1969 FORD MUSTANG lock

04-05-04
Specifications

04-05-04

ATTACHING TORQUE SPECIFICATIONS -(By Axle Ring Gear Diameter)

Description

Differential Bearing Cap Bolt- 7 1/4"

8"

All Others

Differential Bearing Adjusting

Nut Lock Bolts

Carrier
to
Housing Stud Nuts-

8", 8 3/4", 9" 8 3/8"

Pinion Retainer
to
Carrier Bolts-

8", 8 3/4", 9" 9 3/8"

Ring Gear Attaching Bolts-

7 1/4"

All Others

Differential Pinion Shaft

Lock Pin
•
8 1/2" Only
Torque Lbs.
Ft.

40-55

55-70

70-85

12-25

25-40

30-45

40-55

65-80

15-22
Description

Rear Cover Screw and Washer

Assemblies
-8
1/4" &
8
1/2

Only

Oil Filler Plug

Rear Axle Shaft Bearing Retainer

Bolt Nuts:

Falcon,
Fairlane, Montego,

Mustang and Cougar (All)

Ford & Meteor (Exc.
8 1/2" R.G.)

Mercury,
T
Bird

Lincoln Continental (All)

Brake Backing Plate Bolt Nuts-

Ford & Meteor
8
1/2" Only
Torque Lbs.
Ft.

25-35

25-50

20-40

50-75

30-55

20-40

LUBRICANT
CAPACITIES
AND CHECKING PROCEDURES®

Vehicle

Falcon,
Mustang

Cougar, Fairlane, Falcon

Montego, Mustang

Ford,
Meteor

Ford,
Meteor

Cougar, Fairlane, Falcon, Ford,

Mercury, Meteor, Montego, Mustang

Lincoln,
Thunderbird
Engine

(C.I.D.)

170,
200

250,
302

240,
302

240,
302

351,
390,

428,
429

429,
460
Axle

Ratio

All

All

2.80:1,
3.10:1

All Except

2.80:1,
3.10:1

All

All
U.S. Measure

Capacity® (Pints)

2.5

4.0

4.0

5.0

5.0

5.0©
Imperial

Capacity
CD
(Pints)

2

31/5

3 1/5

4.0

4.0

4.0©

©All limited slip and Traction-Lok axles use ESW-M2C-104-A lubricant (C6AZ-19580-C).

All conventional axles use ESW-M2C-105-A lubricant (C6AZ-19580-B).

©Approximate refill capacity-Actual lubricant capacities are determined
by
filling
to
bottom
of
filler hole.

©To check these axles, the plug should be backed
out
slowly.
If
seepage occurs around the threads, the plug should
be
turned back
in

immediately to avoid any drainage. This indicates that the specified amount
of
lubricant
is
present
in
the axle.

SPECIAL TOOLS

FORD,
MERCURY, METEOR

Ford Tool No.

T66L-4204-L

T57L-500-A

T50T-100-A

TOOL-4235-C

T00L-4621-A

TOOL-1225-D

T00L42344

TOOL-1177

TOOL-U75-AB

T57L4220-A

T00L4221-AE

T00L-4221-AF

T66P-4220-P

TOOL-4851-K
Former No.

42211 or

42211-A

6005-M

6005-MS

B-160

4235C

—

—

4234-A

4245-B

1175-AB

—

4221-AF

T57L-4851-A

4851-K
Description

Limited-Slip Differential Check

Bench Fixture

Impact Hammer

Axle Shaft Remover

Drive Pinion Bearing and

Rear Wheel Bear Replacer

Rear Wheel Bearing Remover

Rear Wheel Bearing Installer

Rear Wheel Bearing Oil Seal Installer

Rear Wheel Bearing Oil Seal Remover

Differential Bearing Remover

Differential Bearing Remover

U-Joint
Flange Holder
Ford Tool No.

T53T4851-A

T00L4858-D

T57L4614-A

T00L4621-K

T53L-200-A

T57L-4625-A or

T00L4625-K

T57L4616-A or

T00L4615-D

T58L-101-A

T55P4616-A2

T57L4621-B or

T00L4621-L

T58L4676-A

T00L4858-E
Former No.

