1969 FORD MUSTANG oil pressure

03-02-16
Suspension

03-02-16

2.
Place a jack under the outer end

of the arm.

3.
Tape the upper and lower spring

insulators to the spring.

4.
Compress the coil spring with

Tool 5310-A (Fig. 23) and place the

spring and insulators in position. Be

sure both ends of the spring are prop-

erly seated, and raise the arm. Guide

the spindle boss over the ball joint

stud.

5.
Install the ball joint stud retain-

ing nut and torque it to specification.

Continue tightening the nut to line up

the cotter pin hole. Install a new cot-

ter pin.

6. Connect the stabilizer bar to the

lower arm. Torque the nut to specifi-

cation.

7.
Connect the drag strut to the

lower arm. Torque the nuts to specifi-

cation.

8. Install the shock absorber.

9. Tighten the splash shield attach-

ing bolts to specifications.

10.
Install the hub and rotor on the

spindle and adjust the wheel bearings.

11.
Install the caliper to the spindle

and tighten the attaching bolts to

specifications. Check for the correct

flexible hose routing (Part 2-2).

12.
Install the wheel and tire on the

hub.
Torque the wheel lug nuts to

specifications and remove the support

stands.

13.
With the front end weight of

the car on the wheels, torque the

lower arm-to-crossmember bolt at-

taching nut to specification.

FRONT SUSPENSION

LOWER ARM

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK III

Removal

1.
Raise the front of the vehicle and

position safety stands under both sides

of the frame just back of the lower

arms.

2.
Remove the hub cap or wheel

cover.

3.
If equipped with drum type

brakes—Remove the wheel and tire

and brake drum as an assembly. Re-

move the brake backing plate attach-

ing bolts and remove the backing

plate from the spindle. Wire the back-

ing plate to the underbody to prevent

damage to the brake hose.

4.
If equipped with disc brakes-

—Remove the wheel and tire from the
•Tool—5310-A

F 1491-A

FIG. 23—Coil Spring Compressed

for Installation

F1437-A

FIG. 24—Removing Front Spring

—Lower Arm Replacement

hub.
Remove 2 bolts and washers that

attach the caliper and brake hose to

the spindle. Remove the caliper from

the rotor and wire it to the underbody

to prevent damage to the brake hose.

Then, remove the hub and rotor from

the spindle.

5.
Disconnect the lower end of the

shock absorber, and push it up to the

retracted position.

6. Disconnect the stabilizer bar link

from the lower arm.

7.
Remove the cotter pins from the

upper and lower ball joint stud nuts.

8. Remove 2 bolts and nuts attach-

ing the strut to the lower arm.

9. Loosen the lower ball joint stud

nut one or two turns. Do not remove

the nut from the stud at this time.

10.
Install Tool T57P-3OO6-A bet-

ween the upper and lower ball joint

studs (Fig. 7). The tool should be

seated firmly against the ends of both

studs and not against the stud nuts.

11.
With a wrench, turn the adapter

screw until the tool places the stud

under tension. Tap the spindle near

the lower stud with a hammer to loos-
en the stud in the spindle. Do not

loosen the stud from the spindle with

tool pressure only.

12.
Position a floor jack under the

lower arm (Fig. 24) and remove the

lower ball joint stud nut.

13.
Lower the floor jack and re-

move the sprina and insulator (Fie.

25).

14.
Remove one nut and bolt at-

taching the lower control arm to the

No.
2 crossmember and remove the

lower arm (Fig. 24).

Installation

1.
Position the lower arm to the

No.
2 crossmember and loosely install

the attaching bolt and nut (Fig. 1).

2.
Position the spring and insulator

to the upper spring pad and lower

arm. Using a floor jack, compress the

spring and guide the lower ball joint

stud into the spindle hole.

3.
Install the ball joint stud attach-

ing nut and torque to specification.

Continue to tighten the nut until the

cotter pin hole is in line with the nut

slots.
Install a cotter pin in the upper

and lower ball joint studs.

4.
Pull the shock absorber down

and connect it to the lower arm.

5.
Position the strut and bumper to

the lower arm. Install the attaching

bolts and nuts and torque to specifica-

tion.

