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3-1

PART 3-1 PAGE PART 3-4 PAGE


SUSPENSION,
STEERING, WHEELS PART 3-5 . . . . .3-34

POWER
STEERING
AND TIRES GENERAL SERVICE. 3-1
PART 3-2 WHEELSAND TIRES. . . . . . .3-44
SUSPENSION """""""" . .3-11
PART 3-6
PART 3-3 SPECIFICATIONS.. . . . . . 3-49
MANUAL STEERING. . . . . . . . . . .

SUSPENSION, STEERING, WHEELS


AND TIRES GENERAL SERVICE
Section Page Section Page
1 Diagnosis and Testing 3-1 SteeringGearLubricant Checking
Manual Steering 3-1 Procedure 3-8
Power Steering 3-1 Mustang 3-8
Front Wheel Alignment Checks. . . . . . . . . . . . . .3-4 Comet, Falcon, and Fairlane 3-8
Equipment Installation. . . . . . . . . . . . . . . . . . .3-4 3 Cleaning and Inspection 3-9
Caster 3-6 SteeringGear Cleaningand Inspection. . . . . . . . 3-9
Camber 3-6 Flushing the Power Steering System 3-9
Toe-In 3-6 Front End GeneralInspection. . . . . . . . . . . . . . .3-9
Front Wheel Turning Angle. . . . . . . . . . . . . .3-6 Wheel Inspection 3-9
2 Common Adjustments and Repairs .3-6 Upper Ball Joint Inspection .3-10
Caster and Camber Adjustments 3-6 Lower Ball Joint Inspection. . . . . . . . . . . . . . . .3-10
Mustang 3-6 ShockAbsorbers 3-10
Comet, Falcon, and Fairlane 3-7
Toe-In and Steering Wheel Alignment
Adjustments 3-7

D DIAGNOSIS AND TESTING


MANUAL STEERING Check Pump Belt fluid to raise the level to the base of
Table 1 lists various steering gear If the pump belt is broken, glazed, the filler neck. Do Dot overfill the res-
and linkage trouble symptoms and or worn, replace with a new belt. Use ervoir.
possible causes. Several of these only the specified type of belt.
symptoms are also common to sus- . Check For Fluid Leaks
pension frame, and wheel and tire Check The Belt Tension
troubles. For this reason, be sure that If the belt is too loose or too tight, 1. If the power steering fluid does
the cause of the trouble is in the it should be adjusted to the proper not already include yellowish green
steering gear or linkage before adjust- tension as outlined in Part 3-4. dye, pre-mix one teaspoonful of oil-
ing, repairing, or replacing any of the A "used belt" is one that has run soluble aniline dye with 2 pints of au-
steering parts. 15 minutes or longer. tomatic transmission fluid CIAZ-
] 9582-A. Then refill the reservoir
POWER STEERING Check Fluid Level with the dye solution.
Start the engine, turn the steering 2. With the engine running at idle
PRELIMINARY TESTS wheel all the way to the left and speed, turn the steering wheel all the
The following preliminary checks right several times, and shut off the way to the right stop and to the left
should always be made before per- engine. stop several times to distribute the
forming any trouble-shooting opera- Check the fluid level in the reser- dye solution throughout the hydraulic
tions. voir. If the level is low, add enough system. Do not hold the wheel against
3-2
GROUP 3 - SUSPENSION,
STEERING,
WHEELS
AND TIRES

each wheel stop for more than 3 to seals. A power cylinder seal kit the effort required to turn the wheel
5 seconds. should be used to correct leakage. at least one complete revolution in
3. Shut off the engine, and check Do not replace the power cylinder as. both directions. See Part 3-6 for the
for leaks. sembly unless the piston rod is scored specified torque which should be ap-
Fitting and Tube Seat Leak. Since or has a dull gray finish instead of a proximately equal in both directions.
most fluid leaks occur at the fittings high luster chrome finish.
and connections in a power steering Pump-Fluid Pressure Test
Check Turning Effort
hydraulic system, these parts should A fluid pressure test will show
be checked before any other part is With the front wheels properly whether the pump or some other unit
aligned and tire pressures correct, in the power steering system is caus-
replaced. check the effort required to turn the
1. With the engine running at idle ing trouble in the system. Steps out-
steering wheel. lined below should be followed to de-
speed, raise the car on a hoist.
1. With the car on dry concrete, termine the cause of the trouble.
2. Clean the outside of the con- set the parking brakes.
trol valve and the power cylinder, the 1. Measure the pump belt tension.
2. With the engine warmed up and When adjusting the belt tension on
bottom surfaces of the pump, and all running at idle speed, turn the steer-
lines and fittings. Dirt, oil, and grease the power steering pump, do not pry
ing wheel to the left and right several against the pump to obtain the prop-
should be removed from all areas times to warm the fluid.
where leaks may exist. er belt load.
3. Attach a torque wrench to the A half-inch cast boss has been in-
3. Tighten all fittings, using a spe- steering wheel hub. (Fig. 1). Check corporated on the front face of the
cial 5-flat tube wrench. Do not tight-
pump cover plate onto which a 9/16
en the fitting with a standard open
inch open end wrench can be fitted to
end wrench. If a properly tightened
fitting leaks, replace the seat. pry the pump and obtain the proper
belt tension.
Pump, Control Valve, and Power
2. Disconnect the pressure line
Cylinder Leak. If the fittings and con-
hose from the pump outlet, and install
nections do not leak, check the other a 0-2000 psi pressure gauge and shut
parts of the system.
off valve between the end of the hose
Check the hose connection at the and the pump outlet (Fig. 2).
pump for leaks, and tighten the hose Be sure that the pressure gauge is
clamp if necessary. between the pump and the shut off
Pump Leaks. If leakage occurs at valve, all connections are tight, and
the pump reservoir seal, pump outlet the shut off valve is fuUy open.
valve seals, or the support stud seal, 3. Connect a tachometer.
check the torque of the outlet valve 4. Start the engine and operate it
nut and the support stud nut. If ~;~:~~h (In. Lb.)~ C 1270-B at idle speed for at least two minutes
torque is within specifications, replace to warm up the fluid.
the reservoir seal, outlet valve seals, FIG. 1 -Checking Turning S. Cycle the steering wheel from
or the support stud seal, whichever is Effort- Typical stop-to-stop several times to expel any
required if leaks are evident other
than the lines.
Control Valve Leaks. If the control
valve is leaking (somewhere other
than the tube seats), replace all the
seals, using a control valve seal kit.
Use all the parts in the kit, and be
sure they are correctly installed.
When assembling the new seals in the
valve, an application of silicone
grease to the internal parts will help
to provide a better seal against future
leakage. Apply grease to the center-
ing spring area, especially on the cap
and spacer mating surfaces. Coat the
threads of the cap retaining bolts
with grease. The rubber boot seals,
the actuator assembly, and the met-
al cup seals in the control valve
should also be coated with silicone
grease.
Some oil remaining from the man-
ufacturing processesmay be found in
the sleeve near the ball stud. Do not
confuse this oil with leaking fluid
from the hydraulic system.
Power Cylinder Leaks. The power
cylinder may leak at the piston rod
PART 3-1 - SUSPENSION,
STEERING.
WHEELS
AND TIRESGENERAL
SERVICE
3-.1

air from the system; stop the engine. sure is higher, inspect the hoses for afore and cause undue pump and/ or
Remove the reservoir filler cap and kinks and obstructions. steering gear wear. Engine rpm
check the fluid level in the reservoir. 7. Increase the engine speed to should not exceed fast idle during
If necessary, add lubricant CIAZ- 1000 rpm; then, slowly close the this test.
19582-A to the proper level. gauge shut-off valve. With the valve
6. With the engine running at ap- fully closed, the pump pressure
proximately 500 rpm and no steering should be 750 to 900 psi. If pressure is more or less than
effort applied, and the lubricant at Do not close the valve for more specification, replace the pump as-
normal operating temperature, the than a few seconds (maximum 5 sec- sembly. If pressure is as specified and
pressure gauge should show a pres- onds), as this would abnormally in- steering efforts are heavy, the gear
sure of less than SO psi. If the pres- crease the lubricant (fluid) temper- and! or control valve could be at fault.

STEERING TROUBLE DIAGNOSIS GUIDE

If the steering wheel binds or sticks check the spool adjustment. If the ad-
when turned, or if poor recovery to justment is correct, overhaul or re-
the straight-ahead position occurs, place the control valve.
check the Pitman arm ball stud in the
Check the control valve travel reg-
control valve sleeve. If the ball stud ulator stop adjustment. If the stop is
is rubbing against the edge of the
drawn up too tightly, the ball stud
sleeve slot, the roll pin may be miss- will bind in the seats.Adjust the stop
BINDING OR POOR ing. as required.
RECOVERY If either of the idler arm bushings
are worn or damaged, replace both Check the control valve sleeveand
the socket tube for damage. Replace
bushings.
Check the steering gear adjustment parts that show signs of damage, and
(Section 2). adjust the travel regulator stop.
Check the operation of the control Check for possible interference be-
valve spool in the valve housing. If tween the steering wheel and the
the spool is binding in the housing, steering column.

If the effort required to turn the tering spring adjustment. Adjust if re-
steering wheel is greater than normal quired (Section 2).
for the entire travel of the front Check the control valve spool for
wheels, check the tire pressure then, movement. If the spool does not
test the fluid pressure. Be sure that move freely, check for, and eliminate,
there are no leaks, that the reservoir interference between the socket tube
is properly filled, and that the belt is and the valve sleeve. If the spool is
properly adjusted. If the pump output sticking in the housing, remove the
pressure is low, the pump may be de- spool and check the spool lands for
fective and should be replaced. burrs. Small burrs may be removed
HAP.D STEERING If the pressure test shows that the with crocus cloth if the edges of the
trouble is in the control valve or pow- valve lands are not rounded in the
er cylinder, remove and inspect these process. If the spool cannot be re-
units. Repair or replace any damaged paired, replace the control valve.
parts. Check the control valve ball stud
If the pressure test indicates that for free movement in the ball stud
the pressures throughout the system seats. If the stud is binding in the
are within specifications, check the seats, adjust the travel regulator stop.
following items in the order given: If the hard steering still persists,
Check the control valve spool cen- check the front end alignment.

If excessive free play or lost mo- valve travel regulator stop


tion is noticed when steering, check
the steering gear preload and mesh Check the control valve centering
adjustment. spring adjustment. If the spring ad-
EXCESSIVEFREE PLAY Check for excessive clearance be- justment nut is loose, tighten the nut
tween the steering arm ball stud and until it is snug, and then back off the
the ball stud seats. If the ball stud is nut not more than 1/4turn. Excessive
loose in the seats, adjust the control tightening may damage the stop pin.

CONTINUED ON NEXT PAGE


3-4 GROUP 3 SUSPENSION,STEERING,WHEELSAND TIRES

STEERING TROUBLE DIAGNOSIS GUIDE (Continued)

Check the pump belt tension. A and cause noise.


loose or glazed belt can cause belt Noise may result if the specified
squeal. A glazed belt, even when hose is not used or if it is improperly
NOISE routed. If noise still exists with the
properly adjusted, may slip.
Excessive torque at the pressure specified hose properly installed and
line joints may distort the tube seats routed, the pump should be replaced.

A loose pump belt or air in the fluid bushings or improper mounting nut
can cause chatter against the wheel torque. Replace the bushings if worn.
stops during an extremely sharp turn. Torque the nut to specification.
Check the belt tension, and adjust Check the power cylinder piston
STEERING CHATTER it to specifications or fill the reservoir rod insulators for looseness.If the in-
if necessary. sulators are worn, replace them. If
Check for looseness in the idler the mounting nut is loose, torque it
arm rod connection. Loosenessat this to specification, and torque the lock-
point may be due to worn mounting nut to specification.

Check the control valve spool cen- ing may damage the stop pin.
tering spring adjustment. If the ad- Check for looseness between the
RATTLES justment is loose, tighten the nut until control valve ball stud and the ball
snug, and then back off the nut not stud seats. If the stud is loose in the
more than V4 turn. Excessive tighten- seats,adjust the travel regulator stop.

Check the entire system for dam- for resistance to movement. If the
age, replacing parts as necessary. piston moves easily with little or no
Tighten a loose pump belt. resistance, the internal parts of the
Test the fluid pressure to determine power cylinder are broken or dam-
whether the trouble is in the pump, aged. Replace the power cylinder if
the control valve, or the power cyl- broken or damaged.
inder. Maladjustment of the control valve
If the pressure test indicates that spool centering spring can cause a
LOSS OF POWER ASSIST the pump is at fault, replace the loss of either right or left power as-
pump. sist. Check the adjustment, and read-
If the pressure test indicates that just if necessary.Replace all defective
the control valve or power cylinder parts.
is at fault, check as follows: Check the operation of the control
Disconnect the power cylinder pis- valve check valve. If the check valve
ton rod from the idler arm bracket. does not operate freely, replace the
Operate the piston by hand to check check valve assembly.

FRONT WHEEL ALIGNMENT EQUIPMENT INSTALLATION adjustment, install the alignment


CHECKS Equipment used for front wheel spacers as follows to establish the
Do not attempt to check and ad- alignment inspection must be accu- curb height.
just front wheel alignment without rate. Alignment height spacers (Figs. Insert the pin in the spacer hole
first making a preliminary inspection 3 and 4) are used to check caster, marked for the model being checked
of the front-end parts. camber. The spacers should be (Mustang rear does not use the pin).
Check all the factors of front wheel omitted when checking toe-in. Raise the front of the car and po-
alignment except the turning angle 1. Drive the car in a straight line sition the alignment spacers between
before making any adjustments. The far enough to establish the straight- the suspension upper arm and the
turning angle should be checked only ahead position of the front wheels, spring tower as shown in Fig. 3. The
after caster, camber, and toe-in have and mark the steering wheel hub and lower end of the spacer should be
been adjusted to specification. the steering column collar (Fig. 5). placed over the head of the ball joint
The front wheel alignment specifi- Do not adjust the steering wheel front outside attaching rivet. Posi-
cations, given in Part 3-6 are correct spoke position at this time. If the tion the alignment spacers for the
only when the car is at "Curb front wheels are turned at any time rear of the car between the rear axle
Height." Before checking or adjust- during the inspection, align the marks and the side rail as shown in (Fig. 4).
ing the alignment factors, the suspen- to bring the wheels back to the 3. Install the w h eel alignment
sion alignment spacers (Tool T65P- straight-ahead position. equipment on the car. Whichever
3OOO-Bor C) must be installed to ob- 2. With the car in position for the type of equipment is used, follow the
tain the curb heights. front end alignment inspection and installation and inspection instruc-
PART 3-1 SUSPENSION,STEERING,WHEELSAND TIRES GENERALSERVICE 3-5

TABLE l-Trouble Symptomsand PossibleCauses

POSSIBLE CAUSES OF TROUBLE

'b.
c
~ ~
'u; u
'" ~
<
.=
~
GO bo
Q
~
C e
\I) ~ :6
"' "C
~ "c; ~ GO
'" E
0 '" ~
... -'
c Q.
i= .~
~ e -;;
:;
~ '" :6 '"
~ "- .: ~ c : -= U)
"C ~
>- "C "C :; - bO
"'
\I) C "Q; C "0 -- "Q; iX c
CQ GO GO cu = ~
.,
-~
.c "C C .c .~
bD bD ~ 0 .:
(; Q ...

,I
~ "ci)
.= ~ A. .. ~
= ~
'E .. GO >- 0 ., 0 GO
~ "C ~

~
GO ~
~
GO
GO
Q
>-
=
Q in
6
~
~
'"
~
~
co
~
bO
-
~
E
0
c ~

0
Co
'"
=
v; e Q
- V) c .. '"
>. e - .- 0 IV
0 "C Go >- "C C "C
~ :c = "C ~
~
0
:; "C Q E .-
C
.c
bO
~ GO
~ '"
= ~ in = i= = c V) : ~

1. IncorrectTire Pressure x x x x x x x x x
i~Sizes Not Uniform x x x 1--i1 x Ix
I 3. Overloaded
or Unevenly
loadedVehicle ~x, x iXlTri
4. PowerSteeringFluidLevelLow-Leak x XI X
---
5. Sagging
or BrokenSpring x \ x I, x lXIX-IX
6. Glazed,
looseor BrokenPowerSteeringPumpBelt x x
7. RearSpringTieBoltOffCenter x
8. BrokenRearSpringTieBolts xI x x
9. RearSpringFrontHanger
Mislocated x
10. BentSpindleArm
11. BentSpindle
12. lack of lubrication xI x
x
x ~ x
~ x
13. Air in PowerSteeringSystem x x xl
I 14. Obstruction in Power Steering Lines x x
115.looseor WeakShockAbsorber x ~
16. Looseor WornSuspensionArm Bushings x
17. BindingFront SuspensionBall Joints or SteeringLinkage x x x ~
18. Loose,Worn,or DamagedSteeringLinkageor Connections x x x x
19. LooseSteeringGearMountings
~x x x
20. InsufficientSteeringPumpPressure x x x
21. Incorrect SteeringGearAdjustment x x x x x XI X I I I. I A

22. Incorrect BrakeAdjustment x x X' x


23. Incorrect FrontWheelBearingAdjustment x x x x x ~

24. WheelOut of Balance x x x x


I 25. Incorrect Front Wheel Alignment x x x x XI X I X
I 26. Out.ot.RoundWheel-orBrakeDrum x x
I 27. Frameor UnderbodyOutof Alignment
28. Bent RearAxle Housing
x
~x x
x ~
29. ExcessiveWearof SteeringPumpInternal Parts
30. SteeringGearValveSpoolBindingor out of Adjustment x x x
31. Obstruction
WithinSteeringGear x x x

~
3-6 GROUP 3 - SUSPENSION,
STEERING,
WHEELS
AND TIRES

POSITIVE
CAMBER
-1i-J NEGATIVE~ II-POSITIVE
I i CASTER fY CASTER
,~L OF TIRE ~
~~

~/{
rn
CAMBER FRONT OF
'
~
~-

ANGLE CAR F1216-A


ALIGNMENT MARKS F1267-B

FIG. 5-Straight Ahead FIG. 6-Caster and Camber


Position Marks-Typical Angles
CASTER used to check and adjust toe-in. Toe-
Check the caster angle at each in should only be checked and ad-
front wheel. justed after the caster and camber
FIG. 3-Typical Front has been adjusted to specification.
Caster is the forward or rearward
Alignment Spacer tilt of the top of the wheel spindle Check the toe-in with the front
Installation (Fig. 6). If the spindle tilts to the wheels in the straight-ahead position.
rear, caster is positive. If the spindle Run the engine so that the power
Tool - T 65 P - 3000 B o. C tilts to the front, caster is negative. steering control valve will be in the
The correct caster angle, or tilt, is center (neutral) position (if so
specified in Part 3-6. The maximum equipped). Measure the distance be-
difference between both front wheel tween the extreme front and also be-
caster angles should not exceed V2o. tween the extreme rear of both front
However, a difference of not more wheels. The difference between these
than 1/4° is preferred. two distances is the toe-in.
Correct toe-in, or inward pointing
of both front wheels at the front, is
CAMBER
specified in Part 3-6.
Check the camber angle at each
front wheel. FRONT WHEEL TURNING
Camber is the amount the front ANGLE
wheels are tilted at the top (Fig. 6). When the inside wheel is turned
If a wheel tilts outward, camber is 20°, the turning angle of the outside
positive. If a wheel tilts inward, cam- wheel should be as specified in Part
ber is negative. The correct camber 3-6. The turning angle cannot be ad-
angle, or outward (positive) tilt, is justed directly, because it is a result
specified in Part 3-6. The maximum
of the combination of caster, camber,
FIG. 4-Typical Rear difference between both front wheel and toe-in adjustments and should,
camber angles should not exceed V2o.
Alignment Spacer therefore, be measured only after
However, a difference of not more
Installation than l/4 ° is preferred. these adjustments have been made. If
the turning angle does not measure to
specifications, check the spindle or
tions provided by the equipment TOE.IN other suspensionparts for a bent con-
manufacturer. Alignment height spacers are not dition.

COMMON ADJUSTMENTS AND REPAIRS


After front wheel alignment factors Equipment Installation is installed be- have been removed or installed,
have been checked, make the neces- fore adjusting the caster and camber. torque the nuts to specification. Cast-
sary adjustments. Do not attempt to Caster and camber can be adjusted er and camber adjusting shims are
adjust the front wheel alignment by by removing or installing shims be- available in 1/32-inch and V8-inch
bending the suspension or steering tween the inner shaft of the front sus- thickness.
pension upper arm and the under- The 1/32 inch shims should be
parts.
body (Fig. 7). placed against the fender housing
Both caster and camber adjustment sheet metal or between the 1/8 inch
CASTER AND CAMBER
can be made at the same time by shims.
ADJUSTMENTS
loosening the nuts on the two bolts
MUSTANG that fasten the inner shaft to the un- CASTER
Be sure all the equipment listed in derbody. After the required shims To adjust caster,removeor install
PART 3-1 -SUSPENSION,STEERING,
WHEELS
AND TIRESGENERAL
SERVICE 3-7

--
ADJUSTING SHIMS F1O82-C

FIG. 7-Caster and Camber


Adjustments-Mustang

shims at either the front bolt or the


rear bolt (Fig. 7).
The removal of shims at the front
bolt or the installation of shims at the
rear bolt will cause the upper ball
joint to move forward. The removal
of shims at the rear bolt or the instal-
lation of shims at the front bolt will
causethe ball joint to move rearward.
A 1/32-inchchange of shim thickness
at either bolt will change the caster
angle approximately 1/2o. The differ- FIG. 8-Caster and Camber Adjustments-Comet, Falcon, and
ence between the shim stack thick-
Fairlane
ness at the two bolts should not ex-
ceed 1/16inch (Fig. 7). To adjust the camber, loosen the ec-
centric bolt nut and rotate the bolt SLEEVE
CAMBER and eccentric clockwise from the high
To adjust camber, remove or in- position to increase camber or coun-
stall equal shim thickness at both terclockwise to decrease camber.
bolts (Fig. 7). After the caster and camber has
The removal of equal shims at both been adjusted to specification, torque
bolts will move the upper ball joint the lower arm eccentric bolt nut and
inward. The installation of equal the strut front nut to specification.
shims at both bolts will move the ball
joint outward. A 1/16-inchchange of
shim thickness at both bolts will TOE-IN AND STEERING WHEEL
change the camber angle 1/3°. The ALIGNMENT ADJUSTMENTS
Check the steering wheel spoke po- CLAMP BOLTS Fl083-B
total shim stack thickness at each
bolt should not exceed 9/16-inch(Fig. sition when the front wheels are in
FIG. 9-Spindle Connecting
7). the straight-ahead position. If the
spokes are not in their normal posi- Rod Sleeve-Typical
COMET, FALCON, AND tion, they can be properly adjusted spoke alignment (Figs. 11 and 12).
F AIRLANE while toe-in is being adjusted. 3. Recheck toe-in and steering
Caster is controlled by the front 1. Loosen the two clamp bolts on wheel spoke alignment. If toe-in is
suspension strut (Fig. 8). To obtain each spindle connecting rod sleeve correct and the steering wheel spokes
positive caster, loosen the strut front (Fig. 9). are still not in their normal position,
nut and tighten the strut rear nut 2. Adjust toe-in. If the steering turn both connecting rod sleevesup-
against the bushing. To obtain neg- wheel spokes are in their normal po- ward or downward the same number
ative caster, loosen the strut rear nut sition, lengthen or shorten both rods of turns to move the steering wheel
and tighten the strut front nut against equally to obtain correct toe-in (Fig. spokes (Fig. 11 and 12).
the bushing. 10). If the steering wheel spokes are 4. When toe-in and steering wheel
Camber is controlled by the ec- not in their normal position, make the spoke alignment are both correct,
centric cam located at the lower arm necessary rod adjustments to obtain torque the clamp bolts on both con-
attachment to the side rail (Fig. 8). correct toe-in and steering wheel nectin.!t rod sleeves to specification.
TURN DOWNWARD TO TURN TURN UPWARD TO The sleeve position should be as
INCREASE ROD LENGTH DOWNWARD INCREASEROD LENGTH
TURN UPWARD shown in Fig. 13 when the clamp
TO DECREASE TO DECREASE
ROD LENGTH ROD LENGTH bolts are tightened.