4851-A, D

—

4614

4621-K

—

4625-K

—

—

—

—

4676-F

4858-E
Description

U-Joint
Flange Remover

U-Joint
Flange Remover

Drive Pinion Retainer Support

Pinion Rear Bearing Cone Remover

Handle Adapter

Pinion Pilot Bearing Remover and

Installer

Pinion Front Bearing Cup Remover

and Replacer

Puller Attachment—For Bearing

Cup Removal

Pinion Rear Bearing Cup Remover

and Replacer

Pinion Rear Bearing Cone Installer

Drive Pinion Oil Seal Replacer

U-Joint
Flange and Pinion Bearing

Replacerprocarmanuals.com

04-05-05
Specifications

04-05-05

SPECIAL TOOLS

FORD MERCURY, METEOR (Continued)

Ford Tool No.

T57L-4221-A1 or

Tool-4222-K

TOOL 6565-AB

TOOL 6565

TOOLS 4201-C

andD

TOOL-T57L-

4067-A

TOOL-T50T-100-A

T00L-T66L-

12132-B

CJ-6625 (Snap-

On)
Foniisr
NO.

4222-H

6565-AB

6565

4201-C

4067-B

—

—

—
Description

Differential Bearing Installer

Adapter

Dial Indicator

Differential Backlash and Runout

Gauge with Universal Bracket, Dial

Indicator and Bracket

Differential Bearing Adjuster Wrench

Impact Hammer-Long

Adapter

Puller
Ford Tool No.

TOOL-T60K-

7697-B

T00L-T65F-

1177-A

T00L-T65L-

4851-A

TOOL-OTC-951

T00L-T67P-

4616-A

TOOL-T53T-

4621-C
Fomor No.

—

—

—

—

—
Description

Transmission Extension Housing

Bushing Repiacer

Rear Wheel Bearing Oil Seal Repiacer

Flange (Universal Joint) Axle End

Remover

Universal Puller

Pinion Bearing Cups Repiacer

Pinion Bearing Cone Repiacer

COUGAR, FAIRLANE, FALCON,

Ford Tool No.

T50T-100-A

T58L-101-A

T62L-201-A

T56L-400-A

T57L-500-A

T00L-1175-AB

T50T-100-Aand

TOOL-1175-AB

T60K-1177-B

T60K-1225-Aor

T00L-1225-C

TOOL-1225-B

T00L-T54-P-

3044-A

T00L-T57L-

4067-A

T57L-4067-Aor

T60K-4067-A

TOOL-4201-C

andD

T65K-4204A or

T59L-4204-A

T00L-4221-AL

T57L-4221-A

T00L-4222-H

T66L-4235-A
Former No.

B-160

-

4851-A

-

1175-AB

1175-AE

1177-B

4067-B

4221 or

4211-A

4201-C

4067-E

4221-AL

4222-K

4222
MONTEGO, MUSTANG

Description

Impact Hammer

Puller Attachment

Handle Adapter

Puller

Bench Mounted Holding Fixture

Grease Seal Remover (Head Only)

Seal Remover

Rear Wheel Bearing Oil Seal

Axle Shaft Bearing Remover and Repiacer

Axle Shaft Searing Remover

Axle Shaft Bearing Repiacer

Front Suspension Upper and Lower Arm

Overhaul Tool Kit

Differential Bearing Adjuster Nut

Wrench

Limited-Slip Differential Check

Differential Backlash and Runout Gauge

With Universal Bracket, Dial Indicator

and Bracket

Differential Bearing Adjuster Nut

Wrench

Differential Bearing Cone Remover

Pilot (Use with T00L-4221C or

T00L-4851-A)

Differential Bearing Cone Repiacer

Differential Bearing Cone Repiacer

Rear Axle Shaft Assembly Remover

Adapter
Ford Tool No.

T57L-4614-A

T00L-4615-J

T60K-4616-A

T57L-4616-A

T57L-4616-A2

T55P-4616-A2

T00L-4621-K

T62F-4621A

T62F-4625-A

T55P-4676-A

T62F4676A

T53T-4851A

T57L-4851-A

T00L-4858-E

T65K-4204-A

T59L-4204-A

T00L-6565-AB

TOOL-6565
Former No.

