1969 FORD MUSTANG steering wheel adjustment

03-02-08
Suspension

03-02-08

IN-VEHICLE ADJUSTMENTS AND REPAIRS

HOISTING INSTRUCTIONS

Damage to steering linkage compo-

nents and front suspension struts may

occur if care is not exercised when po-

sitioning the hoist adapters of 2 post

hoists prior to lifting the vehicle.

If a 2 post hoist is used to lift the

vehicle, place the adapters under the

lower arms or the No. 1 crossmember.

Do not allow the adapters to contact

the steering linkage. If the adapters

are placed under the crossmember, a

piece of wood (2 x 4 x 16 inches)

should be placed on the hoist channel

between the adapters. This will pre-

vent the adapters from damaging the

front suspension struts.

UPPER BALL JOINT

REPLACEMENT

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK III

1.
Raise the vehicle high enough to

provide working space, and place a

support under the lower arm. If a

chain hoist or a jack that has a nar-

row contact pad is to be used on the

bumper to raise the vehicle, distribute

the load along the bumper by using a

steel plate 3 or 4 inches long as a con-

tact pad to prevent damaging the

bumper.

2.
Remove the wheel and tire.

3.
Drill a
1/8-inch
hole through

each upper ball joint retaining rivet.

Using a large chisel, cut off the rivets.

4.
Remove the upper arm suspen-

sion bumper.

5.
Remove the cotter pin and nut

from the upper ball joint stud.

6. Place a box wrench over the

lower end of the ball joint remover

tool, and position the tool as in Fig. 7.

The tools should seat firmly against

the ends of both studs, and not

against the lower stud nut.

7.
Turn the wrench until both studs

are under tension, and then, with a

hammer, tap the spindle near the

upper stud to loosen the stud from the

spindle. Do not loosen the stud with

tool pressure alone. Remove the ball

joint.

8. Clean the end of the arm, and

remove all burrs from the hole edges.

Check for cracks in the metal at the

holes,
and replace the arm if it is

cracked.
F1436-A

FIG. 7—Disconnecting Ball

Joints—Typical

9. Attach the new ball joint to the

upper arm. Use only the specified

bolts,
and nuts. Do not rivet the new

ball joints to the arm. Torque the nuts

to specification.

10 Install the upper arm suspension

bumper. Torque the nut to specifica-

tion.
11.
Position the ball joint stud in

the spindle bore, and torque the at-

taching nut to specification. Install a

new cotter pin.

12.
Install the wheel and tire.

13.
Remove the safety stands, and

lower the vehicle.

14.
Check and, if necessary, adjust

caster, camber, and toe-in. Whenever

any part of the front suspension has

been removed and installed, front

wheel alignment must be checked.

COUGAR, FAIRLANE,

FALCON, MONTEGO,

MUSTANG

1.
Position a support between the

upper arm and frame side rail as

shown in Figs. 8 and 9; then, raise the

vehicle and position safety stands.

2.
Remove the wheel and tire.

3.
Remove the cotter pin and nut

from the upper ball joint stud.

4.
Position the ball joint remover

tool as shown in Fig. 10. The tool

should seat firmly against the ends of

both studs, and not against the lower

stud nut. It may be necessary to re-

move the lower ball joint cotter pin if

it prevents the tool from seating on

the lower stud.

5.
Turn the tool with a wrench until

both studs are under tension, and

then, with a hammer, tap the spindle

near the upper stud to loosen the stud

F 1496-A

FIG. 8—Upper arm Support—Mustangprocarmanuals.com

03-02-19

Suspension

03-02-19

6. Raise the upper arm to free the

ball joint stud from the spindle. Wire

the upper end of the spindle to the un-

derbody to prevent damage to the

brake hose.

7.
Mark the position of the upper

arm shaft on the underbody member

to facilitate making caster and camber

adjustments after installation of the

upper arm.

8. Remove the suspension upper

arm-to-underbody attaching bolts,

lock washers, and attaching nuts.

Then, remove the upper arm.

