1969 FORD MUSTANG oil

03-08-06

Ford Design Integral Power Steering Gear

03-08-06

VALVE HOUSING

7W-T65P

C1239 -A

FIG. 7—Removing or Installing Lock

Nut

drain the remaining fluid from the

gear.

2.
Mount the gear in a soft-jawed

vise.

3.
Remove the lock nut and the

brass washer from the adjusting screw.

4.
Turn the input shaft to either

stop then, turn it back approximately

1 3/4 turns to center the gear.

5.
Remove the two sector shaft

cover attaching screws and the
identif-

ication tag.

6. Tap the lower end of the sector

shaft with a soft-hammer to loosen it,

then lift the cover and shaft from the

housing as an assembly. Discard the

O-ring.

7.
Turn the sector shaft cover coun-

terclockwise off the adjuster screw.

8. Remove the four valve housing

attaching bolts. Lift the valve housing

from the steering gear housing while

holding the piston to prevent it from

rotating off the worm shaft. Remove

the valve housing and the lube passage

O-rings and discard them.

9. Stand the valve body and piston

on end with the piston end down. Ro-

tate the input shaft counterclockwise

out of the piston allowing the ball

bearings to drop into the piston.

10.
Place a cloth over the open end

of the piston and turn it upside down

to remove the balls.

11.
Remove the two screws that at-

tach the ball guide clamp (Fig. 6) to

the ball nut and remove the clamp and

the guides.

12.
Install the valve body assembly

in the holding fixture (do not clamp

in a vise) and remove the lock nut and

the attaching nut as shown in Fig. 7.

13.
Carefully slide the input shaft,

worm and valve assembly out of the

valve housing. Due to the close diame-

trical clearance between the spool and

housing, the slightest cocking of the

spool may cause it to jam in the hous-

ing.

14.
Remove the shim from the

valve housing bore.
OIL SEAL

INLET TUBE SEAT

OUTLET TUBE SEAT
DUST SEAL

G1549-A

FIG.
8—Valve Housing Disassembled

Too/-T<

Tool-

T57L-500-A ,^^^

G1364-A

FIG. 9—Removing Bearing and Oil

Seal

PARTS REPAIR

OR REPLACEMENT

Valve Housing

1.
Remove the dust seal (Fig. 8)

from the rear of the valve housing

with Tools T59L-100-B and T58L-

101-A and discard the seal.

2.
Remove the snap ring from the

valve housing.

3.
Turn the fixture to place the

valve housing in an inverted position.

4.
Insert special tool in the valve

body assembly opposite the seal end

and gently tap the bearing and seal

out of the housing as shown in Fig.

9. Discard the seal. Caution must be

exercised when inserting and removing

the tool to prevent damage to the

valve bore in the housing.

5.
Remove the fluid inlet and outlet

tube seats with an EZ-out if they are

damaged.
Press Ra
Tool-

T65P-3524-A7

G1363-A

FIG. 10—Installing Valve Housing

Bearing

6. Coat the fluid inlet and outlet

tube seats with vaseline and position

them in the housing. Install and tight-

en the tube nuts to press the seats to

the proper location.

7.
Coat the bearing and seal surface

of the housing with a film of vaseline.

8. Position the bearing in the valve

housing. Seat the bearing in the valve

housing with the tool shown in Fig.

10.
Make sure that the bearing is

free to rotate.

9. Dip the new oil seal in gear lu-

bricant; then, place it in the housing

with the metal side of the seal facing

outward. Drive the seal into the hous-

ing until the outer edge of seal does

not quite clear the snap ring groove

(Fig. 11).

10.
Place the snap ring in the hous-

ing; then, drive on the ring with the

tool shown in Fig. 11 until the snap

ring seats in its groove to properly lo-

cate the seal.procarmanuals.com

03-08-07
Ford Design Integral Power Steering Gear

03-08-07

Press Ram
Tool-

T65P.3524-A1

G1362-A

FIG.
17—Installing
Oil Seal in

Valve Housing

11.
Place the dust seal in the hous-

ing with the dished side (rubber side)

facing out. Drive the dust seal into

place with the tool shown in Fig. 11.

the seal must be located behind the

undercut in the input shaft when it is

installed.

