1969 FORD MUSTANG Volume One Chassis

03-08-01
Ford Design Integral Power Steering Gear

03-08-01

PART
3-8
Ford Design Integral Power

Steering Gear

COMPONENT INDEX

STEERING GEAR

Adjustments

Cleaning
and
Inspection
(See

Part 03-01)

Description

Disassembly
and
Assembly

Overhaul

Removal
and
Installation

VALVE CENTERING SHIM

Removal
and
Installation

VALVE SPOOL CENTERING CHECK
MODEL APPLICATION
All Models
Ford

08-02

08-01

08-05

08-06

08-03

08-03

08-02
Mercury
08-02

08-01

08-05

08-06

08-03

08-03

08-02
Meteor
08-02

08-01

08-05

08-06

08-03

08-03

08-02
Cougar
N/A

N/A

N/A

N/A

N/A

N/A

N/A
Fairlane
N/A

N/A

N/A

N/A

N/A

N/A

N/A
Falcon
N/A

N/A

N/A

N/A

N/A

N/A

N/A
Montego
N/A

N/A

N/A

N/A

N/A

N/A

N/A
Mustang
N/A

N/A

N/A

N/A

N/A

N/A

N/A
Lincoln-
Continental
08-02

08-01

08-05

08-06

08-03

08-03

08-02
Thunderbird
08-02

08-01

08-05

08-06

08-03

08-03

08-02
Continental-
Mark
III
08-02

08-01

08-05

08-06

08-03

08-03

08-02

DESCRIPTION

The Ford integral power steering

unit
(Fig. 1) is a
torsion-bar type
of

hydraulic assisted system. This system

furnishes power
to
reduce
the
amount

of turning effort required
at the
steer-

ing wheel.
It
also reduces road shock

and vibrations.

The torsion
bar
power steering unit

includes
a
worm
and
one-piece rack

piston, which
is
meshed
to the
gear

teeth
on the
steering sector shaft.
The

unit also includes
a
hydraulic valve,

valve actuator, input shaft
and
torsion

bar assembly which
are
mounted
on

the
end of the
worm shaft
and
operat-

ed
by the
twisting action
of the tor-

sion
bar.

The torsion-bar type
of
power steer-

ing gear
is
designed with
the one
piece
rack-piston, worm
and
sector shaft
in

one housing
and the
valve spool
in an

attaching housing
(Fig. 1).
This makes

possible internal fluid passages
bet-

ween
the
valve
and
cylinder, thus
eli-

minating
all
external lines
and
hoses,

except
the
pressure
and
return hoses

between
the
pump
and
gear assembly.

The power cylinder
is an
integral

part
of the
gear housing.
The
piston
is

double acting,
in
that fluid pressure

may
be
applied
to
either side
of the

piston.

A selective metal shim located
in

the valve housing
of the
gear
is for the

purpose
of
tailoring steering gear
ef-

forts.
If
efforts
are not
within specifi-

cations they
can be
changed
by in-
creasing
or
decreasing shim thickness

as follows:

Efforts heavy
to the
left—Increase

shim thickness.

Efforts light
to the
left—Decrease

shim thickness.

A change
of one
shim size will
in-

crease
or
decrease steering efforts
ap-

proximately
1 1/2
in-lbs.

Shims
are
available
in the
following

thicknesses
and are
notched
on the

outside diameter
for
identification:

0.0057-0.0063 inch—0 notch

0.0077-0.0083 inch—1 notch

0.0097-0.0103 inch—2 notches

0.0117-0.0123 inch—3 notches

0.0137-0.0143 inch—4 notches

Do
not use
more than
one
shim.
procarmanuals.com

03-08-02
Ford Design Integral Power Steering Gear

03-08-02

-INPUT SHAFT

OUTLET PORT

INLET PORT

CONTROL VALVE HOUSING

SECTOR SHAFT COVER

SECTOR SHAFT ADJUSTMENT SCREW

LOCK NUT

IDENTIFICATION TAG

SECTOR SHAFT

FIG.
1—Power
Steering Gear
G1545- A

IN-VEH1CLE ADJUSTMENTS AND REPAIRS

VALVE SPOOL

CENTERING CHECK

1.
Install a 0-2000 psi pressure

gauge Tool T56L-33610-D in the pres-

sure line between the power steering

pump outlet port and the integral

steering gear inlet port.

