic pump,
driven by the crankshaft, draws auto-
matic transmission fluid down the res-
ervoir and provides fluid pressure for
the system. Steering gear lubrication
is also provided by the same fluid
from the reservoir. Within the pump
itself is a flow-control and pressure-
relief valve which governs the pres-
sures within the steering system ac-
cording to the varying conditions of
operation. After fluid has passed from
the gear, it returns to the reservoir.
REMOVAL AND INSTALLATION
POWER STEERING PUMP
REMOVAL
1.
Open the hood, and install fend-
er covers.
2.
If the vehicle is equipped with air
conditioning, loosen the compressor
adjusting and support bracket bolts
and remove the drive belt.
3.
Loosen the generator adjusting
and support bracket bolts, and remove
the drive belts.
4.
Remove the fan, pulley, and spa-
cer.
5.
Raise the vehicle.
6. Remove the crankshaft damper
bolt and washer. Remove the damper
with Tool 6306-AG. Remove the drive
key.
7.
Disconnect the pump inlet line at
the pump, and plug the end of the line
to prevent the loss of fluid. Disconnect
the pump pressure line at the pump.
8. Remove the pump-to-engine
front cover cap screws, and remove
the pump. Remove the seal from the
front cover.
INSTALLATION
1.
Install a new seal on the engine
front cover.
2.
Align the slot in the pump rotor
shaft with the drive key in the crank-
shaft, and slide the pump onto the
shaft. Install the pump-to-engine front
cover cap screws. Torque the cap
screws to specification.
3.
Connect the pump inlet line and
the pressure line.
4.
Install the damper drive key,
damper, washer and bolt. Torque the
bolt to specification.
5.
Install the fan, pulley, and spa-
cer. Install the generator drive belts.
Adjust the belt tension, and tighten
the adjusting and support bracket
bolts.
6. If the vehicle is equipped with air
conditioning, install the compressor
drive belt. Adjust the belt tension, and
tighten the adjusting and support
bracket bolts.
7.
Run the engine at idle speed,
and check the fluid level in the reser-
voir. If required, add the specified au-
tomatic transmission fluid. Turn on
the windshield wipers. Rotate the
steering wheel from stop to stop sever-
al times to bleed the air from the sys-
tem. Recheck the fluid level.
POWER STEERING PUMP
RESERVOIR
WITHOUT AIR
CONDITIONING
Removal
1.
Remove the reservoir cover andprocarmanuals.com
Page 171 of 413
03-11-03
Eaton Power Steering Pump
03-11-03
POWER STEERING PUMP
DISASSEMBLY
A clean working area should be
used when overhauling the power
steering pump. Foreign matter picked
up on working parts may cause dam-
age or failure of the unit. Clean con-
tainers should be used for parts.
1.
Drain the fluid from the pump.
Remove the pump cover-to-housing
cap screws (Fig. 1). Place the pump
on the bench, cover side down. Lift
the housing from the cover.
2.
Remove the large and the small
O-rings from the pump cover. Remove
the O-ring from the pressure plate
hub.
3.
Remove the pressure plate-
to-cover screws, and remove the plate.
Lift the cam ring off the dowel pins.
4.
Remove the rollers. Lift the
rotor off the shaft, and remove the
drive key from the shaft. Remove the
dowel pins from the cover.
5.
Remove the rotor shaft from the
cover. Do not remove the snap ring
from the shaft unless it, or the shaft,
is damaged.
6. Pry the rotor shaft seals out of
the cover and the housing.
7. Do not disturb the control valve
unless diagnosis indicated a control
valve problem or foreign matter in the
valve. To remove the valve, drive the
roll pin out of the housing. Remove
the plug and O-ring, control valve,
and the spring. If the plug or valve is
stuck, tap the end of the housing on a
piece of wood or tap it with a soft-
faced hammer. Remove the O-ring
from the plug.
ASSEMBLY
Apply automatic transmission fluid
to all parts as they are assembled. Al-
ways use new seals and O-rings.
1.