Worm and Valve

1.
Remove the snap ring from the

end of the actuator.

2.
Slide the control valve spool

(Fig. 6) off the actuator.

3.
Install the valve spool evenly and

slowly with a slight oscillating motion

into the flanged end of valve housing

with the Valve identification groove

between the valve spool lands out-

ward, checking for freedom of valve

movement within the housing working

area. The valve spool should enter the

housing bore freely and fall by its own

weight.

4.
If the valve spool is not free,

check for burrs at the outward edges

of the working lands in the housing

and remove with a hard stone.

5.
Check the valve for burrs and if

burrs are found, stone the valve in a

radial direction only. Check for free-

dom of the valve again.

6. Remove the valve spool from the

housing.

7.
Slide the spool onto the actuator

making, sure that the groove in the

spool annulus is toward the worm.

8. Install the snap ring to retain the

spool.

9. Check the clearance between the

spool and the snap ring. The clearance

should be between 0.002-0.005 inch. If

the clearance is not within these lim-

its,
select a snap ring that will allow a

clearance of 0.003 inch.
STEERING GEAR HOUSING

J

UPPER SEAL

I LOWER SEAL

SNAP RING

SPACER WASHER

FIG. 12—Steering Gear Housing Disassembled

Tool - T59L - 100-B

Tool T57L-500 - A

G1551-A

FIG. 13—Removing Lower Seal

Piston and Ball Nut

1.
Remove the teflon ring and the

O-ring (Fig. 7) from the piston and

ball nut.

2.
Dip a new O-ring in gear lubri-

cant and install it on the piston and

ball nut.

3.
Install a new teflon ring on the

piston and ball nut being careful not

to stretch it any more than necessary.

Steering Gear Housing

1.
Remove the snap ring and the

spacer washer (Fig. 12) from the

lower end of the steering gear housing.

2.
Remove the lower seal from the

housing as shown in Fig. 13. Lift the

spacer washer from the housing.

3.
Remove the upper seal in the

same manner as the lower seal.

4.
Dip both sector shaft seals in

gear lubricant.
SHORT END

AWAY

FROM SEAL
G1550-A

Press Rom

G1374-A

FIG. 14—Installing Sector Shaft

Inner Seal

5. Apply Lubricant to the sector

shaft seal bore of the housing and

position the sector shaft inner seal

into the housing with the lip facing in-

ward. Press the seal into place with

the tool shown in Fig. 14. Place a spa-

cer washer (0.090 inch) on top of the

seal and apply more Lubricant to the

housing bore.

6. Place the outer seal in the hous-

ing with the lip facing inward and

press it into place as shown in Fig. 15.

Then, place a 0.090 inch spacer wash-

er on top of the seal.

7.
Position the snap ring in the

housing. Press the snap ring into the

housing with the tool shown in Fig. 15

to properly locate the seals and en-

gage the snap ring in the groove.

STEERING GEAR

ASSEMBLY

Do not clean, wash, or soak seals in

cleaning solvent.procarmanuals.com

03-09-04
Saginaw Design Integral Power Steering Gear

03-09-04

CLAMP

BALL
RETURN GUIDE
TEFLON
RINGS (3)

VALVE
SPOOL

0-RING SPOOL

SEAL

INLET
PORT SEAT

CHECK
VALVE

RETURN
PORT

SEAT

SPRING
STUB
SHAFT

ASSEMBLY

TEFLON
RING

RACK-PISTON
END PLUG

O-RING

HOUSING
END PLUG

RETAINING
RING
FLEXIBLE

COUPLING

'BEARING
LOCK

NUT

GROUND
STRAP

RETAINING
RING

DUST
SEAL

OIL
SEAL

ADJUSTER
PLUG

O-RING SEAL

THRUST
BEARING

SPACER

BEARING
RETAINER

SPOOL
SPRING

RETAINING
RING

FIG. 4—Steering Gear Disassembled

SPANNER
WRENCH

Tool - T65P-

lG
1646-A

FIG. 5—Removing Adjuster Plug
14.
Pull the stub shaft and valve as-

sembly from the housing.

