group 3 suspension, steering, wheels & tires

3-1

PART 3-1SUSPENSION, STEERING, WHEELS

AND TIRES GENERAL SERVICE.

PART 3-2SUSPENSION """"""""

PART 3-3MANUAL STEERING. . . . . . . . . . .

PAGE PART 3-4POWER STEERING PART 3-5

WHEELS AND TIRES. . . .

PART 3-6SPECIFICATIONS. . . . . . .

PAGE. . . . .3-34

3-1

. . .3-44. .3-11

3-49

SUSPENSION, STEERING, WHEELSAND TIRES GENERAL SERVICE

Section Page1 Diagnosis and Testing 3-1

Manual Steering 3-1Power Steering 3-1Front Wheel Alignment Checks. . . . . . . . . . . . . .3-4

Equipment Installation. . . . . . . . . . . . . . . . . . .3-4Caster 3-6Camber 3-6Toe-In 3-6Front Wheel Turning Angle. . . . . . . . . . . . . .3-6

2 Common Adjustments and Repairs .3-6Caster and Camber Adjustments 3-6

Mustang 3-6Comet, Falcon, and Fairlane 3-7

Toe-In and Steering Wheel AlignmentAdjustments 3-7

Section PageSteering Gear Lubricant Checking

Procedure 3-8Mustang 3-8Comet, Falcon, and Fairlane 3-8

3 Cleaning and Inspection 3-9Steering Gear Cleaning and Inspection. . . . . . . . 3-9Flushing the Power Steering System 3-9Front End General Inspection. . . . . . . . . . . . . . .3-9Wheel Inspection 3-9Upper Ball Joint Inspection .3-10Lower Ball Joint Inspection. . . . . . . . . . . . . . . .3-10Shock Absorbers 3-10

fluid to raise the level to the base ofthe filler neck. Do Dot overfill the res-ervoir.

Check For Fluid Leaks

1. If the power steering fluid doesnot already include yellowish greendye, pre-mix one teaspoonful of oil-soluble aniline dye with 2 pints of au-tomatic transmission fluid CIAZ-] 9582-A. Then refill the reservoirwith the dye solution.

2. With the engine running at idlespeed, turn the steering wheel all theway to the right stop and to the leftstop several times to distribute thedye solution throughout the hydraulicsystem. Do not hold the wheel against

D DIAGNOSIS AND TESTINGMANUAL STEERING Check Pump Belt

Table 1 lists various steering gear If the pump belt is broken, glazed,and linkage trouble symptoms and or worn, replace with a new belt. Usepossible causes. Several of these only the specified type of belt.symptoms are also common to sus- .pension frame, and wheel and tire Check The Belt Tensiontroubles. For this reason, be sure that If the belt is too loose or too tight,the cause of the trouble is in the it should be adjusted to the propersteering gear or linkage before adjust- tension as outlined in Part 3-4.ing, repairing, or replacing any of the A "used belt" is one that has runsteering parts. 15 minutes or longer.

POWER STEERING Check Fluid LevelStart the engine, turn the steering

PRELIMINARY TESTS wheel all the way to the left andThe following preliminary checks right several times, and shut off the

should always be made before per- engine.forming any trouble-shooting opera- Check the fluid level in the reser-tions. voir. If the level is low, add enough

GROUP 3 - SUSPENSION, STEERING, WHEELS AND TIRES3-2

seals. A power cylinder seal kitshould be used to correct leakage.Do not replace the power cylinder as.sembly unless the piston rod is scoredor has a dull gray finish instead of ahigh luster chrome finish.

Check Turning EffortWith the front wheels properly

aligned and tire pressures correct,check the effort required to turn thesteering wheel.

1. With the car on dry concrete,set the parking brakes.

2. With the engine warmed up andrunning at idle speed, turn the steer-ing wheel to the left and right severaltimes to warm the fluid.

3. Attach a torque wrench to thesteering wheel hub. (Fig. 1). Check

~;~:~~h (In. Lb.)~ C 1270- B

FIG. 1 -Checking TurningEffort- Typical

the effort required to turn the wheelat least one complete revolution inboth directions. See Part 3-6 for thespecified torque which should be ap-proximately equal in both directions.

Pump-Fluid Pressure TestA fluid pressure test will show

whether the pump or some other unitin the power steering system is caus-ing trouble in the system. Steps out-lined below should be followed to de-termine the cause of the trouble.

1. Measure the pump belt tension.When adjusting the belt tension on

the power steering pump, do not pryagainst the pump to obtain the prop-er belt load.

A half-inch cast boss has been in-corporated on the front face of thepump cover plate onto which a 9/16inch open end wrench can be fitted topry the pump and obtain the properbelt tension.

2. Disconnect the pressure linehose from the pump outlet, and installa 0-2000 psi pressure gauge and shutoff valve between the end of the hoseand the pump outlet (Fig. 2).

Be sure that the pressure gauge isbetween the pump and the shut offvalve, all connections are tight, andthe shut off valve is fuUy open.

3. Connect a tachometer.4. Start the engine and operate it

at idle speed for at least two minutesto warm up the fluid.

S. Cycle the steering wheel fromstop-to-stop several times to expel any

each wheel stop for more than 3 to5 seconds.

3. Shut off the engine, and checkfor leaks.

Fitting and Tube Seat Leak. Sincemost fluid leaks occur at the fittingsand connections in a power steeringhydraulic system, these parts shouldbe checked before any other part isreplaced.

1. With the engine running at idlespeed, raise the car on a hoist.

2. Clean the outside of the con-trol valve and the power cylinder, thebottom surfaces of the pump, and alllines and fittings. Dirt, oil, and greaseshould be removed from all areaswhere leaks may exist.

3. Tighten all fittings, using a spe-cial 5-flat tube wrench. Do not tight-en the fitting with a standard openend wrench. If a properly tightenedfitting leaks, replace the seat.

Pump, Control Valve, and PowerCylinder Leak. If the fittings and con-nections do not leak, check the otherparts of the system.

Check the hose connection at thepump for leaks, and tighten the hoseclamp if necessary.

Pump Leaks. If leakage occurs atthe pump reservoir seal, pump outletvalve seals, or the support stud seal,check the torque of the outlet valvenut and the support stud nut. Iftorque is within specifications, replacethe reservoir seal, outlet valve seals,or the support stud seal, whichever isrequired if leaks are evident otherthan the lines.

Control Valve Leaks. If the controlvalve is leaking (somewhere otherthan the tube seats), replace all theseals, using a control valve seal kit.Use all the parts in the kit, and besure they are correctly installed.When assembling the new seals in thevalve, an application of siliconegrease to the internal parts will helpto provide a better seal against futureleakage. Apply grease to the center-ing spring area, especially on the capand spacer mating surfaces. Coat thethreads of the cap retaining boltswith grease. The rubber boot seals,the actuator assembly, and the met-al cup seals in the control valveshould also be coated with siliconegrease.

Some oil remaining from the man-ufacturing processes may be found inthe sleeve near the ball stud. Do notconfuse this oil with leaking fluidfrom the hydraulic system.

Power Cylinder Leaks. The powercylinder may leak at the piston rod

PART 3-1 - SUSPENSION, STEERING. WHEELS AND TIRES GENERAL SERVICE3-.1

afore and cause undue pump and/ orsteering gear wear. Engine rpmshould not exceed fast idle duringthis test.

sure is higher, inspect the hoses forkinks and obstructions.

7. Increase the engine speed to1000 rpm; then, slowly close thegauge shut-off valve. With the valvefully closed, the pump pressureshould be 750 to 900 psi.

Do not close the valve for morethan a few seconds (maximum 5 sec-onds), as this would abnormally in-crease the lubricant (fluid) temper-

air from the system; stop the engine.Remove the reservoir filler cap andcheck the fluid level in the reservoir.If necessary, add lubricant CIAZ-19582-A to the proper level.

6. With the engine running at ap-proximately 500 rpm and no steeringeffort applied, and the lubricant atnormal operating temperature, thepressure gauge should show a pres-sure of less than SO psi. If the pres-

If pressure is more or less thanspecification, replace the pump as-sembly. If pressure is as specified andsteering efforts are heavy, the gearand! or control valve could be at fault.

STEERING TROUBLE DIAGNOSIS GUIDE

BINDING OR POORRECOVERY

check the spool adjustment. If the ad-justment is correct, overhaul or re-place the control valve.

Check the control valve travel reg-ulator stop adjustment. If the stop isdrawn up too tightly, the ball studwill bind in the seats. Adjust the stopas required.

Check the control valve sleeve andthe socket tube for damage. Replaceparts that show signs of damage, andadjust the travel regulator stop.

Check for possible interference be-tween the steering wheel and thesteering column.

If the steering wheel binds or stickswhen turned, or if poor recovery tothe straight-ahead position occurs,check the Pitman arm ball stud in thecontrol valve sleeve. If the ball studis rubbing against the edge of thesleeve slot, the roll pin may be miss-ing.

If either of the idler arm bushingsare worn or damaged, replace bothbushings.

Check the steering gear adjustment(Section 2).

Check the operation of the controlvalve spool in the valve housing. Ifthe spool is binding in the housing,

tering spring adjustment. Adjust if re-quired (Section 2).

Check the control valve spool formovement. If the spool does notmove freely, check for, and eliminate,interference between the socket tubeand the valve sleeve. If the spool issticking in the housing, remove thespool and check the spool lands forburrs. Small burrs may be removedwith crocus cloth if the edges of thevalve lands are not rounded in theprocess. If the spool cannot be re-paired, replace the control valve.

Check the control valve ball studfor free movement in the ball studseats. If the stud is binding in theseats, adjust the travel regulator stop.

If the hard steering still persists,check the front end alignment.

HAP.D STEERING

If the effort required to turn thesteering wheel is greater than normalfor the entire travel of the frontwheels, check the tire pressure then,test the fluid pressure. Be sure thatthere are no leaks, that the reservoiris properly filled, and that the belt isproperly adjusted. If the pump outputpressure is low, the pump may be de-fective and should be replaced.

If the pressure test shows that thetrouble is in the control valve or pow-er cylinder, remove and inspect theseunits. Repair or replace any damagedparts.

If the pressure test indicates thatthe pressures throughout the systemare within specifications, check thefollowing items in the order given:

Check the control valve spool cen-

valve travel regulator stop

Check the control valve centeringspring adjustment. If the spring ad-justment nut is loose, tighten the nutuntil it is snug, and then back off thenut not more than 1/4 turn. Excessivetightening may damage the stop pin.

EXCESSIVE FREE PLAY

If excessive free play or lost mo-tion is noticed when steering, checkthe steering gear preload and meshadjustment.

Check for excessive clearance be-tween the steering arm ball stud andthe ball stud seats. If the ball stud isloose in the seats, adjust the control

CONTINUED ON NEXT PAGE

3-4 GROUP 3 SUSPENSION, STEERING, WHEELS AND TIRES

STEERING TROUBLE DIAGNOSIS GUIDE (Continued)

Check the pump belt tension. Aloose or glazed belt can cause beltsqueal. A glazed belt, even whenproperly adjusted, may slip.

Excessive torque at the pressureline joints may distort the tube seats

and cause noise.Noise may result if the specified

hose is not used or if it is improperlyrouted. If noise still exists with thespecified hose properly installed androuted, the pump should be replaced.

NOISE

bushings or improper mounting nuttorque. Replace the bushings if worn.Torque the nut to specification.

Check the power cylinder pistonrod insulators for looseness. If the in-sulators are worn, replace them. Ifthe mounting nut is loose, torque itto specification, and torque the lock-nut to specification.

STEERING CHATTER

A loose pump belt or air in the fluidcan cause chatter against the wheelstops during an extremely sharp turn.Check the belt tension, and adjustit to specifications or fill the reservoirif necessary.

Check for looseness in the idlerarm rod connection. Looseness at thispoint may be due to worn mounting

Check the control valve spool cen-tering spring adjustment. If the ad-justment is loose, tighten the nut untilsnug, and then back off the nut notmore than V4 turn. Excessive tighten-

ing may damage the stop pin.Check for looseness between the

control valve ball stud and the ballstud seats. If the stud is loose in theseats, adjust the travel regulator stop.

RATTLES

LOSS OF POWER ASSIST

Check the entire system for dam-age, replacing parts as necessary.Tighten a loose pump belt.

Test the fluid pressure to determinewhether the trouble is in the pump,the control valve, or the power cyl-inder.

If the pressure test indicates thatthe pump is at fault, replace thepump.

If the pressure test indicates thatthe control valve or power cylinderis at fault, check as follows:

Disconnect the power cylinder pis-ton rod from the idler arm bracket.Operate the piston by hand to check

for resistance to movement. If thepiston moves easily with little or noresistance, the internal parts of thepower cylinder are broken or dam-aged. Replace the power cylinder ifbroken or damaged.

Maladjustment of the control valvespool centering spring can cause aloss of either right or left power as-sist. Check the adjustment, and read-just if necessary. Replace all defectiveparts.

Check the operation of the controlvalve check valve. If the check valvedoes not operate freely, replace thecheck valve assembly.

adjustment, install the alignmentspacers as follows to establish thecurb height.

Insert the pin in the spacer holemarked for the model being checked(Mustang rear does not use the pin).

Raise the front of the car and po-sition the alignment spacers betweenthe suspension upper arm and thespring tower as shown in Fig. 3. Thelower end of the spacer should beplaced over the head of the ball jointfront outside attaching rivet. Posi-tion the alignment spacers for therear of the car between the rear axleand the side rail as shown in (Fig. 4).

3. Install the w h eel alignmentequipment on the car. Whichevertype of equipment is used, follow theinstallation and inspection instruc-

FRONT WHEEL ALIGNMENTCHECKS

Do not attempt to check and ad-just front wheel alignment withoutfirst making a preliminary inspectionof the front-end parts.

Check all the factors of front wheelalignment except the turning anglebefore making any adjustments. Theturning angle should be checked onlyafter caster, camber, and toe-in havebeen adjusted to specification.

The front wheel alignment specifi-cations, given in Part 3-6 are correctonly when the car is at "CurbHeight." Before checking or adjust-ing the alignment factors, the suspen-sion alignment spacers (Tool T65P-3OOO-B or C) must be installed to ob-tain the curb heights.

EQUIPMENT INSTALLATIONEquipment used for front wheel

alignment inspection must be accu-rate. Alignment height spacers (Figs.3 and 4) are used to check caster,camber. The spacers should beomitted when checking toe-in.

1. Drive the car in a straight linefar enough to establish the straight-ahead position of the front wheels,and mark the steering wheel hub andthe steering column collar (Fig. 5).Do not adjust the steering wheelspoke position at this time. If thefront wheels are turned at any timeduring the inspection, align the marksto bring the wheels back to thestraight-ahead position.

2. With the car in position for thefront end alignment inspection and

SUSPENSION, STEERING, WHEELS AND TIRES GENERAL SERVICE 3-5PART 3-1

TABLE l-Trouble Symptoms and Possible Causes

POSSIBLE CAUSES OF TROUBLE

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x x x x x1. Incorrect Tire Pressure

1--i1 x I xi~Sizes Not Uniform

iXlTriI 3. Overloaded or Unevenly loaded Vehicle

4. Power Steering Fluid Level Low-Leak x X I X---x \ x I, x lXIX-IX5. Sagging or Broken Spring

x xxxx

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6. Glazed, loose or Broken Power Steering Pump Belt

7. Rear Spring Tie Bolt Off Center

x I x8. Broken Rear Spring Tie Bolts

~9. Rear Spring Front Hanger Mislocated

~xx

10. Bent Spindle Arm

11. Bent Spindle

12. lack of lubrication

13. Air in Power Steering System

xx I x xx x

xxl

xI 14. Obstruction in Power Steering Lines

~~x

x115. loose or Weak Shock Absorber

16. Loose or Worn Suspension Arm Bushings

x

~xx x

xxx

xx

x17. Binding Front Suspension Ball Joints or Steering Linkage

18. Loose, Worn, or Damaged Steering Linkage or Connections

19. Loose Steering Gear Mountings

xxx

xx

20. Insufficient Steering Pump Pressure

X I X Ixxxx

x I I. I A

X' xx

xx xxx x

xx

21. Incorrect Steering Gear Adjustment

22. Incorrect Brake Adjustment

23. Incorrect Front Wheel Bearing Adjustment~

x x24. Wheel Out of Balance

x X I X I XxI 25. Incorrect Front Wheel Alignment

xxI 26. Out.ot.Round Wheel-or Brake Drum

~~xI 27. Frame or Underbody Out of Alignment x

x28. Bent Rear Axle Housing

29. Excessive Wear of Steering Pump Internal Parts xxx

xx

x30. Steering Gear Valve Spool Binding or out of Adjustment

31. Obstruction Within Steering Gear x

GROUP 3 - SUSPENSION, STEERING, WHEELS AND TIRES3-6

POSITIVECAMBER

-1i-J NEGATIVE~ II-POSITIVEI i CASTER fY CASTER

,~L OF TIRE ~

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CAMBER FRONT OFCARANGLE F1216-A

FIG. 6-Caster and Camber

Anglesused to check and adjust toe-in. Toe-in should only be checked and ad-justed after the caster and camberhas been adjusted to specification.

Check the toe-in with the frontwheels in the straight-ahead position.Run the engine so that the powersteering control valve will be in thecenter (neutral) position (if soequipped). Measure the distance be-tween the extreme front and also be-tween the extreme rear of both frontwheels. The difference between thesetwo distances is the toe-in.

Correct toe-in, or inward pointingof both front wheels at the front, isspecified in Part 3-6.

FRONT WHEEL TURNINGANGLE

When the inside wheel is turned20°, the turning angle of the outsidewheel should be as specified in Part3-6. The turning angle cannot be ad-justed directly, because it is a resultof the combination of caster, camber,and toe-in adjustments and should,therefore, be measured only afterthese adjustments have been made. Ifthe turning angle does not measure tospecifications, check the spindle orother suspension parts for a bent con-dition.

FIG. 3-Typical Front

Alignment SpacerInstallation

~-

ALIGNMENT MARKS F1267-B

FIG. 5-Straight AheadPosition Marks-Typical

CASTERCheck the caster angle at each

front wheel.Caster is the forward or rearward

tilt of the top of the wheel spindle(Fig. 6). If the spindle tilts to therear, caster is positive. If the spindletilts to the front, caster is negative.The correct caster angle, or tilt, isspecified in Part 3-6. The maximumdifference between both front wheelcaster angles should not exceed V2 o.However, a difference of not morethan 1/4 ° is preferred.

Tool - T 65 P - 3000 B o. C

CAMBERCheck the camber angle at each

front wheel.Camber is the amount the front

wheels are tilted at the top (Fig. 6).If a wheel tilts outward, camber ispositive. If a wheel tilts inward, cam-ber is negative. The correct camberangle, or outward (positive) tilt, isspecified in Part 3-6. The maximumdifference between both front wheelcamber angles should not exceed V2 o.However, a difference of not morethan l/4 ° is preferred.

FIG. 4-Typical Rear

Alignment SpacerInstallation

tions provided by the equipmentmanufacturer.

TOE.INAlignment height spacers are not

COMMON ADJUSTMENTS AND REPAIRS

After front wheel alignment factorshave been checked, make the neces-sary adjustments. Do not attempt toadjust the front wheel alignment bybending the suspension or steeringparts.

have been removed or installed,torque the nuts to specification. Cast-er and camber adjusting shims areavailable in 1/32-inch and V8 -inchthickness.

The 1/32 inch shims should beplaced against the fender housingsheet metal or between the 1/8 inchshims.

Equipment Installation is installed be-fore adjusting the caster and camber.

Caster and camber can be adjustedby removing or installing shims be-tween the inner shaft of the front sus-pension upper arm and the under-body (Fig. 7).

Both caster and camber adjustmentcan be made at the same time byloosening the nuts on the two boltsthat fasten the inner shaft to the un-derbody. After the required shims

CASTERTo adjust caster, remove or install

CASTER AND CAMBERADJUSTMENTS

MUSTANGBe sure all the equipment listed in

PART 3-1 -SUSPENSION, STEERING, WHEELS AND TIRES GENERAL SERVICE 3-7

--

ADJUSTING SHIMS F1O82-C

FIG. 7-Caster and Camber

Adjustments-Mustang

FIG. 8-Caster and Camber Adjustments-Comet, Falcon, andFairlane

To adjust the camber, loosen the ec-centric bolt nut and rotate the bolt SLEEVE

and eccentric clockwise from the highposition to increase camber or coun-terclockwise to decrease camber.

After the caster and camber hasbeen adjusted to specification, torquethe lower arm eccentric bolt nut andthe strut front nut to specification.

TOE-IN AND STEERING WHEELALIGNMENT ADJUSTMENTS

Check the steering wheel spoke po-sition when the front wheels are inthe straight-ahead position. If thespokes are not in their normal posi-tion, they can be properly adjustedwhile toe-in is being adjusted.

1. Loosen the two clamp bolts oneach spindle connecting rod sleeve(Fig. 9).

2. Adjust toe-in. If the steeringwheel spokes are in their normal po-sition, lengthen or shorten both rodsequally to obtain correct toe-in (Fig.10). If the steering wheel spokes arenot in their normal position, make thenecessary rod adjustments to obtaincorrect toe-in and steering wheel

CLAMP BOLTS Fl083-B

FIG. 9-Spindle Connecting

Rod Sleeve-Typical

spoke alignment (Figs. 11 and 12).3. Recheck toe-in and steering

wheel spoke alignment. If toe-in iscorrect and the steering wheel spokesare still not in their normal position,turn both connecting rod sleeves up-ward or downward the same numberof turns to move the steering wheelspokes (Fig. 11 and 12).

