1969 FORD MUSTANG height

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

the cover and secure it with a snap down. Move the overtravel lever up vehicle. If delay is not within 4-18 sec-

ring, using snap ring pliers. and down for one minute to vent air onds, recheck the fluid level in the

8. Place the control valve vertically from the delay piston pin chamber. delay chamber. If the level is within

in a vise with the delay chamber Perform a time delay check off the specifications, replace the valve.

9. Install the height control valve.procarmanuals.com

03-10-06
Ford-Thompson Power Steering Pump

03-10-06

7.
Use one of the slippers to com-

press the spring and install the slipper

with the groove in the slipper facing

upward (toward the cam notch). The

flats on the side of the slipper should

be on the left (Fig. 12).

FLATS ON LEFT

DOUBLE STEP

G1350-A

FIG. 72—Correct Slipper

Installation

8. Hold the cam stationary and

turn the rotor either to the right or

left, one space at a time. Repeat Step

7 until all the rotor cavities have been

filled. Be careful when turning the

rotor that the springs and slippers al-

ready inserted do not fall out.

9. Install the cam and rotor assem-

bly onto the pump housing plate with

the fixed dowel passing through the

first hole to the left of the cam notch

when the arrow on the cam OD is

pointing toward the lower pressure

plate (Fig. 13). If the cam and rotor

assembly will not seat, turn the rotor

shaft slightly until the spline teeth

mesh, allowing the cam and rotor to

drop down into position.

FIXED DOWEL D0|JBLE STEP

ARROW POINTING DOWN

G 1351-A

FIG. 13—Cam and Rotor

Installation
10.
Insert the loose fitting dowel

through the cam insert and lower

plate into the hole in the housing plate

assembly. When the loose dowel is

properly installed the heights of the

two dowels must be equal. Squirt the

rotor, springs, slippers and cam insert

with C1AZ-19582-A lubricant.

11.
Place the upper pressure plate

with the face having the tapered notch

down against the cam insert. The

fixed dowel should pass through the

round dowel hole and the loose dowel

through the elongated hole. The slot

between the ears on the pressure plate

OD should match the notch on the

cam insert OD (Fig. 14).

EARS

'G 1352-A

FIG. 74—Upper Pressure Plate

Installation

\ EARS

G1353-B

FIG. 75—Retainer End Plate

Installation

12.
Install the retainer end plate so

the slot on the end plate OD matches

the corresponding notches of the

upper pressure plate and cam (Fig

15).

13.
Install the pump valve assembly

O-ring seal onto the pump valve as-

sembly being careful not to twist the

seal (Fig. 16).

14.
Place the pump valve assembly

on top of the retainer end plate with

the large exhaust slot on the pump

valve in line with the OD notches of

the previously assembled parts. The
stack of parts must be fully seated. If

the pump valve has been installed cor-

rectly, the relief valve stem will be in

line with the lube return hole in the

pump housing plate (Fig. 16).

O-RING SEAL

EARS

G1605-A

FIG. 16 —Valve and Pressure

Spring Installation

Tool 169P-3B586-A

G1606-B

FIG. 17—Pump Housing

Installation

FIG. 18 -Checking Pump

Rotational Torqueprocarmanuals.com

03-13-06

Specifications

03-13-06

TORQUE LIMITS-FRONT SUSPENSION

LINCOLN CONTINENTAL

Description

Brace-Front Suspension to Sidemember (Model 74A Only)

Drag Strut
to
Strut Bracket Assembly

Lower Arm Assembly to Front Crossmember
-
(Attach Bracket)

Lower Arm Assembly to No. 2 Crossmember

Drag Strut
to
Lower Arm Assembly

Wheel Spindle to Lower Arm Ball Joint

Front Wheel Spindle to Upper Arm Ball Joint Assembly

Upper Arm Inner Shaft
to
Upper Arm

Upper Arm and Shaft Assembly to No. 2 Crossmember

Shock Absorber Bracket Assembly to No. 2 Crossmember Bracket

Shock Absorber Assembly to No. 2 Crossmember Assembly (Top End)

