1969 FORD MUSTANG oil

03-02-18
Suspension

03-02-18

5.
Remove the cotter pin from the

upper ball joint stud nut.

6. Loosen the upper ball joint stud

nut one or two turns. Do not remove

the nut from the stud at this time.

7.
Install tool T57P-3006-A be-

tween the upper and lower ball joint

studs with the adapter screw on top

(Fig. 13). The tool should be seated

firmly against the ends of both studs

and not against the nuts or lower stud

cotter pin.

8. With a wrench, turn the adapter

screw until the tool places the stua

under tension. Tap the spindle near

the upper stud with a hammer to loos-

en the stud in the spindle. Do not

loosen the stud from the spindle with

tool pressure only.

9. Remove the tool from between

the ball joint studs and place a floor

jack under the lower arm.

10.
Raise the floor jack to relieve

the pressure from the upper ball joint

stud nut and remove the nut.

11.
Remove the upper arm inner

shaft attaching bolts. Remove the

upper arm and inner shaft as an as-

sembly (Fig. 1).

12.
Remove the bumpei from the

upper arm.

Installation

1.
Position the bumper to the upper

arm and install the nut and washer.

Torque the nut to specifications.

2.
Position the upper arm inner

shaft to the frame side rail and install

the 2 attaching bolts and washers

snug.

3.
Connect the upper ball joint stud

to the spindle and install the attaching

nut. Torque the nut to specification

and continue to tighten the nut until

the cotter pin hole in the stud is in

line with the nut slots. Then, install

the cotter pin.

4.
If equipped with drum type bra-

kes—Adjust the brakes as outlined in

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

drum to the spindle and adjust the

wheel bearings as outlined in Part

3-12.

5.
If equipped with disc brak-

es—Install the wheel and tire on the

hub and adjust the wheel bearings as

outlined in Part 3-12.

6. Install the hub cap or wheel

cover.

7.
Remove the safety stands and

lower the front of the vehicle.

8. Check caster, camber, and toe-in

and adjust as required (Section 2, Part

3-D.
COUGAR, FAIRLANE,

FALCON, MONTEGO,

MUSTANG

Removal

1.
Raise the front of the vehicle,

position safety stands under the

frame, and lower the vehicle slightly.

2.
Remove the wheel and tire.

3.
Remove the shock absorber

lower attaching nuts and washers.

4.
Remove the shock absorber

upper mounting bracket attaching

nuts,
and remove the shock absorber

and bracket as an assembly (Fig. 26).

On all 8-cylinder vehicles, remove

the air cleaner to obtain access for

tool installation.

5.
Install the spring compressor

tool and compress the spring (Figs.

19,
20 and 21).

6. Position a safety stand under the

lower arm.

7.
Remove the cotter pin from the

nut on the upper ball joint stud, and

loosen the nut one or two turns. Do

not remove the nut from the stud at

this time.

8. Position the ball joint remover

tool between the upper and lower ball

joint studs as shown in Fig. 10. The

tool should seat firmly against the

ends of both studs and not against the

stud nuts.

9. Turn the tool with a wrench until

the tool places the studs under consid-

erable tension; then, hit the spindle

smartly near the upper stud with a

hammer to break the stud loose in the

spindle. Do not loosen the stud in the

spindle with tool pressure only. If

both arms are being removed, loosen

the lower stud in the same manner as

the upper stud.

10.
Remove the nut from the upper

stud and lift the stud out of the

spindle.

11.
Remove the upper arm inner

shaft attaching nuts from the engine

compartment, and remove the upper

arm.

12.
Wipe off all loose dirt from the

upper arm parts. Do not wash the ball

joint with a solvent.

Installation

1.
Position the upper arm on the

underbody mounting bracket, and in-

stall the nuts and lock washers on the

two inner shaft attaching bolts. The

specified keystone-type lock washers

must be used. Torque the nuts to

soecification.
2.
Position the upper ball joint stud

in the top of the wheel spindle, and in-

stall the stud nut. Torque the nut to

specification, and continue to tighten

it until the cotter pin hole and slots

line up. Install a new cotter pin.

3.
Release the coil spring, remove

the tool, and install the front shock

absorber and the wheel and tire.

