1969 FORD MUSTANG check engine

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

03-03-02

Automatic Air Leveling System

03-03-02

REMOVAL AND INSTALLATION

AIR COMPRESSOR

REMOVAL

1.
Slip the vacuum line off the in-

take fitting on the side of the com-

pressor (Fig. 2).

2.
Disconnect the output line from

the rear of compressor.

3.
Remove the three compressor at-

taching nuts from the bracket. Lift the

compressor from the mounting brack-

et.

INSTALLATION

1.
Place the star washer on each in-

sulator. Position the compressor on

the mounting bracket and install and

torque the three attaching nuts to

specifications.

2.
Connect the vacuum line to the

intake fitting at the side of the com-

pression.

3.
Start the engine and check the

compressor output.

4.
Connect the output line to the

nylon fitting at the rear of the com-

pressor (Fig. 2).

HEIGHT CONTROL VALVE

REMOVAL

1.
Raise the vehicle on a hoist. It
may be more convenient to support

the rear of the frame with two jack

stands and lower the, axle to provide

greater accessability to the valve.

2.
Disconnect the compressor line

from the intake port of the height

control valve (Fig. 3).

3.
Disconnect the air cylinder line

from the rear of the height control

valve.

4.
Disconnect the link from the

height control valve lever.

5.
Remove the two control valve-

to-mounting bracket attaching screws

and remove the valve.

INSTALLATION

1.
Position the height control valve

to the mounting bracket and install

the two attaching screws. Torque the

screws to specification.

2.
Connect the link to the height

control valve lever.

3.
Connect the compressor line to

the height control valve.

4.
Connect the air cylinder line to

the height control valve.

5.
Set the height control valve lever

as required to obtain the correct trim

height.

6. After obtaining the correct trim
height, check the operation of the air

leveling system.

AIR CYLINDER

REMOVAL

1.
Raise the vehicle on a hoist with

the hoist under the rear axle housing.

Place jack stands under the frame side

rails.

2.
Disconnect the air cylinder line

from the fitting on the lower end of

the cylinder (Fig. 4).

3.
Lower the hoist and axle housing

until the rear shock is fully extended.

4.
Squeeze all air from the bag and

install the valve cap.

5.
Remove the air cylinder from the

rear spring.

INSTALLATION

1.
Make sure all the air is out of

the bag and the valve cap is on.

2.
Position the air cylinder in the

spring with the inlet at the lower end.

3.
Remove the valve cap and con-

nect the air cylinder line to the cylin-

der.

4.
Remove the jack stands and

lower the vehicle.

VACUUM INTAKE LINE

INSULATORS

NYLON FITTING

MOUNTING BRACKET

FIG. 2—Compressor Installed
STAR WASHERS

COMPRESSOR
F 1364-Aprocarmanuals.com

03-04-03
Automatic Air Leveling System — Lincoln Continental

03-04-03

outlet lines to their respective parts.

3.
Adjust the trim height as de-

tailed in Section 4.

4.
Connect the link to the arm.

5.
Remove the jack stands and

lower the vehicle.

SUPER LIFT SHOCK ABSORBER

REMOVAL

1.
Raise the vehicle and place jack

stands under the axle to compress the

super lift.

2.
Loosen the air line or lines (right

super lift) slowly to release the air
from the system. Then, disconnect the

line or lines.

3.
Remove the three mounting plate

attaching screws from the upper end

of the super lift.

4.
Remove the attaching nut and

washer from the lower end of the

super lift and remove it from the vehi-

cle.

5.
Remove the nut, outer washer

and the insulator that attach the super

lift to the mounting plate. Remove the

plate, remaining insulator and washer.

INSTALLATION

1.
Position a washer, insulator,

mounting plate, insulator, washer and
nut on the stud at the upper end of

the super lift. Torque the nut to speci-

fication.

2.
Install the mounting plate, outer

insulator, washer and nut on the stud.