Shock Absorber Assembly Lower Arm Spring Seat Reinforcement Assembly

Upper Ball Joint
to
Control Arm

Stabilizer Bar Assembly
to
Underbody

Stabilizer Bar
to
Lower Arm

Jounce Bumper Assembly
to
Strut (Lower Arm)

Front Splash Shield to Spindle

Caliper to Spindle
FtLbs

90-110

70-90

55-75

110-140

70-90

70-90

55-75

25-35

100-125

40-55

20-30

20-30

21-29

20-30

5-10

22-28

9-14

100-140

TORQUE LIMITS-REAR SUSPENSION

FORD, MERCURY, METEOR

Description

Shock Absorber
to
Frame (Upper Attachment)

Upper Arm to Axle Bracket (Nut)

Track Bar to Axle Track Bar Stud

Track Bar Stud to Axle

Track Bar
to
Frame (Bolt Torque)

Track Bar Stud to Axle Bracket (Nut)

Wheel Lug Nut

Brake Backing Plate and Bearing Retainer to Axle-All Cars except those with 240
or
302 CID Engines

Brake Backing Plate and Bearing Retainer to Axle-All Cars with 240
or
302 CID Engines

Shock Absorber to Axle (Lower Attachment)

Bumper Assembly
to
Frame

Lower Arm to Axle-Bolt

Lower Arm to Axle-Nut

Upper Arm
to
Frame-BoU

Upper Arm
to
Frame-Nut

Lower Arm
to
Frame-Bolt

Lower Arm
to
Frame-Nut

Bumper Assembly to No. 4 Crossmember

Universal Joint
U-Bolt
Nut

Air Leveling Compressor
to
Apron

Height Control Valve to Bracket

Height Control Valve Bracket to No. 4 Crossmember
FtLbs

20-28

90-100

80-105

100-130

80-105

80-105

70-115

50-70

20-30

50-35

9-13

90-120

70-90

90-120

70-90

90-120

70-90

9-13

10-15

10-13

17-25

9-13procarmanuals.com

04-01-10
General Axle Service

04-01-10

The pattern taken during disassem-

bly should be helpful in judging if

gears can be re-used. Worn gears can-

not be rebuilt to correct a noisy condi-

tion. Gear scoring is the result of ex-

cessive shock loading or the use of an

incorrect lubricant. Scored gears can-

not be re-used.

Examine the teeth and thrust surfa-

ces of the differential gears. Wear on

the hub of the differential gear can

cause a chucking noise known as

chuckle when the vehicle is driven at

low speeds. Wear of splines, thrust

surfaces, or thrust washers, can con-

tribute to excessive drive line back-

lash.

BEARING CUPS AND

CONE AND ROLLER

ASSEMBLIES

Check bearing cups for rings,

scores, galling, or excessively worn

wear patterns. Pinion cups must be

solidly seated. Check by attempting to

insert a 0.0015-inch feeler between

these cups and the bottoms of their

bores.

When operated in the cups, cone

and roller assemblies must turn with-

out roughness. Examine the roller

ends for wear. Step-wear on the roller

ends indicates the bearings were not

preloaded properly, or the rollers were

slightly misaligned.

If inspection reveals either a defec-

tive cup or a defective cone and roller

assembly, both parts should be re-

placed to avoid early failure.

DIFFERENTIAL BEARING

ADJUSTING NUTS

Temporarily install the bearing caps

and test the fit of the adjusting nuts in

their threads. The nuts should turn

easily when the caps are tightened to

25 ft-lbs. The faces of the nuts that

contact the bearing cups must be

smooth and square. Replace the nuts

or examine the threads in the carrier
if their fit is not proper. Be sure that

the bearing caps and adjusting nuts

are on the side they were machined to

fit. Observe the punch marks and

scribe marks made during disassem-

bly.

U-JOINT FLANGE

Be sure that the eai» of the flange

have not been damaged in removing

the drive shaft or in removing the

flange from the axle. The end of the

flange that contacts the front pinion

bearing inner race as well as the flat

surface of the pinion nut counterbore

must be smooth. Polish these surfaces

if necessary. Roughness aggravates

backlash noises and causes wear of

the flange and pinion nut with a resul-

tant loss in pinion bearing preload.