15.
Lift the worm, lower thrust

bearing and the races from the hous-

ing.

REPAIR
OF SUB-

ASSEMBLIES

Do not clean, wash, or soak seals in

cleaning solvent.

STEERING GEAR HOUSING

1.
Remove the snap ring (Fig. 7)
G
1647-A

that secures the sector shaft seals in

the lower end of the housing. Remove

the lower spacer washer.

2.
Remove the lower seal (double

lip),
spacer washer, upper seal (single

lip) with Tools T85L-1O1-A and

T59L-100-B (Fig. 8).

3.
Check the housing bearing for

wear and remove the bearing only if

worn or damaged. Working from the

lower end of the housing (Fig. 9) press

the bearing out of the housing. Dis-

card the bearing.

.HOUSING
LOWER
SEAL (DOUBLE LIP)

Tool
- T 65P-3D517-A

G
1645-A

FIG. 6—Removing Rack Piston

into the end of the rack-piston until it

contacts the worm shaft. Rotate the

stub shaft in a counterclockwise direc-

tion until the worm is free of the

rack-piston. Withdraw the rack-piston

from the housing making sure that the

tool is held all the way in the piston

to prevent dropping the balls. Do not

disassemble the rack-piston at this

time.
SNAP

RING

INLET
PORT

SEAT

RETUkN
PORT

SEAT

G
1643-A

FIG. 7—Steering Gear Housing Disassembledprocarmanuals.com

03-09-05
Saginaw Design Integral Power Steering Gear

03-09-05

Tool . T59L -100S

FIG. 8—Removing Sector

Shaft Seals

Too/
-
T65P -3576-C

G 1641-A

FIG. 9—Removing Sector

Shaft Bearings

4.
Working from
the
upper
end of

the housing, press
in a new
bearing

until
the
upper
end
is
0.030 inch below

the housing bore. When installing
the

bearing, make sure
it is
pressed
in

from
the
identification
end
(stamped

end).

5.
Lubricate
new
sector shaft seals

(Fig.
7) in
C1AZ-19582-A hydraulic

fluid. Install
the
single
lip
seal first,

then
a
back-up washer. Using special

tool
(Fig. 10),
drive
the
seal
and
wash-

er
in far
enough
to
provide clearance

for
the
other seal
and
back-up washer

and
the
retaining ring.
The
seal must

not bottom
on the end of
the
counter-

bore.
Install
the
double
lip
seal
and

the second back-up washer. Again using
the special tool, drive
the
seal
and

back-up washer
in
only
far
enough
to

provide clearance
for the
retaining

ring. Install
the
sector shaft seal
re-

taining ring with snap ring pliers,

making certian that
the
ring
is
seated

properly.

6.
To
remove
a
damaged port seat,

use
a
5/16-18 inch
U.S.
thread

(coarse)
tap and
turn
it
two
turns into

the seat.

7.
Thread
a
bolt
and nut
with
a
flat

washer into
the
tapped hole
(Fig.
11).

8. Hold
the
bolt from turning
and

tighten
the nut to
extract
the
seat.

Discard
the
seat.

9. Remove
the
check valve
and

spring from
the
inlet port.

10.
Blow
all
chips from
the
hous-

ing.

11.
Position
the
spring, check valve

and
new
seat
in the
inlet port.

12.
Use the
tool shown
in Fig. 12

and drive
the
seat into place.

.
T65P-3D642-A

G1287-
A

FIG.
10
— Installing Sector

Shaft Seal

5/16
•
16x2"

BOLT
13.
Install
the
outlet port seat
in

the same manner.

