seats 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 6 of 413
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
Page 7 of 413
01-01-03
Vehicle Identification
01-01-03
BODY SERIAL AND STYLE CODES-(continued)
MONTEGO
Body
Serial
Code
01
02
06
07
10
11
12
11
12
10
11
Body
Style
Code
65A
54A
54B
65B
54D
65D
76D
65 E
76B
54C
65C
Body Type
2-Door Hardtop-formal
(Sports Coupe)®
4-Door Sedan (Sports)®
4-Door Sedan®
2-Door Hardtop-Formal®
4-Door Sedan®
2-Door Hardtop-Formal®
Convertible®
2-Door Hardtop-Formal©
Convertible®
4-Door Sedan®
2-Door Hardtop-Formal®
Model
Comet
Montego
Montego MX
Montego MX
Montego MX Brougham
MUSTANG
15
63A
2-Door Hardtop Fastback®
(GT Appearance Opt.®) Cyclone
15
63C
2-Door Hardtop Fastback®
16
63H
2-Door Hardtop Fastback®
(Sports Appearance Opt.©) Cyclone CJ
03
71B
Montego®
08
71C
Montego MX®
08
71A
Montego MX (Woodgrain)®
Station Wagons-4 Door
©Bench Seat ©Split Bench ©Bucket Seats
THUNDERBIRD
Body Body
Serial Style
Code Code
Body Type
Model
83
65A
2-Door Hardtop®
83
65C
2-Door Hardtop®
84
65B
2-Door Landau
®
84
65D
2-Door Landau
®
87
57B
4-Door Landau
©
87
57C
4-Door Landau
®
©Bench Seat ©Split Bench ©Bucket Seats ©Blind Quarter Roof
FALCON
Body
Serial
Code
10
11
20
22
21
12
23
Body
Style
Code
62A
54A
62B
62C
54B
71A
71B
©Bench Seat
Body Type
2-Door Sedan®
4-Door Sedan®
2-Door Sedan®
2-Door Sports Coupe®
4-Door Sedan©
Standard©
Futura©
©Split Bench
Model
Standard
Futura
Station Wagons
-4 Door
©Bucket Seat
Body
Serial
Code
01
02
03
01
02
03
01
01
01
02
Body
Style
Code
65A
63A
76A
65B
63B
76B
65C
65D
65E
63C
©Bench Seat
Body Type
2-Door Hardtop©©
2-Door Fastback©®
Convertible®®
2-Door Hardtop®®
2-Door Fastback®©
Convertible©®
2-Door Hardtop®
2-Door Hardtop®
2-Door Hardtop©
2-Door Fastback®
Model
Standard
Luxury
Standard
Luxury
Grand
Machl
©Split Bench ©Bucket Seats ©Hi-Back Bucket
FORD
Body
Serial
Code
50
51
52
53
Body
Style
Code
62E
54 E
62B
54B
Body Type
2-Door Sedan®
4-Door Sedan®
2-Door Sedan®
4-Door Sedan®
Model
Custom
Custom 500
54
54A
4-Door Sedan®
55
63B
2-Door Hardtop-Fastback®
58
65C
2-Door Hardtop-Formal®
Galaxie 500
56
57
60
61
64
62
66
57B
76A
63C
76B
54C
65A
57F
4-Door Hardtop®
Convertible®
2-Door Hardtop-Fastback®®
Convertible®©
4-Door Sedan®®
2-Door Hardtop-Formal®®
4-Door Hardtop®©
Ford XL
Ford LTD
70
71D
Ranchwagon-6 Passenger©
71
71H
Custom 500 Ranchwagon-
6 Passenger©
72
71J
Custom 500 Ranchwagon-
Dual Face Rear©
73
71B
Country Sedan-6 Passenger®
74
71C
Country Sedan-Dual Face Rear®
75
71E
Country Squire—6 Passenger®
76
71A
Country Squire-Dual Face Rear®
Station Wagons-4 Door
©Bench Seat ©Split Bench ©Bucket Seatsprocarmanuals.com
Page 8 of 413
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
Page 58 of 413
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
Page 67 of 413
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
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 78 of 413
03-02-02
Suspension
03-02-02
COMPONENT INDEX
REAR SPRING
Disassembly
and
Overhaul
Removal
and
Installation
REAR SUSPENSION
Description
REAR SUSPENSION LOWER
ARM
Removal
and
Installation
REAR SUSPENSION UPPER
ARM
Removal
and
Installation
SPRING LEAVES
AND
TIE-BOLT
Removal
and
Installation
STABILIZER
Removal
and
Installation
TRACK
BAR
Removal
and
Installation
UPPER
ARM
-
REMOVED
Removal
and
Installation
UPPER
ARM
SHAFT AND/OR BUSHING
Removal
and
Installation
UPPER BALL JOINT
Removal
and
Installation
MODEL APPLICATION
All
Models
Ford