PINION RETAINER

Be sure that the pinion bearing cups

are seated. Remove any chips or burrs

from the mounting flange. Clean the

groove for the O-ring seal and all lu-

bricant passages. If the cups were re-

moved, examine the bores carefully.

Any nicks or burrs in these bores

must be removed to permit proper

seating of the cups.

CARRIER HOUSING

Make sure that the differential

bearing bores are smooth and the

threads are not damaged. Remove any

nicks or burrs from the mounting sur-

faces of the carrier housing.

DIFFERENTIAL CASE

Make sure that the hubs where the

bearings mount are smooth. Carefully

examine the differential case bearing

shoulders, which may have been dam-

aged when the bearings were removed.

The bearing assemblies will fail if they

do not seat firmly against the shoul-

ders.
Check the fit (free rotation) of
the differential side gears in their

counterbores. Be sure that the mating

surfaces of the two parts of the case

are smooth and free from nicks or

burrs.

LIMITED SLIP AND

TRACTION-LOK

DIFFERENTIAL PARTS

Inspect the clutch plates for uneven

or extreme wear. The dog-eared clutch

plates must be free from burrs, nicks

or scratches which could cause excess-

ive or erratic wear to the bonding ma-

terial of the internally splined clutch

plates.
The internally splined clutch

plates should be inspected for condi-

tion of the bond, bonding material,

and wear. Replace the bonded plates

if their thickness is less than 0.085

inch or if the bonded material is

scored or badly worn. Inspect the

bonded plate internal teeth for wear.

Replace them, if excessive wear is evi-

dent. Bonded plates should be re-

placed as a set only

Examine all thrust surfaces and

hubs for wear. Abnormal wear on

these surfaces can contribute to a

noisy axle.

Inspect the Belleville spring (limited

slip) for proper free height of 1/4

inch.

LUBRICANT LEVEL

The lubricant level should be

checked every 6000 miles with the ve-

hicle in normal curb attitude. The lu-

bricant level should be at the lower

edge of the filler plug hole located in

either the carrier casting or housing

cover. It is unnecessary to periodically

drain the axle lubricant. The factory

fill should remain in the housing for

the life of the vehicle, except when re-

pairs are made. The specified lubri-

cant should be installed when the axle

is overhauled.procarmanuals.com

04-02-11
Rear Axle — Removable Carrier Type

04-02-11

If the axle housing is new, install a

new vent. The hose attaching portion

must face toward the front of the ve-

hicle.

2.
If leather-type wheel bearing ser-

vice seals are to be installed, soak the

new rear wheel bearing oil seals in

SAE 10 oil for 1/2 hour before instal-

lation. Wipe a small amount of an oil

resistant sealer on the outer edge of

each seal before it is installed. Do not

put any of the sealer on the sealing

lip.
Install the oil seals in the ends of

the axle housing with one of the tools

shown in Fig. 10 and 12.

3.
Position the replacement axle

housing under the vehicle, and raise

the axle with a hoist or floor jack.

Connect the suspension lower arms to

their mounting brackets on the axle

housing with pivot bolts and nuts. Do

not tighten the bolts and nuts at this

point.

4.
Position the suspension upper

arm in its mounting bracket on the

axle housing, and install the adjusting

bolt, eccentric washers, lock washer

and nut. Leave the bolt and nut loose

at this point.

5.
Position the brake lines to the

axle housing, and secure with the re-

taining clips.

6. Install the brake backing plates

on the axle housing flanges.

7.
Connect the track bar to the

mounting stud, install the washer and

attaching nut, and torque to specifica-

tions.

8. Position the rear coil springs and

insulators in the pockets provided.

9. Connect the lower studs of the

two rear shock absorbers to the

mounting brackets on the axle hous-

ing. Install the attaching nuts, and

torque to specifications.

10.
Connect the vent tube to the

vent on the housing. If axle housing is

new, install a new vent.

11.
Clean the mating surfaces of

the axle housing and differential car-

rier. Position the carrier on the

mounting studs on the housing using a

new gasket between carrier and hous-

ing. Install the copper washers and the

carrier-to-housing attaching nuts, and

torque to specifications.