4. When toe-in and steering wheelspoke alignment are both correct,torque the clamp bolts on both con-nectin.!t rod sleeves to specification.

shims at either the front bolt or therear bolt (Fig. 7).

The removal of shims at the frontbolt or the installation of shims at therear bolt will cause the upper balljoint to move forward. The removalof shims at the rear bolt or the instal-lation of shims at the front bolt willcause the ball joint to move rearward.A 1/32-inch change of shim thicknessat either bolt will change the casterangle approximately 1/2 o. The differ-ence between the shim stack thick-ness at the two bolts should not ex-ceed 1/16 inch (Fig. 7).

CAMBERTo adjust camber, remove or in-

stall equal shim thickness at bothbolts (Fig. 7).

The removal of equal shims at bothbolts will move the upper ball jointinward. The installation of equalshims at both bolts will move the balljoint outward. A 1/16-inch change ofshim thickness at both bolts willchange the camber angle 1/3 °. Thetotal shim stack thickness at eachbolt should not exceed 9/16-inch (Fig.7).

COMET, FALCON, ANDF AIRLANE

Caster is controlled by the frontsuspension strut (Fig. 8). To obtainpositive caster, loosen the strut frontnut and tighten the strut rear nutagainst the bushing. To obtain neg-ative caster, loosen the strut rear nutand tighten the strut front nut againstthe bushing.

Camber is controlled by the ec-centric cam located at the lower armattachment to the side rail (Fig. 8).

TURN UPWARD TOINCREASE ROD LENGTH

The sleeve position should be asshown in Fig. 13 when the clampbolts are tightened.

TURN DOWNWARD TOINCREASE ROD LENGTH

TURNDOWNWARDTO DECREASEROD LENGTH

TURN UPWARDTO DECREASEROD LENGTH

---. ' SLEEVE RIGHT-HAND SLEEVE

FIG. 10-Spindle Connecting Rod Adjustment

WHEN TOE-IN IS CORRECTTURN BOTH CONNECTING RODSLEEVES UPWARD TO ADJUST

SPOKE POSITION

F1037-B

TURN BOTH CONNECTING ROOSLEEVES OOWNWARD TO

SPOKE POSITION

SHORTEN LEFT RODTO DECREASE TOE.IN

LENGHTENRIGHT RODTO INCREASE TOE.IN

WHEN TOE-IN IS 'NOT CORRECT

LENGTHEN LEFT ROO TOINCREASE TOE.IN

SHORTEN RIGHT RODTD DECREASE TOE.IN

STEERING GEAR LUBRICANTCHECKING PROCEDURE

MUSTANG1. Center the steering wheel.2. Remove the steering gear hous-

ing filler plug.3. Remove the upper cover-to-

housing attaching bolt.4. With a clean punch or like in-

strument, clean out or push inwardthe loose lubricant in the filler plughole and cover to housing attachingbolt hole.

S. Slowly turn the steering wheelto the right stop, lubricant shouldrise within the upper cover bolt hole;then slowly turn the steering wheel tothe left stop, lubricant should risewithin the filler plug hole. If lubricantdoes not rise in both the cover bolthole and the filler plug hole, add lu-bricant until it comes out both holesduring this check.

6. Install the upper cover-to-hous-ing attaching bolt.

ADJUST BOTH RDDS EQUALLY TO ~AINTAIN NORMAL SPOKE POSIT,tON F1254-A

FIG. 11-Toe-ln and Steering Wheel Spoke Adjustments-Comet,Falcon, and Fairlane

WHEN TOE-IN IS CORRECT:TURN BOTH CONNECTINGROD SLEEVES UPWARDTO ADJUST SPOKEPOSITION

TURN BOTHCONNECTING RODSLEEVES DOWNWARDTO ADJUST SPOKEPOSITION

~

II', I

--<. \\

WHEN TOE-IN ISNOT CORRECT: - -

LENGTHEN LEFT ROD TOINCREASE TOE-IN

SHORTEN RIGHT ROD TODECREASF rnF-IN

I

\ ...

\~/\ \\ '.

~ "

"~--_..~..,~., LEFT ROD TODECREASE TOE-IN

LENGTHEN RIGHT RODTn INCREASE TOE-IN

'-

'""'-. - ...~ ~ -- ---

ADJUST BOTH RODS EQUAllY TO MAINTAIN NORMAL SPOKE POSITION FIOJa-B

12-Toe-ln and Steering Wheel Spoke Adjustments-Mustang

COMET, FALCON, ANDFAIRLANE

1. Center the steering wheel.2. Remove the steering gear hous-

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 inwardthe loose lubricant in the filler plughole and cover to housing attachingbolt hole.

5. Slowly turn the steering wheelto the left stop, lubricant should risewithin the lower cover bolt hole; thenslowly turn the steering wheel to theright stop, lubricant should rise with-in the filler plug hole. If lubricantdoes not rise in both the cover bolthole and the filler plug hole, add lu-bricant until it comes out both holesduring this check.

6. Install the lower cover-to-hous-ing attaching bolt and the filler plug.

PART 3-1 SUSPENSION, STEERING, WHEELS AND TIRES GENERAL SERVICE 3-9

FIG. 13-Spindle Connecting Rod Sleeve Clamp Position

CLEANING AND INSPECTION

STEERING GEAR CLEANINGAND INSPECTION

Wash all parts in a cleaning sol-vent and dry with a lint-free cloth.The bearing should not be spun drywith compressed air. Inspect the shaftand worm for scoring, cracks orchecks, and for straightness of theshaft. Check the splines and thethreads on the sector shaft for wearand burrs. Inspect the gear teeth forscoring, pitting and other wear. In-spect the ball bearings for free move-ment, and the cups for wear or irreg-ular surfaces. Check the housing forcracks and the sector shaft needlebearing for free movement or otherwear.

Check the power steering pumppressures. If the pump pressures arenot to specification and there are noexternal fluid leaks, replace the pump.If the pump has a visible leak, replacethe reservoir seal, outlet valve seals,or support stud seal, whichever is re-quired.

the floor. Shake each front wheelgrasping the upper and lower surfacesof the tire to check the front suspen-sion ball joints and mountings forlooseness, wear, and damage. Checkthe brake backing plate mountings.Torque all loose nuts and bolts tospecifications. Replace all worn partsas outlined in Part 3-2.

3. Check the steering gear mount-ings and all steering linkage connec-tions for looseness. Torque all mount-ings to specifications. If any of thelinkage is worn or bent, replace theparts as outlined in Part 3-3.

4. Check the front wheel bearings.If any in-and-out free play is noticed,adjust the bearing to specification(Part 3-5). Replace worn or dam-aged bearings as outlined in Part 3-5.

S. Spin each front wheel with awheel spinner, and check and balanceeach wheel as required.

6. Check the action of the shockabsorbers. If the shock absorbers arenot in good condition, the car maynot settle in a normal, level position,and front wheel alignment may be af-fected.

2. Install a new pump and connectonly the pressure hose to the pump(Part 3-4).

3. Place the oil return line in asuitable container and plug the re-servoir return pipe.

4. Fill the reservoir with lubricantCIAZ-19582-A.

5. Disconnect the coil wire to pre-vent the engine from starting andraise the front wheels off the ground.

6. While approximately two quartsof steering gear lubricant are beingpoured into the reservoir, turn theengine over using the ignition key, atthe same time cycle the steeringwheel from stop to stop.

7. As soon as all of the lubricanthas been poured in, turn off the igni-tion key, and attach the coil wire.

8. Remove the plug from the res-ervoir return pipe, and attach the re-turn hose to the reservoir.

9. Check the reservoir fluid level;if low add fluid to the proper level.Do not overfill.

10. Lower the car.11. Start the engine and cycle the

steering wheel from stop to stop toexpel any trapped air from the sys-tem.

WHEEL INSPECTIONWheel lug nuts should be tightened

to specification at the predelivery in-spection. Loose wheel lug nuts maycause shimmy and vibration. Elong-ated stud holes in the wheels mayalso result from loose lug nuts.

Keep the wheels and hubs clean.Stones wedged between the wheel anddrum and lumps of mud or greasecan unbalance a wheel and tire.

FLUSHING THE POWERSTEERING SYSTEM

Should a power steering pump be-come inoperative, the shaft and pul-ley should be checked for freedom ofrotation. If the pump shaft does notturn freely (binding), it is an indica-tion that there is wear on the pumpinternal components and the need forflushing the steering system, when in-stalling a new pump.

1. Remove the power steeringpump and pulley as outlined in Part3-4.

FRONT END GENERALINSPECTION

Do not check and adjust front\vheel alignment without first makingthe following inspection for front-endmaladjustment, damage, or wear.

1. Check for specified air pres-sures in all four tires.

2. Raise the front of the car off

GROUP 33-10 SUSPENSION, STEERING, WHEELS AND TIRES

SHOCK ABSORBERS

Passenger cars and station wagonsare equipped with hydraulic shock ab-sorbers of the direct-acting type andare nonadjustable and nonrefillable,and cannot be repaired.

Before replacing a shock absorber,check the action of the shock ab-sorbers by grasping the bumper andjouncing the car up and down. If theshock absorbers are in good condi-tion the car will immediately settle toa normal position after the bumper isreleased.

3. Attach a dial indicator to theupper arm. Position the indicator sothat the plunger rests against the un-derside of the spindle at the upperball joint stud.

4. With the dial indicator attachedto the upper arm, position the indi-cator so that the plunger rests againstthe inner side of the wheel rim adja-cent to the upper arm ball joint.

5. Grasp the tire at the top andbottom, and slowly move the tire inand out (Fig. 14). Note the reading(radial play) on the dial indicator. Ifthe reading exceeds specifications(Part 3-6), replace the upper balljoint.

Check for damage that would af-fect the runout of the wheels. Wob-ble or shimmy caused by a damagedwheel will cause premature tire wearand eventually damage the wheelbearings. Inspect the wheel rims fordents that could permit air to leakfrom the tires.

WHEEL BALANCINGSee the instructions provided with

the Rotunda Wheel Balancer.

UPPER BALL JOINTINSPECTION

1. Raise the car on a frame con-tact hoist or by floor jacks placed be-neath the underbody until the wheelfalls to the full down position asshown in Fig. 14. This will unloadthe upper ball joint.

TESTINGTo check a shock absorber re-

moved from a car proceed as fol-lows:

1. Hold the shock absorber in thevertical position wit h the pistonin the same position, push in the pis-ton rod until the shock is extended toits full length.

2. With the shock absorber heldin the same position, push in the pis-ton rod until the shock is compressedto its shortest length.

3. Repeat steps 1 and 2 severaltimes until all the air is expelled.

4. Clamp the lower end (small di-ameter) in a vise in a vertical posi-tion.

S. Extend the shock to its fulllength and then compress it to itsshortest length. There should be aconstant drag during the completecycle. Any sudden loss of drag indi-cates air in the system, loss of fluid,or faulty internal valve operation.Replace defective shock absorbers.

LOWER BALL JOINTINSPECTION

1. Raise the car on a frame con-tact hoist or by floor jacks placed be-neath the underbody until the wheelfalls to the full down position.

2. Ask an assistant to grasp thelower edge of the tire and move thewheel in and out.

3. As the wheel is being moved inand out, observe the lower end ofthe spindle and the lower arm.

4. Any movement between thelower end of the spindle and the low-er arm indicates ball joint wear andloss of preload. If any such move-ment is observed, replace the lowerarm.

During the foregoing check, theupper ball joint will be unloaded andmay move. Disregard all such move-ment of the upper ball joint. Also, donot mistake loose wheel bearings fora worn ball joint.

-"~

F 1235.A

FIG. 14-Measuring Upper BallJoint Radial Play

2. Adjust the wheel bearings asdescribed in Part 3-5.

3-11

SUSPENSION

Page.3-11.3-11.3-12.3-12.3-12

Pa.3-

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3-133-13

3-133-133-143-14,3-143-14

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,3-203-213-21

SectionFront Suspension Upper Arm Mustang. . . . . . . . . . . . . . . . . . . . . . .

Comet, Falcon, and Fairlane Front Suspension Lower Arm Mustang. . . . . . . . . . . . . . . . . . . . . . .

Comet, Falcon, and Fairlane Front Wheel Spindle ., Drum Brakes Disc Brakes Front Shock Absorber. . . . . . . . . . . . .

Rear Shock Absorber. . . . . . . . . . . . . .Mustang. . . . . . . . . . . . . . . . . . . . . .Comet, Falcon, and Fairlane (Except

Convertible) """""",."

Comet and Fairlane Convertible. . .Rear Spring and/ or Bushing. . . . . . . .

Section1 Description and Operation. . . . .

Front Suspension Rear Suspension , 2 In-Car Adjustments and Repairs

Upper Ball Joint Replacement. .Upper Arm Shaft and/or Bushing

Replacement ..., Stabilizer Replacement. . . . . . . .

Lower Arm Strut and/or BushingReplacement ,

Mustang. . . . . . . . . . . . . . . . ,Comet, Falcon, and Fairlane

3 Removal and Installation. . . . . ,

Front Spring Mustang. . . . . . . . . . . . . . . . .

Comet, Falcon, and Fairlane

DESCRIPTION AND OPERATION

SHOCK ABSORBERUPPER MOUNTING SHOCK ABSORBER

BRACKET

Ii

SPRING ~ BUMPER

C;;Q:- I""" BALL JOINT

~,"""UPPER ARM

SPINDLEECCENTRICAND BOLT

STABILIZERBAR

~IF---

LINK

I .~",'

FRONT SUSPENSIONEach front wheel rotates on a

spindle. The upper and lower ends ofthe spindle are attached to upper andlower ball joints which are mountedto an upper and lower arm respective-ly. The upper arm pivots on a bush-ing and shaft assembly which is boltedto the underbody. The lower armpivots on a bolt that is located in anunderbody bracket (Figs. 1 and 14).

A coil spring seats between the up-per arm and the top of the springhousing. A double acting shock ab-sorber is bolted to the arm and thetop of the spring housing.

The swiveling action of the balljoints allow the wheel and spindle as-semblies to move up and down withchanges in road surface. The swivel-ing ball joints also permit the spindlesand wheels to be turned to the left orright by the steering gear and linkage.

The pivoting action of the suspen-sion ar~s provides an up and downmovement for the spindles and wheelsas required by bumps or depressionsin the road surface. The coil springs,shock absorbers and stabilizer barcontrol the front suspension up anddown movements. The struts, whichare connected between the suspensionlower arms and the underbody pre-vent the suspension arms from mov-ing forward and backward.

INSULATORWASHERS

~

LOWERARMSTRUT

LOWERBALL JOINT

JFRONT

RETAINING BOLT

...NUT

F 1084-E

FIG. l-Front Suspension-Typical

ge151516171717181818191919

GROUP 33-12 SUSPENSION, STEERING, WHEELS AND TIRES

REAR SUSPENSIONEach rear wheel, hub, and brake

drum assembly is bolted to the rearaxle shaft flange. The wheel and axleshaft assembly rotates in the rear axlehousing. Two spring pads integralwith the axle housing, rest on two leaftype springs. The axle housing is fas-tened to the springs by spring clips.(V-bolts), spring clip plates and nuts(Figs. 2 and 18). Each spring is sus-pended from the underbody side railby a hanger at tbe front and a shack-le at the rear. The upper end of eachshock absorber is mounted to a brack-et in the underbody. The lower end ismounted to the spring clip plate.

The springs and shock absorbersprovide for up and down movementof the rear axle and wheels as re-quired by changes in the road sur-face. They also cushion road shocks.

F 1085 - 0

FIG. 2-Rear Suspension-Typical

IN-CAR ADJUSTMENTS AND REPAIRS

HOISTING INSTRUCTIONSDamage to suspension and/ or

steering linkage components may oc-cur if care is not exercised when po-sitioning the hoist adapters of 2 posthoists prior to lifting the cat.

If a 2 post hoist is used to lift thecar, place the adapters under thefront suspension lower arms. Do notallow the adapters to contact thesteering linkage.

FIG. 3-Upper Arm Support-Must

three upper ball joint retaining rivetsand remove the ball joint.

7. Clean the end of the arm, andremove all burrs from the hole edges.Check for cracks in the metal at theholes, and replace the arm if it iscracked.

8. Attach the new ball joint to theupper arm. Use only the specifiedbolts, nuts, and washers. Do not rivetthe new ball joint to the arm. Torquethe nuts to specification (Part 3-6).

9. Position the ball joint stud in

UPPER BALL JOINTREPLACEMENT

1. Position a support between theupper arm and frame side rail asshown in Figs. 3 and 4; then, raise thecar 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 toolshould seat firmly against the ends ofboth studs, and not against the lowerstud nut. It may be necessary to re-move the lower ball joint cotter pinif it prevents the tool from seating onthe lower stud.

5. Turn the tool with a wrenchuntil both studs are under tension,and then, with a hammer, tap thespindle near the upper stud to loosenthe stud from the spindle. Do notloosen the stud with tool pressurealone. Raise the stud out of thespindle bore.

6. Using a large chisel, cut off the

'ongthe spindle bore, and torque the re-taining nut to specification. Install anew cotter pin, tighten the nut if nec-essary to line up the cotter pin hole.

10. Lubricate the ball joint, andinstall the wheel and tire. Torque thelug nuts to specification (Part 3-6).

11. Remove the safety stands, andlower the car.

12. Remove the support from be-tween the upper arm and frame.

13. Check and, if necessary, adjustcaster, camber, and toe-in.

PART 3-2 - SUSPENSION 3-13

upper arm outboard from the springtower.

7. Rotate the inner shaft so thatthe retaining studs can be removed.Remove the retaining studs with asoft mallet (Mustang Only).

8. Unscrew the bushings from theshaft and suspension arm; then, re-move the shaft from the arm.

9. Position the shaft in the arm,apply grease to the new bushings andO-rings, and install the bushings looseon the shaft and arm. Turn the bush-ings so that the shaft is exactly cen-tered in the arm. The shaft will beproperly centered when dimensionsA and B in Fig. 6 are equal.--

FIG. 4-Upper-Comet. Falcon. FIG. 7-Torque Upper Arm

Inner Shaft Bushings-Typical

and install the cotter pin, grease capand hub cap or wheel cover.

16. Lower the car and install theshock absorber and upper mountingbracket.

17. Check caster, camber, and toe-in and adjust as necessary (Part 3-1).

FIG. 6-Shaft Centered in

Arm-Typical

10. Fabricate a spacer from a sec-tion of 3/4 -inch diameter pipe or met-al of comparable size and strength.On a Mustang the spacer should be7 7/16 inches long. On a Comet, Fal-con, or Fairlane, the spacer should be6 15/16 inches long.

11. Position the spacer parallelwith the inner shaft, and force thespacer between the flanges of the up-per arm (Fig. 7).

If the spacer can not be forced be-tween the arm flanges due to exces-sive distortion, replace the upper armassembly.

12. With the spacer positioned inthe arm, torque the bushings to speci-fication. Move the arm on the shaftto be sure that no binding exists, thenremove the spacer.

13. Connect the suspension upperarm to the underbody. Install the ad-justing shims (Mustang only) and re-lease the front spring.

14. Remove the spring compressorand position the wheel, tire, and huband drum on the spindle.

15. Install the bearing, washer, ad-justing nut and nut lock. Adjust thewheel bearing as outlined in Part 3-5

UPPER ARM SHAFT AND/ORBUSHING RELACEMENT

1. Remove the shock absorber andupper mounting bracket as an assem-bly.

2. Raise the car on a hoist, installsafety stands, and remove the wheelcover or hub cap.

3. Remove the grease cap from thehub; then, remove the cotter pin, nutlock, adjusting nut and outer bearingfrom the hub.

4. Pull the wheel, tire, and the huband drum off the spindle as an assem-bly.

5. Install the spring compressor,Tool T63P-5310-A or the CometTool 5310-C and compress the spring(Section 3).

6. Remove 2 upper arm to springtower retaining nuts and swing the

STABILIZER REPLACEMENT

1. Raise the car high enough toprovide working space, and place sup-ports under both front wheels.

2. Disconnect the stabilizer fromeach link. Disconnect both stabilizerretaining brackets, and remove thestabilizer.

3. Coat the necessary parts of thestabilizer with RUGL YDE or a com-parable lubricant, and slide new insu-lators onto the stabilizer.

4. Connect the stabilizer retainingbrackets, and connect the stabilizer toboth links. Torque the bracket retain-ing screws and the link bolt nut tospecification.

S. Remove the supports and lowerthe car.

LOWER ARM STRUT AND/ORBUSHING REPLACEMENT

MUSTANG1. Position the block as shown in

Fig. 3 under the upper arm for sup-port.

2. Raise the car, position safetystands, and remove the wheel andtire.

3. Remove the strut - to - bracketforward retaining nut, washer and in-sulator bushings (Fig. 14).

4. Remove the 2 strut-to-iowerarm retaining nuts and bolts; then,

-WOOD BLOCK F 1287-A

Arm Supportand Fairlane

3-14 GROUP 3 SUSPENSION. STEERING. WHEELS AND TIRES

lift the strut with rear insulator bush-ing and washer from the car.

5. Install the new rear washer andinsulator bushing on the forward endof the strut rod.

6. Position the strut into themounting bracket and to the lowersuspension arm. Install the strut-to-arm retaining bolts and nuts, andtorque to specification.

