Ford 1969 Car Shop Manual Volume One Chassis PDF

FOREWORD
The five volumes of this shop manual provide the Service Technician
with complete information for the proper servicing of all the 1969 line
of Ford Passenger Cars.
The information is grouped according to the type of work being per-

formed, such as frequently performed adjustments and repairs, in-
vehicle adjustments, major repair, etc. Specifications, maintenance
information and recommended special tools are included.
The descriptions and specifications in this manual were in effect at the

time this manual was approved for printing. Ford Motor Company
reserves the right to discontinue models at any time, or change specifi-
cations or design, without notice and without incurring obligation.
SERVICE PUBLICATIONS
GENERAL INFORMATION
Individual carline shop manuals have been combined in one Car
Shop Manual divided into five volumes for 1969.
The 1969 Car Shop Manual has been organized into general
Groups as in previous shop manuals. All Groups are listed in the Group
index on the first page of each Volume. Groups not contained in a
given Volume are listed with a solid gray background.
To locate the beginning page of any particular Group, first select

the Volume containing that Group. Bend the manual until the black
mark on the first page of the Group can be seen in line with the Group
title on the first page of the Volume.
The first page of each Group lists the material contained in the
Group under Part headings and also lists the beginning page of each
Part.
On the beginning page of each Part, there is a Part index which

lists in detail all information appearing in the Part, the page where
the information is given, and the vehicles to which the information
applies.
All pages carry a six-digit number which indicates the Group,

Part and Page number.
For Example: Page 03-02-01 indicates

Group 3, Part 2, Page 1
Part Indexes will use only the Part and Page reference numbers.
For Example: Page 03-02-01 will appear in the Part Index as 02-01.
Each Part will start with Page 01.

01-01-01 01-01-01
I 9Y82A848000 | Y89A848000 rMMUNTrNUMBW
I 53A A IA I8H 34 4
^J MODEL YEAR CODE (7) COLOR CODE
2) ASSEMBLY PLANT CODE 0 TRIM CODE
5) BODY SERIAL CODE ® DATE CODE
T) ENGINE CODE (JO) DISTRICT-SPEC. EQUIP. CODE

T) CONSECUTIVE UNIT NO. (lT) REAR AXLE CODE
T) BODY TYPE CODE (12) TRANSMISSION CODE

W1001-A
Fig. 1—Warranty Plates—Passenger Cars
9Y83NI0000I
Fig. 2—Typical Vehicle Identification Number (VIN) Tab

W 1002-A
01-01-02 Vehicle Identification 01-01-02
VEHICLE WARRANTY NUMBER COUGAR

The vehicle warranty number is the first line of numbers and
letters appearing on the Warranty Plates (Fig. 1). The Warranty Body Body
Serial Style
Plate is riveted to the left front door lock face panel. The first Code Code Body Type Model
number indicates the model year. The letter following the model
year number indicates the manufacturing assembly plant. The next 91 65A 2-Door Hardtop© Standard
two numbers designate the Body Serial Code followed by a letter 92 76A Convertible©
expressing the Engine Code. The group of six digits remaining on
the first line indicate the Consecutive Unit Number. 93 65B 2-Door Hardtop© XR-7 Luxury
94 76B Convertible®
VEHICLE DATA 91 65C 2-Door Hardtop® Standard

The vehicle data appears on the second or lower line on the ® Bench Seat ©Split Bench ©Bucket Seats
Warranty Plate. The first two numbers and a letter identify the
Body Style. A letter or a number appears next indicating the MERCURY
Exterior Paint Color followed by a number-letter combination
designating the Interior Trim. To the right of this code appears the Body Body
Date Code indicating the date the car was manufactured. A two- Serial Style
digit number next designates the district in which the car was Code Code Body Type Model
ordered and may appear in conjunction with a Domestic Special Monterey
44 54A 4-Door Sedan©
Order or Foreign Special Order number when applicable. The final 46 65A 2-Door Hardtop-Formal®
two spaces indicate the Rear Axle Ratio (numbers for regular axles, 48 57A 4-Door Hardtop®
letters for locking-types) and the Transmission type (numbers for 45 76A Convertible®
manual, letters for automatic).
CANADA ONLY
40 53M 4-Door Hardtop Sedan® Marquis
OFFICIAL VEHICLE IDENTIFICATION NUMBER 41 65M 2-Door Hardtop-Formal®
42 57M 4-Door Hardtop®
The official Vehicle Identification Number (VIN) for title and
registration purposes is stamped on an aluminum tab that is riveted 54 54C 4-Door Sedan® Monterey-Custom
to the instrument panel close to the windshield on the driver's side 56 65B 2-Door Hardtop-Formal®
of the car and is visible from outside (Fig. 2). 58 57B 4-Door Hardtop®
63 53F 4-Door Hardtop Sedan®© Marquis
MODEL YEAR CODE 66 65F 2-Door Hardtop-Formal®©
68 57 F 4-Door Hardtop®®
The number 9 designates 1969. 65 76F Convertible®®
63 53C 4-Door Hardtop Sedan© Brougham (Option)
ASSEMBLY PLANT CODES 66 65C 2-Door Hardtop-Formal©
68 57C 4-Door Hardtop©
Code Code
Letter Letter 60 63G 2-Door Hardtop (Tunnel Roof)®© Marauder
61 63H 2-Door Hardtop (Tunnel Roof)®®©
A Atlanta L Michigan Truck
B Oakville (Canada) N Norfolk 72 71B 4-Door 2 Seat® Monterey Wagoi
C Ontario Truck P Twin Cities 72 71C 4-Door 3 Seat (Side Facing)®
D Dallas R San Jose
E ., Mahwah S . (Pilot). ...Allen Park 74 71F 4-Door 2 Seat® Monterey-Custom Wagon
F Dearborn T Metuchen 74 71G 4-Door 3 Seat (Side Facing)®
G Chicago U Louisville
H Lorain W Wayne 76 71E 4-Door 2 Seat®© Marquis Colony Park
J Los Angeles X St. Thomas 76 71A 4-Door 3 Seat (Side Facing)®©
K Kansas City Y Wixom
Z St. Louis ©Bench Seat ©Split Bench ©Bucket Seats
METEOR (CANADA)
BODY SERIAL AND STYLE CODES Body Body
The two-digit numeral which follows the assembly plant code Serial Style
identifies the body series. This two-digit number is used in con- Code Code Body Type Model
junction with the Body Style Code, in the Vehicle Data, which
20 54A 4-Door Sedan® Rideau
consists of a two-digit number with a letter suffix. The following
chart lists the Body Serial Codes, Body Style Codes and the model. 21 54B 4-Door Sedan® Rideau 500
23 65B 2-Door Hardtop-Formal®
LINCOLN CONTINENTAL
30 54C 4-Door Sedan® Montcalm
Body Body 35 65C 2-Door Hardtop-Formal®
Serial Style 35 65E 2-Door Hardtop-Formal{5-33)®®
Code Code Body Type 33 57C 4-Door Hardtop®
34 76C Convertible®
82 53A 4-Door Sedan 34 76E Convertible (S-33)®®
80 65A 2-Door Hardtop
24 65F 2-Door Hardtop-Formal®© LeMoyne
27 57F 4-Door Hardtop®®
CONTINENTAL MARK III
28 71B Rideau 500-6 Passenger® Station Wagons.
Body Body 29 71C Rideau 500-Dual Face Rear®
Serial Style 38 71E Mo ntcalm-6 Passenger®
Code Code Body Type 39 71A Montcalm-Dual Face Rear®
89 65A 2-Door Hardtop ©Bench Seat ©Splite Bench ©Bucket Seats
BODY SERIAL AND STYLE CODES-(continued)
MONTEGO MUSTANG
Body Body Body Body
Serial Style Serial Style
Code Code Body Type Model Code Code Body Type Model
01 65A 2-Door Hardtop-formal 01 65A 2-Door Hardtop©© Standard
(Sports Coupe)® Comet 02 63A 2-Door Fastback©®
02 54A 4-Door Sedan (Sports)® 03 76A Convertible®®
06 54B 4-Door Sedan® Montego 01 65B 2-Door Hardtop®® Luxury
07 65B 2-Door Hardtop-Formal® 02 63B 2-Door Fastback®©
03 76B Convertible©®
10 54D 4-Door Sedan® Montego MX
11 65D 2-Door Hardtop-Formal® 01 65C 2-Door Hardtop® Standard
12 76D Convertible®
01 65D 2-Door Hardtop® Luxury
11 65 E 2-Door Hardtop-Formal© Montego MX
12 76B Convertible® 01 65E 2-Door Hardtop© Grand
10 54C 4-Door Sedan® Montego MX Brougham 02 63C 2-Door Fastback® Machl
11 65C 2-Door Hardtop-Formal®
©Bench Seat ©Split Bench ©Bucket Seats ©Hi-Back Bucket
15 63A2-Door Hardtop Fastback®
(GT Appearance Opt.®) Cyclone
15 63C 2-Door Hardtop Fastback®
16 63H 2-Door Hardtop Fastback®
(Sports Appearance Opt.©) Cyclone CJ
03 71B Montego® Station Wagons-4 Door
08 71C Montego MX®
08 71A Montego MX (Woodgrain)® FORD
©Bench Seat ©Split Bench ©Bucket Seats Body Body

Serial Style
Code Code Body Type Model
50 62E 2-Door Sedan® Custom
51 54 E 4-Door Sedan®
52 62B 2-Door Sedan® Custom 500

53 54B 4-Door Sedan®
THUNDERBIRD
54 54A 4-Door Sedan® Galaxie 500
Body Body 55 63B 2-Door Hardtop-Fastback®
Serial Style 58 65C 2-Door Hardtop-Formal®
Code Code Body Type Model 56 57B 4-Door Hardtop®
57 76A Convertible®
83 65A 2-Door Hardtop®
83 65C 2-Door Hardtop® 60 63C 2-Door Hardtop-Fastback®® Ford XL
84 65B 2-Door Landau ® 61 76B Convertible®©
84 65D 2-Door Landau ®
87 57B 4-Door Landau © 64 54C 4-Door Sedan®® Ford LTD
87 57C 4-Door Landau ® 62 65A 2-Door Hardtop-Formal®®
66 57F 4-Door Hardtop®©
©Bench Seat ©Split Bench ©Bucket Seats ©Blind Quarter Roof
70 71D Ranchwagon-6 Passenger© Station Wagons-4 Door
71 71H Custom 500 Ranchwagon-
6 Passenger©
72 71J Custom 500 Ranchwagon-
Dual Face Rear©
73 71B Country Sedan-6 Passenger®
74 71C Country Sedan-Dual Face Rear®
75 71E Country Squire—6 Passenger®
FALCON 76 71A Country Squire-Dual Face Rear®
Body Body ©Bench Seat ©Split Bench ©Bucket Seats
Serial Style
Code Code Body Type Model
10 62A 2-Door Sedan® Standard