12.
Make sure that both the front

and rear pivot bolts of the upper and

the two lower arms are loose, and

then raise the axle assembly to con-

trolled curb height (Fig. 15). Hold the

axle at controlled curb height by plac-

ing blocks or pieces of steel pipe be-

tween the axle housing and the bumper

rear screw on the side rail. (See speci-

fications for dimensions.)
FRAME

TIGHTEN ARM

ATTACHING BOLTS

AT 5-45/64 INCH

HEIGHT POSITION
5-45/64 INCH

HEIGHT FOR

INSTALLATION

OF ARMS

E 1600-B

FIG. 75 -Axle Normal Curb

Height and Controlled Height

for Arm Installation

13.
With the axle at controlled curb

height, torque the suspension upper

and lower arm front pivot bolts and

nuts to specifications. Torque the

lower arm-to-axle housing pivot bolts

and nuts to specifications.

14.
Remove the oil seal replacer

tool from the transmission extension

housing. Position the drive shaft so

that the front U-joint slip yoke splines

to the transmission output shaft.

15.
Connect the drive shaft to the

U-joint flange, aligning the scribe

marks made on the drive shaft end

yoke and the axle U-joint flange dur-

ing the removal procedure. Install the

U-bolts and nuts and torque to speci-

fications.

16.
Carefully slide the two axle

shaft assemblies in the axle housing.

The shorter shaft goes into the left

side of the housing. Use care in slid-

ing the axle shafts into the housing so

that the rough forging of the shaft will

not damage the oil seal. Start the axle

splines into the differential side gear,

and push the shaft in until the rear

wheel bearing bottoms in the housing.

17.
Install the rear wheel bearing

retainers on the attaching bolts on the

axle housing flanges. Install the nuts

on the bolts and torque to specifica-

tions.

18.
If the rear brake shoes were

backed off, adjust the brakes as out-

lined in Part 2-1, and install rubber

plugs in the adjuster slots.

19.
Install the two rear brake

drums and the drum attaching (Tin-

nerman) nuts.

20.
Install the rear wheels and tires.

21.
Fill the rear axle to the bottom

of the filler plug hole located in either

the carrier casting or housing cover

with specified lubricant. Be sure that

the axle is in operating position.

22.
Road test the vehicle to be sure

that pinion and driveshaft angles are
correct. Any shudder during heavy ac-

celeration, or deceleration may require

a pinion and driveshaft angle re-

adjustment as detailed in Driveshaft

and Pinion Angle Adjustment, Group

3,
Part 3-2.

AXLE HOUSING (LEAF

SPRING SUSPENSION)

REMOVAL

1.
Raise the vehicle and support it

with safety stands under the rear

frame member.

2.
Drain the lubricant from the

axle.

3.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

drive shaft at assembly. Disconnect

the drive shaft at the drive pinion

flange.

4.
Disconnect the lower end of the

shock absorbers.

5.
Remove the wheels, brake drums

and both axle shafts as outlined in

Section 2.

6. Remove vent hose front vent

tube (Corbin clamp) and remove vent

tube from brake tube junction and

axle housing.

7.
Remove the hydraulic brake T-

fitting from the axle housing. Do not

open the hydraulic brake system lines.

Remove the hydraulic brake line from

its retaining clip on the axle housing.

8. Remove both axle shaft oil seals

with the tool shown in Fig. 8.

9. Remove both brake backing

plates from the axle housing and sus-

pend them above the housing with

mechanic's wire. The hydraulic brake

lines and the parking brake cables are

still attached to the brake backing

plates.

10.
Support the rear axle housing

on a jack, and then remove the spring

clip nuts. Remove the spring clip

plates (Fig. 16).

11.
Lower the axle housing and re-

move it from under the vehicle.

12.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. See

Section 4, Major Repair Operation*.

INSTALLATION

1.
Raise the axle housing into posi-

tion so that the spring clip plates can

be installed. On a Montego or Fair-

lane,
position the spring upper insula-

tors and retainers between the axle

housing and springs and install theprocarmanuals.com

04-04-04
Rear Axle — Ford Light-Duty (WER)

04-04-04

REMOVAL AND INSTALLATION

AXLE HOUSING

Refer to Fig. 7.

REMOVAL

1.
Raise the vehicle on a hoist.

2.
Remove the wheels and tires

from the brake drums.