2.
Make sure that the valve on the

gauge is in the fully open position.

3.
Check the fluid level in the reser-

voir and fill it to proper level with the

specified fluid.

4.
Start the engine and cycle the

steering wheel from stop-to-stop, to

bring the steering lubricant up to nor-

mal operating temperature. Stop the
engine and recheck the reservoir. Add

fluid if necessary.

5.
With the engine running at ap-

proximately 1000 rpm and the steer-

ing wheel centered, attach an inch-

pound torque wrench to the steering

wheel retaining nut. Apply sufficient

torque to the torque wrench in each

direction, either side of center, to get

a gauge reading of 250 psi.

6. The torque reading should be the

same in both directions when 250 psi

is reached. If the difference between

the readings exceeds 4 in-lbs, the

steering gear must be removed and the

valve centering shim removed from the

valve housing and a thicker or thinner
shim installed. Only one shim is to be

used. If the steering effort is heavy,

the shim thickness should be in-

creased. Shim thickness should be de-

creased if the steering effort is light to

the left.

The out of vehicle procedure for

valve centering check is the same as

for the in vehicle except the torque

and simultaneous pressure reading

must be made at the right and left

stops instead of either side of center.

STEERING GEAR

ADJUSTMENTS

During the vehicle breaking-in peri-

od, it is probable that some of theprocarmanuals.com

03-08-03
Ford Design Integral Power Steering Gear

03-08-03

factory adjustments will change. These

changes in adjustment do not neces-

sarily affect the satisfactory operation

of the steering gear assembly, and

therefore ordinarily do not require

readjustment unless there is excessive

lash or other malfunctioning.

ADJUSTMENT IN

VEHICLE

The only adjustment which can be

performed is the total over center

position load, to eliminate excessive

lash between the sector and rack

teeth.

1.
Disconnect the pitman arm from

the sector shaft.

2.
Disconnect the fluid return line

at the reservoir, at the same time cap

the reservoir return line pipe.

3.
Place the end of the return line

in a clean container and cycle the
INPUT SHAFT

SECTOR SHAFT

ADJUSTMENT SCREW

C1547- A

FIG.
2—Adjusting Mesh Load

steering wheel in both directions as re-

quired, to discharge the fluid from the

gear.
4.
Remove the ornamental cover

from the steering wheel hub and turn

the steering wheel to 45 degrees from

the left stop.

5.
Using an in-lb torque wrench on

the steering wheel nut, determine the

torque required to rotate the shaft

slowly through an approximately 1/8

turn from the 45 degree position.

6. Turn the steering gear back to

center, then determine the torque re-

quired to rotate the shaft back and

forth across the center position. Loos-

en the adjuster nut, and turn the ad-

juster screw in (Fig. 2) until the read-

ing is 8-9 in-lb greater than the torque

45 degrees from the stop.

Tighten the lock nut while holding

the screw in place.

7.
Recheck the readings and replace

pitman arm and steering wheel hub

cover.

8. Connect the fluid return line to

the reservoir and fill the reservoir with

specified lubricant to the proper level.

REMOVAL AND INSTALLATION

REMOVAL

1.
Disconnect the pressure and the

return lines from the steering gear.

Plug the lines and the ports in the

gear to prevent entry of dirt.

2.
Remove the two bolts that secure

the flex coupling to the steering gear

and to the column.

3.
Raise the vehicle and remove the

sector shaft attaching nut.

4.
Remove the Pitman arm from

the sector shaft with Tool T64P-

3590-F.
Remove the tool from the

Pitman arm. Do not damage the

seals.

5.
If working on a vehicle equipped

with a standard transmission, remove

the clutch release lever retracting

spring to provide clearance for remov-

ing the steering gear.
6. Support the steering gear then

remove the three steering gear attach-

ing bolts.