11 54A 4-Door Sedan®
20 62B 2-Door Sedan® Futura

22 62C 2-Door Sports Coupe®
21 54B 4-Door Sedan©
12 71A Standard© Station Wagons
23 71B Futura© - 4 Door
©Bench Seat ©Split Bench ©Bucket Seat

BODY SERIAL AND STYLE CODES-(continued) ENGINE CODES

FAIRLANE Type
Code
Body Body 170 Cu. In. (IV)
Serial Style U 6Cyl.
Code Code T 6Cyl. 200 Cu. In. (IV)
Body Type Model 200 Cu. In. (IV)
2 6 Cyl.®
L 6 Cyl. 250 Cu. In. (IV)
30 65A 2-Door Hardtop-formal® Fairlane
3 6 Cyl CD 250 Cu. In. (IV)
31 54A 4-Door Sedan®
V 6 Cyl." 240 Cu. In. (IV)
5 . 6 Cyl CD 240 Cu. In. (IV)
34 54B 4-Door Sedan® Fairlane 500 240 Cu. In. (IV) Police
35 63B 2-Door Hardtop—Fastback® B .6 Cyl.
E 6 Cyl. 240 Cu. In. (IV) Taxi
33 65B 2-Door Hardtop-formal® 302 Cu. In. (2V)
36 76B Convertible® F 8 Cyl.
6 8 Cyl.® 302 Cu. In. (2V)
D 8 Cyl. 302 Cu. In. (2V) Police & Taxi
35 63E 2-Door Hardtop—Fastback© Fairlane 500 351 Cu. In. (2V)
33 65E 2-Door Hardtop-Formal© H 8 Cyl.
M 8 Cyl. 351 Cu. In. (4V)
36 76E Convertible® 390 Cu. In. (2V)
Y 8 Cyl.
X 8 Cyl.© 390Cu.ln.(2V)
40 65C 2-Door Hardtop-Formal® Torino 390 Cu. In. (4V)
41 54C 4-Door Sedan® S 8 Cyl.©
r t P 8 Cyl.® 428 Cu. In. (4V) Police Interceptor
8 Cyl. 428 Cu. In. (4V) CJ
42 63F 2-Door Hardtop—FastbackCD Torino GT 428 Cu. In. (4V) CJ
44 65F 2-Door Hardtop-Formal® 8 Cyl.®
K 8 Cyl. 429 Cu. In. (2V)
43 76F Convertible® 429 Cu. In. (4V)
N 8 Cyl.
A 8 Cyl. 460 Cu. In. (4V)
42 63D 2-Door Hardtop—Fastback® Torino GT
44 65D 2-Door Hardtop-Formal® ©Low Compression ©Premium Fuel ©Improved Performance
43 76D Convertible® ©High Performance ©Ram Air Induction
46 63B 2-Door Hardtop-Fastback® Cobra
46 63E 2-Door Hardtop-Fastback®
45 65A 2-Door Hardtop-Formal®
45 65E 2-Door Hardtop-formal®
32 71D Fairlane® Station Wagons-4 Door CONSECUTIVE UNIT NUMBER
37 71B Fairlane 500® Starting Serial Numbers—1969 Passenger Cars
38 71E Fairlane Torino Squire® 100,001—Ford, Fairlane, Falcon, Mustang, Thunderbird
500,001 -Mercury, Montego, Cougar, Meteor
47 66A Ranchero® Ranchero 848,000—Lincoln Continental & Continental Mark III
48 66B Ranchero 500®
48 66B Ranchero 500® Ranchero
(Opt.)
49 66C Ranchero® Ranchero GT EXTERIOR PAINT COLOR CODES
49 66D Ranchero®
©Bench Seat ©Split Bench ©Bucket Seats Reference
Code Number Color
REAR AXLE RATIO CODES A .. 1724-A 1Black
B 3059-A Maroon
Conventional Limited-Slip Ratio
c
D
3197-A
3303-A
Dk. Ivy Green Met.
Pastel Gray
1 J 2.50:1 E 3191-A Lt. Aqua
2 K 2.75:1 F 3065-A . . Dk. Aqua Met. (Brt.)
3 L 2.79:1 G 3203-A Med. Orchid Met.
4 M 2.801 H .. ,.2067-A Lt. Green
5 N 2.83:1 | 2041-A Med. Lime Met.
6 0 3.00:1 J 3080-A Dk. Aqua Met.
7 P 3.10:1 K 3204-A Dk. Orchid Met.
8 Q 3.20:1 L . . 3060-A Lt. Gray Met.
9 R 3.25:1 M 1619-A .. White
A S 3.50:1 N 921-A Platinum
B T 3.07:1 p 3064-A Med. Blue Met.
C U 3.08:1 Q 1624-A Med. Blue Met.
D V 3.91:1 R 3198-A . . Lt. Gold
E W 4.30:1 S. .. . 3199-A Med. Gold Met.
T 2008-A Red
TRANSMISSION CODES u 1070-A Med. Aqua Met.
v 3201-A Lt. Aurora Copper IVIet.
Code Type W 3120-A Yellow
X 3061-A . . . Dk. Blue Met.
1 3-Speed Manual Y 3202-A Burnt Orange Met.
5 4-Speed Manual-wide ratio (2.78 1st Gear) z2 . 2044-A Dk. Grey Met.
6 4-Speed Manual-close ratio (2.32 1st Gear) .. 3071-A . . Lt. Ivy Yellow
W Automatic (C4) (XP-3) 3 1730-A Calypso Coral
U Automatic (C6) (XPL) 4 3230-A Med. Emerald Met.
Y Automatic (MX) 6. . . . 3077-A Med. Blue Met. (Brt)
X Automatic (FMX) 7 3193-A Lt. Emerald Green Met.
Z Automatic (C6 Special) (XPL, Special)® 8 3190-A Lt. Blue
..M6J-49B.. Red Primer
©For Police & trailer towing - Not available with bucket seats ....M6J-50B. Grey Primer
INTERIOR TRIM CODES INTERIOR TRIM CODES-(continued)

Code Trim Schemes Code Trim Schemes
1A Black Vinyl (Cougar, Falcon) 5D Dk. Red Knit and/or Vinyl
1A Black Cloth & Vinyl 5D Dk. Red Leather & Vinyl (Lincoln)
IB Med. Blue Cloth/Lt. Blue Vinyl 5F Med. Saddle Leather & Vinyl (Lincoln)
IB Med. or Lt. Blue Vinyl 5G Dk. Ivy Gold Knit and/or Vinyl
IB Dk. Blue Cloth & Vinyl 5G Dk. Ivy Gold Cloth & Vinyl
(Lincoln, T-Bird, Mark III, Mercury) 5G Dk. Ivy Gold Leather & Vinyl (Lincoln)
IB Lt. Blue Cloth & Vinyl 5K Lt. Aqua Cloth & Vinyl (Montego)
(Ford, Montego, Meteor) 5K Lt. Aqua Vinyl
ID Dk. Red Cloth and Vinyl 5K Lt. Aqua Leather & Vinyl (Lincoln)
IF Med. Saddle Vinyl (Cougar) 5W White w/Black Knit and/or Vinyl
1G Dk. Ivy Gold Cloth & Vinyl 5W White w/Black Leather & Vinyl (Lincoln)
1G Lt. Ivy Gold Vinyl (Cougar) 5Y Lt. Nugget Gold Cloth & Vinyl
IK Lt. Aqua Cloth and/or Vinyl 5Y Lt. Nugget Gold Knit and/or Vinyl (Mustang,
IP Med. Grey Cloth & Vinyl (Mark III) Fairlane)
1Y Lt. Nugget Gold Vinyl (Cougar-Falcon) 5Y Lt. Nugget Gold Leather & Vinyl (Lincoln)
1Y Lt. Nugget Gold Cloth & Vinyl 6A Black Knit and/or Vinyl
2A Black Vinyl 6A Black Cloth & Vinyl (Lincoln)
2A Black Leather & Vinyl (Lincoln) 6A Black Leathe; & Vinyl (Cougar)
2A Black Leather (Mark III) 6B Dk. or Lt. Blue Vinyl
2B Dk. or Lt. Blue Vinyl 6B Dk. Blue Leather & Vinyl (Cougar)
2B Dk. Blue Leather & Vinyl (Lincoln) 6D Dk. Red Knit and/or Vinyl
2B Dk. Blue Leather (Mark III) 6D Dk.Red Leather & Vinyl (Cougar)
2D Dk. Red Vinyl 6F Med. Saddle Leather I Vinyl
2D Dk. Red Leather & Vinyl (Lincoln) 6G Dk. Ivy Gold Vinyl
2D Dk. Red Leather (Mark III) 6G Dk. Ivy Gold Leather & Vinyl (Cougar)
2F Med. Saddle Vinyl (Cougar) 6K Lt. Aqua Vinyl
2F Med. Saddle Leather & Vinyl (Lincoln) 6K Lt. Aqua Leather & Vinyl (Cougar)
2F Med. Saddle Leather (Mark III) 6W White w/Black Vinyl
2G Lt. or Dk. Ivy Gold Vinyl 6Y Lt. Nugget Gold Vinyl
2G Dk. Ivy Gold Leather & Vinyl (Lincoln) 6Y Lt. Nugget Gold Leather & Vinyl (Cougar)
2G Dk. Ivy Gold Leather (Mark III) 7A Black Vinyl
2K Lt. Aqua Vinyl 7A Black Cloth & Vinyl (Fairlane)
2K Lt. Aqua Leather & Vinyl (Lincoln) 7A Black Leather & Vinyl (Lincoln)
2K Lt. Aqua Leather (Mark III) 7B Lt. Blue Vinyl (Cougar, Montego, Ford)
2P Med. Grey Leather (Mark III) 7B Dk. Blue Cloth & Vinyl
2U Pastel Parchment w/Black Leather (Mark III) 7B Dk. Blue Leathe; & Vinyl (Lincoln)
2W Whitew/Black Vinyl 7D Dk. Red Vinyl (Mustang)
2W White w/Black Leather & Vinyl (Lincoln) 7D Dk. Red Cloth & Vinyl
2W Whitew/Black Leather (Mark III) 7G Dk. Ivy Gold Cloth and/or Vinyl
2Y Lt. Nugget Gold Vinyl 7G Dk. Ivy Gold Leather & Vinyl (Lincoln)
2Y Lt. Nugget Gold Leather & Vinyl (Lincoln) 7K Lt. Aqua Cloth & Vinyl
2Y Lt. Nugget Gold Leather (Mark III) 7W White w/Black Vinyl
3A Black w/Red Knit and/or Vinyl (Mustang, 7W White Leather & Vinyl (Lincoln)
Montego) 7Y Lt. Nugget Gold Cloth & Vinyl
3A Black Knit and/or Vinyl 7Y Lt. Nugget Gold Vinyl
3A Black Cloth & Vinyl (Ford, Meteor, Mustang)
3A Black Leather & Vinyl (Lincoln) 8A Black Knit and/or Vinyl
3B Lt. Blue Knit and/or Vinyl 8A Black Leather & Vinyl (T-Bird)
3B Lt. or Dk. Blue Cloth & Lt. Blue Vinyl 8B Dk. or Lt. Blue Knit and/or Vinyl
3B Lt. Blue Cloth & Vinyl 8D Dk. Red Knit and/or Vinyl
(Fairlane, Ford, Montego, Meteor) 8F Med. Saddle Knit and/or Vinyl
3B Med. Blue Cloth & Lt. Blue Vinyl 8G Dk. Ivy Gold Knit and/or Vinyl
3B Dk. Blue Cloth & Vinyl (T-Bird, Mercury) 8K Lt. Aqua Knit and/or Vinyl
3B Dk. Blue Leather & Vinyl (Lincoln) 8W White w/Black and/or Vinyl
3D Dk.Red Cloth & Vinyl 8W White w/Black Leather & Vinyl (T-Bird)
3D Dk. Red Knit and/or Vinyl 8Y Lt. Nugget Gold Knit and/or Vinyl
3G Dk. Ivy Gold Cloth & Vinyl 9A Black Knit and/or Vinyl
3G Dk. Ivy Gold Leather & Vinyl (Lincoln) 9A Black Cloth & Vinyl (Ford, Meteor)
3K Lt. Aqua Cloth & Vinyl 9B Lt. Blue Knit and/or Vinyl
3W White w/Black Knit and/or Vinyl 9B Dk. Blue Cloth & Vinyl (Ford, Meteor)
3W Whitew/Black Leather & Vinyl (Lincoln) 9D Dk. Red Knit and/or Vinyl
3Y Lt. Nugget Gold Cloth & Vinyl 9D Dk. Red Cloth & Vinyl (Ford-Meteor)
3Y Lt. Nugget Gold Knit and/or Vinyl (T-Bird) 9G Dk. Ivy Gold Cloth & Vinyl
4A Black Cloth & Vinyl 9K Lt. Aqua Cloth & Vinyl
4A Black Knit and/or Vinyl 9Y Lt. Nugget Gold Cloth and/or Vinyl
4B Dk. Blue Vinyl 9Y Lt. Nugget Gold Knit and/or Vinyl
4B Dk. or Lt. Blue Vinyl AA(1W) White Vinyl With Black (Cougar)
4D Dk.Red Vinyl AA Black Cloth & Vinyl (Lincoln)
4G Dk. Ivy Gold Cloth & Vinyl AB(1W) White Vinyl With Blue (Cougar)
4G Dk. Ivy Gold Vinyl AB Lt. Blue Cloth & Vinyl (Lincoln)
4K Lt. Aqua Vinyl AD(1W) White Vinyl With Red (Cougar)
4W White w/Black Vinyl AG(1W) White Vinyl With Ivy Gold (Cougar)
4Y Lt. Nugget Gold Knit and/or Vinyl AG Lt. Ivy Gold Cloth & Vinyl (Lincoln)
5A Black Cloth & Vinyl AK (1W) White Vinyl With Aqua (Cougar)
5A Black Knit and/or Vinyl AK Lt. Aqua Cloth & Vinyl (Lincoln)
5A Black Leather & Vinyl (Lincoln) AL Lt. Silver Cloth & Vinyl (Lincoln)
5B Lt. Blue Cloth and/or Vinyl AY Lt. Nugget Gold Cloth & Vinyl (Lincoln)
5B Lt. Blue Knit and/or Vinyl AY(1W) White Vinyl With Nugget Gold (Cougar)
5B Dk. Blue Leather & Vinyl (Lincoln) BA(2W) White Vinyl With Black (Cougar)
5B Dk. Blue Cloth & Vinyl (Mercury) BA Black Vinyl (Fairlane)
5D Dk.Red Cloth & Vinyl (Montego) BB(2W) White Vinyl With Blue (Cougar)
INTERIOR TRIM CODES-(continued) INTERIOR TRIM CODES-(contlnuad)