Torque the nut to specification.

3.
Attach the mounting plate and

shock absorber to the crossmember

with the attaching screws to specifica-

tions.

4.
Connect the lower end of the

super lift to the mounting stud with

the washers and attaching nut. Torque

the nut to specification.

5.
Connect the air line or lines

(right super lift) to the super lift.

6. Start the engine and check for

leaks.

3 IN-VEHICLE ADJUSTMENTS AND REPAIRS

REGULATOR ADJUSTMENT HEIGHT CONTROL VALVE

The regulator may be adjusted if

the regulator pressure is under 100 psi

with the reservoir pressure at a mini-

mum of 140 psi. If the regulated pres-

sure exceeds 130 psi, the regulator

must be replaced.

To adjust the regulator, remove the

boot and reposition the sleeve and re-

tainer deeper into the body of the re-

gulator, using a deep well socket (Fig.

4).
If the regulator pressure remains

under 100 psi, replace regulator.
SILICONE FLUID

REPLACEMENT

If the height control valve time

delay does not fall within specifica-

tion, the silicone fluid must be re-

placed. Then repeat the time delay

test. If delay is still not within specifi-

cations, replace the height control

valve.

1.
Remove control valve and clean
the exterior of the valve thoroughly.

2.
Position the valve with delay

plug on top. Remove delay plug and

drain silicone fluid from the chamber.

Remove the O-ring from the chamber

(Fig. 5), and discard the O-ring.

3.
Remove the cover plate retaining

ring, using snap ring pliers. Remove

the delay cover from the valve body.

Remove the O-ring from the chamber,

and discard the O-ring.

4.
Place a new O-ring over the

delay plug and install the plug. Tor-

que the plug to 20-30 in-lbs. .

5.
Pour silicone fluid into the delay

piston chamber until fluid level is 5/16

inch below the top edge of the body.

Add or remove fluid with an eye drop-

per until the proper fluid level is

reached.

6. Hold the control valve body in a

vise with the delay chamber elevated

slightly. Carefully operate the lever to

purge trapped air from the fluid.

7.
Place a new O-ring in the groove

around the delay piston bore. Install

5/16" TO

FLUID LEVEL

F 1405 A

FIG. 4—Adjusting Regulator
F1406 A

FIG. 5—Replacing Silicone Fluidprocarmanuals.com

03-05-14
Steering Columns And Linkage

03-05-14

8. Connect the turn signal and

emergency flasher switch wires at the

multiple connectors. Connect the wires

to the neutral start switch. Adjust-

ments for the neutral start switch are

detailed in Group 7 of this manual.

9. Connect the tilt-column control

cable to the release cable retainer and

vacuum motor (if so equipped). To re-

move cable slack, loosen the bracket

attaching screw and pull it slightly

toward the column, then tighten the

screw. If difficulty in adjusting this

control is experienced, the retainer

slot may be filed to gain additional

travel.

10.
Install the instrument panel

steering column plate and cover and

the instrument panel lower outer fin-

ish panel.

11.
Connect the negative cable to

the battery.

12.
Start the engine and check the

operation of the steering column and

switches.

LINCOLN CONTINENTAL

Removal

1.
Disconnect the battery.

2.
Disconnect the rod from the
lever at the lower end of the selector

tube.

Loosen the clamp bolt that locks

the flexible coupling to the steering

shaft.

3.
Working from the underside of

the steering wheel spoke, remove the

two screws that secure the crash pad.

Remove the pad. Do not use a ham-

mer or knock-off type wheel puller.

Striking the puller or shaft may cause

damage to the bearings and/or col-

lapsible column. Remove the steering

wheel as shown in Fig. 15.

4.
Remove the instrument panel

steering column finish plate.

5.
Remove the four screws that at-

tach the lower retainer to the dash

panel.

6. Disconnect the turn signal switch

and emergency flasher wires at the

connectors. Disconnect the wires from

the neutral start switch.