Installation

1.
Position the upper arm shaft on

the underbody member. Line up the

shaft with the marks made before re-

moval of the arm.

2.
Install the attaching bolts and

lock washers. FABRICATE A

TOOL, AS SHOWN IN Fig. 27, to

hold the nut in place while starting the

attaching bolt into the nut. Remove

the tool; then, tighten the attaching

bolts to specification.

3.
Guide the ball joint stud into the

spindle. Install the attaching nut and

torque it to specification. Continue

tightening the nut to line up the cotter

pin hole. Install a new cotter pin.

4.
Install the wheel and tire, and

torque the wheel lug nuts to specifica-

tion.

5.
With the front end weight of the

car on the wheels, torque the bolts at

the ends of the upper arm shaft to

specification if the bushings were re-

placed.

6. Check the front wheel alignment.

FRONT WHEEL SPINDLE

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK III

Removal

1.
Raise the vehicle until the front

wheel clears the floor, and place a

support under the frame.

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 (Part

3-12). Remove the brake backing

plate attaching bolts and remove the

backing plate from the spindle. Wire

the backing plate to the underbody to

prevent damage to the brake hose.
1/16" GAUGE
-*.

STEEL (REFERENCE)

—3/16'
3/8'

1/2" DIAMETER PLUG WELD

F 1501-A

FIG. 27 -Upper Arm Shaft Installing Tool

4.
If equipped with disc brakes—re-

move the wheel and tire from the hub.

Remove 2 bolts and washers retaining

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 (Part 3-12). Remove 3

bolts attaching the splash shield to the

spindle and remove the splash shield.

5.
Remove the steering connecting

rod from the spindle arm with tool

OTC462.

6. Remove the cotter pins from

both ball joint stud nuts, and loosen

the nuts one or two turns. Do not re-

move the nuts from the studs at this

time.

7.
Install the ball joint remover tool

between the upper and lower ball joint

studs (Fig. 7). The tool sho.uld seat

firmly against the ends of both studs

and not against the stud nuts.

8. Turn the tool nut with a wrench

until the tool places the studs under

tension, and, with a hammer, tap the

spindle near the stud to loosen them

in the spindle. Do not loosen the studs

in the spindle with tool pressure only.

9. Position a floor jack under the

lower control arm.

10.
Remove the ball joint stud nuts

and lower the lower arm enough to re-

move the spring and the spindle.
Installation

1.
Position the spindle to the lower

ball joint stud and install the attaching

nut. Torque the nut to specification.

Continue to tighten the nut until the

cotter pin hole is in line with the slots

in the nut. Then, install the cotter pin.

2.
Position the spring and raise the

lower arm and guide and upper ball

joint stud into the spindle hole and in-

stall the attaching nut. Torque the nut

to specification and install the cotter

pin as outlined in the preceeding step.

3.
Remove the floor jack from

under the lower arm.

4.
Attach the steering connecting

rod to the spindle and install the nut.

Torque the nut to specification. Con-

tinue to tighten the nut until the cotter

pin hole is in line with the slots in the

nut. Then, install the cotter pin.

5.
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 Part 2-2. Install the wheel,

tire,
and drum to the spindle and ad-

just the wheel bearings as outlined in

Part 3-12).

6. If equipped with disc brak-

es—Install the splash shield on the

spindle and torque the attaching bolts

to specification (Part 3-13). Install theprocarmanuals.com

03-05-01
Steering Columns And Linkage

03-05-01

PART 3-5 Steering
Columns
and Linkage

COMPONENT INDEX

ADJUSTING SLEEVE (LINKAGE)

Removal and Installation

CENTER LINK (LINKAGE)

Removal and Installation

LOCKING LEVER (TILT-AWAY COLUMN)

Removal and Installation

PITMAN ARM (LINKAGE)

Removal and Installation

SPINDLE CONNECTING ROD ASSEMBLY

(Inner and Outer Ends)