ADJUSTER PLUG

1.
Lift
the
adjuster plug
off
the
stub

shaft
(Fig.
4).

2.
Pry the
thrust bearing retainer

off
the
adjuster plug
as
shown
in Fig.

13.
Be
careful
not to
score
the
needle

bearing bore. Discard
the
retainer.

3.
Lift
the
spacer, thrust bearing,

races
and the
O-ring, from
the
plug

(Fig.
14).
Discard
the
O-ring.

4.
If
necessary
to
replace
the
roller

bearing, remove
the
dust seal retaining

ring. Working from
the
spacer
end of

the adjuster plug, remove
the
roller

bearing,
oil
seal
and the
dust seal
as

shown
in Fig. 15.

G1639-A

FIG.
12
-Installing Inlet Port

BEARING RETAINER

G1640-A

FIG. 11 —Removing Port Seat
C1638-A

FIG. 73—Removing Thrust

Bearing Retainer

If
the
roller bearing does
not
need

replacing
do not
remove
it. Pry the

dust seal
and the oil
seal from
the ad-

juster plug with
a
screwdriver.

5.
Place
a new
roller bearing
on the

tool shown
in Fig.
15
with
the
bearing

manufacturer's identification facing

toward
the
tool.

6. Position
the
bearing
and
tool
in

the bore. Drive
the
bearing into
the

plug until
it is
flush with
the
bottom

surface
of the
stub shaft seal bore.

7.
Lubricate
a new oil
seal with

C1AZ-19582-A. Install
the
seal with

Tool T65P-3D536-A pressing
it
intoprocarmanuals.com

03-09-06
Saginaw Design Integral Power Steering Gear

03-09-06

ADJUSTER
PLUG

DUST
SEAL

FIG. 14 —Adjuster Plug Disassembled

the plug far enough to provide clear-

ance for the dust seal and the snap

ring.

8. Lubricate a new dust seal

C1AZ-19582-A and install it with

smooth rubber surface facing outward.

9. Secure the dust seal with the

ring, making sure that the ring is

properly seated.

10.
Lubricate a new O-ring seal

with vaseline and install it on the ad-

juster plug.

11.
Assemble the thrust bearing

outer race, thrust bearing, inner race,

and the thrust bearing spacer on the

adjuster plug (Fig. 16).
OIL
RETAINING

SEAL
RING

G
1637-A

12.
Press a new bearing retainer

into the bearing bore. The radial loca-

tion of the dimples is not important.

STUB SHAFT AND

VALVE ASSEMBLY

The control valve and spool is a se-

lect fit and cannot be serviced other

BEARING
AND

RACES

1636-A

FIG. 15 —Removing or Installing

Roller Rearing from Adjuster Plug
G
1635-A

FIG.
76
—Installing Thrust

Bearing Retainer

SPOOL
SPRING

DOWEL
BEARING

RACE

G1634-A

FIG. 77—Control Valve Disassembled
than removing the spool to replace the

dampener O-ring or replace the three

teflon seals or O-rings under the teflon

seals.

1.
Remove the cap to worm O-ring

and discard it (Fig. 17).

2.
Work the rear coil of spool

spring onto the stub shaft bearing sur-

face.
Do not pry on the valve body.

Slide the spring off the shaft.

3.
Extreme care must be used when

removing the valve spool. The diame-

tral clearance between the valve body

and the spool may be as low as 0.0004

inch. The slightest cocking of the

spool may jam it in the valve body.

a. To remove the valve spool, hold

the valve assembly in both hands with

the stub shaft pointing downward.