4614

4615-J

4615-HF

4625-HR

4615-
E

andP

4615-
E

andF

-

4621-K

4625-AC

land 2

4676-G

4676-
H

4851-A

4858-D

4851-K

4858-
E

—

44211 and

44211-A

6565-AB

6565
Description

Drive Pinion and Drive Pinion Retainer

Assembly Support

Drive Pinion Front Bearing Cup Remover

Pinion Bearing Cup Repiacer

Pinion Front Bearing Cup Remover

Pinion Front Bearing Cup Repiacer

Pinion Rear Bearing Cup Repiacer

Drive Pinion Rear Bearing Cone Remover

Pinion Bearing Cone Repiacer

Drive Pinion Pilot Bearing Remover

and Repiacer

Drive Pinion Oil Seal Repiacer

Drive Pinion Oil Seal Repiacer

Flange (Universal Joint) Axle End

Remover

Universal Joint Flange Holder

Companion Flange and Pinion Bearing

Repiacer

Limited-Slip Differential Torque Check

Adapter

Locking Differential Torque Check

Adapter

Dial Indicator

T68P-4946-A - Traction-Lok Shim Template Toolprocarmanuals.com

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

05-01-05
Drive Shaft
05-01-05

MAJOR REPAIR OPERATIONS

DISASSEMBLY (SINGLE

UNIVERSAL JOINT —

FORD DESIGN)

1.
Place the drive shaft in a vise

being careful not to damage it.

2.
Remove the snap rings that re-

tain the bearings in the slip yoke and

in the drive shaft.

3.
Position the tool shown in Fig. 9

on the shaft and press the bearing out

of the slip yoke. If the bearing cannot

be pressed all the way out of the yoke,

remove it with vise grip or channel

lock pliers.

4.
Reposition the tool to press on

the spider to remove the bearing from

the opposite side of the yoke.

5.
Remove the yoke from the spi-

der.

6. Remove the bearings and spider

from the drive shaft in the same man-

ner.

C 1781-A

FIG. 9—Removing Universal Joint

Bearing
7.
Clean all foreign matter from the

yoke area at each end of the drive

shaft.

ASSEMBLY (SINGLE

UNIVERSAL JOINT-

FORD DESIGN)

1.
Start a new bearing into the

yoke at the rear of the drive shaft.

2.
Position the spider in the rear

yoke and press the bearing 1/4 inch

below the surface (Fig. 10).

3.
Remove the tool and install a

new snap ring.

4.
Start a new bearing into the op-

posite side of the yoke.

5.
Install the tool and press on the

bearing until the opposite bearing con-

tacts the snap ring.

6. Remove the tool and install a

new snap ring. It may be necessary to

grind the surface of the snap ring to

CENTER YOKE
Adapter

C 2062-A

FIG. 11— Partially Pressing Bearing

from Center Yoke

Tool-CJ91B

C 1782-A

FIG. 10—Installing Universal Joint

Bearing
permit easier entry.

7.
Reposition the drive shaft and

install the new spider and two new

bearings in the same manner as the

rear yoke.

8. Position the slip yoke on the spi-

der and install two new bearings,

nylon thrust bearings and snap rings.

9. Check the joint for freedom of

movement. If a bind has resulted from

misalignment during the foregoing

SPIDER

C206J-A

FIG. 12—Removing Bearing from

Center Yoke

BEARING CUP

SPIDER

C 2064-A

FIG. 13—Removing Bearing Cup

from Centering Yoke Socket

C 2065-A

FIG.
14
— Removing Center

Socket Yokeprocarmanuals.com

05-01-06

Drive Shaft

05-01-06

procedures, a sharp rap on the yokes

with a brass hammer will seat the

bearings needles and usually provide

freedom of movement. Care must be

taken to support the shaft end during

this operation, as well as preventing

blows to the bearings themselves. Do

not install the drive shaft unless the

universal joints are free of bind.

DISASSEMBLY (DOUBLE

CARDAN JOINT — LINCOLN

CONTINENTAL — DANA DESIGN)

1.
Mark the position of the spiders,

the center yoke, and the centering

socket yoke as related to the stud

yoke which is welded to the front of

the drive shaft tube. The spiders must

be assembled with the bosses in their

original position to provide proper

clearance.

2.
Remove the snap rings that se-

cure the bearings in the front of the

center yoke.

3.
Position the tool as shown in

Fig. 11. Thread the tool clockwise

until the bearing protrudes approxi-

mately 3/8 inch out of the yoke.

4.
Remove the drive shaft from the

vise.

5.
Tighten the bearing in the vise

and drive on the center yoke as shown

in Fig. 12 to free it from the bearing.

CENTER

YOKE

C 2066-A

FIG. 15—Removing Bearing from

Rear of Center Yoke

SLINGER RING

CENTER YOKE
6. Lift the two bearings (Fig. 13)

from the spider at this time.