Removal and Installation

STATIONARY STEERING COLUMNS

Description

STEERING COLUMN

Alignment

Removal and Installation

STEERING COLUMN SHIFT TUBE

Removal and Installation

STEERING COLUMN UPPER BEARING

Removal and Installation

STEERING IDLER ARM AND BRACKET

ASSEMBLY

Removal and Installation

STEERING WHEEL

Removal and Installation

Spoke Position Adjustment

TILT-AWAY STEERING COLUMN

Description

TILT STEERING COLUMN

Description

TILT WHEEL STEERING COLUMN

STEERING SHAFT

Removal and Installation

VACUUM MOTOR (TILT-AWAY COLUMN)

Removal and Installation

VACUUM RELEASE VALVE (TILT-AWAY

COLUMN)

Removal and Installation
MODEL APPLICATION
All
Models

05-19

05-20

05-20

05-01

05-14

05-02

05-20

05-02

05-02
Ford
N/A

05-19

N/A

05-08

N/A

05-01

05-16

N/A

N/A
Mercury
N/A

05-19

N/A

05-08

N/A

05-01

05-16

N/A

N/A
Meteor
N/A

05-19

N/A

05-08

N/A

05-01

05-16

N/A

N/A
Cougar
05-06

05-19

N/A

05-10

05-02

N/A

N/A

05-05

05-05
Fairlane
N/A

05-19

N/A

05-09

N/A

N/A

N/A

N/A

N/A
Falcon
N/A

05-19

N/A

05-09

N/A

N/A

N/A

N/A

N/A
Montego
N/A

05-19

N/A

05-09

N/A

N/A

N/A

N/A

N/A
Mustang
05-06

05-19

N/A

05-10

05-02

N/A

N/A

05-05

05-05
Lincoln-
Continental
N/A

05-19

05-06

05-11

N/A

05-01

05-16

N/A

N/A
Thunderbird
05-06

05-19

05-07

05-14

05-02

N/A

N/A

05-05

05-05
Continental-
Mark
III
N/A

05-19

05-06

05-11

N/A

05-01

05-16

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.

1 DESCRIPTION

STATIONARY STEERING COLUMNS

The steering column is of the col-

lapsible type to lessen the possibility

of injury to the driver of the vehicle

should he become involved in an acci-
dent. The lower end of the steering

column tube at the bellows area will

collapse approximately six inches

upon a hard impact.

The shift tube and the steering shaft

are provided with plastic dowels and
will shear and allow them to collapse

in proportion to the outer tube upon

impact.

Once the steering column has been

collapsed, a complete new column

must be installed with new brackets
procarmanuals.com

03-05-02
Steering Columns
And
Linkage

03-05-02

which also will shear away during
im-

pact.

TILT STEERING COLUMNS

The steering column
is of the col-

lapsible type
to
lessen
the
possibility

of injury
to the
driver
of the
vehicle

should
he
become involved
in an
acci-

dent.
The
lower
end of the
steering

column tube
at the
bellows area will

collapse approximately
six
inches

upon
a
hard impact.

The shift tube
and the
steering shaft

are provided with plastic dowels
and

will shear
and
allow them
to
collapse

in proportion
to the
outer tube upon

impact.

Once
the
steering column
has
been

collapsed,
a
complete
new
column
must
be
installed.

The tilt column features nine driv-

ing positions (four
up and
four down

from
a
center position).
The
.column

also features
a
turn signal switch with

a lane-changer position turn indicating

position
and
emergency warning flash-

er control.

TILT-AWAY STEERING COLUMNS

The tilt-away steering column
fea-

tures nine driving positions (four
up

and four down from
a
center position)

and
a
tilt-away position that
is
auto-

matically accomplished
on
Mustang

and Cougar models when
the
ignition

key
is
turned
to the
OFF
position
and

the left door
is
opened.
On
Thunder-

bird models,
the
tilt-away occurs when
the shift lever
is
placed
in
PARK
and

the driverns door
is
opened.

The steering column
is of the col-

lapsible type
to
lessen
the
possibility

of injury
to the
driver
of the
vehicle

should
he
become involved
in an
acci-

dent.
The
lower
end of the
steering

column tube
at the
bellows area will

collapse approximately
six
inches

upon
a
hard impact.