3.
Position a drain pan and loosen

the rear axle cover to housing attach-

ing bolts. Drain the housing.

4.
Remove the attaching (Tinner-

man) nuts that secure the brake drums

to the axle shaft flanges, and then re-

move the drums (Fig. 7).

5.
Remove the axle housing cover

bolts,
cover and gasket. Discard the

gasket. Remove the drain pan.

6. Disconnect the drive shaft at the

drive pinion companion flange. Re-

move the drive shaft from the trans-

mission extension housing. Install an

oil seal replacer tool in the transmis-

sion housing to prevent leakage. Refer

to the transmission group for the ap-

propriate tool.

7.
Disconnect the lower end of the

shock absorbers at the mounting

brackets.

8. Disconnect the track bar from

the axle housing stud. If the axle

housing is to be replaced, transfer the

stud to the new housing.

9. Position safety stands under the

rear frame members. Lower the vehi-

cle with the hoist and allow the axle

to lower far enough to relieve rear

spring tension.

10.
Remove the pinion shaft lock

bolt and pinion shaft (Fig. 2), differ-

ential pinion gears and thrust washers.

11.
Push the axle shaft(s) inward

toward the center of the axle housing.

Remove the C-locks from the inner

ends of the axles (Fig. 3). Remove the

axle shafts from the housing. Extreme

care must be used to avoid contacting

the axle shaft seal lip with any portion

of the axle shaft other than the seal

journal.

12.
Disconnect the vent hose from

the rear vent tube and remove all

brake lines from the axle housing re-

taining clips.

13.
Remove the brake backing

plate attaching nuts and the plates

from the axle housing. Suspend the

plates above the axle housing with

mechanics wire. The hydraulic brake

lines and the parking brake cables will

remain attached to the brake backing

plates.
14.
Support the rear axle housine

on a jack.

15.
Remove the right and left rear

springs and insulators.

16.
Remove the nuts, washers and

pivot bolts that connect the suspension

lower arms to the axle housing. Dis-

connect both arms from the axle

housing.

17.
Disconnect the upper suspen-

sion arm from the axle housing by re-

moving the pivot bolt, nut, lock wash-

er and two eccentric washers.

18.
Lower the rear axle to the floor

with the jack and remove the axle

from under the vehicle.

19.
Remove the wheel bearings and

oil seals with the tool shown in Fig. 4.

20.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. Refer

to Section 4, Major Repair Operation

for the procedure.

INSTALLATION

1.
Lightly coat the wheel bearing

rollers with axle lubricant. Install

wheel bearings in the axle housing

with the tool shown in Fig. 5. The

bearings should seat firmly against the

shoulder.

2.
Wipe all lubricant from the oil

seal bore before installing the seal. If

axle housing is being replaced, new

seals must be installed.

3.
Inspect the original seal for

nicks,
scuffs or abnormal wear, and

replace if necessary. New seals are

pre-packed with lubricant and do not

require an oil soak.

4.
Install the seal with the tool

shown in Fig. 6. Installation without

the use of the proper tool will distort

the seal and cause leakage.

5. Raise the rear axle into position

under the vehicle with a hoist or floor

jack. Connect the suspension lower

arms to their mounting brackets on

the axle housing with pivot bolts and

nuts.
Do not tighten the mounting

bolts at this point.

6. Position the suspension upper

arm in its mounting bracket on the

axle housing and install the adjusting

bolt, eccentric washers, lock washer

and nut. Do not tighten the mounting

bolt at this point.

7.
Place the rear coil springs and

insulators into position in the pockets

provided.
8. Place the brake backing plates

on the axle housing flanges, install 4

attaching bolts and nuts and torque

them to specifications.

9. Position the brake lines to the

axle housing and secure them with the

retaining clips. If the axle housing is

new, install a new vent. When install-

ing the new axle vent apply a small

amount of Locktite (C5AZ-19554-B)

to prevent oil leakage between vent

and axle housing. Connect the vent

tube to the vent.

10.
Install the pinion side gears and

thrust washer.

11.
Slide the axle shafts into place

in the axle housing. Exercise care that

splines or any portion of the axle

shafts do not damage the oil seals and

that they engage with the splines of

the differential side gears.

