1969 FORD MUSTANG engine oil

03-12-07
Wheels And Tires

03-12-07

Tool - 7277- K

F 1263-A

FIG. 17—Installing Front Wheel Bearing Cup

13.
Pack the bearing cone and roll-

er assemblies with wheel bearing

grease. A bearing packer is desirable

for this operation. If a packer is not

available, work as much lubricant as

possible between the rollers and cages.

Lubricate the cone surfaces with

grease.

14.
Place the inner bearing cone

and roller assembly in the inner cup.

Apply a light film of grease to the lips

of the grease retainer and install the

new grease retainer with the tool

shown in Fig. 18. Be sure the retainer

is properly seated.

15.
Install the hub and rotor as-

sembly on the wheel spindle. Keep the

hub centered on the spindle to prevent

damage to the grease retainer or the

spindle threads.

16.
Install the outer bearing cone

and roller assembly and the flat wash-

er on the spindle, then install the ad-

justing nut.

17.
Adjust the wheel bearings as

outlined in Section 2, and install a

new cotter pin. Bend the ends of the

cotter pin around the castellations of

the nut lock to prevent interference

with the radio static collector in the

grease cap. Install the grease cap.

18.
Install the caliper to the spindle

and torque the attaching bolts to spe-

cifications as detailed in Group 2.

19.
Install the wheel and tire on the

hub.

20.
Install the hub cap or wheel

cover.

21.
Before driving the vehicle,

pump the brake pedal several times to

obtain normal brake lining to rotor

clearance and restore normal brake

pedal travel.
FRONT HUB AND DRUM

ASSEMBLY REPLACEMENT

When the hub and drum assembly

is replaced, new bearings and a grease

retainer must be installed in the new

assembly. The new grease retainer

should be soaked in light engine oil at

least 30 minutes before installation.

1.
Raise the vehicle until the wheel

and tire clears the floor. Pry off the

hub cap or wheel cover, and remove

the wheel and tire from the hub and

drum assembly.

2.
Remove the grease cap from the

hub.
Remove the cotter pin, nut lock

adjusting nut, and flat washer from

the spindle. Remove the outer bearing

cone and roller assembly (Fig. 1).

3.
Pull the hub and drum assembly

off the wheel spindle.

4.
Remuve the grease retainer and

the inner bearing cone and roller as-

sembly from the hub with Tool

1175AE.

5.
Remove the protective coating

from the new hub and drum with car-

buretor degreaser.

6. Pack the inside of the hub with

specified wheel bearing grease. Add

lubricant to the hub only until the

grease is flush with the inside diame-

ter of both bearing cups (Fig. 15).

7.
All old grease should be com-

pletely cleaned from the bearings be-

fore repacking them with new grease.

Pack the bearing cone and roller

assemblies with wheel bearing grease.

A bearing packer is desirable for this

operation. If a packer is not available,

work as much lubricant as possible

between the rollers and cages. Lubri-

cate the cone surfaces with grease.
8. Place the inner bearing cone and

roller assembly in the inner cup, and

install the new grease retainer with the

reverse end of the tool shown in Fig.

6. Be sure that the retainer is properly

seated.

9. Adjust the brake shoes as out-

lined in Group 2.

10.
Install the new hub and drum

assembly on the wheel spindle. Keep

the hub centered on the spindle to pre-

vent damage to the grease retainer.

11.
Install the outer bearing cone

and roller assembly and the flat wash-

er on the spindle; then, install the ad-

justing nut (Fig. 1).

12.
Position the wheel and tire on

the new hub and drum assembly. In-

stall the wheel hub nuts and tighten

them alternately in order to draw the

wheel evenly against the hub and

drum.

13.
Adjust the wheel bearings as

outlined in Section 2, and install a

new cotter pin. Bend the ends of the

cotter pin around the castellations of

the nut lock to prevent interference

with the radio static collector in the

grease cap. Install the grease cap.

14.
Install the hub cap or wheel

cover.

FRONT HUB AND ROTOR

ASSEMBLY REPLACEMENT

When the hub and rotor assembly is

replaced, new bearings and a grease

retainer must be installed in the new

assembly.

1.
Raise the vehicle until the wheel

and tire clear the floor. Pry off the

hub cap or wheel cover, and remove

the wheel and tire from the hub and

rotor assembly.