- STEERING GEAR LUBRICANT


--. ' SLEEVE RIGHT-HAND SLEEVE F1037-B CHECKING PROCEDURE
FIG. 10-Spindle Connecting Rod Adjustment MUSTANG
1. Center the steering wheel.
WHEN TOE-IN IS CORRECT TURN BOTH CONNECTING ROO 2. Remove the steering gear hous-
TURN BOTH CONNECTING ROD SLEEVES OOWNWARD TO
SLEEVES UPWARDTO ADJUST SPOKE POSITION
ing filler plug.
SPOKE POSITION 3. Remove the upper cover-to-
housing attaching bolt.
4. With a clean punch or like in-
strument, clean out or push inward
the loose lubricant in the filler plug
hole and cover to housing attaching
bolt hole.
S. Slowly turn the steering wheel
to the right stop, lubricant should
rise within the upper cover bolt hole;
then slowly turn the steering wheel to
WHEN TOE-IN IS ' SHORTEN LEFT ROD
the left stop, lubricant should rise
NOT CORRECT TO DECREASE TOE.IN within the filler plug hole. If lubricant
LENGTHEN LEFT ROO TO
LENGHTENRIGHT ROD
does not rise in both the cover bolt
INCREASE TOE.IN hole and the filler plug hole, add lu-
TO INCREASE TOE.IN
SHORTEN RIGHT ROD bricant until it comes out both holes
TD DECREASE TOE.IN during this check.
6. Install the upper cover-to-hous-
ADJUST BOTH RDDS EQUALLY TO ~AINTAIN NORMAL SPOKE POSIT,tON F1254-A
ing attaching bolt.
FIG. 11-Toe-ln and SteeringWheel SpokeAdjustments-Comet,
Falcon,and Fairlane
COMET, FALCON, AND
WHEN TOE-IN IS CORRECT: TURNBOTH FAIRLANE
TURN BOTH CONNECTING CONNECTING ROD 1. Center the steering wheel.
ROD SLEEVESUPWARD SLEEVESDOWNWARD
TO ADJUST SPOKE TO ADJUST SPOKE 2. Remove the steering gear hous-
POSITION POSITION ing filler plug.
3. Remove the lower cover-to-
housing attaching bolt.
4. With a clean punch or like in-
~ strument, clean out or push inward
the loose lubricant in the filler plug
hole and cover to housing attaching
bolt hole.
5. Slowly turn the steering wheel
--< to the left stop, lubricant should rise
. \
,II'
I \
\ ... within the lower cover bolt hole; then
WHEN TOE-IN IS
NOT CORRECT:- - slowly turn the steering wheel to the
LENGTHENLEFT ROD TO
~'- "
I \~/
\ \ _..~..,~., LEFTROD TO
right stop, lubricant should rise with-
INCREASETOE-IN \ '. DECREASETOE-IN in the filler plug hole. If lubricant
-
SHORTENRIGHT ROD TO "~--
'""'-.
...~ ~ LENGTHEN
-- RIGHT
--- ROD
does not rise in both the cover bolt
DECREASFrnF-IN Tn INCREASETOE-IN hole and the filler plug hole, add lu-
bricant until it comes out both holes
ADJUST BOTH RODS EQUAllY TO MAINTAIN NORMAL SPOKE POSITION FIOJa-B during this check.
6. Install the lower cover-to-hous-
12-Toe-ln and Steering Wheel Spoke Adjustments-Mustang ing attaching bolt and the filler plug.
PART 3-1 SUSPENSION,STEERING,WHEELSAND TIRES GENERALSERVICE 3-9

FIG. 13-Spindle ConnectingRod SleeveClampPosition

CLEANING AND INSPECTION

STEERING GEAR CLEANING 2. Install a new pump and connect the floor. Shake each front wheel
AND INSPECTION only the pressure hose to the pump grasping the upper and lower surfaces
Wash all parts in a cleaning sol- (Part 3-4). of the tire to check the front suspen-
vent and dry with a lint-free cloth. 3. Place the oil return line in a sion ball joints and mountings for
The bearing should not be spun dry suitable container and plug the re- looseness,wear, and damage. Check
with compressedair. Inspect the shaft servoir return pipe. the brake backing plate mountings.
and worm for scoring, cracks or 4. Fill the reservoir with lubricant Torque all loose nuts and bolts to
checks, and for straightness of the CIAZ-19582-A. specifications. Replace all worn parts
shaft. Check the splines and the 5. Disconnect the coil wire to pre- as outlined in Part 3-2.
threads on the sector shaft for wear vent the engine from starting and 3. Check the steering gear mount-
and burrs. Inspect the gear teeth for raise the front wheels off the ground. ings and all steering linkage connec-
scoring, pitting and other wear. In- 6. While approximately two quarts tions for looseness.Torque all mount-
spect the ball bearings for free move- of steering gear lubricant are being ings to specifications. If any of the
ment, and the cups for wear or irreg- poured into the reservoir, turn the linkage is worn or bent, replace the
ular surfaces. Check the housing for engine over using the ignition key, at parts as outlined in Part 3-3.
cracks and the sector shaft needle the same time cycle the steering 4. Check the front wheel bearings.
bearing for free movement or other wheel from stop to stop. If any in-and-out free play is noticed,
wear. 7. As soon as all of the lubricant adjust the bearing to specification
Check the power steering pump has been poured in, turn off the igni- (Part 3-5). Replace worn or dam-
pressures. If the pump pressures are tion key, and attach the coil wire. aged bearings as outlined in Part 3-5.
not to specification and there are no 8. Remove the plug from the res- S. Spin each front wheel with a
external fluid leaks, replace the pump. ervoir return pipe, and attach the re- wheel spinner, and check and balance
If the pump has a visible leak, replace turn hose to the reservoir. each wheel as required.
the reservoir seal, outlet valve seals, 9. Check the reservoir fluid level; 6. Check the action of the shock
or support stud seal, whichever is re- if low add fluid to the proper level. absorbers. If the shock absorbers are
Do not overfill. not in good condition, the car may
quired.
10. Lower the car. not settle in a normal, level position,
11. Start the engine and cycle the and front wheel alignment may be af-
FLUSHING THE POWER steering wheel from stop to stop to fected.
STEERING SYSTEM expel any trapped air from the sys-
Should a power steering pump be- tem.
come inoperative, the shaft and pul- WHEEL INSPECTION
ley should be checked for freedom of Wheel lug nuts should be tightened
rotation. If the pump shaft does not FRONT END GENERAL to specification at the predelivery in-
turn freely (binding), it is an indica- INSPECTION spection. Loose wheel lug nuts may
tion that there is wear on the pump Do not check and adjust front cause shimmy and vibration. Elong-
internal components and the need for \vheel alignment without first making ated stud holes in the wheels may
flushing the steering system, when in- the following inspection for front-end also result from loose lug nuts.
stalling a new pump. maladjustment, damage, or wear. Keep the wheels and hubs clean.
1. Remove the power steering 1. Check for specified air pres- Stoneswedged between the wheel and
pump and pulley as outlined in Part sures in all four tires. drum and lumps of mud or grease
3-4. 2. Raise the front of the car off can unbalance a wheel and tire.
3-10 GROUP 3 SUSPENSION,
STEERING,
WHEELS
AND TIRES

Check for damage that would af- 3. Attach a dial indicator to the SHOCK ABSORBERS
fect the runout of the wheels. Wob- upper arm. Position the indicator so
Passengercars and station wagons
ble or shimmy caused by a damaged that the plunger restsagainstthe un- are equipped with hydraulic shock ab-
wheel will cause premature tire wear derside of the spindle at the upper
sorbers of the direct-acting type and
and eventually damage the wheel ball joint stud. are nonadjustable and nonrefillable,
bearings. Inspect the wheel rims for 4. With the dial indicator attached and cannot be repaired.
dents that could permit air to leak to the upper arm, position the indi-
from the tires. Before replacing a shock absorber,
cator so that the plungerrestsagainst
check the action of the shock ab-
WHEEL BALANCING the inner side of the wheelrim adja-
sorbers by grasping the bumper and
cent to the upper arm ball joint.
See the instructions provided with jouncing the car up and down. If the
the Rotunda Wheel Balancer. 5. Grasp the tire at the top and shock absorbers are in good condi-
bottom, and slowly move the tire in tion the car will immediately settle to
UPPER BALL JOINT and out (Fig. 14). Note the reading a normal position after the bumper is
INSPECTION (radial play) on the dial indicator. If released.
1. Raise the car on a frame con- the reading exceeds specifications
tact hoist or by floor jacks placedbe- (Part 3-6), replace the upper ball
neath the underbodyuntil the wheel joint. TESTING
falls to the full down position as To check a shock absorber re-
shown in Fig. 14. This will unload LOWER BALL JOINT moved from a car proceed as fol-
the upper ball joint. INSPECTION lows:
1. Raise the car on a frame con- 1. Hold the shockabsorberin the
tact hoist or by floor jacks placed be- vertical position wit h the piston
neath the underbody until the wheel in the sameposition,push in the pis-
falls to the full down position. ton rod until the shockis extendedto
2. Ask an assistant to grasp the its full length.
lower edge of the tire and move the 2. With the shock absorber held
wheel in and out. in the sameposition,push in the pis-
3. As the wheel is being moved in ton rod until the shockis compressed
and out, observe the lower end of to its shortestlength.
the spindle and the lower arm. 3. Repeat steps 1 and 2 several
4. Any movement between the times until all the air is expelled.
lower end of the spindle and the low- 4. Clamp the lower end (small di-
er arm indicates ball joint wear and ameter) in a vise in a vertical posi-
loss of preload. If any such move- tion.
ment is observed, replace the lower S. Extend the shock to its full
-"~ arm. length and then compressit to its
F 1235.A
During the foregoing check, the shortest length. There should be a
FIG. 14-Measuring Upper Ball upper ball joint will be unloaded and constant drag during the complete
Joint Radial Play may move. Disregard all such move- cycle. Any suddenloss of drag indi-
ment of the upper ball joint. Also, do catesair in the system,loss of fluid,
2. Adjust the wheel bearings as not mistake loose wheel bearings for or faulty internal valve operation.
describedin Part 3-5. a worn ball joint. Replace defective shock absorbers.
3-11

SUSPENSION

Section Page Section Page


1 Description and Operation. . . . . .3-11 Front Mustang. Suspension ......................
Upper Arm .3- 15
2 In-Car Adjustments and Repairs
Rear
Front Suspension
Suspension ,
.3-11 .3- 15
.3-12 Front Mustang.
Comet, Suspension Falcon, . . . . . . . . . . . . . . . . . . . . . .
Lower
and Fairlane Arm .3- 16
.3-12 .3- 17
Upper Ball Joint Replacement. . .3-12 .3- 17
Upper Arm Shaft and/or Bushing Front
Front Comet,
Disc
Drum Shock
Wheel Brakes BrakesFalcon, Absorber.
Spindle and ., Fairlane . . . . . . . . . . . . .3- 17
StabilizerReplacement Replacement.
..., ....... 3-13 .3- 18
3-13 .3- 18
Lower Arm Strut and/or Bushing .3- 18
Replacement , 3-13 .3- 19
Mustang. ..............., 3-13 Rear Shock Absorber. . . . . . . . . . . . . . .3- 19
Comet, Falcon, and Fairlane 3-14 Mustang. . . . . . . . . . . . . . . . . . . . . . .3- 19
3 Removal and Installation. ...., 3-14 Comet,Falcon,andFairlane(Except
Mustang. ................ ,3-14 Convertible) """""",." ,3-20
Comet and Fairlane Convertible. . .
Front Spring

3-14 3-21
Comet, Falcon, and Fairlane ,3-15 Rear Spring and/or Bushing. . . . . . . . 3-21

DESCRIPTION AND OPERATION


FRONT SUSPENSION
Each front wheel rotates on a
spindle. The upper and lower ends of
SHOCKABSORBER
the spindle are attached to upper and UPPER MOUNTING SHOCK ABSORBER
lower ball joints which are mounted BRACKET

to an upper and lower arm respective-


ly. The upper arm pivots on a bush-
ing and shaft assemblywhich is bolted Ii

to the underbody. The lower arm SPRING


~ BUMPER
pivots on a bolt that is located in an
underbody bracket (Figs. 1 and 14).
C;;Q:-
A coil spring seats between the up-
per arm and the top of the spring
I""" BALL JOINT

housing. A double acting shock ab-


sorber is bolted to the arm and the UPPER ARM ~,"""
top of the spring housing.
The swiveling action of the ball
joints allow the wheel and spindle as- SPINDLE
ECCENTRIC
semblies to move up and down with AND BOLT
changes in road surface. The swivel-
ing ball joints also permit the spindles
STABILIZER
~
and wheels to be turned to the left or
BAR ---
LINK IF
right by the steering gear and linkage. I .~",'

The pivoting action of the suspen-


sion ar~s provides an up and down INSULATOR ~
WASHERS
movement for the spindles and wheels
as required by bumps or depressions
in the road surface. The coil springs,
shock absorbers and stabilizer bar
LOWER
control the front suspension up and STRUT ARM
down movements. The struts, which
...
LOWER J
are connected between the suspension BALL JOINT
NUT FRONT
lower arms and the underbody pre- RETAININGBOLT
F 1084-E
vent the suspension arms from mov-
ing forward and backward. FIG. l-Front Suspension-Typical
3-12 GROUP 3 SUSPENSION,
STEERING,
WHEELS
AND TIRES

REAR SUSPENSION
Each rear wheel, hub, and brake
drum assemblyis bolted to the rear
axle shaft flange.The wheel and axle
shaft assemblyrotatesin the rear axle
housing. Two spring pads integral
with the axlehousing,rest on two leaf
type springs.The axle housingis fas-
tened to the springsby spring clips.
(V-bolts), spring clip plates and nuts
(Figs. 2 and 18). Each spring is sus-
pendedfrom the underbodysiderail
by a hangerat tbe front and a shack-
le at the rear. The upper end of each
shockabsorberis mountedto a brack-
et in the underbody.The lower end is
mountedto the springclip plate.
The springs and shock absorbers
provide for up and down movement
F 1085- 0 of the rear axle and wheels as re-
quired by changesin the road sur-
FIG. 2-Rear Suspension-Typical face. They also cushionroad shocks.

IN-CAR ADJUSTMENTS AND REPAIRS


HOISTING INSTRUCTIONS
Damage to suspension and/ or
steering linkage components may oc-
cur if care is not exercised when po-
sitioning the hoist adapters of 2 post
hoists prior to lifting the cat.
If a 2 post hoist is used to lift the
car, place the adapters under the
front suspension lower arms. Do not
allow the adapters to contact the
steering linkage.

UPPER BALL JOINT


REPLACEMENT
1. Position a support between the
upper arm and frame side rail as
shown in Figs. 3 and 4; then, raise the
car and position safety stands.
2. Remove the wheel and tire.
3. Remove the cotter pin and nut
from the upper ball joint stud.
4. Position the ball joint remover
tool as shown in Fig. 5. The tool
should seat firmly against the ends of FIG. 3-Upper Arm Support-Must 'ong
both studs, and not against the lower
stud nut. It may be necessary to re- three upper ball joint retaining rivets the spindle bore, and torque the re-
move the lower ball joint cotter pin and remove the ball joint. taining nut to specification.Install a
if it prevents the tool from seating on 7. Clean the end of the arm, and new cotter pin, tighten the nut if nec-
the lower stud. remove all burrs from the hole edges. essary to line up the cotter pin hole.
5. Turn the tool with a wrench Check for cracks in the metal at the 10. Lubricate the ball joint, and
until both studs are under tension, holes, and replace the arm if it is install the wheeland tire. Torque the
and then, with a hammer, tap the cracked. lug nuts to specification(Part 3-6).
spindle near the upper stud to loosen 8. Attach the new ball joint to the 11. Removethe safetystands,and
the stud from the spindle. Do not upper arm. Use only the specified lower the car.
loosen the stud with tool pressure bolts, nuts, and washers. Do not rivet 12. Removethe support from be-
alone. Raise the stud out of the the new ball joint to the arm. Torque tween the upper arm and frame.
spindle bore. the nuts to specification (Part 3-6). 13. Checkand, if necessary, adjust
6. Using a large chisel, cut off the 9. Position the ball joint stud in caster,camber,and toe-in.
PART 3-2 - SUSPENSION 3-13

upper arm outboard from the spring


tower.
7. Rotate the inner shaft so that
the retaining studs can be removed.
Remove the retaining studs with a
soft mallet (Mustang Only).
8. Unscrew the bushings from the
shaft and suspension arm; then, re-
move the shaft from the arm.
9. Position the shaft in the arm,
apply grease to the new bushings and
O-rings, and install the bushings loose
on the shaft and arm. Turn the bush-
ings so that the shaft is exactly cen-
tered in the arm. The shaft will be
properly centered when dimensions
-- WOOD
-
BLOCK F 1287-A
A and B in Fig. 6 are equal.

FIG. 4-Upper Arm Support


-Comet. Falcon. and Fairlane FIG. 7-Torque Upper Arm
Inner Shaft Bushings-Typical

and install the cotter pin, greasecap


and hub cap or wheel cover.
16. Lower the car and install the
shock absorberand upper mounting
bracket.
17. Check caster, camber, and toe-
in and adjust as necessary (Part 3-1).

STABILIZER REPLACEMENT
1. Raise the car high enough to
FIG. 6-Shaft Centered in provide working space,and place sup-
Arm-Typical ports under both front wheels.
2. Disconnect the stabilizer from
10. Fabricate a spacer from a sec- each link. Disconnect both stabilizer
tion of 3/4-inch diameter pipe or met-
retaining brackets, and remove the
al of comparable size and strength. stabilizer.
On a Mustang the spacer should be
3. Coat the necessaryparts of the
7 7/16inches long. On a Comet, Fal-
stabilizer with RUGL YDE or a com-
con, or Fairlane, the spacer should be
parable lubricant, and slide new insu-
6 15/16inches long. lators onto the stabilizer.
11. Position the spacer parallel 4. Connect the stabilizer retaining
with the inner shaft, and force the
UPPER ARM SHAFT AND/OR brackets, and connect the stabilizer to
spacer between the flanges of the up-
BUSHING RELACEMENT both links. Torque the bracket retain-
per arm (Fig. 7). ing screws and the link bolt nut to
1. Removethe shockabsorberand If the spacer can not be forced be-
uppermounting bracketas an assem- tween the arm flanges due to exces- specification.
S. Remove the supports and lower
bly. sive distortion, replace the upper arm the car.
2. Raisethe car on a hoist, install assembly.
safety stands,and removethe wheel 12. With the spacer positioned in LOWER ARM STRUT AND/OR
cover or hub cap. the arm, torque the bushings to speci- BUSHING REPLACEMENT
3. Removethe greasecap from the fication. Move the arm on the shaft
hub; then, removethe cotter pin, nut to be sure that no binding exists, then MUSTANG
lock, adjustingnut and outer bearing remove the spacer. 1. Position the block as shown in
from the hub. 13. Connect the suspension upper Fig. 3 under the upper arm for sup-
4. Pull the wheel,tire, and the hub arm to the underbody. Install the ad- port.
and drum off the spindleas an assem- justing shims (Mustang only) and re- 2. Raise the car, position safety
bly. lease the front spring. stands, and remove the wheel and
5. Install the spring compressor, 14. Remove the spring compressor tire.
Tool T63P-5310-A or the Comet and position the wheel, tire, and hub 3. Remove the strut - to - bracket
Tool 5310-Cand compressthe spring and drum on the spindle. forward retaining nut, washer and in-
(Section3). 15. Install the bearing, washer, ad- sulator bushings (Fig. 14).
6. Remove2 upper arm to spring justing nut and nut lock. Adjust the 4. Remove the 2 strut-to-iower
tower retaining nuts and swing the wheel bearing as outlined in Part 3-5 arm retaining nuts and bolts; then,
3-14 GROUP 3 SUSPENSION.
STEERING.
WHEELS
AND TIRES

lift the strut with rear insulator bush- car. Removethe tool supportingthe Installation
ing and washer from the car. upper arm. 1. Install the nut, washer and bush-
5. Install the new rear washer and ing on the strut.
insulator bushing on the forward end COMET, FALCON, AND
2. Position the strut to the front
of the strut rod. FAIRLANE
bushing bracket and to the lower arm.
6. Position the strut into the Removal Install the strut to lower arm attach-
mounting bracket and to the lower 1. Raisethe car and install safety ing bolts and nuts and torque to spec-
suspension arm. Install the strut-to- stands. ification.
arm retaining bolts and nuts, and 2. Remove the lower arm strut 3. Position the strut front bushing
torque to specification. front retainingnut, washerand bush- and washer on the strut and install
7. Install the forward insulator ing at the frame bracket {14). the adjusting nut.
bushing, washer, and nut to the for- 3. Remove 2 bolts and nuts at- 4. Tighten the strut adjusting nuts
ward end of the strut and torque the taching the strut to the lower arm against the strut frame bracket.
strut rod nut to specification. and removethe strut. s. Lower the car and check caster,
8. Install the wheel and tire, re- 4. Remove the bushing, washer camber and toe-in and adjust as nec-
move the safetv stands and lower the and nut from the strut. essary
.