7.
While supporting the steering

column, remove the bolts that attach

the lower clamp to the upper bracket

(Fig. 15). Lift the column from the ve-

hicle.

Installation

1.
Position the column in the vehi-
cle,
making sure that the steering

shaft engages the flex coupling.

2.
Install the column retainer-

to-dash panel attaching screws, but do

not tighten them.

3.
Install the lower clamp and the

attaching nuts. Tighten the nuts fing-

ertight.

4.
Move the lower flange as re-

quired to center the steering shaft in

the tube. Aligning procedures are de-

tailed in Part 3-1. Tighten the lower

flange attaching nuts when the shaft is

centered.

5.
Connect the shift rod to the shift

lever at the lower end of the column.

6. Install and tighten the flex cou-

pling attaching bolt.

7.
Tighten the instrument panel-

to-clamp attaching nuts.

8. Connect the turn signal and

emergency flasher switch wirss at the

multiple connectors. Connect the wires

to the neutral start switch. Adjust-

ments for the neutral start switch are

detailed in Group 7 of this manual.

9. Install the instrument panel

steering column finish plate.

10.
Install the steering wheel and

crash pad.

MAJOR REPAIR OPERATIONS

STEERING COLUMN

SHIFT TUBE REPLACEMENT

STATIONARY COLUMN

WITH STANDARD

TRANSMISSION

Removal

1.
Working from the underside of

the steering wheel spoke, remove the

two screws that secure the crash pad.

Remove the pad. (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 con-

trols,
refer to Group 16 for removal

instructions).

2.
Remove the steering wheel from

the steering shaft with tool T67L-

3600-A (Fig. 1). Then, remove the

tool from the steering wheel. 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 bear-
ing or the collapsible column.

3.
Remove the steering column

from the vehicle.

4.
Remove the selector lever from

the hub (Fig. 16).

5.
Remove the bearing upper snap

ring. It may be necessary to pull the

turn signal switch out to remove the

snap ring.

6. Remove the screws that attach

the shift tube bearing, shift arms, and

shift tube to the lower end of the

steering column.

7.
Slip the shift tube and steering

shaft from the lower end of the steer-

ing column tube. The upper bearing

has a slight press fit on the steering

shaft.

8. Remove the C-washer from the

upper end of the steering shaft, and

pull the shift tube from the steering

shaft.

9. Remove the shift tube bearing

from the lower end of the tube

Installation

1.
Position the shift tube bearing
(Fig. 16) on the tube and insert the

steering shaft in the shift tube.

2.
Install the C-washer on the

upper end of the steering shaft.

3.
Insert the shift tube and steering

shaft into the steerint column tube

and install the three attaching screws

at the lower end of the steering col-

umn tube.

4.
Position the bearing and insula-

tor on the shaft if it was disturbed

during removal. Work it down onto

the shaft as far as possible, then place

a piece of 3/4 ID x 2 1/8 inch pipe

over the end of shaft and install the

steering wheel attaching nut (Fig. 2).

5.
Tighten the nut until the bearing

is seated in the flange, then remove

the nut and pipe from the shaft.

6. Position the turn signal switch

on the flange and install the three at-

taching screws. Install the upper snap

ring.

7.
Install the selector lever and the

turn signal lever in the column.

8. Adjust and install the neutral

start switch as detailed in Group 7.

9. Install the steering column in the

vehicle.procarmanuals.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
-
.-. •
-"
•.:,.17''i.a—
r.iMI.
A

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

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

03-07-03

5.
Lower the vehicle and disconnect

the fluid return hose from the reser-

voir.

6. Disconnect the fluid pressure

hose from the pump outlet fitting.

7.
Remove 1 bolt attaching the

hoses,
insulator, and the retainer to

the frame side rail and remove the

hoses,
and the insulator and retainer

as an assembly from the vehicle.