LINCOLN CONTINENTAL

Removal

1.
Place a jack under the outer end

of the suspension lower arm and raise

the arm. Refer to Fig. 22.

2.
Remove the wheel and tire.

3.
Remove the cotter pin from the

upper ball joint stud. Loosen the nut

one or two turns.

4.
Place a box wrench over the

lower end of the ball joint remover

tool, and position the tool as in Fig.

13.
The tool should seat firmly against

the ends of both studs, and not

against the upper stud nut.

5.
Turn the wrench until both studs

are under tension, and then, tap the

spindle with a hammer near the upper

stud to loosen it from the spindle. Do

not loosen the stud with tool pressure

alone. Remove the nut.

UPPER MOUNTING BRACKET

LOWER RETAINING BOLTS F 1490-A

FIG. 26—Removing or Installing

Front Shock Absorber—Typicalprocarmanuals.com

03-02-21
Suspension

03-02-21

8. Place a box wrench over the

lower end of the ball joint remover

tool, and position the tool as in Fig.

13.
The tool should seat firmly against

the ends of both studs, and not

against the stud nuts.

9. Turn the wrench until both studs

are under tension, and then, tap the

spindle with a hammer near the studs

to loosen them from the spindle. Do

not loosen
the
studs with tool pressure

alone.

10.
Place a jack under the outer

end of the lower arm, and raise the

arm several inches. Remove both ball

stud nuts, and remove t^e spindle.

Installation

1.
Position the new spindle onto the

upper and lower ball joint studs, in-

stall the stud nuts and tighten the nuts

to specifications. Continue to tighten

both nuts until the cotter pin holes

line up with the slots, then install new

cotter pines.

2.
Connect the spindle connecting

rod to the spindle arm. Install the re-

taining nut and tighten the nut to

specification. Continue to tighten the

nut until the cotter pin hole lines up

with the slot, then install a new cotter

pin.

3.
Install the gasket and splash

shield on the spindle. Tighten the at-

taching bolts to specifications.

4.
Install the hub and rotor on the

spindle.

5.
Install the caliper to the spindle

and tighten the attaching bolts to spe-

cifications. Check for the correct flex-

ible hose routing (Part 2-2).

6. Install the wheel and tire and ad-

just the wheel bearings (Part 3-12).

7.
Lubricate the steering stop on

the lower arm and the mating flat on

the spindle with the specified lubri-

cant.

8. Remove the safety stands, lower

the car and check camber, caster and

toe-in.

FRONT SHOCK ABSORBER

REPLACEMENT

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK III

1.
Remove the nut, washer, and

bushing from the shock absorber

upper end.

2.
Raise the vehicle on a hoist and

install safety stands.
3.
Remove 2 bolts attaching the

shock absorber to the lower arm and

remove the shock absorber.

4.
Place a washer and bushing on

the shock absorber top stud and posi-

tion the shock absorber inside the

front spring. Install the 2 lower at-

taching bolts and torque them to spe-

cifications.

5.
Remove the safety stands and

lower the vehicle.

6. Place a bushing and washer on

the shock absorber top stud and in-

stall the attaching nut. Torque it to

specification.

COUGAR, FAIRLANE,

FALCON, MONTEGO,

MUSTANG

Removal

1. Raise the hood and remove 3

shock absorber upper mounting

bracket-to-spring tower attaching

nuts.

2.
Raise the front of the vehicle and

place safety stands under the lower

arms.

3.
Remove 2 shock absorber lower

attaching nuts and washers.

4.
Lift the shock absorber and

upper bracket from the spring tower

(Fig. 26) and remove the bracket from

the shock absorber.

Installation

1. Install the upper mounting

bracket on the shock absorber and

torque to specification.

2.
Position the shock absorber and

upper mounting bracket in the spring

tower, making sure the shock absor-

ber lower studs are in the pivot plate

holes.

3.
Install the 2 washers and attach-

ing nuts on the shock absorber lower

studs and torque to specification.

4.
Install the 3 shock absorber

upper mounting bracket-to-spring

tower attaching nuts and torque to

specification. Then, remove the safety

stands and lower the vehicle.