6. Torque the lower arm to No. 2

crossmember attaching bolt and nut to

specifications.

7.
Position the stabilizer bar link to

the lower arm and install the attach-

ing nuts.

8. If equipped with drum type

brakes—Position the brake backing

plate to the spindle and install the at-

taching bolts. Torque the bolts to spe-

cification. Adjust the brakes as out-

lined in Group 2. Install the wheel,

tire,
and drum to the spindle and ad-

just the wheel bearings as outlined in

Part 3-12.

If equipped with disc brakes-Install

the hub and rotor on the spindle.

Position the caliper over the rotor and

install the attaching bolts. Torque the

bolts to specification. Install the

wheel and tire on the wheel hub and

adjust the wheel bearings as outlined in

Part 3-12.

9. Install the hub cap or wheel

cover.

10.
Remove the safety stands and'

lower the vehicle.

11.
Check the caster, camber, and

toe-in and adjust as required (Section

2,
Part 3-1).procarmanuals.com

03-02-18
Suspension

03-02-18

5.
Remove the cotter pin from the

upper ball joint stud nut.

6. Loosen the upper ball joint stud

nut one or two turns. Do not remove

the nut from the stud at this time.

7.
Install tool T57P-3006-A be-

tween the upper and lower ball joint

studs with the adapter screw on top

(Fig. 13). The tool should be seated

firmly against the ends of both studs

and not against the nuts or lower stud

cotter pin.

8. With a wrench, turn the adapter

screw until the tool places the stua

under tension. Tap the spindle near

the upper stud with a hammer to loos-

en the stud in the spindle. Do not

loosen the stud from the spindle with

tool pressure only.

9. Remove the tool from between

the ball joint studs and place a floor

jack under the lower arm.

10.
Raise the floor jack to relieve

the pressure from the upper ball joint

stud nut and remove the nut.

11.
Remove the upper arm inner

shaft attaching bolts. Remove the

upper arm and inner shaft as an as-

sembly (Fig. 1).

12.
Remove the bumpei from the

upper arm.

Installation

1.
Position the bumper to the upper

arm and install the nut and washer.

Torque the nut to specifications.

2.
Position the upper arm inner

shaft to the frame side rail and install

the 2 attaching bolts and washers

snug.

3.
Connect the upper ball joint stud

to the spindle and install the attaching

nut. Torque the nut to specification

and continue to tighten the nut until

the cotter pin hole in the stud is in

line with the nut slots. Then, install

the cotter pin.

4.
If equipped with drum type bra-

kes—Adjust the brakes as outlined in

Part 2-2. Install the wheel, tire, and

drum to the spindle and adjust the

wheel bearings as outlined in Part

3-12.

5.
If equipped with disc brak-

es—Install the wheel and tire on the

hub and adjust the wheel bearings as

outlined in Part 3-12.

6. Install the hub cap or wheel

cover.

7.
Remove the safety stands and

lower the front of the vehicle.

8. Check caster, camber, and toe-in

and adjust as required (Section 2, Part

3-D.
COUGAR, FAIRLANE,

FALCON, MONTEGO,

MUSTANG

Removal

1.
Raise the front of the vehicle,

position safety stands under the

frame, and lower the vehicle slightly.

2.
Remove the wheel and tire.

3.
Remove the shock absorber

lower attaching nuts and washers.

4.
Remove the shock absorber

upper mounting bracket attaching

nuts,
and remove the shock absorber

and bracket as an assembly (Fig. 26).

On all 8-cylinder vehicles, remove

the air cleaner to obtain access for

tool installation.

5.
Install the spring compressor

tool and compress the spring (Figs.

19,
20 and 21).

6. Position a safety stand under the

lower arm.

7.
Remove the cotter pin from the

nut on the upper ball joint stud, and

loosen the nut one or two turns. Do

not remove the nut from the stud at

this time.

8. Position the ball joint remover

tool between the upper and lower ball

joint studs as shown in Fig. 10. The

tool should seat firmly against the

ends of both studs and not against the

stud nuts.

9. Turn the tool with a wrench until

the tool places the studs under consid-

erable tension; then, hit the spindle

smartly near the upper stud with a

hammer to break the stud loose in the

spindle. Do not loosen the stud in the

spindle with tool pressure only. If

both arms are being removed, loosen

the lower stud in the same manner as

the upper stud.

