1969 FORD MUSTANG automatic

02-02-22
Brake System

02-02-22

BRAKE VACUUM BOOSTER -2005

AUTOMATIC I

TRANSMISSION

HAIR PIN RETAINER

330699-S2

SPACER

STOP LIGHT SWITCH-13480

STANDARD

TRANSMISSION
BUSHING
BUSHING

PUSH ROD

BRAKE PEDAL ASSEMBLY
CLUTCH

PEDAL

ASSEMBLY

H 1557-C

FIG. 30—Master Cylinder Installation—Power Brake-

Fairlane, Montego and Falcon

ASSIST

SPRING BRACKET CLUTCH ASSIST

\ SPRING

BRAKE PEDAL

SHAFT

CLUTCH

PEDAL

CLUTCH PEDAL

TO EQUALIZER ROD

HI643-
A

FIG. 31—Master Cylinder Installation-

Power Brake—Mustang and Cougar
6. Bleed the dual-master cylinder

and the primary and secondary brake

systems. Centralize the pressure dif-

ferential valve. Refer to H>draulic

System Bleeding and Centralizing of

the Differential Valve, Part 2-1, Sec-

tion 2 for the proper procedure.

7.
Operate the brakes several times,

then check for external hydraulic

leaks.

PRESSURE DIFFERENTIAL

VALVE AND PROPORTIONING

VALVE ASSEMBLY

REMOVAL

1.
Disconnect the brake warning

light wire from the pressure differen-

tial valve assembly switch (Figs. 17

thru 21). To prevent damage to the

brake warning switch wire connector,

expand the plastic lugs to allow re-

moval of the shellwire connector from

the switch body.

2.
Loosen the tube nuts connecting

the primary and secondary inlet and

outlet tubes at the pressure differential

valve assembly and remove the tubes.

3.
Remove the screw or screws re-

taining the pressure differential valve

assembly to the chassis and remove

the valve assembly.

4.
On disc brake equipped vehicles,

place the pressure differential valve

assembly and mounting bracket in a

vise.
Loosen the proportioning valve

tube nuts at the differential valve and

at the proportioning valve. Remove

the proportioning valve from the

mounting bracket.

5.
If the differential valve is to be

replaced, remove the brake warning

lamp switch and install the switch in

the new differential valve. The pres-

sure differential valve assembly, the

brake warning lamp switch, and the

proportioning valve are separate units

and each is serviced as a separate as-

sembly only.

INSTALLATION

1.
On disc brake equipped vehicles,

connect the proportioning valve inlet

and outlet tubes to the proportioning

valve and differential valve bodies.

Tighten the tube nuts to specification.

2.
Mount the pressure differential

valve assembly on the chassis and in-

stall the attaching screw or screws.

3.
Connect the primary and second-

ary inlet and outlet tubes to the pres-

sure differential valve assembly and

tighten the tube nuts to specifications.procarmanuals.com

02-02-26
Brake System

02-02-26

14.
Remove the clutch pedal assist

spring.

15.
On non-power brakes, remove

the retainer clip from the clutch and

brake pedal shaft, then remove the

clutch pedal and shaft assembly, the

brake pedal assembly, and the bush-

ings from the pedal support bracket.

On power brakes, remove the retainer

nut from the brake pedal shaft then

remove the pedal shaft, the brake

pedal assembly and the bushings from

the pedal support bracket.

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

bushings in their proper places on the

clutch and brake pedal assemblies.

2.
On non-power brakes, position

the brake pedal to the pedal support

bracket, then install the clutch pedal

and shaft assembly through the sup-

port bracket and brake pedal assem-

bly. On power brakes position the

brake pedal to the pedal support

bracket, then install the pedal shaft

and nut.

3.
Install the clutch pedal assist

spring and pivot the clutch pedal

against its bumper stop. Secure the

pedal to the stop with a small C-

clamp as shown in Figs. 28 and 31.

4.
Position the pedal support

bracket assembly to the dash panel,

and to the steering column retainer

studs.

5.
Align the pedal support bracket

holes with the holes in the dash panel

and install the two attaching sheet

metal screws. On power brakes install

the nuts on the brake booster studs.