The shift tube
and the
steering shaft

are provided with plastic dowels
and

will shear
and
allow them
to
collapse

in proportion
to the
outer tube upon

impact.

Once
the
steering column
has
been

collapsed,
a
complete
new
column

must
be
installed along with mounting

brackets which will also shear away

during impact.

IN-VEHICLE ADJUSTMENTS
AND
REPAIRS

STEERING WHEEL SPOKE

POSITION ADJUSTMENT

When
the
steering gear
is on the

high point,
the
front wheels should
be

in
the
straight-ahead position
and the

steering wheel spokes should
be in

their normal position with
the
Pitman

arm pointing directly forward.
If the

spokes
are not in
their normal posi-

tion, they
can be
adjusted without
dis-

turbing
the
toe-in adjustment (Part

3-1).

STEERING WHEEL

REPLACEMENT

1.
Disconnect
the
negative cable

from
the
battery.

2.
Working from
the
underside
of

the steering wheel spoke, remove
the

crash
pad
attaching screws. Lift
the

crash
pad
from
the
wheel.
(On
Conti-

nental Mark
III
models,
pry out the

crash
pad
insert
and
remove
the two

screws that secure
the
crash
pad. Re-

move
the
crash
pad. On
models

equipped with steering wheel mounted

speed controls, refer
to
Group
16 for

removal instructions). Remove
the

horn ring
(if so
equipped)
by
turning

it counterclockwise.

3.
Remove
the
steering wheel
nut,

and then remove
the
steering wheel

with tool T67L-3600-A
(Fig. 1). Do

not
use a
knock-off type steering

wheel puller
or
strike
the end of the

steering shaft with
a
hammer. Striking

the puller
or
shaft will damage
the

bearing
or the
collapsible column.

4.
Transfer
all
serviceable parts
to

the
new
steering wheel.

5.
Position
the
steering wheel
on

the shaft
so
that
the
alignment mark
on
the hub of the
wheel
is
adjacent
to

the
one on the
shaft. Install
a new

locknut
and
torque
it to
specifications.

6. Install
the
horn ring
(if so

equipped)
and
crash
pad.

STEERING COLUMN UPPER

BEARING REPLACEMENT

STATIONARY COLUMNS

Removal

1. Disconnect
the
horn wire
and the

turn indicator wires
at the
connector.

2.
Working from
the
underside
of

the steering wheel spoke, remove
the

two crash
pad
attaching screws. Lift

the crash
pad
from
the
wheel.
(On

Continental Mark
III
models,
pry out

the crash
pad
insert
and
remove
the

two screws that secure
the
crash
pad.

Remove
the
crash
pad. On
models

equipped with steering wheel mounted

speed controls, refer
to
Group
16 for

7oo/-T67L-3600-A
removal instructions). Remove
the

horn ring
(if so
equipped)
by
turning

it counterclockwise.

3.
Remove
the
steering wheel
at-

taching
nut.
Remove
the
steering

wheel using tool T67L-3600-A
(Fig.

1).
Do not use a
knock-off type steer-

ing wheel puller
or
strike
the end of

the steering shaft with
a
hammer.

Striking
the
puller
or
shaft will
dam-

age
the
bearing
or the
collapsible
col-

umn.

4.
Remove
the
turn indicator lever.

5.
Remove
the
turn signal switch

attaching screws. Lift
the
switch over

the
end of the
steering shaft
and
place

it
to one
side.

6. Remove
the
snap ring from
the

top
of the
steering shaft.

7.
Loosen
the two
flange-to-steering

column tube attaching bolts
to
disen-

gage them from
the
tube.

8. Raise
the
flange upward while

BEARING
AND

INSULATOR

Spacer

G 1502 -B

FIG.
1—Removing
Steering Wheel
G 1497-A

FIG. 2—Installing Upper Bearingprocarmanuals.com

03-05-07

Steering Columns And Linkage
03-05-07

the steering column
(F in Fig. 8).

7.
Disconnect
the
transmission shift

rod
at the
shift tube.