REMOVAL AND INSTAllATION


HOISTING INSTRUCTIONS TooI-T63P.5310.A
ft Screw Detoil A3-Lower PI,
Damage to suspension and / or
steering linkage components may oc-
cur if care is not exercised when po-
sitioning the hoist adapters of 2 post
hoists prior to lifting the car.
If a 2 post hoist is used to lift the
car, place the adapters under the
front suspension lower arms. Do not
allow the adapters to contact the
steering linkage.
FRONT SPRING
MUSTANG
Removal
1. Raise the front of the car, posi-
tion safety stands under the frame,
and lower the car slightly.
2. Remove the wheel and tire as-
.
Detail A4-Reta;ner F1237-A
sembly.
3. Remove the shock absorber FIG. 9-Compressing or
lower retaining nuts and washers. Releasing Spring on Mustang-
4. Remove the shock absorber Lower View
upper mounting bracket retaining
nuts, and remove the shock absorber the spring by turning the tool shaft
and bracket as an assembly (Fig. nut clockwise (Fig. 8) until the spring
15). clears the suspensionupper arm.
S. On all 8-cylinder cars, remove 9. Remove the upper suspension
the air cleaner to obtain access for arm inner shaft retaining nuts from
tool installation. the engine compartment, and pull the
6. Position the upper plate (Tool FIG. 8-Compressing or arm, shaft, and retaining bolts away
T64K-53l0-A) at the spring upper Releasing Spring on from the underbody. Measure and
seat; place the bearing of tool T63P- note the total shim thickness at each
Mustang-Upper View
53l0-A on the plate and insert the inner shaft retaining bolt. Swing the
tool shaft (detail AI) through the gages the groove in the shaft screw upper arm and shaft assembly 1800
bearing and upper plate with the tool below the plate as shown. The tang out to provide clearance for spring
nut (detail A2) against the bearing of the retainer engagesthe cut-out in removal (Fig. 10).
as shown in Fig. 8. the plate. 10. Turn the tool shaft nut coun-
7. Install the tool lower plate (de- 8. Insert a 1h-inch square drive terclockwise until the spring is re-
tail A3) under the third coil from the Ilexhandle wrench in the drive hole leased (Fig. 8). Hold the tool lower
bottom (Fig. 9). Secure the plate to in the lower plate to prevent the tool plate from turning during spring re-
the shaft screw (detail AI) with the and spring from turning (Fig. 9). lease. Use a l/2-inch square drive flex-
retainer (detail A4). The retainer en- While thus holding the tool, compress handle wrench (Fig. 9).
PART 3-2 SUSPENSION 3-15

nuts, and torque to specification. In- tower retaining nuts and swing the
stall the shock absorber lower retain- upper arm outboard from the spring
ing nuts on the bolts at the under- tower (Fig. 13).
side of the spring lower seat and 7. Release the spring compressor
torque to specification. tool and remove the tool from the
10. Install the wheel and tire as- spring. Then, remove the spring from
sembly, remove the safety stands and the car (Fig. 10).
lower the car.
11. Check and, if necessary, ad. Installation
just caster, camber, and toe-in. 1. Place the spring upper insulator
on the spring and secure in place with
COMET, FALCON, AND tape.
FAIRLANE 2. Position the spring in the spring
tower. Install the spring compressor,
Removal Tool T63P-5310-A and compress the
1. Removethe shockabsorberand spring.
upper mounting bracket as an as- 3. Swing the upper arm inboard
sembly. and insert the bolts through the holes
2. Raisethe car on a hoist, install in the side of the spring tower.. Then,
safety stands,and removethe wheel install the retaining nuts and torque
cover or hub cap. them to specification.
3. Remove the grease cap from 4. Releasethe spring pressure and
FIG. 10-Removing or the hub; then, removethe cotter pin, guide the spring into the upper arm
nut lock, adjusting nut and outer spring seat. The end of the spring
Installing Spring-Mustang bearing from the hub. must seat against the tab on the
4. Pull the wheel,tire and the hub spring seat.
11. Remove the components of the and drum off the spindleas an assem- 5. Remove the spring compressor
spring compressing tool; then, remove bly. and position the wheel, tire, and hub
the spring as shown in Fig. 10. 5. Install the spring compressor, and drum on the spindle.
Tool T63P-5310-A or the Comet 6. Install the bearing, washer, ad-
Installation Tool 5310-C(Fig. 11), and compress justing nut and nut lock. Adjust the
1. With the upper arm turned out the spring (Figs. 9 and 12). Either wheel bearing as outlined in Part 3-5
of the way for clearance, install the tool can be used. and install the cotter pin, grease cap,
spring in the housing (Fig. 10). 6. Remove2 upper arm to spring and hub cap or wheel cover.
2. Install the spring compressor
tool and compress the spring. 7. Lower the car and install the
3. Swing the suspensionupper arm shock absorber and upper mounting
assembly inboard, and insert the arm bracket.
inner shaft retaining bolts through the 8. Check caster, camber, and toe-
mounting holes in the underbody. in and adjust as necessary (Part 3-1).
4. From inside the engine com-
FRONT SUSPENSION UPPER
partment, install but do not tighten ARM
the nuts and lockwashers on the two
inner shaft retaining bolts. The speci- MUSTANG
fied keystone type lock washers must Removal
be used.
1. Raise the front of the car, posi-
s. Install the adjusting shims on
tion safety stands under the frame,
both bolts between the inner shaft
and lower the car slightly.
and the underbody. Install the same
shim thicknesses that were removed 2. Remove the wheel and tire as-
from each bolt when the arm was dis- sembly.
connected. Torque the inner shaft re- 3. Remove the shock absorber
taining nuts to specification. lower retaining nuts and washers.
6. Turn the tool shaft nut counter- 4. Remove the shock absorber up-
clockwise to release the spring (Fig. per mounting bracket retaining nuts,
8). As the spring is being released, and remove the shock absorber and
guide the spring into its lower seat. bracket as an assembly (Fig. 15).
7. Remove the components of the On all 8-cylinder cars, remove the
spring tool. air cleaner to obtain access for tool
8. Position the shock absorber in installation.
the spring housing so that the holes 5. Install the spring compressor,
in the upper mounting bracket en- Tools T63P-5310-A and T64K-5310-
gage the upper retaining studs in the A and compress the spring (Figs. 8
housing (Fig. 15). The lower retain- and 9).
ing bolts go through the mounting 6. Position a safety stand under
holes in the spring lower seat. the lower arm.
9. Install the bracket retaining 7. Remove the cotter pin from the
3-16 GROUP 3 - SUSPENSION,
STEERING,
WHEELS
AND TIRES

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. 5. The
tool should seat firmly against the
ends of both studs and not against the
stud nuts.
9. Turn the tool with a wrencb un-
til the tool places the studs under ten-
sion; then, tap the spindle near the
upper stud with a hammer to loosen
the stud in the spindle. Do not loosen
the stud in the spindle with tool pres-
sure only. If both arms are being re-
moved, loosen the lower stud in the
same manner as the upper stud.
10. Remove the nut from the up-
per stud and lift the stud out of the
spindle.
11. Remove the upper arm inner
shaft retaining nuts from the engine
compartment, and remove the upper
arm. Measure and note the total shim
thickness at each inner shaft bolt.
12. Wipe off all loose dirt from the
-- - ~- upper arm parts. Do not wash the ball
T 63p.53100A T 66p.53100A OR B "1288-A joint with a solvent.
FIG. 12-Spring CompressorInstalled-Upper View-Comet, Falcon Installation
and Fairlane 1. Position the upper arm on the
underbodymountingbracket,and in-
stall but do not tighten the nuts and
lockwasherson the two inner shaft
retaining bolts. The specified key-
stone-typelockwashersmust be used.
2. Install the adjusting shims on
both bolts betweenthe inner shaft
and the underbody.Install the same
shim thicknessesthat were removed
from both bolts during disassembly
(Fig. 7, Part 3-1). Torque the nuts to
specification.
3. Position the upper ball joint
stud in the top of the wheel spindle,
and install the stud nut. Torque the
nut to specification,and continueto
tighten it until he cotter pin hole and
slotsline up. Install a new cotter pin.
4. Releasethe coil spring, remove
the tool, and install the front shock
absorberand the wheel and tire as-
sembly.
COMET, FALCON, AND
FAIRLANE
Removal
1. Removethe front shockabsorb-
er from the car.
2. Raisethe car and install safety
standsunder the frame siderails.
3. Removethe hub cap or wheel
FIG. 13-Compressing Spring-LowerView-Comet,Falcon, cover and the wheel and tire.
and Fairlane 4. Install the spring compressor,
PART 3-2 - SUSPENSION 3-17

Tools T63P-5310-A (Tool-5310-C- FRONT SUSPENSION LOWER and slots are aligned, and install a new
Comet), T64K5310-A or B, and ARM cotter pin.
T66P-5310-Aor B and compressthe 6. Torque the lower arm-to-un-
MUSTANG derbody pivot bolt and nut to speci-
spring (Fig. 13).
5. Removethe cotter pin from the fication.
Removal
upper ball joint stud and loosenthe 7. Remove the safety stands and
1. Position a support betweenthe
stud nut. lower the car.
upper arm and side rail as shownin
6. Position the ball joint remover Fig. 3. 8. Remove the support from be-
tool as shown in Fig. 5. The tool 2. Raise the car, position safety tween the upper arm and frame.
stands, and remove the wheel and 9. Check and, if necessary, adjust
shouldseatfirmly againstthe endsof
tire. caster, camber, and toe-in.
both studsand not againstthe lower
stud nut. It may be necessaryto re- 3. Removethe stabilizer bar and COMET, FALCON, AND
movethe lower ball joint cotter pin if link retaining nut, disconnectthe bar FAIRLANE
it preventsthe tool from seatingon from the link, and remove the link
the stud. bolt. Removal
4. Removethe strut to lower arm 1. Raise the car and position safe-
7. Turn the tool with a wrenchun- retaining nuts and bolts. Remove
til both studsare under tension;then, ty stands under the side rails.
the steeringarm stop from the strut. 2. Remove the hub cap or wheel
tap the spindle near the upper stud 5. Removethe cotter pin from the
with a hammer to loosen the stud cover.
nut on the lower ball joint stud, and 3. Remove the wheel, tire, and hub
from the spindle. Do not loosenthe loosenthe nut one or two turns. Do and drum as an assembly.
stud with tool pressurealone. not removethe nut from the stud at 4. Remove the stabilizer bar link
8. Removethe ball joint remover this time. retaining nut and remove the wash-
tool and remove the ball joint stud 6. Straightenthe cotter pin on the ers, bushings, spacer, and link bolt
nut from the stud. upper ball joint stud nut. Positionthe
ball joint remover tool betweenthe (Fig. 14).
9. Remove2 nuts and washersre- 5. Remove the 2 strut to lower
taining the upper arm to the spring upper and lower ball joint studs in
arm attaching nuts and bolts.
tower. Pull the upper arm awayfrom the reverseposition from that shown
in Fig. 5. The tool shouldseatfirmly 6. Remove the lower ball joint
the spring tower, lift the ball joint aginst the ends of both studs and stud nut cotter pin and loosen the nut
stud from the spindle, and remove not against the stud nuts. one or two turns. Do not remove the
the upper arm from the car. 7. Turn the tool with a wrenchun- nut from the stud at this time.
10. Remove2 nuts and bolts and til the tool placesthe studsunder ten- 7. Position the ball joint remover
removethe spring pivot from the up- sion,and tap the spindlenearthe low- tool between the upper and lower ball
per arm. er stud with a hammerto loosenthe joint studs in the reverse position (up-
stud in the spindle.Do not loosenthe side down) from that shown in Fig.
Installation stud in the spindlewith tool pressure 14. The tool should seat firmly against
1. Position the spring pivot to the only. If both armsare beingremoved, the ends of both studs and not against
loosen the upper stud in the same the stud nuts.
upper arm and install the 2 attaching
manner as the lower stud. 8. Turn the tool with a wrench un-
bolts and nuts. Torque the nuts to
8. Removethe nut from the low- til the studs are under tension. Tap
specification. er ball joint stud, and lower the arm. the spindle near the lower stud with a
2. Position the upper arm to the hammer to loosen the stud in the
9. Removethe lower arm to un-
spring tower and the ball joint stud derbody pivot bolt, nut and washer. spindle. Do not loosen the stud with
to the spindle. Install but do not Remove the lower arm. tool pressure only.
tighten the ball joint stud nut. 9. Remove the tool and remove
3. Position the upper arm to Installation the nut from the lower ball joint stud.
spring tower and install the washers 1. Position the lower arm to the 10. Mark the location of the ec-
and retaining nuts. Torque the nuts underbody bracket and install the centric and eccentric bolt at the low-
to specification. pivot bolt, washer,and nut loose. er arm to underbody attachment.
4. Releasethe spring compressor 2. Raisethe lower arm, guide the 11. Remove the nut, bolt, and ec-
tool while aligning the spring with lower ball joint stud into the spindle centrics attaching the lower arm to
the upper arm springpivot. Then, re- bore, and install the stud retaining the underbody and remove the low-
movethe tool. nut loose. er arm.
5. Torque the ball joint stud nut 3. Install the stabilizer link bolt, Installation
to specification(Part 3-6). Continue washers,bushingsand spacer.Con-
nect the stabilizerbar to the link. In- 1. Position the lower arm to the
to tighten the nut until the slots in underbody and install the bolt, ec-
the nut are in line with the hole in stall the retaining nut and torque to
centrics, and nut.
the ball joint stud. Then, install a specifications(Fig. 14).
4. Position the strut and steering 2. Position the ball joint stud in the
new cotter pin. arm stopto the lower arm. Install the spindle bore and install the retaining
6. Install the wheel and tire and retaining bolts and nuts, and torque nut.
the hub cap or wheel cover. to specification. 3. Adjust the eccentrics to the
7. Remove the safety standsand 5. Torque the lower ball joint stud previous marked location and torque
lower the car. nut to specification,continueto tight- the nut to specification (Part 3-6).
8. Install the shock absorber. en the nut until the cotter pin hole 4. Position the strut to the lower
3-18 GROUP 3 - SUSPENSION,STEERING,WHEELSAND TIRES

BUSHING
g 3047
INSULATOR
5415 I~
Ir- ~~

I~ BRACKET
) ,
i -fi-18AO17 ~" .
-,...
. "\ ~

,. ~ :-:"---:UPPERBALL
- 0 ~ ~i;? ~ " -JOINT 3082
SPRING
, S310

r;;;j(i'~:;;:i~ ',..
\6 ~
LOWERARM

-(O'\\~cr I
~
3042
--
at
""

...t~!:;
\Ii-
':~;;$;i;;

~"
;,; ~:~~7ER\,~
-::r'~ ~~ ~CAM
~'"
3048
.
SHOCK ABSORBER
18045

:
r
~
~
BUSHING
- ,t )))1/ ~ ~3~--~~

i '""'
.~ 1 SEAT~
3042 I
,

I
~

"
( SEAT
3388

1
\
304~
WASHER BUSHING 3A187
3A187 3A187

STABILIZER BAR
~ BUSHING
5A486

SPACER
.5490
~
. ~
STUD '"\
SPINDLE
3105-6

5482
~ BUSHING J' 5A486
,
~- ,
LDWER BALL JDINT
BRACKET ~-=:=5_5~- /
5486 3042
F 1152-C

FIG. 14-Front Suspension


Assembly-Comet,Falcon,and Fairlane-Typicalof Mustang

arm and install the attaching bolts 4. Pull the wheel, hub, and drum and guide the upper ball joint stud in-
and nuts. Torque the nuts to specifi- assembly off the wheel spindle. to the spindle. Install the stud nut.
cation (Part 3-6). 5. Remove the brake carrier plate 3. Torque the upper stud nut and
5. Position the stabilizer bar link from the spindle. Support the plate to then the lower stud nut to specifica-
to the lower arm and install the bolt, prevent damage to the brake hose. tion. Continue to tighten both nuts
washers,bushings,spacer,and retain- 6. Disconnect the spindle connect- until the cotter pin holes and slots
ing nut. Torque the nut to specifica- ing rod end from the spindle arm us- line up. Install new cotter pins.
tion (Part 3-6). ing Tool 3290-C. 4. Connect the spindle connecting
6. Torque the lower ball joint stud 7. Remove the cotter pins from rod end to the spindle arm.
nut to specification (Part 3-6) and both ball joint stud nuts, and loosen 5. Install the brake carrier plate
install the cotter pin. the nuts one or two turns. Do not re- on the spindle, and torque the bolts
7. Install the wheel, tire, and hub move the nuts from the studs at this to specification.
and drum on the spindle and adjust time. 6. Install the wheel and drum and
the wheel bearing (Part 3-5). 8. Position the ball joint remover adjust the wheel bearing (Part 3-5).
8. Install the hub cap or wheelcov- tool between the upper and lower ball 7. Remove the safety stands, and
er, removethe safetystands,and low- joint studs (Fig. 5). The tool lower the car.
er the car. should seat firmly against the ends of 8. Remove the support from be-
9. Check caster, camber, and toe- both studs and not against the stud tween the upper arm and frame.
in and adjust as necessary. nuts. 9. Check and, if necessary, adjust
9. Turn the tool with a wrench un- caster, camber, and toe-in.
FRONT WHEEL SPINDLE til the tool places the studs under ten-
DRUM BRAKES sion, and, with a hammer, tap the DISC BRAKES
Removal spindle near the studs to loosen them
in the spindle. Do not loosen the Removal
1. Position a support betweenthe studs in the spindle with tool pres- 1. Remove the hub cap or wheel
upper arm and frame as shown in sure alone. cover, and remove the wheel and tire
Figs. 3 and 4; then, raisethe car and 10. Remove the stud nuts and re- from the hub.
position safetystands. move the spindle from both studs. 2. Remove two bolts attaching the
2. Removethe hub cap or wheel caliper to the caliper bracket. Re-
cover. Installation move the caliper from the rotor and
3. Remove the grease cap from 1. Position the spindle on the low- wire it to the underbody to prevent
the hub; then, remove the adjusting er ball joint stud and install the stud damage to the brake hose.
nut, washer,and outer bearing cone nut (Fig. 14). 3. Remove the grease cap from
and roller assembly. 2. Raise the lower suspensionarm, the hub, then, remove the adiustinll
PART 3-2 SUSPENSION 3-19

nut, washer,and outer bearing cone clearance and restore normal brake 3. Install the 2 washersand re-
and roller assembly. pedal travel. taining nuts on the shock absorber
4. Pull the hub and rotor assembly lower studs and torque to specifica-
off the wheelspindle. FRONT SHOCK ABSORBER tion.
5. Removefour bolts and nuts and REMOVAL 4. Install the 3 shockabsorberup-
removethe splashshield and caliper 1. Raise the hood and remove 3
per mountingbracketto springtower
bracket from the spindle. retainingnuts and torque to specifica-
shock a'bsorber upper mounting
6. Disconnectthe spindleconnect tion. Then, removethe safety stands
bracket to spring tower retaining
ing rod end from the spindlearm us- and lower the car.
nuts.
ing Tool-3290-C. 2. Raise the front of the car and
7. Remove the cotter pins from REAR SHOCK ABSORBER-
place safety stands under the lower
both ball joint stud nuts, and loosen arms. MUSTANG
the nuts one or two turns. Do not re- 3. Remove 2 shock absorber lower
move the nuts from the studsat this Removal
retaining nuts and washers (Fig. 15).
time. 4. Lift the shock absorber and up- 1. Disconnect the shock absorber
8. Position the ball joint remover per bracket from the spring tower from the spring clip plate (Fig. 18).
tool betweenthe upper and lower ball (Fig. 15) and remove the bracket 2. On the passenger car, remove
joint studs (Fig. 5). The tool should from the shock absorber. the shock absorber accesscover from
seat firmly againstthe ends of both the luggage compartment (Fig. 16).
studsand not againstthe stud nuts.
9. Turn the tool with a wrenchun- SHOCK ABSORBER ACCESS COVER
til the tool placesthe studsunder ten-
sion, and, with a hammer, tap the
spindlenear the studsto loosenthem
in the spindle. Do not loosen the
studs in the spindle with tool pres-
sure alone.
10. Positiona floor jack under the
lower suspensionarm.
11. Removethe upper and lower
ball joint stud nuts; lower the jack
and remove the spindle.
Installation
1. Position the spindle on the low-
er ball joint stud and install the stud
nut (Fig 14). Torque the nut to
specification and install the cotter pin.
2. Raise the lower suspension arm,
and guide the upper ball joint stud in-
to the spindle. Install the stud nut.
LUGGAGE COMPARTMENT
3. Torque the nut to specifications FLOOR PANEL Fl086-A
and install the cotter pin. Then, re-
move the floor jack. FIG. 16-Rear Shock
4. Connect the spindle connecting Absorber Access(over
rod end to the spindle arm and install
the retaining nut. Torque the nut to On the Ranchero, remove the re-
specification and install the cotter taining screws, and lift the forward
pin. half of the floor panel from the body;
S. Position the caliper bracket and then, remove the access cover from
splash shield to the spindle and install the opening in the floor pan over the
the attaching bolts and nuts. Torque LOWER RETAINING BOLTS F1239-A shock absorber.
the nuts and bolts to specification. On station wagons, remove the ac-
6. Install the hub and rotor on the FIG. 1 5-Removing or cess cover from the opening in the
spindle. Installing Front Shock seat riser over the shock absorber.
7. Position the caliper to the ro- 3. Remove the shock absorber up-
Absorber-Typical
tor and caliper bracket and install the per retaining nut.
attaching bolts. INSTALLATION 4. Compress the shock absorber
8. Install the wheel and tire on the 1. Install the upper mounting and remove it from the car. Remove
hub anI;! adjust the wheel bearing bracket on the shock absorber and the bushings and washers from the
(Part 3L5). torque to specification. shock absorber studs.
9. Install the hub cap or wheel 2. Position the shock absorber and
cover. upper mounting bracket in the spring Installation
10. Before driving the car, pump tower, making sure the shock ab- 1. Place the bushings and washers
the brake pedal several times to ob- sorber lower studs are in the pivot on the shock absorber studs.
t,,;n nnrm"J hr"~p linino tn rntnr nl"tp hnlp~ 2- rnnn~~t the linneT ~tud to the
3-20 GROUP 3 SUSPENSION,
STEERING,
WHEELS
AND TIRES

mounting, and install the bushing, remove the shock absorber access spring clip plate (Fig. 18). Compress
washer, and nut on the stud. Torque coverfrom the floor pan. Removethe the shock absorber and remove it
the nut to specification, and install nut, outer washer,and rubber bush- from the car.
the cover (on a station wagon or car). ing that retain the shock absorberto 4. If the shock absorber is serv-
On the Ranchero, after installing the upper mounting in the floor pan iceable and requires new bushings re-
the nut to specification, and install (Fig. 17). move the inner bushings and washers
stall the forward half of the floor from the shock absorber studs.
panel. SHOCK ABSORBER
UPPERRETAININGNUT
3. Connect the lower stud to the Installation
spring clip plate, and install the bush- 1. Place the inner washerand
ing, washer, and nut on the stud. Be bushing on each shock absorber stud.
sure the spring clip plate is free of 2. Expand the shock absorber and
burrs. Tighten the nut to specifica- position it to the spring clip plate and
tion. to the mounting in the floor pan.
COMET, FALCON, AND 3. Connect the lower stud to the
FAIRLANE (EXCEPT CONVERT- spring clip plate, and install the bush-
ing, washer, and nut on the stud (Fig.
IBLE) VER "11~~_4
~