12.
Install the axle shaft C-lock O-

ring and C-lock on the inner end of

the shaft and push the shaft outward

so that the shaft lock seats in the

counterbore of the differential side

gear.

13.
Position the pinion differential

gears and thrust washers 180 degrees

apart to the differential side gears.

Revolve the gear assembly until the

holes in the differential case are al-

igned with the pinion gears.

14.
Position the differential pinion

shaft through the case and pinions, al-

igning the hole in the shaft with the

lock bolt hole. Install the lock bolt

and tighten it to specification.

15.
Clean the gasket mounting sur-

face of the rear axle housing and the

cover. Install a new cover gasket,

cover and the attaching bolts. Torque

the bolts to specification.

16.
Raise the rear axle on a hoist

and remove the safety stands.

17.
Connect the track bar to the

mounting stud. Install the washer and

nut. Torque the nut to specification.

18.
Connect the two rear shock ab-

sorbers to the mounting brackets on

the axle housing and torque the at-

taching nuts to specification.

19.
Make sure that both the front

and rear pivot bolts of the upper and

the two lower arms are loose, then

raise the axle assembly to the con-

trolled height (Fig. 8). Hold the axle

at the controlled height by placing

blocks or pieces of steel pipe between

the axle housing and the bumper rear

screw on the side rail.procarmanuals.com

04-04-06
Rear Axle — Ford Light-Duty (WER)

04-04-06

20.
With the axle at controlled

height, torque the suspension upper

and lower arm front pivot bolts and

nuts to specifications. Torque the

lower arm to axle housing pivot bolts

and nuts to specifications.

21.
Remove the oil seal replacer

from the transmission extension hous-

ing. Install the drive shaft in the ex-

tension housing. Align the scribe

marks on the cups, flange and drive

shaft and connect the drive shaft at

the drive pinion flange. Torque the at-

taching bolts to specification
FRAME

TIGHTEN ARM

ATTACHING BOLTS

AT 5-45/64 INCH

HEIGHT POSITION
5-45/64 INCH

HEIGHT FOR

INSTALLATION

OF ARMS

E 1600-B

FIG.8—
Axle
Normal Curb Height

and Controlled Height for Arm

Installation
22.
Install the brake drum and at-

taching (Tinnerman) nuts.

23.
Install the wheel and tire on the

brake drum. Install the wheel covers.

24.
Adjust the drive shaft and pin-

ion angle to specification.

25.
Add the amount of specified lu-

bricant required to reach to the bot-

tom of the filler plug hole. Make sure

the rear axle is in running position.

Install the filler plug and torque it to

specification.

26.
Lower the vehicle.

4 MAJOR REPAIR OPERATIONS

DISASSEMBLY OF AXLE
The rear axle components are

shown in Fig. 9.

DIFFERENTIAL SIDE GEAR

AXLE SHAFT C-WASHER \

DIFFERENTIAL PINION SHAFT

THRUST WASHER

BEARING ASSEMBLY

CUP
THRUST WASHER

^^ DIFFERENTIAL PINION GEAR

BEARING ADJUSTING NUT

DIFFERENTIAL

PINION SHAFT

LOCK BOLT

LOCK WASHER
BOLT

LOCK WASHER

ADJUSTING NUT LOCK

DRIVE GEAR ATTACHING BOLT

BEARING CAP

AXLE HOUSING ASSEMBLY

PINION AND RING GEAR

PINION LOCATING SHIM(S)

BEARING CUP

BOLT

NUT

BEARING CUP

COLLAPSIBLE SPACER

AXLE SHAFT

E 1572-C

FIG. 9—Disassembled Light-Duty (WER) Rear Axleprocarmanuals.com

05-03-04
Clutch

05-03-04

bushings, position the clutch pedal and

bushings in the pedal support.

8. Install the retaining ring on the

clutch pedal shaft.

9. Position the assist spring in the

pedal support bracket and the assist

spring bracket. Rotate the assist

spring bracket clockwise until the

upper bolt holes line up and install the

bolt. Torque both the upper and lower

bolts to specification.

10.
Check the clutch pedal free

travel and adjust as required.