Code Trim Schemes Code Trim Schemes
BB Lt. Blue Vinyl (Fairlane) HY(8W) White Vinyl With Nugget Gold (Cougar)
BB Lt. Blue Leather & Vinyl (Lincoln) HY Lt. Nugget Gold Knit and/or Vinyl
BD(2W) ..White Vinyl With Red (Cougar) JA Black Knit and/or Vinyl
BG(2W) White Vinyl With Ivy Gold (Cougar) JB Lt. Blue Cloth & Vinyl (Lincoln)
BG Lt. Ivy Gold Leather & Vinyl (Lincoln) JG Lt. Ivy Gold Cloth & Vinyl
BK(2W) White Vinyl With Aqua (Cougar) JW .....White w/Black Knit and/or Vinyl
BY(2W) White Vinyl With Lt. Nugget Gold (Cougar) JY Lt. Nugget Gold Knit and/or Vinyl
BY Lt. Nugget Gold Vinyl (Fairlane) JY Lt. Nugget Gold Cloth & Vinyl (Lincoln)
CA Black Cloth & Vinyl KA Black Knit and/or Vinyl
CA Black Vinyl (Montego) KA Black Cloth & Vinyl (Ford-Mercury-Meteor)
CB Dk. Blue Cloth & Vinyl KA Black Leather & Vinyl (Lincoln)
CB Lt. Blue Vinyl (Montego) KB Dk. Blue Cloth & Vinyl
CD Dk. Red Cloth & Vinyl KB .....Med. Blue Cloth & Lt. Blue Vinyl (Ford-Montego)
CD Dk. Red Vinyl KB Dk. Blue Leather & Vinyl (Lincoln)
CG Dk. Ivy Gold Cloth & Vinyl KD Dk. Red Cloth & Vinyl
CG Lt. Ivy Gold Leather & Vinyl (Lincoln) KG Dk. Ivy Gold Leather & Vinyl (Lincoln)
CK Lt. Aqua Cloth & Vinyl KG Dk. Ivy Gold Cloth & Vinyl
CY Lt. Nugget Gold Cloth & Vinyl KL Lt. Silver Leather & Vinyl (Lincoln)
CY Lt. Nugget Gold Vinyl (Montego) KW White W/Black Leather & Vinyl (Lincoln)
DA Black Cloth & Vinyl KY Lt. Nugget Gold Knit and/or Vinyl
DA(4W) White Vinyl With Black (Cougar) KY Lt. Nugget Gold Cloth & Vinyl
DA Black Knit and/or Vinyl LA Black Knit and/or Vinyl
DB Dk. Blue Cloth & Vinyl LA Black Leather & Vinyl (Lincoln)
DB Dk. Blue Vinyl (Mercury) LB Lt. Blue Knit and/or Vinyl
DB(4W) White Vinyl With Blue (Cougar) LB Dk. Blue Leather & Vinyl (Lincoln)
DD(4W) White Vinyl With Red (Cougar) LD Dk. Red Knit and/or Vinyl
DD Dk. Red Knit and/or Vinyl LE Lt. & Med. Beige Vinyl
DD Dk. Red Cloth & Vinyl LG Dk. Ivy Gold Leather & Vinyl (Lincoln)
DG Dk. Ivy Gold Vinyl LW White w/Black Knit and/or Vinyl
DG Dk. Ivy Gold Cloth & Vinyl LW White w/Black Leather & Vinyl (Lincoln)
DK Lt. Aqua Cloth & Vinyl LY Lt. Nugget Gold Knit and/or Vinyl
DW White w/Black Knit and/or Vinyl MA Black Vinyl
DY Lt. Nugget Gold Cloth & Vinyl MB Lt. Blue Vinyl
DY Lt. Nugget Gold Vinyl (Mercury) MD Dk Red Vinyl
EA Black Knit and/or Vinyl MW White w/Black Vinyl
EA Black Cloth & Vinyl NA Black Knit and/or Vinyl
EB Dk. Blue Cloth & Vinyl NB Lt. Blue Vinyl
ED Dk. Red Cloth & Vinyl NY Lt. Nugget Gold Knit and/or Vinyl
EG Dk. Ivy Gold Cloth & Vinyl PA Black Vinyl
EK Lt. Aqua Cloth & Vinyl PB Lt. Blue Vinyl
EW White w/Black Knit and/or Vinyl PY Lt. Nugget Gold Vinyl
EY Lt. Nugget Gold Cloth & Vinyl QA Black Knit and/or Vinyl
FA Black Knit and/or Vinyl )B . Lt Blue Vinyl
FA(6W) White Vinyl With Black (Cougar) JW White Knit and/or Vinyl
FB Lt. or Dk. Blue Vinyl Lt. Nugget Gold Vinyl
FB(6W) White Vinyl With Blue (Cougar) Black Knit and/or Vinyl
FD Dk. Red Knit and/or Vinyl RA Black Leather & Vinyl
FD(6W) White Vinyl With Red (Cougar) RB Lt. Blue Knit and/or Vinyl
FG Dk. Ivy Gold Vinyl RD Dk. Red Knit and/or Vinyl
FG(6W) White Vinyl With Ivy Gold (Cougar) RD Dk. Red Leather & Vinyl
FK(6W) White Vinyl With Lt. Aqua (Cougar) RW White w/Black Leather & Vinyl
FW White w/Black Knit and/or Vinyl RW White W/Black Knit and/or Vinyl
FY Lt. Nugget Gold Vinyl RY Lt. Nugget Gold Knit and/or Vinyl
FY(6W) White Vinyl With Nugget Gold (Cougar) SB Lt. Blue Leather & Vinyl (Lincoln)
GA Black Vinyl SG Lt. Ivy Gold Leather & Vinyl (Lincoln)
GB Lt. Blue Vinyl TG Lt. Ivy Gold Leather & Vinyl (Lincoln)
GD Dk. Red Vinyl VA Black Knit and/or Vinyl
GG Dk. Ivy Gold Vinyl VB Dk Blue Vinyl
GY Lt. Nugget Gold Vinyl VG Dk. Ivy Gold Vinyl
HA Black Knit and/or Vinyl VW White w/Black Knit and or Vinyl
HA(8W) White Vinyl With Black (Cougar) VY Lt. Nugget Gold Vinyl
HA Black Leather & Vinyl (Mercury) WA Black Knit and/or Vinyl
HB Lt. Blue Vinyl WW White w/Black Knit and/or Vinyl
HB (8W) White Vinyl With Blue (Cougar) WY Lt. Nugget Gold Knit and/or Vinyl
HD Dk. Red Vinyl YA Black Cloth & Vinyl
HD Dk. Red Leathe; & Vinyl (Mercury) YB Dk. Blue Cloth & Vinyl
HD(8W) White Vinyl With Dk. Red (Cougar) YD Dk. Red Cloth & Vinyl
HG Dk. Ivy Gold Vinyl YG Dk. Ivy Gold Cloth & Vinyl
HG(8W) White Vinyl With Ivy Gold (Cougar) YK Lt. Aqua Cloth & Vinyl
HK Lt. Aqua Vinyl YY Lt. Nugget Gold Cloth & Vinyl
HK(8W) White Vinyl With Lt. Aqua (Cougar) ZA Black Cloth & Vinyl
HW White w/Black Leather & Vinyl (Mercury) ZB Dk. Blue Cloth & Vinyl
HW White w/Black Vinyl (Fairlane) ZG Dk. Ivy Gold Cloth & Vinyl
DATE CODES
A number signifying the date precedes the month code letter. A
second-year code letter will be used if the model exceeds 12 months.
LINCOLN-MERCURY
Code Code Code District Code District
Month First Year Second Year
11 Boston 34 ... Detroit
January ....A.. 15 New York 41 .. Chicago
February ...B.. 16 Philadelphia 42 .. St. Louis
March ...C. 17 Washington 46 ... Twin Cities
April ...D.. 21 Altanta 51 Denver
May ...E.. 22 Dallas 52 Los Angeles
June . . . F.. 23 Jacksonville 53 Oakland
July . . . G. 26 Memphis 54 Seattle
August ...H. 31 Buffalo 84 Home Office Reserve
September ...J.. 32 Cincinnati
October .. K. 33 Cleveland 90's... Export
November . ...L.
December ...M.
FORD OF CANADA
DISTRICT CODES (DSO) Code District Code District
Units built on a Domestic Special Order, Foreign Special Order,
or other special orders will have the complete order number in
Bl Central B4. Midwestern
B2 Eastern B6. Western
this space. Also to appear in this space is the two-digit code number B3 Atlantic B7. . Pacific
of the District which ordered the unit. If the unit is a regular I I thru 17.. Export
production unit, only the District code number will appear.
Note: Canadian Lincoln-Mercury units use prefix " A " in place of«"B".
FORD
Code District Code District
11... Boston 51 . . . Denver