6. Install the two cap screws at-

taching the pedal support bracket to

the upper cowl bracket.

7. Install the cap screw attaching

the pedal support bracket to the top

inner cowl bracket (Figs. 28 and 31).

8. Install the inner nylon washer,

the master cylinder push rod, and the

bushing on the brake pedal pin. Posi-

tion the stop light switch so that it

straddles the push rod with the switch

slot on the pedal pin and the switch

outer hole just clearing the pin. Slide

the switch completely onto the pin,

and install the outer nylon washer as

shown in Figs. 28 and 31. Secure

these parts to the pin with the
self-

locking retainer.

9. Connect the stop light switch

wires to the connector.

10.
Connect the clutch pedal-

to-equalizer rod to the clutch pedal

assembly with the bushing and the

spring clip retainer. Apply SAE 10
engine oil to the bushing. Remove the

C-clamp from the clutch pedal.

11.
Working from the engine side

of the dash panel, on non-power

brakes, install the two cap screws at-

taching the pedal support bracket to

the dash panel. Then install the two

screws attaching the master cylinder

to the dash panel. On power brakes

install the cap screws retaining the

brake booster to the dash panel.

12.
Install the steering column.

Refer to Part 3-4, Section 2 for pro-

cedure.

13.
Adjust the clutch pedal free

play (Group 5) to specification, if re-

quired.

14.
Check the Brake Pedal Free

Height and Travel Measurements

(Part 2-1, Section 1).

15.
Connect the ground cable to the

battery.

FAIRLANE, MONTEGO,

FALCON, MUSTANG

AND COUGAR-

AUTOMATIC TRANSMISSION

Removal

1. Disconnect the stop light switch

wires at the connector.

2.
Remove the self-locking pin and

slide the stop light switch off the

brake pedal pin just far enough for

the switch outer hole to clear the pin.

Then lower the switch away from the

pin. Slide the master cylinder or

booster push rod and the nylon wash-

ers and bushing off from the brake

pedal pin (Figs. 27, 28, 30 and 31).

3.
On all vehicles except Mustang

and Cougar with power brakes, re-

move the self-locking pin and washer

from the brake pedal shaft, then re-

move the shaft, the brake pedal as-

sembly and the bushings from the

pedal support bracket. On Mustang

and Cougar vehicles with power

brakes, remove the locknut and bolt

from the pedal. Remove the pedal as-

sembly from the support bracket (Fig.

3).

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

the bushings in their proper places on

the pedal assembly and pedal support

bracket (Figs. 27, 28, 30 and 31).

2.
Position the brake pedal assem-

bly to the support bracket, then install

the pedal shaft or bolt through the

support bracket and brake pedal as-

sembly. Install the retainer or locknut.
3.
Install the inner nylon washer,

the master cylinder or booster push

rod, and the bushing on the brake

pedal pin. Position the switch so that

it straddles the push rod with the

switch slot on the pedal pin, and the

switch outer hole just clearing the pin.

Slide the switch completely onto the

pin, and install the outer nylon washer

as shown in Figs. 27, 28, 30 and 31.

Secure these parts to the pin with the

self-locking pin.

4.
Connect the stop light switch

wires to the connector, and install the

wires in the retaining clip.

Check the Brake Pedal Free Height

and Travel Measurements, Part 2,

Section 1.

THUNDERBIRD
AND

CONTINENTAL MARK
III

Removal

1.
Loosen the booster mounting

nuts.

2.
Disconnect the stop light switch

wires at the connector.

3.
Remove the hairpin retainer.

Slide the stop light switch off from

the brake pedal pin just far enough

for
the
switch outer hole
to
clear
the

pin,
and then lift the switch straight

upward from the pin. Slide the master

cylinder push rod and the nylon wash-

ers and bushing off from the brake

pedal pin (Fig. 32).

4.
Remove the pivot bolt and nut

that holds the pedal to the pedal sup-

port bracket. Remove the brake pedal

assembly from the pedal support

bracket, and remove the bushings.

Installation

1. Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

the bushings in their proper places on

the pedal assembly (Fig. 32).