Push lightly on the valve spool with a

small rod by inserting the rod through

the openings in the end cap (Fig. 18)

until the spool is far enough out of the

valve so that it may be grasped by the

hand. Withdraw the spool with a

steady oscillating pull to prevent jam-

ming. If slight sticking occurs, make a

gentle attempt to reverse the with-

drawal procedure. If this does not free

the spool, it has become cocked in the

valve body bore. Do not attempt to

force the spool in or out if it becomes

cocked. In this case, continue to disas-

semble the valve assembly as follows

and return to the spool as described

later. Remove the stub shaft, torsion

bar, and end cap assembly by holding

the thumbs on the valve body as

shown in Fig. 18. Tap the torsion bar

lightly against the workbench. This

will dislodge the cap from the valve

body to cap pin. The stub shaft, tor-

sion bar and end cap assembly can

now be removed from the valve body.

b.
If the valve spool has become

cocked as described in step 3 above, it

can now be freed. By visual inspection

on a flat surface it can be determined

in which direction the spool is cocked.

A few very light taps with a light soft

plastic or raw-hide mallet should align

the spool in the bore and free it. Do

not tap with anything metallic. If

spool can be rotated, it can be re-

moved.

4.
Remove O-ring dampener seal

from the spool and discard it.

5.
Carefully cut the valve rings and

the ring back-up seals, remove and

discard them, providing the rings show

evidence of excessive wear. The valve

rings are made of filled teflon and it is

very unusual that replacement is re-

quired.

6. Remove the dampener O-ring

from the valve spool and discard it.procarmanuals.com

03-10-03
Ford-Thompson Power Steering Pump

03-10-03

EIGHT CYLINDER WITH

AIR CONDITIONER

1.
Remove the power steering fluid

from the pump reservoir by discon-

necting the fluid return hose from the

reservoir and allow the fluid to drain

in a suitable container.

2.
Disconnect the pressure hose

from the pump.

3.
Remove 3 bolts from the front of

the pump and the one nut at the rear

that attach the pump to the mounting

bracket and remove the drive belt

from the pump pulley.

4.
Loosen the upper pump bracket-

to-engine attaching bolt and remove

the bolt in the belt adjusting slot. Re-

move the pump.

5.
Position the pump to the bracket

and install the bracket-to-pump at-

taching bolts and nuts. Tighten to spe-

cifications.

6. Place the belt on the pump pul-

ley. Adjust the belt tension as outlined

in Section 2 and tighten the bolts and

nut to specification.

7.
Torque the pressure hose fitting

hex nut to specification. Then, connect

the pressure hose to the fitting and

torque the hose nut to specification.

8. Connect the return hose to the

power steering pump and tighten the

clamp.

9. Fill the pump with automatic

transmission fluid C1AZ-19582-A.

Bleed the air from the system (Part

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

quired.

POWER STEERING PUMP

PULLEY REPLACEMENT

REMOVAL

1.
Drain as much of the fluid as

possible from the pump through filler

pipe.

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

the end of the pump shaft to prevent

damage to the shaft end by the tool

screw.

3.
Install the pulley remover, Tool

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

place the tool and pump in a vise as

shown in Fig. 3.

4.
Hold the pump and rotate the

tool nut counterclockwise to remove

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

removed without in and out pressure

on the pump shaft to prevent damage

to internal thrust areas.

INSTALLATION

1.
Position the pulley to the pump

shaft and install Tool T65P-3A733-A

as shown in Fig. 4.

2.
Hold the pump and rotate the

tool nut clockwise to install the pulley

on the shaft. The pulley face will be

flush with end of pump shaft. Install

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

ternal thrust areas.

3.
Remove the tool.

POWER STEERING PUMP

RESERVOIR REPLACEMENT

Reservoir replacement must be done

on a clean workbench. Cleanliness of

work area and tools is extremely im-

portant when repairing any hydraulic

unit. Thoroughly clean the exterior of

the pump with a suitable cleaning sol-

vent. Do not clean, wash or soak the

shaft oil seal in solvent. Plug the inlet

and outlet openings with plugs or

masking tape before cleaning the

pump exterior or removing the reser-

voir.

REMOVAL

1.
Assemble the adapter plate (Tool

T69P-3A674-A) to the bench mounted

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

the pump and pulley on the adapter

plate, pulley facing down.