18). Be sure the spring clip plate is


Removal FIG. 17-Rear Shock free of burrs. Tighten the nut to
1. Open the luggage compartment Absorber Upper Mounting specification.
door, and remove the spare wheel and 4. From the luggage compart-
tire. On a station wagon, remove the 3. Raise the car and remove the re- ment, install the bushing washer and
floor bed panel (14 screws). taining nut, outer washer and bush- retaining nut to the upper mounting
2. Fold back the floor mat and ing from the shock absorber at the stud (Fig. 17). Torque to specifica-

F 1153-C

FIG. 1 8 .Rear SprinQand Shock Absorber-Typical


PART 3-2 - SUSPENSION 3-21

tion. On a station wagon,replacethe


fioo~bed panel (14 screws).
5. Place the sparewheel and tire
in the luggagecompartment,and se-
cure it in the storageposition.
COMETANDFAIRLANE
CONVERTmLE
1. Remove the rear seat cushion
and seat back.
2. Partially raisethe car on a hoist.
With an assistantunder the car hold-
ing the shock absorber,remove the
nut from the top of the shock ab-
sorber.
3. Remove the lower shock ab-
sorberattachingnut and removethe
shock absorber.
4. Position the washersand bush-
ings on the shock absorbe~and posi-
tion the shock absorberto the lower
attachment.Install the bushing,wash-
er, and retaining nut and torque FIG. 19-Rear Spring Front Bushing Removal-Typical
the nut to specification(Part 3-6). specialtool combinationto the spring nut on the hanger bolt and tighten
5. Lower the car and install the front eyeas shownin Fig. 20. finger tight.
bushing,washer,and retainingnut on 2. While holding the tool nut, tight- 6. Torque the rear shacklelock-
the top of the shockabsorber.Torque en the tool bolt againstthe tool thrust nuts to specification.
the nut to specification. washer, adapter, and detail A4 to 7. Lower the rear axleuntil it rests
6. Install the rear seat back and force the bushinginto the spring eye on the spring.Positionthe springclip
seatcushion. as shown. plate on the clips (U-bolts). Install
3. Position the spring under the the V-bolt nuts and torque to specifi-
REAR SPRING AND/OR
rear axle and insert the shackleas- cation.
BUSHING sembly into the rear hanger bracket 8. Connect the lower end of the
REMOVAL and the rear eyeof the spring. shock absorber to the spring clip
1. Raise the car on a hoist and 4. Install the shackle inner bush- plate.
placesupportsbeneaththe underbody ings, the shackleplate, and the lock- 9. Place safety stands under the
and under the axle. nuts. Tighten the locknuts finger rear axle, lower the car until the
2. Disconnect the lower end of tight. spring is in the approximate curb
tbe shock absorberfrom the spring 5. Position the spring front eye in load position, and then torque ~he
clip plate, and push the shockout of the front hanger,slip the washeron front hangerstud locknut to specifi-
the way. the front hangerbolt, and (from the cation.
3. Remove the spring clip plate inboard side) insert the bolt through 10. Removethe safety standsand
nuts from the V-bolts; then, remove the hanger and eye. Install the lock lower the car.
the plate (Fig. 18). T64K-5781-B2 (Adapter)
4. Removethe two retainingnuts, , -83 (Nut)
I -81 (BaIt)
the rear shackle bar, and the two
shackle inner bushings.
5. Removethe rear shackleassem-
bly and the two outer bushings.
6. Removethe front hanger bolt,
nut, and washerfrom the eye at the
forward end of the spring. Lift out
the spring assembly.
7. If the front bushingis beingre-
placed,assemble the specialtool com- Too/-T64N-S78I-AI,- A4.
bination to the bushingin the spring
front eye asshownin Fig. 19.
8. While holding the tool nut, Tool

tighten the tool bolt againstthe tool


thrust washer, the adapter, and de-
tail AI. This operationwill force the
bushingout of the spring eyeinto de-
tail A4 of the tool asshown. '"

SPRING FR~T EYE


F1241-A
INSTALLATION
1. Assemble the bushing and the FIG. 20-Rear Springfront BushingInstallation-Typical
~
3-22

MANUAL STEERING

Section Page
21 Steering Gear Worm and Sector
Description
In-Car Adjustment and Repairs
.3-22
.3-23

Adjustments. . . . . . . . . . . . . . . . . . . . . . . 3-23
Steering Wheel Spoke Position
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . .3-24
Steering Wheel Replacement. . . . . . . . . . . . . .3-24
Steering Column Shift Tube
Replacement. ...................... 3-24
Falcon With Standard Transmission-
Comet and Fairlane With Standard
Transmission and Standard Steering. .3-24
Comet and Fairlane With Standard
Transmission and Power Steering... .3-24
Falcon With Automatic Transmission-
Comet and Fairlane With Automatic
Transmission and Standard Steering. . 3-25
Comet and Fairlane With Automatic
Transmission and Power Steering. . . . 3-26
Steering Column Upper Bearing
Replacement """"""""""'" 3-26
Comet and Fairlane With Power
Steering. . . . . . . . . . . . . . . . . . . . . . . . . 3-27
All ModelsExceptCometand
FairlaneWith PowerSteering. . . . . . . . 3-27

DESCRIPTION
The steeringgear (Fig. 1) is of the The worm bearing preload is con- in the housing cover.
worm and recirculatingball type.The trolled by the large bearing adjuster A steering gear identification tag
sectorshaft rotatesin needlebearings which is threaded into the housing.
that are pressedinto the gear hous- The sector shaft mesh load is con- is provided under one of the cover
ing. trolled by an adjusting screw located attachinlZ bolts (PilZ. 2).
PART 3-3 - MANUALSTEERING 3-23

SERIAL NUMBER OR DATE CODE G1218-A

FIG. 2-Steering Gear


Identification Tag

HOISTING INSTRUCTIONS 1. Disconnect the Pitman arm


from the sector shaft.
ADJUSTER LOCK NUT FILLERPLUG
Damage to suspension and/or 2. Remove the steering wheel,
steering linkage components may oc- spring and the centering cone from
cur if care is not exercised when po- the shaft and note the relation of the
sitioning the hoist adapters of 2 post shaft to the bearing.
hoists prior to lifting the car. 3. If the shaft is not centered,at-
If a 2 post hoist is used to lift the tach a spring scaleto it.
car, place the adapters under the 4. Center the shaft by pulling on
front suspension lower arms. Do not the scaleand note the reading.
allow the adapters to contact the 5. If more than 20 lbs. pull is re-
quired to center the shaft, the steer-
steering linkage. ing column should be aligned as de-
tailed in steeringgearinstallation,be-
STEERING GEAR WORM AND fore adjustingthe preload and mesh
SECTOR ADJUSTMENTS load.
6. Loosenthe nut which locks the
The ball nut assembly and the sec- sector adjusting screw (Fig. 3), and
tor gear must be adjusted properly turn the adjusting screw counter-
to maintain minimum steering shaft clockwise. - - -. --
end play (a factor of preload adjust- 7. Measurethe worm bearingpre- SECTORSHAFT
ment) and minimum backlash be- load by attaching an in.-Ib. torque ADJUSTING SCREW G1071-B
tween sector gear and ball nut. There wrenchto the steeringwheelnut (Fig.
are only two possible adjustments 4). With the steeringwheeloff center, FIG. 3-Steering Gear
within the recirculating balltype read the pull required to rotate the Adjustments- Typical
steering gear, ahd these should be input shaft approximately 11/2turns
made in the following order to avoid either sideof center.If the torque or (Part 3-6), adjust as explained in the
damage or gear failure. preload is not within specification next step.
3-24 GROUP 3 - SUSPENSION,STEERING,WHEELSAND TIRES

taching nut and remove the steering taching screws and remove the bear-
wheel from the shaft, using the tool ing retainer and turn signal switch
shown in Fig. 5. from the steering column (Fig. 6).
8. Lift the spring and centering
sleeve from the steering shaft.
9. Loosen 2 flange bolt nuts re-
taining the flange to the steering col-
umn tube (Fig. 6).
10. Pull upward on the shift lever
socket and remove the flange and
shift lever socket from the steering
column.
11. Lift the shift tube from the
steering column.

Installation
FIG. 4-Checking Pre-load 1. Position the shift tube in the
- Typical steering column and through the
Tool - 3600 - AA
or Tool 3826
shift arms. Be sure the shift tube is
8. Loosen the steering shaft bear- Gl272-A inserted through both shift anus.
ing adjuster lock nut, and tighten or 2. Position the shift lever socket
back off the bearing adjuster (Fig. 3) FIG. 5-Removing Steering on the steeringcolumn and engageit
to bring the preload within the spec- Wheel- Typical with the shift tube (Fig. 6).
ified limits. 3. Position the flange to the hub
9. Tighten the steering shaft bear- 3. With the front wheels straight
so that the headsof the 2 flangebolts
ing adjuster lock nut, and recheck the forward, position the steeringwheel engagein the slots of the steering
on the steeringshaft with the post on
preload. the steeringwheel hub at the top. column tube. Then, tighten the 2
10. Turn the steering wheel slowly flangebolt nuts.
to either stop. Turn gently against the 4. Apply Loctite Sealer (C3AZ-
4. Position the centeringsleeveon
stop to avoid possible damage to the 19554-A) to the steering shaft the steeringshaft and seatit into the
baD return guides. Then rotate the threadsand install the steeringwheel
nut on the shaft. Torque the nut to flangebearing.
wheel 2Y4 turns to center the ball 5. Feed the turn signal switch
nut. specification. wires through the steering column
5. With the front wheels straight
11. Turn the sector adjusting and position the switch and bearing
screw clockwise until the specified forward (post on steeringwheel hub retainer to the flange.
pull (Part 3-6) is necessaryto rotate
at the top), install the horn ring (or 6. Install the 3 bearing retainer
the worm past its center high spot button) assembly and the related attaching screws.
(Fig. 4). No perceptible backlash is parts. 7. Position the shift lever to the
permissable at 30° on either side of shift lever socket and install the
center. STEERINGCOLUMN SHIFT
TUBE REPLACEMENT springs and trunnion.
12. While holding the sector ad- 8. Apply 2 drops of Loctite sealer
justing screw, tighten the locknut to FALCON WITH STANDARD (C3AZ-19554-A) to the threads of
specification and recheck the back- TRANSMISSION-COMET AND the turn signalswitchlever and install
lash adjustment. FAIRLANE WIm STANDARD the lever.
13. Connect the Pitman arm to. the TRANSMISSION AND 9. Positionthe spring and steering
sector shaft and torque to specifica- STANDARD STEERING wheelon the steeringshaft and install
tion. Removal the retaining nut. Torque the nut to
1. Openthe hood and inserta fab- specificationand apply 2 drops of
STEERING WHEEL SPOKE ricated alignment tool (Group 6) Loctite sealer(C3AZ-19554-A)to the
POSITION ADJUSTMENT through the column tube and shift junction of the nut and steeringshaft
When the steering gear is on the arms to retain the shift mechanism threads.
high point, the front wheels should in neutral. 10. Install the spring and horn
be in the straight-ahead position and 2. Disconnectthe turn signal and ring or button on the steeringwheel
the steering wheel spokes should be in horn wires at the steering column and connectthe turn signaland horn
their normal position with the Pitman connectors. wires at the connectors.
arm pointing directly forward. If the 3. Remove the horn ring and 11. Adjust the shift linkage, if re-
spokes are not in their normal posi- spring from the steeringwheel. quired, and remove the alignment
tion, they can be adjusted without 4. Removethe steeringwheel re- tool.
disturbing the toe-in adjustment taining nut and remove the steering
(Refer to Part 3-1). COMET AND FAIRLANE WITH
wheel with Tool 3600-AA (Fig. 5). STANDARD TRANSMISSION
5. Remove the trunnion and AND POWER STEERING
STEERING WHEEL springsretainingthe shift lever in the
REPLACEMENT socketand removethe shift lever. Removal
1. Removethe horn ring (or but- 6. Removethe turn signal switch 1. Open the hood and insert a
ton) assemblyand related parts. lever. fabricated alignment tool (Group 6)
2. Removethe steeringwheel at- 7. Remove 3 bearing retainer at- through the column tube and shift
G 1384-A

FIG. 6-Steering ColumnDisassembled-Typical

arms to retain the shift mechanism 12. Lift the shift tube from the the turn signal switch lever and install
in neutral. steering column. the lever.
2. Disconnectthe turn signal and 10. Position the spring and steer-
horn wires at the steering column Installation ing wheel on the steering shaft and
connectors. 1. Position the shift tube in the install the retaining nut. Torque the
3. Remove the horn ring and steering column and through the nut to specification and apply 2 drops
spring from the steering wheel. shift arms and spacer. Be sure the of Loctite sealer (C3AZ-19554-A) to
4. Removethe steeringwheel re- shift tube is inserted through both the junction of the nut and steering
taining nut and remove the steering shift arms. shaft threads.
wheel with Tool 3600-AA (Fig. 5). 2. Position the shift lever socket 11. Install the spring and horn
S. Remove the trunnion and on the steering column and engage ring (or button) on the steering
springsretainingthe shift lever in the it with the shift tube (Fig. 6). wheel.
socketand removethe lever. 3. Position the flange to the hub 12. Adjust the shift linkage, if re-
6. Removethe turn signal switch so that the heads of the 2 flange bolts quired, and remove the alignment pin
lever. engagein the slots of the steering col- from the shift arms and steering col-
7. Remove3 bearing retainer at- umn tube. Then, tighten the 2 flange umn.
taching screws and remove the bolt nuts. 13. Connect the turn signal and
bearing retainer and turn signal 4. Position the bearing on the horn wires at the steering column
switchfrom the steeringcolumn (Fig. steering shaft and seat in the flange connectors.
6). with Tool T62F-3576-A, if necessary.
8. Remove the snap ring from the 5. Remove the tool and install the FALCON WITH AUTOMATIC
steering shaft. snap ring on the shaft. TRANSMISSION
9. Loosen 2 flange bolt nuts re- 6. Feed the turn signal switch COMET AND FAIRLANE WIm
taining the flange to the steering col- wires through the steering column AUTOMATIC TRANSMISSION
umn tube (Fig. 6). and position the switch and bearing AND STANDARD STEERING
10. Pull upward on the shift lever retainer to the flange.
socket and tap the end of the steer- 7. Install the 3 bearing retainer Removal
ing shaft with a soft hammer. This is attaching screws. 1. Open the hood and disconnect
to break the bearing loose from the 8. Position the shift lever to the the shift rod from the steeringcol-
shaft. shift lever socket and install the roll umn shift arm.
11. Remove the bearing, flange, pin. 2. Loosenthe steeringgearto side
and shift lever socket from the steer- 9. Apply 2 drops of Loctite sealer rail retainingbolts.
ing column. (C3AZ-19554-A) to the threads of 3. Disconnectthe turn signal and
horn wires at the steering column steering column bracket is straight 5. Removethe steer~ngwheel re-
connectors. up and down on the left side of the taining nut and remove the steering
4. Remove the horn ring (or but- column. wheel with Tool 3600-AA (Fig. 5).
ton) and spring from the steering 5. Slide the steering column down 6. Removethe insulationfrom the
wheel. on the steering shaft until the shift dashpanel in the areaof the steering
5. Remove the steering wheel re- arm contacts the dash panel. It may column.
taining nut and remove the steering be necessary to apply a slight down- 7. Remove2 screwsclampingthe
wheel with Tool 3600-AA (Fig. 5). ward pressure to the steering column dash panel seal retainer to the steer-
6. Remove the insulation from the so the bracket will clear the instru- ing column. Then, remove 5 screws
dash panel in the area of the steering ment panel. attaching the retainer to the dash
column. 6. Rotate the steering column so panel and removethe retainer.
7. Remove 5 dash panel seal re- the shift arm clears the dash panel 8. Remove 2 bolts attaching the
tainer attaching screws (Fig. 6) and opening and slide the column down steering column to the instrument
remove the seal from the steering col- until the shift arm is through the panel support and removethe steer-
umn opening. Then, slide the seal opening. Then, rotate the steering ing column from the car.
up the steering column. column so that the steering column 9. Removethe snapring from the
8. Remove 2 bolts attaching the bracket is in position at the instru- steeringshaft and remove the steer-
steering column to the instrument ment panel support bracket. ing shaft from the steeringcolumn.
panel support. 7. Loosely install the 2 steering 10. Placethe selectorlever in the
9. Apply tape to the area around column bracket to support bracket neutral position and removethe shift
the instrument panel steering column attaching bolts (Fig. 6). tube to steeringcolumnhub retaining
opening to protect the finish on the 8. Position the seal and retainer screwlocatedon the undersideof the
panel. to the steering column and dash pan- hub.
10. Place the transmission selec- el and install the attaching screws 11. Pull the shift tube out of the
tor lever in the low gear position. (Fig. 6). lower end of the steeringcoiumn.
11. Turn the steering column 1/4 9. Position the upper bearing
turn counterclockwise. Pull the steer- sleeve and spring on the steering
ing column upward on the steering shaft. Installation
shaft until the shift arm contacts the 10. Position the steering wheel on
dash panel in the engine compart- the steering shaft and install the re- 1. Position the shift tube in the
ment. taining nut. Torque the nut to speci- steering column and install the re-
12. Rotate the steering column fication and apply 2 drops of Loc- taining screw.
clockwise until the shift arm clears tite sealer (C3AZ-19554-A) to the 2. Insert the steeringshaft in the
the opening in the dash panel. Then, junction of the nut and steering shaft steeringcolumn and place the upper
pull upward on the column until the threads. bearing sleeveon the upper end of
steering column attaching bracket 11. Install the spring and horn the column.Install the springand nut
clears the instrument panel. It may ring (or button) on the steering on the steering shaft to retain the
be necessary to apply a slight down- wheel. shaft in the column.
ward pressure on the steering column 12. Connect the horn and turn 3. Position the steeringcolumn in
so the bracket will clear the instru- signal wires at the multiple connector. the car and looselyinstall the steer-
ment panel. 13. Connect the shift linkage to ing column to instrumentpanel sup-
13. Rotate the steering column the shift arm. port bolts.
until the shift arm is pointing down 14. Torque the steering gear at- 4. Install the 2 bolts and nuts at-
and remove the column from the taching bolts to specification. taching the flex joint to the steering
car. 15. Torque the steering column shaft.
14. Place the steering column on bracket to support brace attaching 5. Position the dash panel open-
a bench and move the transmission bolts to specification. ing seal and retainer to the dash
selector lever to the neutral position. 16. Check and adjust the shift panel and install the 7 attaching
15. Remove the shift tube to linkage as required. screws.
steering column hub retaining screw 6. Install the insulationto the dash
located on the underside of the hub. COMET AND FAIRLANE WITH panel in the areaof the steeringcol-
16. Pull the shift tube out of the AUTOMATIC TRANSMISSION umn.
steering column from the lower end. AND POWER STEERING 7. Remove the nut from the
steeringshaft and position the steer-
Removal ing wheelon the shaft. Install the re-
Installation 1. Open the hood and disconnect taining nut and torque to specifica-
1. Position the shift tube in the the shift linkage from the steering col- tion (Part 3-6).
steering column and install the re- umn shift arm. 8. Apply 2 drops of Loctite sealer
taining screw. 2. Remove 2 bolts and nuts re- (C3AZ-19554-A)to the junction of
2. Place the steering column over taining the flex coupling to the steer- the steeringshaft and nut threads.
the steering shaft with the shift arm ing shaft. 9. Torque the steeringcolumn to
pointing down. 3. Disconnect the turn signal and instrument panel attaching bolts to
3. Slide the steering column down horn wires at the steering column specification (Part 3-6).
on the steering shaft until the bracket connectors. 10. Install the horn ring and spring
is near the instrument panel opening. 4. Remove the 'horn ring (or but- and connectthe turn signaland horn
4. Rotate the steering column ton) and spring from the steering wires at the connector.
about V2 turn until the top of the wheel. 11. Connect the shift linkage to
PART 3-3 MANUALSTEERING 3-27

the steering column shift arm and ad- 9. Install the flex coupling clamp diameter in the steering shaft open-
just as required. bolt. ing of the flange and drive the bear-
10. Position the turn signal switch ing out of the flange from the bottom
STEERING COLUMN UPPER and bearing retainer to the flange side.
BEARING REPLACEMENT and install the 3 retaining screws. 8. Position the 2 flange bolts in the
11. Apply 2 drops of Loctite seal- flange holes. Start the flange bolt nuts
COMET AND FAIRLANE WITH er (C3AZ-19554-A) to the turn sig-
POWER STEERING on the flange bolts about 1V2 turns.
nal switch lever and install the lever. 9. Position the flange to the col-
1. Disconnect the horn wire and
umn so that the heads of the 2 flange
the turn indicator wires at the con-
ALL MODELS EXCEPT COMET bolts engage in the slots of the steer-
nectors. Remove the horn ring (or
AND FAIRLANE WITH POWER ing column tube. Then, tighten the 2
button) and the spring.
STEERING flange bolt nuts.
2. Remove the steering wheel at-
taching nut. Remove the steering 10. Lubricate the bearing and in-
1. Disconnect the horn wire and
wheel (Fig. 5) with a puller. stall it in the flange.
the turn indicator wires at the con-
3. Remove the turn indicator nectors. Remove the horn ring (or 11. Position the turn signal switch
lever. Remove the upper bearing re- button) and the spring. and bearing retainer to the flange
tainer screws and move the turn 2. Remove the steering wheel at- and install the 3 retaining screws.
signal switch to one side. taching nut. Remove the steering 12. Install the centering sleeveand
4. Remove 1 bolt clamping the wheel (Fig. 5) with a puller, Tool spring on the steering shaft.
flex coupling on the steering shaft. 3600-AA. 13. Position the steering wheel on
5. Remove the snap ring from the 3. Remove the 3 bearing retainer the steering shaft and install the re-
steering shaft. screws and remove the bearing re- taining nut. Torque the nut to speci-
6. Pull up on the steering shaft to tainer. fication and apply 2 drops of Loctite
remove the bearing from the flange 4. Lift the turn signal switch up sealer (C3AZ-19554-A) to the junc-
and remove the bearing from the and over the steering shaft and posi- tion of the nut and steering shaft
steering shaft. tion it to one side. threads.
7. Lubricate the bearing and po- 5. Remove the centering sleeve 14. Install the horn ring (or but-
sition it on the steering shaft. Use and spring from the steering shaft. ton) and spring on the steering
Tool T62F-3576-A to seat the bear- 6. Remove 2 flange bolt nuts (Fig. wheel.
ing, if necessary. 6) and lift the flange from the steer- 15. Connect the turn signal and
8. Install the snap ring on the ing column. horn wires at the connectors and
steering shaft. 7. Place a socket of the correct check the operation of both units.