7.
Work steering gear free of the

flex coupling and remove it from the

vehicle.

8. If the flex coupling stayed on the

input shaft, lift if off the shaft at this

time.

INSTALLATION

1.
Slide the flex coupling into place

on the steering shaft. Turn the steer-

ing wheel so that the spokes are in the

horizontal position.

2.
Center the steering gear input

shaft.

3.
Slide the steering gear input

shaft into the flex coupling and into
place on the frame side rail. Install

the three attaching bolts and torque

them to specification.

4.
Make sure that the wheels are in

the straight ahead position, then in-

stall the Pitman arm on the sector

shaft. Install and tighten the sector

shaft and install and tighten the at-

taching bolts to specification.

5.
Move the flex coupling into

place on the input and steering co-

lumn shaft and install and tighten the

attaching bolts to specification.

6. Connect and tighten the fluid

pressure and the return line to the

steering gear.

7.
Fill the power steering pump and

cycle the steering gear. Check for

leaks and again check the fluid level.

Add fluid as required.

MAJOR REPAIR OPERATIONS

In most cases, complete disassembly

of the power steering gear will not be

necessary. It is suggested that only

those assemblies that are faulty be dis-

assembled. Disassembly and reassem-

bly of the unit and the subassemblies

must be made on a clean workbench.

As in repairing any hydraulically op-

erated unit, cleanliness is of utmost

importance. Therefore, the bench,
tools,
and parts must be kept clean at

all times. Thoroughly clean the exter-

ior of the unit with a suitable solvent

and when necessary, drain as much of

the hydraulic oil 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.
VALVE CENTERING

SHIM REPLACEMENT

1.
Hold the steering gear over a

drain pan in an inverted position and

cycle the input shaft several times to

drain the remaining fluid from the

gear.

2.
Mount the gear in a soft-jawed

vise.procarmanuals.com

03-08-04
Ford Design Integral Power Steering Gear

03-08-04

3.
Turn the input shaft to either

stop then, turn it back approximately

1 3/4 turns to center the gear.

4.
Remove the two sector shaft

cover attaching screws and the
identif-

ication tag.

5.
Tap the lower end of the sector

shaft with a soft-faced hammer to

loosen it, then lift the cover and shaft

from the housing as an assembly. Dis-

card the O-ring.

6. Remove the four valve housing

attaching bolts. Lift the valve housing

from the steering gear housing while

holding the piston to prevent it from

rotating off the worm shaft.

7.
Remove the valve housing and

the lube passage O-ring and discard

them.

8. Place the valve housing, worm

and piston assembly in the bench

mounted holding fixture Tool T57L-

500-A with the piston on the top.

9. Rotate the piston upward (back

off) 3 1/2 turns.

10.
Insert Tool T66P-3553-C (with

the arm facing away from the piston)

into a bolt hole in the valve housing.

Rotate the arm into position under

the piston (Fig. 3).

11.
Using Tool T66P-3553-B, loos-

en the worm bearing lock nut.

12.
Hold the lock nut up out of the

way and loosen the attaching nut (Fig.

4).

13.
Lift the piston-worm assembly

from the valve housing. During remov-

al hold the piston to prevent it.from

spinning off of the shaft.

14.
Change the power steering valve

centering shim.

15.
Install the piston-worm assem-

bly into the valve housing. Hold the

piston worm to prevent it from spin-

ning off of the shaft.

16.
Install the valve housing attach-

ing nut and torque to specification

(Fig. 5).

17.
Install the power steering worm

bearing lock nut with Tool T66P-

3553-B and torque to specifications.

18.
Rotate the piston upward (back

off) 1/2 turn and remove Tool T66P-

3553-C.

19.
Remove the valve housing,

worm, and piston assembly from the

holding fixture.

20.
Position a new lube passage O-

ring in the counterbore of the gear

housing.

21.
Apply vaseline to the teflon seal

on the piston.