N/A
02-23
02-02
02-24
02-25
N/A
02-11
02-25
N/A
N/A
02-08
Mercury
N/A
02-23
02-02
02-24
02-25
N/A
02-11
02-25
N/A
N/A
02-08
Meteor
N/A
02-23
02-02
02-24
02-25
N/A
02-11
02-25
N/A
N/A
02-08
Cougar
N/A
02-25
02-04
N/A
N/A
N/A
02-11
N/A
N/A
02-09
02-08
Fairlane
N/A
02-25
02-04
N/A
N/A
N/A
02-11
N/A
N/A
02-09
02-08
Falcon
N/A
02-25
02-04
N/A
N/A
N/A
02-11
N/A
N/A
02-09
02-08
Montego
N/A
02-25
02-04
N/A
N/A
N/A
02-11
N/A
N/A
02-09
02-08
Mustang
N/A
02-25
02-04
N/A
N/A
N/A
02-11
N/A
N/A
02-09
02-08
Lincoln-
Continental
02-28
02-26
02-04
N/A
N/A
02-29
N/A
N/A
02-27
N/A
02-10
Thunderbird
N/A
02-23
02-02
02-24
02-25
N/A
02-11
02-25
N/A
N/A
02-08
Continental-
Mark III
N/A
02-23
02-02
02-24
02-25
N/A
02-11
02-25
N/A
N/A
02-08
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.
DESCRIPTION
FRONT SUSPENSION
Each front wheel rotates
on a
spindle.
The
upper
and
lower ends
of
the spindle
are
attached
to
upper
and
lower ball joints which
are
mounted
to
an upper
and
lower
arm
respectively.
The upper
arm
pivots
on a
bushing
and shaft assembly which
is
bolted
to
the frame.
The
lower
arm
pivots
on a
bolt
in the
front crossmember (Figs.
1,
2
and 3). A
coil spring seats between
the lower (upper
on
Cougar, Fairlane,
Falcon, Montego
and
Mustang)
arm
and
the top of the
spring housing.
A
double action shock absorber
is
bolted
to
the arm and the top of the
spring
housing.
REAR SUSPENSION
FORD, MERCURY,
METEOR, THUNDERBIRD
AND
CONTINENTAL MARK
III
Each rear wheel,
hub, and
brake
drum assembly
is
bolted
to the
rear
axle shaft flange.
The
axle shaft
as-
sembly rotates
in the
rear axle hous-
ing.
The rear axle housing
is
suspended
from
the
frame
by a
coil spring
and
shock absorber
at
each side
of the ve-
hicle
and by
three arms
(one
upper
and
two
lower) which pivot
in the
frame members
(Fig.
4).
Each coil spring
is
mounted
be-
tween
a
lower seat, which
is
welded
to
the axle housing,
and an
upper seat
which
is
integral with
the
frame.
The upper
end
of
the
rear shock
ab-
sorber
is
attached
to the
spring upper
seat;
the
lower
end is
bolted
to a
bracket
on the
axle housing.
The upper suspension
arm
attaches
to
the
right side
of the
axle housing
through
an
eccentric pivot bolt
and a
bracket which
is
welded
to the top of
the housing.
The
forward
end of the
arm
is
connected
by a
pivot bolt
to
the frame crossmember.
Each lower suspension
arm
attaches
to
one end of the
axle housing
through
a
pivot bolt
and a
bracket
which
is
welded
to the
underside
of
the housing.
The
forward
end of the
arm
is
connected
by a
pivot bolt
to
the frame side member.
A track
bar is
connected between
the upper
arm
bracket
on the
axle
housing
and a
mounting bracket
on
the left frame side rail.
procarmanuals.com
Page 100 of 413
03-02-24
Suspension
03-02-24
LOCK NUT
INSULATOR
NG
NUT
MOUNTING STUD
WASHER
LOCK WASHER
FIG. 31—Rear Shock Absorber Mounting
F1486-A
TRACK BAR
MOUNTING
STUD AXLE
VENT
SHOCK
ABSORBER
MOUNTING
BRACKET
SHOCK
ABSORBER
MOUNTING
BRACKET
V-V.
FIG. 32—Removing or Installing Rear Spring—Typical
COIL SPRING
F1438-A
Place jack stands under the frame side
rails.
2.
Disconnect the lower studs of the
two rear shock absorbers from the
mounting brackets on axle housing.
3.
Lower the hoist and axle housing
until the coil springs are released (Fig.
32).
4.
Remove the springs and the insu-
lators from the vehicle.
Installation
1.
Position the spring in the upper
and lower seats with an insulator be-
tween each seat and the spring.
