1969 FORD MUSTANG torque

03-08-05

Ford Design Integral Power Steering Gear

03-08-05

rque Wrench

Tool-T66P-3553-C

G1366-A

FIG.
5—Installing Valve Housing Attaching
Nut
24.
Align
the
lube passage
in the

valve housing with
the
one
in
the gear

housing,
and
install but
do
not tighten

the attaching bolts.

25.
Rotate
the
ball
nut so
that
the

teeth
are in the
same place
as
the sec-

tor teeth. Tighten
the
four valve hous-

ing attaching bolts
to
specification.

26.
Position
the
sector shaft cover

O-ring
in the
steering gear housing.

Turn
the
input shaft
as
required
to

center
the
piston.

27.
Apply vaseline
to the
sector

shaft journal; then, position
the
sector

shaft
and
cover assembly
in
the
gear

housing. Install
the
steering gear iden-

tification
tag and the
two sector shaft

cover attaching bolts.

28.
Position
an
in-lb torque wrench

on
the
gear input shaft
and
adjust
the

meshload
to
approximately
4
in-lbs.

Then, torque the sector shaft cover
at-

taching bolts
to
specification (Part

3-13).

29.
After
the
cover attaching bolts

have been tightened
to
specification,

adjust
the
meshload
to
specification

with
an
in-lb torque wrench.

STEERING GEAR

DISASSEMBLY

1.
Hold
the
steering gear over
a

drain
pan
in an
inverted position
and

cycle
the
input shaft several times
to

CENTERING SHIM

WORM AND VALVE ASSEMBLY

LOCK NUT

PISTON AND BALL NUT
VALVE HOUSING

TEFLON RING

•BALL GUIDE CLAMP

0-RING
BALL GUIDES

G1548-A

FIG.
6 —
Ball
Nut and
Valve Housing Disassembledprocarmanuals.com

03-08-08
Ford Design Integral Power Steering Gear

03-08-08

LONG END

AWAY FROM

SEAL
Press Ram

G1375-A

FIG. 15— Installing Sector Shaft

Outer Seal

1.
Mount the valve housing in the

holding fixture with the flanged end

up.

2.
Place the required thickness

valve spool centering shim (Fig. 6) in

the housing. Use one shim only.

3.
Carefully install the worm and

valve in the housing.

4.
Install the attaching nut in the

housing and torque it to specification

(Part 3-13).

5.
Install the lock nut (Fig. 7) and

torque it to specification (Part 3-13).

6. Place the piston on the bench

with the ball guide holes facing up.

Insert 44ie worm shaft into the piston

so that the first groove is in alignment

with the hole nearest to the center of

the piston (Fig. 16).

7.
Place the ball guide in the pis-

ton. Place the 27 balls in the ball

guide (Fig. 16) turning the worm in a

clockwise direction as viewed from the

input end of the shaft. If all of the

balls have not been fed into the guide

upon reaching the right stop, rotate

the input shaft in one direction and

then in the other while installing the

balls.
After the balls have been in-

stalled, do not rotate the input shaft
FIRST GROOVE OF WORM SHOULD BE IN

ALIGNMENT WITH THIS HOLE

G1554-A

FIG. 16—Assembling Piston on Worm Shaft

INPUT SHAFT

SECTOR
SHAFT

ADJUSTMENT
SCREW

G1547-A

FIG. 77—Adjusting Mesh

or the piston more than 3 1/2 turns

off the right stop to prevent the balls

from falling out of the circuit.

8. Secure the guides in the ball nut

with the clamp (Fig. 6).

9. Position a new lube passage O-

ring in the counterbore of the gear

housing.
10.
Apply vaseline to the teflon seal

on the piston.

11.
Place a new O-ring on the valve

housing.

12.
Slide the piston and valve into

the gear housing being careful not to

damage the teflon seal.

13.
Align the lube passage in the

valve housing with the one in the gear

housing, and install but do not tighten

the attaching bolts.

14.
Rotate the ball nut so that the

teeth are in the same plane as the sec-

tor teeth. Tighten the four valve hous-

ing attaching bolts to specifications.

15.
Position the sector shaft cover

O-ring in the steering gear housing.

Turn the input shaft as required to

center the piston.

16.
Apply vaseline to me sector

shaft journal then position the sector

shaft and cover assembly in the gear

housing. Install the steering identifica-

tion tag and two sector shaft cover at-

taching bolts. Torque the bolts to spe-

cifications.

17.
Attach an in-lb torque wrench

to the input shaft. Adjust the mesh

load to specifications as shown in Fig.