10.
Remove the nut from the upper

stud and lift the stud out of the

spindle.

11.
Remove the upper arm inner

shaft attaching nuts from the engine

compartment, and remove the upper

arm.

12.
Wipe off all loose dirt from the

upper arm parts. Do not wash the ball

joint with a solvent.

Installation

1.
Position the upper arm on the

underbody mounting bracket, and in-

stall the nuts and lock washers on the

two inner shaft attaching bolts. The

specified keystone-type lock washers

must be used. Torque the nuts to

soecification.
2.
Position the upper ball joint stud

in the top of the wheel spindle, and in-

stall the stud nut. Torque the nut to

specification, and continue to tighten

it until the cotter pin hole and slots

line up. Install a new cotter pin.

3.
Release the coil spring, remove

the tool, and install the front shock

absorber and the wheel and tire.

LINCOLN CONTINENTAL

Removal

1.
Place a jack under the outer end

of the suspension lower arm and raise

the arm. Refer to Fig. 22.

2.
Remove the wheel and tire.

3.
Remove the cotter pin from the

upper ball joint stud. Loosen the nut

one or two turns.

4.
Place a box wrench over the

lower end of the ball joint remover

tool, and position the tool as in Fig.

13.
The tool should seat firmly against

the ends of both studs, and not

against the upper stud nut.

5.
Turn the wrench until both studs

are under tension, and then, tap the

spindle with a hammer near the upper

stud to loosen it from the spindle. Do

not loosen the stud with tool pressure

alone. Remove the nut.

UPPER MOUNTING BRACKET

LOWER RETAINING BOLTS F 1490-A

FIG. 26—Removing or Installing

Front Shock Absorber—Typicalprocarmanuals.com

03-02-21
Suspension

03-02-21

8. Place a box wrench over the

lower end of the ball joint remover

tool, and position the tool as in Fig.

13.
The tool should seat firmly against

the ends of both studs, and not

against the stud nuts.

9. Turn the wrench until both studs

are under tension, and then, tap the

spindle with a hammer near the studs

to loosen them from the spindle. Do

not loosen
the
studs with tool pressure

alone.

10.
Place a jack under the outer

end of the lower arm, and raise the

arm several inches. Remove both ball

stud nuts, and remove t^e spindle.

Installation

1.
Position the new spindle onto the

upper and lower ball joint studs, in-

stall the stud nuts and tighten the nuts

to specifications. Continue to tighten

both nuts until the cotter pin holes

line up with the slots, then install new

cotter pines.

2.
Connect the spindle connecting

rod to the spindle arm. Install the re-

taining nut and tighten the nut to

specification. Continue to tighten the

nut until the cotter pin hole lines up

with the slot, then install a new cotter

pin.

3.
Install the gasket and splash

shield on the spindle. Tighten the at-

taching bolts to specifications.

4.
Install the hub and rotor on the

spindle.

5.
Install the caliper to the spindle

and tighten the attaching bolts to spe-

cifications. Check for the correct flex-

ible hose routing (Part 2-2).

6. Install the wheel and tire and ad-

just the wheel bearings (Part 3-12).

7.
Lubricate the steering stop on

the lower arm and the mating flat on

the spindle with the specified lubri-

cant.

8. Remove the safety stands, lower

the car and check camber, caster and

toe-in.

FRONT SHOCK ABSORBER

REPLACEMENT

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK III

1.
Remove the nut, washer, and

bushing from the shock absorber

upper end.

2.
Raise the vehicle on a hoist and

install safety stands.
3.
Remove 2 bolts attaching the

shock absorber to the lower arm and

remove the shock absorber.

4.
Place a washer and bushing on

the shock absorber top stud and posi-

tion the shock absorber inside the

front spring. Install the 2 lower at-

taching bolts and torque them to spe-

cifications.

5.
Remove the safety stands and

lower the vehicle.

6. Place a bushing and washer on

the shock absorber top stud and in-

stall the attaching nut. Torque it to

specification.

COUGAR, FAIRLANE,

FALCON, MONTEGO,

MUSTANG

Removal

1. Raise the hood and remove 3

shock absorber upper mounting

bracket-to-spring tower attaching

nuts.