REMOVAL AND INSTAllATION


HOISTING INSTRUCTIONS remove the clamp and the insulator. 11. Removenut and washer. In-
Damage to suspension and I or 5. Pull the rubber seal up on the stall Tool T64P-3590-Fand remove
steering linkage components may oc- steering column, fold the floor mat the Pitman arm from the sector
cur if care is not exercised when po- aside, and move the dash panel insu- shaft (Fig. 7).
sitioning the hoist adapters of 2 post lation out of the way.
hoists prior to lifting the car. 6. Remove the retaining screws TooI-
If a 2 post hoist is used to lift the from the steering column weather T64P.3590.F STEERINGGEAR HOUSING
car, place the adapters under the seal on the dash panel. Remove the
front suspension lower arms. Do not steering column cover plates and
allow the adapters to contact the gasket.
steering linkage. 7. Slide th'e steering column tube
assembly from the steering gear
STEERING GEAR shaft, guiding the shift lever(s) up
MUSTANG through the opening in the dash
Removal panel.
1. Disconnect the horn and turn 8. Raise the car and remove the
indicator wires under the instrument clutch equalizer and bracket assem-
panel. Also on a car with an auto- bly from the frame side rail and en-
matic transmission, disconnect the gine if so equipped to obtain
Ifeutral switch wires. clearance.
2. Remove the horn ring (or but- 9. On power steering equipped ve-
ton). Remove the steering wheel re- hicles, remove pal nut attaching nut
taining nut and the steering wheel insulator and washer and remove the FIG. 7 -Removing Pitman
(Fig. 5). power steering cylinder rod from the
3. Remove the upper bearing cen- bracket to obtain clearance for re- Arm-Typical
tering sleeve and spring. movaJ of Pitman arm. 12. Remove steering gear retain-
4. Remove the steering column 10. Remove the inlet pipe from ing bolts.
clamp to instrument panel bolts and the manifold to obtain clearance. 13. Lower the car and disconnect
3-28 GROUP 3 - SUSPENSION,
STEERING,
WHEELS
AND TIRES

the wires from the left bank of spark bolts and pivoting the gear up and 2. Remove the horn ring from the
plugs to prevent damaging them. down. steering wheel.
14. On vehicles equipped with col- Horizontal movement of the steer- 3. Remove the steering wheel re-
umn mounted- shift mechanism, dis- ing shaft can be accomplished by taining nut and remove the steering
connect the tr~nsmission shift rod(s) loosening the steering column to in- wheel with Tool 3600-AA (Fig. 5).
at the gear shift lever(s). strument panel retaining bracket and 4. Remove 5 steering column re-
15. Remove brake booster if nec- moving the column to the left or tainer attaching screws and remove
essary. right. the retainer from the steering col-
16. Remove the support rod from Should additional horizontal move- umn and dash panel (Fig. 6). Slide
cowl to spring tower (except Comet). ment be required to align the steering the seal up the steering column.
17. Loosen air cleaner to obtain shaft, it will be necessary to insert 5. Remove the 2 steering column
clearance if necessary. shim(s) of proper thickness between clamp to instrument panel support at-
18. Lift the steering gear and the steering gear assembly and the taching bolts.
shaft assembly from the engine com- vehicle side rail. Front end alignment 6. Remove the upper bearing cen-
partment by raising the gear up and shims can be used for this purpose. tering sleeve and spring from the
forward past the engine and spring After the steering shaft is centered, steering shaft.
tower taking care not to soil or tear torque all bolts to specification. 7. Disconnect the shift linkage
the front seat fabric with the end of 10. Position the upper bearing from the steering column shift arms.
the steering shaft. centering sleeve and spring. After ap- 8. Raise the car and remove the
plying Lubriplate to the upper surface Pitman arm retaining nut and re-
Installation of the steering shaft upper bearing move the Pitman arm with Tool
and the horn switch brush plate, posi- T64P-3590-F (Fig. 7).
1. Install the steering gear from tion the steering wheel on the steering 9. Remove the nut retaining the
engine side and guide the shaft shaft and install the retaining nut. clutch release arm return spring
through the dash panel being careful Torque the nut to specification. Then, bracket and remove the bracket and
not to soil or tear the front seat apply 2 drops of Loctite sealer spring (Standard transmission cars
fabric. Install the steering gear at- (C3AZ-19554-A) to the junction of only).
taching bolts but do not tighten. the steering shaft and the retaining 10. Remove the 3 steering gear to
2. Center the steering shaft for nut threads. frame side rail attaching bolts.
straight ahead drive position. Apply Loctite sealer sparingly to 11. Lower the car and remove the
3. Raise car on hoist and install the turn indicator lever threads and steering column from the steering
clutch equalizer assembly to engine install the lever. shaft.
and underbody if car is so equipped. 11. Install the horn ring (or but- 12. Remove the steering gear from
4. Install inlet pipe to manifold. ton) and spring, and steering wheel the caT.
5. Install Pitman arm to the sec- to the center point.
tor shaft and install the lock washer 12. Set gap between column tube Installation
and the torque nut to specification. and steering wheel and tighten col-
6. If equipped with power steer- umn to instrument panel. 1. Position the steering gear in the
ing, install power cylinder rod to 13. Lower the car from the safety car and allow it to rest on the frame
bracket and install insulator washer stands. Connect the horn, turn indi- side rail.
and nut to retain. cator wires, and (on a car with an 2. Position the steering column
7. Partially lower car onto safety automatic transmission) the neutral over the steering shaft and through
stands and install the steering column switch wires. the hole in the dash panel.
tube assembly over the steering shaft, 14. Position the steering column 3. Install the steering gear attach-
guiding the shifting arms through the cover plates and gasket on the dash ing bolts and the clutch release arm
opening In the dash panel. panel and install the retaining screws. return spring, bracket, and nut.
8. Position the steering column as- 15. Position the dash panel insu- 4. Install the Pitman arm and re-
sembly and retaining clamp and insu- lation just above the steering column. taining nut and washer on the sector
lator, and loosely install the attaching Position the floor mat and push the shaft. Torque the nut to specification.
bolts and nuts. rubber seal down to the floor mat. 5. Position the steering column to
9. Tighten the steering gear to 16. Connect the transmission shift the instrument panel and install the
side rail mounting bolts and column rods and correct adjustment of shift 2 retaining bolts. Do not tighten the
to instrument panel retaining bracket. lever(s) and the neutral switch. bolts at this time.
Check steering shaft to column up- 17. Connect ignition wires. 6. Position the seal and retainer to
per bearing clearance. If the shaft 18. Connect cowl to spring tower the dash panel opening and install the
does not touch the bearing, no further support rod (except Comet). attaching screws.
readjustment is required. If the shaft 19. Tighten the air cleaner. 7. Position the upper bearing
is touching the column upper bear- sleeve, spring, and steering wheel on
ing, it will be necessary to check the COMET AND FAIRLANE WITH the steering shaft and install the re-
pull required to center the shaft in STANDARD STEERING taining nut (Fig. 6). Torque the nut
the column, using a fish scale. Where (EXCEPT 390 C.I.D. ENGINE) to specification and apply 2 drops of
pull exceeds 20 Ibs. at either plane AND ALL FALCON Loctite sealer (C3AZ-19554-A) to
to center the shaft in the column, the the junction of the steering shaft and
following correction must be made: Removal retaining nut threads.
Vertical movement of the steering 1. Disconnect the turn signal and 8. Adjust the steering wheel to
shaft can be accomplished by loos- horn wires at the steering column flange clearance to 3/64inch and tight-
ening the steering gear mounting connectors. en the steering column clamp to
PART 3-3 MANUALSTEERING 3-29

instrument panel attaching bolts. flex coupling to steeringshaft retain- steeringgear from the car.
Torque the bolts to specification ing bolts and nuts.
(Part 3-6). 6. Fill the steeringgear with the Installation
9. Install the spring and horn ring specifiedlubricant to the correct level 1. Removethe steeringgearhous-
(or button) on the steeringwheel. (Part 3-1). ing cover from the steeringgear.
10. Connect the turn signal and 2. Positionthe steeringgearin the
horn wires at the steering column COMET AND FAIRLANE car as follows:
connectors. WITH 390 C.I.D. ENGINE AND a. Insert the steeringshaft through
11. Connect the shift rods to the STANDARD STEERING the openingin the dashpanel.
steeringcolumn shift arms. b. Point the output shaft toward
12. Torque the steering gear at- Removal the fender apron. Slide the gear
taching bolts to specification (Part 1. Raise the car and remove the downward and position it to the
3-6) and fill the steering gear with Pitman arm retaining nut and wash- frame side rail.
the specifiedlubricant to the correct er. 3. Install the steering gear hous-
level (Part 3-1). 2. Removethe Pitman arm from ing cover on the gear housing and
the sector shaft with the tool shown adjust the steeringgear (Section2).
COMET AND FAIRLANE in Fig. 7. 4. Position the steering column
WITH POWERSTEERING 3. Removethe 3 steeringgear to over the steeringshaft and looselyin-
side rail attaching bolts and discon- stall the steering column clamp to
Removal nect the shift rods from the shift le- instrument panel retaining bolts.
1. Open the hood and remove 2 vers. 5. Position the steering column
bolts and nuts retaining the flex cou- 4. Lower the car and disconnect openingsealand retainerto the dash
pling to the steeringshaft. the horn and turn signalwires at the paneland install the retainingscrews.
2. Raise the car and remove 3 steeringcolumn multiple disconnects. 6~ Center the steering gear mid-
bolts and a nut retaining the power 5. Removethe horn button or ring way betweena full right and full left
cylinder bracket to the frame side from the steeringwheel, and remove turn and position the steeringwheel
rail. Separatethe bracket from the the steeringwheelretainingnut. on the steeringshaft and install the
side rail and allow the cylinder and 6. Remove the steering wheel retaining nut.
bracket to hang. from the steering shaft with Tool 7. Torque the nut to specification
3. Removethe Pitman arm retain- 3600-AA. Then, remove the tool and apply 2 drops of Loctite sealer
ing nut and washerand remove the from the steeringwheel. (C3AZ-19554-A)to the junction of
Pitman arm from the sector shaft 7. Remove5 screwsattachingthe the nut and steeringshaft threads.
with Tool T64P-3590-F(Fig. 7). steeringcolumn openingsealand re- 8. Install the horn button or ring
4. Remove the nut retaining the tainer to the dashpanel. Removethe and the spring to the steeringwheel.
clutch release arm return spring retainer and slide the seal up the 9. Install the rocker cover on the
bracket and removethe bracket and steeringcolumn. left cylinder head and connect the
spring (Standard transmission cars 8. Remove 2 steering column spark plug wires to the spark plugs
only). clamp to instrument panel retaining (Group 8).
S. Remove3 steeringgear attach- bolts and lift the steering column 10. Position the brake mastercyl-
ing bolts and remove the steering from the steering shaft. inder to the dash panel and install
gear. 9. Open the hood and disconnect the attachingbolts.
the master cylinder brake line from 11. Connectthe brake mastercyl-
Installation the junction block. inder line to the junction block.
1. Positionthe steeringgearto the 10. Removethe brake mastercyl- 12. Raise the car and install the
frame side rail and the flex coupling inder attachingbolts and removethe steering gear to side rail retaining
to the steeringshaft and install the 3 mastercylinder and brake line from bolts. Torque the retaining bolts to
steeringgear attachingbolts. Torque the dash panel. specification(Part 3-6).
the bolts to specification(Part 3-6). 11. Disconnect the spark plug 13. Positionthe Pitman arm to the
2. Install the clutch releasearm wires from numbers 5 through 8 sector shaft and install the retaining
return spring and bracket (Standard spark plugs, and remove the rocker nut. Torque the nut to specification
transmissioncars only). cover from the left cylinder head. (Part 3-6).
3. Position the Pitman arm to the 12. Remove3 steeringgear hous- 14. Bleed the brake hydraulic sys-
sector shaft and install the washer ing cover attachingbolts and remove tem (Part 2-1).
and retaining nut. Torque the nut to the housing cover from the steering 15. Connect the shift rods to the
specification(Part 3-6). gear. shift levers.
4. Position the power cylinder 13. Removethe steeringgearfrom 16. Lower the car and torque the
bracketto the siderail and install the the car as follows: steeringcolumn clamp to instrument
3 retaining bolts and nut. Torque a. Place the steering gear output panel retaining bolts.
the bolts and nut to specification shaft againstthe fender apron. 17. Connectthe horn and turn sig-
(Part 3-6). b. Pull the steering gear up and nal wires at the steeringcolumn mul-
5. Lower the car and install the 2 over the springtower and removethe tiple connectors.
3-30 GROUP3 SUSPENSION,
STEERING,
WHEELS
AND TIRES

MAJOR REPAIR OPERATIONS


STEERING GEAR of wood (Fig. 9) to loosen it from
the housing.
DISASSEMBLY 6. Remove the ball return guide
1. Rotate the steering shaft ap- clamp and the ball return guides
proximately 21/4 turns from either from the ball nut. Keep the ball nut
stop. clamp-side up until ready to remove
2. After removing the sector ad- the balls.
justing screw locknut and the hous- 7. Turn the ball nut over, and ro-
ing cover bolts, remove the sector tate the worm shaft from side to side
shaft with the cover. Remove the until all balls (Mustang-62 balls;
cover from the shaft by turning the Comet, Falcon, and Fairlane-54
screw clockwise. Keep the shim with balls) have dropped out of the nut
the screw (Fig. 8). into a clean pan. With the balls re-

~:~~> HOUSINGCDVER3580

.. SHIM 3A6S7 LOCK NUT 3707,


,;~,
~GASKETj581 WORMBEARING.
~ - ADJUSTING SCREW3S77 AOJUSTER 3A6io'

t( - SECTOR SHAFT 357S


BEARING<;V~
. BEARING 3576 , ,;
3552
FILLER PLUG Press both sector shaft bearings
3538 out of the housing (Fig. 10). Remove
/ BEARING
3571, the seal and the bearings only if there
- 3647 is an indication of wear, damage, or
~ ~ p.\v bearing mislocation. Do not install a
. " ,---
;BALLGuJDE 3523
"', new bearing in a housing in which
) ~CLAMP 3544
---:) the bearing has turned or is found to
'"- -" BEARING CUP 3552 \,
~
'It . be mislocated. A new housing must
be used.
~
STEERING SHAFT 3524

".~ .. , ~.J"- BALL NUl


.' i "\p 3524
ASSEMBLY
1. If the sectorshaftbearingshave
6 BEA,RI~,~
357~ beenremoved,pressnew bearingsin-
- OILSEAL.
3591 to the housing(Fig. 11).
PITMAN ARM 3590

~
~

G 1382-A

8-Manual SteeringGear Disassembled

3. Loosen the worm bearing ad-


juster nut, and remove the adjuster
assembly and the steering shaft up-
per bearing and cup.
4. Carefully pull the steering shaft
and ball nut from the housing. To
avoid possible damage to the ball re-
turn guides, keep the ball nut from
running down to either end of the Wood Block
worm.
Disassemble the ball nut only if - ""~ G1226-A
there is indication of binding or
FIG. 9-Removing Lower
tightuess. E
5. Remove the lower bearing and Bearing Cup from Housing
cup from the housing. It may be nec- moved,the ball nut will slide off the FIG. 11 -Installing Sector
essary to tap the housing on a block worm. Shaft Bearing
PART 3-3 - MANUAL
STEERING 3-31

2. Position a bearing cup in the then in the opposite direction to dis- 14. Position the sector adjusting
adjuster. tribute the balls in the circuit. screw and the adjuster shim, and
3. If the sector shaft oil seal has 7. After the balls (Mustang-31 check the end clearance which
beenremoved,install a new oil seal. balls; Comet, Falcon, and Fairlane- should not exceed 0.002 inch be-
4. Swabthe insidediameterof the 27 balls) are installed, install the ball tween the screw head and the end of
ball nut and the outsidediameterof guide clamp. Check the ball nut to the sector shaft. If clearance is great-
the worm with gear lubricant C3AZ- see that it rotates freely. Torque the er than 0.002 inch, replace the shim.
19578-A prior to assembly.Lay the screw to specification. 15. Thread the sector shaft ad-
steeringshaft on a bench as shown 8. Coat the threads of the steering justing screw into the housing cover.
in Fig. 12. After positioning the shaft bearing adjuster, the housing 16. Install a new gasket on the
shaft, turn the ball nut to place the cover bolts, and the sector adjusting housing cover.
screw with a suitable oil-resistant 17. Rotate the steering shaft until
sealing compound. Do not apply seal- the ball nut teeth are in position to
BAll NUT
er to female threads, and especially mesh with the sector gear, tilting the
-= J. -- avoid getting any sealer on the steer- housing so that the ball nut will tip
ing shaft bearings. toward the housing cover opening.
9. Coat the worm bearings, sector 18. Apply enough gear lubricant
-- - )'
.~ ' SPLINETO RIGHT shaft bearing and gear teeth with C3AZ-19578-A to fill the pocket in
gear lubricant C3AZ-19578-A.
NARROW END OF OF BALL NUT the housing between the sector shaft
10. Clamp the housing in a vise,
TAPERFACING DOWN G1227-A bearings 30% full.
with the sector shaft axis horizontal,
19. Push the housing cover with
FIG. 12-Positioning Ball and position the steering shaft lower
the sector shaft into place.
bearing cup and the bearing in place.
Nut-Typical 11. Position the steering shaft and 20. Turn the cover to one side and
guide holes in the up position. Align ball nut assembly in the housing. fill the housing with Ih lb. of gear
the grooves in the worm and in the 12. Position the steering shaft up- lubricant C3AZ-19578-A.
ball nut by sighting through the ball per bearing on the top of the worm, 21. Install but do not tighten the
guide holes. and install the steering shaft bearing housing cover attaching bolts. Do not
5. Insert the ball guides into the adjuster and cup. Install the lock nut tighten the cover bolts until it is cer-
holes of the ball nut, tapping them with the flat side against the bearing tain that there is some lash between
lightly with a wood handle of a screw adjuster and the letter outward. the ball nut and the sector gear teeth.
driver if necessary to seat them. Leave the nut loose. 22. After loosely installing the sec-
6. Insert the balls (Mustang-62 13. After installing the steering tor shaft adjusting screw .lock nut, ad-
balls; Comet, Falcon, and Fairlane- wheel nut on the steering shaft, ad- just the sector shaft mesh to the spec-
54 balls) into the hole in the top of just the worm bearing preload, using ified mesh load, then tighten the ad-
each ball guide. It may be necessary an inch-pound torque wrench to justing screw lock nut. Remove the
to rotate the shaft sli~htly one way, check for specified preload. steering wheel nut.

STEERING LINKAGE REPAIR


The manual steering linkage (Figs. ends of the rod sleeves,have non- to specification and install the cotter
13, 14, and 15) consists of the Pit- adjustable,spring-loadedball studs. pin.
man arm, the steering arm-to-idler A rod end should be replacedwhen 6. Check and, if necessary, ad-
arm rod, the steering idler arm, and excessivelooseness at the ball stud is just toe-in (Part 3-1). Mter toe-in is
the spindle connecting rods (tie rods). noticed. checked and adjusted, torque the old
Do not attempt to straighten bent 1. Removethe cotter pin and nut sleeve clamp bolts to specification.
linkage; use new parts. from the worn rod end ball stud. Add four pounds torque if new bolts
2. Disconnect the end from the are used. The tie rod sleeve clamps
spindle,connectingarm, Pitmanarm, must be installed as shown in Fig. 13,
HOISTING INSTRUCTIONS
or idler arm as shownin Fig. 16. Part 3-1, to prevent interference with
Damage to suspension and/or the side rail.
steering linkage components may oc- 3. Loosen the connecting rod
cur if care is not exercised when po- sleeve clamp bolts, and count the
sitioning the hoist adapters of 2 post number of turns neededto remove SPINDLE SLEEVE REPLACEMENT
hoists prior to lifting the car. the rod end from the sleeve.Discard A spindle sleeve should be re-
II a 2 post hoist is used to lift the all rod end parts that were removed placed if it becomes worn or dam-
car, place the adapters under the from the sleeve.All new parts should aged (Figs. 13, 14, and 15). Do not
front suspension lower arms. Do not be used when a spindle connecting attempt to straighten the sleeve if
allow the adapters to contact the rod end is replaced. threaded portion is damaged.
steering linkage. 4. Thread a new rod end into the 1. Remove the spindle connecting
sleeve,but do not tighten the sleeve rod ends as described in the previous
SPINDLE CONNECTING ROD clamp bqlts at this time. sub-section.
END REPLACEMENT 5. Insert the stud in the part from 2. Screw the spindle rod ends into
The spindle connecting rod ends, which the old one was removed,and the new sleeve the same number of
which are threaded into the outer install the stud nut. Torque the nut turns as the ends that were removed.
FIG. 13-Typical SteeringLinkage-Comet,Falcon,and Fairlane
,.,
ill' \ \ and the spindle arm. Install the at-
..
,
II
II
\\ \ taching nut, torque it to specifica-

~
J !I, \ tion, and install the cotter pin.

\
SPINDLECa-INECTINGRDD IDLERARM STEERING ARMoTO-
IDLER AR~..RO~i i 4. Check and, if necessary,adjust
H "1 toe-in (Part 3-1). After toe-in is
i I I II II I checked and adjuste~ torque the
. I I ,'i o.\.' I
i' I; o...! \ ,__0- sleeve clamp bolts to specification.
.. I, -<, \
\ :\
\, \
\ \
\\,.
SPINDLE C~NECTING
~
..
"'" .. ,
~
~i
-,
- ;'
I
I ,
'1.0.'"
~..
~"~.."
,-,
"..'
\
I
,..' '".,,'(00;__,_--
\.." o:oo.::.o_o,,~,
t:~:...~;::.~>::'oo
,
0 The sleeveclamp must be installed
with the bolt down to prevent inter-
..",
ferencewith the side rail.
ROD END
""'-.
,..",. ,,, "'..,.
"""~" £i" STEERING ARM- TO-IDLER ARM
, 0-
ROD REPLACEMENT
, """,,:
J 1/1
,, 'I",
'"
'\):\...'\,\
,.,.,
The rod connecting the Pitman
~
.. ,-, , ,
., .' , I'

\ arm and the idler arm is non-adjust-


-
CLAMPS MUST BE ASSEMBLED
.
.' I~,
".
\ \ ...
,:::l-"
..'..1
I
,,
,I,
'.
''. ,
,i

1./
Ii'Ii

able and is provided with tapered


:
holes to accommodate the ball studs
'
, \ V/ "'-.. ./,/
WITH BOLTS IN BOTTOM '\".'
\ : t \
, \
HORIZONTAL POSITION AS " (Figs. 13, 14, and 15). The rod
SHOWN \\ ,\ \ "
""",,,
,

should be replaced when damaged or


'.', when worn at the ball studs.