2.
Install the brake pedal assembly

and bushings to the support bracket,

and then install the pivot bolt through

the support bracket and brake pedal

assembly. Install the pivot bolt nut

and torque to specifications.

3.
Install the inner nylon washer,

the master cylinder push rod, and the

bushing on the brake pedal pin. Posi-

tion the switch so that it straddles the

push rod with the switch slot on the

pedal pin and the switch outer hole

just clearing the pin. Slide the switch

completely onto the pin, install the

outer nylon washer as shown in Fig.

32.
Secure these parts to the pin with

the hairpin retainer.procarmanuals.com

02-02-30
Brake System

02-02-30

7.
Disconnect the wire lead at the

parking brake warning light switch

and remove the control assembly.

Installation

1.
Connect the wire lead to the

parking brake warning light switch.

2.
Position the control assembly to

the cowl inner side panel and install

the three attaching screws.

3.
Connect the ball-end of the park-

ing brake front cable assembly to the

control assembly, and install the hair-

pin retainer.

4.
Position the cable ball in the

notch in the brake clevis.

5.
Position the left air vent assem-

bly to the dash and instrument panels.

Install the four bolts and one nut re-

taining the air vent to the panels.

6. Check the operation of the park-

ing brake. Adjust the parking brake.

MUSTANG AND COUGAR

Removal

Refer to Fig. 36.

1.
Make sure the parking brake is

completely released,

2.
Remove all tension from the rear

cables by backing off the jam nut and

adjusting nut from the equalizer.

3.
Disconnect the wire lead at the

parking brake warning light switch (if

so equipped).

4.
Remove the parking brake front

cable ball retaining clip from the clev-

is.

5.
Remove the parking brake warn-

ing light switch and attaching screw (if

so equipped).

6. Disconnect the cable ball from

the notch in the brake clevis.

7.
Remove the three screws that at-

tach the control assembly to the left

cowl inner side panel.

8. Pull the control away from the

cowl, panel. Remove the hair-pin re-

tainer securing the front cable assem-

bly to the control assembly. Remove

the control assembly

Installation

1.
Connect the ball-end of the park-

ing brake front cable assembly to the

control assembly, and install the hair-

pin retainer.

2.
Position the control assembly to

the cowl inner side panel and install

the three attaching screws.
3.
Position the parking brake warn-

ing light switch and install the attach-

ing screw. Connect the parking brake

warning light switch wire lead (if vehi-

cle is so equipped).

4.
Position the cable ball in the

notch in the brake clevis.

5.
Check the operation of the park

ing brake. Adjust the parking brake.

THUNDERBIRD AND

CONTINENTAL MARK III

Removal

Refer to Fig. 37.

1.
Remove the two nuts retaining

the control to the dash panel.

2.
Remove two screws from the left

scuff plate.

3.
Remove one screw retaining the

left cowl trim panel and remove the

panel.

4.
Remove the two screws retaining

the left air duct and remove the air

duct.

5.
Remove the two screws retaining

the dimmer switch and position the

switch out of the way.

6. Remove the clip retaining the

cable assembly to the control.

7.
Disconnect the cable ball from

the control clevis.

8. Disconnect the vacuum hose at

the brake release.

9. Remove the bolt retaining the

control to the cowl side bracket and

remove the control.

Installation

1.
Position the parking brake con-

trol in the vehicle.

2.
Install the cable assembly in the

control and connect the cable ball to

the control clevis.

3.
Install the clip retaining the

cable to the control.

4.
Install the bolt retaining the con-

trol to the cowl side bracket.

5.
Connect the vacuum hose to the

parking brake release vacuum motor.

6. Position the dimmer switch and

install the retaining screws.

7.
Position the air duct and install

the retaining screws.

8. Position the cowl trim panel and

install the retaining screw.

9. Install the two scuff plate screws.

10.
Install the two nuts retaining

the control to the dash panel.

11.
Adjust the parking brakf
LINCOLN CONTINENTAL

Removal

Refer to Fig. 38.

1.
Raise the vehicle on a hoist.

2.
Loosen the parking brake cable

adjusting nut, remove the return

spring and remove the cable ball end

from the equalizer.