7. Install the forward insulatorbushing, washer, and nut to the for-ward end of the strut and torque thestrut rod nut to specification.

8. Install the wheel and tire, re-move the safetv stands and lower the

car. Remove the tool supporting theupper arm.


Removal1. Raise the car and install safety

stands.2. Remove the lower arm strut

front retaining nut, washer and bush-ing at the frame bracket {14).

3. Remove 2 bolts and nuts at-taching the strut to the lower armand remove the strut.

4. Remove the bushing, washerand nut from the strut.

Installation1. Install the nut, washer and bush-

ing on the strut.2. Position the strut to the front

bushing bracket and to the lower arm.Install the strut to lower arm attach-ing bolts and nuts and torque to spec-ification.

3. Position the strut front bushingand washer on the strut and installthe adjusting nut.

4. Tighten the strut adjusting nutsagainst the strut frame bracket.

s. Lower the car and check caster,camber and toe-in and adjust as nec-essary .

REMOVAL AND INSTAllATION

TooI-T63P.5310.Aft Screw Detoil A3-Lower PI,

.Detail A4-Reta;ner F1237-A

FIG. 9-Compressing orReleasing Spring on Mustang-Lower View

the spring by turning the tool shaftnut clockwise (Fig. 8) until the springclears the suspension upper arm.

9. Remove the upper suspensionarm inner shaft retaining nuts fromthe engine compartment, and pull thearm, shaft, and retaining bolts awayfrom the underbody. Measure andnote the total shim thickness at eachinner shaft retaining bolt. Swing theupper arm and shaft assembly 1800out to provide clearance for springremoval (Fig. 10).

10. Turn the tool shaft nut coun-terclockwise until the spring is re-leased (Fig. 8). Hold the tool lowerplate from turning during spring re-lease. Use a l/2-inch square drive flex-handle wrench (Fig. 9).

HOISTING INSTRUCTIONS

Damage to suspension and / orsteering linkage components may oc-cur if care is not exercised when po-sitioning the hoist adapters of 2 posthoists prior to lifting the car.


FRONT SPRING

MUSTANG

Removal1. 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-sembly.

3. Remove the shock absorberlower retaining nuts and washers.

4. Remove the shock absorberupper mounting bracket retainingnuts, and remove the shock absorberand bracket as an assembly (Fig.15).

S. On all 8-cylinder cars, removethe air cleaner to obtain access fortool installation.

6. Position the upper plate (ToolT64K-53l0-A) at the spring upperseat; place the bearing of tool T63P-53l0-A on the plate and insert thetool shaft (detail AI) through thebearing and upper plate with the toolnut (detail A2) against the bearingas shown in Fig. 8.

7. Install the tool lower plate (de-tail A3) under the third coil from thebottom (Fig. 9). Secure the plate tothe shaft screw (detail AI) with theretainer (detail A4). The retainer en-

FIG. 8-Compressing or

Releasing Spring onMustang-Upper View

gages the groove in the shaft screwbelow the plate as shown. The tangof the retainer engages the cut-out inthe plate.

8. Insert a 1h -inch square driveIlexhandle wrench in the drive holein the lower plate to prevent the tooland spring from turning (Fig. 9).While thus holding the tool, compress

PART 3-2 SUSPENSION 3-15

nuts, and torque to specification. In-stall the shock absorber lower retain-ing nuts on the bolts at the under-side of the spring lower seat andtorque to specification.

10. Install the wheel and tire as-sembly, remove the safety stands andlower the car.

11. Check and, if necessary, ad.just caster, camber, and toe-in.

FIG. 10-Removing orInstalling Spring-Mustang


Removal1. Remove the shock absorber and

upper mounting bracket as an as-sembly.

2. Raise the car on a hoist, installsafety stands, and remove the wheelcover or hub cap.

3. Remove the grease cap fromthe hub; then, remove the cotter pin,nut lock, adjusting nut and outerbearing from the hub.

4. Pull the wheel, tire and the huband drum off the spindle as an assem-bly.

5. Install the spring compressor,Tool T63P-5310-A or the CometTool 5310-C (Fig. 11), and compressthe spring (Figs. 9 and 12). Eithertool can be used.

6. Remove 2 upper arm to spring

11. Remove the components of thespring compressing tool; then, removethe spring as shown in Fig. 10.

Installation1. With the upper arm turned out

of the way for clearance, install thespring in the housing (Fig. 10).

2. Install the spring compressortool and compress the spring.

3. Swing the suspension upper armassembly inboard, and insert the arminner shaft retaining bolts through themounting holes in the underbody.

4. From inside the engine com-partment, install but do not tightenthe nuts and lockwashers on the twoinner shaft retaining bolts. The speci-fied keystone type lock washers mustbe used.

s. Install the adjusting shims onboth bolts between the inner shaftand the underbody. Install the sameshim thicknesses that were removedfrom each bolt when the arm was dis-connected. Torque the inner shaft re-taining nuts to specification.

6. Turn the tool shaft nut counter-clockwise to release the spring (Fig.8). As the spring is being released,guide the spring into its lower seat.

7. Remove the components of thespring tool.

8. Position the shock absorber inthe spring housing so that the holesin the upper mounting bracket en-gage the upper retaining studs in thehousing (Fig. 15). The lower retain-ing bolts go through the mountingholes in the spring lower seat.

9. Install the bracket retaining

tower retaining nuts and swing theupper arm outboard from the springtower (Fig. 13).

7. Release the spring compressortool and remove the tool from thespring. Then, remove the spring fromthe car (Fig. 10).

Installation1. Place the spring upper insulator

on the spring and secure in place withtape.

2. Position the spring in the springtower. Install the spring compressor,Tool T63P-5310-A and compress thespring.

3. Swing the upper arm inboardand insert the bolts through the holesin the side of the spring tower.. Then,install the retaining nuts and torquethem to specification.

4. Release the spring pressure andguide the spring into the upper armspring seat. The end of the springmust seat against the tab on thespring seat.

5. Remove the spring compressorand position the wheel, tire, and huband drum on the spindle.

6. Install the bearing, washer, ad-justing nut and nut lock. Adjust thewheel bearing as outlined in Part 3-5and install the cotter pin, grease cap,and hub cap or wheel cover.

7. Lower the car and install theshock absorber and upper mountingbracket.

8. Check caster, camber, and toe-in and adjust as necessary (Part 3-1).

FRONT SUSPENSION UPPERARM

MUSTANG

Removal1. 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-sembly.

3. Remove the shock absorberlower retaining nuts and washers.

4. Remove the shock absorber up-per mounting bracket retaining nuts,and remove the shock absorber andbracket as an assembly (Fig. 15).

On all 8-cylinder cars, remove theair cleaner to obtain access for toolinstallation.

5. Install the spring compressor,Tools T63P-5310-A and T64K-5310-A and compress the spring (Figs. 8and 9).

6. Position a safety stand underthe lower arm.

7. Remove the cotter pin from the

3-16 GROUP 3 - SUSPENSION, STEERING, WHEELS AND TIRES

nut on the upper ball joint stud, andloosen the nut one or two turns. Donot remove the nut from the stud atthis time.

8. Position the ball joint removertool between the upper and lower balljoint studs as shown in Fig. 5. Thetool should seat firmly against theends of both studs and not against thestud nuts.

9. Turn the tool with a wrencb un-til the tool places the studs under ten-sion; then, tap the spindle near theupper stud with a hammer to loosenthe stud in the spindle. Do not loosenthe stud in the spindle with tool pres-sure only. If both arms are being re-moved, loosen the lower stud in thesame manner as the upper stud.

10. Remove the nut from the up-per stud and lift the stud out of thespindle.

11. Remove the upper arm innershaft retaining nuts from the enginecompartment, and remove the upperarm. Measure and note the total shimthickness at each inner shaft bolt.

12. Wipe off all loose dirt from theupper arm parts. Do not wash the balljoint with a solvent.

-- - ~-T 63p.53100A T 66p.53100A OR B

FIG. 12-Spring Compressor Installed-Upper View-Comet, Falconand Fairlane

"1288-A

Installation1. Position the upper arm on the

underbody mounting bracket, and in-stall but do not tighten the nuts andlockwashers on the two inner shaftretaining bolts. The specified key-stone-type lockwashers must be used.

2. Install the adjusting shims onboth bolts between the inner shaftand the underbody. Install the sameshim thicknesses that were removedfrom both bolts during disassembly(Fig. 7, Part 3-1). Torque the nuts tospecification.

3. Position the upper ball jointstud in the top of the wheel spindle,and install the stud nut. Torque thenut to specification, and continue totighten it until he cotter pin hole andslots line up. Install a new cotter pin.

4. Release the coil spring, removethe tool, and install the front shockabsorber and the wheel and tire as-sembly.


Removal1. Remove the front shock absorb-

er from the car.2. Raise the car and install safety

stands under the frame side rails.3. Remove the hub cap or wheel

cover and the wheel and tire.4. Install the spring compressor,

FIG. 13-Compressing Spring-Lower View-Comet, Falcon,and Fairlane


FRONT SUSPENSION LOWERARM

MUSTANG

Tools T63P-5310-A (Tool-5310-C-Comet), T64K5310-A or B, andT66P-5310-A or B and compress thespring (Fig. 13).

5. Remove the cotter pin from theupper ball joint stud and loosen thestud nut.

6. Position the ball joint removertool as shown in Fig. 5. The toolshould seat firmly against the ends ofboth studs and not against the lowerstud nut. It may be necessary to re-move the lower ball joint cotter pin ifit prevents the tool from seating onthe stud.

7. Turn the tool with a wrench un-til both studs are under tension; then,tap the spindle near the upper studwith a hammer to loosen the studfrom the spindle. Do not loosen thestud with tool pressure alone.

8. Remove the ball joint removertool and remove the ball joint studnut from the stud.

9. Remove 2 nuts and washers re-taining the upper arm to the springtower. Pull the upper arm away fromthe spring tower, lift the ball jointstud from the spindle, and removethe upper arm from the car.

10. Remove 2 nuts and bolts andremove the spring pivot from the up-per arm.

Removal1. Position a support between the

upper arm and side rail as shown inFig. 3.

2. Raise the car, position safetystands, and remove the wheel andtire.

3. Remove the stabilizer bar andlink retaining nut, disconnect the barfrom the link, and remove the linkbolt.

4. Remove the strut to lower armretaining nuts and bolts. Removethe steering arm stop from the strut.

5. Remove the cotter pin from thenut on the lower ball joint stud, andloosen the nut one or two turns. Donot remove the nut from the stud atthis time.

6. Straighten the cotter pin on theupper ball joint stud nut. Position theball joint remover tool between theupper and lower ball joint studs inthe reverse position from that shownin Fig. 5. The tool should seat firmlyaginst the ends of both studs andnot against the stud nuts.

7. Turn the tool with a wrench un-til the tool places the studs under ten-sion, and tap the spindle near the low-er stud with a hammer to loosen thestud in the spindle. Do not loosen thestud in the spindle with tool pressureonly. If both arms are being removed,loosen the upper stud in the samemanner as the lower stud.

8. Remove the nut from the low-er ball joint stud, and lower the arm.

9. Remove the lower arm to un-derbody pivot bolt, nut and washer.Remove the lower arm.

and slots are aligned, and install a newcotter pin.

6. Torque the lower arm-to-un-derbody pivot bolt and nut to speci-fication.

7. Remove the safety stands andlower the car.




Removal1. Raise the car and position safe-

ty stands under the side rails.2. Remove the hub cap or wheel

cover.3. Remove the wheel, tire, and hub

and drum as an assembly.4. Remove the stabilizer bar link

retaining nut and remove the wash-ers, bushings, spacer, and link bolt(Fig. 14).

5. Remove the 2 strut to lowerarm attaching nuts and bolts.

6. Remove the lower ball jointstud nut cotter pin and loosen the nutone or two turns. Do not remove thenut from the stud at this time.

7. Position the ball joint removertool between the upper and lower balljoint studs in the reverse position (up-side down) from that shown in Fig.14. The tool should seat firmly againstthe ends of both studs and not againstthe stud nuts.

8. Turn the tool with a wrench un-til the studs are under tension. Tapthe spindle near the lower stud with ahammer to loosen the stud in thespindle. Do not loosen the stud withtool pressure only.

9. Remove the tool and removethe nut from the lower ball joint stud.

10. Mark the location of the ec-centric and eccentric bolt at the low-er arm to underbody attachment.

11. Remove the nut, bolt, and ec-centrics attaching the lower arm tothe underbody and remove the low-er arm.

Installation1. Position the lower arm to the

underbody and install the bolt, ec-centrics, and nut.

2. Position the ball joint stud in thespindle bore and install the retainingnut.

3. Adjust the eccentrics to theprevious marked location and torquethe nut to specification (Part 3-6).

4. Position the strut to the lower

Installation1. Position the lower arm to the

underbody bracket and install thepivot bolt, washer, and nut loose.

2. Raise the lower arm, guide thelower ball joint stud into the spindlebore, and install the stud retainingnut loose.

3. Install the stabilizer link bolt,washers, bushings and spacer. Con-nect the stabilizer bar to the link. In-stall the retaining nut and torque tospecifications (Fig. 14).

4. Position the strut and steeringarm stop to the lower arm. Install theretaining bolts and nuts, and torqueto specification.

5. Torque the lower ball joint studnut to specification, continue to tight-en the nut until the cotter pin hole

Installation1. Position the spring pivot to the

upper arm and install the 2 attachingbolts and nuts. Torque the nuts tospecification.

2. Position the upper arm to thespring tower and the ball joint studto the spindle. Install but do nottighten the ball joint stud nut.

3. Position the upper arm tospring tower and install the washersand retaining nuts. Torque the nutsto specification.

4. Release the spring compressortool while aligning the spring withthe upper arm spring pivot. Then, re-move the tool.

5. Torque the ball joint stud nutto specification (Part 3-6). Continueto tighten the nut until the slots inthe nut are in line with the hole inthe ball joint stud. Then, install anew cotter pin.

6. Install the wheel and tire andthe hub cap or wheel cover.

7. Remove the safety stands andlower the car.

8. Install the shock absorber.


BUSHING3047

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INSULATOR Ir- ~~5415 I~

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LOWER ARM3042 I-- - (O'\\~ cr at~CAM 3048

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\SPINDLE3105-6

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WASHER BUSHING 3A1873A187 3A187 1i'" "' "

~STABILIZER BAR5482

STUD '"\5A486 ,LDWER BALL JDINT3042

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F 1152-C

FIG. 14-Front Suspension Assembly-Comet, Falcon, and Fairlane-Typical of Mustang

arm and install the attaching boltsand nuts. Torque the nuts to specifi-cation (Part 3-6).

5. Position the stabilizer bar linkto the lower arm and install the bolt,washers, bushings, spacer, and retain-ing nut. Torque the nut to specifica-tion (Part 3-6).

6. Torque the lower ball joint studnut to specification (Part 3-6) andinstall the cotter pin.

7. Install the wheel, tire, and huband drum on the spindle and adjustthe wheel bearing (Part 3-5).

8. Install the hub cap or wheel cov-er, remove the safety stands, and low-er the car.

9. Check caster, camber, and toe-in and adjust as necessary.

FRONT WHEEL SPINDLEDRUM BRAKES

Removal1. Position a support between the

upper arm and frame as shown inFigs. 3 and 4; then, raise the car andposition safety stands.

2. Remove the hub cap or wheelcover.

3. Remove the grease cap fromthe hub; then, remove the adjustingnut, washer, and outer bearing coneand roller assembly.

and guide the upper ball joint stud in-to the spindle. Install the stud nut.

3. Torque the upper stud nut andthen the lower stud nut to specifica-tion. Continue to tighten both nutsuntil the cotter pin holes and slotsline up. Install new cotter pins.

4. Connect the spindle connectingrod end to the spindle arm.

5. Install the brake carrier plateon the spindle, and torque the boltsto specification.

6. Install the wheel and drum andadjust the wheel bearing (Part 3-5).

7. Remove the safety stands, andlower the car.



DISC BRAKES

Removal1. Remove the hub cap or wheel

cover, and remove the wheel and tirefrom the hub.

2. Remove two bolts attaching thecaliper to the caliper bracket. Re-move the caliper from the rotor andwire it to the underbody to preventdamage to the brake hose.

3. Remove the grease cap fromthe hub, then, remove the adiustinll

4. Pull the wheel, hub, and drumassembly off the wheel spindle.

5. Remove the brake carrier platefrom the spindle. Support the plate toprevent damage to the brake hose.

6. Disconnect the spindle connect-ing rod end from the spindle arm us-ing Tool 3290-C.

7. Remove the cotter pins fromboth ball joint stud nuts, and loosenthe nuts one or two turns. Do not re-move the nuts from the studs at thistime.

8. Position the ball joint removertool between the upper and lower balljoint studs (Fig. 5). The toolshould seat firmly against the ends ofboth studs and not against the studnuts.

9. Turn the tool with a wrench un-til the tool places the studs under ten-sion, and, with a hammer, tap thespindle near the studs to loosen themin the spindle. Do not loosen thestuds in the spindle with tool pres-sure alone.

10. Remove the stud nuts and re-move the spindle from both studs.

Installation1. Position the spindle on the low-

er ball joint stud and install the studnut (Fig. 14).

2. Raise the lower suspension arm,

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PART 3-2 SUSPENSION 3-19

3. Install the 2 washers and re-taining nuts on the shock absorberlower studs and torque to specifica-tion.

4. Install the 3 shock absorber up-per mounting bracket to spring towerretaining nuts and torque to specifica-tion. Then, remove the safety standsand lower the car.

clearance and restore normal brakepedal travel.

FRONT SHOCK ABSORBER

REMOVAL1. Raise the hood and remove 3

shock a'bsorber upper mountingbracket to spring tower retainingnuts.

2. Raise the front of the car andplace safety stands under the lowerarms.

3. Remove 2 shock absorber lowerretaining nuts and washers (Fig. 15).

4. Lift the shock absorber and up-per bracket from the spring tower(Fig. 15) and remove the bracketfrom the shock absorber.

REAR SHOCK ABSORBER-

MUSTANG

Removal1. Disconnect the shock absorber

from the spring clip plate (Fig. 18).2. On the passenger car, remove

the shock absorber access cover fromthe luggage compartment (Fig. 16).

SHOCK ABSORBER ACCESS COVER

nut, washer, and outer bearing coneand roller assembly.

4. Pull the hub and rotor assemblyoff the wheel spindle.

5. Remove four bolts and nuts andremove the splash shield and caliperbracket from the spindle.

6. Disconnect the spindle connecting rod end from the spindle arm us-ing Tool-3290-C.

7. Remove the cotter pins fromboth ball joint stud nuts, and loosenthe nuts one or two turns. Do not re-move the nuts from the studs at thistime.

8. Position the ball joint removertool between the upper and lower balljoint studs (Fig. 5). The tool shouldseat firmly against the ends of bothstuds and not against the stud nuts.

9. Turn the tool with a wrench un-til the tool places the studs under ten-sion, and, with a hammer, tap thespindle near the studs to loosen themin the spindle. Do not loosen thestuds in the spindle with tool pres-sure alone.

10. Position a floor jack under thelower suspension arm.

11. Remove the upper and lowerball joint stud nuts; lower the jackand remove the spindle.

Fl086-ALUGGAGE COMPARTMENT

FLOOR PANEL

FIG. 16-Rear ShockAbsorber Access (over

On the Ranchero, remove the re-taining screws, and lift the forwardhalf of the floor panel from the body;then, remove the access cover fromthe opening in the floor pan over theshock absorber.

On station wagons, remove the ac-cess cover from the opening in theseat riser over the shock absorber.

3. Remove the shock absorber up-per retaining nut.

4. Compress the shock absorberand remove it from the car. Removethe bushings and washers from theshock absorber studs.

LOWER RETAINING BOL TS F1239-A

FIG. 1 5-Removing orInstalling Front Shock

Absorber-Typical

INSTALLATION1. Install the upper mounting

bracket on the shock absorber andtorque to specification.

2. Position the shock absorber andupper mounting bracket in the springtower, making sure the shock ab-sorber lower studs are in the pivotnl"tp hnlp~

Installation1. Position the spindle on the low-

er ball joint stud and install the studnut (Fig 14). Torque the nut tospecification 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.

3. Torque the nut to specificationsand install the cotter pin. Then, re-move the floor jack.

4. Connect the spindle connectingrod end to the spindle arm and installthe retaining nut. Torque the nut tospecification and install the cotterpin.

S. Position the caliper bracket andsplash shield to the spindle and installthe attaching bolts and nuts. Torquethe nuts and bolts to specification.

6. Install the hub and rotor on thespindle.

7. Position the caliper to the ro-tor and caliper bracket and install theattaching bolts.

8. Install the wheel and tire on thehub anI;! adjust the wheel bearing(Part 3L5).

9. Install the hub cap or wheelcover.

10. Before driving the car, pumpthe brake pedal several times to ob-t,,;n nnrm"J hr"~p linino tn rntnr

Installation1. Place the bushings and washers

on the shock absorber studs.2- rnnn~~t the linneT ~tud to the


remove the shock absorber accesscover from the floor pan. Remove thenut, outer washer, and rubber bush-ing that retain the shock absorber tothe upper mounting in the floor pan(Fig. 17).

spring clip plate (Fig. 18). Compressthe shock absorber and remove itfrom the car.