~,

..;:.;..;.,.;..
MUSTANG-6.CYLINDER
/'~ ";;4 @ 1. Remove the cotter pins and
~ nuts from the ball studs at the sec-

-\
e-
\
tor shaft arm and the idler arm, and
remove the steering arm-to-idler arm
rod (Fig. 16).
!'I!iI'---"'-' 2. Position the new steering arm-
G 1380-A
to-idler arm rod on the idler arm and
the steering arm.
FIG. 14-6-Cylinder Manual Steering Linkage-Mustang 3. Install the ball stud retaining
Do not tighten the clamp bolts at this 3. Position the sleeve assembly on nuts and torque to specification.
timp. the Pitman arm (or the idler arm) 4. Install cotter pins, lubricate the
PART 3-3 MANUAL STEERING 3-33
the Pitman arm from the rod with
Tool-3290-C and remove the rod.
Installation
1. Replace the rubber seals on the
spindle connecting rod ends, if re-
quired.
2. Position the steering arm-to-
idler arm rod to the Pitman arm and
idler arm and install the retaining
nuts. Torque the nuts to the low end
of the specification. Continue to tight-
en each nut until the slots in the nut
align with the hole in the stud. Then
install the cotter pin.
3. Position the spindle connecting
rod ends to the steering arm-to-idler
arm rod and install the retaining nuts.
Torque the nuts to the low end of the
specification. Continue to tighten
each nut until the slots in the nut
align with the hole in the stud. Then,
install the cotter pin.
4. Remove the safety stands, low-
er the car, check and adjust toe-in to
specification (Part 3-1).
STEERING IDLER ARM
AND/OR BUSHING
1. Raise the car and remove the
cotter pin and nut retaining the idler
FIG. lS-8-Cylinder Manual Steeringlinkage-Power Typical- arm to the steering arm-to-idler arm
rod (Figs. 13, 14, and 15).
Mustang 2. Remove the cotter pin and nut
Too/-3290-C THREADPROTECTOR 3. Disconnectthe spindleconnect- retaining the idler arm to the brack-
ing rod endsfrom the steeringarm- et and remove the idler arm.
to-idler arm rod with Tool-3290-C 3. Place the idler arm in a vise
(Fig. 16). and replace the bushings as shown in
4. Remove 1 cotter pin and nut Fig. 17.
retaining the idler arm to the steer- 4. Position the idler arm to the
ing arm-to-idlerarm rod and discon- bracket and steering arm-to-idler
nect the idler arm from the rod with arm rod and install the retaining nuts
Tool-3290-C. and cotter pins.
5. Remove1 cotter pin and nut re- 5. Lower the car and check caster,
taining the Pitman arm to the steer- camber and toe-in and adjust if re-
ing arm-to-idlerarm rod. Disconnect Quired.

FIG. 16-Disconnecting
Steeringlinkage Ball
Stud-Typical
power steering ball stud socket, if
necessary.
5. Check and, if necessary,adjust
toe-in (Part 3-1).
COMET, FALCON, FAIRLANE,
AND 8 CYLINDER MUSTANG

Removal
1. Raise the car on a hoist and po-
sition safety stands.
2. Removethe 2 cotter pins and
nuts retaining both spindle connect-
ing rod ends to the steeringarm-to-
idler arm rod (Fig. 13).
3.34

POWER STEERING

Section Page Section Page


1 Description and Operation. . . . . . . . . . . . . . . .3-34 Power Steering Pump. . . . . . . . . . . . .. . . . .. .3-38
Description. . . . . . . . . . . . . . . . . . . . . . . . . . .3-34 Power Steering Pump Pulley.
68 Cylinder . . . . . . . . . . .. .3-38
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34 . . . . . . . .. . .3-38
Power Pressure Relief Valve.
Flow Steering
Control Pump
Valve ............. .3-36 . . . . . . .. . . .3-38
.3-36 Power Steering Control Valve. . .. . . . . . . . .3-39
.3-37 Mustang-6 Cylinder. . . . . . . . . . . . . . . . . .3-39
2 In-Car Adjustmentsand Repairs. . . . . . . . . .3.37 Comet, Falcon, and Fairlane . . .. . . . . . . . .3-39
PowerSteeringPumpBelt Tension 4 Major Repair Operations. . . . . . ... .. .3-40

Power
Cylinder
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . 3-37 ... .. . .3-40
Control Valve CenteringSpring Adjustment 3-37 Control Assembly.
Tube
Disassembly ValveSeat ................
Replacement . ... . .3-40
Control Valve to Power Steering ... .3-40
Cylinder Hose. . . . . . . . . . . . . . . . . . . . . . 3-37 . . . . . . .. . . .3-41
PowerSteeringPumpto Control Valve . . . . . . . . . . .3-41
Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Power Cylinder Seal. . . . . . . . . . .3-42
3 Removaland Installation. . . . . . . . . . . . . . . 3-38 Power Steering Pump Reservoir
SteeringGear. . . . . . . . . . . . . . . . . . . . . . . . 3-38 Replacement ..., 3-42

DESCRIPTION AND OPERATION


DESCRIPTION crankshaft,draws fluid from the res- turns to the reservoir.
The Power SteeringSystem(Fig. ervoir and providesfluid pressurefor The power steeringpump is a belt
1) is a hydraulically controlled link- the system.Within the pump itself is driven slippertype pump which is in-
age-type steering system which in- a pressure-reliefvalve which governs tegral with the reservoir. It is con-
cludesan integralpump and fluid res- the pressureswithin the steeringsys- structed so that the reservoir is at-
ervoir, a control valve, a power cyl- tem accordingto the varying condi- tachedto the rear side of the pump
inder, the connectingfluid lines, and tions of operation. After fluid has housing front plate and the pump
the steering linkage. The hydraulic passedfrom the pump to the control body is incasedwithin the reservoir.
pump, belt-driven from the engine valve and the power cylinder, it re-
OPERATION
The control valve, operated by
steeringwheel movement,directsthe
pressure developed by the pump.
When the front wheels are in the
straight-aheadposition, the control
valve spool is held in the center
(neutral) position by its centering
spring. Fluid then flows around the
valve lands and returns to the reser-
voir (Fig. 2). Within the control
valve body there is a reaction limit-
ing valve which reduces parking
effort.
When force of about 4 poundsis
exerted for a left turn, the valve
spool overcomesthe pressureof the
centering spring and moves toward
the right end of the valve. As a re-
sult, pressureis exertedon the right
sideof the power cylinderpiston,and
fluid in the left end of the cylinderre-
turns to the reservoir(Fig. 2).
If the direction of the force on the
steeringwheel is reversed,the front
G 1233-C
wheelswill turn to the straight for-
FIG. l-Power SteeringSystem ward position. Or as force on the
PART 3-4 - POWER
STEERING 3-35

r.'f--1\.
.. - ,..,
FLUID FLOW-STRAIGHT-AHEAD
PUMP
ANDRESERV(\I"
DRIVING J ,-r--"
'I "
II
...
II
CHECKVALVE 11 I'
'I ., II II
(IN CONTROLHOUSING) l ' I I
:I II "'"'"'"'~
II
II II II II
'II
II
II
I I,
r
II
..IJ I
II
::
II

II
II II,
:I
' I ,
or, ,
,.
J1 I
: 1,,1
'I I
1 'I I
II
I I
I I
:l I r \,
, r {o{, II II
I,1 II ~~
j , I II

I,
\.0-
--'--,:-.- ;; =.::-:::~:,:::_-:£?~~:~~--:::~-~---~.r'-' i! ):
lro -~-, I ,..' II
1 I III I

II
"I. ,-( \ I I

I:
\~ _1-1 I' 'L__Jl
Ii" I
," II I
,--_v., I
.)..1-.
-,' 1

~=~-j
" ,

POWERCYLINDER ~.J
PUMP PRESSURE
CONTROLVALVE I I
~-c:. -.:;;-- -=--=::-- RETURN PRESSURE
, /~-
, I~_I I --' , ,
""' , '\ '
,_-
~--"'
'\
\
i I
'",,
\,
, ,
-- "'~--- 71
,-- --~~',/
"'--::==::-~
FLUID FLOW-LEFT TURN ..
..
'f- -", PUMP AND RESERVDIR
II
"I
..,.--1'
,\
,I
I, I I
(I
II
I \
II
I ,
, CHECKVALVE
(IN CONTROLHOUSING)
I'
I,
\ I
I'
II
I'
I I I,
\I I , I I
'I"
II
",\
I I \'
1 I I, ~, ,1
II I I",
( I' ' ,
\\ I ',"\' , II
1 I I'

\ If, \ 1/", II
II I ~ ',\! // 11 II
I \ I-}" .r--_J~" I, II
r-:;::::"'--
-_.
,II"I 'I'
II II ~ . -::- .r~-' I I , ,
~ ,-- r- ' I
\1 II '-'-- -' "
II II ',:'"1"-- ~~:,~J:=.3=-::
-~r ""' ~~-,-,
'0' ,\ I I /
\1 II .., --"'1-( 'L--~'
II \.) , '
\~--- I
. , II I I

,--}.
- -I
,,,/,
.:0(- -I
r--- "-, } :" I I

~;~ POWERCYLINDER
'..L~.j

CONTROLVALVE -~-:.-;---=--:::-- - PUMP PRESSURE

""" ..-l --'

,, ~illmlilliRETURN PRESSURE

---'--~~~-
~
I
I
' "
I"
('\
---~
~
I
--
'---
~~
,

R~At:TION PRESSURE
,I
L.
,
\_-~---""--'
~--
"'-
//
,
,
...
""'-'
.
,-- --/"

.
""--::==::--

--~.
FLUID
FLOW-RIGHT
TUR~
-',:"
.,. I,r--'
"rT--1\
0'

,,,, I' CHECK


VALVE
PUMP AND RFSFRVnlR
"
" I'
/,
I' "
I, ,: (INCONTROL
HOUSING) ,I .'
,I I'
,
II
,I
1/
II "
II
/1
I'
,I 1/' ~, "
,...1/
. ',
:' /1"' I 'I "
III ,"/', I 1 I ",, ' ,
I, / I' , \ III/, "
II , I ':~ {~ :'
":, /!I' t~ .~,--- ~ .- - r..,---", r
/ ,-, ,I .: ,I
"-
---~~:,~-,=-:J=-" " ,I
" .. ''
--~---
1/ ":""',
--1--
... -"-~j")
~-~-, "/1 ,1
'/ I' ,-- '-. I .
lol___I.J "I , ,~'I-_J'
,.~q :: 1
,I I
,
, '/1 . '0'
.\..I-~ ,

o.rr;=~- POWER CYLINDER


I ,
~ PUMP PRESSURE
'.2.J

"",C',
,,'--'-'
' I
... - --:'-:'---::'-=::"

',,-~,-'J
I'
~-'
'"
'"'
~"
,

' I
I !!Ii!!!! RETURN PRESSURE
ii.
I ' ' ,
\, ,'"--c;;:-",-" /1 REACTION PRESSURE
, ,
, , '>--- ,
G1O37.C
'-::':::=::::::-'
FIG. 2-Fluid Flow Diagram
~
3-36 GROUP 3 SUSPENSION,
STEERING,
WHEELS
AND TIRES

steering wheel falls below approxi-


mately 4 pounds the valve spool cen-
tering spring forces the spool back
to the center position and there the
pressure on both sides of the power
cylinder piston is equal. With normal
forward driving movement of the car
and in the absenceof operative pres-
sure within the power cylinder, the
front wheels will seek to return to the
straight ahead position. This is a nor-
mal effect of the front wheel align-
ment.
For a right turn, the directional
forces explained above are reversed
(Fig. 2).
If, for any reason, the pump fails
to deliver fluid pressure, the car may
be steered without pump pressure.

POWER STEERING PUMP


The pump rotor has 8 slippers and
springs which rotate inside a cam in-
sert containing two lobes 180° from
each other. The cam insert and the
pump port plates provide a sealed
chamber within which the rotor and
slippers rotate between the two lobes
for pump operation.
As the rotor turns, the slippers are
forced outward against the inner
surface of the cam insert by a com-
bination of centrifugal force, slipper
spring force and fluid pressure acting
on the under side of the slipper. A
pair of adjacent slippers, along with
the surfaces of the rotor, cam and
pressure plates, form a sealed cham-
ber within the crescent-shaped void.
As this sealed chamber moves
through the crescent shaped void its
volume changes, resulting in a pump-
ing action.
As the rotor rotates 90° (Fig. 3),
the slipper slides outward in its slot,
riding on the cam and the volume of
the sealed chamber increases. This
creates a vacuum and sets up a suc-
tion area. With the inlet port placed
in this area, the chamber will fill with
fluid. As the rotor rotates from 90°
to 180°, the volume of the sealed
chamber decreases, thus creating a
pressure area. The pressure or outlet
port is located in this area. While this
pumping action is going on between
0° and 180°, the same condition is
occurring between 180° and 360°.
This combination creates what is
known as a balanced rotor pump.
The two pressure and suction quad-
rants are diametrically opposite each
other.

FLOW CONTROL VALVE FIG. 4-Power Steering Pump-Sectional View


Since the pump is a constantdis- will vary directly with the pump gear requires a relatively high con-
placementpump, the internal flow speed. However, a power steering stantrate of flow in the parking zone
PART 3-4 POWERSTEERING 3-37

and up to approximately 2800 RPM the spool valve. The differential in case of a road load of sufficient mag-
and thereafter a lower rate of flow. pressure thus created on the spool nitude, the steering gear will not ac-
This is accomplished by means of a valve increases steadily and propor- cept any flow from the pump, except
variable orifice mechanism shown in tionally with increasing RPM and for a very limited volume of oil due
Fig. 4. this moves the valve progressively to leakage past valve seals. Because
All of the internal pump flow is back into its bore, thus increasing the of this resistance, excessivehydraulic
ported from the pumping mechanism opening of the bypass port. pressure would be developed, if it
(rotor, slippers, and cam insert), The metering pin (Fig. 4) travels were not limited by the pressure re-
through passageA into the flow con- with the spool valve decreasing the lief valve.
trol zone. All of flow goes through net area of the orifice at higher When relief pressure is reached,
the orifice and out into the line until speeds. This action reduces flow to the pressure relief ball is forced off
the bypass port is cracked open. This the steering gear. its seat, allowing oil to pass through
is the regulation point. The oil drops the spool valve and dump into the
in pressure in moving through the PRESSURE RELIEF VALVE bypass port (Fig. 4). The relief valve
orifice. The lower pressure is then When the steering wheel is turned will continue to limit oil pressure to
sensed through a hole drilled in the completely to the stop position in the the relief setting for the duration of
cover communicating to the rear of right or left turn direction, or in the the overload condition.

IN-CAR ADJUSTMENTS AND REPAIRS

HOISTING INSTRUCTIONS 3. Recheckthe belt tension.When 5. Fill the power steering pump
Damage to suspension and/ or the tension has been correctly ad- reservoirwith fluid to the proper lev.
steering linkage components may oc- justed, torque the bolts and the nut el (Part 3-1).
cur if care is not exercised when posi- to specification. 6. Start the engine and turn the
tioning the hoist adapters of 2 post steering wheel to each end of its
hoists prior to lifting the car. CONTROL VALVE CENTERING travel severaltimes to cycle the sys-
If a 2 post hoist is used to lift the SPRING ADJUSTMENT tem. Then, checkfor leaks.
car, place the adapters under the COMET, FALCON, AND 7. Stopthe engineand againcheck
front suspension lower arms. Do not FAIRLANE the power steering fluid level. Add
allow the adapters to contact the fluid asrequired.
1. Raise the car and remove 2
steering linkage. spring cap retaining screwsand lock POWER STEERINGPUMP TO
washersand remove the spring cap. CONTROL VALVE HOSE
PUMP BELT TENSION 2. Tighten the adjustingnut snug;
ADJUSTMENT COMET, FALCON, AND
then, loosenthe nut Y4 turn. Do not
Pump drive belt tension cannot tightenthe adjustingnut too tight. FAIRLANE
be checked accurately using the 3. Position the spring cap to the
thumb pressure or belt deflection Removal
valve housing and install the 2 re.
methods. Correct belt adjustment is taining screwsand washers. 1. Remove the fluid from the
assured only with the use of a belt 4. Lower the car. pump reservoirwith a suctiongun.
tension gauge. 5. Start the engineand check the 2. Raisethe car on a hoist.
1. Check the belt tension with a turning effort with a spring scale. 3. Removethe clamp retainingthe
belt tension gauge (T63L-8620-A). With the spring scaleattachedto the hosetubesto the control valve.
With a new belt, or one that has been rim of the steeringwheel, the effort 4. Disconnectthe fluid return and
run for less than 15 minutes, the ten- to turn the wheel in both directions pressurehosesfrom the control valve
sion should be within 120-150 lbs. should not exceed12 pounds. and allow the fluid to drain into a
With a belt that has been run for pan.
more than 15 minutes; the tension CONTROL VALVE TO POWER 5. Lower the car and disconnect
should be within 90.120 lbs. STEERINGCYLINDER HOSE the fluid return hose from the reser.
2. To adjust the belt, loosen the voir.
mounting bolts incorporated on the COMET, FALCON, AND 6. Disconnect the fluid pressure
front face of the pump cover plate FAIRLANE hosefrom the pump outlet fitting.
(hub side) and one nut at the rear. 1. Raise the car on a hoist and 7. Remove 1 bolt attaching the
Place a 9/16inch open end wrench on place a drain pan under the power hoses,insulator, and the retainer to
the projecting 1/2 inch boss on the cylinder. the frame side rail and remove the
front face of the pump cover plate 2. Disconnectthe hose from the hoses,and the insulator and retainer
and pry upward to adjust belt tension. power cylinder and allow the fluid to as an assemblyfrom the car.
When adjusting the power steering drain from the hose.Then, disconnect 8. Removethe pressureand return
pump belt tension, do not pry against the hosefrom the control valve. hosesfrom the retainerand insulator.
the pump or reservoir to obtain the 3. Connectthe hoseto the control
proper belt tension. The reservoir will valve and power cylinder. Installation
be deformed when pried on or 4. Remove the drain pan and 1. Install the pressureand return
pressedagainst and a leak will result. lower the car. hosesin the insulator and retainer.
Position the assemblyto the frame let fitting and torque the fitting to fluid, C1AZ-19582-A, to the proper
siderail and install the attachingbolt. specification. level (Part 3-1).
2. Placea hoseclamp on the fluid 4. Raise the car and connect the 7. Start the engine and turn the
return hoseand install the hoseon the pressureand return lines to the con- steering wheel to each end of its
power steeringpump reservoirreturn trol valve. travel several times to cycle the sys-
fitting. 5. Install the clamp to retain the tem. Then, check for fluid leaks.
3. Torque the pump outlet fitting hosetubesto the control valve. 8. Stop the engine and again check
to specification (Part 3-6). Then, 6. Lower the car and fill the pow- the power steering fluid level (Part
connectthe pressurehoseto the out- er steering pump reservoir with 3-1). Add fluid as required.