8. Working under
the
hood, install

the aligning spacer (Fig.
9)
around
the

visible portion
of the
steering shaft

and slide
it up the
shaft into
the
steer-

ing column.
It may be
necessary
to

move
the
shaft back
and
forth
to
com-

pletely install
the
spacer.

9.
At
this point
the
steering column

assembly, being loose,
may
have

dropped toward
the
steering gear

grounding
the
steering shaft
on the

steering gear input shaft.
To
properly

establish
the
steering shaft
to
steering

gear clearance, insert
a 1/8
diameter

rod
or
drill through
the
opening
in the

upper half
of the
flex coupling.

10.
Tighten
to a
snug
fit
(approxi-

mately
2-3
ft-lb)
the
nuts retaining
the

toe plates
to the
dash panel
(B in Fig.

8).

11.
If the
aligning spacer cannot
be

rotated freely,
the
dash panel holes

must
be
filed
or
reamed
for
greater

travel
(as
mentioned
in the
second

paragraph
at the
beginning
of
this

procedure).

12.
Tighten
all
nuts
and
bolts

(noted
as C, D and E in
Fig.
8) in the

passenger compartment
to a
snug
fit

(approximately 2-3 ft-lb). Again check

aligning spacer
for
looseness. Perform

these tightening operations
in
alpha-

betical order.

13.
Tighten
the
lateral adjustment

bolt
(F in Fig. 8) to
snug
fit.
Again

check
the
aligning spacer
for
loose-

ness.

14.
Tighten
all
bolts and nuts
to the

proper torque value (listed
in Fig. 8)

in alphabetical order.

15.
Remove
the
steering shaft
al-

igning spacer.

16.
Remove
the 1/8
diameter
rod or

drill previously inserted
in the
flex

coupling.

17.
Reinstall
the
trim
at the
instru-

ment panel
to
steering column mount-

ing.

LINCOLN CONTINENTAL

If
a
condition
of
high shift
or
steer-

ing effort
is
experienced
it may be

caused
by
improper alignment
of the

energy absorbing steering column.
The

following procedures outline
the
steps

necessary
to
correctly realign either

fixed
or
tilt columns:

1.
Disconnect
the
battery.

2.
Loosen four
toe
plate attaching

nuts (Fig.
10).

3.
Loosen
one toe
plate
to
steering

column clamp bolt
and nut.
Check

alignment
of
steering shaft
to
shift
-HANDLE PORTION

2-3/4"
-*- 3/4"

BEND AROUND

STEERING SHAFT
DIMENSION
A:

STANDARD COLUMN 7/16"

TILT WHEEL COLUMN
1-1/8"

•2-3/4

FABRICATE ALIGNING SPACER OUT OF

PLASTIC SHIPPING COLLAR PROVIDED

ON SERVICE DRIVESHAFTS, OR OUT
OF

1/32"—1/16" CARDBOARD
STEERING SHAFT

ALIGNMENT SPACER-BEND AROUND

STEERING SHAFT (DIMENSION
A)
AND

SLIDE UP THE SHAFT INTO COLUMN

G1537-A

FIG. 9—Aligning Spacer Fabrication
and
Insertion

BRAKE PEDAL

SUPPORT BRACKET

PART

A-TOE PLATE

B-CLAMP

C-C0LUMN BRACKET

D-BRAKE PEDAL

SUPPORT BRACKET
TORQUE VALUE

8-12 FT. LB.

3-5 FT. LB.

10-15
FT.
LB.

8-12 FT. LB.

G1541-A

FIG. 10—Steering Column Alignment Locations
and
Torque

Specifications—Lincoln Continentalprocarmanuals.com

03-06-02
Manual Steering

03-06-02

IN-VEHICLE ADJUSTMENTS AND REPAIRS

STEERING WORM AND

SECTOR

GEAR ADJUSTMENTS

The ball nut assembly and the sec-

tor gear must be adjusted properly to

maintain minimum steering shaft end

play (a factor of preload adjustment)

and minimum backlash between sector

gear and ball nut. There are only two

possible adjustments within the recir-

culating ball-type steering gear, and

these should be made in the following

order to avoid damage or gear failure.