17.procarmanuals.com

03-09-01
Saginaw Design Integral Power Steering Gear

03-09-01

PART 3-9 Saginaw Design

Integral Power Steering Gear

COMPONENT INDEX

STEERING GEAR

Cleaning and Inspection (See Page 03-01)

Description

Disassembly and Assembly

Mesh Load Adjustment

Removal and Installation

Overhaul
MODEL APPLICATION
All
Models
Ford

09-01

09-03

09-01

09-02

09-04
Mercury
N/A

N/A

N/A

N/A

N/A

N/A
Meteor
N/A

N/A

N/A

N/A

N/A

N/A
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
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/\

N/A
Continental-
Mark III
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.

DESCRIPTION

The Rotary Valve Safety power

steering gear operates entirely on dis-

placing fluid to provide hydraulic fluid

pressure assists only when turning. As

the entire gear assembly is always full

of fluid, all internal components of the

gear are immersed in fluid making

periodic lubrication unnecessary. In

addition, this fluid acts as a cushion
to absorb road shocks that may be

transmitted to the driver. All fluid

passages are internal except the pres-

sure and return hoses between the

gear and pump.

The rotary valve provides a smooth

transmission through the driving range

of steering wheel effort. A torsion bar

transmits the road feel to the driver.
Response of the steering gear to effort

applied to the steering wheel has been

greatly increased.

The rack-piston nut is one piece and

is geared to the sector shaft. Lash be-

tween the sector shaft and rack-piston

nut is maintained by an adjusting

screw which is retained in the end o\'

the shaft uear (Eiiz.l).

IN-VEHICLE ADJUSTMENTS AND REPAIRS

During the breaking in period of

the vehicle, it is probable that some

of the factory adjustments will change.

These changes in adjustment do not

necessarily affect the satisfactory op-

eration of the steering gear assembly

and ordinarily do not require re-ad-

justment unless there is excessive lash

or other malfunctioning. The only ad-

justment that should be performed in

the vehicle is the total over center

position load (mesh load) to eliminate

excessive lash between the sector shaft

and rack teeth.

MESH LOAD ADJUSTMENT

1.
Disconnect the Pitman arm from
the sector shaft and remove the steer-

ing wheel hub.

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

steering wheel in both directions as

required, to discharge the fluid from

the gear.

4.
Turn the gear 1/2 turn off cen-

ter (either direction). Using a 24 in-

lb torque wrench on the steering wheel

nut, determine the torque required to

rotate the shaft slowly through a 20

degree arc.

5.
Turn the sear back to center and
repeating the method of reading tor-

que as in Step 4, above, loosen the

adjuster lock nut, turn the screw in-

ward with a 7/32-inch Allen wrench

until the reading is equal to 6 in-lbs

in excess of Step 4 above, and retigh-

ten the lock nut while holding the

screw in place.

6. Recheck the readings and re-

place the Pitman arm and the steering

wheel hub.

7.
Connect the fluid return line to

the reservoir and fill the reservoir

with C1AZ-I9582-A Fluid to the

proper level.
procarmanuals.com

03-09-02

Saginaw Design Integral Power Steering Gear

03-09-02

WORM

ADJUSTER PLUG

TORSION BAR

STUB SHAFT

SEAL

NEEDLE BEARINGS

TEFLON RING

TEFLON SEALS

SECTOR SHAFT

FIG.l —
Power
Steering Gear—Sectional View
G 1650-A

REMOVAL
AND
INSTALLATION

REMOVAL

1.
Disconnect
the
pressure
and the

return line 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

Pitman arm attaching nut.

4.
Remove
the
Pitman arni from

the sector shaft with Tool T64P-3590-

F.
Remove
the
tool from
the
Pitman

arm.

5.
If
working
on a
vehicle equipped

with
a
standard transmission, remove
the clutch release lever retracting spring

to provide clearance
for
removing
the

steering gear.

6. Support
the
steering gear then

remove
the
three steering gear attach-

ing bolts.

7.
Work
the
steering gear free
of

the flex coupling
and
remove
it
from

the vehicle.

8.
If
the flex coupling stayed
on the

input shaft, lift
it 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
ihe
wheels
are

in
the
straight-ahead position, then

install
the
Pitman
arm on the
sector

shaft. Install
and
tighten
the
sector

shaft attaching nut to specification.