22.
Place a new O-ring on the valve

housing.

23.
Slide the piston and valve into

the gear housing being careful not to

damage the teflon seal.
G1365-A

FIG. 3—Removing Worm Bearing Lock Nut

Tool-T66P-3553-C

G1367-A

FIG. 4—Removing Valve Housing Attaching Nutprocarmanuals.com

03-08-05

Ford Design Integral Power Steering Gear

03-08-05

rque Wrench

Tool-T66P-3553-C

G1366-A

FIG.
5—Installing Valve Housing Attaching
Nut
24.
Align
the
lube passage
in the

valve housing with
the
one
in
the gear

housing,
and
install but
do
not tighten

the attaching bolts.

25.
Rotate
the
ball
nut so
that
the

teeth
are in the
same place
as
the sec-

tor teeth. Tighten
the
four valve hous-

ing attaching bolts
to
specification.

26.
Position
the
sector shaft cover

O-ring
in the
steering gear housing.

Turn
the
input shaft
as
required
to

center
the
piston.

27.
Apply vaseline
to the
sector

shaft journal; then, position
the
sector

shaft
and
cover assembly
in
the
gear

housing. Install
the
steering gear iden-

tification
tag and the
two sector shaft

cover attaching bolts.

28.
Position
an
in-lb torque wrench

on
the
gear input shaft
and
adjust
the

meshload
to
approximately
4
in-lbs.

Then, torque the sector shaft cover
at-

taching bolts
to
specification (Part

3-13).

29.
After
the
cover attaching bolts

have been tightened
to
specification,

adjust
the
meshload
to
specification

with
an
in-lb torque wrench.

STEERING GEAR

DISASSEMBLY

1.
Hold
the
steering gear over
a

drain
pan
in an
inverted position
and

cycle
the
input shaft several times
to

CENTERING SHIM

WORM AND VALVE ASSEMBLY

LOCK NUT

PISTON AND BALL NUT
VALVE HOUSING

TEFLON RING

•BALL GUIDE CLAMP

0-RING
BALL GUIDES

G1548-A

FIG.
6 —
Ball
Nut and
Valve Housing Disassembledprocarmanuals.com

03-08-06

Ford Design Integral Power Steering Gear

03-08-06

VALVE HOUSING

7W-T65P

C1239 -A

FIG. 7—Removing or Installing Lock

Nut

drain the remaining fluid from the

gear.

2.
Mount the gear in a soft-jawed

vise.

3.
Remove the lock nut and the

brass washer from the adjusting screw.

4.
Turn the input shaft to either

stop then, turn it back approximately

1 3/4 turns to center the gear.

5.
Remove the two sector shaft

cover attaching screws and the
identif-

ication tag.

6. Tap the lower end of the sector

shaft with a soft-hammer to loosen it,

then lift the cover and shaft from the

housing as an assembly. Discard the

O-ring.

7.
Turn the sector shaft cover coun-

terclockwise off the adjuster screw.

8. Remove the four valve housing

attaching bolts. Lift the valve housing

from the steering gear housing while

holding the piston to prevent it from

rotating off the worm shaft. Remove

the valve housing and the lube passage

O-rings and discard them.

9. Stand the valve body and piston

on end with the piston end down. Ro-

tate the input shaft counterclockwise

out of the piston allowing the ball

bearings to drop into the piston.

10.
Place a cloth over the open end

of the piston and turn it upside down

to remove the balls.

11.
Remove the two screws that at-

tach the ball guide clamp (Fig. 6) to

the ball nut and remove the clamp and

the guides.

12.
Install the valve body assembly

in the holding fixture (do not clamp

in a vise) and remove the lock nut and

the attaching nut as shown in Fig. 7.

13.
Carefully slide the input shaft,

worm and valve assembly out of the

valve housing. Due to the close diame-

trical clearance between the spool and

housing, the slightest cocking of the

spool may cause it to jam in the hous-

ing.