1.
Disconnect the Pitman arm from

the steering Pitman-to-idler arm rod.

2.
Loosen the nut which locks the

sector adjusting screw (Fig. 3), and

turn the adjusting screw counterclock-

wise.
(On models equipped with the

Cobra Jet engine, it may be necessary

to use a suitable holding tool with an

extension and a long screwdriver to

make the gear adjustment).

3.
Measure the worm bearing pre-

load by attaching an in-lb torque

wrench to the steering wheel nut (Fig.

4).
With the steering wheel off center,

read the pull required to rotate the

input shaft approximately 1 1/2 turns

either side of center. If the torque or

preload is not within specification

(Part 3-1), adjust as explained in the

next step.
.•ADJUSTER
LOCK
NUT

SECTOR
SHAFT

ADJUSTING
SCREW
G
1627-A

FIG. 3—Steering Gear

Adjustments—Typical

4.
Loosen the steering shaft bearing

adjuster lock nut, and tighten or back

off the bearing adjuster (Fig. 1) to

bring the preload within the specified

limits.

5.
Tighten the steering shaft bear-

ing adjuster lock nut, and recheck the

preload.

6. Turn the steering wheel slowly to

either stop. Turn gently against the

stop to avoid possible damage to the

ball return guides. Then rotate the

wheel 2-3/4 turns to center the ball

nut.
7.
Turn the sector adjusting screw

clockwise until the specified torque

(Part 3-13) is necessary to rotate the

worm past its center (high spot) (Fig.

1).

8. While holding the sector adjust-

ing screw, tighten the sector adjusting

screw locknut to specification, and re-

check the backlash adjustment.

9. Connect the Pitman arm to the

steering arm-to-idler arm rod.

G-1495-A

FIG. 4—Checking Steering Gear

Preload—Typical

REMOVAL AND INSTALLATION

STEERING GEAR

REMOVAL

1.
Remove the bolt(s) that retains

the flex coupling to the steering shaft.

2.
Remove the nut and lock washer

that secures the Pitman arm to the

sector shaft using Tool T64P-3590-F

(Fig. 5).

3.
To obtain clearance on some

models equipped with standard trans-

mission, it may be necessary to dis-

connect the clutch linkage. On some

8-cylinder models, it may be necessary

to lower the exhaust system.

4.
Remove the steering gear-to-side

rail bolts and remove the gear.
Too /-MB
STEERING
GEAR
HOUSING

T64P-3590.F

(PITMAN
"APU'^M
-
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F'G.
5—Removing Pitman Arm
INSTALLATION

1.
Position the steering gear and

flex coupling in place; then, install

and torque the steering gear-to-side

rail bolts to specification (Part 3-13).

2.
If the clutch linkage has been

disconnected, reposition, install and

adjust it. If the exhaust system has

been lowered, reinstall it to its proper

position.

3.
Position the Pitman arm and the

sector shaft and install the attaching

nut and lock washer. Torque the nut

to specification.

4.
Install and connect the flex cou-

pling attaching nut(s) and torque it to

specification (Part 3-13).procarmanuals.com

03-07-02
Ford Design Non-Integral Power Steering System

03-07-02

PUMP AND RESERVOIR

CONTROL VALVE

POWER CYLINDER

FIG. 7—Non-Integral Power Steering System
G 1651-A

IN-VEHICLE ADJUSTMENTS
AND
REPAIRS

HOISTING INSTRUCTIONS

Damage
to
suspension and/or steer-

ing linkage components
may
occur
if

care
is not
exercised when positioning

the hoist adapters
of 2
post hoists

prior
to
lifting
the
vehicle.

If
a 2
post hoist
is
used
to
lift
the

vehicle, place
the
adapters under
the

front suspension lower arms.
Do not

allow
the
adapters
to
contact
the

steering linkage.

CONTROL VALVE CENTERING

SPRING ADJUSTMENT

1.
Raise
the
vehicle
and
remove
2

spring
cap
attaching screws
and
lock

washers
and
remove
the
spring
cap.