3.
Lower the vehicle.

4.
Disconnect the battery.

5.
Disconnect the wire harness con-

nector and two vacuum hoses at the

Automatic Temperature Control box.

6. Working inside the vehicle, re-

move the windshield wiper control

knob and bezel from the lower control

panel.

7.
Remove the screws retaining the

lower control panel. Lower the control

panel and disconnect wire harnesses

and vacuum hoses. Position the con-

trol panel aside.

8. Remove the screw retaining the

plastic wire cover and place 'the cover

aside.

9. Disconnect three vacuum hoses

and the wiring harness at the Auto-

matic Temperature Control box.

10.
Remove the two screws retain-

ing the Automatic Temperature Con-

trol box to the dash panel and remove

the box for clearance.

11.
Disconnect the ball end of the

cable from the control clevis.

12.
Remove the four bolts retaining

the control to the dash panel and

lower instrument panel flange.

13.
Disconnect the vacuum release

hose from the control and remove the

control assembly from the vehicle.

Installation

1.
Position the control assembly to

the dash panel and instrument panel

flange and install the four retaining

screws.

2.
Connect the vacuum release hose

to the control assembly.

3.
Connect the cable ball to the

control clevis.

4.
Position the Automatic Temper-

ature Control box to the dash panel

and install the retaining screws.

5.
Connect the wiring harness and

vacuum hoses to the Automatic Tem-

perature Control box.

6. Position the plastic wire covei

and install the retaining screw.

7.
Connect the wire harnesses and

vacuum lines to the lower control

panel and position the panel to the inprocarmanuals.com

02-02-34
Brake System

02-02-34

strument panel. Install the lower con-

trol panel retaining screws.

8. Install the windshield wiper con-

trol bezel and knob.

9. Working in the engine compart-

ment connect the wire harness and

vacuum hoses to the Automatic Tem-

perature Control box.

10.
Connect the battery cable.

11.
Raise the vehicle on a hoist.

12.
Connect the cable ball to the

equalizer and install the equalizer

lever return ^spring.

13.
Adjust the parking brake cable

tension.

14.
Lower the vehicle.

PARKING BRAKE ACTUATOR—

TO CONTROL CABLE

FORD, MERCURY

AND METEOR

Removed

1.
Raise the vehicle on a hoist.

2.
Loosen the actuator lever to

equalizer cable adjusting nut at the

equalizer (Fig. 34).

3.
Disconnect the cable ball from

the clevis on the actuator lever.

4.
Remove spring clip that retains

the cable to the frame.

5.
From inside of passenger com-

partment, remove spring clip that re-

tains the cable to the parking brake

control. Disconnect the cable ball

from the control assembly.

6. Remove the cable assembly from

the vehicle.

Installation

1.
Position the cable through the

provided openings and in the approxi-

mate final installation position.

2.
Install the hairpin retainer on the

cable at the frame crossmember.

3.
Connect the ball end of the cable

to the parking brake control. Install

the cable-to-control hairpin retaining

clip.

4.
Position the cable seal at the

dash panel, and slide the retaining clip

upward to seal the cable at the dash

opening.

5.
Connect the ball end of the cable

to the clevis on the actuator lever.

6. Adjust the parking brake (Part

2-1,
Section 2).

7.
Lower vehicle on hoist.
THUNDERBIRD AND

CONTINENTAL MARK III

Removal

Refer to Fig. 37.

1.
Partially raise the vehicle.

2.
Back off the adjusting nut at the

equalizer to relieve the tension on the

cable.

3.
Remove the spring at the actua-

tor lever and disconnect the control

cable from the clevis on the lever.

4.
Remove the clip retaining the

control cable assembly to
thq*.
frame

bracket. B

5.
Attach a length of wire to the

control cable.

6. Working inside the vehicle re-

move two screws retaining the left

scuff plate.

7.
Remove one screw and remove

the left cowl side trim panel.

8. Remove the two screws retaining

the left air duct to the inner panel and

remove the air duct.

9. Remove the two screws retaining

the dimmer switch and position the

dimmer switch back out of the way.