REMOVAL AND INSTAllATION

HOISTING INSTRUCTIONS Torque to specification. Installation


Damage to suspension and/or 2. Position the pulley to the pump 1. Position the pump to the brack-
steering linkage components may oc- shaft and install tool T65P-3A733A. et and loosely install the 2 pivot bolts
cur if care is not exercised when po- Press the pulley on the shaft. (Refer and 2 adjusting bolts.
sitioning the hoist adapters of 2 post to Fig. 4 for tool installation.) Then, 2. Position the drive belt on the
hoists prior to lifting the car. remove the tool. pulley and adjust the belt tension to
If a 2 post hoist is used to lift the 3. Position the pump and bracket specification with tool T63L-8620-A
car, place the adapters under the to the engine and install the attach- (Section 2). Tighten the adjusting
front suspension lower arms. Do not ing bolts and spacers. bolts and pivot bolts to specification.
allow the adapters to contact the 4. Install one bolt to attach the 3. Torque the outlet fitting hex
steering linkage. brace to the bottom of the bracket. nut to specification (Part 3-6). Then,
Torque the bracket attaching bolts to connect the pressure hose to the fit-
STEERING GEAR specification (Part 3-6). ting and torque the hose nut to speci-
Refer to Group 3-3, Section 3 for 5. Position the belt on the pulley fication.
detailed instructions. and adjust the belt tension to speci- 4. Connect the return hose to the
fication with Tool T63L-8620-A (Sec- reservoir and tighten the clamp.
POWER STEERING PUMP tion 2). 5. Fill the pump reservoir to the
6. Torque the outlet fitting hex correct level with transmission fluid
6-CYLINDER
nut to specification. Then, connect the C1AZ-19582-A. Start the engine and
Removal pressure hose to the fitting and torque turn the steering wheel to each end
1. Remove the fill cap from the the hose nut to specification. of its travel several times to cycle
reservoir and remove the fluid with 7. Connect the return hose to the the system and check for leaks. Check
a suction gun. reservoir and tighten the clamp. the fluid level, fill as required, and
2. Disconnect the fluid return hose 8. Fill the radiator with coolant. install the fill cap.
from the reservoir. 9. Fill the pump reservoir to the
3. Disconnect the oil pressure hose correct level with transmission fluid POWER STEERING PUMP
from the pump. (CIAZ-19582-A). Start the engine PULLEY
4. Loosen the adjusting bolts and and turn the steering wheel to each
end of its travel several times to cycle REMOVAL
remove the drive belt from the pul-
the system and check for leaks. Other than pulley removal and res-
ley. ervoir or seal replacement, the pump
5. Drain the coolant from the ra- Check the fluid level (Section 1, Part
3-1) and fill as required and install should not be disassembled but re-
diator and remove 3 bolts and spac-
the fill cap. placed as a unit.
ers attaching the pump bracket to the
1. Drain as much of the fluid a~
engine. Remove one bolt attaching
possible from the pump through the
the support to the lower edge of the
8.CYLINDER fill pipe.
bracket and remove the pump and
2. Install a %-16 capscrew in the
bracket from the car.
Removal end of the pump shaft to prevent
6. Place the bracket in a vise and
install a 3/8-16 capscrew in the end of damage to the shaft end by the tool
1. Remove the fill cap from the screw.
the pump shaft. reservoirand removethe fluid with a 3. Install the pulley remover tool,
7. Install tool T63L-I0300-B on suctiongun. T63L-10300-B on the pulley hub,
the pulley and remove the pulley 2. Disconnectthe fluid return hose and place the tool and pump in a
from the pump shaft. Refer to Fig. from the reservoir. vise as shown in Fig. 5.
S for tool installatioq. 3. Disconnectthe oil pressurehose 4. Hold the pump and rotate the
8. Remove 3 bolts retaining the from the pump. tool nut counterclockwise to remove
pump to the bracket and remove the 4. Loosenthe belt adjustingbolts the pulley (Fig. 5).
pump from the bracket. and nut and remove the drive belt
from the pump pulley. .INSTALLATION
Installation 5. Remove3 bolts and 1 nut re- 1. Position the pulley to the pump
1. Position the pump to the brack- taining the pump to the bracket and shaft and install Tool T65P-3A733-
et and install the 3 retaining bolts. removethe pump from the car. A as shown in Fig. 6.
PART 3-4 POWER STEERING 3-39

the control valve, at the valve. Allow the Pitman arm with the castellated
the lines to drain into a container. nut and a cotter pin.
2. Disconnect the lines leading 3. Securethe end of the control
from the power steeringpump to the valve to the steering arm-to-idler
control valve at the valve. Allow the arm rod with two bolts, lock washers
lines to drain into a container. Re- and nuts.
move the clamp that secures the 4. Connect the pressureline and
lines to the valve. the oil return line to their respective
3. Removethe two bolts that se- fittings on the valve. Install the line
cure the control valve to the steer- retaining clamp around the valve.
ing arm-to-idlerarm rod. 5. Connectthe two lines from the
4. Removethe cotter pin and the power cylinder to their respectivefit-
castellatednut that securesthe con- tings on the valve.
trol valve to the Pitman arm. 6. Fill the reservoirto the correct
S. Disconnect the control valve level.
from the Pitman arm as shown in 7. Start the engine and turn the
Fig. 7. steering wheel to each end of its
travel severaltimes to cycle the sys-
tem. Stop the engine.
8. Checkthe fluid level and fill as
necessary.Install the fill cap.
9. Start the engineand checkfor
leaks.
FIG. 5-Removing Pulley COMET, FALCON, AND
From Pump FAIRLANE
2. Hold the pump and rotate the Removal
tool nut clockwiseto install the pul- 1. Disconnectthe 4 fluid line fit-
ley on the shaft. The pulley face will tings at the control valve, and drain
be flush with the end of the pump the fluid from the lines. Turn the
shaft.Install the pulley without in and front wheelsto the left and right sev-
out pressureon the shaft to prevent eral times to force all the fluid from
damageto internal thrust areas. the system.
3. Removethe tool. 2. Loosen the clamping nut and
bolt at the right-hand end of the
sleeve.
3. Removethe roll pin from the
steeringarm to idler arm rod through
the slot in the sleeve.
Installation 4. Remove the control valve ball
~
"
"," '" 1. Place the stud in a straight ver-
tical position. Measure from the cen-
stud nut.
5. Using the tool shownin Fig. 9,
ter of the stud parallel to the bolt removethe ball stud from the sector
mounting surface (Fig. 8) to the shaft arm.
VALVE
Tool-3290-C BAll STUD PITMAN ARM

Too/.T65P.3A733-A
f

G1274. A
FIG. 8-Control Valve
FIG. 6-Pulley Installation Length Adjustment-Mustang
POWER STEERING 6-Cylinder FIG. 9-Control Valve Ball
CONTROL VALVE center of the first bolt hole. The dis- Stud Removal
MUSTANG-6 CYLINDER tance should be from 4Ys-43/16inches
(6 cyl. models only). If not within 6. After turning the front wheels
Removal these limits adjust the length as re- fully to the left, unthreadthe control
1. Disconnect the pressure lines quired.
valve from the steeringarm to idler
leadin1! from the power cylinder to 2. Secure the control valve stud to arm rod.
~
3-40 GROUP3 SUSPENSION,
STEERING,
WHEELS
AND TIRES

Installation Install a new cotter pin. STEERINGARM-TO-IDLERARM ROD


1. Threadthe valveonto the steer- 7. Connect the fluid lines to the
ing arm to idler arm rod until about control valve, and tighten all fittings
four threads are still visible on the securely.Do not over-tighten.
rod. 8. Fill the fluid reservoirwith the
2. Positionthe ball stud in the sec- specifiedfluid to the F mark on the
tor shaft arm. dip stick.
3. Measure the distance between 9. Start the engine and run it at
the center of the greaseplug in the idle speedfor about two minutesto
sleeveand the center of the stud at warm the fluid in the power steering
the inner end of the left-hand spindle system.
connecting rod (Fig. 10). The dis- 10. Turn the steering wheel all
tance should be 55/8 inches. If the the way to the left and right several
distanceis not correct,disconnectthe times,and checkthe systemfor fluid FIG. 11 -Disconnecting Power
ball stud from the sector shaft arm leaks. Cylinder Stud
and turn the valve on the steering 11. Increase the engine speed to
arm to idler arm rod to increaseor about 1000 rpm, and turn the steer- 4. Disconnect the power cylinder
decreasethe distance. ing wheel all the way to the left and stud from the steering arm-to-idler
right severaltimes. arm rod as shown in Fig. 11.
12. Stop the engine,and checkthe 5. Remove the insulator sleeveand
control valve and hose connections washer from the end of the power
for fluid leaks. Correct the causeof cylinder rod.
any leaks. 6. Inspect the tube fittings and the
13. Check the fluid level, and re- seats in the power cylinder for nicks,
till the reservoir if necessary. burrs or damage. Replace the seats
14. With the enginerunningcheck in the cylinder or the tubes as re-
the position of the steering wheel quired.
when the front wheels are in the
straight-aheadposition. Do not make INST ALLA nON
any adjustments until toe-in is 1. Install the washer, sleeve and
checked. the insulator on the end of the power
15. Keep the enginerunning, and cylinder rod.
checktoe-in. If either toe-in or steer- 2. Extend the rod as far as pos-
ing wheel position is not correct sible. Insert the rod in the bracket
make all necessaryadjustments(Part on the frame and compress the rod
~-- ~ ~
3-1) at the spindle connectingrod as necessary to insert the stud in the
lUBRICATION PLUG G1157-A sleeves. steering arm-to-idler arm rod. Secure
16. Check the effort to turn the the stud with a castellated nut and a
FIG. 10 -Control Valve wheelsin both directions.The effort cotter pin.
Installation Measurement- should be about equal in both direc- 3. Secure the power cylinder rod
Typical-Comet, Falcon, tions. with an insulator, washer, nut and a
and Fairlane pal nut.
POWER CYLINDER 4. Connect each of the two fluid
4. When the correct distance is lines to their respective part in the
obtained and the ball stud is posi- REMOVAL
cylinder.
tioned in the sector shaft arm, align 1. Disconnect the two fluid lines 5. Fill the reservoir to the correct
the hole in the steeringarm to idler from the power cylinder and allow level.
arm rod with the slot near the end of them to drain into a container. 6. Start the engine and turn the
the valve sleeve.Install the roll pin 2. Removethe pal nut, attaching steering wheel to each end of its
in the rod hole to lock the valve in nut, washer and the insulator from travel several times to cycle the sys-
position on the rod. the end of the power cylinder rod. tem. Stop the engine.
5. Torque the valve sleeveclamp 3. Removethe cotter pin and cas- 7. Check the fluid level and fill as
bolt to specification. tellated nut that securesthe power necessary. Install the fill cap.
6. Install the nut on the ball stud, cylinder stud to the steeringarm-to- 8. Start the engine and check for
and torque the nut to specification. idler arm rod. leaks.

MAJOR REPAIR OPERATIONS


CONTROL VALVE cap from the valve housing (Fig. 12). 3. Remove the nut from the end
When holding the control valve for of the valve spool bolt. Remove the
DISASSEMBLY
disassembly,use a softjawed vise, and washers, spacer, centering spring,
1. Wipe all fluid and loose dirt clamp the valve only around the adapter, and bushing from the bolt
from the outsideof the control valve. sleeve flange to prevent damage to and the valve housing.
2. Removethe centeringspring the housing, spool, or sleeve. 4. Remove the two bolts that hold
PART 3-4 POWER STEERING 3-41

FIG. 12-Control Valve Disassembled-Typical


the valve housingand the sleeveto-
gether, and separate the housing I ~~ ~~ "':'",'" '"

from the sleeve. l GREASE


PLUG
:!
1 .,
5. Removethe plug from the valve
sleeve.
6. Push the valve spool out of the I VALVE
centering spring end of the valve SPOOL
housing, and remove the seal from BOLT
th~ spool.
7. Remove the spacer, bushing, STOP
and seal from the sleeve end of the PIN
valve housing.
FIG. 14-Removing Reaction
8. Drive the stop pin out of the BALL STUD""'"
travel regulator stop with a punch SOCKET TRAVEL""'" Valve Plug
REGULATOR
STOP G1030-8
,.,
and hammer (Fig. 13). Pull the head tapped hole. The washer must be
of the valve spool bolt tightly large enough to cover the hose seat
against the travel regulator stop be- FIG. 13-Removing Stop Pin port.
fore driving the pin out of the stop. 3. Insert the bolt in the tapped
-Typical hole, and using the nut as a puller,
9. Turn the travel regulator stop
counterclockwise in the valxe sleeve and a-ring, removethe reaction lim- remove the hose seat.
to remove the stop from the sleeve. iting valve (Fig. 14). 4. Place a new hose seat in the
10. Remove the valve spool bolt, port, and thread a bolt of suitable
spacer, and rubber washer from the
TUBE SEAT REPLACEMENT size into the port. Tighten the bolt
travel regulator stop. If a hoseseatis worn or damaged enough to bottom the seat in the
11. Remove the rubber boot and
it should be replaced.It can be re- port.
clamp from the valve sleeve. moved with an Easy-Outtool, or by
puller. ASSEMBLY
using
a
bolt
of
appropriate
size
as
12. Slide the bumper, spring, and Before assembling the control
ball stud seat out of the valve sleeve, 1. Tap the existing hole in the valve, coat all parts except the seals
and remove the ball stud socket from hose seat, using a starting tap of suit- with Automatic Transmission Fluid.
the sleeve. able size. Be sure to remove all metal Coat the seals with lubricantCOAZ-
13. After removing the return port chips from the hose seat port after 19553-A.
hose seat, remove the return port re- tapping. 1. Install the reaction limiting
lief valve. 2. Place a nut and large flat wash- valve, the spring, and the plug.
14. After removing the spring plug er on a bolt of the same size as the 2. Install the return port relief

~
3-42 GROUP3 SUSPENSION,STEERING,WHEELSAND TIRES

valve and the hose seat. same time, guide the lip of the seal so that the valve can be positioned
3. Insert one of the ball stud seats over the spool with a small screw- in a vise as shown in Fig 18. Then
(flat end first) into the ball stud driver. Do not nick or scratch the push forward on the cap end of the
socket, and insert the threaded end seal or the spool during installation. valve to check the valve spool for
of the ball stud into the socket. 11. Place the sleeve end of the free movement.
4. Place the socket in the control housing on a flat surface so that the
valve sleeve so that the threaded end seal, bushing, and spacer are at the
of the ball stud can be pulled out bottom end and push down the valve
through the slot in the sleeve (Fig. spool until it stops.
15). 12. Carefully install the spool seal
and bushing in the centering spring
end of the housing. Press the seal
/.,..
against the end of the spool, guid-
ing the seal over the spool with a
small screwdriver. Do not nick or
~ ~
r~
scratch the seal or the spool dur-
ing installation.
13. Pick up the housing, and slide
CONTROL { the spool back and forth in the hous- FIG. 18-lnspecting Valve
VALVE SLEEVE ing to check for free movement.
14. Place the valve sleeve on the Spool Movement
BALL STUD SEAT
housing so that the ball stud is on 20. Turn the valve around in the
BALL:
the same side of the housing as the vise, and push forward on the sleeve
BALL STUD SOCKET/' G103 5-A
ports for the two power cylinder end to check the spool for free
FIG. 15-lnstalling Ball lines. Install the two bolts in the movement.
Socket, Seal and Bracket sleeve, and torque them to specifica-
tions. POWER CYLINDER SEAL
s. Place the other ball stud seat, 15. Place the adapter on the cen-
the spring, and the bumper (Fig. 12) tering spring end of the housing, and REMOVAL
in the socket, and install and securely install the bushing, washers, spacers, 1. Clamp the power cylinder in a
tighten the travel regulator stop. and centering spring on the valve vise, and remove the snap ring from
6. Loosen the stop just enough to spool bolt. the end of the cylinder. Be careful
align the nearest hole in the stop 16. Compress the centering spring, not to distort or crack the cylinder
with slot in the ball stud socket, and and install the nut on the bolt. Tight- in the vise.
install the stop pin in the ball stud en the nut snug, then loosen it not 2. Pull the piston rod out all the
socket, travel regulator stop, and more than 1/4 turn (Fig. 17). Exces- way to remove the scraper, bush-
valve spool bolt (Fig. 13). sive tightening of the nut may break ing, and seals. If the seals cannot be
7. Install the rubber boot, clamp, the stop pin at the travel regulator removed in this manner, remove
and the plug on the control valve them from the cylinder with a sharp
stop.
sleeve. Make sure that the lubrica- pick. Take care, when using a pick,
tion fitting is turned on tightly and not to damage the shaft or seal seat.
does not bind on the ball stud socket.
8. Insert the valve spool in the INSTALLATION
valve housing. Rotate the spool while When replacing the power cylin-
inserting it in the housing (Fig. 16). der seals, install all of the parts sup-
plied in the repair kit for the cylin-
der being repaired.
1. Coat the new seals with lubri-
cant COAZ-19553-A and place the
parts (Fig. 19) on the piston rod
which has been coated with the same
grease.
G 1034- B 2. Push the rod in all the way, and
install the parts in the cylinder with
FIG. 17 -Adjusting Centering a deep socket slightly smaller than
the cylinder opening (Fig. 20).
G103'i-B Spring
17. Move the ball stud back and POWER STEERING PUMP
FIG. 16-lnserting Valve
forth in the sleeve slot to check the RESERVOIR REPLACEMENT
Spool spool for free movement. See Part Reservoir replacement must be
9. Move the spooltoward the cen- 3-6 for the specified travel. Apply done on a clean workbench. Clean-
tering spring end of the housing,and COAZ-19553-A (silicone) grease at liness of work area and tools is
place the small seal bushing, and the sealing areas. extremely important when repairing
spacerin the sleeveend of the hous- IS. Install the centering spring any hydraulic unit. Thoroughly clean
ing. cap on the valve housing, and torque the exterior of the pump with a
10. Pressthe valve spool against the two cap bolts to specification. suitable cleaning solvent. Do not im-
the inner lip of the seal and, at the 19. Install the nut on the ball stud merse the shaft oil seal in solvent.
PART 3-5 WHEELS
AND TIRES 3-43

INSERT
SEAL RUBBERWIPER
SEAL
RETAINER
SCRAPER

-
--::-: '/61
SEATS. -_/,/,>~
SNAP RING

Gl031-B

FIG. 19-Power Cylinder

TOOL
T57L-500-A FIG. 22-Gasket Locations
the rear of the reservoir and on the
outer edgesonly.
5. Inspectthe assemblyto be sure
the reservoiris evenly seatedon the
pump housingplate.
6. Position the serviceindentifica-
tion tag on the outlet fitting and in-
stall the outlet fitting hex nut. Torque
the nut to specification(Part 3-6).
FIG. 20-lnstalling Power Do not exceedspecification.
Cylinder Seals 7. Install the stud nut and torque
to specification.
Plug the inlet and outlet openings
with plugs or masking tape before
cleaning the pump exterior or re-
moving the reservoir.
WOOO
REMOVAL FIG. 21 -Removing Pump BLOCK

1. Position the pump in a bench Reservoir I


I
mountedholding fixture, Tool T57L- .
500-A. let fitting, a new copper gasket on
2. Rotate the pump so the pulley the supportstud, and a new reservoir
side is facing down and remove the O-ring seal on the pump housing
outlet fitting hex nut, stud nuts, and plate (Fig 22). The old gasketsand
service identification tag. seal should never be re-used.
3. Invert the pump so the pulley 2. Apply vaselineto the reservoir
side is facing up and remove the O-ring sealand to the inside edgeof
reservoir by tapping around the the new reservoir flange. Do not
flange with a wood block (Fig. 21). twist the O-ring seal.
4. Remove the reservoir a-ring 3. Position the reservoir over the
seal, the outlet fitting gasket, and pump and align the reservoir with
the support stud copper gasketfrom the outlet fitting and the stud hole.
TOOLTS7L
the pump. 4. Install the reservoir on the - ~ 1359-A
pump and O-ring seal with a plastic
INSTALLATION or rubber hammer and a block of FIG. 23-lnstalling Reservoir
1. Install a new gasketon the out- wood as shown in Fig. 23. Tap at on Pump

~
3-44

WHEELS AND TIRES

Section Page Section Page


1 Description and Operation. . . . . .3-44 4 Major Repair Operations. . . . . . . .
Wheel and Tire Installation 3-46
2 In-Car Adjustment
Front
RearWheel Wheel and Repairs . .3-44 3-46
.3-44 Front WheelGreaseSealand
.3-45 BearingReplacement and!or
Front Wheel Bearing Adjustment .3-45 Repacking. . . . . . . . . . . . . . . . . . ,3-46
3 Removal and Installation. .... . .3-45 Disc Brakes .'.'.'..'...""
Drum Brakes 3-47
Wheel and Tire Removal. . . . . . .3-45 3-47
Removing Tire From Wheel. . . .3-45 Front Hub and Drum Replacement 3-47
Installing Tire on Wheel. . . . . . .3-45 Front Hub and Rotor Replacement 3-48

DESCRIPTION AND OPERATION

FRONT WHEEL
HUB AND BRAKE ~ INNER GREASE
Each front wheel and tire assem- DRUMASSEMBLY BEARING RETAINER
bly is bolted to its respective front CUP

hub and brake drum or rotor on ADJUSTING


NUT
OUTER
BEARING \
\
,l
Mustang with disc brakes (optional OUTER ClIP
on Mustang models). Two opposed BEARING
CONE AND \;:::...,.
tapered roller bearings are installed ROLLER
GREASE ~
in each hub. A grease retainer is CAP
installed at the inner end of the hub INNERBEARING
to prevent lubricant from leaking in- , Q CONE AND
ROLLER
to the drum or on the rotor. The ~
entire assembly is retained to its
spindle by the adjusting nut, nut lock COTTER
WASHER

NUT/
..@
/
IL- WHEEL
ASSEMBLY
and cotter pin (Figs. I and 2). PIN- ~
NUT
.~~" HUB BOLT" ~
"."...
F1056-C

REAR WHEEL FIG. 1-Front Hub, Bearings and Grease Retainer-Drum Brakes

The rear brake drum assembly is GREASE


HUB AND RDTOR
ASSEMBLY
~ INNER
RETAINER
retained to studs on the rear axle BEARING
CUP
shaft flange by three speed nuts. The
ADJUSTING OUTER
wheel and tire assembly mounts on BEARING
NIIT
the same rear axle shaft flange studs OUTER CUP
BEARING
and is held against the hub and drum CONE AND ~
by the wheel nuts. The rear wheel GREASE ~
bearing is pressed onto the axle shaft CAp
..- INNERBEARING
just inside the shaft flange, and the
-- CONE AND
entire assembly is retained to the ROLLER
rear axle housing by the bearing re-
tainer plate which is bolted to the WASHER ~ -WHEEL
housing flange. COTTER
NUT
NUT/ ASSEMBLY
PIN
The inner end of each axle shaft LOCK HUB BOLTI "~/- F 1259- A
is splined to the differential in the
rear axle. FIG. 2-Front Hub, Bearings and Grease Retainer-Disc Brakes

~
PART 3-5 WHEELS
AND TIRES 3-45

IN-CAR ADJUSTMENTS AND REPAIRS


HOISTING INSTRUCTIONS three turns. Then, rock the wheel 8. Install a new cotter pin, and
Damage to suspension and/or and rotor assembly in and out several bend the ends of the cotter pin
steering linkage components may oc- times to push the shoe and linings around the castellated flange of the
cur if care is not exercised when away from the rotor. nut lock.
positioning the hoist adapters of 2 S. While rotating the wheel, hub, 9. Check the front wheel rotation.
post hoists prior to lifting the car. and drum or rotor assembly, torque If the wheel rotates properly, install
li a 2 post hoist is used to lift the the adjusting nut to 17-25 ft-ibs to the grease cap and the hub cap or
car, place the adapters under the seat the bearings (Fig 3). wheel cover. If the wheel still rotates
front suspension lower arms. Do not 6. Locate the nut lock on the ad- roughly or noisily, clean or replace
allow the adapters to contact the justing nut so that the castellations the bearings and cups as required
on the lock are aligned with the cot- (Section 4).
steering linkage.
ter pin hole in the spindle. 10. Before driving the car (if
FRONTWHEEL BEARING 7. Back off both the adjusting nut equipped with disc brakes), pump the
ADJUSTMENT and the nut lock together until the brake pedal several times to obtain
next castellation on the nut lock normal brake lining to rotor clear-
The front wheel bearings should aligns with the cotter pin hole in the ance and restore normal brake pedal
be adjustedif the wheel is too loose travel.
spindle.
on the spindle or if the wheel does
not rotate freely. The following pro-
cedurewill bring the bearingadjust-
ment to specification.
1. Raise the car until the wheel
and tire clear the floor.
2. Pry off the hub cap or wheel
cover and remove the grease cap
from the hub.
3. Wipe the excessgrease from WITH DRUM AND WHEEL
INSTAll lOCK ON NUT SO THAT
the end of the spindle, and remove ROTATING, TORQUE THE
CA5TEllATION5 AREALIGNED
ADJUSTING
the cotter pin and nut lock. NUT TO 17.25 It lb. WITH COTTERPIN HOLE.
4. If equipped with disc brakes,
loosen the bearing adjusting nut FIG. 3-Front Wheel Bearing Adjustment

REMOVAL AND INSTAllATION


HOISTING INSTRUCTIONS mounting machine. Be sure that the wheel downward, and insert two tire
Damage to suspension and/ or outer side of the wheel is positioned irons about 8 inches apart between
steering linkage components may oc- downward. If tire irons are used fol- the tire inner bead and the back side
cur if care is not exercised when low the procedure given here. of the wheel rim. Use only tire irons
positioning the hoist adapters of 2 1. Remove the valve cap and core, with rounded edges or irons designed
post hoists prior to lifting the car. and deflate the tire completely. for demounting tubeless tires.
If a 2 post hoist is used to lift the 2. With a bead loosening tool, 4. Leave one tire iron in position,
car, place the adapters under the break loose the tire side walls from and pry the rest of the bead over the
front suspension lower arms. Do not the wheel (Fig. 4). rim with the other iron. Take small
allow the adapters to contact the 3. Position the outer side of the "bites" with the iron around the tire
steering linkage. in order to avoid damaging the seal-
ing surface of the tire bead.
WHEEL AND TIRE REMOVAL
5. Stand the wheel and tire up-
1. Pry off the wheel hub cap or right with the tire outer bead in the
cover. Loosen but do not remove drop center well at the bottom of the
the wheel lug nuts. wheel. Insert the tire iron between
2. Raise the car until the wheel the bead and the edge of the wheel
and tire clear the floor. rim, and pry the wheel out of the
3. Remove the wheel lug nuts tire.
from the bolts, and pull the wheel
and tire assembly from the hub and
drum or rotor. INSTALLING TIRE ON WHEEL
1. If a used tire is being installed
REMOVING TIRE FROM remove all dirt from the tire.
Fl058-A
WHEEL If a tire is being mounted to the
The tire can be demounted on a FIG. 4-Bead LooseningTool original wheel, clean the rim with
3-46 GROUP 3 SUSPENSION,
STEERING,
WHEELS
AND TIRES

emery cloth or fine steel wool. Check the side walls) are evenly visible just
the rim for dents. above the rim flanges all the way
If a new wheel is being installed, around the tire. If the rings are not
coat a new valve with RUGL YDE even, deflate the tire completely and
or similar rubber lubricant and posi- inflate it again.
tion the valve to the new wheel. Use 6. When the rings are properly
a rubber hammer or a valve replac- positioned, deflate the tire to the
ing tool to seat the valve firmly recommended pressure.
against the inside of the rim. F1021-A
2. Apply RUGL YDE or a simi- FIG. 5-Tubeless Tire WHEEL AND TIRE
lar rubber lubricant to the sealing INSTAllATION
surface on both tire beads. With the MountingBand
1. Cleanall dirt from the hub and
outer side of the wheel down, pry
a torniquet of heavy ~ord around drum or rotor.
the beads over the wheel rim with
two tire irons. Do not use a hammer the circumference of the tire. Tighten 2. Position the wheel and tire as-
or maDet to force the beads over the cord with a tire iron. Center the sembly on the hub and drum or
the rim. tire on the wheel with a rubber rotor. Install the wheel lug nuts and
3. Align the balance mark on the mallet. tighten them alternately in order to
tire with the valve on the wheel. 5. Give the tire a few quick bursts draw the wheel evenly against the
4. Hold the beads against the rim of air to seat the beads properly, hub and drum or rotor.
flanges by positioning a tire mount- then inflate the tire to 40 pounds 3. Lower the car to the floor, and
ing band over the tire (Fig 5). If a pressure. Check to see that the bead torque the lug nuts to specification
mounting band is not available, tie positioning rings (outer rings near (Part 3-6).