LINCOLN CONTINENTAL

Removal

1.
Remove the stud nut at the

upper eye of the shock absorber. Re-

move the upper eye stud bracket to

crossmember attaching bolt and re-

move the stud bracket. Refer to Fig.

22.
2.
Remove the bolts which attach

the shock absorber to the suspension

lower arm. Lower, and remove the

shock absorber.

3.
Examine the shock absorber unit

and rubber bushings. Replace parts

that are defective, deteriorated, or

worn.

Installation

1. Fully extend the shock absorber

and position it inside the coil spring.

Connect the lower end of the shock

absorber to the suspension lower arm.

Torque the attaching nuts to specifica-

tion.

2.
Insert the upper bracket stud

through the bushing in the shock ab-

sorber upper eye. Install the stud

bracket to crossmember attaching

bolt. Do not tighten the bolt: at this

time.

3.
Install the upper eye bracket

stud nut. Torque the nut to specifica-

tion.

4.
Torque the stud bracket- to-

crossmember attaching bolt to specifi-

cation.
The
shock absorber upper
eye

stud
nut
must
be
tightened
to com-

press
the
rubber bushing before
the

stud bracket
is
bolted
to the

crossmember;
otherwise,
the
upper
at-

tachment could
be
loose
and
noisy.

REAR SHOCK ABSORBER

REPLACEMENT

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK 1(11

1.
Raise the vehicle on a hoist.

2.
Remove the shock absorber at-

taching nut, washer and insulator

from the upper stud at the upper side

of the spring upper seat. Compress the

shock absorber to clear the hole in the

spring seat, and remove the inner in-

sulator and washer from the upper at-

taching stud.

3.
Remove the self-locking attach-

ing nut, and disconnect the shock ab-

sorber lower stud from the mounting

bracket on the rear axle housing (Fig.

4).

4.
Expel all air by performing step

3 On Vehicle Tests in Part 3-1.

5.
Place the inner washer and insu-

lator on the upper attaching stud, and

position the shock absorber so that

the upper attaching stud enters the

hole in the spring upper seat. While

holding the shock absorber in this po-

sition, install the outer insulator andprocarmanuals.com

03-02-24

Suspension

03-02-24

LOCK NUT

INSULATOR

NG

NUT

MOUNTING STUD

WASHER

LOCK WASHER

FIG. 31—Rear Shock Absorber Mounting
F1486-A

TRACK BAR

MOUNTING

STUD AXLE

VENT
SHOCK

ABSORBER

MOUNTING

BRACKET
SHOCK

ABSORBER

MOUNTING

BRACKET

V-V.

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

F1438-A

Place jack stands under the frame side

rails.

2.
Disconnect the lower studs of the

two rear shock absorbers from the

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

until the coil springs are released (Fig.

32).

4.
Remove the springs and the insu-

lators from the vehicle.
Installation

1.
Position the spring in the upper

and lower seats with an insulator be-

tween each seat and the spring.

2.
Raise the hoist and axle housing

with the spring in position and con-

nect the lower studs of the rear shock

absorbers to the mounting brackets on

the axle housing. Install the attaching

nuts,
and torque to specifications.

3.
Remove the jack stands and

lower the vehicle.

REAR SUSPENSION

LOWER ARM

FORD, MERCURY,

METEOR, THUNDERBIRD,

CONTINENTAL MARK III

Removal

1.
Raise the vehicle on a hoist and

place jack stands under the frame side

rails.

2.
Remove the attaching nut and

bolt from the frame track bar mount-

ing bracket and disconnect the bar

from the stud (Fig. 4).

3.
Lower the axle enough to relieve

spring pressure.

4.
Support axle under differential

pinion nose as well as under axle.

5.
Remove the lower arm pivot bolt

and nut from the axle bracket. Then,

disengage the lower arm from the

bracket.

6. Remove the pivot bolt and nut

from the frame bracket and remove

the lower arm from the vehicle.

Installation

The rear suspension lower arms are

not interchangeable. The lower arm

for the left side can be identified by

notches in the bushing flange (Fig. 4).

The right arm does not have the

notches.

1.
Position the lower arm in the

bracket on the frame side rail. Install

a new pivot bolt and new nut (Fig.

33).
Do not tighten the nut at this

time.