Install the control valve spring in
the housing. Install the valve with the
small sensing hole in the end of the
valve toward the spring. Install a new
O-ring on the plug. The plug O-ring is
1/8 inch smaller in diameter than the
bypass O-ring. Make sure the proper
O-ring is used. Install the plug and a
new roll pin (Fig. 1).
2.
The rotor shaft oil seals are in-
stalled in the cover and the housing
with Tool 3583-J, which consists of a
driver and an adapter. The procedure
is as follows:
a. Support the cover on wood
blocks (Fig. 2) to provide tool clear-
ance.
Use clean blocks that will not
nick or damage the inner face of the
cover.
b.
Start the seal (metal shell up-
ward) square!y into the bore with fin-
ger pressure. Place the adapter on the
driver with the square corner of the
FIG. 2—Preparation for Installing
Rotor Shaft Seals
adapter toward the seal (Fig. 2). Drive
the seal into the cover, as shown in
Fig. 3, until it bottoms.
Driving the seal beyond this point
can damage it. Install the seal in the
pump housing in the same manner.
3.
Install the rotor shaft in the
FIG. 3—Installing Rotor
Shaft Seals
cover as shown in Fig. 4 to prevent
damage to the seal.
4.
Install the dowel pins in the
cover. Place the rotor drive key in the
shaft. Install the rotor on the shaft
with the drive key groove aligned with
the key and the counterbored side of
the rotor toward the cover so that it
goes over the snap ring.
5.
Place the cam ring on the dowel
pins with the chamfered edge upward
(Fig. 5). Place the rollers in the rotor.
6. Place the pressure plate on the
dowel pins. Install and tighten the
screws to 20 in-lbs torque. Install the
O-ring on the pressure plate hub. In-
stall O-rings in the groove at the fluid
bypass hole and around the cam ring
(Fig. 6).
7.
Place the tool shown in Fig. 6 in
the rotor shaft to prevent damage to
the oil seal, then install the housing on
the cover. Install and torque the cap
screws to 15-20 ft-lbs.
FIG. 5—Cam Ring Installation
FIG. 4—Installing Rotor Shaft
in Cover
FIG. 6—O-Ring Installationprocarmanuals.com
Page 247 of 413
04-05-06
Specifications
04-05-06
THUNDERBIRD, CONTINENTAL MARK
III
Ford Tool No.
T50T-100-A
T50T-100-A&
TOOL-1175-AB
T00L-1225-DA
TOOL-4005
TOOL-4020-B
T57L-4067-A
TOOL-4201
TOOL-4201-C
TOOL-4205-B
TOOL-4205-C
T00L-4221-C
T00L-4222-H
T00L-4235-C
T00L-4245-B
Former No.
T50T-100-C
1175-AE
1225-DA
4005
4020-B
_
4201
4201-C
4205-B
4205-C
4221-C
4222-H
4235-C
4245-B
Description
Slide Hammer
Seal Remover
Rear Wheel Bearing Remover
Engine Repair Stand Axle Adapter-
Keyed Shaft
Pinion Depth Gauge-Complete With
Depth Micrometer and Gauge Block
Differential Bearing Adjuster Wrench
Pinion Shaft Drive
Nut
Differential Backlash
&
Runout
Gauge With Univ. Bracket, Dial
Indicator and Bracket
Differential Assembly Bench Holder
Axle Housing Dummy Bearings (1
pr.)
Differential Side Bearing Remover
Differential Bearing Cone Replacer
Axle Shaft
&
Bearing Remover
Wheel Bearing Seal Replacer
Ford Tool No.