2.
Remove 2 bolts and washers that

attach the caliper to the spindle. Re-

move the caliper from the rotor and

wire it to the underbody to prevent

damage to the brake hose.

3.
Remove the grease cap from the

hub.
Remove the cotter pin, nut lock,

adjusting nut, and flat washer from

the spindle; then, remove the outer

bearing cone and roller assembly,

(Fig. 2).

4.
Pull the hub and rotor off the

spindle.

5.
Remove the protective coating

from the new hub and rotor with car-

buretor degreaser.

6. Grease and install the inner

bearing cone and roller assembly in

the inner bearing cup. Apply a light

film of grease on the grease retainerprocarmanuals.com

04-02-13

Rear Axle
—
Removable Carrier Type
04-02-13

lower insulators. Torque
the
spring

clip nuts
to
specification.

2.
Place
the
brake backing plates
in

their normal position
on the
axle

housing.

3.
Install
new
axle shaft
oil
seals

with
the
tool shown
in Fig. 10.
Soak

the
new
seals
in
light weight engine
oil

(SAE
10) for 1/2
hour before install-

ing them. Installation without
use of

the proper tool will distort
the
seal

and cause leakage. Coat
the
outside
edges
of the new oil
seal with
a non-

hardening type
of
sealer such
as Per-

matex
No. 2 or its
equivalent.

4.
Install
the
axle shafts, brake

drums
and
wheels
as
outlined
in Sec-

tion
2.

5.
Attach
the
hydraulic brake line

T fitting
to the
axle housing,
and se-

cure
the
hydraulic brake line
in its re-

tainer
on the
axle housing.

6. Install vent tube
to
brake tube

junction
and
install vent hose
to
vent
tube.

7.
Raise
the
axle housing
and con-

nect
the
shock absorbers.

8. Connect
the
rear
end of the
drive

shaft
to the
axle U-joint flange, align-

ing
the
scribe marks made
on the

drive shaft
end
yoke
and the
axle
U-

joint flange.

9. Fill
the
axle with
the
proper

grade
and
amount
of
lubricant.

10.
Road test
the
vehicle.

MAJOR REPAIR OPERATIONS

DISASSEMBLY
OF

DIFFERENTIAL CARRIER

CONVENTIONAL

DIFFERENTIAL

A disassembled view
of the
rear

axle assembly
is
shown
in Fig. 17.

After mounting
the
carrier
in a

holding fixture, disassemble
the car-

rier
as
outlined
in the
following proce-

dures:

1.
Mark
one
differential bearing

cap
and the
mating bearing support

with punch marks
to
help position
the

parts properly during assembly
of the

carrier. Also, mark
one of the
bearing

adjusting nuts
and the
carrier with

AXLE SHAFT-4725
RETAINER RING-1100
scribe marks
for
proper location
dur-

ing assembly.

2.
Remove
the
adjusting
nut
locks,

bearing caps,
and
adjusting nuts. Then

lift
the
differential case assembly
out

of
the
carrier.

(Remove
the
bearing caps
by tap-

ping
the
caps lightly with
a
soft
mal-

let).

3.
Remove
the
differential bearings

with
the
tools shown
in Fig. 18.

4.
Mark
the
differential case, cover,

and ring gear
for
assembly
in the
orig-

inal position.

5.
Remove
the
bolts that attach
the

ring gear
to the
differential case. Press

the gear from
the
case
or tap it off

with
a
soft-faced hammer.

6. With
a
drift, drive
out the
differ-

AXLE HOUSING-4010

DIFFERENTIAL

PINION SHAFT-4211
ential pinion shaft lock
pin (Fig. 19),

and separate
the
2-piece differential

case.

7.
Drive
out the
pinion shaft with
a

brass drift
(Fig. 20).

8. Remove
the
gears
and
thrust

washers
(Fig. 48).

LIMITED-SLIP DIFFERENTIAL

1.
Remove
the
differential case

from
the
carrier
and
remove
the
bear-

ings from
the
differential case
in the

same manner
as the
conventional
dif-

ferential case.