13 . . . . . . N e w York 53 .. .Kansas City
15... Newark 54 .. Omaha
1 6 . . . ...Philadelphia 55 ...St. Louis
17... Washington 56 .. Davenport
21... Atlanta 61 .. Dallas
22 . . . Charlotte 62 . . . Houston
2 4 . . . ...Jacksonville 63 .. Memphis
25... Richmond 64 .. New Orleans
2 8 . . . . ...Louisville 65 .. .Oklahoma City
3 2 . . . . . ...Cleveland 71 . . . Los Angeles
3 3 . . . . . . . Detroit 72 ...San Jose
35... Lansing 73 ...Salt Lake City
3 7 . . . ...Buffalo 74 ...Seattle
3 8 . . . . . . . .Pittsburgh 75 .. .Phoenix
41... Chicago 83 .. Government
43... Milwaukee 84 . . . Home Office Reserve
44... Twin Cities 85 .. American Red Cross
4 6 . . . . ...Indianapolis 89 ...Transportation Services
47... Cincinnati 90's .. ...Export
02-01-01 02-01-01
GROUP
2
PART 2-1 PAGE PART 2-3 PAGE
General Brake Service 02-01-01 Specifications 02-03-01
PART 2-2
Brake System 02-02-01
Part 2-1 General Brake Service

MODEL APPLICATION
Continental-
Thunderbird
Continental
All Models
Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
COMPONENT INDEX
Cougar
Meteor
alcon
Ford
F
ANTI SKID CONTROL SYSTEM
Tests N/A N/A N/A N/A N/A N/A N/A N/A N / A 01-03 01-03
BRAKE BOOSTER
Adjustments 01-04
Cleaning and Inspection 01-07
Tests 01-02
BRAKE PEDAL
Free Height Test 01-01
Total Travel Test 01-01
DISC BRAKES
Service Precautions 01-07
DRUM BRAKES
HYDRAULIC SYSTEM BLEEDING 01-05
PARKING BRAKE CONTROL
Vacuum Release Test 01-03 01-03 01-03 N / A N / A N/A N/A N / A 01-03 01-03 01-03
PARKING BRAKE LINKAGE
Adjustment 01-03 01-03 01-03 01-03 01-03 01-03 01-03 01-03 01-04 01-04 01-04
PRESSURE DIFFERENTIAL VALVE
Adjustment (Centralize) 01-07
A page number indicates that the item is for the vehicle listed at the head of the column.
N / A indicates that the item is not applicable to the vehicle listed.
1 BRAKE SYSTEM TESTS

Always check the fluid level in the BRAKE PEDAL FREE pedal linkage for missing, worn, or
master cylinder before performing the HEIGHT AND TRAVEL damaged bushings, or loose attaching
test procedures. If the fluid level is not MEASUREMENTS bolts and replace them, if required.
within 1/4 inch of the top of the mas- 3. If the pedal free height is still
ter cylinder reservoirs, add Ford With the engine running for full out of specification, check the brake
Brake Fluid — Extra Heavy Duty — power brake operation, measure the pedal booster or master cylinder to be
Part Number C6AZ-19542-A (ESA- brake pedal free height, and check the sure the correct parts are installed.
M6C25-A) or equivalent for all brake brake pedal travel with the use of the Replace the worn or damaged parts as
applications. The extra heavy duty Brake Pedal Pressure Gauge, Tool necessary.
brake fluid is colored blue for identifi- WRE-5OO-5O as follows:
cation purposes. Do not mix low tem- BRAKE PEDAL TRAVEL
perature brake fluids with the speci- BRAKE PEDAL FREE HEIGHT MEASUREMENT
fied brake fluid. MEASUREMENT
Should one of the wheel brakes be 1. Insert a slender, sharp pointed 1. Install a Brake Pedal Effort
locked and the vehicle must be moved, prod through the carpet and sound Gauge on the brake pedal pad (Fig. 2).
open the bleeder screw long enough to deadener to the dash panel metal and 2. Hook a steel measuring tape to
let out a few drops of brake fluid. measure the distance to the brake the brake pedal as shown in Fig. 1.
This bleeding operation will release pedal (Fig. 1). Measure and record the distance from
the brakes but will not correct the 2. If the position of the pedal is not the brake pedal free height position to
cause of trouble. within specification, check the brake the reference point, which is at the six
02-01-02 Brakes 02*01-02
o'clock position on the steering wheel

STEERING WHEEL RIW
rim.
3. With the steel tape still hooked
to the brake pedal depress the brake
pedal by pressing downward on the
brake pedal effort gauge. Apply a 50
pound load to the center of the pedal
by observing the pressure gauge, and
measure the distance from the brake
pedal to the fixed reference point on
the steering wheel rim parallel to the
centerline of the steering column.
CHECKING POINTS 4. The difference between the brake
pedal free height and the depressed
STEERING COLUMN-
pedal measurement under a 50 pound
TOEBOARD OR STEEL MEASURING TAPE load should be within the specified
DASH METAL maximum pedal travel service specifi-
cation B in Fig. I.
PEDAL FREE PEDAL FREE
5. If the pedal travel is more than
PEDAL
VEHICLE TYPE HEIGHT-A the specified maximum shown in Fig.
HEIGHT-B" TRAVEL-C
1, dimension C, make several sharp
FORD, MERCURY AND METEOR NON-POWER DRUM 8.09-7.17 3.10 reverse stops (equivalent to 50 pounds
pedal pressure) with a forward stop
FORD, MERCURY AND METEOR POWER DRUM & DISC 6.18-5.99 3.27
before each. Move the vehicle in rev-
FORD, MERCURY AND METEOR NON-POWER DISC 8.65-7.82 2.18 erse and forward for a distance of ap-
FORD, MERCURY AND METEOR POLICE POWER DISC 7.58-6.72 3.27 proximately ten feet; then, apply the
brakes sharply and hold the brake
FAIRLANE, MONTEGO AND FALCON NON-POWER DRUM 8.13-6.91 2.90
pedal down until the vehicle is com-
FAIRLANE, MONTEGO AND FALCON POWER DISC 7.25-5.71 2.35 pletely stopped. This will actuate the
MUSTANG AND COUGAR NON-POWER DRUM 7.49-6.43 2.58 brake self-adjusters. If these stops do
not bring the brake pedal travel within
MUSTANG AND COUGAR POWER DISC 6.25-5.56 1.75
specification, make several additional
THUNDERBIRD POWER DISC 5.96-5.04 3.00 forward and reverse stops as outlined
CONTINENTAL MARK III POWER DISC 5.96-5.04 3.00 above.
LINCOLN CONTINENTAL
6. If the second series of stops do
POWER DISC 6.50-5.50 2.25
not bring the brake pedal travel within
NOTE:AgB DIMENSION TO BE MEASURED TO SHEET METAL specification, remove the brake drums
and check the brake adjusters to make
C DIMENSION TO BE MEASURED PARALLEL TO THE VERTICAL CENTERLINE OF THE sure they are functioning. Check the
STEERING COLUMN WITH A 50 POUND LOAD APPLIED TO THE CENTERLINE OF THE brake linings for wear or damage. Re-
BRAKE PEDAL PAD. (CHECKS ON POWER BRAKE VEHICLES MADE WITH ENGINE RUNNING
pair or replace all worn or damaged
parts and non-functioning adjusters.
Adjust the brake lining outside diame-
H1630-A
ter to the approximate inside diameter
of the brake drum with Rotunda Tool
FIG. 1 — Brake Pedal Height and Travel Measurements HRE-8650 (Fig. 12, Part 2-2).
Tool-WRE-l 7. If all the brake adjusters, brake
drums and linings are functional and
the brake travel is not within specifi-
cations, check the pedal linkage for
missing or worn bushings, or loose at-
tachments. Bleed the brakes and cen-
tralize the differential valve.
POWER BRAKE
FUNCTIONAL TEST
1. Check the hydraulic brake sys-
tem for leaks or insufficient fluid.
2. With the transmission in neutral,
stop the engine and apply the parking
brake. Depress the brake pedal several
times to exhaust all vacuum in the
system.
HI525-A 3. With the engine shut off and all
vacuum in the system exhausted, dep-
ress the pedal, and hold it in the ap-
FIG. 2—Brake Pedal Effort Gauge Installed plied position. Start the engine If the
02-01-03 Brakes 02-01-03
vacuum system is operating, the pedal be adapted to any other vacuum hose Pump Tester 345. This can be accom-
will tend to fall away under foot pres- or rubber connector in the vacuum plished by removing the hose from
sure and less pressure will be required systems. each component and attaching it to
to hold the pedal in the applied posi- Failure to maintain 10 inches of the vacuum gauge. Connect two dis-
tion. If no action is felt, the vacuum vacuum (Hg.) during vacuum system tributor tester vacuum hose adapters
booster system is not functioning. tests could be caused by a loose hose together with a coupling as a connec-
If the brake pedal movement feels connection, resulting in a vacuum tor to attach the gauge. A minimum
spongy, bleed the hydraulic system to leak. When checking for vacuum be- of ten inches of vacuum is required to
remove air from the system. Refer to tween two points, trace the hose along actuate the parking brake vacuum
Hydraulic System Bleeding, Part 1, the entire routing to be sure it is not motor. Do not remove any of the vac-
Section 2. crossed with another hose and con- uum hoses from the junction block
nected to the wrong connection. unless the junction block is being re-
VACUUM TESTS—VACUUM All of the vacuum parking brake placed, as the plastic nipples are thin
RELEASE PARKING BRAKES control checks are to be performed and very brittle and damage may re-
with the engine running at idle speed. sult. If a minimum reading is not
Leaks in the parking brake hoses or present when checking each of the
Visually check the operation of the a disconnected or improperly con- aforementioned components, they
brake linkage as the brake pedal is nected hose can usually be found by must be replaced.
depressed. Then, check the operation listening for a hissing sound along the
of the brake linkage when the manual hose routings. Under no circumstances
r e l e a s e lever is activiated. These ROAD TEST
should air pressure be applied to the
checks should indicate whether the vacuum system as the actuator dia-
manual parking brake control linkage A road test should be conducted
phragm in the parking brake vacuum only when the operator is sure the
is operating properly or requires re- motor may be damaged.
pair or adjustment due to inability of brakes will stop the vehicle.
1. Start the engine and run it at If the road test reveals one or more
the parking brake to hold against idle speed. With the transmission shift
moderate vehicle movement. Perform problem conditions, correct all mal-
control in neutral, depress the parking functions of the vacuum system, brake
tests of the parking brake system and brake pedal to apply the parking
controls after making certain the link- booster and hydraulic system prior to
brake. Move the transmission shift removing brake drums, brake calipers,
age and manual controls operate control to D range and observe the
properly. brake shoes and linings or backing
parking brake pedal to see that the plates.
When testing a parking brake vacu- pedal moves upward and the parking
um release system, a minimum of 10 brake releases. If the parking brake
ANTI-SKID CONTROL
inches of vacuum (Hg.) should be releases, the parking brake vacuum
available at all points where vacuum is control is working properly. SYSTEM TESTS
applied. This can be checked with a 2. If the parking brake does not re- No adjustments or repairs are to be
Rotunda Fuel Pump Tester Gauge lease, test for vacuum at the steering performed on the skid control system.
(ARE345) and two Distributor Tester column neutral switch port in the Damaged or worn parts are to be re-
hose adapters (Marked Q) connected junction block, vacuum lines and the placed.
together with a coupling. This allows parking brake release vacuum motor. Refer to Ford Car and Truck Diag-
the Fuel Pump Tester Gauge hose to Use the Rotunda Vacuum and Fuel nosis Manual for Testing procedures.
COMMON ADJUSTMENTS AND REPAIRS