2.
Raise the front of the vehicle and

place safety stands under the lower

arms.

3.
Remove 2 shock absorber lower

attaching nuts and washers.

4.
Lift the shock absorber and

upper bracket from the spring tower

(Fig. 26) and remove the bracket from

the shock absorber.

Installation

1. Install the upper mounting

bracket on the shock absorber and

torque to specification.

2.
Position the shock absorber and

upper mounting bracket in the spring

tower, making sure the shock absor-

ber lower studs are in the pivot plate

holes.

3.
Install the 2 washers and attach-

ing nuts on the shock absorber lower

studs and torque to specification.

4.
Install the 3 shock absorber

upper mounting bracket-to-spring

tower attaching nuts and torque to

specification. Then, remove the safety

stands and lower the vehicle.

LINCOLN CONTINENTAL

Removal

1.
Remove the stud nut at the

upper eye of the shock absorber. Re-

move the upper eye stud bracket to

crossmember attaching bolt and re-

move the stud bracket. Refer to Fig.

22.
2.
Remove the bolts which attach

the shock absorber to the suspension

lower arm. Lower, and remove the

shock absorber.

3.
Examine the shock absorber unit

and rubber bushings. Replace parts

that are defective, deteriorated, or

worn.

Installation

1. Fully extend the shock absorber

and position it inside the coil spring.

Connect the lower end of the shock

absorber to the suspension lower arm.

Torque the attaching nuts to specifica-

tion.

2.
Insert the upper bracket stud

through the bushing in the shock ab-

sorber upper eye. Install the stud

bracket to crossmember attaching

bolt. Do not tighten the bolt: at this

time.

3.
Install the upper eye bracket

stud nut. Torque the nut to specifica-

tion.

4.
Torque the stud bracket- to-

crossmember attaching bolt to specifi-

cation.
The
shock absorber upper
eye

stud
nut
must
be
tightened
to com-

press
the
rubber bushing before
the

stud bracket
is
bolted
to the

crossmember;
otherwise,
the
upper
at-

tachment could
be
loose
and
noisy.

REAR SHOCK ABSORBER

REPLACEMENT

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK 1(11

1.
Raise the vehicle on a hoist.

2.
Remove the shock absorber at-

taching nut, washer and insulator

from the upper stud at the upper side

of the spring upper seat. Compress the

shock absorber to clear the hole in the

spring seat, and remove the inner in-

sulator and washer from the upper at-

taching stud.

3.
Remove the self-locking attach-

ing nut, and disconnect the shock ab-

sorber lower stud from the mounting

bracket on the rear axle housing (Fig.

4).

4.
Expel all air by performing step

3 On Vehicle Tests in Part 3-1.

5.
Place the inner washer and insu-

lator on the upper attaching stud, and

position the shock absorber so that

the upper attaching stud enters the

hole in the spring upper seat. While

holding the shock absorber in this po-

sition, install the outer insulator andprocarmanuals.com

03-02-24

Suspension

03-02-24

LOCK NUT

INSULATOR

NG

NUT

MOUNTING STUD

WASHER

LOCK WASHER

FIG. 31—Rear Shock Absorber Mounting
F1486-A

TRACK BAR

MOUNTING

STUD AXLE

VENT
SHOCK

ABSORBER

MOUNTING

BRACKET
SHOCK

ABSORBER

MOUNTING

BRACKET

V-V.

FIG. 32—Removing or Installing Rear Spring—Typical
COIL SPRING

F1438-A

Place jack stands under the frame side

rails.

2.
Disconnect the lower studs of the

two rear shock absorbers from the

mounting brackets on axle housing.
3.
Lower the hoist and axle housing

until the coil springs are released (Fig.

32).

4.
Remove the springs and the insu-

lators from the vehicle.
Installation

1.
Position the spring in the upper

and lower seats with an insulator be-

tween each seat and the spring.

2.
Raise the hoist and axle housing

with the spring in position and con-

nect the lower studs of the rear shock

absorbers to the mounting brackets on

the axle housing. Install the attaching

nuts,
and torque to specifications.

3.
Remove the jack stands and

lower the vehicle.