8. Remove the pressure and return

hoses from the retainer and insulator.

INSTALLATION

1.
Install the pressure and return
hoses in the insulator and retainer.

Paint stripe on pressure hose must be

aligned with slot in insulator. Paint or

tape band on return hose must be cen-

tered in insulator. Position the assem-

bly to the frame side rail and install

the attaching bolt.

2.
Place a hose clamp on the fluid

return hose and install the hose on the

power steering pump reservoir return

fitting.

3.
Torque the pump outlet fitting to

specification (Part 3-13). Then, con-

nect the pressure hose to the outlet fit-

ting and torque the fitting to specifica-

tion.
4.
Raise the vehicle and connect the

pressure and return lines to the con-

trol valve.

5.
Install the clamp to retain the

hose tubes to the control valve.

6. Lower the vehicle and fill the

power steering pump reservoir with

fluid, C1AZ-19582-A, to the proper

level (Part 3-1).

7.
Start the engine and turn the

steering wheel to each end of its travel

several times to cycle the system.

Then, check for fluid leaks.

8. Stop the engine and again check

the power steering fluid level (Part

3-1). Add fluid as required.

REMOVAL AND INSTALLATION

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.

STEERING GEAR

Refer to Group 3-6, Section 3 for

detailed instructions.

POWER STEERING PUMP

Refer to Group 3-10, Section 3 for

detailed instructions.

POWER STEERING CONTROL

VALVE

REMOVAL

1.
Disconnect the 4 fluid line fit-

tings at the control valve, and drain

the fluid from the lines. Turn the front

wheels to the left and right several

times to force all the fluid from the

system.

2.
Loosen the clamping nut and

bolt at the right end of the sleeve.

3.
Remove the roll pin from the

steering arm-to-idler arm rod -through

the slot in the sleeve.

4.
Remove the control valve ball

stud nut.

5.
Using the tool shown in Fig. 3,

remove the ball stud from the sector

shaft arm.
VALVE

Too/-3290-C BALL STUD PITMAN ARM

FIG. 3—Removing Control Valve

Ball Stud

6. After turning the front wheels

fully to the left, unthread the control

valve from the center link steering

arm-to-idler arm rod.

INSTALLATION

1.
Thread the valve onto the center

link until about four threads are still

visible on the link.

2.
Position the ball stud in the sec-

tor shaft arm.

3.
Measure the distance between

the center of the grease plug in the

sleeve and the center of the stud at the

inner end of the left spindle connect-

ing rod (Fig. 4). The distance should

be 5 5/8 inches for Montego, Falcon

and Fairlane vehicles. The distance

should be 4 7/8 inches for Mustang

and Cougar models. If the distance is

not correct, disconnect the ball stud

from the sector shaft arm and turn the

valve on the center link to increase or

decrease the distance.

4.
When the correct distance is ob-

tained and the ball stud is positioned

in the sector shaft arm, align the hole

in the steering arm-to-idler arm rod

with the slot near the end of the valve
sleeve. Install the roll pin in the rod

hole to lock the valve in position on

the rod.

5.
Torque the valve sleeve clamp

bolt to specification.

6. Install the nut on the ball stud,

and torque the nut to specification.

Install a new cotter pin.

7.
Connect the fluid lines to the

control valve, and tighten all fittings

securely. Do not over-tighten.

8. Fill the fluid reservoir with the

specified fluid to the cross hatched

area on the dip stick.

9. Start the engine and run it at

idle speed for about two minutes to

warm the fluid in the power steering

system.

10.
Turn the steering wheel all the

way to the left and right several times,

and check the system for fluid leaks.

11.
Increase the engine speed to

about 1000 rpm, and turn the steering

wheel all the way to the left and right

several times.

CONTROL VALVE CONNECTING ROD STUD

LUBRICATION PLUG

G1653-A

FIG. 4—Control Valve Installation

Measurements—All Modelsprocarmanuals.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