5.
Move the flex coupling into place

on
the
input shaft
and
steering columnprocarmanuals.com

03-09-07

Saginaw Design Integral Power Steering Gear

03-09-07

VALVE SPOOL

DAMP EN
ERO-RING

TORSION BAR

G 1633-A

FIG. 18 —Removing Spool

from Valve Body

7.
Dip three new valve body O-

rings and teflon rings in C1AZ-

19582-A lubricant. Install the O-rings

on the valve body being careful not to

twist them. Slide the three teflon rings

into place over the O-rings being care-

ful not to stretch them any more than

necessary.

8. Lubricate a new dampener O-

ring and install it in the spool groove.

9. Assemble the stub shaft in the

valve body making sure that the

groove in the cap engages the pin in

the body. Tap the cap lightly with a

soft-faced hammer to seat it in the

valve body.

10.
Dip the valve spool in C1AZ-

19582-A. With the notch of the spool

toward the valve body, carefully slide

the spooi over the shaft and into the

body rotating it slightly to permit easy

entry. Make sure that the dampener

O-ring is distributed evenly to prevent

TEFLON RING
damage. Guide the spool to engage

the notch with the dowel in the body.

11.
Place the spool spring on the

stub shaft with the larger diameter

toward the spool. Work the small end

of the spring down over the shaft until

the small end is seated in the groove

of the stub shaft.

12.
If, during the assembly of the

valve, the stub shaft and end cap as-

sembly is allowed to slip out of en-

gagement with the valve body pin, the

spool will be permitted to enter the

valve body too far. The dampener O-

ring seal will expand into the valve

body fluid grooves preventing with-

drawal of the spool. Attempt to with-

draw the spool with a slight pull and

much rotary motion. If this does not

free the spool after several tries, make

sure that the spool is free to rotate;

place the valve body on a flat surface

with the notched end up, and tap the

spool with a wooden or plastic rod

until the O-ring seal is cut and the

spool can be removed. Replace the

dampener O-ring seal and proceed

with the assembly procedure as be-

fore.

RACK-PISTON

1.
Cut the teflon ring and the O-

ring from the piston.

2.
Place the assembly on a clean

lint-free cloth and remove the screws

that attach the ball return guide clamp

to the rack piston and remove the

clamp (Fig. 19).

3.
Lift the ball return guides from

the rack-piston.

4.
Remove Tool T65P-3D517-A

from the piston and remove the re-

maining balls.

5.
Thoroughly clean all parts.

END PLUG

RACK PI STON

DARK COLORED BALLS

(11 REQUIRED)

V

0-RING

POLISHED BALLS

(II REQUIRED)

BALL RETURN GUIDE

CLAMP

B

G1296. A
6. Lubricate a new O-ring and tef-

lon ring. Install the O-ring on the pis-

ton being qareful not to twist it. Slide

the teflon ring into place being careful

not to stretch it any more than neces-

sary.

7.
Slide worm (Fig. 20) fully into

the rack-piston. Load 16 balls into the

guide hole nearest the teflon ring

while slowly rotating the worm count-

erclockwise to feed the balls through

circuit. Alternate the dark colored

balls with the polished balls through

the circuit.

TEFLON RING

FIG. 19—Rack-Piston Disassembled
G 1632-A

FIG. 20—Assembling Rack Piston

Apply Lubriplate liberally to one of

the ball return guides and install the

six remaining balls in the guide. Place

the other half of the guide in position

and insert them into holes in the

rack-piston. Be sure that the dark ball

in the guide is installed next to the

polished ball in the rack-piston. Install

the ball return guide clamp with

screws and lock washers. Tighten the

screws to 8-12 ft-lbs.

8. The worm groove is ground with

a high point in the center. V/hen the

rack-piston passes over this high point

there should be a preload of 1-4 in-

lbs.
Clamp the rack-piston in a vise

with soft jaws with the worm shaft

pointing up. To avoid distortion, do

not tighten the vise too tight.

9. Place the valve assembly on the

worm, engaging the worm drive pins.

Rotate the worm until it extends 1

1/4 inch from the rack-piston to the

thrust bearing face. This is the center

position.

10.
Place an in-lb torque wrench

with a 3/4-inch-deep wall 12-point

socket on the stub shaft, and rotate

the wrench through an arc of approxi-

mately 60 degrees in both directions

several times, then take a torque read-

ing. The highest average reading ob-

tained with the worm rotating should

be between 1-4 in-lbs.

11.
If this reading is too high or

too low a new set of balls should beprocarmanuals.com

03-09-08
Saginaw Design Integral Power Steering Gear

03-09-08

Code

Size

6

7

8

9

10

11
Diameter

Mean

0.28117

0.28125

0.28133

0.28141

0.28149

0.28157
Size Range of Ball

(Inch)

0.28112-0.28122

0.28120-0.28130

0.28128-0.28138

0.28136-0.28146

0.28144-0.28154

0.28152-0.28162

FIG. 21 —Worm Ball Sizes

installed. Service replacement balls are

available in the sizes shown in (Fig.