REAR SUSPENSION

LOWER ARM

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK III

Removal

1.
Raise the vehicle on a hoist and

place jack stands under the frame side

rails.

2.
Remove the attaching nut and

bolt from the frame track bar mount-

ing bracket and disconnect the bar

from the stud (Fig. 4).

3.
Lower the axle enough to relieve

spring pressure.

4.
Support axle under differential

pinion nose as well as under axle.

5.
Remove the lower arm pivot bolt

and nut from the axle bracket. Then,

disengage the lower arm from the

bracket.

6. Remove the pivot bolt and nut

from the frame bracket and remove

the lower arm from the vehicle.

Installation

The rear suspension lower arms are

not interchangeable. The lower arm

for the left side can be identified by

notches in the bushing flange (Fig. 4).

The right arm does not have the

notches.

1.
Position the lower arm in the

bracket on the frame side rail. Install

a new pivot bolt and new nut (Fig.

33).
Do not tighten the nut at this

time.

2.
Position the lower arm to the

axle bracket and install a new bolt

and new nut (Fig. 33). Do not tighten

the nut at this time.

3.
Raise the axle.

4.
Install alignment spacers be-

tween the rear axle and frame (Fig. 3,

Part 3-1). Then, torque the lower armprocarmanuals.com

03-08-03
Ford Design Integral Power Steering Gear

03-08-03

factory adjustments will change. These

changes in adjustment do not neces-

sarily affect the satisfactory operation

of the steering gear assembly, and

therefore ordinarily do not require

readjustment unless there is excessive

lash or other malfunctioning.

ADJUSTMENT IN

VEHICLE

The only adjustment which can be

performed is the total over center

position load, to eliminate excessive

lash between the sector and rack

teeth.

1.
Disconnect the pitman arm from

the sector shaft.

2.
Disconnect the fluid return line

at the reservoir, at the same time cap

the reservoir return line pipe.

3.
Place the end of the return line

in a clean container and cycle the
INPUT SHAFT

SECTOR SHAFT

ADJUSTMENT SCREW

C1547- A

FIG.
2—Adjusting Mesh Load

steering wheel in both directions as re-

quired, to discharge the fluid from the

gear.
4.
Remove the ornamental cover

from the steering wheel hub and turn

the steering wheel to 45 degrees from

the left stop.

5.
Using an in-lb torque wrench on

the steering wheel nut, determine the

torque required to rotate the shaft

slowly through an approximately 1/8

turn from the 45 degree position.

6. Turn the steering gear back to

center, then determine the torque re-

quired to rotate the shaft back and

forth across the center position. Loos-

en the adjuster nut, and turn the ad-

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

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

45 degrees from the stop.

Tighten the lock nut while holding

the screw in place.

7.
Recheck the readings and replace

pitman arm and steering wheel hub

cover.

8. Connect the fluid return line to

the reservoir and fill the reservoir with

specified lubricant to the proper level.

REMOVAL AND INSTALLATION

REMOVAL

1.
Disconnect the pressure and the

return lines from the steering gear.

Plug the lines and the ports in the

gear to prevent entry of dirt.

2.
Remove the two bolts that secure

the flex coupling to the steering gear

and to the column.

3.
Raise the vehicle and remove the

sector shaft attaching nut.

4.
Remove the Pitman arm from

the sector shaft with Tool T64P-

3590-F.
Remove the tool from the

Pitman arm. Do not damage the

seals.

5.
If working on a vehicle equipped

with a standard transmission, remove

the clutch release lever retracting

spring to provide clearance for remov-

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

remove the three steering gear attach-

ing bolts.

7.
Work steering gear free of the

flex coupling and remove it from the

vehicle.

8. If the flex coupling stayed on the

input shaft, lift if off the shaft at this

time.

INSTALLATION

1.
Slide the flex coupling into place

on the steering shaft. Turn the steer-

ing wheel so that the spokes are in the

horizontal position.

2.
Center the steering gear input

shaft.

3.
Slide the steering gear input

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

the three attaching bolts and torque

them to specification.

4.
Make sure that the wheels are in

the straight ahead position, then in-

stall the Pitman arm on the sector

shaft. Install and tighten the sector

shaft and install and tighten the at-

taching bolts to specification.