PARKING BRAKE LINKAGE
ADJUSTMENT
L.H. REAR WHEEL CABLE - 2 A 8 0 9 > 2A791 (2 REQUIRED)
FORD, MERCURY, METEOR,

FAIRLANE, MONTEGO, EQUALIZER-TO-ACTUATOR CABLE-2A815
FALCON, MUSTANG
AND COUGAR
Check the parking brake cables
when the brakes are fully released. If1
the cables are loose, adjust them as
follows:
1. Fully release the parking brake
pedal by pulling the release lever.
R.H. REAR WHEEL CABLE-2A635
2. Depress the parking brake pedal
until it is engaged in the first notch of
the control. On a vacuum release ADJUSTING NUT-2A812
brake, the first notch will be approxi- H 1537-C

mately two inches of pedal travel.
3 . R a i s e the vehicle. With the FIG. 3—Parking Brake Adjustment—Ford, Mercury, Meteor,
transmission in neutral, turn the ad- Thunderbird and Continental Mark III
justing nut forward against the equal-
izer (Figs. 3 and 4) until there is 100
02-01-04 Brakes 02-01-04
ft-lb breakaway torque. The breaka- THUNDERBIRD, POWER BRAKE MASTER

way torque is the torque required to CONTINENTAL MARK III, CYLINDER PUSH ROD
turn the rear wheels the direction of AND LINCOLN
ADJUSTMENT
forward rotation with a torque wrench CONTINENTAL
and tool shown in Fig. 5. The torque
measurement must be made relative to Check the parking brake cables The push rod is provided with an
the center line of the wheel. when the brakes are fully released. If adjustment screw to maintain the cor-
4. Release the parking brake, and the cables are loose, adjust them as rect relationship between the booster
check to make sure that the brake follows: control valve plunger and the master
shoes return to the fully released posi- 1. Fully release the parking brake cylinder. If the plunger is too long it
tion. pedal by pushing down the manual re- will prevent the master cylinder piston
5. Depress the parking brake pedal lease lever. from completely releasing hydraulic
to the third notch. Under normal con- 2. Depress the parking brake pedal pressure and can cause the brakes to
ditions, this will hold the vehicle satis- 1 1/4 inch from its normal released drag. If the plunger is too short it will
factorily. position. result in excess pedal travel and an
6. Release the parking brake again, 3. Raise the vehicle with the trans- undesirable clunk in the booster area.
and check as in step 4. mission in neutral. The adjustment screw is set to the
7. If the rear brakes do not fully 4. Loosen the lock nut and turn the correct height at the time of original
release, check the cables for kinks or adjusting nut forward against the assembly of the power unit. Under
binds. Free the cables as required. equalizer (Figs. 3 and 6) until there is normal service the adjustment screw
8. Lower the vehicle. Remove the 100 ft-lbs breakaway torque. The does not require any further attention
torque wrench and tool. Install the breakaway torque is the torque re- providing the original push rod assem-
wheel attaching nuts and torque them quired to turn the rear wheels the di- bly remains in the original unit.
to specification. Install the wheel rection of forward rotation with a tor- If a check of the push rod adjust-
cover. que wrench and tool shown in Fig. 5. ment is necessary, the push rod length
The torque measurement must be may be verified with a push rod length
RETAINER-*^ REAR WHEEL
NUT made relative to the centerline of the gauge and measured with the engine
(CABLE ASSEMBLY
wheel. Tighten the lock nut. running to apply vacuum to the boost-
EQUALIZER
5. Release the parking brake, and er (Fig. 7).
check to make sure that the brake The push rod length verification and
shoes return to the fully released posi- adjustment of Midland-Ross power
tion. brake booster assemblies must be
SPRING-2A651 JAM NUT
6. Depress the parking brake pedal done according to the following proce-
PARKING
SPRING SEAT-2A616 until it is fully engaged. dure:
BRAKE CABLE
AND CONDUIT 7. Release the parking brake again,
ASSEMBLY-2853 and check as in step 5. REAR WHEEL ADJUSTING NUT
8. Depress the pedal 1/2 inch. The CABLES
H1631-A brakes should not drag.
9. If the rear brakes do not fully EQUALIZER
FIG. 4—Parking Brake Linkage release, check the cables for kinks or
Adjustment—Fairlane, Montego, binds. Free the cables as required.
Falcon, Mustang and Cougar 10. Lower the vehicle. Remove the
torque wrench and tool. Install the
wheel attaching nuts and torque them
to specification. Install the wheel SPRING
cover.
CABLE ASSEMBLY H1632-A

Tool-T59L 4204-A,
T65K 4204-A,
T66L-4204-A,
FIG. 6—Parking Brake Linkage
OR Adjustment—Lincoln Continental
Tool-4421UA
#16 U.J>.S. GAUGE SHEET STEEL
\
i
0.980"
0.995"
1
H1087-E
E1897-A
FIG. 7—Push Rod Gauge
FIG. 5—Checking Parking Brake Breakaway Torque Dimensions
02-01-05 Brakes 02-01-05
1. Disconnect the master cylinder sion against the push rod is required and rear) hydraulic brake systems are
from the booster assembly and secure to assure that the push rod is firmly individual systems and are bled separ-
away from the booster without discon- seated in the booster assembly.) See ately. Bleed the longest line first on
necting the brake tubes. Figure 8. the individual system being serviced.
2. Reinstall the air filter assembly 3. Install the master cylinder on the During the complete bleeding opera-
on the booster if it was removed with brake booster and tighten the retain- tion, DO NOT allow the reservoir to
the master cylinder (Fig. 8). ing nuts to the specified torque. run dry. Keep the master cylinder res-
3. Install and tighten the master Do not set up side forces on the ervoirs filled with Ford Fluid—Extra
cylinder retaining nuts to retain the push rod as it may break the valve Heavy Duty — Part Number C6AZ-
air filter assembly securely against the plunger. 19542-A (ESA-M6C 25-A). The extra
booster body and to seal the booster This is an approximate adjustment heavy duty brake fluid is colored blue
bellows against air leaks. only. To verify the adjustment, look for identification purposes. Do not
4. Place the gauge against the through the make-up (rear) port of the mix low temperature brake fluids with
master cylinder mounting surface of master cylinder when installing the the specified fluid during the bleeding
the air filter assembly. master cylinder to the booster. The operations. Never re-use brake fluid
5. Adjust the push rod screw to master cylinder piston should not which has been drained from the hy-
provide a slight tension against the move more than 0.015 inch as it con- draulic systems.
inner edge of the adjustment gauge tacts the push rod. No movement 1. If t h e m a s t e r c y l i n d e r is
slot. (Approximately 5 pounds of ten- (exact contact) is ideal. equipped with a bleed screw, loosen
sion against the push rod is required the bleed screw. Push the brake pedal
to assure that the push rod is firmly down slowly through its full travel.
seated in the booster assembly.) HYDRAULIC SYSTEM BLEEDING Close the bleeder fitting and return
6. Remove the retaining nuts from AND CENTRALIZING OF THE the pedal to the fully released posi-
the booster master cylinder mounting DIFFERENTIAL VALVE tion. Repeat this operation until fluid
studs. is free of air bubbles, then tighten the
7. Install the master cylinder on the When any part of the hydraulic sys- bleeder screw. Do not use the second-
brake booster and tighten the retain- tem has been disconnected for repair ary piston stop screw, located on the
ing nuts to the specified torque. or replacement, air may enter the sys- bottom of the master cylinder to bleed
The push rod length verification of tem and cause spongy pedal action. the brake system. Loosening or re-
the Bendix power b r a k e booster Bleed the hydraulic system after it has moving this screw could result in dam-
assemblies is accomplished as follows: been properly connected, to be sure age to the secondary piston or stop
1. Disconnect the master cylinder that all air is expelled. screw.
from the booster assembly and secure 2. To bleed the secondary (rear)
away from the booster without discon- MANUAL BLEEDING brake system, position a suitable 3/8
necting the brake tubes. inch box wrench (Fig. 9) on the bleed-
2. Adjust the push rod screw to The Lincoln Continental hydraulic er fitting on the brake wheel cylinder.
provide a slight tension against the brake system is to be bled only with Attach a rubber drain tube to the
inner edge of the adjustment gauge pressure bleeding equipment. bleeder fitting. The end of the tube
slot. (Approximately 5 pounds of ten- The primary and secondary (front should fit snugly around the bleeder
fitting.
MANIFOLD CHECK VALVE-2365 19-25 IN. LB. APPROXIMATELY 45°
TIGHTEN RETAINING NUTS

