recommended oil FORD MUSTANG 1969 Volume One Chassis

02-01-08
Brakes

02-01-08

BEARING CUP

DIMENSION "B"

0.755 MINIMUM

DIMENSION "A'

0.395 MINIMUM

H1532-B

FIG. 12—Disc Brake Rotor Service

Limits—Lincoln Continental

per splash shield or the bleeder screw

fitting.

4.
Front wheel bearing end play is

critical and must be within specifica-

tions.

5.
Be sure the vehicle is centered on

the hoist before servicing any front

end components, to avoid bending or

damaging the rotor splash shield on

full right or left wheel turns.

6. The proportioning valve should

not be disassembled or adjustments

attempted on it.

7.
Riding of the brake pedal (com-

mon on left foot applications) should

be avoided during vehicle operation.

8. The wheel and tire must be re-

moved ' separately from the brake

rotor, unlike drum brakes where the
wheel, tire and drum are removed as a

unit.

9. On floating caliper type disc

brakes whenever the caliper is re-

moved the caliper locating pins should

be inspected for wear or damage.

10.
On floating caliper type disc

brakes, the caliper assembly must be

removed from the spindle prior to re-

moval of the shoe and lining assem-

blies.

11.
On floating caliper type disc

brakes the calipers must not be inter-

changed from one side to the other.

When the caliper is installed on its

proper anchor plate and spindle, the

bleeder screw will point to the rear of

the vehicle (Fig. 22). If a caliper is in-

stalled on the wrong side of the vehi-

cle,
it is not possible to bleed the sys-

tem properly.

12.
Do not attempt to clean or re-

store oil or grease soaked brake lin-

ings.
When contaminated linings are

found, brake linings must be replaced

in complete axle sets.

DRUM BRAKES

1.
Remove the wheel from the

drum, and remove the drum as out-

lined in Part 2-2, Section 2.

2.
Brush all dust from the backing

plates and interior of the brake

drums.

3.
Inspect the brake shoes for ex-

cessive lining wear or shoe damage. If

the lining is worn within 1/32 inch of

the rivet heads or if the shoes are

damaged, they must be replaced. Re-

place any lining that had been con-

taminated with oil, grease or brake
fluid. Replace lining in axle sets. Prior

to replacement of lining, the drum di-

ameter should be checked to deter-

mine if oversize linings must be in-

stalled.

4.
Check the condition of brake

shoes,
retracting springs, hold-down

springs, and drum for signs of over-

heating. If the shoes have a slight blue

coloring, indicating overheating, re-

placement of the retracting and hold-.

down springs is strongly recommended.

Overheated springs lose their pull and

could cause the new lining i:o wear

prematurely, if they are not replaced.

5. If the vehicle has 30,000 or more

miles of operation on the brake linings

or signs of overheating are present

when relining brakes, the wheel cylin-

ders should be disassembled and in-

spected for wear and entrance of dirt

into the cylinder. The cylinder cups

should be replaced, thus avoiding fu-

ture problems.

6. Inspect all other brake parts and

replace any that are worn or dam-

aged.

7.
Inspect the brake drum and, if

necessary, refinish. Refer to Part 2-2,

Section 4 for refinishing.

BRAKE BOOSTER

Check the booster operation as

noted in Part 2-1, Section 1, Power

Brake Functional Test. If the brake

booster is damaged or defective, re-

place it with a new booster. The brake

booster is serviced only as an assem-

bly.procarmanuals.com

02-02-39
Brake System

02-02-39

MAJOR REPAIR OPERATIONS

BRAKE DRUM REFINISHING

Minor scores on a brake drum can

be removed with sandpaper. A drum

that is excessively scored or shows a

total indicator runout of over 0.007

inch should be turned down. Remove

only enough stock to eliminate the

scores and true up the drum. The refi-

nished diameter must not exceed 0.060

inch oversize.

Check the inside diameter of the

brake drum with a brake drum mi-

crometer (Tool FRE-14^1).

If the drum diameter is less than

0.030 inch oversize after refinishing^

standard lining may be installed. If

the drum diameter is 0.030—0.060

inch oversize after refinishing, oversize

lining must be installed.

After a drum is turned down, wipe

the refinished surface with a cloth

soaked in clean denatured alcohol. If

one drum is turned down, the opposite

drum on the same axle should also be

cut down to the same size.

ROTOR REFINISHING

Rotunda Disc Brake Attachment,

FRE-2249-2, is the only recommended

tool to refinish the disc brake rotors.

The step-by-step resurfacing procedure

provided with the tool must be ad-

hered to.