2.
Place
the
differential case
in a

hydraulic press,
and
apply about
one

ton pressure across
the
case bearing

hubs while removing
the
ring gear
at-

FLAT WASHER (LIMITED SLIP ONLY)

DRIVE GEAR ATTACHING BOLT

DIFFERENTIAL CASE COVER -4206

DIFFERENTIAL PINION GEAR-4215

THRUST WASHER-4230

ADJUSTING NUT-4067

CARRIER HOUSING-4025

DRIVE PINION-4610
PINION BEARING

SPACER-4662

PINION FRONT

BEARING-4621

RING GEAR

PILOT BEARING-4A242

FIG. 17—Rear Axle Disassembled—Typical
PILOT BEARING

RETAINER-4627

PINION REAR

BEARING CUP-4616
DEFLECTOR-4859

PINION RETAINER-4668

SEAL-4676
FLANGE_4858
E1750-Aprocarmanuals.com

04-03-06

Rear Axles — Integral Carrier Type

04-03-06

9. Install a new integral nut and

ivasher on the pinion shaft. (Apply a

small amount of lubricant on the

washer side of the nut.)

10.
Hold the flange with the tool

shown in Fig. 9 while the nut is being

tightened.

11.
Tighten the pinion shaft nut,

rotating the pinion occasionally to in-

sure proper bearing seating, (Fig. 6)

and take frequent preload readings

until the preload is at the original rec-

orded reading established in step 3.

12.
After original preload has been

reached, tighten the pinion nut slowly,
until an additional preload of 6 to 12

in-lbs has been added.

The preload should not exceed the

amount shown above, or bearing fail-

ure may result.

Under no circumstances should the

pinion nut be backed off to lessen pre-

load. If this is done, a new pinion

bearing spacer must be installed. (In

addition, the U-joint flange must

never be hammered on, or pneumatic-

-tools used.)

13.
Remove the oil seal replacer

tool from the transmission extension
housing. Install the front end of the

drive shaft on the transmission output

shaft.

14.
Connect the rear end of the

drive shaft to the axle U-joint flange,

aligning the scribe marks made on the

drive shaft end yoke and the axle U-

joint flange (Fig. 14).

15.
Check the lubricant level. Make

sure the axle is in running position.

Add whatever amount of specified lu-

bricant is required to reach the lower

edge of the filler plug hole, located in

the carrier casting or housing cover.

REMOVAL AND INSTALLATION

REAR AXLE HOUSING

REMOVAL

1.
Raise the vehicle and support it

with safety stands under the rear

frame member.

2.
Drain the lubricant from the

axle.

3.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

drive shaft at assembly (Fig. 14). Dis-

connect the drive shaft at the drive

pinion flange.

4.
Disconnect the lower end of the

shock absorbers.

5.
Remove the wheels, brake drums

and both axle shafts as outlined in the

foregoing Section 2.

6. Remove vent hose front vent

tube (Corbin clamp) and remove vent

tube from brake tube junction and

axle housing.

7.
Remove the hydraulic brake T-
fitting from the axle housing. Do not

open the hydraulic brake system lines.

Remove the hydraulic brake line from

its retaining clip on the axle housing.

8. Remove both axle shaft oil seals

with the tools shown in Fig. 8.

9. Remove both brake backing

plates from the axle housing and sus-

pend them above the housing with me-

chanic's wire. The hydraulic brake

SCRIBE MARKS

5/16-24

4 REQ'D.

12-15
LB.
FT.

U-BOLT - 4529 2 REQ'D.

E 1783-A

FIG. 14—Drive Shaft-to-Axle

U-Joint
Connection

El231-A

FIG. 73—Rear Axle Installation—Typical
lines and the parking brake cables are

still attached to the brake carrier

plates.

10.
Support the rear axle housing

on a jack, and then remove the spring

clip nuts. Remove the spring clip

plates (Fig. 13)

11.
Lower the axle housing and re-

move it from under the vehicle.

12.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. See

Section 4, Major Repair Operations.

INSTALLATION

1.
Raise the axle housing into posi-

tion so that the spring clip plates can

be installed. On a Montego or Fair-

lane,
position the spring upper insula-

tors and retainers between the axle

housing and springs and install the

lower insulators. Torque the spring

clip nuts to specification.

2.
Place the brake backing plates in

their normal position on the axle

housing. Use new gaskets on each side

of the brake backing plates.

3.
Install new axle shaft oil seals

with the tool shown in Fig. 8. Soak

the new seals in light weight engine oil

(SAE 10) for 1/2 hour before install-

ing them. Installation without use of

the proper tool will distort the seal

and cause leakage. Coat the outside

edges of the new oil seal with a non-

hardening type of sealer such as Per-

matex No. 2 or its equivalent.