10.
Remove the clip retaining the

cable assembly to the control and re-

move the cable ball from the control

clevis.

11.
Pull the cable up through the

opening in the dash panel and remove

the cable from the length of wire.

Installation

1.
Attach the cable to the length of

wire and pull the cable down through

the opening in the dash panel.

2.
Position the upper end of the

control cable to the control. Connect

the cable ball to the control clevis and

install the clip retaining the cable

housing to the control.

3.
Remove the length of wire from

the cable assembly and position the

cable in the frame bracket. Install the

retainer,

4.
Connect the cable ball to the

clevis on the actuator lever and install

the actuator lever spring.

5.
Adjust the parking brake.

6. Reposition the dimmer switch

and install the retaining screws.

7.
Position the air duct to the inner

panel and install the retaining screws.

& Position the cowl side trim panel

and install the retaining screw.

9. Install the two screws in the

scuff plate.
PARKING BRAKE

EQUALIZER TO CONTROL

CABLE

FAIRLANE, MONTEGO

AND FALCON

Removal

Refer to Fig. 35.

1.
Make certain the parking brake

is fully released.

2.
Raise the vehicle on a hoist. Re-

move the two nuts that attach the

cable to the equalizer. Remove the

equalizer, spring seat and spring.

3.
Remove the hairpin retainer

holding the cable assembly to i:he body

bracket and remove the cable from

the slot in the bracket.

4.
Lower the vehicle partially.

5.
Remove the hairpin retainer

which retains the cable assembly to

the control.

6. Remove the cable bolt retaining

clip from the control clevis and dis-

connect the cable ball from the clevis.

7.
Pull the cable down through the

opening in the floor pan and frame

side rail.

Installation

1.
Route the new cable through

the frame side rail and up through

the opening in the floor pan. Pull the

cable up into position.

2.
Connect the cable ball in the con-

trol clevis.

3.
Insert the cable housing into

the control and install the hairpin re-

tainer.

4.
Raise the vehicle.

5.
Position the cable in the body

bracket and install the hairpin re-

tainer.

6. Position the spring, spring re-

tainer and equalizer on the cable and

install the two nuts.

7.
Adjust the parking brake.

MUSTANG AND COUGAR

Removal

Refer to Fig. 36.

1.
Make certain the parking brake

is fully released.

2.
Raise the vehicle on a hoist. Re-

move the two nuts that attach the

cable to the equalizer. Remove the

equalizer spring seat and spring.

3.
Remove the hairpin retainer

holding the cable assembly to the

body bracket and pull the cable out

of the side rail access holes.procarmanuals.com

02-02-35
Brake System

02-02-35

4.
Attach a wire to the end of the

cable to assist in routing new cable.

5.
Lower the vehicle.

6. Remove the parking brake front

cable ball retaining clip from the

clevis.

7.
Disconnect the cable ball from

the notch in the brake clevis.

8.. Remove the hairpin retainer and

remove the cable assembly from the

brake control assembly.

9. Pull the cable assembly up through

the opening in the floor and remove

the wire from the end of the cable.

Installation

Refer to Fig. 36.

1.
Connect the wire to the end of

the cable assembly and pull the cable

down through the opening in the

floor. Remove the wire.

2.
Connect the cable assembly to

the brake control assembly and in-

stall the hairpin retainer.

3.
Position the ball end of the

cable in the notch of the brake clevis.

4.
Raise the vehicle on a hoist.

5.
Pull the cable grommet into po-

sition and route the cable through

the access holes in the side rail and

under the fuel line.

6. Insert the cable into the body

bracket and install the hairpin re-

tainer.

7.
Position the spring, spring seat,

and equalizer on the cable and install

the two nuts.

8. Adjust the parking brake.

LINCOLN CONTINENTAL

Removal

1.
Raise the car on a hoist. Dis-

connect the parking brake cable from

the equalizer lever underneath the

car (Fig. 38).

2.
Remove the retaining clip at the

cable bracket, and disengage the cable

from the bracket (Fig. 38).

3.
Remove the supporting clip re-

taining bolts and remove the support

plate from the underbody.

4.
Lower the car on a hoist.

5.
With the parking brake in the

fully released position, disconnect the

cable at the control assembly.