TO SECURE AIR FILTER
AGAINST BOOSTER BODY
AND BELLOWS
H1300-B
ADJUST PUSH ROD SCREW TO
PROVIDE A SLIGHT TENSION
(APPROXIMATELY 5 LBS.) . 9—Wrench for Bleeding
AGAINST THE GAUGE Brake Hydraulic System
3. Submerge the free end of the

tube in a container partially filled with
clean brake fluid, and loosen the
bleeder fitting approximately 3/4 turn.
4. Push the brake pedal down slow-
ly through its full travel. Close the
bleeder fitting, then return the pedal
to the full-released position. Repeat
this operation until air bubbles cease
PUSH ROD GAUGE to appear at the submerged end of the
bleeder tube.
5. When the fluid is completely free
PUSH ROD ADJUSTMENT-MIDLAND-ROSS PUSH ROD ADJUSTMENT-BENDIX
of air bubbles, close the bleeder fitting
H1589-A and remove the bleeder tube.
6. Repeat this procedure at the
FIG. 8—Brake Booster Push Rod Measurement brake wheel cylinder on the opposite
02-01-06 Brakes 02-01-06
side. Refill the master cylinder reser- the bleed screw and bleed the master be removed to gain access to the
voir after each wheel cylinder is bled cylinder until the fluid is free of air bleeder fittings on the calipers. Also
and install the master cylinder cover bubbles; then, tighten the bleed screw. on Lincoln Continental models the
and gasket. Be sure the diaphragm Do not use the secondary piston stop metering valve release rod must be
type gasket is properly positioned in screw, located on the bottom of the pulled outward and held a minimum
the master cylinder cover. When the master cylinder, to bleed the master of 1/16 inch (Fig. 10) while bleeding
bleeding operation is completed, the cylinder. the primary brake system.
fluid level should be filled to within 4. If the rear wheel cylinders, the 10. If the vehicle contains drum-
1/4 inch of the top of the reservoirs. secondary brake system, are to be type front brakes and the primary
7. If the primary (front brake) sys- bled, position a 3/8 inch box wrench (front) brake system is to be bled, re-
tem is to be bled. Repeat steps 2 (Fig. 9) on the bleeder fitting on the peat steps 4 through 7, starting at the
through 6 at the right front brake cal- right rear brake wheel cylinder. At- right front wheel cylinder ending at
iper or cylinder and ending at the left tach a bleeder tube to the bleeder fit- the left front wheel cylinder.
front brake caliper or cylinder. ting. The end of the tube should fit
8. On disc brake equipped models snugly around the bleeder fitting. 11. When the bleeding operation is
be sure that the front brake pistons completed, close the bleeder tank
5. Open the valve on the bleeder
are returned to their normal positions tank to admit pressurized brake fluid valve and remove the tank hose from
and that the shoe and lining assem- to the master cylinder reservoir. the adapter fitting.
blies are properly seated by depressing 6. Submerge the free end of the 12. On disc brake equipped ve-
the brake pedal several times until tube in a container partially filled with hicles, be sure that the front brake
normal pedal travel is established. clean brake fluid, and loosen the pistons are returned to their normal
9. Centralize the pressure differen- bleeder fitting. positions and that the shoe and lining
tial valve. Refer to the Centralizing 7. When air bubbles cease to ap- assemblies are properly seated by dep-
the Pressure Differential Valve proce- pear in the fluid at the submerged end ressing the brake pedal several times
dures which follow. of the bleeder tube, close the bleeder until normal pedal travel is esta-
fitting and remove the tube. blished.
PRESSURE BLEEDING 8. Repeat steps 3 through 7 at the 13. Remove the Pressure Bleeder
left rear wheel cylinder. Adapter Tool. Fill the master cylinder
The Lincoln Continental hydraulic 9. If the vehicle is equipped with reservoirs to within 1/4 inch of the
brake system is to be bled only with disc brakes, repeat steps 4 through 7, top. Install the master cylinder cover
pressure bleeding equipment. starting at the right front disc caliper and gasket. Be sure the Diaphragm
Bleed the longest lines first. The and ending at the left front disc cali- type gasket is properly positioned in
bleeder tank should contain enough per. the master cylinder cover.
new Ford Brake Fluid to complete the On Lincoln Continental models the 14. Centralize the pressure differen-
bleeding operation. Use Ford Brake front wheel and tire assemblies must tial valve as follows.
Fluid — Extra Heavy Duty — Part
Number C6AZ-19542-A (ESA-
M6C25-A) or equivalent for all brake
applications. The brake fluid is col-
ored blue for identification purposes.
Do not mix low temperature brake
fluid with the specified brake fluid
during the bleeding operations. Never
re-use brake fluid that has been
drained from the hydraulic system.
The tank should be charged with ap-
proximately 10 to 30 pounds of air
pressure. Never exceed 50 pounds
pressure.
1. Clean all dirt from the master METERING VALVE
BLEEDER RETAINER
cylinder reservoir cover.
2. Remove the master cylinder res-
ervoir cover and rubber gasket, and
fill the master cylinder reservoir with
the specified brake fluid. Install the
pressure bleeder adapter tool to the
master cylinder, and attach the bleed-
er tank hose to the fittng on the
adapter.
Master cylinder pressure bleeder
adapter tools can be obtained from
SEE
the various manufacturers of pressure VIEW A
bleeding equipment. Follow the in-
structions of the manufacturer when
installing the adapter.
HI 644-A
3 . If t h e m a s t e r c y l i n d e r is RELEASE ROD
equipped with a bleed screw, loosen FIG. 10—Disc Brake Metering Valve—Lincoln Continental
02-01-07 Brakes 02-01-07
CENTRALIZING THE light after a repair operation, a pres- differential valve is moved to a cen-
PRESSURE DIFFERENTIAL sure differential or unbalance condi- tralized position and the brake warn-
VALVE tion must be created in the opposite ing light goes out; then, immediately
brake system from the one that was tighten the outlet port tube nut.
After a failure of the primary (front repaired or bled last. 2. Check the fluid level in the mas-
brake) or secondary (rear brake) sys- 1. Turn the ignition switch to the ter cylinder reservoirs and fill them to
tem has been repaired and bled, the ACC or ON position. Loosen the dif- within 1/4 inch of the top with the
dual-brake warning light will usually ferential valve assembly brake tube specified brake fluid, if necessary.
continue to be illuminated due to the nut at the outlet port on the opposite 3. Turn the ignition switch to the
pressure differential valve remaining in side of the brake system that was OFF position.
the off-center position. wheel balanced, repaired and/or bled 4. Before driving the vehicle, check
To centralize the pressure differen- last. Depress the brake pedal slowly to the operation of the brakes and be
tial valve and turn off the warning build line pressure until the pressure sure that a firm pedal is obtained.
CLEANING AND INSPECTION

DISC BRAKES Rotunda Disc Brake Attachment inboard rotor face (dimension B)
FRE-2249-2 is the only approved tool and the outboard rotor surface and
1. Remove the wheel and tire and to be used to refinish the disc brake the inboard bearing cup (dimension
the shoe and lining assemblies as out- rotors. The step-by-step resurfacing A), must be observed when remov-
lined in Part 2-2, Section 2. procedure provided with the tool must ing material from the rotor braking
be adhered to. surfaces.
2. On all models except Lincoln
The finished braking surface of the When the runout check is finished
Continental, make thickness measure-
rotor must be flat and parallel within be sure to adjust the bearings as out-
ments with a micrometer across the
0.0007 inch; lateral runout must not lined in Group 3, in order to prevent
thinnest section of the shoe and lining.
exceed 0.003 inch total indicator bearing failure.
If the assembly has worn to a thick-
ness of 0.230-inch (shoe and lining to- reading, braking surface are to be 80/15 6. Check the rotor for scoring. Mi-
gether) or 0.030-inch (lining material micro inches. nor scores can be removed with a
only) at any one of three measuring On all models except Lincoln Con- fine emery cloth. If the rotor is ex-
locations or if there is more than tinental the minimum limiting dimen- cessively scored, refinish it as out-
0.125 taper from end to end or if lin- sion from the inboard bearing cup to lined in step 5 or replace the rotor,
ing shows evidence of brake fluid con- the inboard rotor face and the mini- if required.
tamination, replace all (4) shoe and mum rotor thickness dimension, must 7. Visually check the caliper. If the
lining assemblies on both front wheels. be observed when removing material caliper housing is leaking it should be
On Lincoln Continental brakes from the rotor braking surfaces. A replaced. If a seal is leaking the cali-
make three thickness measurements ball and gage bar (Rotunda Kit FRE per must be disassembled and new
with a micrometer across the middle 70160) is to be used when checking .seals installed. If a piston is seazed
section of the shoe and lining. Take minimum dimensions (Fig. 11). in the bore a new caliper housing is
one reading at each side and one in required.
the center. If the assembly has worn On Lincoln Continental models the
to a thickness of 0.231 inch (shoe and FALCON-FAIRLANE 875 MIN
two halves of the caliper assembly
MUSTANG-COUGAR should never be separated. Damage or
lining together) or 0.066 inch (lining MONTEGO
material only) at any one of the three failure of one requires replacement of
measuring locations, replace all (4) both as a unit.
shoe and lining assemblies on both Check the brake hoses for signs of
front wheels. cracking, leaks or abrasion. Replace
3. Check the caliper to spindle at- .046 MAX-** them if necessary.
taching bolts torque. Torque them to
DISC BRAKE SERVICE
specification, if required.
PRECAUTIONS
4. To check rotor runout, first
eliminate the wheel bearing end play 1. Grease or any other foreign ma-
by tightening the adjusting nut. After .119 MAX. terial must be kept off the caliper as-
tightening the nut, check to see that sembly, surfaces of the rotor and ex-
the rotor can still be rotated. ternal surfaces of the hub during serv-
5. Clamp a dial indicator to the ice operations. Handling of the rotor
caliper housing so that the stylus con- FORD-MERCURY and caliper assemblies should be done
METEOR - THUNDERBIRD
tact the rotor at a point approximate- in a way to avoid deformation of the
1.12 M I N . - ^ H1633-A
ly 1 inch from the outer edge. Rotate brake rotor and nicking or scratching
the rotor and take an indicator read- ?? — Disc Brake Rotor of brake linings.
ing. If the reading exceeds 0.003 inch Service Limits—All Models Except 2. If a caliper piston is removed for
total lateral runout on the indicator, Lincoln Continental any reason, the piston seal must be re-
replace or resurface the disc brake placed.
rotor. The following requirement must On Lincoln Continental models the 3. During removal and installation
be met when resurfacing disc brake minimum limiting dimension (Fig. 12) of a wheel assembly, exercise care not
rotors: from the inboard bearing cup to the to interfere with and damage the cali-
02-01-08 Brakes 02-01-08
wheel, tire and drum are removed as a fluid. Replace lining in axle sets. Prior
unit. to replacement of lining, the drum di-
9. On floating caliper type disc ameter should be checked to deter-
brakes whenever the caliper is re- mine if oversize linings must be in-
moved the caliper locating pins should stalled.
be inspected for wear or damage. 4. Check the condition of brake
10. On floating caliper type disc shoes, retracting springs, hold-down
BEARING CUP
brakes, the caliper assembly must be springs, and drum for signs of over-
removed from the spindle prior to re- heating. If the shoes have a slight blue
DIMENSION " B "
moval of the shoe and lining assem- coloring, indicating overheating, re-
0.755 MINIMUM blies. placement of the retracting and hold-.
11. On floating caliper type disc down springs is strongly recommended.
brakes the calipers must not be inter- Overheated springs lose their pull and
DIMENSION " A '
0.395 MINIMUM
changed from one side to the other. could cause the new lining i:o wear
When the caliper is installed on its prematurely, if they are not replaced.
proper anchor plate and spindle, the 5. If the vehicle has 30,000 or more
bleeder screw will point to the rear of miles of operation on the brake linings
H1532-B the vehicle (Fig. 22). If a caliper is in- or signs of overheating are present
stalled on the wrong side of the vehi- when relining brakes, the wheel cylin-
FIG. 12—Disc Brake Rotor Service cle, it is not possible to bleed the sys- ders should be disassembled and in-
Limits—Lincoln Continental tem properly. spected for wear and entrance of dirt
12. Do not attempt to clean or re- into the cylinder. The cylinder cups
per splash shield or the bleeder screw store oil or grease soaked brake lin- should be replaced, thus avoiding fu-
fitting. ings. When contaminated linings are ture problems.
4. Front wheel bearing end play is found, brake linings must be replaced 6. Inspect all other brake parts and
critical and must be within specifica- in complete axle sets. replace any that are worn or dam-
tions. DRUM BRAKES aged.
5. Be sure the vehicle is centered on 7. Inspect the brake drum and, if
the hoist before servicing any front 1. Remove the wheel from the necessary, refinish. Refer to Part 2-2,
end components, to avoid bending or drum, and remove the drum as out- Section 4 for refinishing.
damaging the rotor splash shield on lined in Part 2-2, Section 2.
full right or left wheel turns. 2. Brush all dust from the backing
6. The proportioning valve should plates and interior of the brake BRAKE BOOSTER
not be disassembled or adjustments drums.
attempted on it. 3. Inspect the brake shoes for ex- Check the booster operation as
7. Riding of the brake pedal (com- cessive lining wear or shoe damage. If noted in Part 2-1, Section 1, Power
mon on left foot applications) should the lining is worn within 1/32 inch of Brake Functional Test. If the brake
be avoided during vehicle operation. the rivet heads or if the shoes are booster is damaged or defective, re-
8. The wheel and tire must be re- damaged, they must be replaced. Re- place it with a new booster. The brake
moved ' separately from the brake place any lining that had been con- booster is serviced only as an assem-
rotor, unlike drum brakes where the taminated with oil, grease or brake bly.
02-02-01 Brake System 02-02-01
Part 2-2 Brake System