2.
Tighten
the
adjusting
nut
snug

(90-100 in-lbs); then, loosen
the nut

1/4 turn. Make sure that
the nut ro-

tates
1/4
turn
(90
degrees)
on the

threads
of the
bolt.
Do not
tighten
the

adjusting
nut too
tight.

3.
Position
the
spring
cap to the

valve housing. Lubricate
and
install

the
two
attaching screws
and
washers.

Torque
the
screws
to
72-100 in-lbs.

4.
Lower
the
vehicle.

5.
Start
the
engine
and
check
the

turning effort with
a
spring scale.

With
the
spring scale attached
to the

rim
of the
steering wheel,
the
effort
to
turn
the
wheel
in
both directions

should
not
exceed
12
pounds.

CONTROL VALVE
TO
POWER

STEERING CYLINDER HOSE

1.
Raise
the
vehicle
on a
hoist
and

place
a
drain
pan
under
the
power

cylinder.

2.
Disconnect
the
hose from
the

power cylinder
and
allow
the
fluid
to

drain from
the
hose. Then, disconnect

the hose from
the
control valve.

3.
Connect
the
unmarked
end of

the shorter tube
(9 7/16 in
long)
to

valve port
C
(Fig. 2). Hold
the
tube
so

that
the
bend parallels
the
surface
of

valve shown
in Fig. 2,
tighten
the nut.

PLANE
OF
TUBE BEND
IN

3A717 HOSE
TO BE
PARALLEL

WITH THIS SURFACE ON VALVE.

CLEARANCE BETWEEN

COUPLING TO
BE 1/16-

1/8 INCH
IN
THIS AREA

G 1503-A

FIG. 2—Power Steering Hose

Installation
Connect
the
opposite
end to the
lower

port
in the
cylinder. Hold
the
tube
se-

curely while tightening
the nut to pre-

vent twisting
the
tube. Connect
the

other tube
(9 5/8 in
long)
to
port
A,

making sure that tube
is
parallel with

the other tube.

4.
Remove
the
drain
pan and
lower

the vehicle.

5.
Fill
the
power steering pump res-

ervoir with fluid
to the
proper level

(Part
3-1).

6. Start
the
engine
and
turn
the

steering wheel
to
each
end of its
travel

several times
to
cycle
the
system.

Then, check
for
leaks.

7.
Stop
the
engine
and
again check

the power steering fluid level.
Add

fluid
as
required.

POWER STEERING PUMP

TO CONTROL VALVE HOSE

REMOVAL

1.
Remove
the
fluid from
the
pump

reservoir with
a
suction
gun.

2.
Raise
the
vehicle
on a
hoist.

3.
Remove
the
clamp retaining
the

hose tubes
to the
control valve.

4.
Disconnect
the
fluid return
and

pressure hoses from
the
control valve

and allow
the
fluid
to
drain into
a

pan.procarmanuals.com

03-07-04
Ford Design Non-Integral Power Steering System

03-07-04

12.
Stop the engine, and check the

control valve and hose connections for

fluid leaks. Correct the cause of any

leaks.

13.
Check the fluid level, and refill

the reservoir if necessary.

14.
With the engine running check

the position of the steering wheel

when the front wheels are in the

straight-ahead position.Do not make

any adjustments until toe-in is

checked.

15.
Keep the engine running, and

check toe-in. If either toe-in or steer-

ing wheel position is not correct make

all necessary adjustments (Part 3-1) at

the spindle connecting rod sleeves.

16.
Check the effort to turn the

wheels in both directions. The effort

should be about equal in both direc-

tions.

POWER CYLINDER

REMOVAL

1.
Disconnect the two fluid lines

from the power cylinder and allow

them to drain into a container.
CENTER LINK

POWER CYLINDER

Tool- T64P-3590-F

G 1654-A

FIG. 5—Disconnecting Power

Cylinder Stud

2.
Remove the 'pal nut, attaching

nut, washer and the insulator from the

end of the power cylinder rod.