2.
Remove the outlet fitting hex nut

and the service identification tag.

3.
Invert the pump so the pulley is

facing up and remove the reservoir by

tapping around the flange with a wood

block (Fig. 5).

4.
Remove the reservoir O-ring seal

and the outlet fitting gasket from the

pump.

INSTALLATION

Tool • T 63 L-

10300 -

G 1477 A

FIG. 3—Removing Power

Steering Pump Pulley
1478 A

FIG. 4—Installing Power

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

fitting and a new reservoir O-ring seal

on the pump housing plate (Fig. 6).

The old gasket and seal should never

be re-used.

Too/
T57L 500-A

G1602-A

FIG. 5—Removing Pump

Reservoirprocarmanuals.com

03-10-04
Ford-Thompson Power Steering Pump

03-10-04

OUTLET FITTING

GASKET
Wood Block

0-RING SEAL

G1345-
-500-
A

G1603- A

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

on Pump—Typical
2.
Apply vaseline to the reservoir

O-ring seal and to the inside edge of

the new reservoir flange. Do not twist

the O-ring seal.

3.
Position the reservoir over the

pump and align the notch in the reser-

voir flange with the notch in the outer

diameter of the plate and bushing as-

sembly.

4.
Install the reservoir on the pump

and O-ring seal with a plastic or rub-

ber hammer and a block of wood as

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

reservoir and on the outer edges only.

5.
Inspect the assembly to be sure

the reservoir is evenly seated on the

pump housing plate.

6. Position the service identification

tag on the outlet fitting and install the

outlet fitting hex nut. Torque the nut

to specification (Part 3-13). Do not

exceed specification.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

Disassembly of the pump and its

subassemblies must be made on a

clean work bench. In repairing any

hydraulically operated unit, cleanliness

is of utmost importance. Clean the ex-

terior of the unit with a suitable sol-

vent and drain as much of the fluid as

possible.

If only the reservoir is to be re-

moved, plug the inlet and outlet open-

ings with masking tape or plugs. Do

not immerse the shaft oil seal in sol-

vent. If only the rotor shaft seal is to

be replace, see Rotor Shaft Seal Re-

placement outlined in this section.

1.
Assemble the adapter plate (Tool

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

ed holding fixture Tool T57L-5OO-A

(Fig. 8).

2.
Position the pump assembly,

with pulley assembled, on the adapter

plate, pulley facing down.

3.
Remove the outlet fitting nut and

the service identification tag.

4.
Invert the pump assembly and,

using a block of wood and a rubber or

plastic hammer, remove the pump res-

ervoir and seal by tapping around the

flange of the reservoir and on the und-

erside of the filler neck.

5.
Again invert the pump assembly,

loosen and remove the pump housing

retention bolts and remove the pump

housing.
6. If necessary, remove the fol-

lowing components from the pump

housing: the housing cover, the O-ring

seal and the pressure springs. These

components normally will remain in

the pump housing when it is removed.

7.
Remove and discard the pump

cover gasket.

8. Remove the retainer end plate

and upper pressure plate (in some

pumps, the end plate and upper pres-

sure plate are integral).

9. Remove the loose fitting dowel

pin. Be careful not to bend the fixed

dowel pin which remains in the hous-

ing plate assembly.

10.
Remove the rotor assembly

being careful to prevent the springs

and slippers from falling out and be-

coming lost. Do not disassemble fur-

ther unless the lower pressure plate,

housing plate, rotor shaft and/or seal

is to be replaced.

11.
Invert the pump assembly and,

using Tool T63L-1O3OO-B, remove the

pulley.

12.
Clean any rust, road dirt, burrs,

scoring, etc. from the pulley end of

the rotor shaft prior to removal of the

shaft from the housing plate. The

shaft must come out without restric-

tions to prevent scoring or damage to

the bushing. Remove the pump rotor

shaft.