2.
Position the lower arm to the

axle bracket and install a new bolt

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

the nut at this time.

3.
Raise the axle.

4.
Install alignment spacers be-

tween the rear axle and frame (Fig. 3,

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

03-02-29

Suspension

03-02-29

SPRING LEAVES

AND TIE-BOLT

LINCOLN CONTINENTAL

Check for broken spring leaves. In-

spect the anti-squeak inserts between

the leaves, and replace them if they

are worn. The spring leaves must be

dry and free of oil and dirt before new

inserts are installed.
If the spring center tie-bolt requires

replacement, clamp the spring in a

vise to keep the spring compressed

during bolt removal and installation.

REAR SHACKLE AND

HANGER ASSEMBLY

LINCOLN CONTINENTAL

Inspect the rear shackle, bushings,

and studs for wear or damage. Re-

place parts where necessary (Fig. 6).
If the rear shackle bushings are to

be replaced, it will be necessary to re-

move the rear hanger assembly. Tor-

que the hanger attaching bolts to

specification when installed.procarmanuals.com

03-03-01
Automatic
Air
Leveling System

03-03-01

PART
3-3
Automatic
Air
Leveling System

COMPONENT INDEX

AIR COMPRESSOR

Disassembly
and
Overhaul

Removal
and
Installation

AIR CYLINDER

Removal
and
Installation

DESCRIPTION

HEIGHT CONTROL VALVE

Disassembly
and
Overhaul

Removal
and
Installation
MODEL APPLICATION
All
Models
Ford

03-03

03-02

03-02

03-01

03-03

03-02
Mercury
03-03

03-02

03-02

03-01

03-03

03-02
Meteor
03-03

03-02

03-02

03-01

03-03

03-02
Cougar
N/A

N/A

N/A

N/A

N/A

N/A
Fairlane
N/A

N/A

N/A

N/A

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.
Falcon
N/A

N/A

N/A

N/A

N/A

N/A
Montego
N/A

N/A

N/A

N/A

N/A

N/A
Mustang
N/A

N/A

N/A

N/A

N/A

N/A
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A

N/A
Thunderbird
N/A

N/A

N/A

N/A

N/A

N/A
Continental-
Mark III
N/A

N/A

N/A

N/A

N/A

N/A

DESCRIPTION

The automatic level control
is an

accessory item
on the
Ford, Mercury

and Meteor vehicles
(Fig. 1).
This
de-

vice
is a
supplement
to the
rear coil

spring suspension,
and
will automati-
cally maintain
the
rear standing height

of
the
vehicle
at an
approximate
con-

stant position compensating
for
vary-

ing loaded conditions.
The
system

consists
of a
vacuum operated
com-
pressor, control valve,
air
cylinders

and
the
connecting lines
and
fittings.

In
the
event
of
accidental
air
loss,
the

conventional coil springs will support

the vehicle.

RUBBER
AIR
CYLINDER

WITHIN COIL SPRING
HEIGHT CONTROL

VALVE
RUBBER
AIR
CYLINDER

WITHIN COIL SPRING

RUBBER VACUUM LINE
TO
VACUUM

DISTRIBUTION CONNECTOR

RED CLAMP STATION WAGON ONLY

COMPRESSOR

NYLON
AND
STEEL LINES

FROM VALVE
TO
CYLINDERS

FIG.
1
—
Air Leveling System
FT475-A
procarmanuals.com

03-05-20
Steering Columns And Linkage

03-05-20

placed if it becomes worn or damaged

(Figs.
18 through 21). Do not attempt

to straighten the sleeve if damaged.

1.
Remove the spindle connecting

rod end assemblies as described in the

previous sub-section.

2.
Screw the spindle rod end assem-

blies into the new sleeve the same

number of turns as the ends that were

removed. Do not tighten the clamp

bolts at this time.

3.
Position the sleeve and end as-

sembly on the center link and the

spindle arm. Install the attaching nut,

torque it to specification, and install

the cotter pin.

4.
Check and, if necessary, adjust

toe-in (Part 3-1). After toe-in is

checked and adjusted, oil the sleeve

clamp bolts then torque them to speci-

fication. The sleeve clamp must be in-

stalled as shown in Figs. 18 through

21.