4. If the shock absorber is serv-iceable and requires new bushings re-move the inner bushings and washersfrom the shock absorber studs.

SHOCK ABSORBER UPPER RETAINING NUT

"11~~_4

Installation1. Place the inner washer and

bushing on each shock absorber stud.2. Expand the shock absorber and

position it to the spring clip plate andto the mounting in the floor pan.

3. Connect the lower stud to thespring clip plate, and install the bush-ing, washer, and nut on the stud (Fig.18). Be sure the spring clip plate isfree of burrs. Tighten the nut tospecification.

4. From the luggage compart-ment, install the bushing washer andretaining nut to the upper mountingstud (Fig. 17). Torque to specifica-

VER ~

FIG. 17-Rear ShockAbsorber Upper Mounting

3. Raise the car and remove the re-taining nut, outer washer and bush-ing from the shock absorber at the

mounting, and install the bushing,washer, and nut on the stud. Torquethe nut to specification, and installthe cover (on a station wagon or car).

On the Ranchero, after installingthe nut to specification, and installstall the forward half of the floorpanel.

3. Connect the lower stud to thespring clip plate, and install the bush-ing, washer, and nut on the stud. Besure the spring clip plate is free ofburrs. Tighten the nut to specifica-tion.

COMET, FALCON, ANDFAIRLANE (EXCEPT CONVERT-IBLE)

Removal1. Open the luggage compartment

door, and remove the spare wheel andtire. On a station wagon, remove thefloor bed panel (14 screws).

2. Fold back the floor mat and

F 1153-C

.Rear SprinQ and Shock Absorber-TypicalFIG. 1 8


tion. On a station wagon, replace thefioo~ bed panel (14 screws).

5. Place the spare wheel and tirein the luggage compartment, and se-cure it in the storage position.

COMETANDFAIRLANECONVERTmLE

1. Remove the rear seat cushionand seat back.

2. Partially raise the car on a hoist.With an assistant under the car hold-ing the shock absorber, remove thenut from the top of the shock ab-sorber.

3. Remove the lower shock ab-sorber attaching nut and remove theshock absorber.

4. Position the washers and bush-ings on the shock absorbe~ and posi-tion the shock absorber to the lowerattachment. Install the bushing, wash-er, and retaining nut and torquethe nut to specification (Part 3-6).

5. Lower the car and install thebushing, washer, and retaining nut onthe top of the shock absorber. Torquethe nut to specification.

6. Install the rear seat back andseat cushion.

FIG. 19-Rear Spring Front Bushing Removal-Typical

special tool combination to the spring nut on the hanger bolt and tightenfront eye as shown in Fig. 20. finger tight.

2. While holding the tool nut, tight- 6. Torque the rear shackle lock-en the tool bolt against the tool thrust nuts to specification.washer, adapter, and detail A4 to 7. Lower the rear axle until it restsforce the bushing into the spring eye on the spring. Position the spring clipas shown. plate on the clips (U-bolts). Install

3. Position the spring under the the V-bolt nuts and torque to specifi-rear axle and insert the shackle as- cation.sembly into the rear hanger bracket 8. Connect the lower end of theand the rear eye of the spring. shock absorber to the spring clip

4. Install the shackle inner bush- plate.ings, the shackle plate, and the lock- 9. Place safety stands under thenuts. Tighten the locknuts finger rear axle, lower the car until thetight. spring is in the approximate curb

5. Position the spring front eye in load position, and then torque ~hethe front hanger, slip the washer on front hanger stud locknut to specifi-the front hanger bolt, and (from the cation.inboard side) insert the bolt through 10. Remove the safety stands andthe hanger and eye. Install the lock lower the car.

T64K-5781-B2 (Adapter), -83 (Nut)

I -81 (BaIt)

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Too/-T64N-S78I-AI, - A4.

Tool

REAR SPRING AND/ORBUSHING

REMOVAL1. Raise the car on a hoist and

place supports beneath the underbodyand under the axle.

2. Disconnect the lower end oftbe shock absorber from the springclip plate, and push the shock out ofthe way.

3. Remove the spring clip platenuts from the V-bolts; then, removethe plate (Fig. 18).

4. Remove the two retaining nuts,the rear shackle bar, and the twoshackle inner bushings.

5. Remove the rear shackle assem-bly and the two outer bushings.

6. Remove the front hanger bolt,nut, and washer from the eye at theforward end of the spring. Lift outthe spring assembly.

7. If the front bushing is being re-placed, assemble the special tool com-bination to the bushing in the springfront eye as shown in Fig. 19.

8. While holding the tool nut,tighten the tool bolt against the toolthrust washer, the adapter, and de-tail AI. This operation will force thebushing out of the spring eye into de-tail A4 of the tool as shown.

'"

SPRING FR~T EYE F1241-A

FIG. 20-Rear Spring front Bushing Installation-TypicalINSTALLATION

1. Assemble the bushing and the

3-22

MANUAL STEERING

Page.3-22

.3-23

3-23

. .3-24

. .3-24

3-24

.3-24

.3-24

3-25

3-26

3-26

3-27

Section1 Description 2 In-Car Adjustment and Repairs Steering Gear Worm and Sector

Adjustments. . . . . . . . . . . . . . . . . . . . . . .Steering Wheel Spoke Position

Adjustment. . . . . . . . . . . . . . . . . . . . . . . .Steering Wheel Replacement. . . . . . . . . . . .Steering Column Shift Tube

Replacement. . . . . . . . . . . . . . . . . . . . . . .Falcon With Standard Transmission-

Comet and Fairlane With StandardTransmission and Standard Steering.

Comet and Fairlane With StandardTransmission and Power Steering...

Falcon With Automatic Transmission-Comet and Fairlane With AutomaticTransmission and Standard Steering. .

Comet and Fairlane With AutomaticTransmission and Power Steering. . . .

Steering Column Upper BearingReplacement """"""""""'"Comet and Fairlane With Power

Steering. . . . . . . . . . . . . . . . . . . . . . . . .All Models Except Comet and

Fairlane With Power Steering. . . . . . . . 3-27

DESCRIPTION

The steering gear (Fig. 1) is of theworm and recirculating ball type. Thesector shaft rotates in needle bearingsthat are pressed into the gear hous-ing.

The worm bearing preload is con-trolled by the large bearing adjusterwhich is threaded into the housing.The sector shaft mesh load is con-trolled by an adjusting screw located

in the housing cover.

A steering gear identification tag

is provided under one of the cover

attachinlZ bolts (PilZ. 2).

PART 3-3 - MANUAL STEERING 3-23

SERIAL NUMBER OR DATE CODE G1218-A

FIG. 2-Steering GearIdentification Tag

FILLER PLUGADJUSTER LOCK NUTDamage to suspension and/or

steering linkage components may oc-cur if care is not exercised when po-sitioning the hoist adapters of 2 posthoists prior to lifting the car.


STEERING GEAR WORM ANDSECTOR ADJUSTMENTS

The ball nut assembly and the sec-tor gear must be adjusted properlyto maintain minimum steering shaftend play (a factor of preload adjust-ment) and minimum backlash be-tween sector gear and ball nut. Thereare only two possible adjustmentswithin the recirculating balltypesteering gear, ahd these should bemade in the following order to avoiddamage or gear failure.

1. Disconnect the Pitman armfrom the sector shaft.

2. Remove the steering wheel,spring and the centering cone fromthe shaft and note the relation of theshaft to the bearing.

3. If the shaft is not centered, at-tach a spring scale to it.

4. Center the shaft by pulling onthe scale and note the reading.

5. If more than 20 lbs. pull is re-quired to center the shaft, the steer-ing column should be aligned as de-tailed in steering gear installation, be-fore adjusting the preload and meshload.

6. Loosen the nut which locks thesector adjusting screw (Fig. 3), andturn the adjusting screw counter-clockwise.

7. Measure the worm bearing pre-load by attaching an in.-Ib. torquewrench to the steering wheel nut (Fig.4). With the steering wheel off center,read the pull required to rotate theinput shaft approximately 11/2 turnseither side of center. If the torque orpreload is not within specification

- - -. --SECTOR SHAFT

ADJUSTING SCREW

FIG. 3-Steering Gear

Adjustments- Typical

G1071-B

(Part 3-6), adjust as explained in thenext step.

HOISTING INSTRUCTIONS


taching nut and remove the steeringwheel from the shaft, using the toolshown in Fig. 5.

taching screws and remove the bear-ing retainer and turn signal switchfrom the steering column (Fig. 6).

8. Lift the spring and centeringsleeve 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 leversocket and remove the flange andshift lever socket from the steeringcolumn.

11. Lift the shift tube from thesteering column.

FIG. 4-Checking Pre-load- Typical

Tool - 3600 - AAor Tool 3826 Gl272-A8. Loosen the steering shaft bear-

ing adjuster lock nut, and tighten orback off the bearing adjuster (Fig. 3)to bring the preload within the spec-ified limits.

9. Tighten the steering shaft bear-ing adjuster lock nut, and recheck thepreload.

10. Turn the steering wheel slowlyto either stop. Turn gently against thestop to avoid possible damage to thebaD return guides. Then rotate thewheel 2Y4 turns to center the ballnut.

11. Turn the sector adjustingscrew clockwise until the specifiedpull (Part 3-6) is necessary to rotatethe worm past its center high spot(Fig. 4). No perceptible backlash ispermissable at 30° on either side ofcenter.

12. While holding the sector ad-justing screw, tighten the locknut tospecification and recheck the back-lash adjustment.

13. Connect the Pitman arm to. thesector shaft and torque to specifica-tion.

STEERING WHEEL SPOKEPOSITION ADJUSTMENT

When the steering gear is on thehigh point, the front wheels shouldbe in the straight-ahead position andthe steering wheel spokes should be intheir normal position with the Pitmanarm pointing directly forward. If thespokes are not in their normal posi-tion, they can be adjusted withoutdisturbing the toe-in adjustment(Refer to Part 3-1).

STEERING WHEELREPLACEMENT

1. Remove the horn ring (or but-ton) assembly and related parts.

2. Remove the steering wheel at-

Installation1. Position the shift tube in the

steering column and through theshift arms. Be sure the shift tube isinserted through both shift anus.

2. Position the shift lever socketon the steering column and engage itwith the shift tube (Fig. 6).

3. Position the flange to the hubso that the heads of the 2 flange boltsengage in the slots of the steeringcolumn tube. Then, tighten the 2flange bolt nuts.

4. Position the centering sleeve onthe steering shaft and seat it into theflange bearing.

5. Feed the turn signal switchwires through the steering columnand position the switch and bearingretainer to the flange.

6. Install the 3 bearing retainerattaching screws.

7. Position the shift lever to theshift lever socket and install thesprings and trunnion.

8. Apply 2 drops of Loctite sealer(C3AZ-19554-A) to the threads ofthe turn signal switch lever and installthe lever.

9. Position the spring and steeringwheel on the steering shaft and installthe retaining nut. Torque the nut tospecification and apply 2 drops ofLoctite sealer (C3AZ-19554-A) to thejunction of the nut and steering shaftthreads.

10. Install the spring and hornring or button on the steering wheeland connect the turn signal and hornwires at the connectors.

11. Adjust the shift linkage, if re-quired, and remove the alignmenttool.

COMET AND F AIRLANE WITHSTANDARD TRANSMISSIONAND POWER STEERING

Removal1. Open the hood and insert a

fabricated alignment tool (Group 6)through the column tube and shift

FIG. 5-Removing SteeringWheel- Typical

3. With the front wheels straightforward, position the steering wheelon the steering shaft with the post onthe steering wheel hub at the top.

4. Apply Loctite Sealer (C3AZ-19554-A) to the steering shaftthreads and install the steering wheelnut on the shaft. Torque the nut tospecification.

5. With the front wheels straightforward (post on steering wheel hubat the top), install the horn ring (orbutton) assembly and the relatedparts.

STEERING COLUMN SHIFTTUBE REPLACEMENTFALCON WITH STANDARDTRANSMISSION-COMET ANDFAIRLANE WIm STANDARDTRANSMISSION ANDSTANDARD STEERING

Removal1. Open the hood and insert a fab-

ricated alignment tool (Group 6)through the column tube and shiftarms to retain the shift mechanismin neutral.

2. Disconnect the turn signal andhorn wires at the steering columnconnectors.

3. Remove the horn ring andspring from the steering wheel.

4. Remove the steering wheel re-taining nut and remove the steeringwheel with Tool 3600-AA (Fig. 5).

5. Remove the trunnion andsprings retaining the shift lever in thesocket and remove the shift lever.

6. Remove the turn signal switchlever.

7. Remove 3 bearing retainer at-

G 1384-A

FIG. 6-Steering Column Disassembled-Typical

arms to retain the shift mechanismin neutral.


3. Remove the horn ring andspring from the steering wheel.


S. Remove the trunnion andsprings retaining the shift lever in thesocket and remove the lever.

6. Remove the turn signal switchlever.

7. Remove 3 bearing retainer at-taching screws and remove thebearing retainer and turn signalswitch from the steering column (Fig.6).

the turn signal switch lever and installthe lever.

10. Position the spring and steer-ing wheel on the steering shaft andinstall the retaining nut. Torque thenut to specification and apply 2 dropsof Loctite sealer (C3AZ-19554-A) tothe junction of the nut and steeringshaft threads.

11. Install the spring and hornring (or button) on the steeringwheel.

12. Adjust the shift linkage, if re-quired, and remove the alignment pinfrom the shift arms and steering col-umn.

13. Connect the turn signal andhorn wires at the steering columnconnectors.

FALCON WITH AUTOMATICTRANSMISSIONCOMET AND FAIRLANE WImAUTOMATIC TRANSMISSIONAND STANDARD STEERING

8. Remove the snap ring from thesteering 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 leversocket and tap the end of the steer-ing shaft with a soft hammer. This isto break the bearing loose from theshaft.

11. Remove the bearing, flange,and shift lever socket from the steer-ing column.

12. Lift the shift tube from thesteering column.


steering column and through theshift arms and spacer. Be sure theshift tube is inserted through bothshift arms.

2. Position the shift lever socketon the steering column and engageit with the shift tube (Fig. 6).

3. Position the flange to the hubso that the heads of the 2 flange boltsengage in the slots of the steering col-umn tube. Then, tighten the 2 flangebolt nuts.

4. Position the bearing on thesteering shaft and seat in the flangewith Tool T62F-3576-A, if necessary.

5. Remove the tool and install thesnap ring on the shaft.

6. Feed the turn signal switchwires through the steering columnand position the switch and bearingretainer to the flange.

7. Install the 3 bearing retainerattaching screws.

8. Position the shift lever to theshift lever socket and install the rollpin.

9. Apply 2 drops of Loctite sealer(C3AZ-19554-A) to the threads of

Removal1. Open the hood and disconnect

the shift rod from the steering col-umn shift arm.

2. Loosen the steering gear to siderail retaining bolts.

3. Disconnect the turn signal and

5. Remove the steer~ng wheel re-taining nut and remove the steeringwheel with Tool 3600-AA (Fig. 5).

6. Remove the insulation from thedash panel in the area of the steeringcolumn.

7. Remove 2 screws clamping thedash panel seal retainer to the steer-ing column. Then, remove 5 screwsattaching the retainer to the dashpanel and remove the retainer.

8. Remove 2 bolts attaching thesteering column to the instrumentpanel support and remove the steer-ing column from the car.

9. Remove the snap ring from thesteering shaft and remove the steer-ing shaft from the steering column.

10. Place the selector lever in theneutral position and remove the shifttube to steering column hub retainingscrew located on the underside of thehub.

11. Pull the shift tube out of thelower end of the steering coiumn.

horn wires at the steering columnconnectors.

4. Remove the horn ring (or but-ton) and spring from the steeringwheel.


6. Remove the insulation from thedash panel in the area of the steeringcolumn.

7. Remove 5 dash panel seal re-tainer attaching screws (Fig. 6) andremove the seal from the steering col-umn opening. Then, slide the sealup the steering column.

8. Remove 2 bolts attaching thesteering column to the instrumentpanel support.

9. Apply tape to the area aroundthe instrument panel steering columnopening to protect the finish on thepanel.

10. Place the transmission selec-tor lever in the low gear position.

11. Turn the steering column 1/4turn counterclockwise. Pull the steer-ing column upward on the steeringshaft until the shift arm contacts thedash panel in the engine compart-ment.

12. Rotate the steering columnclockwise until the shift arm clearsthe opening in the dash panel. Then,pull upward on the column until thesteering column attaching bracketclears the instrument panel. It maybe necessary to apply a slight down-ward pressure on the steering columnso the bracket will clear the instru-ment panel.

13. Rotate the steering columnuntil the shift arm is pointing downand remove the column from thecar.

14. Place the steering column ona bench and move the transmissionselector lever to the neutral position.

15. Remove the shift tube tosteering column hub retaining screwlocated on the underside of the hub.

16. Pull the shift tube out of thesteering column from the lower end.

Installation

1. Position the shift tube in thesteering column and install the re-taining screw.

2. Place the steering column overthe steering shaft with the shift armpointing down.

3. Slide the steering column downon the steering shaft until the bracketis near the instrument panel opening.

4. Rotate the steering columnabout V2 turn until the top of the

steering column bracket is straightup and down on the left side of thecolumn.

5. Slide the steering column downon the steering shaft until the shiftarm contacts the dash panel. It maybe necessary to apply a slight down-ward pressure to the steering columnso the bracket will clear the instru-ment panel.

6. Rotate the steering column sothe shift arm clears the dash panelopening and slide the column downuntil the shift arm is through theopening. Then, rotate the steeringcolumn so that the steering columnbracket is in position at the instru-ment panel support bracket.

7. Loosely install the 2 steeringcolumn bracket to support bracketattaching bolts (Fig. 6).

8. Position the seal and retainerto the steering column and dash pan-el and install the attaching screws(Fig. 6).

9. Position the upper bearingsleeve and spring on the steeringshaft.

10. Position the steering wheel onthe steering shaft and install the re-taining nut. Torque the nut to speci-fication and apply 2 drops of Loc-tite sealer (C3AZ-19554-A) to thejunction of the nut and steering shaftthreads.

11. Install the spring and hornring (or button) on the steeringwheel.

12. Connect the horn and turnsignal wires at the multiple connector.

13. Connect the shift linkage tothe shift arm.

14. Torque the steering gear at-taching bolts to specification.

15. Torque the steering columnbracket to support brace attachingbolts to specification.

16. Check and adjust the shiftlinkage as required.

COMET AND FAIRLANE WITHAUTOMATIC TRANSMISSIONAND POWER STEERING

Removal1. Open the hood and disconnect

the shift linkage from the steering col-umn shift arm.

2. Remove 2 bolts and nuts re-taining the flex coupling to the steer-ing shaft.


4. Remove the 'horn ring (or but-ton) and spring from the steeringwheel.


steering column and install the re-taining screw.

2. Insert the steering shaft in thesteering column and place the upperbearing sleeve on the upper end ofthe column. Install the spring and nuton the steering shaft to retain theshaft in the column.

3. Position the steering column inthe car and loosely install the steer-ing column to instrument panel sup-port bolts.

4. Install the 2 bolts and nuts at-taching the flex joint to the steeringshaft.

5. Position the dash panel open-ing seal and retainer to the dashpanel and install the 7 attachingscrews.

6. Install the insulation to the dashpanel in the area of the steering col-umn.

7. Remove the nut from thesteering shaft and position the steer-ing wheel on the shaft. Install the re-taining nut and torque to specifica-tion (Part 3-6).

8. Apply 2 drops of Loctite sealer(C3AZ-19554-A) to the junction ofthe steering shaft and nut threads.

9. Torque the steering column toinstrument panel attaching bolts tospecification (Part 3-6).

10. Install the horn ring and springand connect the turn signal and hornwires at the connector.

11. Connect the shift linkage to

PART 3-3 MANUAL STEERING 3-27

the steering column shift arm and ad-just as required.

9. Install the flex coupling clampbolt.

10. Position the turn signal switchand bearing retainer to the flangeand install the 3 retaining screws.

11. Apply 2 drops of Loctite seal-er (C3AZ-19554-A) to the turn sig-nal switch lever and install the lever.

diameter in the steering shaft open-ing of the flange and drive the bear-ing out of the flange from the bottomside.

8. Position the 2 flange bolts in theflange holes. Start the flange bolt nutson the flange bolts about 1 V2 turns.

9. Position the flange to the col-umn so that the heads of the 2 flangebolts engage in the slots of the steer-ing column tube. Then, tighten the 2flange bolt nuts.

10. Lubricate the bearing and in-stall it in the flange.

11. Position the turn signal switchand bearing retainer to the flangeand install the 3 retaining screws.

12. Install the centering sleeve andspring on the steering shaft.

13. Position the steering wheel onthe steering shaft and install the re-taining nut. Torque the nut to speci-fication and apply 2 drops of Loctitesealer (C3AZ-19554-A) to the junc-tion of the nut and steering shaftthreads.

14. Install the horn ring (or but-ton) and spring on the steeringwheel.

15. Connect the turn signal andhorn wires at the connectors andcheck the operation of both units.

STEERING COLUMN UPPERBEARING REPLACEMENT

COMET AND FAIRLANE WITHPOWER STEERING

1. Disconnect the horn wire andthe turn indicator wires at the con-nectors. Remove the horn ring (orbutton) and the spring.