Former No. Description
TOOL-4616
4616
Drive Pinion Bearing Cup Replacer
(Front)
T00L-4621-A 4621-A Drive Pinion Bearing and Rear Wheel
Bearing Replacer
T00L-4621-BA 4621-BA Rear Pinion Bearing Remover
TOOL-4628 4628 Pinion Rear Bearing Cup Replacer
T00L-4628-B 4628-B Pinion Bearing Front Cup Remover
T00L-4628-D 4628-D Pinion Rear Bearing Cup Remover
T64N-4676-A 4676 Pinion Shaft Oil Seal Replacer
T68P-4851-A
-
Universal Joint Flange Holder
T64N-4858-A 4858-B Companion Flange
&
Pinion Bearing
Replacer
T00L-4858-G 4858-G Pinion Flange Nut Adjusting Wrench
(Use With T64N-4858-A)
TOOL-4859 4859 Companion Flange Dust
Shield
Replacer
T00L-6565-AB
-
Dial Indicator Adapter
TOOL-6565
-
Dial Indicator
T00L-7657-J 7657-J Extension Housing Bushing
&
Seal Replacer
LINCOLN CONTINENTAL
Ford Tool
No.
T00L-4245-B
TOOL-4616
T00L-4621-A
T00L-4621-BA
TOOL-4628
T00L-4628-B
T64N-4628-B
T00L-4628-D
T64N-4676-A
T00L-4851-K
T64N-4858-A
T00L-4858-G
TOOL-4859
T00L-6565-AB
TOOL 6565
T00L-7657-J
Former
No.
4245-B
4616
4621-A
4621-BA
4628
4628-B
4628-D
4676
T57L-4851-A
4858-B
4858-G
4859
7657-J
Description
Wheel Bearing Seal Replacer
Drive Pinion bearing
Cup
Replacer (Front)
Drive Pinion Bearing
and
Rear
Wheel Bearing Replacer
Rear Pinion Bearing Remover
Pinion Rear Bearing
Cup
Replacer
Pinion Bearing Front
Cup
Remover
Pinion Rear Bearing Cup Remover
Pinion Shaft
Oil
Seal Replacer
Universal Joint Flange Holder
Companion Flange
&
Pinion Bearing
Replacer
Pinion Flange
Nut
Adjusting Wrench
(Use With T64N-4858-A)
Companion Flange Dust Shield
Replacer
Dial Indicator Adapter
Dial Indicator
Extension Housing Bushing
&
Seal Replacer
Ford Tool
No.
Former
No.
T50T-100-A
T50T-100-A&
TOOL-1175-AB
TOOL-1225-DA
TOOL-4000-C
TOOL-4005
TOOL-4020-B
TOOL-4201
TOOL-4201-C
TOOL-4204-A
TOOL-4205-B
TOOL-4205-C
T00L-4209-C
T00L-4221-C
T00L-4222-H
T00L-4235-C
Description
T50T-100-C Slide Hammer
1175-AE
1225-DA
4000-C
4005
4020-B
4201
4201-C
4205-B
4205-C
4209-C
4221-C
4222-H
4235-C
Seal Remover
Rear Wheel Bearing Remover
Differential Housing Spreader
Engine Repair Stand Axle Adapter-
Keyed Shaft
Pinion Depth Gauge-Complete With
Depth Micrometer
and
Gauge
Block
Pinion Shaft Drive
Nut
Differential Backlash
&
Runout
Gauge With Univ. Bracket, Dial
Indicator
and
Bracket
Limited Slip Differential Check
Differential Assembly Bench Holder
Axle Housing Dummy Bearings
(1
pi")
Pinion Tension Scale With
4209-C12 Socket
Differential Side Bearing Remover
Differential Bearing Cone Replacer
Axle Shaft
&
Bearing Removerprocarmanuals.com
Page 303 of 413
07-01-12
General Transmission Service
07-01-12
the transmission,
any
metal particles
or clutch plate
or
band material that
may have been carried into
the
cooler
should
be
removed from
the
system
by
flushing
the
cooler
and
lines before
the transmission
is put
back into serv-
ice.
In no
case should
an
automatic
transmission having
a
clutch
or
band
failure
or
other internal trouble result-
ing
in
fluid contamination,
be put
back into service without first flushing
the transmission
oil
cooler.
To flush
the oil
cooler, follow
the
instruct!
on >
provided with
the
Rotun-
da Automatic Transmission Torque
Converter
and
Cooler Cleaner
LRE-
60081.
INSPECTION
TURBINE
AND
STATOR
END
PLAY CHECK
A special tool
(Fig. 19)
must
be
used
to
check
the
condition
of the
converter. This special tool
is
used
to
check
the
turbine
and
stator
end
play
and
the
operation
of the
one-way
sta-
tor clutch.