CENTER LINK

REPLACEMENT

The center link connecting the Pit-

man arm and the idler arm is non-

adjustable and is provided with ta-

pered holes to accommodate the ball

studs (Figs. 18 through 21). The link

should be replaced when damaged or

when worn at the ball studs. On Lin-

coln Continental models, the link

should be replaced if excessive loose-

ness is noticed in either ball stud sock-

et.

REMOVAL

1.
Raise the vehicle on a hoist and

position safety stands.

2.
Remove the cotter pins and nuts

that attach both inner connecting rod

ends to the center link (Figs. 18

through 21).

3.
Disconnect the inner connecting

rod ends from the center link using

Tool 3290-C (Fig. 22).

4.
Remove the cotter pin and nut

attaching the idler arm to the center

link. Disconnect the idler arm from

the center link using Tool 3290-C for

Lincoln Continental models only.

5.
Remove the cotter pin and nut

attaching the Pitman arm to the cen-

ter link. Disconnect the Pitman arm

from the center link (use Tool 3290-C)

and remove the center link. On ve-

hicles equipped with the non-integral

power steering system, remove the

center link from the control valve as

detailed in Part 3-7.

INSTALLATION

1.
Replace the rubber seals on the
spindle connecting rod ends, if re-

quired.

2.
Position the center link to the

Pitman arm and idler arm and install

the attaching nuts loosely. On all ve-

hicles except Lincoln Continental

models, place the idler arm and the

front wheels in the straight ahead po-

sition to insure keeping the steering

wheel aligned and to prevent bushing

damage after the attaching nuts have

been torqued. On Lincoln Continental

models, insure that the seal is properly

installed on the center link. Torque

the nuts to the low end of the specifi-

cation. Continue to tighten each nut

until the slots in the nut align with the

hole in the stud. Then install a new

cotter pin.

3.
Position the spindle connecting

rod ends to the center link and install

the attaching nuts. Torque the nuts to

the low end of the specification. Con-

tinue to tighten each nut until the

slots in the nut align with the hole in

the stud. Then, install a new cotter

pin.

4.
Remove the safety stands, lower

the vehicle, check and adjust toe-in to

specification (Part 3-1).

STEERING IDLER ARM

AND BRACKET ASSEMBLY

REPLACEMENT

REMOVAL

If the idler arm bushings are worn

the complete idler arm assembly must

be replaced. In Lincoln Continental

models, if the socket at the idler

bracket is excessively loose, replace

the complet assembly.

1.
Remove the cotter pin and nut

attaching the steering center link at

the idler arm (Figs. 18 through 21).

2.
Disconnect the center link from

the idler arm (on Lincoln Continental

models, use Tool 3290-C).

3.
Remove the two bolts that attach

the idler arm and bracket assembly to

the frame.

INSTALLATION

1.
Secure the new idler arm and

bracket assembly to the frame with

the two attaching bolts (nuts and flat

washers as shown in Figs. 18, 19 and

21).

2.
On all vehicles except Lincoln

Continental models, place the idler

arm and the front wheels in the

straight ahead position to insure keep-

ing the steering wheel aligned and to
prevent bushing damage after the at-

taching nut has been torqued. Insert

the center link stud through the hole

in the end of the idler arm and install

the nut and washer.

On Lincoln Continental models, in-

sert the center link stud through the

hole in the end of the idler arm insur-

ing that the seal is properly installed

on the center link.

3.
Torque the idler arm rod nut to

specification and install a new cotter

pin.

PITMAN ARM

REPLACEMENT

REMOVAL

1.
Remove the cotter pin from the

castellated nut that attaches the steer-

ing center link to the Pitman arm.

Remove the castellated nut.

2.
Disconnect the steering center

link from the Pitman arm with tool

3290-C.

3.
Remove the Pitman arm attaching

nut and lock washer.

4.
Position the front wheels in the

straight ahead position. Remove the

Pitman arm with tool T64P-3590-F

(Fig. 23).

INSTALLATION

1.
With the front wheels in the

straight ahead position, place the Pit-

man arm on the sector shaft making

sure it is pointing forward.

2.
Install the nut and lock washer.

Torque the nut to specification.