21).

12.
Note the ball size stamped on

the rack-piston and install the next

size larger balls to increase the pre-

load. If no number is stamped on the

rack-piston, the original ball code size

was No. 7.

A change of one ball size larger will

increase the preload approximately

one in-lb. Final preload on replace-

ment balls should be 2-3 in-lbs.

Remove the valve assembly from

the worm and the rack-piston from

the vise.

13.
Insert Tool T65P-3D517-A into

the plug end of the rack and piston to

contact the worm shaft (Fig. 22).

Apply pressure on the tool while ro-

tating the worm shaft out of the pis-

ton and rack. Leave the tool in place

until the piston is installed in the

housing.

END OF TOOL MUST BE IN

CONTACT WITH WORM

SHAFT

Tool * T65P-3D517-A

FIG. 22—Installing Tool

in Raek-Piston
G 1631-A
ASSEMBLY OF

STEERING GEAR

1.
Secure the steering gear housing

in a vise.

2.
Lubricate the worm shaft, lower

thrust bearing, and races; then posi-

tion the thrust bearing and races on

the worm.

Align the valve body drive pin on

the worm, with the narrow pin slot in

the valve body. Be sure O-Ring seal

between the valve body and the worm

head is installed.

3.
Position the valve assembly and

the worm shaft in the housing as a

unit (Fig. 23). Do not push against the

stub shaft as this could cause the stub

shaft and cap to pull out of the valve

body, allowing the spool seal to slip

into valve body fluid grooves. Install

the valve assembly by pushing on the

outer diameter of the valve body hous-

ing with the finger tips. Be sure that

the teflon rings are not binding inside

the housing. The valve assembly is

correctly seated when the fluid return

hole in the gear housing is fully vis-

ible.

4.
Place the tool shown in Fig. 24

over the end of the stub shaft.

5.
Lubricate a new adjuster plug

O-ring and install it in the adjuster

plug groove.

6. Install the adjuster plug over the

end of the stub shaft and tighten it

DRIVE PIN
just enough to be sure all parts are

properly seated. Remove Tool T65P-

3A537-B.

7.
Install the adjuster plug locknut

loosely on the plug.

8. Tighten the adjuster plug with

wrench J7624 while rotating the input

shaft. As soon as additional drag is

noted, back the adjuster plug off 1/8

turn. Measure the input shaft drag

with an in-lb torque wrench.

9. Tighten the adjuster plug (Fig.

25) to obtain a 1-3 in-lb preload in ex-

cess of the drag that was measured

previously. Tighten the adjuster plug

lock nut and recheck the thrust bear-

ing preload. Total preload must not

exceed 8 in-lbs.

10.
Install Tool T65P-3805-A in

the steering gear housing. Position the

rack-piston as shown in Fig. 26. Be

sure that Tool T65P-3D517-A is con-

tacting the worm shaft. Push the

rack-piston inward until it contacts

the worm shaft while keeping pressure

applied to Tool T65P-3D517-A. Turn

the stub shaft clockwise until the

middle rack groove in the rack-piston

is aligned with the center of sector

shaft roller bearing. Remove the tool

from the housing.

11.
Lubricate a new O-ring with

C1AZ-19582-A and position it in the

sector shaft cover.

12.
Thread the sector shaft cover

on the adjusting screw until it bottoms

then back it off 1 1/2 turns.

13.
Install the sector shaft so that

the center gear tooth meshes with the

center groove in the rack-piston. Be

sure that the cover O-ring is in place

before pushing the cover down on the

housing.

14.
Install the cover screws and

lock washers. Tighten to 30-35 ft-lbs.

15.
Install a new adjuster lock nut

halfway on the adjuster screw.

16.
Install the end plug in the

rack-piston. Tighten the plug to 50-

100 ft-lbs torque.

17.
Lubricate a new housing end

plug O-ring and install it in the hous-

ing.

18.
Place the end plug in the gear

housing and seat it against the O-ring

seal. It may be necessary to tap the

Tool
T65P-3A537-B

STUB SHAFT

ADJUSTER

PLUG

G 1630-A

FIG. 23—Installing Valve and Worm Shaft in Housing
G 1629-A

FIG. 24 —Installing Adjuster Plugprocarmanuals.com

03-09-09
Saginaw Design Integral Power Steering Gear

03-09-09

Tool • T65P-3D517-A

LOCK NUT

ADJUSTER PLUG

G1628-A

FIG. 25
—
Adjusting Thrust Preload

end plug lightly with
a
soft-faced mal-

let
to
seat
it
properly.