5.
Move the flex coupling into

place on the input and steering co-

lumn shaft and install and tighten the

attaching bolts to specification.

6. Connect and tighten the fluid

pressure and the return line to the

steering gear.

7.
Fill the power steering pump and

cycle the steering gear. Check for

leaks and again check the fluid level.

Add fluid as required.

MAJOR REPAIR OPERATIONS

In most cases, complete disassembly

of the power steering gear will not be

necessary. It is suggested that only

those assemblies that are faulty be dis-

assembled. Disassembly and reassem-

bly of the unit and the subassemblies

must be made on a clean workbench.

As in repairing any hydraulically op-

erated unit, cleanliness is of utmost

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

all times. Thoroughly clean the exter-

ior of the unit with a suitable solvent

and when necessary, drain as much of

the hydraulic oil as possible. Handle

all parts very carefully to avoid nicks,

burrs,
scratches and dirt, which could

make the parts unfit for use. Do not

clean, wash or soak seals in cleaning

solvent.
VALVE CENTERING

SHIM REPLACEMENT

1.
Hold the steering gear over a

drain pan in an inverted position and

cycle the input shaft several times to

drain the remaining fluid from the

gear.

2.
Mount the gear in a soft-jawed

vise.procarmanuals.com

03-10-03
Ford-Thompson Power Steering Pump

03-10-03

EIGHT CYLINDER WITH

AIR CONDITIONER

1.
Remove the power steering fluid

from the pump reservoir by discon-

necting the fluid return hose from the

reservoir and allow the fluid to drain

in a suitable container.

2.
Disconnect the pressure hose

from the pump.

3.
Remove 3 bolts from the front of

the pump and the one nut at the rear

that attach the pump to the mounting

bracket and remove the drive belt

from the pump pulley.

4.
Loosen the upper pump bracket-

to-engine attaching bolt and remove

the bolt in the belt adjusting slot. Re-

move the pump.

5.
Position the pump to the bracket

and install the bracket-to-pump at-

taching bolts and nuts. Tighten to spe-

cifications.

6. Place the belt on the pump pul-

ley. Adjust the belt tension as outlined

in Section 2 and tighten the bolts and

nut to specification.

7.
Torque the pressure hose fitting

hex nut to specification. Then, connect

the pressure hose to the fitting and

torque the hose nut to specification.

8. Connect the return hose to the

power steering pump and tighten the

clamp.

9. Fill the pump with automatic

transmission fluid C1AZ-19582-A.

Bleed the air from the system (Part

3-1) and check for leaks and again
check the fluid level. Add fluid as re-

quired.

POWER STEERING PUMP

PULLEY REPLACEMENT

REMOVAL

1.
Drain as much of the fluid as

possible from the pump through filler

pipe.

2.
Install a 3/8-16 inch capscrew in

the end of the pump shaft to prevent

damage to the shaft end by the tool

screw.

3.
Install the pulley remover, Tool

T63L-1O3OO-B, on pulley hub, and

place the tool and pump in a vise as

shown in Fig. 3.

4.
Hold the pump and rotate the

tool nut counterclockwise to remove

the pulley (Fig. 3). The pulley must be

removed without in and out pressure

on the pump shaft to prevent damage

to internal thrust areas.

INSTALLATION

1.
Position the pulley to the pump

shaft and install Tool T65P-3A733-A

as shown in Fig. 4.

2.
Hold the pump and rotate the

tool nut clockwise to install the pulley

on the shaft. The pulley face will be

flush with end of pump shaft. Install

the pulley without in and out pressure
on the shaft to prevent damage to in-

ternal thrust areas.

3.
Remove the tool.

POWER STEERING PUMP

RESERVOIR REPLACEMENT

Reservoir replacement must be done

on a clean workbench. Cleanliness of

work area and tools is extremely im-

portant when repairing any hydraulic

unit. Thoroughly clean the exterior of

the pump with a suitable cleaning sol-

vent. Do not clean, wash or soak the

shaft oil seal in solvent. Plug the inlet

and outlet openings with plugs or

masking tape before cleaning the

pump exterior or removing the reser-

voir.

