1969 FORD MUSTANG ESP

03-05-09

Steering Columns And Linkage

03-05-09

FAIRLANE, FALCON

AND MONTEGO

Removal

1.
Disconnect the battery cable

from the negative post.

2.
Disconnect the turn signal switch

wires at the connector.

3.
Disconnect the neutral start

siwtch (with automatic transmission)

and back-up light switch wires from

the switches.

4.
Disconnect the transmission con-

trol rod(s) from the lever(s) at the

lower end of the column.

5.
Remove the bolt that secures the

flex coupling to the steering gear (Fig.

12).
6. Remove the nuts and bolts that

secure the column retainer and seal at

the toe plate.

7.
Disconnect the nuts that secure

the column upper and lower brackets

to the brake pedal support bracket

and the dash panel.

8. Lift the column from the vehicle.

Installation

1.
Position the steering column in

the vehicle. Make sure that the wheels

are in the straight ahead position and

that the steering wheel spokes are in a

horizontal position when the flex cou-

pling engages the input shaft splines.

2.
Install but do not tighten the

nuts that secure the column upper and

lower brackets to the brake pedal sup-
port bracket and the dash panel.

Make certain the column is properly

positioned relative to the flex coupling

inpui shaft connection.

3.
Install and tighten the flex cou-

pling-to-steering gear attaching bolt.

4.
Tighten the nuts at the brake

pedal support bracket and the dash

panel.

5.
Install and tighten the nuts and

bolts that secure the column retainer

and seal at the toe plate.

6. Connect the transmission control

rod(s) to the lever(s) at the lower end

of the column.

7.
Connect the neutral start switch

(if so equipped) and back-up light

switch to their respective terminals.

8. Connect the turn signal switch

wires.

COLUMN UPPER \

BRACKET-3506 V

BRAKE PEDAL

SUPPORT BRACKET

TRIMSHROUD-3530

UPPER CLAMP-3507,

COLUMN LOWER

BRACKET-3R547

•
FLEXCOUPLING-3A525
^INTERMEDIATE

BRACKET-3676

VIEW AA

G1616-A

FIG. 11—Steering Column Installation—Ford, Mercury, Meteorprocarmanuals.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

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

03-09-01
Saginaw Design Integral Power Steering Gear

03-09-01

PART 3-9 Saginaw Design

Integral Power Steering Gear

COMPONENT INDEX

STEERING GEAR

Cleaning and Inspection (See Page 03-01)

Description

Disassembly and Assembly

Mesh Load Adjustment

Removal and Installation

Overhaul
MODEL APPLICATION
All
Models
Ford

09-01

09-03

09-01

09-02

09-04
Mercury
N/A

N/A

N/A

N/A

N/A

N/A
Meteor
N/A

N/A

N/A

N/A

N/A

N/A
Cougar
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
Falcon
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
Mustang
N/A

N/A

N/A

N/A

N/A

N/A
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A

N/A
Thunderbird
N/A

N/A

N/A

N/A

N/\

N/A
Continental-
Mark III
N/A

N/A

N/A

N/A

N/A

N/A

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

The Rotary Valve Safety power

steering gear operates entirely on dis-

placing fluid to provide hydraulic fluid

pressure assists only when turning. As

the entire gear assembly is always full

of fluid, all internal components of the

gear are immersed in fluid making

periodic lubrication unnecessary. In

addition, this fluid acts as a cushion
to absorb road shocks that may be

transmitted to the driver. All fluid

passages are internal except the pres-

sure and return hoses between the

gear and pump.

The rotary valve provides a smooth

transmission through the driving range

of steering wheel effort. A torsion bar

transmits the road feel to the driver.
Response of the steering gear to effort

applied to the steering wheel has been

greatly increased.

The rack-piston nut is one piece and

is geared to the sector shaft. Lash be-

tween the sector shaft and rack-piston

nut is maintained by an adjusting

screw which is retained in the end o\'

the shaft uear (Eiiz.l).

IN-VEHICLE ADJUSTMENTS AND REPAIRS

During the breaking in period of

the vehicle, it is probable that some

of the factory adjustments will change.

These changes in adjustment do not

necessarily affect the satisfactory op-

eration of the steering gear assembly

and ordinarily do not require re-ad-

justment unless there is excessive lash

or other malfunctioning. The only ad-

justment that should be performed in

the vehicle is the total over center

position load (mesh load) to eliminate

excessive lash between the sector shaft

and rack teeth.

MESH LOAD ADJUSTMENT

1.
Disconnect the Pitman arm from
the sector shaft and remove the steer-

ing wheel hub.

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

steering wheel in both directions as

required, to discharge the fluid from

the gear.

4.
Turn the gear 1/2 turn off cen-

ter (either direction). Using a 24 in-

lb torque wrench on the steering wheel

nut, determine the torque required to

rotate the shaft slowly through a 20

degree arc.