CRUISE-O-MATIC
Too/-T58L-7902-A
C-4 AND C-6 TRANSMISSION
Tool-T59P.7902.Bor 7937-B
ON C-4 AND C-6 TRANSMISSION
Tool-T64L-7902-A
D
1499-E
FIG. 19—Converter Checking Tool
1.
Insert
the
tool (Fig.
19)
into
the
converter pump drive
hub
until
it
bot-
toms.
2.
Install
the
guide over
the con-
verter pump drive
hub.
3.
Expand
the
split fiber bushing
in
the turbine spline
by
tightening
the
adjusting
nut.
Tighten
the
adjusting
nut until
the
tool
is
securely locked
into
the
spline.
4.
Attach
a
dial indicator
to the
tool (Fig.
20 or
21). Position
the
indi-
cator button
on a
converter pump
drive
hub, and set the
dial face
at 0
(zero).
5.
Lift
the
tool upward
as far as it
will
go and
note
the
indicator reading.
The indicator reading
is the
total
end
play which
the
turbine
and
stator
share.
If the
total
end
play exceeds
the limits specified
in
Part 7-5, replace
the converter unit.
6. Loosen
the
adjusting
nut to
free
the split bushing,
and
then remove
the
tool from
the
converter.
STATOR ONE-WAY CLUTCH
CHECK
1.
Install
the
stator outer race hold-
ing tool
in one of the
four holes
pro-
vided
in the
stator (Fig.
20 or 21).
2.
Insert
the
tool
in the
converter
pump drive hub.
As the
tool enters
the
converter,
the
pins will engage
the sta-
tor clutch inner race spline.
3.
Place
a
torque wrench
on the
tool (Fig.
20 or
21).
The
tool (and
sta-
tor inner race) should turn freely
clockwise (from
the
pump drive
hub
inside
the
converter).
It
should lock
up
and hold
a 10
ft-lb pull when
the
wrench
is
turned counterclockwise.
Try
the
clutch
for
lockup
and
hold
in
at least five different locations around
the converter.
On
the
C4
or C6
Auto-
matics,
the
metal ring holding
the
locking tool will have
to be
held
by
hand during this check.
4.
If the
clutch fails
to
lock
up and
hold
a 10
ft-lb torque, replace
the
converter unit.
STATOR
TO
IMPELLER
INTERFERENCE CHECK
1.
Position
the
front pump assem-
bly
on a
bench with
the
spline
end of
the stator shaft pointing
up
(Fig.
22).
2.
Mount
a
converter
on the
pump
so that
the
splines
on the
one-way
clutch inner race engage
the
mating
splines
of the
stator support,
and the
converter
hub
engages
the
pump drive
gear.
3.
While holding
the
pump station-
ary, try
to
rotate the converter counter-
clockwise.
The
converter should
ro-
tate freely without
any
signs
of
inter-
ference
or
scraping within
the
convert-
er assembly.
4.
If
there
is an
indication
of
scrap-
ing,
the
trailing edges
of the
stator
blades
may be
interfering with
the
leading edges
of the
impeller blades.
In such cases, replace
the
converter.
STATOR
TO
TURBINE
INTERFERENCE CHECK
1.
Position
the
converter
on the
bench front side down.
2.
Install
a
front pump assembly
to
engage
the
mating splines
of
the
stator
support
and
stator,
and
pump drive
gear lugs.
3.
Install
the
input shaft, engaging
the splines with
the
turbine
hub (Fig.
23).
4.
While holding
the
pump station-
ary, attempt
to
rotate
the
turbine with
the input shaft.
The
turbine should
ro-
tate freely
in
both directions without
any signs
of
interference
or
scraping
noise.
5.
If
interference exists,
the
stator
front thrust washer
may be
worn,
al-
lowing
the
stator
to hit the
turbine.
In
such cases,
the
converter must
be re-
placed.