MUSTANG, COUGAR

1.
Disconnect the battery ground

cable.

2.
Remove the steering column.

Refer to Group 3 of this manual for

the procedure.

3.
Remove the two capscrews re-

taining the master cylinder or booster

to the dash panel. Then remove the

two capscrews retaining the pedal sup-

port bracket to the dash panel.

4.
Working inside the vehicle, dis-

connect the clutch pedal-to-equalizer

rod at the clutch pedal by removing

the retainer and bushing.

5.
Secure the clutch pedal against

the bumper stop with a small C-clamp

as shown in Fig. 6.

6. Disconnect the stop light switch

wires at the connector.

7.
Remove the switch retainer and

slide the stop light switch off the

brake pedal pin just far enough for

the switch outer hole to clear the pin.

Then lower the switch away from the

pin.
Remove the master cylinder push

CLUTCH PEDAL ASSIST SPRING
rod, bushing and nylon washer from

the brake pedal pin.

8. Remove the screw retaining the

pedal support bracket to the top inner

cowl bracket (Fig. 6).

9. Remove the two sheet metal

screws retaining the pedal support

bracket to the dash panel.

10.
Remove the two screws retain-

ing the pedal support bracket to the

upper cowl brace and lower the pedal

support bracket away from the steer-

ing column studs.

11.
Remove the pedal support

bracket assembly from the vehicle.

12.
Mount the bracket in a vise.

13.
Remove the small C-clamp se-

curing the clutch pedal to the bumper.

Slowly pivot the pedal away from the

bumper until the assist spring can be

lifted from its seat.

14.
Remove the retainer clip from

the clutch and brake pedal shaft.

Then, remove the clutch pedal and

shaft assembly, brake pedal assembly,

and bushings from the pedal support

bracket.

15.
Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

bushings in their proper places on the

brake and clutch pedal assemblies.

16.
Position the brake pedal to the

pedal support bracket. Install the

clutch and brake pedal shaft through

the pedal support and brake pedal as-

sembly. Install the retainer.

17.
Install the clutch pedal assist

spring and pivot the pedal against its

bumper stop. Secure the pedal against

the bumper with a small C-clamp as

TOP INNER COWL-TO-BRACKET

RETAINING SCREW

C2057-A

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

18.
Position the pedal support

bracket assembly to the dash panel

and to the steering column retainer

studs.

19.
Align the pedal support bracket

holes with the holes in the dash panel

and install the two sheet metal screws.

20.
Install the two capscrews at-

taching the pedal support bracket to

the upper cowl bracket.

21.
Install the screw attaching the

support bracket to the top inner cowl

bracket (Fig. 6).

22.
Install the inner nylon washer,

bushing master cylinder push rod on

the brake pedal pin. Position the stop

light switch so that it straddles the

push rod with the switch slot on the

pedal pin and the switch outer hole

just clearing the pin. Slide the switch

completely onto the pin, and install

the outer nylon washer. Secure with

the self-locking pin.

23.
Connect the stop light switch

wires to the connector and install the

wires to the retaining clip.

24.
Connect the clutch pedal-

to-equalizer rod to the clutch pedal

assembly with the bushing and retain-

er and remove the C-clamp from the

bracket.

25.
Working from the engine side

of the dash panel, install the two cap-

screws attaching the pedal support

bracket to the dash panel. Then install

the two screws attaching the master

cylinder to the dash panel.

26.
Install the steering column.

Refer to Group 3 of this manual for

the procedure.

27.
Adjust the clutch pedal free

travel.

28.
Check the brake pedal free

height and travel measurements

(Group 2).

29.
Connect the battery ground

cable.

CLUTCH PEDAL AND/OR

BUSHING REMOVAL

AND INSTALLATION

MOM EGO, FALCON

FAIRLANF

1.
Remove the retaining clip (Fig.

2) that secures the equalizer rod to the

clutch pedal. Disconnect the rod from

the pedal.

2.
Remove the lower bolt retaining

the assist spring bracket to the pedal

support. Then, loosen the upper

bracket retaining bolt (approximately

4 turns) and disconnect the spring

from the clutch pedal and bracket.

3.
Disconnect the brake pedal push

rod from the brake pedal.procarmanuals.com