REMOVAL

1.
Assemble the adapter plate (Tool

T69P-3A674-A) to the bench mounted

fixture tool (T57L-5OO-A). Position

the pump and pulley on the adapter

plate, pulley facing down.

2.
Remove the outlet fitting hex nut

and the service identification tag.

3.
Invert the pump so the pulley is

facing up and remove the reservoir by

tapping around the flange with a wood

block (Fig. 5).

4.
Remove the reservoir O-ring seal

and the outlet fitting gasket from the

pump.

INSTALLATION

Tool • T 63 L-

10300 -

G 1477 A

FIG. 3—Removing Power

Steering Pump Pulley
1478 A

FIG. 4—Installing Power

Steering Pump Pulley
1.
Install a new gasket on the outlet

fitting and a new reservoir O-ring seal

on the pump housing plate (Fig. 6).

The old gasket and seal should never

be re-used.

Too/
T57L 500-A

G1602-A

FIG. 5—Removing Pump

Reservoirprocarmanuals.com

03-10-04
Ford-Thompson Power Steering Pump

03-10-04

OUTLET FITTING

GASKET
Wood Block

0-RING SEAL

G1345-
-500-
A

G1603- A

FIG. 6—Gasket Locations
FIG.
7—Installing
Reservoir

on Pump—Typical
2.
Apply vaseline to the reservoir

O-ring seal and to the inside edge of

the new reservoir flange. Do not twist

the O-ring seal.

3.
Position the reservoir over the

pump and align the notch in the reser-

voir flange with the notch in the outer

diameter of the plate and bushing as-

sembly.

4.
Install the reservoir on the pump

and O-ring seal with a plastic or rub-

ber hammer and a block of wood as

shown in Fig. 7. Tap at the rear of the

reservoir and on the outer edges only.

5.
Inspect the assembly to be sure

the reservoir is evenly seated on the

pump housing plate.

6. Position the service identification

tag on the outlet fitting and install the

outlet fitting hex nut. Torque the nut

to specification (Part 3-13). Do not

exceed specification.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

Disassembly of the pump and its

subassemblies must be made on a

clean work bench. In repairing any

hydraulically operated unit, cleanliness

is of utmost importance. Clean the ex-

terior of the unit with a suitable sol-

vent and drain as much of the fluid as

possible.

If only the reservoir is to be re-

moved, plug the inlet and outlet open-

ings with masking tape or plugs. Do

not immerse the shaft oil seal in sol-

vent. If only the rotor shaft seal is to

be replace, see Rotor Shaft Seal Re-

placement outlined in this section.

1.
Assemble the adapter plate (Tool

T69P-3A674-A) to the bench mount-

ed holding fixture Tool T57L-5OO-A

(Fig. 8).

2.
Position the pump assembly,

with pulley assembled, on the adapter

plate, pulley facing down.

3.
Remove the outlet fitting nut and

the service identification tag.

4.
Invert the pump assembly and,

using a block of wood and a rubber or

plastic hammer, remove the pump res-

ervoir and seal by tapping around the

flange of the reservoir and on the und-

erside of the filler neck.

5.
Again invert the pump assembly,

loosen and remove the pump housing

retention bolts and remove the pump

housing.
6. If necessary, remove the fol-

lowing components from the pump

housing: the housing cover, the O-ring

seal and the pressure springs. These

components normally will remain in

the pump housing when it is removed.

7.
Remove and discard the pump

cover gasket.

8. Remove the retainer end plate

and upper pressure plate (in some

pumps, the end plate and upper pres-

sure plate are integral).

9. Remove the loose fitting dowel

pin. Be careful not to bend the fixed

dowel pin which remains in the hous-

ing plate assembly.

10.
Remove the rotor assembly

being careful to prevent the springs

and slippers from falling out and be-

coming lost. Do not disassemble fur-

ther unless the lower pressure plate,

housing plate, rotor shaft and/or seal

is to be replaced.

11.
Invert the pump assembly and,

using Tool T63L-1O3OO-B, remove the

pulley.

12.
Clean any rust, road dirt, burrs,

scoring, etc. from the pulley end of

the rotor shaft prior to removal of the

shaft from the housing plate. The

shaft must come out without restric-

tions to prevent scoring or damage to

the bushing. Remove the pump rotor

shaft.