The converter crankshaft pilot
should
be
checked
for
nicks
or dam-
aged surfaces that could cause inter-
ference when installing
the
converter
into
the
crankshaft. Check
the con-
verter front pump drive
hub for
nicks
or sharp edges that would damage
the
pump seal.
OUTPUT SHAFT
AND
PRIMARY
SUN
GEAR SHAFT
(FMX TRANSMISSION)
1.
Inspect
the
thrust surfaces
and
journals
for
scores. Inspect
the
inter-
nal gear
for
broken
or
worn teeth.
2.
Inspect
the
aluminum sleeve
for
scores
or
leakage. Inspect
the
ring
grooves
for
burrs.
3.
Inspect
the
keyway
and
drive
ball pocket
for
wear,
and
inspect
the
splines
for
burrs, twist
or
wear.
4.
Inspect
the
output shaft sleeve
for alignment with
the
governor drive
ball (Fig.
24).
5.
Inspect
the
external parking gear
teeth
for
damage
and the
speedometer
drive gear teeth
for
burrs.
6.
If
either
the
output shaft
or
ring
gear
has
been replaced, place
the as-
sembled unit with
the
gear face down
on
the
bench, push
the
shaft down-
ward,
and
check
the
clearance
be-
tween
the top of the
snap ring
and its
groove
(Fig. 25).
If
this clearance
ex-
ceeds 0.002 inch, replace
the
snap ring
with
a
thicker ring
to
reduce
the
clear-
ance
to
less than 0.002 inch. Selectiveprocarmanuals.com
Page 314 of 413
07-02-06
C4 Automatic Transmission
07-02-06
PLUG-7256
•HANDLE-7217
BUTTON-7C439
DIAL HOUSING
ASSEMBLY-7E034
POINTER BACK-UP
SHIELD
ENGAGE FLATS OF STUD IN SLOT OF
ROD BEFORE APPLYING TORQUE
D2022-A
FIG. 8—Manual Linkage—Console Shift—Mustang
ACTUATOR LEVER ATTACHING BOLT
D1812-A
FIG. 9—Neutral Start Switch Adjustments—Console Shift—Ford-Meteor
9. Turn the ignition key to the
ACC position and place the selector
lever in the reverse position and check
the operation of the back-up lights.
Turn the key off.
10.
Place the console top panel on
the console and install the retaining
screws.
11.
Position the selector lever de-
tent control and handle on the selector
lever and secure with the four plates
and attaching screws.
FAIRLANE-MONTEGO
1.
With the manual linkage proper-
ly adjusted, check the starter en-
gagement circuit in all positions. The
circuit must be open in all drive posi-
tions and closed only in park and neu-
tral.
Gauge Pin
(No.43 Drill)
NEUTRAL START
SWITCH
Dl759-A
70—Neutral Start Switch
Adjustments—Console Shift—
Fairlane-Montegoprocarmanuals.com
Page 315 of 413
07-02-07
C4 Automatic Transmission
07-02-07
2.
Remove the selector lever handle
from the lever.
3.
Remove the trim panel from the
top of the console.
4.
Remove the cover and dial indi-
cator as an assembly.
5.
Remove the four screws that se-
cure the selector lever retainer to the
selector lever housing. Lift the retainer
from the housing.
6. Loosen the two combination
starter neutral and back-up light
switch attaching screws (Fig. 10).
7.
Move the selector lever back and
forth until the gauge pin (No. 43 drill)
can be fully inserted into the gauge
pin holes (Fig. 10).
8. Place the transmission selector
lever firmly against the stop of the
neutral detent position.
9. Slide the combination starter
neutral and back-up light switch for-
ward or rearward as required, until
the switch actuating lever contacts the
selector lever.
10.
Tighten the switch attaching
screws and remove the gauge pin.
Check for starting in the park posi-
tion.
11.
Turn the ignition key to the
ACC position and place the selector
lever in the reverse position and check
the operation of the back-up lights.
Turn the key off.
12.
Position the selector lever re-
tainer to the selector lever housing.
Install the four attaching screws.
13.
Install the cover and dial indi-
cator.
14.
Install the trim panel on the top
of the console. Install the selector
lever handle.