6. Raise the vehicle on a hoist. Re-

move the left front fender apron

splash shield retaining bolts and the

splash shield.

7.
Remove the two bolts securing

the parking brake control to equaliz-

er cable bracket to the dash panel

and remove the cable from the vehicle.
Installation

1.
Route the parking brake control

to equalizer cable to the control as-

sembly and the equalizer, and install

the two bolts that retain the cable

to the dash panel (Fig. 38).

2.
Install the left fror%/ender apron

splash shield and the ^u attaching

bolts.

3.
Lower the vehicle.

4.
Connect the control cable to the

clevis on the control assembly.

5.
Raise the car on a hoist.

6. Position the supporting clip and

cable on the vehicle and install the

retaining bolts. Do not tighten the

bolts.
Position the cable armor ap-

proximately 1/2 inch to the right of

the clip (looking toward the rear of

the car) and tighten the retaining

bolts.

7.
Position the equalizer control

cable to the support bracket and in-

stall the retaining hairpin clip.

8. Connect the ball end of the con-

trol cable to the equalizer lever.

9. Adjust the parking brake linkage

(Part
2-1,
Section 2).

10.
Check the operation of the auto-

matic release mechanism.

PARKING BRAKE

ACTUATOR-TO-EQUALIZER

CABLE

FORD, MERCURY,

METEOR, THUNDERBIRD

AND CONTINENTAL

MARK III

Removal

Refer to Figs. 34 and 37.

1.
Raise the vehicle on a hoist.

2.
Remove the lock and adjusting

nut which retains the cable to the

equalizer.

3.
Remove the cable end from the

equalizer.

4.
Unhook the cable from the act-

uator, and remove from the vehicle. *

Installation

1.
Insert new cable end into act-

uator.

2.
Insert cable end into equalizer

and tighten the adjusting nut snug.

Install the lock nut.

3.
Adjust the parking brake cable

tension and check operation as out-

lined in Part
2-1,
Section 2.

4.
Lower the vehicle.
PARKING BRAKE EQUALIZER

TO REAR WHEEL CABLE

FORD, MERCURY,

METEOR, THUNDERBIRD

AND CONTINENTAL

MARK III

Removal

1.
Raise the vehicle and tffosen the

parking brake equalizer rod" adjusting

nut. Disconnect the equalizer from the

rear cables (Figs. 34 and 37).

2.
Compress the prongs on the left

cable-to-frame side member retainer

so the prong can pass through the

side-member. Remove the clip that at-

taches the left cable to the left lower

arm. Pull the cable thru the frame left

side member.

3.
Compress the prongs on the

right cable-to-frame side member re-

tainer bracket so the prong can pass

through the bracket. Remove the clips

retaining the right cable to the frame

crossmember.

4.
Remove the rear wheel cover and

wheel. Remove the three Tinnerman

nuts that hold the brake drum in place

and remove the drum.

5.
Working on the wheel side of the

rear brake, remove the automatic

brake adjuster spring. Compress the

prongs on the parking brake cable re-

tainer so that they can pass through

the hole in the brake backing plate.

Draw the cable retainer through the

hole.

6. With the spring tension off the

parking brake lever, lift the cable out

of the slot in the lever and remove the

cable through the backing plate hole.

Installation

1.
Pull enough of the parking brake

cable through the housing so that the

end of the cable may be inserted over

the slot in the parking brake lever on

the rear brake shoe.

2.
Pull the excess slack from the

cable, and insert the cable housing

into the brake backing plate access

hole so that the retainer prongs ex-

pand. The prongs must be securely

locked in place. Install the automatic

brake adjuster spring.