G1663-A

FIG. 23— Removing Pitman

Arm—Typicalprocarmanuals.com

03-06-03
Manual Steering

03-06-03

MAJOR REPAIR OPERATIONS

STEERING GEAR

DISASSEMBLY

1. Rotate the steering shaft 3 turns

from either stop.

2.
After removing the sector adjust-

ing screw locknut and the housing

cover bolts (Fig. 6), remove the sector

shaft with the cover. Remove the

cover from the shaft by turning the

screw clockwise. Keep the shim with

the screw.

HOUSING
•
3548
6. Turn the ball nut over, and ro-

tate the worm shaft from side to side

until all 50 balls have dropped out of

the nut into a clean pan. With the

balls removed, the ball nut will slide

off the worm.

7. Remove the upper bearing cup

from the bearing adjuster and the

lower cup from the housing. It may be

necessary to tap the housing or the

adjuster on a block of wood to jar the

bearing cups loose.

8. If the preliminary inspection

GASKET
• 3581

SHIM-3A657 COVER
AND

BUSHING
•
3583

SECTOR SHAFT

ADJUSTING SCREW
.
3577

•BEARING-3576

SEAL
- 3591

G 1623-A

FIG. 6—Sector Shaft
and
Housing Disassembled

-^-HOUSING-3548

BEARING
CUP •
3552

BALL
NUT

BEARING-3571

FILLER PLUG-3556
LOCK NUT-3707

3524 BEARING
CUP \
SEAL-3738

•GUIDE -3523

• BEARINGS
•
3647

.CLAMP-3544
BEARING
• 3571

G 1624-A

FIG. 7—Steering Shaft
and
Related Parts Disassembled

3.
Loosen the worm bearing adjust-

er nut, and remove the adjuster as-

sembly and the steering shaft upper

bearing (Fig. 7).

4.
Carefully pull the steering shaft

and ball nut from the housing, and i •-

move the steering shaft lower bearr g.

To avoid possible damage to the ball

return guides, keep
the
ball
nut
from

running down
to
either
end of the

worm.

Disassemble
the
ball only
if
there
is

indication
of
binding
or
tightness.

5.
Remove the ball return guide

clamp and the ball return guides from

the ball
nut.
Keep
the
ball
nut
clamp-

side up until ready to remove the

balls.
shows damage, press the sector shaft

bearing and the oil seal from the

housing (Fig. 8).

ASSEMBLY

1. If the sector shaft bearing and

oil seal have been removed, press a

new bearing into the housing and in-

stall a new oil seal. Do not clean,

wash or soak seals in cleaning solvent

(Fig.
7).
Apply
the
recommended

steering gear lubricant
to the
bearing

and seals.

2.
Install a bearing cup in the lower

end of the housing and in the adjuster.

3.
If the seal in the bearing adjuster

was removed, install a new seal.
Tool
-
T62F
•
3576
- A

G 1622-A

FIG.
8—Removing
Oil
Seal

and Bearing

4.
Insert the ball guides into the

holes of the ball nut, tapping them

lightly with a wood handle of a screw

driver if necessary to seat them.

5.
Insert 25 balls into the hole in

the top of each ball guide. It may be

necessary to rotate the shafi: slightly

one way, then in the opposite direc-

tion to distribute the balls in the cir-

cuit.

6. After the 50 balls are installed,

install the ball guide clamp. Torque

the screws to specification. Check the

worm shaft to make sure that it ro-

tates freely.

7. Coat the threads of the steering

shaft bearing adjuster, the housing

cover bolts, and the sector adjusting

screw with a suitable oil-resisi:ant seal-

ing compound. Do not apply sealer to

female threads and especially avoid

getting any sealer on the steering shaft

bearings.

8.
Coat the worm bearings, sector

shaft bearings, and gear teeth with

steering gear lubricant.

9. Clamp the housing in a vise, with

the sector shaft axis horizontal, and

position the steering shaft lower bear-

ing in its cup.

10.
Position the steering shaft and

ball nut assemblies in the housing.