2. Remove the steering wheel at-taching nut. Remove the steeringwheel (Fig. 5) with a puller.

3. Remove the turn indicatorlever. Remove the upper bearing re-tainer screws and move the turnsignal switch to one side.

4. Remove 1 bolt clamping theflex coupling on the steering shaft.

5. Remove the snap ring from thesteering shaft.

6. Pull up on the steering shaft toremove the bearing from the flangeand remove the bearing from thesteering shaft.

7. Lubricate the bearing and po-sition it on the steering shaft. UseTool T62F-3576-A to seat the bear-ing, if necessary.

8. Install the snap ring on thesteering shaft.

ALL MODELS EXCEPT COMETAND FAIRLANE WITH POWERSTEERING

1. Disconnect the horn wire andthe turn indicator wires at the con-nectors. Remove the horn ring (orbutton) and the spring.

2. Remove the steering wheel at-taching nut. Remove the steeringwheel (Fig. 5) with a puller, Tool3600-AA.

3. Remove the 3 bearing retainerscrews and remove the bearing re-tainer.

4. Lift the turn signal switch upand over the steering shaft and posi-tion it to one side.

5. Remove the centering sleeveand spring from the steering shaft.

6. Remove 2 flange bolt nuts (Fig.6) and lift the flange from the steer-ing column.

7. Place a socket of the correct


11. Remove nut and washer. In-stall Tool T64P-3590-F and removethe Pitman arm from the sectorshaft (Fig. 7).

TooI-T64P.3590.F STEERING GEAR HOUSING

FIG. 7 -Removing Pitman

Arm-Typical

HOISTING INSTRUCTIONSDamage to suspension and I or



STEERING GEARMUSTANG

Removal1. Disconnect the horn and turn

indicator wires under the instrumentpanel. Also on a car with an auto-matic transmission, disconnect theIfeutral switch wires.

2. Remove the horn ring (or but-ton). Remove the steering wheel re-taining nut and the steering wheel(Fig. 5).

3. Remove the upper bearing cen-tering sleeve and spring.

4. Remove the steering columnclamp to instrument panel bolts and

remove the clamp and the insulator.5. Pull the rubber seal up on the

steering column, fold the floor mataside, and move the dash panel insu-lation out of the way.

6. Remove the retaining screwsfrom the steering column weatherseal on the dash panel. Remove thesteering column cover plates andgasket.

7. Slide th'e steering column tubeassembly from the steering gearshaft, guiding the shift lever(s) upthrough the opening in the dashpanel.

8. Raise the car and remove theclutch equalizer and bracket assem-bly from the frame side rail and en-gine if so equipped to obtainclearance.

9. On power steering equipped ve-hicles, remove pal nut attaching nutinsulator and washer and remove thepower steering cylinder rod from thebracket to obtain clearance for re-movaJ of Pitman arm.

10. Remove the inlet pipe fromthe manifold to obtain clearance.

12. Remove steering gear retain-ing bolts.

13. Lower the car and disconnect


the wires from the left bank of sparkplugs to prevent damaging them.

14. On vehicles equipped with col-umn mounted- shift mechanism, dis-connect the tr~nsmission shift rod(s)at the gear shift lever(s).

15. Remove brake booster if nec-essary.

16. Remove the support rod fromcowl to spring tower (except Comet).

17. Loosen air cleaner to obtainclearance if necessary.

18. Lift the steering gear andshaft assembly from the engine com-partment by raising the gear up andforward past the engine and springtower taking care not to soil or tearthe front seat fabric with the end ofthe steering shaft.

2. Remove the horn ring from thesteering wheel.


4. Remove 5 steering column re-tainer attaching screws and removethe retainer from the steering col-umn and dash panel (Fig. 6). Slidethe seal up the steering column.

5. Remove the 2 steering columnclamp to instrument panel support at-taching bolts.

6. Remove the upper bearing cen-tering sleeve and spring from thesteering shaft.

7. Disconnect the shift linkagefrom the steering column shift arms.

8. Raise the car and remove thePitman arm retaining nut and re-move the Pitman arm with ToolT64P-3590-F (Fig. 7).

9. Remove the nut retaining theclutch release arm return springbracket and remove the bracket andspring (Standard transmission carsonly).

10. Remove the 3 steering gear toframe side rail attaching bolts.

11. Lower the car and remove thesteering column from the steeringshaft.

12. Remove the steering gear fromthe caT.

Installation

1. Install the steering gear fromengine side and guide the shaftthrough the dash panel being carefulnot to soil or tear the front seatfabric. Install the steering gear at-taching bolts but do not tighten.

2. Center the steering shaft forstraight ahead drive position.

3. Raise car on hoist and installclutch equalizer assembly to engineand underbody if car is so equipped.

4. Install inlet pipe to manifold.5. Install Pitman arm to the sec-

tor shaft and install the lock washerand the torque nut to specification.

6. If equipped with power steer-ing, install power cylinder rod tobracket and install insulator washerand nut to retain.

7. Partially lower car onto safetystands and install the steering columntube assembly over the steering shaft,guiding the shifting arms through theopening In the dash panel.

8. Position the steering column as-sembly and retaining clamp and insu-lator, and loosely install the attachingbolts and nuts.

9. Tighten the steering gear toside rail mounting bolts and columnto instrument panel retaining bracket.

Check steering shaft to column up-per bearing clearance. If the shaftdoes not touch the bearing, no furtherreadjustment is required. If the shaftis touching the column upper bear-ing, it will be necessary to check thepull required to center the shaft inthe column, using a fish scale. Wherepull exceeds 20 Ibs. at either planeto center the shaft in the column, thefollowing correction must be made:

Vertical movement of the steeringshaft can be accomplished by loos-ening the steering gear mounting

bolts and pivoting the gear up anddown.

Horizontal movement of the steer-ing shaft can be accomplished byloosening the steering column to in-strument panel retaining bracket andmoving the column to the left orright.

Should additional horizontal move-ment be required to align the steeringshaft, it will be necessary to insertshim(s) of proper thickness betweenthe steering gear assembly and thevehicle side rail. Front end alignmentshims can be used for this purpose.After the steering shaft is centered,torque all bolts to specification.

10. Position the upper bearingcentering sleeve and spring. After ap-plying Lubriplate to the upper surfaceof the steering shaft upper bearingand the horn switch brush plate, posi-tion the steering wheel on the steeringshaft and install the retaining nut.Torque the nut to specification. Then,apply 2 drops of Loctite sealer(C3AZ-19554-A) to the junction ofthe steering shaft and the retainingnut threads.

Apply Loctite sealer sparingly tothe turn indicator lever threads andinstall the lever.

11. Install the horn ring (or but-ton) and spring, and steering wheelto the center point.

12. Set gap between column tubeand steering wheel and tighten col-umn to instrument panel.

13. Lower the car from the safetystands. Connect the horn, turn indi-cator wires, and (on a car with anautomatic transmission) the neutralswitch wires.

14. Position the steering columncover plates and gasket on the dashpanel and install the retaining screws.

15. Position the dash panel insu-lation just above the steering column.Position the floor mat and push therubber seal down to the floor mat.

16. Connect the transmission shiftrods and correct adjustment of shiftlever(s) and the neutral switch.

17. Connect ignition wires.18. Connect cowl to spring tower

support rod (except Comet).19. Tighten the air cleaner.

COMET AND FAIRLANE WITHSTANDARD STEERING(EXCEPT 390 C.I.D. ENGINE)AND ALL FALCON

Removal


Installation

1. Position the steering gear in thecar and allow it to rest on the frameside rail.

2. Position the steering columnover the steering shaft and throughthe hole in the dash panel.

3. Install the steering gear attach-ing bolts and the clutch release armreturn spring, bracket, and nut.

4. Install the Pitman arm and re-taining nut and washer on the sectorshaft. Torque the nut to specification.

5. Position the steering column tothe instrument panel and install the2 retaining bolts. Do not tighten thebolts at this time.

6. Position the seal and retainer tothe dash panel opening and install theattaching screws.

7. Position the upper bearingsleeve, spring, and steering wheel onthe steering shaft and install the re-taining nut (Fig. 6). Torque the nutto specification and apply 2 drops ofLoctite sealer (C3AZ-19554-A) tothe junction of the steering shaft andretaining nut threads.

8. Adjust the steering wheel toflange clearance to 3/64 inch and tight-en the steering column clamp to


steering gear from the car.flex coupling to steering shaft retain-ing bolts and nuts.

6. Fill the steering gear with thespecified lubricant to the correct level(Part 3-1).

instrument panel attaching bolts.Torque the bolts to specification(Part 3-6).

9. Install the spring and horn ring(or button) on the steering wheel.

10. Connect the turn signal andhorn wires at the steering columnconnectors.

11. Connect the shift rods to thesteering column shift arms.

12. Torque the steering gear at-taching bolts to specification (Part3-6) and fill the steering gear withthe specified lubricant to the correctlevel (Part 3-1).

COMET AND FAIRLANEWITH 390 C.I.D. ENGINE ANDSTANDARD STEERING

Removal1. Raise the car and remove the

Pitman arm retaining nut and wash-er.

COMET AND FAIRLANEWITH POWER STEERING

Removal1. Open the hood and remove 2

bolts and nuts retaining the flex cou-pling to the steering shaft.

2. Raise the car and remove 3bolts and a nut retaining the powercylinder bracket to the frame siderail. Separate the bracket from theside rail and allow the cylinder andbracket to hang.

3. Remove the Pitman arm retain-ing nut and washer and remove thePitman arm from the sector shaftwith Tool T64P-3590-F (Fig. 7).

4. Remove the nut retaining theclutch release arm return springbracket and remove the bracket andspring (Standard transmission carsonly).

S. Remove 3 steering gear attach-ing bolts and remove the steeringgear.

Installation1. Remove the steering gear hous-

ing cover from the steering gear.2. Position the steering gear in the

car as follows:a. Insert the steering shaft through

the opening in the dash panel.b. Point the output shaft toward

the fender apron. Slide the geardownward and position it to theframe side rail.

3. Install the steering gear hous-ing cover on the gear housing andadjust the steering gear (Section 2).

4. Position the steering columnover the steering shaft and loosely in-stall the steering column clamp toinstrument panel retaining bolts.

5. Position the steering columnopening seal and retainer to the dashpanel and install the retaining screws.

6~ Center the steering gear mid-way between a full right and full leftturn and position the steering wheelon the steering shaft and install theretaining nut.

7. Torque the nut to specificationand apply 2 drops of Loctite sealer(C3AZ-19554-A) to the junction ofthe nut and steering shaft threads.

8. Install the horn button or ringand the spring to the steering wheel.

9. Install the rocker cover on theleft cylinder head and connect thespark plug wires to the spark plugs(Group 8).

10. Position the brake master cyl-inder to the dash panel and installthe attaching bolts.

11. Connect the brake master cyl-inder line to the junction block.

12. Raise the car and install thesteering gear to side rail retainingbolts. Torque the retaining bolts tospecification (Part 3-6).

13. Position the Pitman arm to thesector shaft and install the retainingnut. Torque the nut to specification(Part 3-6).

14. Bleed the brake hydraulic sys-tem (Part 2-1).

15. Connect the shift rods to theshift levers.

16. Lower the car and torque thesteering column clamp to instrumentpanel retaining bolts.

17. Connect the horn and turn sig-nal wires at the steering column mul-tiple connectors.

2. Remove the Pitman arm fromthe sector shaft with the tool shownin Fig. 7.

3. Remove the 3 steering gear toside rail attaching bolts and discon-nect the shift rods from the shift le-vers.

4. Lower the car and disconnectthe horn and turn signal wires at thesteering column multiple disconnects.

5. Remove the horn button or ringfrom the steering wheel, and removethe steering wheel retaining nut.

6. Remove the steering wheelfrom the steering shaft with Tool3600-AA. Then, remove the toolfrom the steering wheel.

7. Remove 5 screws attaching thesteering column opening seal and re-tainer to the dash panel. Remove theretainer and slide the seal up thesteering column.

8. Remove 2 steering columnclamp to instrument panel retainingbolts and lift the steering columnfrom the steering shaft.

9. Open the hood and disconnectthe master cylinder brake line fromthe junction block.

10. Remove the brake master cyl-inder attaching bolts and remove themaster cylinder and brake line fromthe dash panel.

11. Disconnect the spark plugwires from numbers 5 through 8spark plugs, and remove the rockercover from the left cylinder head.

12. Remove 3 steering gear hous-ing cover attaching bolts and removethe housing cover from the steeringgear.

13. Remove the steering gear fromthe car as follows:

a. Place the steering gear outputshaft against the fender apron.

b. Pull the steering gear up andover the spring tower and remove the

Installation1. Position the steering gear to the

frame side rail and the flex couplingto the steering shaft and install the 3steering gear attaching bolts. Torquethe bolts to specification (Part 3-6).

2. Install the clutch release armreturn spring and bracket (Standardtransmission cars only).

3. Position the Pitman arm to thesector shaft and install the washerand retaining nut. Torque the nut tospecification (Part 3-6).

4. Position the power cylinderbracket to the side rail and install the3 retaining bolts and nut. Torquethe bolts and nut to specification(Part 3-6).

5. Lower the car and install the 2


MAJOR REPAIR OPERATIONS

STEERING GEAR

DISASSEMBLY1. Rotate the steering shaft ap-

proximately 21/4 turns from eitherstop.

2. After removing the sector ad-justing screw locknut and the hous-ing cover bolts, remove the sectorshaft with the cover. Remove thecover from the shaft by turning thescrew clockwise. Keep the shim withthe screw (Fig. 8).

of wood (Fig. 9) to loosen it fromthe housing.

6. Remove the ball return guideclamp and the ball return guidesfrom the ball nut. Keep the ball nutclamp-side up until ready to removethe balls.

7. Turn the ball nut over, and ro-tate the worm shaft from side to sideuntil all balls (Mustang-62 balls;Comet, Falcon, and Fairlane-54balls) have dropped out of the nutinto a clean pan. With the balls re-

~:~~> HOUSINGCDVER3580

. . SHIM 3A6S7

~GASKETj581~ - ADJUSTING SCREW 3S77

LOCK NUT 3707,,;~,

WORM BEARING.AOJUSTER 3A6io'

t(BEARING<;V~, ,;

3552Press both sector shaft bearings

out of the housing (Fig. 10). Removethe seal and the bearings only if thereis an indication of wear, damage, orbearing mislocation. Do not install anew bearing in a housing in whichthe bearing has turned or is found tobe mislocated. A new housing mustbe used.

- SECTOR SHAFT 357S

. BEARING 3576

FILLER PLUG3538

/ BEARING 3571 ,

~ ~ p.\v. "- 3647

;BALLGuJDE 3523,--- "',) ~CLAMP 3544

~'It

---:).

STEERING SHAFT 3524'"- -" BEARING CUP 3552 \,

".~~.. , ~.J"-i .' "\p

6 BEA,RI~,~ 357~- OIL SEAL. 3591

BALL NUl3524 ASSEMBLY

1. If the sector shaft bearings havebeen removed, press new bearings in-to the housing (Fig. 11).

PITMAN ARM 3590

~~

G 1382-A

8-Manual Steering Gear Disassembled

Wood Block

E

3. Loosen the worm bearing ad-juster nut, and remove the adjusterassembly and the steering shaft up-per bearing and cup.

4. Carefully pull the steering shaftand ball nut from the housing. Toavoid possible damage to the ball re-turn guides, keep the ball nut fromrunning down to either end of theworm.

Disassemble the ball nut only ifthere is indication of binding ortightuess.

5. Remove the lower bearing andcup from the housing. It may be nec-essary to tap the housing on a block

FIG. 11 -Installing SectorShaft Bearing

- ""~ G1226-A

FIG. 9-Removing LowerBearing Cup from Housingmoved, the ball nut will slide off theworm.

PART 3-3 - MANUAL STEERING 3-31

2. Position a bearing cup in theadjuster.

3. If the sector shaft oil seal hasbeen removed, install a new oil seal.

4. Swab the inside diameter of theball nut and the outside diameter ofthe worm with gear lubricant C3AZ-19578-A prior to assembly. Lay thesteering shaft on a bench as shownin Fig. 12. After positioning theshaft, turn the ball nut to place the

BAll NUT

-= J. --

14. Position the sector adjustingscrew and the adjuster shim, andcheck the end clearance whichshould not exceed 0.002 inch be-tween the screw head and the end ofthe sector shaft. If clearance is great-er than 0.002 inch, replace the shim.

15. Thread the sector shaft ad-justing screw into the housing cover.

16. Install a new gasket on thehousing cover.

17. Rotate the steering shaft untilthe ball nut teeth are in position tomesh with the sector gear, tilting thehousing so that the ball nut will tiptoward the housing cover opening.

18. Apply enough gear lubricantC3AZ-19578-A to fill the pocket inthe housing between the sector shaftbearings 30% full.

19. Push the housing cover withthe sector shaft into place.

20. Turn the cover to one side andfill the housing with Ih lb. of gearlubricant C3AZ-19578-A.

21. Install but do not tighten thehousing cover attaching bolts. Do nottighten the cover bolts until it is cer-tain that there is some lash betweenthe ball nut and the sector gear teeth.

22. After loosely installing the sec-tor shaft adjusting screw .lock nut, ad-just the sector shaft mesh to the spec-ified mesh load, then tighten the ad-justing screw lock nut. Remove thesteering wheel nut.

-- - )'.~ ' SPLINE TO RIGHT

NARROW END OF OF BALL NUTTAPER FACING DOWN G1227-A

FIG. 12-Positioning BallNut-Typicalguide holes in the up position. Alignthe grooves in the worm and in theball nut by sighting through the ballguide holes.

5. Insert the ball guides into theholes of the ball nut, tapping themlightly with a wood handle of a screwdriver if necessary to seat them.

6. Insert the balls (Mustang-62balls; Comet, Falcon, and Fairlane-54 balls) into the hole in the top ofeach ball guide. It may be necessaryto rotate the shaft sli~htly one way,

then in the opposite direction to dis-tribute the balls in the circuit.

7. After the balls (Mustang-31balls; Comet, Falcon, and Fairlane-27 balls) are installed, install the ballguide clamp. Check the ball nut tosee that it rotates freely. Torque thescrew to specification.

8. Coat the threads of the steeringshaft bearing adjuster, the housingcover bolts, and the sector adjustingscrew with a suitable oil-resistantsealing compound. Do not apply seal-er to female threads, and especiallyavoid getting any sealer on the steer-ing shaft bearings.

9. Coat the worm bearings, sectorshaft bearing and gear teeth withgear lubricant C3AZ-19578-A.

10. Clamp the housing in a vise,with the sector shaft axis horizontal,and position the steering shaft lowerbearing cup and the bearing in place.

11. Position the steering shaft andball nut assembly in the housing.

12. Position the steering shaft up-per bearing on the top of the worm,and install the steering shaft bearingadjuster and cup. Install the lock nutwith the flat side against the bearingadjuster and the letter outward.Leave the nut loose.

13. After installing the steeringwheel nut on the steering shaft, ad-just the worm bearing preload, usingan inch-pound torque wrench tocheck for specified preload.

STEERING LINKAGE REPAIR

The manual steering linkage (Figs.13, 14, and 15) consists of the Pit-man arm, the steering arm-to-idlerarm rod, the steering idler arm, andthe spindle connecting rods (tie rods).Do not attempt to straighten bentlinkage; use new parts.

to specification and install the cotterpin.

6. Check and, if necessary, ad-just toe-in (Part 3-1). Mter toe-in ischecked and adjusted, torque the oldsleeve clamp bolts to specification.Add four pounds torque if new boltsare used. The tie rod sleeve clampsmust be installed as shown in Fig. 13,Part 3-1, to prevent interference withthe side rail.

ends of the rod sleeves, have non-adjustable, spring-loaded ball studs.A rod end should be replaced whenexcessive looseness at the ball stud isnoticed.

1. Remove the cotter pin and nutfrom the worn rod end ball stud.

2. Disconnect the end from thespindle, connecting arm, Pitman arm,or idler arm as shown in Fig. 16.

3. Loosen the connecting rodsleeve clamp bolts, and count thenumber of turns needed to removethe rod end from the sleeve. Discardall rod end parts that were removedfrom the sleeve. All new parts shouldbe used when a spindle connectingrod end is replaced.

4. Thread a new rod end into thesleeve, but do not tighten the sleeveclamp bqlts at this time.

5. Insert the stud in the part fromwhich the old one was removed, andinstall the stud nut. Torque the nut

SPINDLE SLEEVE REPLACEMENT

A spindle sleeve should be re-placed if it becomes worn or dam-aged (Figs. 13, 14, and 15). Do notattempt to straighten the sleeve ifthreaded portion is damaged.

1. Remove the spindle connectingrod ends as described in the previoussub-section.

2. Screw the spindle rod ends intothe new sleeve the same number ofturns as the ends that were removed.

HOISTING INSTRUCTIONSDamage to suspension and/or


II a 2 post hoist is used to lift thecar, place the adapters under thefront suspension lower arms. Do notallow the adapters to contact thesteering linkage.

SPINDLE CONNECTING RODEND REPLACEMENT

The spindle connecting rod ends,which are threaded into the outer

FIG. 13-Typical Steering Linkage-Comet, Falcon, and Fairlane

and the spindle arm. Install the at-taching nut, torque it to specifica-tion, and install the cotter pin.