14.
Remove the shim from the

valve housing bore.
OIL SEAL

INLET TUBE SEAT

OUTLET TUBE SEAT
DUST SEAL

G1549-A

FIG.
8—Valve Housing Disassembled

Too/-T<

Tool-

T57L-500-A ,^^^

G1364-A

FIG. 9—Removing Bearing and Oil

Seal

PARTS REPAIR

OR REPLACEMENT

Valve Housing

1.
Remove the dust seal (Fig. 8)

from the rear of the valve housing

with Tools T59L-100-B and T58L-

101-A and discard the seal.

2.
Remove the snap ring from the

valve housing.

3.
Turn the fixture to place the

valve housing in an inverted position.

4.
Insert special tool in the valve

body assembly opposite the seal end

and gently tap the bearing and seal

out of the housing as shown in Fig.

9. Discard the seal. Caution must be

exercised when inserting and removing

the tool to prevent damage to the

valve bore in the housing.

5.
Remove the fluid inlet and outlet

tube seats with an EZ-out if they are

damaged.
Press Ra
Tool-

T65P-3524-A7

G1363-A

FIG. 10—Installing Valve Housing

Bearing

6. Coat the fluid inlet and outlet

tube seats with vaseline and position

them in the housing. Install and tight-

en the tube nuts to press the seats to

the proper location.

7.
Coat the bearing and seal surface

of the housing with a film of vaseline.

8. Position the bearing in the valve

housing. Seat the bearing in the valve

housing with the tool shown in Fig.

10.
Make sure that the bearing is

free to rotate.

9. Dip the new oil seal in gear lu-

bricant; then, place it in the housing

with the metal side of the seal facing

outward. Drive the seal into the hous-

ing until the outer edge of seal does

not quite clear the snap ring groove

(Fig. 11).

10.
Place the snap ring in the hous-

ing; then, drive on the ring with the

tool shown in Fig. 11 until the snap

ring seats in its groove to properly lo-

cate the seal.procarmanuals.com

03-08-07
Ford Design Integral Power Steering Gear

03-08-07

Press Ram
Tool-

T65P.3524-A1

G1362-A

FIG.
17—Installing
Oil Seal in

Valve Housing

11.
Place the dust seal in the hous-

ing with the dished side (rubber side)

facing out. Drive the dust seal into

place with the tool shown in Fig. 11.

the seal must be located behind the

undercut in the input shaft when it is

installed.

Worm and Valve

1.
Remove the snap ring from the

end of the actuator.

2.
Slide the control valve spool

(Fig. 6) off the actuator.

3.
Install the valve spool evenly and

slowly with a slight oscillating motion

into the flanged end of valve housing

with the Valve identification groove

between the valve spool lands out-

ward, checking for freedom of valve

movement within the housing working

area. The valve spool should enter the

housing bore freely and fall by its own

weight.

4.
If the valve spool is not free,

check for burrs at the outward edges

of the working lands in the housing

and remove with a hard stone.

5.
Check the valve for burrs and if

burrs are found, stone the valve in a

radial direction only. Check for free-

dom of the valve again.

6. Remove the valve spool from the

housing.

7.
Slide the spool onto the actuator

making, sure that the groove in the

spool annulus is toward the worm.

8. Install the snap ring to retain the

spool.

9. Check the clearance between the

spool and the snap ring. The clearance

should be between 0.002-0.005 inch. If

the clearance is not within these lim-

its,
select a snap ring that will allow a

clearance of 0.003 inch.
STEERING GEAR HOUSING

J

UPPER SEAL

I LOWER SEAL

SNAP RING

SPACER WASHER

FIG. 12—Steering Gear Housing Disassembled

Tool - T59L - 100-B

Tool T57L-500 - A

G1551-A

FIG. 13—Removing Lower Seal

Piston and Ball Nut

1.
Remove the teflon ring and the

O-ring (Fig. 7) from the piston and

ball nut.

2.
Dip a new O-ring in gear lubri-

cant and install it on the piston and

ball nut.

3.
Install a new teflon ring on the

piston and ball nut being careful not

to stretch it any more than necessary.