5.
Turn the sear back to center and
repeating the method of reading tor-

que as in Step 4, above, loosen the

adjuster lock nut, turn the screw in-

ward with a 7/32-inch Allen wrench

until the reading is equal to 6 in-lbs

in excess of Step 4 above, and retigh-

ten the lock nut while holding the

screw in place.

6. Recheck the readings and re-

place the Pitman arm and the steering

wheel hub.

7.
Connect the fluid return line to

the reservoir and fill the reservoir

with C1AZ-I9582-A Fluid to the

proper level.
procarmanuals.com

03-10-06
Ford-Thompson Power Steering Pump

03-10-06

7.
Use one of the slippers to com-

press the spring and install the slipper

with the groove in the slipper facing

upward (toward the cam notch). The

flats on the side of the slipper should

be on the left (Fig. 12).

FLATS ON LEFT

DOUBLE STEP

G1350-A

FIG. 72—Correct Slipper

Installation

8. Hold the cam stationary and

turn the rotor either to the right or

left, one space at a time. Repeat Step

7 until all the rotor cavities have been

filled. Be careful when turning the

rotor that the springs and slippers al-

ready inserted do not fall out.

9. Install the cam and rotor assem-

bly onto the pump housing plate with

the fixed dowel passing through the

first hole to the left of the cam notch

when the arrow on the cam OD is

pointing toward the lower pressure

plate (Fig. 13). If the cam and rotor

assembly will not seat, turn the rotor

shaft slightly until the spline teeth

mesh, allowing the cam and rotor to

drop down into position.

FIXED DOWEL D0|JBLE STEP

ARROW POINTING DOWN

G 1351-A

FIG. 13—Cam and Rotor

Installation
10.
Insert the loose fitting dowel

through the cam insert and lower

plate into the hole in the housing plate

assembly. When the loose dowel is

properly installed the heights of the

two dowels must be equal. Squirt the

rotor, springs, slippers and cam insert

with C1AZ-19582-A lubricant.

11.
Place the upper pressure plate

with the face having the tapered notch

down against the cam insert. The

fixed dowel should pass through the

round dowel hole and the loose dowel

through the elongated hole. The slot

between the ears on the pressure plate

OD should match the notch on the

cam insert OD (Fig. 14).

EARS

'G 1352-A

FIG. 74—Upper Pressure Plate

Installation

\ EARS

G1353-B

FIG. 75—Retainer End Plate

Installation

12.
Install the retainer end plate so

the slot on the end plate OD matches

the corresponding notches of the

upper pressure plate and cam (Fig

15).

13.
Install the pump valve assembly

O-ring seal onto the pump valve as-

sembly being careful not to twist the

seal (Fig. 16).

14.
Place the pump valve assembly

on top of the retainer end plate with

the large exhaust slot on the pump

valve in line with the OD notches of

the previously assembled parts. The
stack of parts must be fully seated. If

the pump valve has been installed cor-

rectly, the relief valve stem will be in

line with the lube return hole in the

pump housing plate (Fig. 16).

O-RING SEAL

EARS

G1605-A

FIG. 16 —Valve and Pressure

Spring Installation

Tool 169P-3B586-A

G1606-B

FIG. 17—Pump Housing

Installation

FIG. 18 -Checking Pump

Rotational Torqueprocarmanuals.com

03-12-01

Wheels
And
Tires

03-12-01

PART
3-12
Wheels
And
Tires

COMPONENT INDEX

FRONT
HUB AND
DRUM ASSEMBLY

Removal
and
Installation

FRONT
HUB AND
ROTOR ASSEMBLY

Removal
and
Installation

FRONT WHEEL ASSEMBLY DESCRIPTION

FRONT WHEEL BEARING ADJUSTMENT

FRONT WHEEL GREASE SEAL
AND

BEARING

Removal, Installation, Repacking

HOISTING INSTRUCTIONS

LIFE GUARD TIRE

Balancing

Correcting Vibration
and
Shake

Description

Repairs

REAR WHEEL ASSEMBLY DESCRIPTION

WHEELS AND TIRES (Conventional)

Removal
and
Installation
MODEL APPLICATION
All
Models

12-07

12-07

12-01

12-02

12-05

12-02

12-01

12-03
Ford
N/A

N/A

N/A

N/A
Mercury
N/A

N/A

N/A

N/A
Meteor
N/A

N/A

N/A

N/A
Cougar
N/A

N/A

N/A

N/A
Fairlane
N/A

N/A

N/A

N/A
Falcon
N/A

N/A

N/A

N/A
Montego
N/A

N/A

N/A

N/A
Mustang
N/A

N/A

N/A

N/A
Lincoln-
Continental
12-03

12-03

12-02

12-08
Thunderbird
12-03

12-03

12-02

12-08
Continental-
Mark
III
12-03

12-03

12-02

12-08

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 WHEEL ASSEMBLY

Each front wheel
and
tire
is
bolted

to
its
respective front
hub and
brake

drum
or
rotor assembly.
Two
opposed

tapered roller bearings
are
installed
in

each
hub. A
grease retainer
is in-

stalled
at the
inner
end of the hub to

prevent lubricant from leaking into

the drum
or on the
rotor.
The
entire

assembly
is
retained
to its
spindle
by

the adjusting
nut, nut
lock
and
cotter

pin (Figs.
1 and 2).