The finished braking surfaces of the

rotor must be flat and parallel within

0.0007 inch; lateral runout must not

exceed 0.003 inch total indicator read-

ing, and the surface finish of the brak-

ing surfaces are to be 80/15 micro

inches. The minimum limiting dimen-

sions (Figs. 11 and 12, Part 2-1) from

the inboard bearing cup to the out-

board rotor face and from the inboard

bearing cup to the inboard rotor face

must be observed when removing ma-

terial from the rotor braking surfaces.

On all models except Lincoln Con-

tinental, the limiting dimensions are to

be measured with a ball and gage bar

(Rotunda Kit FRE-70160).

BRAKE SHOE RELINING

Brake linings that are worn to with-

in 1/32 inch of the rivet head or are

less than 0.030 inch thick (bonded lin-

ing) or have been contaminated with

brake fluid, grease or oil must be re-

placed. Failure to replace worn linings

will result in a scored drum. When it
is necessary to replace linings, they

must also be replaced on the wheel on

the opposite side of the vehicle.

Inspect brake shoes for distortion,

cracks, or looseness. If this condition

exists,
the shoe must be discarded. Do

not attempt to repair a defective brake

shoe.

1.
Wash the brake shoes thoroughly

in a clean solvent. Remove all burrs

or rough spots from the shoes.

2.
Check the inside diameter of the

brake drum with a brake drum mi-

crometer (tool FRE-1431). If the di-

ameter is less than 0.030 inches over-

size,
standard lining may be installed.

If the diameter is 0.030—0.060 inches

oversize, oversize lining should be in-

stalled.

3.
Position the new lining on the

shoe.
Starting in the center, insert and

secure the rivets, working alternately

towards each end. Replacement lin-

ings are ground and no further grind-

ing is required.

4.
Check the clearance between the

shoe and lining. The lining must seat

tightly against the shoe with not more

than 0.008 inch clearance between any

two rivets.

RETAINER - 2B245
DUAL MASTER CYLINDER

DISASSEMBLY

1.
Clean the outside of the master

cylinder and remove the filler cover

and diaphragm. Pour out any brake

fluid that remains in the cylinder. Dis-

card the old brake fluid.

2.*
Remove the secondary piston

stop bolt from the bottom of the cyl-

inder (Figs. 40 and 41).

3.
Remove the bleed screw, iL re-

quired.

4.
Depress the primary piston and

remove the snap ring from the retain-

ing groove at the rear of the master

cylinder bore (Fig. 42). Remove the

push rod and the primary piston as-

sembly from the master cylinder bore.

Do not remove the screw that retains

the primary return spring retainer, re-

turn spring, primary cup and protec-

tor on the primary piston. This assem-

bly is factory pre-adjusted and should

not be disassembled.

5.
Remove the secondary piston as-

sembly. Do not remove the outlet tube

seats,
outlet check valves and outlet

SECONDARY SYSTEM

BRAKE OUTLET
COVER -2166

GASKET-2167

MASTER CYLINDER -2155

SNAP RING -7821

BOOT

PUSH ROD

PRIMARY PISTON

ASSEMBLY - 2169

tTUBE SEAT-

2B220
* SECONDARY PISTON

ASSEMBLY - 2A502

• NOT USED ON POWER BRAKE EQUIPPED VEHICLES

fNOT SERVICED

•REPLACE AS AN ASSEMBLY ONLY

H 1499-B

FIG. 40— Dual Master Cylinder Disassembled—Except Disc Brakesprocarmanuals.com

03-06-03
Manual Steering

03-06-03

MAJOR REPAIR OPERATIONS

STEERING GEAR

DISASSEMBLY

1. Rotate the steering shaft 3 turns

from either stop.

2.
After removing the sector adjust-

ing screw locknut and the housing

cover bolts (Fig. 6), remove the sector

shaft with the cover. Remove the

cover from the shaft by turning the

screw clockwise. Keep the shim with

the screw.

HOUSING
•
3548
6. Turn the ball nut over, and ro-

tate the worm shaft from side to side

until all 50 balls have dropped out of

the nut into a clean pan. With the

balls removed, the ball nut will slide

off the worm.

7. Remove the upper bearing cup

from the bearing adjuster and the

lower cup from the housing. It may be

necessary to tap the housing or the

adjuster on a block of wood to jar the

bearing cups loose.