4.
Install the axle shafts, brake

drums and wheels as outlined in Sec-

tion 2.

5.
Attach the hydraulic brake line

T fitting to the axle housing, and se-

cure the hydraulic brake line in its re-

tainer on the axle housing.

6. Install vent tube to brake tubeprocarmanuals.com

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

04-05-06

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

05-02-04
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

05-03-04
Clutch

05-03-04

bushings, position the clutch pedal and

bushings in the pedal support.

8. Install the retaining ring on the

clutch pedal shaft.

9. Position the assist spring in the

pedal support bracket and the assist

spring bracket. Rotate the assist

spring bracket clockwise until the

upper bolt holes line up and install the

bolt. Torque both the upper and lower

bolts to specification.

10.
Check the clutch pedal free

travel and adjust as required.

MUSTANG, COUGAR

1.
Disconnect the battery ground

cable.

2.
Remove the steering column.

Refer to Group 3 of this manual for

the procedure.

3.
Remove the two capscrews re-

taining the master cylinder or booster

to the dash panel. Then remove the

two capscrews retaining the pedal sup-

port bracket to the dash panel.

4.
Working inside the vehicle, dis-

connect the clutch pedal-to-equalizer

rod at the clutch pedal by removing

the retainer and bushing.

5.
Secure the clutch pedal against

the bumper stop with a small C-clamp

as shown in Fig. 6.

6. Disconnect the stop light switch

wires at the connector.

7.
Remove the switch retainer 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.
Remove the master cylinder push

CLUTCH PEDAL ASSIST SPRING
rod, bushing and nylon washer from

the brake pedal pin.

8. Remove the screw retaining the

pedal support bracket to the top inner

cowl bracket (Fig. 6).

9. Remove the two sheet metal

screws retaining the pedal support

bracket to the dash panel.

10.
Remove the two screws retain-

ing the pedal support bracket to the

upper cowl brace and lower the pedal

support bracket away from the steer-

ing column studs.

11.
Remove the pedal support

bracket assembly from the vehicle.

12.
Mount the bracket in a vise.

13.
Remove the small C-clamp se-

curing the clutch pedal to the bumper.

Slowly pivot the pedal away from the

bumper until the assist spring can be

lifted from its seat.

14.
Remove the retainer clip from

the clutch and brake pedal shaft.

Then, remove the clutch pedal and

shaft assembly, brake pedal assembly,

and bushings from the pedal support

bracket.

15.
Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

bushings in their proper places on the

brake and clutch pedal assemblies.

16.
Position the brake pedal to the

pedal support bracket. Install the

clutch and brake pedal shaft through

the pedal support and brake pedal as-

sembly. Install the retainer.

17.
Install the clutch pedal assist

spring and pivot the pedal against its

bumper stop. Secure the pedal against

the bumper with a small C-clamp as

TOP INNER COWL-TO-BRACKET

RETAINING SCREW

C2057-A

FIG.
6—Clutch
Pedal —Mustang and Couga?
shown in Fig. 6.

18.
Position the pedal support

bracket assembly to the dash panel

and to the steering column retainer

studs.

19.
Align the pedal support bracket

holes with the holes in the dash panel

and install the two sheet metal screws.

20.
Install the two capscrews at-

taching the pedal support bracket to

the upper cowl bracket.

21.
Install the screw attaching the

support bracket to the top inner cowl

bracket (Fig. 6).

22.
Install the inner nylon washer,

bushing master cylinder push rod on

the brake pedal pin. Position 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. Secure with

the self-locking pin.

23.
Connect the stop light switch

wires to the connector and install the

wires to the retaining clip.

24.
Connect the clutch pedal-

to-equalizer rod to the clutch pedal

assembly with the bushing and retain-

er and remove the C-clamp from the

bracket.

25.
Working from the engine side

of the dash panel, install the two cap-

screws attaching the pedal support

bracket to the dash panel. Then install

the two screws attaching the master

cylinder to the dash panel.

26.
Install the steering column.

Refer to Group 3 of this manual for

the procedure.

27.
Adjust the clutch pedal free

travel.

28.
Check the brake pedal free

height and travel measurements

(Group 2).

29.
Connect the battery ground

cable.