MUSTANG
1.
With the manual lever properly
NEUTRAL
START
SWITCH
(D1439-A
FIG. 11—Neutral Start Switch
Adjustments—Console Shift—
Mustang
adjusted, loosen the two switch attach-
ing bolts (Fig. 11).
2.
With the transmission manual
lever in neutral, rotate the switch and
insert the gauge pin (No. 43 drill
shank end) into the gauge pin holes of
the switch. The gauge pin has to be
inserted to a full 31/64 inch into the
three holes of the switch (Fig. 11).
3.
Torque the two switch attaching
bolts to specification. Remove the
gauge pin from the switch.
4.
Check the operation of the
switch. The engine should start only
with the transmission selector lever in
Neutral and Park.
NEUTRAL START SWITCH
REPLACEMENT—CONSOLE SHIFT
On vehicles equipped with a column
mounted neutral start switch, refer to
Part 7-1, Section 2, for the replace-
ment procedures.
FORD-METEOR
1.
Remove the four screws and
plates securing the selector lever
handle to the lever. Remove the
handle and detent control.
2.
Remove the two screws from the
rear of the console top panel. Pull the
panel back to unhook it from the
front of the console and remove the
panel.
3.
Remove the two screws securing
the dial indicator assembly to the se-
lector lever housing and remove the
indicator assembly.
4.
Disconnect the neutral start
switch wires at the plug connector.
Remove the wires from under the re-
taining clip.
5.
Remove the two screws securing
the neutral start switch to the selector
lever housing and remove the switch
(Fig. 9).
6. Position the neutral start switch
to the selector lever housing and in-
stall the two attaching screws.
7.
Adjust the neutral start switch as
outlined under the Neutral Start
Switch Adjustment procedures in this
section.
8. Connect the neutral start switch
wires to the plug connector. Position
the wires in the retaining clip and
close the clip.
9. Place the console top panel on
the console and install the retaining
screws.
10.
Position the selector lever de-
tent control and handle on the selector
lever and secure with the four plates
and attaching screws.
FAIRLANE-MONTEGO
1.
Remove the selector lever handle
from the lever.
2.
Remove the trim panel from the
top of the console.
3.
Remove the cover and dial indi-
cator as an assembly.
4.
Remove the four screws that se-
cure the selector lever retainer to the
selector lever housing. Lift the retainer
from the housing.
5.
Remove the two screws securing
the neutral start switch to the selector
lever housing. Disconnect the neutral
start switch wires at the plug connec-
tor and remove the switch.
6. Position the neutral start switch
to the selector lever housing and in-
stall the two attaching screws.
7.
With the selector lever in neu-
tral,
move the selector lever back and
forth until the gauge pin (No. 43 drill)
can be fully inserted into the gauge
pin holes (Fig. 10).
8. Place the transmission selector
lever firmly against the stop of the
neutral detent position.
9. Slide the combination starter
neutral and back-up light switch for-
ward or rearward as required, until
the switch actuating lever contacts the
selector lever.
10.
Tighten the switch attaching
screws and remove the gauge pin.
11.
Connect the neutral start switch
wires to the plug connector and check
for starting in the park position.
12.
Position the selector lever re-
tainer to the selector lever housing.
Install the attaching screws.
13.
Install the cover and dial indi-
cator.
14.
Install the trim panel on the top
of the console. Install the selector
lever handle
MUSTANG
1.
Remove the downshift linkage
rod from the transmission downshift
lever.
2.
Apply penetrating oil to the
downshift lever shaft and nut. Remove
the transmission downshift outer lever
retaining nut and lever (Fig. 11).
3.
Remove the two neutral start
switch attaching bolts.
4.
Disconnect the multiple wire
connector. Remove the neutral switch
from the transmission.
5.
Install the neutral start switch on
the transmission. Install the two at-
taching bolts.
6. With the transmission manual
lever in neutral, rotate the switch and
install gauge pin (No. 43 drill) into
the gauge pin hole (Fig. 11).
7.
Tighten the switch attaching
bolts to specification and remove the
gauge pin.procarmanuals.com