4. Check and, if necessary, adjusttoe-in (Part 3-1). After toe-in ischecked and adjuste~ torque thesleeve clamp bolts to specification.The sleeve clamp must be installedwith the bolt down to prevent inter-ference with the side rail.

i I. I

~

STEERING ARMo TO-IDLER AR~..RO~i i \~H "1

I II II II ,'i o.\.' I

i' I; o...! \ ,__0-.. I, -<, \

I , "..' I-, I '1.0.'" ,-, \ 0- ;' ~.. ,..' '".,,'(00;__,_--

~"~.." \.." o:oo.::.o_o,,~,t:~:...~;::.~>::'oo ,

\ : \ \\ \ \\ ~"'" , \ ,. .. ,

SPINDLE C~NECTING .. ..",

ROD END ,..",.

~i, "'.., ., ,"""~"""'-.

£i" , 0-

J 1/1, '", ",, 'I, I'

i Ii, Ii'

1././,/

""",,:,.,.,.. ,-, ,., .'

\ ..'..1

,:::l-"

STEERING ARM- TO-IDLER ARMROD REPLACEMENT

The rod connecting the Pitmanarm and the idler arm is non-adjust-able and is provided with taperedholes to accommodate the ball studs(Figs. 13, 14, and 15). The rodshould be replaced when damaged orwhen worn at the ball studs.

~-CLAMPS MUST BE ASSEMBLED

WITH BOLTS IN BOTTOMHORIZONTAL POSITION AS

SHOWN

,'\ ,):\...'\ \.' I~, \

\. ". ...

' , \ V/ "'-..

'\".'

"" ,

""",,,

~,

@~

..;:.;..;.,.;..

";;4

e-\-\

!'I!iI'---"'-' G 1380-A

MUSTANG-6.CYLINDER1. Remove the cotter pins and

nuts from the ball studs at the sec-tor shaft arm and the idler arm, andremove the steering arm-to-idler armrod (Fig. 16).

2. Position the new steering arm-to-idler arm rod on the idler arm andthe steering arm.

3. Install the ball stud retainingnuts and torque to specification.

4. Install cotter pins, lubricate the

FIG. 14-6-Cylinder Manual Steering Linkage-MustangDo not tighten the clamp bolts at this 3. Position the sleeve assembly ontimp. the Pitman arm (or the idler arm)

,., \ \, ill'. II \ \ \. II \J !I,SPINDLE Ca-INECTING RDD IDLER ARM

I '., '., ' ,: ,I,\ : t \

, \

\\ \,\'.',

/'~


FIG. lS-8-Cylinder Manual Steering linkage-Power Typical-Mustang

THREAD PROTECTORToo/-3290-C 3. Disconnect the spindle connect-ing rod ends from the steering arm-to-idler arm rod with Tool-3290-C(Fig. 16).

4. Remove 1 cotter pin and nutretaining the idler arm to the steer-ing arm-to-idler arm rod and discon-nect the idler arm from the rod withTool-3290-C.

5. Remove 1 cotter pin and nut re-taining the Pitman arm to the steer-ing arm-to-idler arm rod. Disconnect

the Pitman arm from the rod withTool-3290-C and remove the rod.

Installation1. 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 andidler arm and install the retainingnuts. Torque the nuts to the low endof the specification. Continue to tight-en each nut until the slots in the nutalign with the hole in the stud. Theninstall the cotter pin.

3. Position the spindle connectingrod ends to the steering arm-to-idlerarm rod and install the retaining nuts.Torque the nuts to the low end of thespecification. Continue to tighteneach nut until the slots in the nutalign 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 tospecification (Part 3-1).

STEERING IDLER ARMAND/OR BUSHING

1. Raise the car and remove thecotter pin and nut retaining the idlerarm to the steering arm-to-idler armrod (Figs. 13, 14, and 15).

2. Remove the cotter pin and nutretaining the idler arm to the brack-et and remove the idler arm.

3. Place the idler arm in a viseand replace the bushings as shown inFig. 17.

4. Position the idler arm to thebracket and steering arm-to-idlerarm rod and install the retaining nutsand cotter pins.

5. Lower the car and check caster,camber and toe-in and adjust if re-Quired.

FIG. 16-DisconnectingSteering linkage BallStud- Typical

power steering ball stud socket, ifnecessary.

5. Check and, if necessary, adjusttoe-in (Part 3-1).

COMET, FALCON, FAIRLANE,AND 8 CYLINDER MUSTANG

Removal1. Raise the car on a hoist and po-

sition safety stands.2. Remove the 2 cotter pins and

nuts retaining both spindle connect-ing rod ends to the steering arm-to-idler arm rod (Fig. 13).

3.34

POWER STEERING

Page.3-34.3-34.3-34.3-36.3-36.3-37.3.37

Page. . . .. . . . .. .3-38. . . . . . . . .. .3-38. . . . . . . .. . .3-38. . . . . . .. . . .3-38. .. . . . . . . . .3-39. . . . . . . . . . .3-39. .. . . . . . . . .3-39

... .. .3-40... .. . .3-40. ... . .3-40

... .3-40. . . . . . .. . . .3-41. . . . . . . . . . .3-41

.3-42

SectionPower Steering Pump. . . . . . . . .

6 Cylinder 8 Cylinder Power Steering Pump Pulley. . .

Power Steering Control Valve.Mustang-6 Cylinder. . . . . . .Comet, Falcon, and Fairlane .

Power Cylinder 4 Major Repair Operations. . . . . .

Control Valve Disassembly Tube Seat Replacement Assembly. . . . . . . . . . . . . . . . .

Power Cylinder Seal. . . . . . . . . .Power Steering Pump Reservoir

Replacement ...,

3-373-37

3-37

3-373-383-38

Section1 Description and Operation. . . . . . . . . . . . . . .

Description. . . . . . . . . . . . . . . . . . . . . . . . . .Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Steering Pump Flow Control Valve Pressure Relief Valve. . . . . . . . . . . . . .

2 In-Car Adjustments and Repairs. . . . . . . . .Power Steering Pump Belt Tension

Adjustment. . . . . . . . . . . . . . . . . . . . . . . .Control Valve Centering Spring AdjustmentControl Valve to Power Steering

Cylinder Hose. . . . . . . . . . . . . . . . . . . . . .Power Steering Pump to Control Valve

Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Removal and Installation. . . . . . . . . . . . . . .

Steering Gear. . . . . . . . . . . . . . . . . . . . . . . . 3-42


crankshaft, draws fluid from the res-ervoir and provides fluid pressure forthe system. Within the pump itself isa pressure-relief valve which governsthe pressures within the steering sys-tem according to the varying condi-tions of operation. After fluid haspassed from the pump to the controlvalve and the power cylinder, it re-

DESCRIPTIONThe Power Steering System (Fig.

1) is a hydraulically controlled link-age-type steering system which in-cludes an integral pump and fluid res-ervoir, a control valve, a power cyl-inder, the connecting fluid lines, andthe steering linkage. The hydraulicpump, belt-driven from the engine

turns to the reservoir.The power steering pump is a belt

driven slipper type pump which is in-tegral with the reservoir. It is con-structed so that the reservoir is at-tached to the rear side of the pumphousing front plate and the pumpbody is incased within the reservoir.

OPERATIONThe control valve, operated by

steering wheel movement, directs thepressure developed by the pump.When the front wheels are in thestraight-ahead position, the controlvalve spool is held in the center(neutral) position by its centeringspring. Fluid then flows around thevalve lands and returns to the reser-voir (Fig. 2). Within the controlvalve body there is a reaction limit-ing valve which reduces parkingeffort.

When force of about 4 pounds isexerted for a left turn, the valvespool overcomes the pressure of thecentering spring and moves towardthe right end of the valve. As a re-sult, pressure is exerted on the rightside of the power cylinder piston, andfluid in the left end of the cylinder re-turns to the reservoir (Fig. 2).

If the direction of the force on thesteering wheel is reversed, the frontwheels will turn to the straight for-ward position. Or as force on the

G 1233-C

FIG. l-Power Steering System

PART 3-4 - POWER STEERING 3-35

J- ,.., ... ,-r--"'I "II II

11 I'II IIl ' I IIIII IIII II

.. IJ I : :r II II'I1,,1 I II: 1 'I I I I

J 1 I I I, r {o{, II II

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

,-( \ I I

I ' 'L__JlIi I"II I)..1-. 1. -,'" ,~.J

FLUID FLOW-STRAIGHT-AHEAD DRIVING

PUMP AND RESERV(\I"CHECK VALVE

(IN CONTROL HOUSING) "'"'"'"'~

..'f--1r. \.'I: III'IIIIII: I: lI, 1j ,

.,IIIIIII I,II,' I ,

,.or, ,

I r \,

II ~~I I \.0I -

I,II

I:

_1-1

--'--,:-.-"I.

\~

,", I,--_v.~=~-j POWER CYLINDER

I I

~-c:. -.:;;-- -=--=::--/~- I I --', , ~_I , ," , '\ '\" ,_- ' \' ~--"' i I'",, "'~--- 71\, --

, , ~',/,-- --~"'--::==::-~

PUMP PRESSURECONTROL VALVE

RETURN PRESSURE

FLUID FLOW-LEFT TURN ....,.--1'II ,\

PUMP AND RESERVDIR "I ,II, I II' I'I, II\ I I'I I II

'I "" ,\~, ,1( I' ' ,

',"\' , II1/", I I// 11 I I

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,-- r- ' I I '-' ,'-'-- " 'I~~:,~J:=.3=-:: II"~~-,-, , I I-~r ""' '0' \ /

.., --"'1-( 'L--~', '

I I I. , II,,/, ,-I.:0(-

:" I I'..L~.j

..'f- -",

(I II CHECK VALVEI I ,I \ I , (IN CONTROL HOUSING)I I I,\ I I ,I I \'1 I I,II

I I",

1 I I'\ \ \ If, \ III I ~ ',\!I \ I-}"II II ~\1 IIII II\1 III I \.)\~---

~

r-:;::::"'-- -_. . ~ -::-

',:'"1"--

,--}.- -I"-, }r---~;~ POWER CYLINDER

-~-:.-;---=--:::-- -~ I I --'""" ..-l , ,

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

, ---'--~~~- ,I, \_-~---""--' // ~-- "'-

, , ... ""'-'

,-- --/"

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

FLUID FLOW-RIGHT TUR~

PUMP AND RFSFRVnlR

PUMP PRESSURE

~illmlilli RETURN PRESSURE

~ R~At:TION PRESSUREL.

CONTROL VALVE

--~. .-',:".,. ,r--' I 0'

" I'" /,I' ",I .',I I'II I'" /1~, ",...1/ . ' ,I 'I "

I ",, ' ,III/, "

r {~ :' : I.- - r..,---" , / ,-, ,I . ,---~~:,~-,=-:J=-" " ,I- /1 '--~-- .... ~-~-, " . '-"-~j") " ,1

'-. I ." ,~'II , -_J':: 1,I I.\..I-~'0' ,'.2.J

.rT--1\" I',,,, CHECK VALVEI, ,: (IN CONTROL HOUSING)II 1/,,I II, I 1/'

:' /1"' 1II ,"I /', II , / I' , \II , I ':~: , I' t~" /! "-

1/ "'/ I'lol___I.J

.~,--- ~

":""',--1--

,--

,.~q,

'/1, .o.rr;=~- POWER CYLINDERI ,

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

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

\ ,'" /1, , --c;;:-",-" ,

, , '>--- ,

'-::':::=::::::-'

~ PUMP PRESSURE

I !!Ii!!!! RETURN PRESSUREii.

REACTION PRESSURE

G1O37.C

FIG. 2-Fluid Flow Diagram


steering wheel falls below approxi-mately 4 pounds the valve spool cen-tering spring forces the spool backto the center position and there thepressure on both sides of the powercylinder piston is equal. With normalforward driving movement of the carand in the absence of operative pres-sure within the power cylinder, thefront wheels will seek to return to thestraight ahead position. This is a nor-mal effect of the front wheel align-ment.

For a right turn, the directionalforces explained above are reversed(Fig. 2).

If, for any reason, the pump failsto deliver fluid pressure, the car maybe steered without pump pressure.

POWER STEERING PUMPThe pump rotor has 8 slippers and

springs which rotate inside a cam in-sert containing two lobes 180° fromeach other. The cam insert and thepump port plates provide a sealedchamber within which the rotor andslippers rotate between the two lobesfor pump operation.

As the rotor turns, the slippers areforced outward against the innersurface of the cam insert by a com-bination of centrifugal force, slipperspring force and fluid pressure actingon the under side of the slipper. Apair of adjacent slippers, along withthe surfaces of the rotor, cam andpressure plates, form a sealed cham-ber within the crescent-shaped void.As this sealed chamber movesthrough the crescent shaped void itsvolume 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 ofthe sealed chamber increases. Thiscreates a vacuum and sets up a suc-tion area. With the inlet port placedin this area, the chamber will fill withfluid. As the rotor rotates from 90°to 180°, the volume of the sealedchamber decreases, thus creating apressure area. The pressure or outletport is located in this area. While thispumping action is going on between0° and 180°, the same condition isoccurring between 180° and 360°.This combination creates what isknown as a balanced rotor pump.The two pressure and suction quad-rants are diametrically opposite eachother.

FIG. 4-Power Steering Pump-Sectional View

will vary directly with the pump gear requires a relatively high con-speed. However, a power steering stant rate of flow in the parking zone

FLOW CONTROL VALVESince the pump is a constant dis-

placement pump, the internal flow

PART 3-4 POWER STEERING 3-37

and up to approximately 2800 RPMand thereafter a lower rate of flow.This is accomplished by means of avariable orifice mechanism shown inFig. 4.

All of the internal pump flow isported from the pumping mechanism(rotor, slippers, and cam insert),through passage A into the flow con-trol zone. All of flow goes throughthe orifice and out into the line untilthe bypass port is cracked open. Thisis the regulation point. The oil dropsin pressure in moving through theorifice. The lower pressure is thensensed through a hole drilled in thecover communicating to the rear of

case of a road load of sufficient mag-nitude, the steering gear will not ac-cept any flow from the pump, exceptfor a very limited volume of oil dueto leakage past valve seals. Becauseof this resistance, excessive hydraulicpressure would be developed, if itwere not limited by the pressure re-lief valve.

When relief pressure is reached,the pressure relief ball is forced offits seat, allowing oil to pass throughthe spool valve and dump into thebypass port (Fig. 4). The relief valvewill continue to limit oil pressure tothe relief setting for the duration ofthe overload condition.

the spool valve. The differential inpressure thus created on the spoolvalve increases steadily and propor-tionally with increasing RPM andthis moves the valve progressivelyback into its bore, thus increasing theopening of the bypass port.

The metering pin (Fig. 4) travelswith the spool valve decreasing thenet area of the orifice at higherspeeds. This action reduces flow tothe steering gear.

PRESSURE RELIEF VALVEWhen the steering wheel is turned

completely to the stop position in theright or left turn direction, or in the



steering linkage components may oc-cur if care is not exercised when posi-tioning the hoist adapters of 2 posthoists prior to lifting the car.


PUMP BELT TENSIONADJUSTMENT

Pump drive belt tension cannotbe checked accurately using thethumb pressure or belt deflectionmethods. Correct belt adjustment isassured only with the use of a belttension gauge.

1. Check the belt tension with abelt tension gauge (T63L-8620-A).With a new belt, or one that has beenrun for less than 15 minutes, the ten-sion should be within 120-150 lbs.With a belt that has been run formore than 15 minutes; the tensionshould be within 90.120 lbs.

2. To adjust the belt, loosen themounting bolts incorporated on thefront face of the pump cover plate(hub side) and one nut at the rear.Place a 9/16 inch open end wrench onthe projecting 1/2 inch boss on thefront face of the pump cover plateand pry upward to adjust belt tension.When adjusting the power steeringpump belt tension, do not pry againstthe pump or reservoir to obtain theproper belt tension. The reservoir willbe deformed when pried on orpressed against and a leak will result.

5. Fill the power steering pumpreservoir with fluid to the proper lev.el (Part 3-1).

6. Start the engine and turn thesteering wheel to each end of itstravel several times to cycle the sys-tem. Then, check for leaks.

7. Stop the engine and again checkthe power steering fluid level. Addfluid as required.

POWER STEERING PUMP TOCONTROL VALVE HOSE


Removal1. Remove the fluid from the

pump reservoir with a suction gun.2. Raise the car on a hoist.3. Remove the clamp retaining the

hose tubes to the control valve.4. Disconnect the fluid return and

pressure hoses from the control valveand allow the fluid to drain into apan.

5. Lower the car and disconnectthe fluid return hose from the reser.voir.

6. Disconnect the fluid pressurehose from the pump outlet fitting.

7. Remove 1 bolt attaching thehoses, insulator, and the retainer tothe frame side rail and remove thehoses, and the insulator and retaineras an assembly from the car.

8. Remove the pressure and returnhoses from the retainer and insulator.

3. Recheck the belt tension. Whenthe tension has been correctly ad-justed, torque the bolts and the nutto specification.

CONTROL VALVE CENTERINGSPRING ADJUSTMENT


1. Raise the car and remove 2spring cap retaining screws and lockwashers and remove the spring cap.

2. Tighten the adjusting nut snug;then, loosen the nut Y4 turn. Do nottighten the adjusting nut too tight.

3. Position the spring cap to thevalve housing and install the 2 re.taining screws and washers.

4. Lower the car.5. Start the engine and check the

turning effort with a spring scale.With the spring scale attached to therim of the steering wheel, the effortto turn the wheel in both directionsshould not exceed 12 pounds.

CONTROL VALVE TO POWERSTEERING CYLINDER HOSE


1. Raise the car on a hoist andplace a drain pan under the powercylinder.

2. Disconnect the hose from thepower cylinder and allow the fluid todrain from the hose. Then, disconnectthe hose from the control valve.

3. Connect the hose to the controlvalve and power cylinder.

4. Remove the drain pan andlower the car.

Installation1. Install the pressure and return

hoses in the insulator and retainer.

fluid, C1AZ-19582-A, to the properlevel (Part 3-1).

7. Start the engine and turn thesteering wheel to each end of itstravel several times to cycle the sys-tem. Then, check for fluid leaks.

8. Stop the engine and again checkthe power steering fluid level (Part3-1). Add fluid as required.

let fitting and torque the fitting tospecification.

4. Raise the car and connect thepressure and return lines to the con-trol valve.

5. Install the clamp to retain thehose tubes to the control valve.

6. Lower the car and fill the pow-er steering pump reservoir with

Position the assembly to the frameside rail and install the attaching bolt.

2. Place a hose clamp on the fluidreturn hose and install the hose on thepower steering pump reservoir returnfitting.

3. Torque the pump outlet fittingto specification (Part 3-6). Then,connect the pressure hose to the out-


Torque to specification.2. Position the pulley to the pump

shaft and install tool T65P-3A733A.Press the pulley on the shaft. (Referto Fig. 4 for tool installation.) Then,remove the tool.

3. Position the pump and bracketto the engine and install the attach-ing bolts and spacers.

4. Install one bolt to attach thebrace to the bottom of the bracket.Torque the bracket attaching bolts tospecification (Part 3-6).

5. Position the belt on the pulleyand adjust the belt tension to speci-fication with Tool T63L-8620-A (Sec-tion 2).

6. Torque the outlet fitting hexnut to specification. Then, connect thepressure hose to the fitting and torquethe hose nut to specification.

7. Connect the return hose to thereservoir and tighten the clamp.

8. Fill the radiator with coolant.9. Fill the pump reservoir to the

correct level with transmission fluid(CIAZ-19582-A). Start the engineand turn the steering wheel to eachend of its travel several times to cyclethe system and check for leaks.Check the fluid level (Section 1, Part3-1) and fill as required and installthe fill cap.

8.CYLINDER




STEERING GEARRefer to Group 3-3, Section 3 for

detailed instructions.

POWER STEERING PUMP

6-CYLINDER

Removal1. Remove the fill cap from the

reservoir and remove the fluid witha suction gun.

2. Disconnect the fluid return hosefrom the reservoir.

3. Disconnect the oil pressure hosefrom the pump.

4. Loosen the adjusting bolts andremove the drive belt from the pul-ley.

5. Drain the coolant from the ra-diator and remove 3 bolts and spac-ers attaching the pump bracket to theengine. Remove one bolt attachingthe support to the lower edge of thebracket and remove the pump andbracket from the car.

6. Place the bracket in a vise andinstall a 3/8 -16 capscrew in the end ofthe pump shaft.

7. Install tool T63L-I0300-B onthe pulley and remove the pulleyfrom the pump shaft. Refer to Fig.S for tool installatioq.

8. Remove 3 bolts retaining thepump to the bracket and remove thepump from the bracket.

Removal1. Remove the fill cap from the

reservoir and remove the fluid with asuction gun.

2. Disconnect the fluid return hosefrom the reservoir.

3. Disconnect the oil pressure hosefrom the pump.

4. Loosen the belt adjusting boltsand nut and remove the drive beltfrom the pump pulley.

5. Remove 3 bolts and 1 nut re-taining the pump to the bracket andremove the pump from the car.

Installation1. Position the pump to the brack-

et and loosely install the 2 pivot boltsand 2 adjusting bolts.

2. Position the drive belt on thepulley and adjust the belt tension tospecification with tool T63L-8620-A(Section 2). Tighten the adjustingbolts and pivot bolts to specification.

3. Torque the outlet fitting hexnut to specification (Part 3-6). Then,connect the pressure hose to the fit-ting and torque the hose nut to speci-fication.

4. Connect the return hose to thereservoir and tighten the clamp.

5. Fill the pump reservoir to thecorrect level with transmission fluidC1AZ-19582-A. Start the engine andturn the steering wheel to each endof its travel several times to cyclethe system and check for leaks. Checkthe fluid level, fill as required, andinstall the fill cap.