19.
Snap
the
retainer ring
in
place

with
the
fingers.
Tap
lightly
on the

ring
to be
sure
the
ring
is
bottomed

securely
in the
housing.

20.
Turn
the
input shaft
to the
full

left
or
right position then turn
it
back

approximately
1 3/4
turns
to
center

the worm.
RACK PISTON

Tool - T65P.3805-A

FIG. 26—Installing Rack-Piston

21.
Place
an
in-lb torque wrench
on

the input shaft
as
shown
in Fig. 27.

22.
With
the
gear
on
center
and the

sector shaft adjuster backed
off,
meas-

ure
the
total drag. With
the
gear
on

center, adjust
the
sector shaft thrust

screw
so
that preload
is 4-8
in-lbs
in

excess
of
total preload
and
drag.

Readings
are to be
made through
an

arc
not
exceeding
20
degrees with
the

gear
on
center. Tighten
the
lock
nut.

23.
After obtaining
the
proper mesh

load, tighten
the
sector shaft adjust-

ment screw lock
nut to
20-30 ft-lbs.
jG1302
A

G1303-A

FIG. 27—Adjusting Sector

Shaft Mesh Loadprocarmanuals.com

03-10-02

Ford-Thompson Power Steering Pump

03-10-02

LOWER PRESSURE

PLATE 3D590

SPRING-3D601

UPPER PRESSURE

PLATE -3A645

RETAINER END

PLATE-3D589

CAM AND ROTOR

ASSEMBLY-
-3D607

SCREW AND WASHER

ASSEMBLY-379376-S
PULLEY-3D673

PUMP SHAFT

SEAL 3B592

PLATE AND BUSHING

ASSEMBLY-3D643

0-RING

382744-S

HOUSING GASKET

3A760

G1343-B

FIG. 2—Power Steering Pump Disassembled

To adjust the belt on 8 cyl. engines

loosen the mounting bolt in the ad-

justing slot and the nut directly above

the adjusting slot. Place a suitable pry

bar between the cast boss on the

pump mounting bracket and the cast

boss on the pump cover plate and pry

upward to correct tension.

Do not pry against the reservoir to

obtain proper belt load as it can be

deformed and cause a leak.

3.
Recheck the belt tension. When

the tension has been correctly adjusted,
tighten the bolts and the fiut to speci-

fication (Part 3-13).

POWER STEERING

PUMP DRIVE BELT

REPLACEMENT

1.
Loosen the idler pulley attaching

bolts and remove the compressor drive

belt if equipped with an air condition-

er.

2.
Loosen 3 bolts and one nut at-
taching the power steering pump to

the pump bracket, and remove the

pump drive belt.

3.
Position the power steering

pump drive belt on the pulleys.

4.
Adjust the drive belt tension as

outlined in Section 2 to specification

(Part 3-13) and tighten the pump at-

taching bolts and one nut to specifica-

tion.

5.
Install the compressor drive belt

if equipped with an air conditioner

and adjust to specification (Part 16).

REMOVAL AND INSTALLATION

POWER STEERING

PUMP REPLACEMENT

EIGHT CYLINDER

WITHOUT AIR

CONDITIONER AND

ALL SIX CYLINDER

1.
Remove the power steering fluid

from the pump reservoir by discon-

necting the fluid return hose at the

reservoir, and allow the fluid to drain

into 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

(rear nut on 8 cyl. engines only) that

attach the pump to the mounting

bracket; disconnect the belt from the

pulley and remove the pump from the

vehicle.

4.
Position the pump to the mount-

ing bracket and install the 3 bolts at

the front of pump and (rear nut on 8

cyl.
engines only) the 1 nut at the

rear. Torque to specification.

5.
Place the belt on the pulley and

adjust the belt tension (Section 2) with
Tool T63L-8620-A and tighten the

bolts and nut to specifications.

6. Torque the pressure hose fitting

hex nut to specification. Then, connect

the pressure hose to the fitting and

torque the hose nut to specification.

7.
Connect the hose to the pump.

Then, tighten the clamp.

8. Fill the power steering pump res-

ervoir with transmission fluid C1AZ-

19582-A and cycle the system to re-

move air from the steering gear sys-

tem.

9. Check for leaks and again check

the fluid level. Add fluid as necessary.procarmanuals.com