2.
Raise the hoist and axle housing
with the spring in position and con-
nect the lower studs of the rear shock
absorbers to the mounting brackets on
the axle housing. Install the attaching
nuts,
and torque to specifications.
3.
Remove the jack stands and
lower the vehicle.
REAR SUSPENSION
LOWER ARM
FORD, MERCURY,
METEOR, THUNDERBIRD,
CONTINENTAL MARK III
Removal
1.
Raise the vehicle on a hoist and
place jack stands under the frame side
rails.
2.
Remove the attaching nut and
bolt from the frame track bar mount-
ing bracket and disconnect the bar
from the stud (Fig. 4).
3.
Lower the axle enough to relieve
spring pressure.
4.
Support axle under differential
pinion nose as well as under axle.
5.
Remove the lower arm pivot bolt
and nut from the axle bracket. Then,
disengage the lower arm from the
bracket.
6. Remove the pivot bolt and nut
from the frame bracket and remove
the lower arm from the vehicle.
Installation
The rear suspension lower arms are
not interchangeable. The lower arm
for the left side can be identified by
notches in the bushing flange (Fig. 4).
The right arm does not have the
notches.
1.
Position the lower arm in the
bracket on the frame side rail. Install
a new pivot bolt and new nut (Fig.
33).
Do not tighten the nut at this
time.
2.
Position the lower arm to the
axle bracket and install a new bolt
and new nut (Fig. 33). Do not tighten
the nut at this time.
3.
Raise the axle.
4.
Install alignment spacers be-
tween the rear axle and frame (Fig. 3,
Part 3-1). Then, torque the lower armprocarmanuals.com
Page 103 of 413
03-02-27
Suspension
03-02-27
MAJOR
REPAIR OPERATIONS
FRONT
SUSPENSION UPPER
ARM
BUSHINGS—ARM
REMOVED
FORD, MERCURY,
METEOR, THUNDERBIRD,
CONTINENTAL MARK III
1.
Remove the nuts and washers
from both ends of the upper arm inner
shaft.
2.
Install Tool T65P-3044-A1 on
the inner shaft and place Tool T65P-
3044-A3 inside the upper arm around
the inner shaft (Fig. 36).
F1440-A
FIG.
36—Removing Upper Arm
Bushings
3.
Position the upper arm in an
arbor press on Tool T65P-3044-A4
(Fig. 36), and press the lower bushing
out of the upper arm.
4.
Remove the bushing from the
inner shaft; turn the assembly over
and remove the bushing from the
other side of the arm. It may be nec-
essary to remove Tool T65P-3044-A1
from the inner shaft and remove the
shaft from the arm to remove the
bushing from the shaft. Then, install
the tool on the shaft and remove the
other bushing.
5. Position the shaft and bushings
to the upper arm and install the bush-
ings and inner shaft in the upper arm
as shown in Fig. 37.
6. Install a washer and new nut on
each end of the inner shaft.
PRESS
RAM
Tool—3069-AA
Tool
- T65P
3044
- A3
Tool
- T65P
3044
- A2
F1441-A
FIG.
37—Installing Upper Arm
Shaft
Bushings
LOWER
ARM OVERHAUL-
ARM
REMOVED
LINCOLN CONTINENTAL
Inspect the lower arm, bushings and
pivot bolt for cracks, bends, wear or
other damage. Replace the arm if nec-
essary.
1. If the ball joint requires replace-
ment, remove the rivet heads with a
chisel. Punch the remaining portion of
the rivets from the holes.
Do not wash the ball joint with sol-
vent. The solvent may attack parts
within the joint.
2.
If the bushing requires replace-
ment, press it out of the arm with
Tool 3069—details H, AA, and AA2
(Fig. 38).
3.
Apply silicone or liquid soap to
the shell of the new bushing. Place the
bushing in the arm with the flange end
(large end) of the bushing at the front
of the arm.
4.
Press the bushing into the arm
until the shoulder on the bushing shell
seats against the arm. Use tool
3069—details H, AA2, and M5 (Fig.
39).
F
1483-A
FIG.
38—Removing Lower Arm
Bushing
PRESS
RAM
1482-A
FIG.
39—Installing Lower Arm
Bushing
5.
If the ball joint was removed, in-
stall the new joint using the parts sup-
plied in the ball joint kit. Torque the
nuts to specification. Make sure the
joint is completely filled with the spec-
ified lubricant.
UPPER
ARM OVERHAUL-
ARM
REMOVED
LINCOLN CONTINENTAL
Inspect the upper arm and the inner
shaft for cracks, bends or other dam-
age.
Replace the parts as required.
Replacement arms come with the
bushings, inner shaft, and ball joint
installed. If the original arm is to beprocarmanuals.com
Page 142 of 413
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