MODEL APPLICATION
Continental-
Thunderbird
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
ANTI SKID CONTROL SYSTEM
Description N/A N/A N/A N/A N/A N/A N/A N/A N/A 02-07 02-07
ANTI SKID CONTROL ACTUATOR
Removal and Installation N/A N/A N/A N/A N/A N/A N/A N/A N/A 02-36 02-36
ANTI SKID CONTROL MODULE
ANTI SKID CONTROL SENSOR
BRAKE BACKING PLATE (DRUM)
Removal and Installation 02-16
BRAKE BOOSTER
Cleaning and Inspection - See Part 2-1
Description 02-06
BRAKE DRUM
Refinishing 02-39
Removal and Installation (Front) 02-09 02-09 02-09 02-09 02-09 02-09 02-09 02-09 02-09 N / A N/A N/A
Removal and Installation (Rear) 02-09
BRAKE PEDAL
Removal and Installation 02-25 02-25 02-25 02-25 02-25 02-25 02-25 02-25 02-27 02-26 02-26
BRAKE SHOES (DRUM)
Adjustments 02-07
Relining 02-39
DISC BRAKE
Description 02-03
DISC BRAKE CALIPER
Cleaning and Inspection 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-42 04-41 02-41
Disassembly and Overhaul 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41 02-41
DISC BRAKE ROTOR AND HUB
Cleaning and Inspection — See Part 2-1
Refinishing 02-39
DISC BRAKE ROTOR SPLASH SHIELD
DISC BRAKE SERVICE PRECAUTIONS
— See Part 2-1
N/A indicates that the item is not applicable to the vehicle listed.
02-02-02 Brake System 02-02-02
MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
COMPONENT INDEX
Mustang
Montego
Mercury
Mark III
Fairlane
Lincoln-
Cougar
Meteor
Falcon
Ford
DISC BRAKE SHOE AND LINING
DRUM BRAKE
Description 02-05
DUAL BRAKE SYSTEM
Description 02-03
HYDRAULIC LINES
Removal and Installation (Hose) 02-08
Removal and Installation (Tube) 02-08
MASTER CYLINDER
Disassembly and Overhaul 02-39
Removal and Installation - Non-Power 02-19 02-19 02-19 02-20 02-20 02-20 02-20 02-20 N/A N/A N/A
Removal and Installation - Power 02-21
PARKING BRAKE
Description 02-06
PARKING BRAKE ACTUATOR TO
CONTROL CABLE
Removal and Installation 02-34 02-34 02-34 N/A N/A N/A N/A N/A N/A 02-34 02-34
PARKING BRAKE ACTUATOR TO
EQUALIZER CABLE
PARKING BRAKE CONTROL
PARKING BRAKE EQUALIZER TO
CONTROL CABLE
Removal and Installation N/A N/A N/A 02-34 02-34 02-34 02-34 02-34 02-35 N/A N/A
PARKING BRAKE EQUALIZER TO
REAR WHEEL CABLE
PRESSURE DIFFERENTIAL VALVE
PRESSURE METERING VALVE
Removal and Installation N/A N/A N/A N/A N/A N/A N/A N/A 02-24 N/A N/A
PROPORTIONING VALVE
WHEELCYLINDER
02-02-03 Brake System 02-02-03
DESCRIPTION
Disc brakes are available as option- DISC BRAKE FLOATING CALIPER—

al equipment for the front wheels on ALL MODELS EXCEPT
Ford, Mercury, Meteor, Fairlane, LINCOLN CONTINENTAL
Montego, Falcon, Mustang and Cou- The disc brake consists of a venti-
gar models and are standard on Thun- lated rotor and caliper assembly. The The caliper asseml.y is made up of
derbird, Continental Mark III, and caliper used on all models except Lin- a floating caliper housing assembly
L i n c o l n C o n t i n e n t a l models. The coln Continental is a single piston and an anchor plate. The anchor plate
dual-master cylinder equipped hydrau- floating caliper (Fig. 3). The caliper is bolted to .the wheel spindle arm by
lic brake system employs single an- used on Lincoln Continental models is two bolts. The floating caliper is at-
c h o r , i n t e r n a l expanding and self- a four piston fixed caliper (Fig. 4). tached to the anchor plate by steel
adjusting drum brake assemblies on A proportioning valve in the rear stabilizers on Ford, Mercury, Meteor,
the rear wheels of vehicles with disc hydraulic circuit provides balanced Thunderbird and Continental Mark
brakes, and on the front and rear braking action between front and rear III models and by one stabilizer on
wheels of all others. brakes. Fairlane, Montego, Falcon, Mustang
A vacuum booster is used with the On all models except Lincoln a and Cougar models. The floating cali-
power disc brake system. pressure impulse valve located at the per slides on two locating pins which
primary inlet of the pressure differen- also attach to the stabilizers. The
tial valve prevents brake fluid surge floating caliper contains the single cyl-
DUAL MASTER CYLINDER
back to the master cylinder reservoir. inder and piston assembly. The cylin-
BRAKE SYSTEM On Lincoln Continental models a der bore contains a piston with a
metering valve, in the hydraulic line molded rubber dust boot to seal the
The dual-master cylinder brake sys- between the differential valve and the cylinder bore from contamination
tem has been incorporated in all mod- front wheel disc brakes, prevents the (Fig. 5). A square section rubber pis-
els to provide increased safety. The front brakes from applying until ap- ton seal is positioned in a groove in
system consists of a dual-master cylin- proximately 125 psi is obtained in the the cylinder bore and is used to pro-
der (Fig. 1), pressure differential valve system (Fig. 21). This delaying action vide sealing between the cylinder and
assembly and a switch (Fig. 2). The is required to prevent the front brakes piston (Fig. 7).
switch on the differential valve acti- from performing all the braking ac- The outer brake shoe and lining as-
vates a dual-brake warning light, lo- tion on low speed stops and thereby sembly is longer than the inner assem-
cated on the instrument panel. increasing the rate of lining wear. bly, and the shoe and lining
DISC BRAKES
RETURN SPRING
(SECONDARY)
RETAINER
PRIMARY SYSTEM BRAKE

FLUID RESERVOIR
BOOT
PUSH ROD
RESIDUAL \ ^
TUBE SEAT | CHECK \
VALVE \
(SECONDARY) (PRIMARY)
BRAKE OUTLET SECONDARY PISTON BRAKE OUTLET PRIMARY PISTON H 1545-A
PORT ASSEMBLY PORT ASSEMBLY
FIG. I — Dual Master Cylinder—Typical

BRAKE WARNING LAMP SWITCH BRAKE WARNING LAMP SWITCH
BRAKE WARNING LAMP SWITCH BRAKE WARNING LAMP SWITCH
PLUNGER IN THE ON POSITION PLUNGER IN OFF POSITION
PISTON
CONNECTOR
VALVE PISTON HAS MOVED

TO LOW PRESSURE AREA. VALVE PISTON IS
WARNING LAMP SWITCH CENTRALIZED. PRIMARY CONNEiCTOR
PLUNGER IS DEPRESSED, AND SECONDARY SYSTEM
LIGHTING THE BRAKE PRESSURES ARE EQUALIZED
WARNING LAMP
LOW PRESSURE SIDE HIGH PRESSURE SIDE U