8. If the preliminary inspection

GASKET
• 3581

SHIM-3A657 COVER
AND

BUSHING
•
3583

SECTOR SHAFT

ADJUSTING SCREW
.
3577

•BEARING-3576

SEAL
- 3591

G 1623-A

FIG. 6—Sector Shaft
and
Housing Disassembled

-^-HOUSING-3548

BEARING
CUP •
3552

BALL
NUT

BEARING-3571

FILLER PLUG-3556
LOCK NUT-3707

3524 BEARING
CUP \
SEAL-3738

•GUIDE -3523

• BEARINGS
•
3647

.CLAMP-3544
BEARING
• 3571

G 1624-A

FIG. 7—Steering Shaft
and
Related Parts Disassembled

3.
Loosen the worm bearing adjust-

er nut, and remove the adjuster as-

sembly and the steering shaft upper

bearing (Fig. 7).

4.
Carefully pull the steering shaft

and ball nut from the housing, and i •-

move the steering shaft lower bearr g.

To avoid possible damage to the ball

return guides, keep
the
ball
nut
from

running down
to
either
end of the

worm.

Disassemble
the
ball only
if
there
is

indication
of
binding
or
tightness.

5.
Remove the ball return guide

clamp and the ball return guides from

the ball
nut.
Keep
the
ball
nut
clamp-

side up until ready to remove the

balls.
shows damage, press the sector shaft

bearing and the oil seal from the

housing (Fig. 8).

ASSEMBLY

1. If the sector shaft bearing and

oil seal have been removed, press a

new bearing into the housing and in-

stall a new oil seal. Do not clean,

wash or soak seals in cleaning solvent

(Fig.
7).
Apply
the
recommended

steering gear lubricant
to the
bearing

and seals.

2.
Install a bearing cup in the lower

end of the housing and in the adjuster.

3.
If the seal in the bearing adjuster

was removed, install a new seal.
Tool
-
T62F
•
3576
- A

G 1622-A

FIG.
8—Removing
Oil
Seal

and Bearing

4.
Insert the ball guides into the

holes of the ball nut, tapping them

lightly with a wood handle of a screw

driver if necessary to seat them.

5.
Insert 25 balls into the hole in

the top of each ball guide. It may be

necessary to rotate the shafi: slightly

one way, then in the opposite direc-

tion to distribute the balls in the cir-

cuit.

6. After the 50 balls are installed,

install the ball guide clamp. Torque

the screws to specification. Check the

worm shaft to make sure that it ro-

tates freely.

7. Coat the threads of the steering

shaft bearing adjuster, the housing

cover bolts, and the sector adjusting

screw with a suitable oil-resisi:ant seal-

ing compound. Do not apply sealer to

female threads and especially avoid

getting any sealer on the steering shaft

bearings.

8.
Coat the worm bearings, sector

shaft bearings, and gear teeth with

steering gear lubricant.

9. Clamp the housing in a vise, with

the sector shaft axis horizontal, and

position the steering shaft lower bear-

ing in its cup.

10.
Position the steering shaft and

ball nut assemblies in the housing.

11.
Position the steering shaft

upper bearing on the top of the worm,

and install the steering shaft bearingprocarmanuals.com

05-02-04
General Clutch Service

05-02-04

CLEANING AND INSPECTION

RELEASE BEARING

Wipe all oil and dirt off the release

bearing. The bearing is prelubricated

and should not be cleaned with sol-

vent.

Inspect the bearing retainer for

loose spring clips and rivets.

Inspect the release bearing assembly

for burrs which may cause the assem-

bly to drag on the transmission bear-

ing retainer. Any such burrs should be

cleaned up with fine crocus cloth. If

burrs are found, inspect the transmis-

sion input shaft bearing retainer for

evidence of scoring. Any scoring

should be polished out with crocus

cloth. Coat the bearing retainer with a

thin film of lithium-base grease

(C3VY-19586-A). Prior to release

bearing installation, apply a light film

of lithium base grease (C3VY-

19586-A) on both sides of the release

lever fork where it contacts the release

bearing hub and retaining springs.

Apply a light film of lithium base

grease (C3VY-19586-A) plate to the

release bearing surface that contacts

the pressure plate fingers. Carefully

fill the grease groove inside the bear-

ing hub with lithium base grease (no

polyethylene). Clean all excess grease

from the bore of the bearing hub. Ex-

cess grease will be forced onto the

spline by the transmission input shaft

bearing retainer and will contaminate

the clutch disc. Also, care must be

exercised when applying lubricants to

the release bearing, release bearing

hub and the release lever fork to avoid

excessive grease from contaminating

the clutch disc.

Hold the bearing inner race and ro-

tate the outer race while applying

pressure to it. If the bearing rotation

is rough or noisy, replace the bearing.