CLUTCH PEDAL AND/OR

BUSHING REMOVAL

AND INSTALLATION

MOM EGO, FALCON

FAIRLANF

1.
Remove the retaining clip (Fig.

2) that secures the equalizer rod to the

clutch pedal. Disconnect the rod from

the pedal.

2.
Remove the lower bolt retaining

the assist spring bracket to the pedal

support. Then, loosen the upper

bracket retaining bolt (approximately

4 turns) and disconnect the spring

from the clutch pedal and bracket.

3.
Disconnect the brake pedal push

rod from the brake pedal.procarmanuals.com

05-03-06
Clutch

05-03-06

8. Remove the starter cable then

remove the starter motor from the fly-

wheel housing.

9. Remove the bolts that secure the

engine rear plate to the front lower

part of the flywheel housing.

10.
Remove the flywheel housing

lower cover (390 CID housing only).

11.
Remove the bolts that attach

the housing to the cylinder block.

12.
Move the housing back just far

enough to clear the pressure plate,

then move it to the right to free the

pivot from the clutch equalizer bar. Be

careful not to disturb the linkage and

assist spring.

13.
Loosen the six pressure plate

cover attaching bolts evenly to release

the spring tension. If the same pres-

sure plate and cover is to be installed

after the clutch is overhauled, mark

the cover and flywheel so that the

pressure plate can be installed in the

same position.

14.
Remove the pressure plate and

the clutch disc from the flywheel.

CLUTCH INSTALLATION

1.
Install the clutch release lever if

it was removed.

2.
Place the clutch disc, and pres-

sure plate assembly in position on the

flywheel. Start the cover attaching

bolts to hold the pieces in place, but

do not tighten them. Avoid touching

the clutch disc facing, dropping the

parts or contaminating them with oil

or grease as clutch chatter may result.

3.
Align the clutch disc with the

tool shown in Fig. 7, and alternately

tighten the bolts a few turns at a time

until they are all tight. Then torque

the six pressure plate cover attaching

bolts to specification before removing

the tool.
4.
Apply a light film of grease

(C3VY-19586-A) to the outside diam-

eter of the transmission front bearing

retainer. Apply a light film of grease

(C3VY-19586-A) to both sides of the

release lever fork where it contacts the

release bearing bore spring clips.

Apply a light film of grease to the re-

lease bearing surface that contacts the

pressure plate release fingers. Fill the

grease groove of the release bearing

hub with lithium base grease (C3VY-

19586-A). Clean all excess grease

from inside the bore of bearing hub.

Excess grease will be forced onto the

spline by the transmission input shaft

bearing retainer and will contaminate

the clutch disc. Also, place the release

bearing and hub on the release lever.

5.
Make certain that the flywheel

housing and the cylinder block mount-

ing surfaces are clean. Position the

felt washer on the pivot in the fly-

wheel housing. Slip the pivot into the

clutch equalizer shaft being careful

not to disturb the linkage and at the

same time position the housing on the

dowels in the cylinder block. Install

and torque the attaching bolts to spec-

ification.

6. Install the starting motor and

connect the cable.

7.
The mounting surfaces of the

transmission and the flywheel housing

must be free of dirt, paint, and burrs.

Install two guide pins in the flywheel

housing lower mounting bolt holes.

Move the transmission forward on the

guide pins until it is tightly positioned

against the flywheel housing.

8. Install the two upper mounting

bolts.
Then, remove the guide pins

and install the two lower mounting

bolts.
Torque all the bolts to specifica-

tion.

9. Raise the rear of the engine and
install the crossmember. Install and

torque the crossmember attaching

bolts to specifications, then lower the

engine.

10.
Install the extension housing-

to-engine rear support attaching bolts.

Torque the bolts to specification.

11.
Remove the transmission jack

and connect the parking brake cable.

12.
If the vehicle is equipped with a

four-speed transmission, connect the

gear shift linkage control bracket to

the extension housing.

13.
Connect the gear shift rods to

the transmission. Adjust the shift link-

age as required.

14.
Connect the release lever retain-

ing spring. Install the flywheel housing

cover (390 CID housing only).

15.
Remove the tool from the

transmission output shaft and install

the drive shaft.

16.
Check the clutch pedal free

travel.

CLUTCH ARBOR CLUTCH DISC

PRESSURE PLATE

C 1788-A

FIG. 7—Installing Clutch Disc —

Typicalprocarmanuals.com