POWER STEERING PUMPPULLEY

REMOVALOther than pulley removal and res-

ervoir or seal replacement, the pumpshould not be disassembled but re-placed as a unit.

1. Drain as much of the fluid a~possible from the pump through thefill pipe.

2. Install a %-16 capscrew in theend of the pump shaft to preventdamage to the shaft end by the toolscrew.

3. Install the pulley remover tool,T63L-10300-B on the pulley hub,and place the tool and pump in avise as shown in Fig. 5.

4. Hold the pump and rotate thetool nut counterclockwise to removethe pulley (Fig. 5).

.INSTALLATION1. Position the pulley to the pump

shaft and install Tool T65P-3A733-A as shown in Fig. 6.

Installation1. Position the pump to the brack-

et and install the 3 retaining bolts.


the control valve, at the valve. Allowthe lines to drain into a container.

2. Disconnect the lines leadingfrom the power steering pump to thecontrol valve at the valve. Allow thelines to drain into a container. Re-move the clamp that secures thelines to the valve.

3. Remove the two bolts that se-cure the control valve to the steer-ing arm-to-idler arm rod.

4. Remove the cotter pin and thecastellated nut that secures the con-trol valve to the Pitman arm.

S. Disconnect the control valvefrom the Pitman arm as shown inFig. 7.

FIG. 5-Removing PulleyFrom Pump

2. Hold the pump and rotate thetool nut clockwise to install the pul-ley on the shaft. The pulley face willbe flush with the end of the pumpshaft. Install the pulley without in andout pressure on the shaft to preventdamage to internal thrust areas.

3. Remove the tool.

Installation1. Place the stud in a straight ver-

tical position. Measure from the cen-ter of the stud parallel to the boltmounting surface (Fig. 8) to the

"~ ' "," "

the Pitman arm with the castellatednut and a cotter pin.

3. Secure the end of the controlvalve to the steering arm-to-idlerarm rod with two bolts, lock washersand nuts.

4. Connect the pressure line andthe oil return line to their respectivefittings on the valve. Install the lineretaining clamp around the valve.

5. Connect the two lines from thepower cylinder to their respective fit-tings on the valve.

6. Fill the reservoir to the correctlevel.

7. Start the engine and turn thesteering wheel to each end of itstravel several times to cycle the sys-tem. Stop the engine.

8. Check the fluid level and fill asnecessary. Install the fill cap.

9. Start the engine and check forleaks.


Removal1. Disconnect the 4 fluid line fit-

tings at the control valve, and drainthe fluid from the lines. Turn thefront wheels to the left and right sev-eral times to force all the fluid fromthe system.

2. Loosen the clamping nut andbolt at the right-hand end of thesleeve.

3. Remove the roll pin from thesteering arm to idler arm rod throughthe slot in the sleeve.

4. Remove the control valve ballstud nut.

5. Using the tool shown in Fig. 9,remove the ball stud from the sectorshaft arm.

VALVEBAll STUDTool-3290-C PITMAN ARM

fToo/.T65P.3A733-A

~

FIG. 9-Control Valve BallStud Removal

6. After turning the front wheelsfully to the left, unthread the controlvalve from the steering arm to idlerarm rod.

G1274. A

FIG. 6-Pulley Installation

POWER STEERINGCONTROL VALVE

MUSTANG-6 CYLINDER

Removal1. Disconnect the pressure lines

leadin1! from the power cylinder to

FIG. 8-Control Valve

Length Adjustment-Mustang6-Cylindercenter of the first bolt hole. The dis-tance should be from 4Ys -43/16 inches(6 cyl. models only). If not withinthese limits adjust the length as re-

quired.2. Secure the control valve stud to


STEERING ARM- TO-IDLER ARM RODInstallation1. Thread the valve onto the steer-

ing arm to idler arm rod until aboutfour threads are still visible on therod.

2. Position the ball stud in the sec-tor shaft arm.

3. Measure the distance betweenthe center of the grease plug in thesleeve and the center of the stud atthe inner end of the left-hand spindleconnecting rod (Fig. 10). The dis-tance should be 55/8 inches. If thedistance is not correct, disconnect theball stud from the sector shaft armand turn the valve on the steeringarm to idler arm rod to increase ordecrease the distance.

FIG. 11 -Disconnecting PowerCylinder Stud

~-- ~

lUBRICATION PLUG~

G1157-A

Install a new cotter pin.7. Connect the fluid lines to the

control valve, and tighten all fittingssecurely. Do not over-tighten.

8. Fill the fluid reservoir with thespecified fluid to the F mark on thedip stick.

9. Start the engine and run it atidle speed for about two minutes towarm the fluid in the power steeringsystem.

10. Turn the steering wheel allthe way to the left and right severaltimes, and check the system for fluidleaks.

11. Increase the engine speed toabout 1000 rpm, and turn the steer-ing wheel all the way to the left andright several times.

12. Stop the engine, and check thecontrol valve and hose connectionsfor fluid leaks. Correct the cause ofany leaks.

13. Check the fluid level, and re-till the reservoir if necessary.

14. With the engine running checkthe position of the steering wheelwhen the front wheels are in thestraight-ahead position. Do not makeany adjustments until toe-in ischecked.

15. Keep the engine running, andcheck toe-in. If either toe-in or steer-ing wheel position is not correctmake all necessary adjustments (Part3-1) at the spindle connecting rodsleeves.

16. Check the effort to turn thewheels in both directions. The effortshould be about equal in both direc-tions.

POWER CYLINDER

REMOVAL1. Disconnect the two fluid lines

from the power cylinder and allowthem to drain into a container.

2. Remove the pal nut, attachingnut, washer and the insulator fromthe end of the power cylinder rod.

3. Remove the cotter pin and cas-tellated nut that secures the powercylinder stud to the steering arm-to-idler arm rod.

4. Disconnect the power cylinderstud from the steering arm-to-idlerarm rod as shown in Fig. 11.

5. Remove the insulator sleeve andwasher from the end of the powercylinder rod.

6. Inspect the tube fittings and theseats in the power cylinder for nicks,burrs or damage. Replace the seatsin the cylinder or the tubes as re-quired.

INST ALLA nON1. Install the washer, sleeve and

the insulator on the end of the powercylinder rod.

2. Extend the rod as far as pos-sible. Insert the rod in the bracketon the frame and compress the rodas necessary to insert the stud in thesteering arm-to-idler arm rod. Securethe stud with a castellated nut and acotter pin.

3. Secure the power cylinder rodwith an insulator, washer, nut and apal nut.

4. Connect each of the two fluidlines to their respective part in thecylinder.

5. Fill the reservoir to the correctlevel.

6. Start the engine and turn thesteering wheel to each end of itstravel several times to cycle the sys-tem. Stop the engine.

7. Check the fluid level and fill asnecessary. Install the fill cap.

8. Start the engine and check forleaks.

FIG. 10 -Control ValveInstallation Measurement-Typical-Comet, Falcon,and Fairlane

4. When the correct distance isobtained and the ball stud is posi-tioned in the sector shaft arm, alignthe hole in the steering arm to idlerarm rod with the slot near the end ofthe valve sleeve. Install the roll pinin the rod hole to lock the valve inposition on the rod.

5. Torque the valve sleeve clampbolt to specification.

6. Install the nut on the ball stud,and torque the nut to specification.


cap from the valve housing (Fig. 12).When holding the control valve for

disassembly, use a softjawed vise, andclamp the valve only around thesleeve flange to prevent damage tothe housing, spool, or sleeve.

CONTROL VALVE

DISASSEMBLY1. Wipe all fluid and loose dirt

from the outside of the control valve.2. Remove the centering spring

3. Remove the nut from the endof the valve spool bolt. Remove thewashers, spacer, centering spring,adapter, and bushing from the boltand the valve housing.

4. Remove the two bolts that hold


FIG. 12-Control Valve Disassembled-Typical

the valve housing and the sleeve to-gether, and separate the housing I ~~from the sleeve. l

5. Remove the plug from the valvesleeve.

6. Push the valve spool out of the Icentering spring end of the valvehousing, and remove the seal fromth~ spool.

7. Remove the spacer, bushing,and seal from the sleeve end of thevalve housing.

8. Drive the stop pin out of thetravel regulator stop with a punchand hammer (Fig. 13). Pull the headof the valve spool bolt tightlyagainst the travel regulator stop be-fore driving the pin out of the stop.

9. Turn the travel regulator stopcounterclockwise in the valxe sleeveto remove the stop from the sleeve.

10. Remove the valve spool bolt,spacer, and rubber washer from thetravel regulator stop.

11. Remove the rubber boot andclamp from the valve sleeve.

12. Slide the bumper, spring, andball stud seat out of the valve sleeve,and remove the ball stud socket fromthe sleeve.

13. After removing the return porthose seat, remove the return port re-lief valve.

14. After removing the spring plug

GREASEPLUG

~~ '" "':'",'"

:!1 .,

~

VALVESPOOLBOLT

STOPPIN

BALL STUD""'"SOCKET TRAVEL""'"

REGULATOR ,., STOP G1030-8

FIG. 13-Removing Stop Pin

-Typicaland a-ring, remove the reaction lim-iting valve (Fig. 14).

TUBE SEAT REPLACEMENTIf a hose seat is worn or damaged

it should be replaced. It can be re-moved with an Easy-Out tool, or byusing a bolt of appropriate size as puller.

1. Tap the existing hole in thehose seat, using a starting tap of suit-able size. Be sure to remove all metalchips from the hose seat port aftertapping.

2. Place a nut and large flat wash-er on a bolt of the same size as the

FIG. 14-Removing ReactionValve Plugtapped hole. The washer must belarge enough to cover the hose seatport.

3. Insert the bolt in the tappedhole, and using the nut as a puller,remove the hose seat.

4. Place a new hose seat in theport, and thread a bolt of suitablesize into the port. Tighten the boltenough to bottom the seat in theport.

ASSEMBLYBefore assembling the control

valve, coat all parts except the sealswith Automatic Transmission Fluid.Coat the seals with lubricantCOAZ-19553-A.

1. Install the reaction limitingvalve, the spring, and the plug.

2. Install the return port relief


so that the valve can be positionedin a vise as shown in Fig 18. Thenpush forward on the cap end of thevalve to check the valve spool forfree movement.

valve and the hose seat.3. Insert one of the ball stud seats

(flat end first) into the ball studsocket, and insert the threaded endof the ball stud into the socket.

4. Place the socket in the controlvalve sleeve so that the threaded endof the ball stud can be pulled outthrough the slot in the sleeve (Fig.15).

/.,..

~r~ ~

FIG. 18-lnspecting ValveSpool Movement

20. Turn the valve around in thevise, and push forward on the sleeveend to check the spool for freemovement.

CONTROL {

VALVE SLEEVE

BALL STUD SEAT

BALL:

BALL STUD SOCKET/' G 103 5-A

FIG. 15-lnstalling BallSocket, Seal and Bracket

s. Place the other ball stud seat,the spring, and the bumper (Fig. 12)in the socket, and install and securelytighten the travel regulator stop.

6. Loosen the stop just enough toalign the nearest hole in the stopwith slot in the ball stud socket, andinstall the stop pin in the ball studsocket, travel regulator stop, andvalve spool bolt (Fig. 13).

7. Install the rubber boot, clamp,and the plug on the control valvesleeve. Make sure that the lubrica-tion fitting is turned on tightly anddoes not bind on the ball stud socket.

8. Insert the valve spool in thevalve housing. Rotate the spool whileinserting it in the housing (Fig. 16).

same time, guide the lip of the sealover the spool with a small screw-driver. Do not nick or scratch theseal or the spool during installation.

11. Place the sleeve end of thehousing on a flat surface so that theseal, bushing, and spacer are at thebottom end and push down the valvespool until it stops.

12. Carefully install the spool sealand bushing in the centering springend of the housing. Press the sealagainst the end of the spool, guid-ing the seal over the spool with asmall screwdriver. Do not nick orscratch the seal or the spool dur-ing installation.

13. Pick up the housing, and slidethe spool back and forth in the hous-ing to check for free movement.

14. Place the valve sleeve on thehousing so that the ball stud is onthe same side of the housing as theports for the two power cylinderlines. Install the two bolts in thesleeve, and torque them to specifica-tions.

15. Place the adapter on the cen-tering spring end of the housing, andinstall the bushing, washers, spacers,and centering spring on the valvespool bolt.

16. Compress the centering spring,and install the nut on the bolt. Tight-en the nut snug, then loosen it notmore than 1/4 turn (Fig. 17). Exces-sive tightening of the nut may breakthe stop pin at the travel regulatorstop.

G 1034 - B

G103'i-B

POWER CYLINDER SEAL

REMOVAL1. Clamp the power cylinder in a

vise, and remove the snap ring fromthe end of the cylinder. Be carefulnot to distort or crack the cylinderin the vise.

2. Pull the piston rod out all theway to remove the scraper, bush-ing, and seals. If the seals cannot beremoved in this manner, removethem from the cylinder with a sharppick. Take care, when using a pick,not to damage the shaft or seal seat.

INSTALLATIONWhen replacing the power cylin-

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 theparts (Fig. 19) on the piston rodwhich has been coated with the samegrease.

2. Push the rod in all the way, andinstall the parts in the cylinder witha deep socket slightly smaller thanthe cylinder opening (Fig. 20).

POWER STEERING PUMPRESERVOIR REPLACEMENT

Reservoir replacement must bedone on a clean workbench. Clean-liness of work area and tools isextremely important when repairingany hydraulic unit. Thoroughly cleanthe exterior of the pump with asuitable cleaning solvent. Do not im-merse the shaft oil seal in solvent.

FIG. 16-lnserting Valve

Spool9. Move the spool toward the cen-

tering spring end of the housing, andplace the small seal bushing, andspacer in the sleeve end of the hous-ing.

10. Press the valve spool againstthe inner lip of the seal and, at the

FIG. 17 -Adjusting Centering

Spring

17. Move the ball stud back andforth in the sleeve slot to check thespool for free movement. See Part3-6 for the specified travel. ApplyCOAZ-19553-A (silicone) grease atthe sealing areas.

IS. Install the centering springcap on the valve housing, and torquethe two cap bolts to specification.

19. Install the nut on the ball stud

PART 3-5 WHEELS AND TIRES 3-43

INSERT

SEAL RUBBER WIPER

RETAINERSEAL

SCRAPER

---::-: '/61

-_/,/,>~SNAP RING

Gl031-B

SEATS.

FIG. 19-Power Cylinder

TOOLT57L-500-A FIG. 22-Gasket Locations

the rear of the reservoir and on theouter edges only.

5. Inspect the assembly to be surethe reservoir is evenly seated on thepump housing plate.

6. Position the service indentifica-tion tag on the outlet fitting and in-stall the outlet fitting hex nut. Torquethe nut to specification (Part 3-6).Do not exceed specification.

7. Install the stud nut and torqueto specification.

WOOOBLOCK

I.

FIG. 21Reservoir

-Removing Pump

I

~

let fitting, a new copper gasket onthe support stud, and a new reservoirO-ring seal on the pump housingplate (Fig 22). The old gaskets andseal should never be re-used.

2. Apply vaseline to the reservoirO-ring seal and to the inside edge ofthe new reservoir flange. Do nottwist the O-ring seal.

3. Position the reservoir over thepump and align the reservoir withthe outlet fitting and the stud hole.

4. Install the reservoir on thepump and O-ring seal with a plasticor rubber hammer and a block ofwood as shown in Fig. 23. Tap at

- ~ 1359-A

FIG. 23-lnstalling Reservoiron Pump

TOOL TS7L

FIG. 20-lnstalling PowerCylinder Seals

Plug the inlet and outlet openingswith plugs or masking tape beforecleaning the pump exterior or re-moving the reservoir.

REMOVAL1. Position the pump in a bench

mounted holding fixture, Tool T57L-500-A.

2. Rotate the pump so the pulleyside is facing down and remove theoutlet fitting hex nut, stud nuts, andservice identification tag.

3. Invert the pump so the pulleyside is facing up and remove thereservoir by tapping around theflange with a wood block (Fig. 21).

4. Remove the reservoir a-ringseal, the outlet fitting gasket, andthe support stud copper gasket fromthe pump.

INSTALLATION1. Install a new gasket on the out-

3-44

WHEELS AND TIRES

Page.3-44.3-44.3-44.3-45.3-45.3-45.3-45.3-45.3-45

Page3-463-46

,3-463-473-473-473-48

Section1 Description and Operation. . . . .

Front Wheel RearWheel 2 In-Car Adjustment and Repairs .

Front Wheel Bearing Adjustment3 Removal and Installation. . . . . .

Wheel and Tire Removal. . . . . .Removing Tire From Wheel. . .Installing Tire on Wheel. . . . . .

SectionWheel and Tire Installation 4 Major Repair Operations. . . . . . . .

Front Wheel Grease Seal andBearing Replacement and! orRepacking. . . . . . . . . . . . . . . . . .Drum Brakes Disc Brakes .'.'.'..'...""

Front Hub and Drum ReplacementFront Hub and Rotor Replacement


~

GREASERETAINER

,l

HUB AND BRAKEDRUM ASSEMBLY

~ INNERBEARING

CUP

FRONT WHEEL

Each front wheel and tire assem-bly is bolted to its respective fronthub and brake drum or rotor onMustang with disc brakes (optionalon Mustang models). Two opposedtapered roller bearings are installedin each hub. A grease retainer isinstalled at the inner end of the hubto prevent lubricant from leaking in-to the drum or on the rotor. Theentire assembly is retained to itsspindle by the adjusting nut, nut lockand cotter pin (Figs. I and 2).

OUTERBEARING

ClIP

ADJUSTINGNUT

\\

OUTERBEARING

CONE ANDROLLER

\;:::...,.GREASE

CAP~

INNER BEARINGCONE AND

ROLLERQ,

IL- WHEELASSEMBLY

~

WASHER ..@

NUT/COTTERPIN-

/NUT"."...

F1056-C~ .~~" HUB BOLT" ~

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

GREASERETAINER

HUB AND RDTOR

ASSEMBLY~ INNER

BEARINGCUP

OUTERBEARING

CUP

ADJUSTINGNIIT

OUTERBEARING

CONE AND ~GREASE

CAp~

..- INNER BEARINGCONE AND

ROLLER--

WASHER ~NUT/

- WHEELASSEMBLYCOTTER

PIN NUTLOCK HUB BOLT I "~/-

FIG. 2-Front Hub, Bearings and Grease Retainer-Disc Brakes

REAR WHEEL

The rear brake drum assembly isretained to studs on the rear axleshaft flange by three speed nuts. Thewheel and tire assembly mounts onthe same rear axle shaft flange studsand is held against the hub and drumby the wheel nuts. The rear wheelbearing is pressed onto the axle shaftjust inside the shaft flange, and theentire assembly is retained to therear axle housing by the bearing re-tainer plate which is bolted to the

housing flange.The inner end of each axle shaft

is splined to the differential in therear axle.

F 1259 - A




steering linkage components may oc-cur if care is not exercised whenpositioning the hoist adapters of 2post hoists prior to lifting the car.

li a 2 post hoist is used to lift thecar, place the adapters under thefront suspension lower arms. Do notallow the adapters to contact thesteering linkage.

8. Install a new cotter pin, andbend the ends of the cotter pinaround the castellated flange of thenut lock.

9. Check the front wheel rotation.If the wheel rotates properly, installthe grease cap and the hub cap orwheel cover. If the wheel still rotatesroughly or noisily, clean or replacethe bearings and cups as required(Section 4).

10. Before driving the car (ifequipped with disc brakes), pump thebrake pedal several times to obtainnormal brake lining to rotor clear-ance and restore normal brake pedaltravel.

three turns. Then, rock the wheeland rotor assembly in and out severaltimes to push the shoe and liningsaway from the rotor.

S. While rotating the wheel, hub,and drum or rotor assembly, torquethe adjusting nut to 17-25 ft-ibs toseat the bearings (Fig 3).

6. Locate the nut lock on the ad-justing nut so that the castellationson the lock are aligned with the cot-ter pin hole in the spindle.

7. Back off both the adjusting nutand the nut lock together until thenext castellation on the nut lockaligns with the cotter pin hole in thespindle.

INSTAll lOCK ON NUT SO THATCA5TEllATION5 ARE ALIGNED

WITH COTTER PIN HOLE.

WITH DRUM AND WHEELROTATING, TORQUE THE

ADJUSTINGNUT TO 17.25 It lb.

FRONT WHEEL BEARINGADJUSTMENT

The front wheel bearings shouldbe adjusted if the wheel is too looseon the spindle or if the wheel doesnot rotate freely. The following pro-cedure will bring the bearing adjust-ment to specification.

1. Raise the car until the wheeland tire clear the floor.

2. Pry off the hub cap or wheelcover and remove the grease capfrom the hub.

3. Wipe the excess grease fromthe end of the spindle, and removethe cotter pin and nut lock.

4. If equipped with disc brakes,loosen the bearing adjusting nut FIG. 3-Front Wheel Bearing Adjustment



steering linkage components may oc-cur if care is not exercised whenpositioning the hoist adapters of 2post hoists prior to lifting the car.


wheel downward, and insert two tireirons about 8 inches apart betweenthe tire inner bead and the back sideof the wheel rim. Use only tire ironswith rounded edges or irons designedfor demounting tubeless tires.