3.
Remove the cotter pin and cas-

tellated nut that secures the power

cylinder stud to the center link.

4.
Disconnect the power cylinder

stud from the center link as shown in

Fig. 5.

5.
Remove the insulator sleeve and

washer from the end of the power cyl-

inder rod.
6. Inspect the tube fittings and the

seats in the power cylinder for nicks,

burrs or damage. Replace the seats in

the cylinder or the tubes as required.

INSTALLATION

1.
Install the washer, sleeve and the

insulator on the end of the power cyl-

inder rod.

2.
Extend the rod as far as possible.

Insert the rod in the bracket on the

frame and compress the rod as neces-

sary to insert the stud in the -center

link. Secure the stud with a castellat-

ed, nut and a cotter pin.

3.
Secure the power cylinder rod

with an insulator, washer, nut and a

pal nut.

4.
Connect each of the two fluid

lines to its respective port in the cylin-

der.

5.
Fill the reservoir to the correct

level.

6. Start the engine and turn the

steering wheel to each end of its travel

several times to cycle the system. Stop

the engine.

7.
Check the fluid level and fill as

necessary. Install the dipstick and cap.

8. Start the engine and check for

leaks.

MAJOR REPAIR OPERATIONS

CONTROL VALVE

DISASSEMBLY

1.
Wipe all fluid and loose dirt

from the outside of the control valve.

2.
Remove the centering spring cap

from the valve housing (Fig. 6).

When holding the control valve for

disassembly, use a soft-jawed vise, and

clamp the valve only around the sleeve

flange to prevent damage to the hous-

ing, spool, or sleeve.

3.
Remove the nut from the end of

the valve spool bolt. Remove the

washers, spacer, centering spring,

adapter, and bushing from the bolt

and the valve housing.

4.
Remove the two bolts that hold

the valve housing and the sleeve to-

gether, and separate the housing from

the sleeve.

5.
Remove the plug from the valve

sleeve.

6. Push the valve spool out of the

centering spring end of the valve hous-

ing, and remove the seal from the

spool.

7.
Remove the spacer, bushing, and

seal from the sleeve end of the valve

housing.
8. Drive the stop pin out of the

travel regulator stop with a punch and

hammer (Fig. 7). Pull the head of the

valve spool bolt tightly against the

travel regulator stop before driving the

pin out of the stop.

9. Turn the travel regulator stop

counterclockwise in the valve sleeve to

remove the stop from the sleeve.

10.
Remove the valve spool bolt,

spacer, and rubber washer from the

travel regulator stop.

11.
Remove the rubber boot and

clamp from the valve sleeve.

12.
Slide the bumper, spring, and

ball stud seat out of the valve sleeve,

and remove the ball stud socket from

the sleeve.

13.
After removing the return port

hose seat, remove the return port re-

lief valve.

14.
After removing the spring plug

and O-ring, remove the reaction limit-

ing valve (Fig. 8).

Tube Seat Replacement

If a hose seat is worn or damaged it

should be replaced. It can be removed

with an Easy-Out tool, or by using a

bolt of appropriate size as a puller.
1.
Tap the existing hole in the hose

seat, using a starting tap of suitable

size.
Be sure to remove all metal chips

from the hose seat port after tapping.

2.
Place a nut and large flat washer

on a bolt of the same size as the

tapped hole. The washer must be large

enough to cover the hose seat port.

3.
Insert the bolt in the tapped

hole,
and using the nut as a puller, re-

move the hose seat.

4.
Place a new hose seat in the

port, and thread a bolt of suitable size

into the port. Tighten the bolt enough

to bottom the seat in the port.

ASSEMBLY

Before assembling the control valve,

coat all parts except the seals with

Automatic Transmission Fluid. Coat

the seals with lubricant COAZ-

19553-A.

1.
Install the reaction limiting

valve, the spring, and the plug.

2.
Install the return port relief valve

and the hose seat.

3.
Insert one of the ball stud seats

(flat end first) into the ball stud sock-

et, and insert the threaded end of the

ball stud into the socket.procarmanuals.com