11.
Position the steering shaft

upper bearing on the top of the worm,

and install the steering shaft bearingprocarmanuals.com

03-08-03
Ford Design Integral Power Steering Gear

03-08-03

factory adjustments will change. These

changes in adjustment do not neces-

sarily affect the satisfactory operation

of the steering gear assembly, and

therefore ordinarily do not require

readjustment unless there is excessive

lash or other malfunctioning.

ADJUSTMENT IN

VEHICLE

The only adjustment which can be

performed is the total over center

position load, to eliminate excessive

lash between the sector and rack

teeth.

1.
Disconnect the pitman arm from

the sector shaft.

2.
Disconnect the fluid return line

at the reservoir, at the same time cap

the reservoir return line pipe.

3.
Place the end of the return line

in a clean container and cycle the
INPUT SHAFT

SECTOR SHAFT

ADJUSTMENT SCREW

C1547- A

FIG.
2—Adjusting Mesh Load

steering wheel in both directions as re-

quired, to discharge the fluid from the

gear.
4.
Remove the ornamental cover

from the steering wheel hub and turn

the steering wheel to 45 degrees from

the left stop.

5.
Using an in-lb torque wrench on

the steering wheel nut, determine the

torque required to rotate the shaft

slowly through an approximately 1/8

turn from the 45 degree position.

6. Turn the steering gear back to

center, then determine the torque re-

quired to rotate the shaft back and

forth across the center position. Loos-

en the adjuster nut, and turn the ad-

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

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

45 degrees from the stop.

Tighten the lock nut while holding

the screw in place.

7.
Recheck the readings and replace

pitman arm and steering wheel hub

cover.

8. Connect the fluid return line to

the reservoir and fill the reservoir with

specified lubricant to the proper level.

REMOVAL AND INSTALLATION

REMOVAL

1.
Disconnect the pressure and the

return lines from the steering gear.

Plug the lines and the ports in the

gear to prevent entry of dirt.

2.
Remove the two bolts that secure

the flex coupling to the steering gear

and to the column.

3.
Raise the vehicle and remove the

sector shaft attaching nut.

4.
Remove the Pitman arm from

the sector shaft with Tool T64P-

3590-F.
Remove the tool from the

Pitman arm. Do not damage the

seals.

5.
If working on a vehicle equipped

with a standard transmission, remove

the clutch release lever retracting

spring to provide clearance for remov-

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

remove the three steering gear attach-

ing bolts.

7.
Work steering gear free of the

flex coupling and remove it from the

vehicle.

8. If the flex coupling stayed on the

input shaft, lift if off the shaft at this

time.

INSTALLATION

1.
Slide the flex coupling into place

on the steering shaft. Turn the steer-

ing wheel so that the spokes are in the

horizontal position.

2.
Center the steering gear input

shaft.

3.
Slide the steering gear input

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

the three attaching bolts and torque

them to specification.

4.
Make sure that the wheels are in

the straight ahead position, then in-

stall the Pitman arm on the sector

shaft. Install and tighten the sector

shaft and install and tighten the at-

taching bolts to specification.

5.
Move the flex coupling into

place on the input and steering co-

lumn shaft and install and tighten the

attaching bolts to specification.

6. Connect and tighten the fluid

pressure and the return line to the

steering gear.

7.
Fill the power steering pump and

cycle the steering gear. Check for

leaks and again check the fluid level.

Add fluid as required.

MAJOR REPAIR OPERATIONS

In most cases, complete disassembly

of the power steering gear will not be

necessary. It is suggested that only

those assemblies that are faulty be dis-

assembled. Disassembly and reassem-

bly of the unit and the subassemblies

must be made on a clean workbench.

As in repairing any hydraulically op-

erated unit, cleanliness is of utmost

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

all times. Thoroughly clean the exter-

ior of the unit with a suitable solvent

and when necessary, drain as much of

the hydraulic oil as possible. Handle

all parts very carefully to avoid nicks,

burrs,
scratches and dirt, which could

make the parts unfit for use. Do not

clean, wash or soak seals in cleaning

solvent.
VALVE CENTERING

SHIM REPLACEMENT

1.
Hold the steering gear over a

drain pan in an inverted position and

cycle the input shaft several times to

drain the remaining fluid from the

gear.

2.
Mount the gear in a soft-jawed

vise.procarmanuals.com