4. Leave one tire iron in position,and pry the rest of the bead over therim with the other iron. Take small"bites" with the iron around the tirein order to avoid damaging the seal-ing surface of the tire bead.

5. Stand the wheel and tire up-right with the tire outer bead in thedrop center well at the bottom of thewheel. Insert the tire iron betweenthe bead and the edge of the wheelrim, and pry the wheel out of thetire.

mounting machine. Be sure that theouter side of the wheel is positioneddownward. If tire irons are used fol-low the procedure given here.

1. Remove the valve cap and core,and deflate the tire completely.

2. With a bead loosening tool,break loose the tire side walls fromthe wheel (Fig. 4).

3. Position the outer side of the

WHEEL AND TIRE REMOVAL1. Pry off the wheel hub cap or

cover. Loosen but do not removethe wheel lug nuts.

2. Raise the car until the wheeland tire clear the floor.

3. Remove the wheel lug nutsfrom the bolts, and pull the wheeland tire assembly from the hub anddrum or rotor.

Fl058-A

FIG. 4-Bead Loosening Tool

INSTALLING TIRE ON WHEEL

1. If a used tire is being installedremove all dirt from the tire.

If a tire is being mounted to theoriginal wheel, clean the rim with

REMOVING TIRE FROMWHEEL

The tire can be demounted on a


the side walls) are evenly visible justabove the rim flanges all the wayaround the tire. If the rings are noteven, deflate the tire completely andinflate it again.

6. When the rings are properlypositioned, deflate the tire to therecommended pressure.

F1021-A

FIG. 5-Tubeless TireMounting Band

emery cloth or fine steel wool. Checkthe rim for dents.

If a new wheel is being installed,coat a new valve with RUGL YDEor similar rubber lubricant and posi-tion the valve to the new wheel. Usea rubber hammer or a valve replac-ing tool to seat the valve firmlyagainst the inside of the rim.

2. Apply RUGL YDE or a simi-lar rubber lubricant to the sealingsurface on both tire beads. With theouter side of the wheel down, prythe beads over the wheel rim withtwo tire irons. Do not use a hammeror maDet to force the beads overthe rim.

3. Align the balance mark on thetire with the valve on the wheel.

4. Hold the beads against the rimflanges by positioning a tire mount-ing band over the tire (Fig 5). If amounting band is not available, tie

a torniquet of heavy ~ord aroundthe circumference of the tire. Tightenthe cord with a tire iron. Center thetire on the wheel with a rubbermallet.

5. Give the tire a few quick burstsof air to seat the beads properly,then inflate the tire to 40 poundspressure. Check to see that the beadpositioning rings (outer rings near

WHEEL AND TIREINSTAllATION

1. Clean all dirt from the hub anddrum or rotor.

2. Position the wheel and tire as-sembly on the hub and drum orrotor. Install the wheel lug nuts andtighten them alternately in order todraw the wheel evenly against thehub and drum or rotor.

3. Lower the car to the floor, andtorque the lug nuts to specification(Part 3-6).


Fl093-A

FIG. 6-lnstalling Front WheelBearing Cup-Falcon 6-Cylinder

specified wheel bearing grease. Addlubricant to the hub only until thegrease is flush with the inside di-ameter of both bearing cups (Fig. 8).

11. All old grease should be com-pletely cleaned from the bearingsbefore repacking them with newgrease. Pack the bearing cone androller assemblies with wheel bearinggrease. A bearing packer is desira-ble for this operation. If a packer isnot available, work as much lubri-cant as possible between the rollers

the inner bearing cone and roller as-sembly from the hub with a drift.

5. Clean the lubricant off theinner and outer bearing cups withsolvent and inspect the cups forscratches, pits, excessive wear, andother damage. If the cups are wornor damaged, remove them with a drift.

6. Soak a new grease retainer inlight engine oil at least 30 minutesbefore installation. Thoroughly cleanthe inner and outer bearing conesand rollers with solvent, and drythem thoroughly. Do not spin thebearing with compressed air.

7. Inspect the cone and roller as-semblies for wear or damage, and re-place them if necessary. The coneand roller assemblies and the bear-ing cups should be replaced as a unitif damage to either is encountered.

8. Thoroughly clean the spindleand the inside of the hub with sol-vent to remove all old lubricant.

Cover the spindle with a cleancloth, and brush all loose dust anddirt from the brake assembly. Toprevent getting dirt on the spindle,carefully remove the cloth from thespindle.

9. If the inner and/ or outer bear-ing cups(s) were removed, install thereplacement cup(s) in the hub withthe tool shown in Figs. 6 or 7. Besure to seat the cups properly in thehub.

10. Pack the inside of the hub with


steering linkage components mayoccur if care is not exercised whenpositioning the hoist adapters of 2post hoists prior to lifting the car.

If a 2 post hoist is used to liftthe car, place the adapters underthe front suspension lower arms. Donot allow the adapters to contact thesteering linkage.

FRONT WHEEL GREASE SEALAND BEARING REPLACEMENTAND/OR REPACKING

If bearing adjustment will noteliminate looseness or rough andnoisy operation, the hub and bear-ings should be cleaned, inspected,and repacked. If the bearing cups orthe cone and roller assemblies areworn or damaged, they should bereplaced.

DRUM BRAKES1. Raise the car until the wheel

and tire clear the floor.2. Remove the wheel cover or

hub cap. Remove the grease capfrom the hub. Remove the cotterpin, nut lock, adjusting nut, and flatwasher from the spindle. Removethe outer bearing cone and rollerassembly (Fig I).


4. Remove the 2rease retainer and


new cotter pin. Bend the ends of thecotter pin around the castellations ofthe nut lock to prevent interferencewith the radio static collector in thegrease cap. Install the grease cap.


INNER CUP OUTER CUPINST ALLA nON INST ALLA nON

Fl057-A

FIG. 7-lnstalling Front Wheel

Bearing Cup-All Fairlane, Comet,and Mustang and 8-CylinderFalcon

LUBRICANT~

Be sure to seat tbe cups properly intbe bubo

12. Pack the inside of the hubwith specified wheel bearing grease.Add lubricant to the hub only untilthe grease is flush with the insidediameter of both bearing cups.

13. All old grease should be com-pletely cleaned from the bearingsbefore packing them with new grease.Pack the bearing cone and roller as-semblies with wheel bearing grease.A bearing packer is desirable forthis operation. If a packer is notavailable, work as much lubricant aspossible between the rollers andcages. Lubricate the cone surfaceswith grease.

14. Place the inner bearing coneand roller assembly in the inner cup,and install the new grease retainerwith the reverse end of the toolshown in Figs. 6 or 7. Be sure tbatthe retainer is properly seated.

15. Install the hub and rotor onthe wheel spindle. Keep tbe bubcentered on the spindle to preventdamage to the grease retainer or tbespindle tbreads.

16. Install the outer bearing coneand roller assembly and the flatwasher on the spindle; then, installthe adjusting nut.

17. Position the caliper over therotor and install the 2 attaching bolts.

18. Install the wheel and tire onthe hub.

19. Adjust the wheel bearings asoutlined in Section 2, and install anew cotter pin. Bend the ends of thecotter pin around the castellations ofthe nut lock to prevent interferencewith the radio static collector in thegrease cap. Install the grease cap.

20. Install the hub cap or wheelcover and lower the car.

F1174-A

FIG. 8-Front Wheel HubLubrication

FRONT HUB AND DRUMREPLACEMENT

When the hub and drum assemblyis replaced, new bearings, cups, andgrease retainer must be installed inthe new assembly. The new greaseretainer should be soaked in lightengine oil at least 30 minutes beforeinstallation.

1. Raise the car until the wheeland tire clears the floor. Pry off thehub cap or wheel cover, and removethe wheel and tire assembly fromthe hub and drum assembly.

1. Remove the grease cap fromthe hub. Remove the cotter pin. nut

DISC BRAKES1. Raise the car until the wheel

and tire clear the floor.2. Remove the wheel cover or hub

cap.3. Remove the wheel and tire from

the hub.4. Remove 2 bolts attaching the

caliper to the caliper bracket. Re-move the caliper from the rotor andwire it to the underbody to preventdamage to the brake hose.

5. Remove the grease cap fromthe hub. Remove the cotter pin, nutlock, adjusting nut, and flat washerfrom the spindle. Remove the outerbearing cone and roller assembly(Fig. 2).

6. Pull the hub and rotor off thewheel spindle.

7. Remove the grease retainer andthe inner bearing cone and roller as-sembly from the hub.

8. Clean the lubricant off the in-ner and outer bearing cups withsolvent and inspect the cups forscratches, pits, excessive wear, andother damage. If the cups are wornor damaged, remove them with adrift.

9. Soak a new grease retainer inlight engine oil at least 30 minutesbefore installation. Thoroughly cleanthe inner and outer bearing conesand rollers with solvent, and drythem thoroughly. Do not spin thebearings with compressed air.

Inspect the cone and roller assem-blies for wear or damage, and re-place them if necessary. The coneand roller assemblies and the bear-ing cups should be replaced as aunit if damage to either is encoun.teredo

10. Thoroughly clean the spindleand the inside of the hub with solventto remove all old lubricant.

Cover the spindle with a cleancloth, and brush all loose dust anddirt from the brake assembly. Toprevent getting dirt on the spindlecarefully remove the cloth from thespindle.

11. If the inner and / or outerbearing cup(s) were removed, installthe replacement cup(s) in the hubwith the tool shown in Figs. 6 or 7.

and cages. Lubricate the cone sur-faces with grease.

12. Place the inner bearing coneand roller assembly in the inner cup,and install the new grease retainerwith the reverse end of the toolshown in Figs. 6 to 7. Be sure thatthe retainer is properly seated.

13. Install the wheel, hub, anddrum assembly on the wheel spin-dle. Keep the hub centered on thespindle to prevent damage to thegrease retainer or the spindle threads.

14. Install the outer bearing coneand roller assembly and the flatwasher on the spindle; then, installthe adjusting nut (Fig. 1).

15. Adjust the wheel bearings asoutlined in Section 2, and install a

and tighten them alternately in orderto draw the wheel evenly againstthe hub and drum. Do not exceedspecifications (Part 3-6).

11. Adjust the wheel bearings asoutlined in Section 2, and install anew cotter pin. Bend the ends of thecotter pin around the castellations ofthe nut lock to prevent interferencewith the radio static collector in thegrease cup. Install the grease cup.


lock, adjusting nut, and flat washerfrom the spindle. Remove the outerbearing cone and roller assembly(Fig. 1).


4. Remove the protective coatingfrom the new hub and drum withcarburetor degreaser. Install new in-ner and outer bearing cups in thenew hub with the tool shown in Figs.6 or 7. Be sure to seat the cupsproperly in the hub.

5. Pack the inside of the hub withspecified wheel bearing grease. Addlubricant to the hub only until thegrease is flush with the inside di-ameter of both bearing cups (Fig.8).

5. Pack the inside of the hub withspecified wheel bearing grease. Addlubricant to the hub only until thegrease is flush with the inside di-ameter of both bearing cups.

6. All old grease should be com-pletely cleaned from the bearingsbefore repacking them with newgrease. Pack the bearing cone androller assemblies with wheel bearinggrease. A bearing packer is desira-ble for this operation. If a packer isnot available, work as much lubri-cant as possible between the rollersand cages. Lubricate the cone sur-faces with grease.

7. Place the inner bearing coneand roller assembly in the inner cup,and install the new grease retainerwith the reverse end of the toolshown in Figs. 6 or 7. Be sure thatthe retainer is properly seated.

8. Install the new hub and rotorassembly on the wheel spindle. Keepthe hub centered on the spindle toprevent damage to the grease re-tainer.

9. Install the outer bearing coneand roller assembly and the flatwasher on the spindle; then, installthe adjusting nut (Fig 2).

10. Position the wheel and tire as-sembly on the new hub and rotor.Install the wheel hub nuts and tightenthem alternately in order to drawthe wheel evenly against the hub androtor. Do not exceed specifications(Part 3-6).

11. Adjust the wheel bearings asoutlined in Section 2, and install anew cotter pin. Bend the ends of thecotter pin around the castellations ofthe nut lock to prevent interferencewith the radio static collector in thegrease cap. Install the grease cap.


FRONT HUB AND ROTORREPLACEMENT

When the hub and rotor assemblyis replaced, new bearings, cups, andgrease retainer must be installed inthe new assembly. The new greaseretainer should be soaked in lightengine oil at least 30 minutes beforeinstallation.

1. Raise the car until the wheeland tire clears the floor. Pry off thehub cap or wheel cover, and removethe wheel and tire assembly fromthe hub and rotor.

2. Remove 2 bolts attaching thecaliper to the caliper bracket. Re-move the caliper from the rotor andwire it to the underbody to preventdamage to the brake hose.

3. Remove the grease cap fromthe hub. Remove the cotter pin, nutlock, adjusting nut, and flat washerfrom the spindle. Remove the outerbearing cone and roller assembly(Fig 2). Pull the hub and rotor offthe wheel spindle.

4. Remove the protective coatingfrom the new hub and rotor withcarburetor degreaser. Install new in-ner and outer bearing cups in thenew hub with the tool shown in Figs.6 or 7. Be sure to seat the cupsproperly in the hub.

6. All old grease should be com-pletely cleaned from the bearingsbefore repacking them with newgrease. Pack the bearing cone androller assemblies with wheel bearinggrease. A bearing packer is desirablefor this operation. If a packer is notavailable, work as much lubricant aspossible between the rollers andcages. Lubricate the cone surfaceswith grease.

7. Place the inner bearing coneand roller assembly in the innercup, and install the new grease re-tainer with the reverse end of thetool shown in Fig. 6 or 7. Be surethat the retainer is properly seated.

8. Install the new hub and drumassembly on the wheel spindle. Keepthe hub centered on the spindle toprevent damage to the grease re-tainer.

9. Install the outer bearing coneand roller assembly and the flatwasher on the spindle; then, installthe adjusting nut (Fig 1).

10. Position the wheel and tireassembly on the new hub and drumassembly. Install the wheel lug nuts

3-49

SPECIFICATIONS

FRONT WHEEL ALIGNMENT

Checking Specifications Optimum Re-setting Specifications

Maximum VariationBetween WheelsCOMET, FALCON AND FAIRLANE Min.

~=---*°¥Sin.

Max.

+1°

+1°

3fa in.

Desired Alignment

0°

.+\140"ii' %i~: c

-Caster

-Yz°

Yz°

MUSTANG

Caster-6 Cyl.

Caster-8 Cyl.

Camber-All

Toe-in

+2°+1° ~

i+1Y4° !,* in. ~

-j,i°j,i°j,i°

}EO'

+~~IL .74 In.

0°"

-1°

~Ye in.

COMET, FALCON AND FAIRLANEOptimum Re.Setting Specifications

Desired Alignment

7Yz°

170/40

King Pin Angle-

Turning Angle of Outside Wheel With 1nside Wheel Turned 20°

BALL JOINTS

Radial Play (Inches)Max. Allowable

lupper Ball Joint

I Lower Ball Joint

-0.250

Replace if Perceptibly Loose


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

:;):

F 1285-A

.Front Suspension Torque limitsFIG. 1

F1286-A

FIG. 2-Rear Suspension Torque limits

STEERING GEAR

COMETFAIRLANE MUSTANG

HCC.AX

SpecialManual

16:1

VEHICLE FALCON-HCA.CA

-HCA.BZ

-HCC-AT HCC-AW

-HCA-CA

-HCA.BY~

Manual

22:1

Power

16:1

Manual

19.9:1

Power

16:1

Manual

22:1

Power

16:1

Gear Type

Gear Ratio

4

3.4

45/8

4-5

33/4

4-5

33/4

3-4

5

4-5

5

4-5

4

3-4

9-10 @8-9 9-10 CD8.9 9-10 @8-9

11 11

Total Preload !Worm Bearingplus Sector Mesh)@ in-ibs

Lube Capacity (Ol)

I lube Type

9-10 f8

(C3AZ-19578-AJ-Power

Power750.900 psi

0.060 in Approx.

New: 120-150 Ibs.

Used: 90-120 Ibs.

I Normal Fluid Pressure Against Either Stop (Engine 1000r~)

Control Valve Spool Travel (from Center)

PowerPower Steering Belt Tension Using tool BT .33.73F

ADJUSTMENTS ALL MODELS:Adjusting screw clearance at bottom of sector shaft T-slot-.OOO"-.002".Sector Shaft end play-steering linkage disconnected-none.With gear mounted in vehicle or on a suitable fixture and posi-tioned on center, and the sector shaft retained to prevent rotation,apply a 15 lb. in. torque on the steering gear input shaft in bothright and left turn directions. The total angular travel of theinput shaft cannot exceed 8V2 degrees, with 8 lb. in. net meshload.

NOTES:@Gear only-not attached to Pitman arm.0Total (mesh load plus worm bearing preload) must be a minimum

of 2 lb. in. greater than worm bearing preload.~Required to rotate input shaft and worm assembly past the

center high point.~Torque required to rotate input shaft at approximately 1'/2

turns either side of center (gear out of vehicle or Pitman armdisconnected)


STEERING GEAR TORQUE LIMITSCOMET, FALCON AND F AIRLANE

STEERING COLUMN TORQUE LIMITS

(f)Residual torque must be 40 ft-lbs minimum

MUSTANG

POWER STEERING PUMP TORQUE LIMITS (FIG. 4)

@Residual torque must be 35 ft-ibs minimum

STEERING LINKAGE TORQUE LIMITS (Fig. 3)

Torque Ft-Lbs

Comet-FalconFairlane Mustang

Standard!PowerIStandard!PowerSteerin~ Steerin~ Steering Steering

Ref.No. Description

28.35 28-35

2

@30-40030-403

28.35 28.35

4

@35-47035.475

025-30<!!30-40

6

35-4318-24

35-4318-247

83-5 3-5

40-55150-225

40-6585-11011~

111<!>35-47 @35-47

12

Cylinder Mounting Bracketto Under body (Side Hole)

Steering Spindle ArmConnecting Rod End toSpindle Arm

Idler Arm MountingBracket to Underbody

Pitman Arm to SteeringArm-to-idier Arm Rod orto Valve and linkAssembly

Steering Spindle ArmConnecting Rod to Steering Arm-to-idle Arm Rod

Cylinder Mounting Bracketto Underbody (BottomHole)

Power Cylinder to BracketPower Cylinder to Bracket

lock Nut

Steering Gear 10 Side RailPitman Arm to Sector Shaft

Power Cylinder to ControlRod

Idler Arm to Steering Arm.to-Idler Arm Rod.

Steering Spindle ArmConnecting Rod andEnd Clamp to AdjustingSleeve

@[email protected]

19-268-14

@Torque to low limit of specificationj then, tighten the nut tothe nearest cotter pin slot and insert the cotter pin.

PART 3-6-SPECIFICATIONS AND SPECIAL TOOLS 3-53

-@-@J-;'

T I1 .!

~ I' ~~ ,.:~ 1:, .:~,.-,, "'""-",,'-""~-Jf~-'--'-'N'I'-:':I. ,.,, ,,"'" ,~ :- ,1 ~.' . '"

/' ..:f ""'" i' ~ :, " ,'-,. ~.. ..' ,,~ '- ~ "

i / .. 'J~~~.(.~~~. :'.'\<b~~t. '..," ". . '. "-:' -"'.: J"'"I .. .-~:-;~~ "., 7 3

4 ,~... ~ " ,&~

..';... .-::--"-'f.:"

, ;;" ,;;;:.: f!"~,-;1 w---IO

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

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

'::'~"".~"",~",.-

/'.~ ,

1~~~~

'6~

.~:;1

,,-:-,,-~"\~%i.~~~ .~'~":',. ~\.,..,II "

, ",.""j II'..p"

'~::""""'"

9

\

,~,

"'-;

1113 I?

I, \'" -,~

G1370-A

FIG. 3-Steering Linkage Torque Limits

FIG. 4-Power Steering Pump Torque Limits

3-54 GROUP 3 SUSPENSION, STEERING. WHEELS AND TIRES

TIRES

TIRE SIZE

6 CYLINDER

TIRE SIZE TIRE SIZE

MODELS 8 CYLINDER (289 C.I.DJ 8 CYLINDER (390 C.I.D.)

STANDARD R.P .0. STANDARD R.P.O. STANDARD R.P.O.

FALCONSedanWagonRanchero

6.50 x 137.35x147.35 x 14

@6.95 x 14

7.75 x 14

6.95 x 147.35x147.35 x 14 7.75 x 14

COMET AND FAIRLANESedanConvertibleHardtopWagon

6.95 x 146.95 x 146.95 x 147.75 x 14

7.35 x 147.35 x 14

I 7.35 x 147.75 x 14-8 Plv

6.95 x 146.95 x 146.95 x 147.75x15

7.35 x [email protected] x [email protected] x 14

7.75 x 14 - 8 Ply

7.75 x [email protected] x [email protected] x 14

7.75 x 14-8 Ply

MUSTANGConvertibleHardtop

Imo. Handling

6.95 x 146.95 x 14

@6.95 x [email protected] x 14

6.95 x 146.95 x 14

@6.95 x 14

@6.95 x [email protected] x 14

@-Standard on model 62C@-110 Level 120 mph dual red band nylon@-Standard with air conditioning

@-110 Level nylon~7.75 x 14 standard on Fairlane GT models

SERVICE TOOLS

7.35 x [email protected] x [email protected] x 147.75 x 14

group 3 suspension, steering, wheels & tires

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