3.
Position the right hand cable and

the two retaining clips and screws on

the rear crossmember. Compress the

prongs on the right cable and position

the cable in the retaining bracket on

the frame side member. Be sure theprocarmanuals.com

03-01-01

PART
3-1
PAGE

Suspension,
Steering, Wheels and

Tires,
General Service 03-01-01

PART
3-2

Suspension 03-02-01

PART
3-3

Automatic
Air
Leveling System ....03-03-01

PART
3-4

Automatic
Air
Leveling System

Lincoln Continental 03-04-01

PART
3-5

Steering Columns and Linkage ... 03-05-01

PART
3-6

Manual Steering 03-06-01

PART
3-7

Ford Design Non-Integral Power

Steering System
03-07-01
PART
3-8
PAGE

Ford Design Integral Power

Steering Gear 03-08-01

PART
3-9

Saginaw Design Integral Power

Steering Gear 03-09-01

PART
3-10

Ford-Thompson Power Steering

Pump 03-10-01

PART
3-11

Eaton Power Steering Pump 03-1
1-01

PART 3-12

Wheels and Tires 03-1 2-01

PART
3-13

Specifications
03-13-01

PART
3-1
Suspension,Steering, Wheels
and

Tires—General Service

COMPONENT INDEX

CASTER AND CAMBER ADJUSTMENTS

FRONT
END
INSPECTION

FRONT WHEEL ALIGNMENT CHECKS

LUBRICANT CHECKING PROCEDURE

POWER STEERING GEAR CLEANING

AND INSPECTION

POWER STEERING PRELIMINARY TESTS

POWER STEERING PUMP

Cleaning
and
Inspection

Flow
and
Pressure Tests

POWER STEERING SYSTEM FLUSHING

SHOCK ABSORBER CHECKS

STEERING WHEEL SPOKE POSITION

Adjustment

TOE-IN ADJUSTMENT

WHEEL BALANCING
MODEL APPLICATION
All
Models

01-08

01-03

01-07

01-09

01-02

01-11

01-07

01-07

01-07
Ford
01-05

01-09

01-02

01-09
Mercury
01-05

01-09

01-02

01-09
Meteor
01-05

01-09

01-02

01-09
Cougar
01-06

01-09

01-02

01-09
Fairlane
01-06

01-09

01-02

01-09
Falcon
01-06

01-09

01-02

01-09
Montego
01-06

01-09

01-02

Gl-09
Mustang
01-06

01-09

01-02

01-09
Lincoln-
Continental
01-06

01-09

01-03

N/A
Thunderbird
01-05

01-09

01-02

01-09
Continental-
Mark
III
01-05

01-10

01-03

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.
procarmanuals.com

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

03-03-01
Automatic
Air
Leveling System

03-03-01

PART
3-3
Automatic
Air
Leveling System

COMPONENT INDEX

AIR COMPRESSOR

Disassembly
and
Overhaul

Removal
and
Installation

AIR CYLINDER

Removal
and
Installation

DESCRIPTION

HEIGHT CONTROL VALVE

Disassembly
and
Overhaul

Removal
and
Installation
MODEL APPLICATION
All
Models
Ford

03-03

03-02

03-02

03-01

03-03

03-02
Mercury
03-03

03-02

03-02

03-01

03-03

03-02
Meteor
03-03

03-02

03-02

03-01

03-03

03-02
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

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.
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/A

N/A
Continental-
Mark III
N/A

N/A

N/A

N/A

N/A

N/A

DESCRIPTION

The automatic level control
is an

accessory item
on the
Ford, Mercury

and Meteor vehicles
(Fig. 1).
This
de-

vice
is a
supplement
to the
rear coil

spring suspension,
and
will automati-
cally maintain
the
rear standing height

of
the
vehicle
at an
approximate
con-

stant position compensating
for
vary-

ing loaded conditions.
The
system

consists
of a
vacuum operated
com-
pressor, control valve,
air
cylinders

and
the
connecting lines
and
fittings.

In
the
event
of
accidental
air
loss,
the

conventional coil springs will support

the vehicle.

RUBBER
AIR
CYLINDER

WITHIN COIL SPRING
HEIGHT CONTROL

VALVE
RUBBER
AIR
CYLINDER

WITHIN COIL SPRING

RUBBER VACUUM LINE
TO
VACUUM

DISTRIBUTION CONNECTOR

RED CLAMP STATION WAGON ONLY

COMPRESSOR

NYLON
AND
STEEL LINES

FROM VALVE
TO
CYLINDERS

FIG.
1
—
Air Leveling System
FT475-A
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