13.
Remove the lower pressure

plate.
PARTS REPAIR OR

REPLACEMENT

ROTOR SHAFT

SEAL REPLACEMENT

Removal

1.
Remove the pulley from the

rotor shaft as described under Power

Steering Pump Pulley Removal.

2.
Position the pump assembly in

T57L-500-A

T69P-3A674-A

•
G1604-A

FIG. 8—Adapter Plate Installationprocarmanuals.com

03-11-03

Eaton Power Steering Pump

03-11-03

POWER STEERING PUMP

DISASSEMBLY

A clean working area should be

used when overhauling the power

steering pump. Foreign matter picked

up on working parts may cause dam-

age or failure of the unit. Clean con-

tainers should be used for parts.

1.
Drain the fluid from the pump.

Remove the pump cover-to-housing

cap screws (Fig. 1). Place the pump

on the bench, cover side down. Lift

the housing from the cover.

2.
Remove the large and the small

O-rings from the pump cover. Remove

the O-ring from the pressure plate

hub.

3.
Remove the pressure plate-

to-cover screws, and remove the plate.

Lift the cam ring off the dowel pins.

4.
Remove the rollers. Lift the

rotor off the shaft, and remove the

drive key from the shaft. Remove the

dowel pins from the cover.

5.
Remove the rotor shaft from the

cover. Do not remove the snap ring

from the shaft unless it, or the shaft,

is damaged.

6. Pry the rotor shaft seals out of

the cover and the housing.

7. Do not disturb the control valve

unless diagnosis indicated a control

valve problem or foreign matter in the

valve. To remove the valve, drive the

roll pin out of the housing. Remove

the plug and O-ring, control valve,

and the spring. If the plug or valve is

stuck, tap the end of the housing on a

piece of wood or tap it with a soft-

faced hammer. Remove the O-ring

from the plug.

ASSEMBLY

Apply automatic transmission fluid

to all parts as they are assembled. Al-

ways use new seals and O-rings.

1.
Install the control valve spring in

the housing. Install the valve with the

small sensing hole in the end of the

valve toward the spring. Install a new

O-ring on the plug. The plug O-ring is

1/8 inch smaller in diameter than the

bypass O-ring. Make sure the proper

O-ring is used. Install the plug and a

new roll pin (Fig. 1).

2.
The rotor shaft oil seals are in-

stalled in the cover and the housing

with Tool 3583-J, which consists of a

driver and an adapter. The procedure

is as follows:

a. Support the cover on wood

blocks (Fig. 2) to provide tool clear-

ance.
Use clean blocks that will not

nick or damage the inner face of the

cover.
b.
Start the seal (metal shell up-

ward) square!y into the bore with fin-

ger pressure. Place the adapter on the

driver with the square corner of the

FIG. 2—Preparation for Installing

Rotor Shaft Seals

adapter toward the seal (Fig. 2). Drive

the seal into the cover, as shown in

Fig. 3, until it bottoms.

Driving the seal beyond this point

can damage it. Install the seal in the

pump housing in the same manner.

3.
Install the rotor shaft in the

FIG. 3—Installing Rotor

Shaft Seals
cover as shown in Fig. 4 to prevent

damage to the seal.

4.
Install the dowel pins in the

cover. Place the rotor drive key in the

shaft. Install the rotor on the shaft

with the drive key groove aligned with

the key and the counterbored side of

the rotor toward the cover so that it

goes over the snap ring.

5.
Place the cam ring on the dowel

pins with the chamfered edge upward

(Fig. 5). Place the rollers in the rotor.

6. Place the pressure plate on the

dowel pins. Install and tighten the

screws to 20 in-lbs torque. Install the

O-ring on the pressure plate hub. In-

stall O-rings in the groove at the fluid

bypass hole and around the cam ring

(Fig. 6).

7.
Place the tool shown in Fig. 6 in

the rotor shaft to prevent damage to

the oil seal, then install the housing on

the cover. Install and torque the cap

screws to 15-20 ft-lbs.

FIG. 5—Cam Ring Installation

FIG. 4—Installing Rotor Shaft

in Cover

FIG. 6—O-Ring Installationprocarmanuals.com