Most release bearing failures are

caused by improper clutch pedal ad-

justments. If the clutch linkage does

not have enough free travel, the re-

lease bearing will constantly touch the

release fingers and will spin whenever

the engine is running.

When installing a release bearing on

vehicles equipped with separate hub

and bearing, use the tool shown in

Fig. 5.

Release bearing failure can be

caused by the release lever contact

points being out of plane. Check the

wear on the release bearing assembly

where the release lever contacts it.

If one side of the assembly shows

more wear than the other, the release
lever is bent out of plane, or is not

centering on the bracket on the fly-

wheel housing.

Misalignment between the engine

and transmission can cause release

bearing failure. Other symptoms of

misalignment are transmission jump-

ing out of gear, especially third gear,

drive line vibration; excessive wear in

the pilot bushing, excessive clutch disc

spin time resulting in gear clash, and

excessive transmission gear wear.

PRESSURE PLATE AND COVER

Inspect the surface of the pressure

plate for burn marks, scores, or rid-

ges.
Generally, pressure plate resur-

facing is not recommended. However

minor burn marks, scores, or ridges

may be removed. During the resurfac-

ing process, the flatness of the pres-

sure plate must be maintained. If the

pressure plate is badly heat-checked or

deeply scored, replace the pressure

plate and cover assembly. Clean pres-

sure plate and flywheel surfaces with a

suitable solvent, such as alcohol to be

sure the surfaces are free from any oil

film. Do not use cleaners with petrole-

um base, and do not immerse the

pressure plate in the solvent.

Place the plate on the floor, being

careful not to score or scratch the sur-

face.
Force each individual finger

down, then release quickly. If the fin-

ger does not return quickly, a binding

condition is indicated, and the pres-

sure plate should be replaced.

The pressure plate should be lubri-

cated with a lithium-base grease be-

tween the driving lugs and the edges

of the pressure plate openings, as

shown in Fig. 6. Depress the pressure

plate fingers fully, apply the lubricant,

and then move the fingers up and

down until the lubricant is worked in.

Do not apply excessive lubricant.

CLUTCH DISC

Inspect the clutch disc facings for

oil or grease. Eliminate the source of

any oil or grease before replacing the

disc. An excessive amount of grease in

the pilot bushing or release bearing

hub will find its way to the disc fac-

ings.
Too much lubricant in the trans-

mission or a plugged transmission

vent will force the transmission lubri-

cant out the input shaft and onto the

disc facings. Also, rear main bearing

oil seal leaks or oil leaks from the fly-

wheel mounting bolts can contaminate

the clutch disc.
Inspect the clutch disc for worn or

loose facings. Check the disc for worn

or loose facings. Check the disc for

distortion and for loose rivets at the

hub.
Check for broken springs.

Springs loose enough to rattle will not

cause noise when the car is operating.

Replace the disc assembly if any of

these defects are present. Be especially

careful when installing a new disc to

avoid dropping it or contaminating it

with oil or grease.

PILOT BUSHING

Check the fit of the clutch pilot

bushing in the bore of the crankshaft.

The bushing is pressed into the

crankshaft and should not be loose.

Inspect the inner surface of the bush-

ing for wear or a bell-mouthed condi-

tion. If the bushing is worn or dam-

aged, replace the bushing with a new

service bearing. Refer to the applica-

ble engine for the replacement proce-

dure.

C 1785-A

FIG. 5—Installing Clutch Release

Bearing on Hub

PRESSURE PLATE

AND COVER

DRIVING

LUG
FLYWHEEL

C2048-A

FIG. 6—Pressure Plate Lubrication

Pointsprocarmanuals.com

07-03-14
FMX Transmission

07-03-14

REMOVAL AND INSTALLATION

An oil impregnated plastic grommet

is incorporated in the end of the man-

ual shift linkage lever arm on all col-

umn shift vehicles. A special tool

T67P-7341-A is required to install the

grommet in the manual lever, and to

install the manual linkage rod into the

grommet. Refer to Part 7-1, Section

2,
for the grommet replacement pro-

cedures.

TRANSMISSION AND

CONVERTER REPLACEMENT—

FORD-METEOR

REMOVAL

1.
Drive the vehicle on a hoist, but

do not raise at this time.

2.
Remove the two upper bolts and

lock washers which attach the con-

verter housing to the engine.

3.
Raise the vehicle and remove the

cover from the lower front side of the

converter housing. Drain the fluid

from the transmission.

4.
Remove one of the converter

drain plugs. Then rotate the converter

180 degrees and remove the other

plug. Do not attempt to turn the con-

verter with a wrench on the converter

stud nuts. If desired, the converter

may be drained after the unit has been

removed from the vehicle.