MAJOR REPAIR OPERATIONS


HOISTING INSTRUCTIONS the inner bearing cone and roller as-
Damage to suspension and/or sembly from the hub with a drift.
steering linkage components may 5. Clean the lubricant off the
occur if care is not exercised when inner and outer bearing cups with
positioning the hoist adapters of 2 solvent and inspect the cups for
post hoists prior to lifting the car. scratches, pits, excessive wear, and
If a 2 post hoist is used to lift other damage. If the cups are worn
the car, place the adapters under or damaged, remove them with a drift.
the front suspension lower arms. Do 6. Soak a new grease retainer in
not allow the adapters to contact the light engine oil at least 30 minutes
steering linkage. before installation. Thoroughly clean
the inner and outer bearing cones
FRONT WHEEL GREASE SEAL and rollers with solvent, and dry
AND BEARING REPLACEMENT them thoroughly. Do not spin the
AND/OR REPACKING bearing with compressed air.
If bearing adjustment will not 7. Inspect the cone and roller as-
eliminate looseness or rough and semblies for wear or damage, and re-
noisy operation, the hub and bear- place them if necessary. The cone
ings should be cleaned, inspected, and roller assemblies and the bear-
and repacked. If the bearing cups or ing cups should be replaced as a unit Fl093-A
the cone and roller assemblies are if damage to either is encountered.
worn or damaged, they should be 8. Thoroughly clean the spindle FIG. 6-lnstalling FrontWheel
replaced. and the inside of the hub with sol- BearingCup-Falcon6-Cylinder
vent to remove all old lubricant.
DRUM BRAKES Cover the spindle with a clean specified wheel bearing grease. Add
1. Raise the car until the wheel cloth, and brush all loose dust and lubricant to the hub only until the
and tire clear the floor. dirt from the brake assembly. To grease is flush with the inside di-
2. Remove the wheel cover or prevent getting dirt on the spindle, ameter of both bearing cups (Fig. 8).
hub cap. Remove the grease cap carefully remove the cloth from the 11. All old grease should be com-
from the hub. Remove the cotter spindle. pletely cleaned from the bearings
pin, nut lock, adjusting nut, and flat 9. If the inner and/ or outer bear- before repacking them with new
washer from the spindle. Remove ing cups(s) were removed, install the grease. Pack the bearing cone and
the outer bearing cone and roller replacement cup(s) in the hub with roller assemblies with wheel bearing
assembly (Fig I). the tool shown in Figs. 6 or 7. Be grease. A bearing packer is desira-
3. Pull the wheel, hub, and drum sure to seat the cups properly in the ble for this operation. If a packer is
assembly off the wheel spindle. hub. not available, work as much lubri-
4. Remove the 2rease retainer and 10. Pack the inside of the hub with cant as possible between the rollers
PART 3-4 WHEELS
AND TIRES 3-47

new cotter pin. Bend the ends of the Be sure to seat tbe cups properly in
cotter pin around the castellations of tbe bubo
the nut lock to prevent interference 12. Pack the inside of the hub
with the radio static collector in the with specified wheel bearing grease.
grease cap. Install the grease cap. Add lubricant to the hub only until
16. Install the hub cap or wheel the grease is flush with the inside
cover. diameter of both bearing cups.
13. All old grease should be com-
DISC BRAKES pletely cleaned from the bearings
INNER CUP OUTER CUP
INSTALLA nON INSTALLA nON 1. Raise the car until the wheel before packing them with new grease.
Fl057-A and tire clear the floor. Pack the bearing cone and roller as-
2. Remove the wheel cover or hub semblies with wheel bearing grease.
FIG. 7-lnstalling Front Wheel cap. A bearing packer is desirable for
BearingCup-All Fairlane,Comet, 3. Remove the wheel and tire from this operation. If a packer is not
and Mustangand 8-Cylinder the hub. available, work as much lubricant as
Falcon 4. Remove 2 bolts attaching the possible between the rollers and
caliper to the caliper bracket. Re- cages. Lubricate the cone surfaces
move the caliper from the rotor and with grease.
wire it to the underbody to prevent 14. Place the inner bearing cone
damage to the brake hose. and roller assembly in the inner cup,
5. Remove the grease cap from and install the new grease retainer
the hub. Remove the cotter pin, nut with the reverse end of the tool
LUBRICANT lock, adjusting nut, and flat washer
~ shown in Figs. 6 or 7. Be sure tbat
from the spindle. Remove the outer the retainer is properly seated.
bearing cone and roller assembly 15. Install the hub and rotor on
(Fig. 2). the wheel spindle. Keep tbe bub
6. Pull the hub and rotor off the
centered on the spindle to prevent
wheel spindle.
damage to the grease retainer or tbe
7. Remove the grease retainer and
spindle tbreads.
the inner bearing cone and roller as-
sembly from the hub. 16. Install the outer bearing cone
and roller assembly and the flat
8. Clean the lubricant off the in-
ner and outer bearing cups with washer on the spindle; then, install
solvent and inspect the cups for the adjusting nut.
scratches, pits, excessive wear, and 17. Position the caliper over the
other damage. If the cups are worn rotor and install the 2 attaching bolts.
or damaged, remove them with a 18. Install the wheel and tire on
drift. the hub.
9. Soak a new grease retainer in 19. Adjust the wheel bearings as
light engine oil at least 30 minutes outlined in Section 2, and install a
before installation. Thoroughly clean new cotter pin. Bend the ends of the
F1174-A the inner and outer bearing cones cotter pin around the castellations of
and rollers with solvent, and dry the nut lock to prevent interference
FIG. 8-Front Wheel Hub them thoroughly. Do not spin the with the radio static collector in the
Lubrication bearings with compressed air. grease cap. Install the grease cap.
Inspect the cone and roller assem- 20. Install the hub cap or wheel
and cages. Lubricate the cone sur- blies for wear or damage, and re- cover and lower the car.
faces with grease. place them if necessary. The cone
12. Place the inner bearing cone and roller assemblies and the bear- FRONT HUB AND DRUM
and roller assembly in the inner cup, ing cups should be replaced as a REPLACEMENT
and install the new grease retainer unit if damage to either is encoun.
teredo When the hub and drum assembly
with the reverse end of the tool is replaced, new bearings, cups, and
shown in Figs. 6 to 7. Be sure that 10. Thoroughly clean the spindle
and the inside of the hub with solvent grease retainer must be installed in
the retainer is properly seated.
to remove all old lubricant. the new assembly. The new grease
13. Install the wheel, hub, and
drum assembly on the wheel spin- Cover the spindle with a clean retainer should be soaked in light
dle. Keep the hub centered on the cloth, and brush all loose dust and engine oil at least 30 minutes before
spindle to prevent damage to the dirt from the brake assembly. To installation.
greaseretainer or the spindle threads. prevent getting dirt on the spindle 1. Raise the car until the wheel
14. Install the outer bearing cone carefully remove the cloth from the and tire clears the floor. Pry off the
and roller assembly and the flat spindle. hub cap or wheel cover, and remove
washer on the spindle; then, install 11. If the inner and / or outer the wheel and tire assembly from
the adjusting nut (Fig. 1). bearing cup(s) were removed, install the hub and drum assembly.
15. Adjust the wheel bearings as the replacement cup(s) in the hub 1. Remove the grease cap from
outlined in Section 2, and install a with the tool shown in Figs. 6 or 7. the hub. Remove the cotter pin. nut
lock, adjusting nut, and flat washer and tighten them alternately in order 5. Pack the inside of the hub with
from the spindle. Remove the outer to draw the wheel evenly against specified wheel bearing grease. Add
bearing cone and roller assembly the hub and drum. Do not exceed lubricant to the hub only until the
(Fig. 1). specifications (Part 3-6). grease is flush with the inside di-
3. Pull the wheel, hub, and drum 11. Adjust the wheel bearings as ameter of both bearing cups.
assembly off the wheel spindle. outlined in Section 2, and install a 6. All old grease should be com-
4. Remove the protective coating new cotter pin. Bend the ends of the pletely cleaned from the bearings
from the new hub and drum with cotter pin around the castellations of before repacking them with new
carburetor degreaser. Install new in- the nut lock to prevent interference grease. Pack the bearing cone and
ner and outer bearing cups in the with the radio static collector in the roller assemblies with wheel bearing
new hub with the tool shown in Figs. grease cup. Install the grease cup. grease. A bearing packer is desira-
6 or 7. Be sure to seat the cups 12. Install the hub cap or wheel ble for this operation. If a packer is
properly in the hub. cover. not available, work as much lubri-
5. Pack the inside of the hub with cant as possible between the rollers
specified wheel bearing grease. Add FRONTHUB AND ROTOR and cages. Lubricate the cone sur-
lubricant to the hub only until the REPLACEMENT faces with grease.
grease is flush with the inside di- 7. Place the inner bearing cone
ameter of both bearing cups (Fig. When the hub and rotor assembly
is replaced, new bearings, cups, and and roller assembly in the inner cup,
8). and install the new grease retainer
6. All old grease should be com- grease retainer must be installed in
the new assembly. The new grease with the reverse end of the tool
pletely cleaned from the bearings shown in Figs. 6 or 7. Be sure that
before repacking them with new retainer should be soaked in light
the retainer is properly seated.
grease. Pack the bearing cone and engine oil at least 30 minutes before
installation. 8. Install the new hub and rotor
roller assemblies with wheel bearing
1. Raise the car until the wheel assembly on the wheel spindle. Keep
grease. A bearing packer is desirable
and tire clears the floor. Pry off the the hub centered on the spindle to
for this operation. If a packer is not
hub cap or wheel cover, and remove prevent damage to the grease re-
available, work as much lubricant as
the wheel and tire assembly from tainer.
possible between the rollers and
cages. Lubricate the cone surfaces the hub and rotor. 9. Install the outer bearing cone
with grease. 2. Remove 2 bolts attaching the and roller assembly and the flat
7. Place the inner bearing cone caliper to the caliper bracket. Re- washer on the spindle; then, install
and roller assembly in the inner move the caliper from the rotor and the adjusting nut (Fig 2).
cup, and install the new grease re- wire it to the underbody to prevent 10. Position the wheel and tire as-
tainer with the reverse end of the damage to the brake hose. sembly on the new hub and rotor.
tool shown in Fig. 6 or 7. Be sure 3. Remove the grease cap from Install the wheel hub nuts and tighten
that the retainer is properly seated. the hub. Remove the cotter pin, nut them alternately in order to draw
8. Install the new hub and drum lock, adjusting nut, and flat washer the wheel evenly against the hub and
assembly on the wheel spindle. Keep from the spindle. Remove the outer rotor. Do not exceed specifications
the hub centered on the spindle to bearing cone and roller assembly (Part 3-6).
prevent damage to the grease re- (Fig 2). Pull the hub and rotor off 11. Adjust the wheel bearings as
tainer. the wheel spindle. outlined in Section 2, and install a
9. Install the outer bearing cone 4. Remove the protective coating new cotter pin. Bend the ends of the
and roller assembly and the flat from the new hub and rotor with cotter pin around the castellations of
washer on the spindle; then, install carburetor degreaser. Install new in- the nut lock to prevent interference
the adjusting nut (Fig 1). ner and outer bearing cups in the with the radio static collector in the
10. Position the wheel and tire new hub with the tool shown in Figs. grease cap. Install the grease cap.
assembly on the new hub and drum 6 or 7. Be sure to seat the cups 12. Install the hub cap or wheel
assembly. Install the wheel lug nuts properly in the hub. cover.
3-49

SPECIFICATIONS

FRONT WHEEL ALIGNMENT


Checking Specifications OptimumRe-settingSpecifications
MaximumVariation
COMET, FALCONAND FAIRLANE Min. Max. BetweenWheels Desired Alignment
- -
Caster +1° Yz° 0°
~
=---*° +1° Yz° .+\140
"ii' %i~: c
¥Sin. 3fain.

MUSTANG
-
Caster-6 Cyl. 0°
"
+2° j,i° }E
Caster-8 Cyl. -1° +1° ~
j,i° O'
i
Camber-All ~ +1Y4° !, j,i° +~~
IL .
Toe-in Yein. * in. ~ 74In.

Optimum Re.Setting Specifications


COMET, FALCONAND FAIRLANE
Desired Alignment

KingPin Angle 7Yz°


-
TurningAngleof OutsideWheelWith1nsideWheelTurned20° 170/40

BALL JOINTS
Radial Play (Inches)
Max. Allowable
-
lupper Ball Joint 0.250
ILower Ball Joint Replace if Perceptibly Loose
3-50 GROUP 3 SUSPENSION,
STEERING,
WHEELS
AND TIRES

FRONT SUSPENSION TORQUE LIMITS (FIG. 1) REAR SUSPENSION TORQUE LIMITS (FIG. 2)

:;):

F 1285-A

FIG. 1 .Front SuspensionTorque limits


F1286-A

FIG. 2-Rear Suspension


Torquelimits

STEERING GEAR
COMET
VEHICLE FAIRLANE MUSTANG FALCON
- - - - -
~ HCA.CA HCA.BZ HCC-AT HCC.AX HCC-AW HCA-CA HCA.BY

Special
GearType Manual Power Manual Manual Power Manual Power
GearRatio 22:1 16:1 19.9:1 16:1 16:1 22:1 16:1

5 4 45/8 33/4 33/4 5 4


4-5 3.4 4-5 4-5 3-4 4-5 3-4
Total Preload!WormBearing
plus Sector Mesh)@in-ibs 9-10 @8-9 9-10 9-10 f CD8.9 9-10 @8-9
LubeCapacity(Ol) 11 8 11
I lube Type (C3AZ-19578-AJ
-
I NormalFluid PressureAgainstEither Stop (Engine1000r~) Power 750.900psi
ControlValveSpoolTravel(from Center) Power 0.060 in Approx.
New:120-150Ibs.
Power Steering Belt Tension Using tool BT.33.73F Power
Used:90-120Ibs.

ADJUSTMENTS ALL MODELS: NOTES:


Adjustingscrew clearanceat bottom of sector shaft T-slot-.OOO"- @Gearonly-not attachedto Pitmanarm.
.002". 0Total (meshload plus worm bearing preload)must be a minimum
Sector Shaft end play-steering linkage disconnected-none. of 2 lb. in. greater than worm bearing preload.
With gear mounted in vehicle or on a suitable fixture and posi- ~Required to rotate input shaft and worm assembly past the
tioned on center, and the sector shaft retainedto prevent rotation, center high point.
apply a 15 lb. in. torque on the steering gear input shaft in both ~Torque required to rotate input shaft at approximately 1'/2
right and left turn directions. The total angular travel of the turns either side of center (gear out of vehicle or Pitman arm
input shaft cannot exceed 8V2 degrees,with 8 lb. in. net mesh disconnected)
load.
3-52 GROUP 3 SUSPENSION,
STEERING,
WHEELS
AND TIRES

STEERING GEAR TORQUE LIMITS STEERING COLUMN TORQUE LIMITS


COMET, FALCON AND F AIRLANE

(f)Residualtorque must be 40 ft-lbs minimum

MUSTANG

POWER STEERING PUMP TORQUE LIMITS (FIG. 4)

@Residualtorque must be 35 ft-ibs minimum

STEERING LINKAGE TORQUE LIMITS (Fig. 3)


Torque Ft-Lbs

Comet-Falcon
Fairlane Mustang

Ref.
No. Description
! I !
Standard Power Standard Power
Steerin~Steerin~Steering Steering

Cylinder Mounting Bracket


to Underbody(SideHole) 28.35 28-35
2 SteeringSpindleArm
ConnectingRodEndto
SpindleArm 030-40 @30-40
3 Idler Arm Mounting
Bracketto Underbody 28.35 28.35
4 PitmanArm to Steering
Arm-to-idierArm Rod or
to Valveand link
Assembly 035.47 @35-47
5 SteeringSpindleArm
ConnectingRodto Steer
ing Arm-to-idleArm Rod <!!30-40 025-30
6 Cylinder Mounting Bracket
to Underbody(Bottom
Hole) 35-43 35-43
7 Power Cylinder to Bracket 18-24 18-24
8 Power Cylinder to Bracket
lock Nut 3-5 3-5
Steering Gear10 Side Rail 40-55 40-65
11~ PitmanArm to SectorShaft 150-225 85-110
11 PowerCylinderto Control
Rod 1<!>35-47 @35-47

12 Idler Arm to SteeringArm.


to-Idler Arm Rod. @60.80 @35-47
13 SteeringSpindleArm
Connecting Rod and
EndClampto Adjusting
Sleeve 8-14 19-26

@Torqueto low limit of specificationj then, tighten the nut to


the nearest cotter pin slot and insert the cotter pin.
PART 3-6-SPECIFICATIONS
ANDSPECIAL
TOOLS 3-53

~ ' ~~ I .:~,.-,,"'",.,
T I
/ ..'
,.:~
/'
, ,,"'" ,~1:,
"-",,'-""~-Jf~-'--'-'N'I'-:':I.
:-
:,..:f""'"
..' i~
,1 ~.'
~ 'J~~~.(.~~~.:'.'\<b~~
,,~ " '-,'-,.
. '"
~ "

-@-@J-;'
..i ".. ' t
1 .! ..
'..,""-:' -"'.: J"'" 7 3
I .. .-~:-;~~ ".,
/'.
~ , 4 ,~

1~~~~
.~:;1
...
~ "
..';...
,&~
.-::--"-'f.:"

,,-:-, , ;;" ,;;;:.: f!"~,-


;1 w---IO
,-~"\~%i.~~~ .~'~":'
,. ~\.,..,II
, ",.""
j II'
"

'6~ :. ,'~
- ,~:;;,::i
'~- ,-"-

,,~ -~-'-
..p" '~"'~~1';:",~,\
f;1
'--;:".'.;.$Y~;A'
"--"""~'
..'
'~::"""" '::'~"".
'" ~"",~",.-

"'-;

\ 11
13 I?
,~,

I, \
'" -,~
G1370-A

FIG. 3-Steering Linkage Torque Limits

FIG. 4-Power SteeringPumpTorqueLimits


3-54 GROUP3 SUSPENSION,
STEERING.
WHEELS
AND TIRES

TIRES

TIRE SIZE TIRESIZE TIRESIZE


MODELS 6 CYLINDER 8 CYLINDER(289 C.I.DJ 8 CYLINDER(390 C.I.D.)
STANDARD R.P.0. STANDARD R.P.O. STANDARD R.P.O.

FALCON
Sedan 6.50x 13 @6.95x 14 6.95x 14
Wagon 7.35x14 7.35x14
Ranchero 7.35x 14 7.75x 14 7.35 x 14 7.75x 14
COMET AND FAIRLANE
Sedan 6.95x 14 7.35x 14 6.95x 14 7.35x 14 7.35x 14 7.75x 14
Convertible 6.95x 14 7.35 x 14 6.95 x 14 @7.35x 14 @7.35x 14 @7.75x 14
Hardtop 6.95x 14 I 7.35x 14 6.95x 14 @7.35x 14 @7.35x 14 @7.75 x 14
Wagon 7.75x 14 7.75x 14-8 Plv 7.75x15 7.75x 14- 8 Ply 7.75x 14 7.75x 14-8 Ply
MUSTANG
Convertible 6.95x 14 @6.95x 14 6.95x 14 @6.95x 14
Hardtop 6.95x 14 @6.95x 14 6.95x 14 @6.95x 14
Imo. Handling @6.95x 14
@-Standard on model62C @-110 Levelnylon
@-110 Level 120 mph dual red bandnylon ~7.75 x 14 standardon FairlaneGTmodels
@-Standard with air conditioning

SERVICE TOOLS

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