REAR WHEEL ASSEMBLY

The rear wheel
hub and
brake drum

assembly
is
attached
to
studs
on the

rear axle shaft flange
by
three speed

nuts.
The
wheel
and
tire mounts
on

the same rear axle shaft flange studs

and
is
held against
the hub and
drum

by
the
wheel nuts.
The
rear wheel

bearing
is
pressed onto
the
axle shaft

just inside
the
shaft flange,
and the
entire assembly
is
retained
to the
rear

axle housing
by the
bearing retainer

HUB
AND
BRAKE

DRUM
ASSEMBLY
plate which
is
bolted
to the
housing

flange.

ADJUSTING

NUT

GREASE

CAP
OUTER

BEARING

OUTER
CUP

BEARING

CONE
AND

ROLLER

NUT
INNER BEARING

CONE
AND

ROLLER

WHEEL

ASSEMBLY

HUB
BOLT'
^£=3^
F1422-A

FIG.
1
—
Front
Hub,
Bearing
and
Grease Retainer Drum Brakes
procarmanuals.com

05-02-01
General Clutch Service

05-02-01

PART
5-2
General Clutch Service

COMPONENT INDEX
MODEL APPLICATION

3

a>
1
o>

il

•U
i
!-

II

CLUTCH DISC

Cleaning and Inspection

02-04
02-04
02-04

02-04
02-04
02-04

02-04
02-04
N/A
N/A

N/A

CHECKING FLYWHEEL HOUSING

ALIGNMENT

02-01
02-01
02-01

02-01
02-01
02-01

02-01
02-01
N/A
N/A

N/A

CORRECTING FLYWHEEL HOUSING

ALIGNMENT

02-03
02-03
02-03

02-03

02-03
02-03

02-03

02-03
N/A
N/A

N/A

PILOT BUSHING

Cleaning and Inspection

02-04
02-04
02-04
02-04

02-04
02-04

02-04

02-04
N/A
N/A

N/A

PRESSURE PLATE AND COVER

Cleaning and Inspection

02-04
02-04
02-04
02-04

02-04
02-04

02-04
02-04
N/A

N/A

N/A

RELEASE BEARING

Cleaning and Inspection

02-04
02-04

02-04
02-04
02-04
02-04

02-04
02-04
N/A

N/A

N/A

A page number indicates that the item is for the vehicle listed at the head of the column.

N/A indicates that the item is not applicable to the vehicle listed.

l
FLYWHEEL HOUSING ALIGNMENT

Alignment of the flywheel housing

bore and rear face with the engine

should be checked as a possible cause

of any of the following troubles- ex-

cessive transmission gear wear, ..ans-

mission jumping out of gear, especial-

ly third gear, drive line vibration, ex-

cessive pilot bushing wear, noisy re-

lease bearing, or excessive clutch spin

time.

INSPECTION

1. With the clutch release bearing

removed, install the indicator pilot

tool shown in Fig. 1.

2.
Clean the faces of the flywheel

housing bolt bosses, and remove all

burrs, nicks, and paint from the

mounting face of the housing.

3.
Install the dial indicator on the

pilot and adjust the holder so the but-

ton will contact a circumference just

inside of the transmission mounting

holes.

4.
Push the flywheel forward to re-

move crankshaft end play. Set the dial

indicator face to read zero.

5.
Remove the spark plugs to alle-

viate compression.

6. Pull the engine crankshaft

through one revolution. The crank-

shaft must be held in the forward po-

sition while rotating it.

7. Note the indicator reading and

mark the maximum point of runout

on the face of the housing (Fig. 1).
8. Position the dial indicator to

check bore alignment (Fig. 1). The

bore must be clean and free of burrs,

nicks and paint.

9. Pull the crankshaft through one

revolution. Note the indicator reading

and mark the maximum point of run-

out on the face of the housing as

shown in Fig. 1.

10.
Remove the dial indicator from

the crankshaft and the housing.

11.
Select the Dia-L-lgner pilot

(Fig. 2) which will fit snugly in the

bore of the flywheel housing.

12.
Press the pilot into place on the

locator on the back of the dial.
13.
Position the Dia-L-lgner on the

face of the housing (Fig. 3) with the

pilot in the bore.

14.
Rotate the face runout arrow to

the positive face runout mark on the

housing.

15.
Without moving the face runout

arrow, rotate arrow A until it is at the

negative bore reading.

16.
Slide arrow A to register the

amount of bore runout on the .010-

line of the white scale. Use the

scale No. to coincide with the pilot

being used.

17.
Rotate arrow B until it points

CHECKING
FACE
RUN OUT

CHECKING
BORE
RUN OUT

C
1783-
A

FIG.
1—Flywheel
Housing Alignment Checkprocarmanuals.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