Steering Gear Housing

1.
Remove the snap ring and the

spacer washer (Fig. 12) from the

lower end of the steering gear housing.

2.
Remove the lower seal from the

housing as shown in Fig. 13. Lift the

spacer washer from the housing.

3.
Remove the upper seal in the

same manner as the lower seal.

4.
Dip both sector shaft seals in

gear lubricant.
SHORT END

AWAY

FROM SEAL
G1550-A

Press Rom

G1374-A

FIG. 14—Installing Sector Shaft

Inner Seal

5. Apply Lubricant to the sector

shaft seal bore of the housing and

position the sector shaft inner seal

into the housing with the lip facing in-

ward. Press the seal into place with

the tool shown in Fig. 14. Place a spa-

cer washer (0.090 inch) on top of the

seal and apply more Lubricant to the

housing bore.

6. Place the outer seal in the hous-

ing with the lip facing inward and

press it into place as shown in Fig. 15.

Then, place a 0.090 inch spacer wash-

er on top of the seal.

7.
Position the snap ring in the

housing. Press the snap ring into the

housing with the tool shown in Fig. 15

to properly locate the seals and en-

gage the snap ring in the groove.

STEERING GEAR

ASSEMBLY

Do not clean, wash, or soak seals in

cleaning solvent.procarmanuals.com

03-08-08
Ford Design Integral Power Steering Gear

03-08-08

LONG END

AWAY FROM

SEAL
Press Ram

G1375-A

FIG. 15— Installing Sector Shaft

Outer Seal

1.
Mount the valve housing in the

holding fixture with the flanged end

up.

2.
Place the required thickness

valve spool centering shim (Fig. 6) in

the housing. Use one shim only.

3.
Carefully install the worm and

valve in the housing.

4.
Install the attaching nut in the

housing and torque it to specification

(Part 3-13).

5.
Install the lock nut (Fig. 7) and

torque it to specification (Part 3-13).

6. Place the piston on the bench

with the ball guide holes facing up.

Insert 44ie worm shaft into the piston

so that the first groove is in alignment

with the hole nearest to the center of

the piston (Fig. 16).

7.
Place the ball guide in the pis-

ton. Place the 27 balls in the ball

guide (Fig. 16) turning the worm in a

clockwise direction as viewed from the

input end of the shaft. If all of the

balls have not been fed into the guide

upon reaching the right stop, rotate

the input shaft in one direction and

then in the other while installing the

balls.
After the balls have been in-

stalled, do not rotate the input shaft
FIRST GROOVE OF WORM SHOULD BE IN

ALIGNMENT WITH THIS HOLE

G1554-A

FIG. 16—Assembling Piston on Worm Shaft

INPUT SHAFT

SECTOR
SHAFT

ADJUSTMENT
SCREW

G1547-A

FIG. 77—Adjusting Mesh

or the piston more than 3 1/2 turns

off the right stop to prevent the balls

from falling out of the circuit.

8. Secure the guides in the ball nut

with the clamp (Fig. 6).

9. Position a new lube passage O-

ring in the counterbore of the gear

housing.
10.
Apply vaseline to the teflon seal

on the piston.

11.
Place a new O-ring on the valve

housing.

12.
Slide the piston and valve into

the gear housing being careful not to

damage the teflon seal.

13.
Align the lube passage in the

valve housing with the one in the gear

housing, and install but do not tighten

the attaching bolts.

14.
Rotate the ball nut so that the

teeth are in the same plane as the sec-

tor teeth. Tighten the four valve hous-

ing attaching bolts to specifications.

15.
Position the sector shaft cover

O-ring in the steering gear housing.

Turn the input shaft as required to

center the piston.

16.
Apply vaseline to me sector

shaft journal then position the sector

shaft and cover assembly in the gear

housing. Install the steering identifica-

tion tag and two sector shaft cover at-

taching bolts. Torque the bolts to spe-

cifications.

17.
Attach an in-lb torque wrench

to the input shaft. Adjust the mesh

load to specifications as shown in Fig.

17.procarmanuals.com