5.
Disconnect the fluid filler tube

from the transmission case. Discon-

nect the vacuum hose from the vacu-

um diaphragm unit and the tube from

the extension housing clip.

6. When the fluid has stopped

draining from the transmission and

converter, remove the flywheel to con-

verter nuts and flat washers. Install

the drain plugs in the converter and

torque to specifications. Install the

converter housing front plate to hold

the converter in place when the trans-

mission is removed.

7.
Disconnect the starter cables

from the starter and remove the start-

er.

8. Disconnect the oil cooler lines

from the transmission. Remove the

transmission vent tube.

9. Disconnect the downshift linkage

from the transmission.

10.
Disconnect the selector rod from

the transmission manual lever with

T67P-7341-A.

11.
Disconnect the speedometer

cable from the extension housing, and

remove the driveshaft.
12.
Support the transmission on a

stand. Remove the engine rear support

to transmission bolts, and raise the

transmission slightly to take the

weight off the cross member. Remove

the cross member. Support the rear

part of the engine.

13.
Remove the remaining convert-

er housing to engine attaching bolts.

Move the assembly to the rear and

down to remove it.

INSTALLATION

1.
If the converter has been re-

moved from the converter housing,

carefully position the converter in the

housing, and then install the housing

lower front cover plate to prevent the

converter from slipping out of the

housing.

2.
Install the transmission vent

tube.
Rotate the converter until the

studs adjacent to the drain plugs are

in a vertical position.

3.
Rotate the flywheel as required

to align the drain plug holes with the

drain plugs in the converter. With the

transmission mounted on a support

stand, move the converter and trans-

mission assembly forward into posi-

tion, using care not to damage the fly-

wheel and the converter pilot.

4.
Install the converter lower

housing-to-engine bolts, then torque

the bolts to specification.

5.
Install the cross member.

6. Lower the transmission until the

extension housing rests on the cross

member, and then install the extension

housing-to-cross member bolts.

7.
The converter must rest squarely

against the flywheel. This indicates

that the converter pilot is not binding

in the engine crankshaft.

8. Install the converter attaching

nuts and flat washers. Install the ac-

cess plates.

9. Connect the oil cooler inlet and

outlet lines to the transmission case.

10.
Coat the front universal joint

yoke seal and spline with B8A-

19589-A lubricant, and install the

drive shaft.

11.
Connect the speedometer cable

at the transmission.

12.
Using tool T67P-7341-A install

a new grommet in the manual lever.

Then secure the manual selector rod

to the lever.

13.
Connect the downshift linkage

and bushing at the transmission

throttle lever.
14.
Install the starter motor.

15.
Connect the fluid filter tube to

the transmission case. Connect the

vacuum hose to the vacuum dia-

phragm unit and the tube to its clip.

16.
Lower the transmission support

stand. Then install the upper two con-

verter housing-to-engine bolts and

tighten them to specification.

17.
Lower the vehicle and fill the

transmission with transmission fluid,

following the recommended procedure.

18.
Check the transmission, con-

verter assembly, and fluid cooler lines

for fluid leaks, and then adjust the

manual and downshift linkages.

TRANSMISSION REPLACEMENT

WITHOUT CONVERTER—

FORD-METEOR

The frame construction of the con-

vertible will not permit the transmis-

sion to be moved rearward enough to

clear the turbine shaft from the con-

verter. For this reason, the converter

and transmission must be removed as

a unit from this model.

REMOVAL

1.
Raise the vehicle on a hoist.

2.
Drain the fluid from the trans-

mission.

3.
Disconnect the hose from the

vacuum diaphragm unit and the tube

from its clip. Disconnect the fluid fill-

er tube from the case.

4.
Remove the cover from the lower

front side of the converter housing.

5.
Remove one of the converter

drain plugs. Then rotate the converter

180 degrees and remove the other

plug. Do not attempt to turn the con-

verter with a wrench on the converter

stud nuts.

6. Disconnect the drive shaft from

the rear axle, and remove the drive

shaft.

7.
Disconnect the fluid cooler lines

from the transmission. Remove the

vent tube.

8. Disconnect the downshift linkage

at the transmission.

9. Disconnect the selector rod from

the transmission manual lever with

tool T67P-7341-A.

10.
Disconnect the speedometer

cable at the extension housing.

11.
Remove the two engine rear

support to transmission bolts.

12.
Position a transmission jack

under the transmission and raise it

slightly to take the weight off the

cross member.procarmanuals.com