7.
Reposition the tool on the yoke

and move the remaining bearing in the

opposite direction so that it protrudes

approximately 3/8 inch out of the

yoke.

8. Grip the bearing in a vise. Drive

on the center yoke to free it from the

bearing (Fig. 12).

9. Remove the spider from the cen-

ter yoke.

10.
Pull the centering socket yoke

off the center stud (Fig. 14). Remove

the rubber seal from the centering ball

stud.

11.
Remove the snap rings from the

center yoke and from the drive shaft

yoke.

12.
Position the tool on the drive

shaft yoke (Fig. 15) and press the

bearing outward until the inside of the

center yoke almost contacts the sling-

er ring at the front of the drive shaft

yoke. Pressing beyond this point can

distort the slinger ring. The arrow in

Fig. 16 illustrates the interference

point.

13.
Clamp the exposed end of the

bearing in a vise and drive on the cen-

ter yoke with a soft-faced hammer to

free it from the bearing.

14.
Reposition the tool and press

on the spider to remove the opposite

bearing.

Tool-CJ91B

C1772-A

FIG. 17—Partially Pressing Bearing

From Center Yoke

C 2067-A

FIG. 16—Center Yoke Interference

Point
C1771-A

FIG. 18—Removing Bearing From

Center Yoke
15.
Remove the center yoke from

the spider.

16.
Remove the spider from the

drive shaft yoke in the same manner.

17.
Clean all serviceable parts in

cleaning solvent. If using a repair kit,

install all of the parts supplied in the

kit. If the drive shaft is damaged, re-

place the complete shaft to be assured

of a balanced assembly.

ASSEMBLY (DOUBLE

CARDON JOINT —

LINCOLN CONTINENTAL —

DANA DESIGN)

1.
To assemble the double cardan

joints,
position the spider in the drive

shaft yoke. Make sure the spider boss-

es (or lubrication plugs on kits) will be

in the same position as originally in-

stalled. Press in the bearing cups. In-

stall the snap rings.

2.
Position the center yoke over the

spider ends and press in the bearing

cups.
Install the snap rings.

3.
Install a new seal on the cen-

tering ball stud. Position the centering

socket yoke on the stud.

4.
Place the front spider in the cen-

ter yoke. Make sure the spider bosses

(or lubrication plugs on kits) are prop-

erly positioned. Press in the bearing

cups and install the snap rings.

5.
Apply pressure on the centering

socket yoke and install the remaining

bearing cup.

6. On kits, remove the plug from

each spider and lubricate the universal

joints.
Reinstall the plug in each spi-

der.

DISASSEMBLY (DOUBLE

CARDAN JOINT — CONTINENTAL

MARK III, THUNDERBORD —

SAGINAW DESIGN)

1.
Working at the rear axle end of

the shaft, mark the position of the spi-

ders,
the center yoke, and the cen-

tering socket yoke as related to the

companion flange. The spiders must

be assembled with the bosses in their

original position to provide proper

clearance.

2.
Position tool CJ91B as shown in

Fig. 17. Thread the tool clockwise

until the injected nylon moulding

snaps and the bearing protrudes ap-

proximately 3/8 inch out of the yoke.

3.
Remove the driveshaft from the

vise.

4.
Tighten the bearing in the vise

and tap on the weld yoke to free the

bearing from the center yoke (Fig.

18).
Do not tap on the driveshaft tube.procarmanuals.com

05-02-03
General Clutch Service
05-02-03

in the direction of the face runout

arrow and its center line is parallel to

the center line of the face runout

arrow.

18.
Determine the amount of the

face runout on the B arrow scale.

19.
The value of the circular line

beneath the amount of face runout

will be the desired reading. If the

reading is in excess of 0.014 inch the

housing alignment is unacceptable.

20.
Remove the Dia-L-lgner gauge

from the flywheel housing.

21.
Install the spark plugs and con-

nect the wires.

ENGINE IN VEHICLE

Since any change in face alignment

will change bore alignment, it may be

possible to correct bore alignment by

changing face alignment. Face align-

ment can be changed by shimming be-

tween the flywheel housing and en-

gine.
Fig. 4 shows the type of shim

which can be fabricated.

Not more than 0.010 inch thickness

shims may be used between the fly-

wheel housing and engine. If a 0.010-

inch shim will not bring face and bore

alignment within limits, replace the

flywheel housing.