13.
Remove the lower pressure

plate.
PARTS REPAIR OR

REPLACEMENT

ROTOR SHAFT

SEAL REPLACEMENT

Removal

1.
Remove the pulley from the

rotor shaft as described under Power

Steering Pump Pulley Removal.

2.
Position the pump assembly in

T57L-500-A

T69P-3A674-A

•
G1604-A

FIG. 8—Adapter Plate Installationprocarmanuals.com

03-11-03

Eaton Power Steering Pump

03-11-03

POWER STEERING PUMP

DISASSEMBLY

A clean working area should be

used when overhauling the power

steering pump. Foreign matter picked

up on working parts may cause dam-

age or failure of the unit. Clean con-

tainers should be used for parts.

1.
Drain the fluid from the pump.

Remove the pump cover-to-housing

cap screws (Fig. 1). Place the pump

on the bench, cover side down. Lift

the housing from the cover.

2.
Remove the large and the small

O-rings from the pump cover. Remove

the O-ring from the pressure plate

hub.

3.
Remove the pressure plate-

to-cover screws, and remove the plate.

Lift the cam ring off the dowel pins.

4.
Remove the rollers. Lift the

rotor off the shaft, and remove the

drive key from the shaft. Remove the

dowel pins from the cover.

5.
Remove the rotor shaft from the

cover. Do not remove the snap ring

from the shaft unless it, or the shaft,

is damaged.

6. Pry the rotor shaft seals out of

the cover and the housing.

7. Do not disturb the control valve

unless diagnosis indicated a control

valve problem or foreign matter in the

valve. To remove the valve, drive the

roll pin out of the housing. Remove

the plug and O-ring, control valve,

and the spring. If the plug or valve is

stuck, tap the end of the housing on a

piece of wood or tap it with a soft-

faced hammer. Remove the O-ring

from the plug.

ASSEMBLY

Apply automatic transmission fluid

to all parts as they are assembled. Al-

ways use new seals and O-rings.

1.
Install the control valve spring in

the housing. Install the valve with the

small sensing hole in the end of the

valve toward the spring. Install a new

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

1/8 inch smaller in diameter than the

bypass O-ring. Make sure the proper

O-ring is used. Install the plug and a

new roll pin (Fig. 1).

2.
The rotor shaft oil seals are in-

stalled in the cover and the housing

with Tool 3583-J, which consists of a

driver and an adapter. The procedure

is as follows:

a. Support the cover on wood

blocks (Fig. 2) to provide tool clear-

ance.
Use clean blocks that will not

nick or damage the inner face of the

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

ward) square!y into the bore with fin-

ger pressure. Place the adapter on the

driver with the square corner of the

FIG. 2—Preparation for Installing

Rotor Shaft Seals

adapter toward the seal (Fig. 2). Drive

the seal into the cover, as shown in

Fig. 3, until it bottoms.

Driving the seal beyond this point

can damage it. Install the seal in the

pump housing in the same manner.

3.
Install the rotor shaft in the

FIG. 3—Installing Rotor

Shaft Seals
cover as shown in Fig. 4 to prevent

damage to the seal.

4.
Install the dowel pins in the

cover. Place the rotor drive key in the

shaft. Install the rotor on the shaft

with the drive key groove aligned with

the key and the counterbored side of

the rotor toward the cover so that it

goes over the snap ring.

5.
Place the cam ring on the dowel

pins with the chamfered edge upward

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

6. Place the pressure plate on the

dowel pins. Install and tighten the

screws to 20 in-lbs torque. Install the

O-ring on the pressure plate hub. In-

stall O-rings in the groove at the fluid

bypass hole and around the cam ring

(Fig. 6).

7.
Place the tool shown in Fig. 6 in

the rotor shaft to prevent damage to

the oil seal, then install the housing on

the cover. Install and torque the cap

screws to 15-20 ft-lbs.

FIG. 5—Cam Ring Installation

FIG. 4—Installing Rotor Shaft

in Cover

FIG. 6—O-Ring Installationprocarmanuals.com