The shim required is one half the

maximum (—) indicator reading, and

should be located at the point of max-

imum minus (—) indicator reading.

If both the bore and face alignment

are out of limits, shim between the

flywheel housing and engine to bring

face alignment within limits. Check

the bore alignment.

If the bore alignment is out of lim-

its and the face alignment is within

limits,
shim the flywheel housing to

the limit of face misalignment and

check the bore alignment. If it is not

within limits, replace the housing.

ENGINE OUT OF VEHICLE

The same procedure to correct

alignment may be used with the en-

gine out of the vehicle or in the vehi-

cle,
up to the point of replacing the

flywheel housing. If the bore align-

ment cannot be brought within limits

by shimming, follow this procedure:

dure:

1.
Remove the flywheel housing

from the engine and remove the dowel

pins.
Install the flywheel housing and

tighten the attaching bolts.

2.
Install the dial indicator (Fig. 1).

Check the face alignment, and shim as
C2068-A

. 3—Dia-L-lgner Gauge Installed

required to bring face alignment with-

in limits.

3.
Position the indicator to check

the bore alignment. If the bore align-

ment is not within limits, reduce the

tension on the flywheel housing at-

taching bolts so that the housing can

be moved by striking it with a lead

hammer or a block of wood and a

steel hammer.

4.
The lateral alignment should be

brought within limits so that an indi-

cator reading is within limits between

the 9 o'clock and the 3 o'clock posi-

tions on the bore circle. When the lat-

eral alignment is within limits the

housing usually can be moved straight

up or down without disturbing the lat-

eral alignment. When alignment is

within limits, torque the housing bolts

and recheck bore alignment.

5.
If the flywheel housing cannot be

moved enough to bring the alignment

within limits, mark the holes restrict-

ing movement, and then remove the

housing and drill the marked bolt

holes 1/32 inch larger.

6. When the flywheel housing bore

alignment is within limits and the at-

taching bolts are at normal torque,
C 178 4-A

FIG. 4— Fabricated Flywheel

Housing Shim

hand ream the dowel pin holes 1/32

inch larger. Use a straight reamer and

ream from the flywheel housing side.

Oversize dowel pins can be made from

drill rod stock.

7.
Remove the flywheel housing

and then install the oversize dowel

pins in the cylinder block. Complete

the assembly in the usual way.

8. Recheck the flywheel housing

with the Dia-L-lgner gauge to make

sure that the housing is within the spe-

cified limits.procarmanuals.com

05-03-02

Clutch
05-03-02

IN-VEHICLE ADJUSTMENTS AND REPAIRS

SPRING-7A600

EQJALIZER ROD-7A516

EQUALIZER BAR-7528

SPRING-7523
FELTWASHER-375475

EQUALIZER
EQUALIZER ROD-7A516

LOCKNUT-34809-S7

RELEASE ROD/

7B543

SNAP RING-7A629

OUTER BRACKET-7507

PIVOT-7A531

RELEASE ROD-7B543

RELEASE ROD-7B543

OUTER EQUALIZER BAR-7528
BUSHING-7526

SPRING-7A632

SNAP RING-7A629

FELT WASHER-375475-S
BUSHING-7543 SPRING-7523

FELT WASHER-358979-S

SPRING-7545

FAIRLANE AND MONTEGO

390 AND 428 ENGINES
FAIRLANE AND MONTEGO

302 AND 351

FIG.
2—Clutch
Pedal and Linkage Adjustment — Fairlane, Montego and Falcon

ASSIST SPRING BRACKET 7535-
ASSIST SPRING 7B572

SPRING

7A632

RELEASE ROD 7B543

390 ENGINE

SAME AS MAIN VIEW

EXCEPT AS SHOWN
351 ENGINE

SAME AS MAIN VIEW

EXCEPT AS SHOWN

C2056-A

FIG.
3—Clutch
Pedal and Linkage Adjustment — Mustang, Cougarprocarmanuals.com

05-03-03
Clutch
05-03-03

CLUTCH PEDAL

ADJUSTMENTS

Adjust
the
clutch pedal free travel

whenever
the
clutch does
not
disen-

gage properly,
or
when
new
clutch

parts
are
installed. Improper adjust-

ment
of the
clutch pedal
is one of the

most frequent causes
of
clutch failure

and
can be a
contributing factor
in

some transmission failures.

FREE TRAVEL

1.
Disconnect
the
clutch return

spring from
the
release lever.

2.
Loosen
the
release lever
rod

locknut
and
adjusting
nut
(Figs.
1, 2

and
3).

3.
Move
the
clutch release lever

rearward until
the
release bearing

lightly contacts
the
clutch pressure

plate release fingers.

4.
Adjust
the rod
length until
the

rod seats
in the
release lever pocket.

5.
Insert
the
specified feeler gauge

between
the
adjusting
nut and the

swivel sleeve. Then tighten
the
adjust-

ing
nut
against
the
gauge finger tight.

6. Tighten
the
locknut against
the

adjusting
nut,
being careful
not to di-

sturb
the
adjustment. Torque
the
lock-

nut
to
specification
and
remove
the

feeler gauge.

7.
Install
the
clutch return spring.

8. Check
the
free travel
at the
pedal

for conformance
to
specification.
Re-
adjust
if
necessary.

9.
As a
final check, measure
the

pedal free travel with
the
transmission

in neutral
and the
engine running
at

about 3000
rpm. If the
pedal free

travel
at
this speed
is not a
minimum

of
1/2
inch, readjust
the
clutch pedal

free travel. Otherwise,
the
release
fin-

gers
may
contact
the
release bearing

continuously, resulting
in
premature

bearing
and
clutch failure. Free travel

must
be
exactly
to
specification.

CLUTCH ASSIST

SPRING REPLACEMENT

(FAIRLANE, FALCON,

MONTEGO)

1.
Remove
the
cotter
pin
from
the

clutch
rod at the
clutch pedal lever
as-

sembly inside
the
passenger compart-

ment.

2.
Grasp
the
clutch pedal lever

firmly
to
prevent slipping
and
remove

the clutch
rod
from
the
lever. Allow

the clutch pedal lever
to
rest
on the

floor panel.

3.
Remove
the
forward bolt secur-

ing
the
assist spring bracket
to the

brake pedal bracket
and
loosen
the

rear bolt
two or
three turns.
Do not

remove
the
rear bolt.

4.
Grasp
the
assist spring bracket

with pliers
and
rotate upward until
the

spring
can be
separated from
the

bracket.

BRAKE PEDAL

BRACKET

CLUTCH ASSIST SPRING

BRACKET
-
7535

CLUTCH PEDAL

7519
5.
Position
the
assist spring
in the

clutch pedal spring bracket
and the

assist spring bracket. Rotate
the

spring bracket downward until
the

forward bolt holes
in the
assist spring

bracket line
up
with
the
holes
in the

brake pedal bracket
(Fig. 4).

6. Install
the
forward bolt retaining

the assist spring bracket
to the
brake

pedal bracket
and
torque
the
forward

and rear bolts
to
specification.

7.
Install
the
clutch
rod to the

clutch pedal lever
and
insert
the
cotter

pin.

CLUTCH PEDAL, PEDAL

ASSIST SPRING AND/OR

BUSHING REMOVAL

AND INSTALLATION

FORD, MERCURY,

METEOR

1.
Remove
the pin
that secures
the

clutch pedal-to-equalizer
rod to the

clutch pedal.

2.
Grasp
the
clutch pecal lever

firmly
to
prevent slipping
and
remove

the clutch
rod
from
the
lever. Allow

the clutch pedal lever
to
rest
on the

floor.

3.
Loosen
the
lower bolt securing

the assist spring bracket
to the
pedal

support bracket
two or
three turns.

Then, remove
the
upper bolt from
the

bracket.
Do not
remove
the
lower

bolt.

4.
Grasp
the
assist spring bracket

with pliers
and
rotate
it
counterclock-

wise until
the
spring
is
free
(Fig 5).

5.
Remove
the
retaining ring from

the
end of the
clutch pedal shaft. Then

remove
the
shaft, bushings
and
clutch

pedal from
the
support.

6. Remove
the
bushings from
the

pedal shaft
and
pedal support
and

transfer
the
rubber pedal
pad.

7.
After lubricating
the
pedal shaft

ASSIST SPRING

LOWER BOLT

ASSIST SPRING BRACKET-

UPPER
BOL"

C 1769-B

FIG. 4—Clutch Pedal Assembly
—
Fairlane, Montego, Falcon
C2058-A

;. 5—Removing Clutch Assist

Spring
—
Ford,
Mercury and Meteorprocarmanuals.com