DRUM BRAKES
TJ
BRAKE WARNING LAMP I
BRAKE FLUID
BRAKE WARNING LAMP
SWITCH PLUNGER IN SWITCH PLUNGER IN
OFF POSITION ON POSITION
REAR BRAKE INLET
CONNECTOR
FRONT BRAKE
REAR BRAKE
INLET
PROPORTIONING
FRONT BRAKE
OUTLET VALVE PISTON IS CENTRALIZED.
OUTLET TO \ VALVE IS BYPASSED
PROPORTIONING VALVE VALVE PISTON HAS MOVED TO LOW
PRIMARY AND SECONDARY SYSTEM PRESSURE AREA. WARNING LAMP SWITCH PLUNGER IS
PRESSURES ARE EQUALIZED DISC BRAKES DEPRESSED, LIGHTING THE BRAKE WARNING LAMP H1634-A
FIG. 2—Pressure Differential Valve and Brake Warning Light Switch
CALIPER ASSEMBLY EXTERNAL

blies are not interchangable (Fig. 23).
TRANSFERTU3E The outboard shoe and lining is fixed
BLEEDER
SCREW to the floating caliper and is retained
by two pins and spring clips. The shoe
and lining assembly consists of fric-
tion material bonded to a metal plate
called the shoe. It is replaced as a
unit.
FIXED CALIPER
LINCOLN CONTINENTAL
The caliper assembly is bolted di-

rectly to the wheel spindle arm by two
bolts. The caliper assembly consists of
two caliper housings bolted together
HUB
AND with each half containing two cylinder
ROTOR bores of 1.938 inch diameter. Each
H1567-B ASSEMBLY H 1647-A
cylinder bore contains a piston with
FIG. 3—Disc Brake Assembly- FIG. 4—Disc Brake Assembly— an attached molded rubber dust boot
Floating Caliper—All Models Fixed Caliper—Lincoln to seal the cylinder bore from contam-
Except Lincoln Continental Continental ination (Fig. 6). Square-section rubber
02-02-05 Brake System 02-02-05
piston seals are positioned in grooves

in the cylinder bores and are used to CALIPER HOUSING
provide hydraulic sealing between the
cylinders and pistons (Fig. 7).
The cylinders are connected hydrau-
PISTON
lically by means of internal passages
in the caliper housings and an external
transfer tube between the two halves
SHOE
of the caliper assembly. One bleeder
screw and fluid inlet fitting is provided LINING
on each caliper assembly.
The shoe and lining assemblies are
located in between parallel machined
abutments within the caliper, and are
supported radially by tabs on the
o'uter ends of the shoe assemblies (Fig. PISTON SEAL
46). The shoes slide axially in the cali-
per abutments by means of the tabs H 1568-B
which ride on machined ledges (bridg-
es) when hydraulic pressure is applied
to the piston (Fig. 6). A shoe and lin- FIG. 5—Floating Caliper Assembly—Sectional View
ing assembly consists of friction mate-
rial riveted to a metal plate called the
shoe. It is replaced as a unit. Clips are
attached to the top of the caliper to
TRANSFER TUBE
retain the shoe and lining assemblies. CALIPER TO ROTOR CLEARANCE
PISTON DUST BOOT
The caliper assembly is mounted on RETAINING GROVE
the front wheel spindle to the rear of CALIPER HOUSING
the wheel vertical centerline.
PISTON
ROTOR SHOE
The cast iron disc is of the ventilat-

ed rotor-type incorporating forty fins LINING
and is attached to, and rotates with
the wheel hub. A splash shield bolted
to the spindle is used primarily to pre- PISTON SEAL
CALIPER DUST
vent road contaminants from contact- BOOT RETAINER
ing the inboard rotor and lining sur-
faces. The wheel provides protection
for the outboard surface of the rotor.
H 1648-A
DRUM BRAKE FIG. 6—Fixed Caliper Assembly—Sectional View
The drum brake system employs

single anchor, internal expanding ancj
self adjusting brake assemblies.
The self-adjusting brake mechanism PISTON SEAL RELAXED
PISTON
consists of a cable, cable guide, ad-
justing lever, adjusting screw assem-
bly, and adjuster spring (Fig. 8). The
cable is hooked over the anchor pin at
the top and is connected to the lever
at the bottom. The cable is routed
along the webb of the secondary brake
shoe by means of the cable guide. The
adjuster spring is hooked to the pri-
mary brake shoe and to the lever. The
automatic adjuster operates only when
the brakes are applied while the vehi-
cle is moving rearward and only when CALIPER HOUSING
the secondary shoe is free to move BRAKES APPLIED BRAKES RELEASED
H1569-B
toward the drum beyond a predeter-
mined point. FIG. 7—Function of Piston Seal
02-02-06 Brake System 02-02-06
SHOE GUIDE (ANCHOR PIN) PLATE SHOE GUIDE (ANCHOR PIN) PLATE PRIMARY SHOE -TC -ANCHOR
WASHER SPRING
PARKING
BRAKE LEVER
RETAINING
CLIP
SECONDARY
SHOE
PRIMARY
SHOE
AUTOMATIC
ADJUSTER
PIVOT SPRING
PARKING NUT
CABLE HOOK
BRAKE CABLE
AND HOUSING
H 1649- A
FIG. 8—Self-Adjusting Brake Assemblies—Typical
BRAKE BOOSTER SYSTEM

nects the actuator to the equalizer. lease type (Fig. 9) is used on the Mer-
The rear brake cables connect the cury, Ford LTD, Meteor LeMoyne,
equalizer assembly to the parking Thunderbird, Continental Mark III
This diaphragm-type brake booster brake lever at each rear secondary and Lincoln Continental models. All
is a self-contained vacuum-hydraulic shoe (Fig. 8). other models use the manual release-
braking unit mounted on the engine Two types of brake pedal control type (Fig. 10).
side of the dash panel. are used. The automatic (vacuum) re- On the automatic-type, the vacuum
The brake booster is of the vacuum
suspended-type which utilizes engine PISTON ROD
intake manifold vacuum and atmos- VACUUM POWER UNIT
pheric pressure for its power.
Adjustment of the push rod and re-
placement of the check valve and RELEASE LEVER
grommet are the only services permit-
ted on the brake booster. The booster
unit is to be exchanged when it is in-
spected, checked and found to be de-
fective.
PARKING BRAKE
An independent foot-operated park-

ing brake control actuates the rear
wheel brake shoes through a cable
linkage. On all models except Ford,
Mercury, Meteor, Thunderbird and
Continental Mark III, the operating
cable is routed from the parking brake
control assembly to the equalizer. On
PEDAL
Ford, Mercury, Meteor, Thunderbird,
and Continental Mark III, the operat-
ing cable is routed from the parking H 1635-A
brake control assembly to the actuator FIG. 9—Parking Brake Control Assembly
assembly. An intermediate cable con- With Automatic Release—Typical
02-02-07 Brake System 02-02-07
ANTI-SKID CONTROL SYSTEM
RELEASE PAWL CAM PIN
The anti-skid control system con-

RELEASE PAWL CAM LEVER sists of three major components (Fig.
39). Mechanically driven electromag-
RELEASE CABLE netic sensors at each rear wheel; an
electronic control module mounted
under the glove box; a vacuum pow-
ered actuator attached to a bracket on
the inside of the right front frame rail
under the toe board.
The sensors consist of steel rings
having teeth on their outer diameters,
pressed on each axle shaft just out-
board of the wheel bearing. The teeth
rotate past corresponding teeth on the
inside diameter of stationary steel
rings mounted in the bearing retain-
ers. Also mounted in the retainers, are
ring-shaped permanent magnets and
coils of wire. Two wires from each
sensor connect the sensors to the con-
trol module.
H 1636- A The control module consists of solid
FIG. 10—Parking Brake Control Assembly state electronic components sealed in
With Manual Release—Typical a container. It is connected to the sen-
sors and to a solenoid on the actuator.
power unit with mounting bracket is in the event of vacuum power failure The actuator is similar to a vacuum
riveted to the control assembly. The or for optional manual release at any brake booster and consists of three
vacuum actuated piston within the time. parts. A chamber divided by a vacuum
unit is connected by a rod to the Hoses connect the power unit and suspended diaphragm; a hydraulic cyl-
upper end of the release lever (Fig. 9). the engine manifold to a vacuum re- inder connected to the diaphragm; and
The lower end of the release lever ex- lease valve in the transmission neutral a solenoid connected electrically to the
tends out for alternate manual release safety switch. control module.
IN-VEHICLE ADJUSTMENTS AND REPAIRS
After any brake service work, ob- To adjust the brake shoes: and tighten the nuts to specification.
tain a firm brake pedal before moving 1. Use Rotunda Tool HRE 8650, 7. Complete the adjustment by
the vehicle. Riding the brake pedal (Fig. 11) to determine the inside diam- applying the brakes several times with
(common on left foot application) eter of the drum braking surface. a minimum of 50 lbs pressure on the
should be avoided when driving the 2. Reverse the tool as shown in Fig. pedal while backing the vehicle. After
vehicle. 11 and adjust the brake shoe diameter each stop the vehicle must be moved
to fit the gauge. Hold the automatic forward.
adjusting lever out of engagement 8. After the brake shoes have been
BRAKE SHOE ADJUSTMENTS—
while rotating the adjusting screw, to properly adjusted, check the operation
DRUM BRAKES prevent burring the screw slots. Make of the brakes by making several stops
sure the adjusting screw rotates freely. while operating in a forward direction.
The hydraulic drum brakes are If necessary, lubricate the adjusting
self-adjusting and require a manual screw threads with a thin, uniform
WHEEL CYLINDER REPAIR-
adjustment only after the brake shoes coating of MIC-100-A.
have been relined, replaced, or when 3. Rotate Tool HRE 8650 around DRUM BRAKE
the length of the adjusting screw has the brake shoes to be sure of the set-
been changed while performing some ting. Wheel cylinders should not be di-
other service operation. The manual 4. Apply a small quantity of high sassembled unless they are leaking or
adjustment is performed with the temperature grease to the points unless new cups and boots are to be
drums removed, using the tool and the where the shoes contact the backing installed. It is not necessary to remove
procedure detailed below. plate, being careful not to get the lu- the brake cylinder from the backing
When adjusting the rear brake bricant on the linings. plate to disassemble, inspect, or hone
shoes, check the parking brake cables 5. Install the drums. Install Tinner- and overhaul the cylinder. Removal is
for proper adjustment. Make sure that man nuts and tighten securely. necessary only when the cylinder is
the equalizer operates freely. 6. Install the wheels on the drums damaged or scored beyond repair.
02-02-08 Brake System 02-02-08
Tool-HRE-8650 Place a boot over each end of the cyl-

inder. Bleed the brake system.
HYDRAULIC LINE REPAIR
Steel tubing is used throughout the

brake system with the exception of the
flexible hoses at the front wheels and
at the fear axle housing brake tube
connection (Figs. 17 thru 21).
Always bleed the applicable pri-
mary or secondary brake system after
primary or secondary brake system
hose or line replacement. Centralize
the pressure differential valve after
bleeding the system.
BRAKE TUBE
REPLACEMENT
If a section of the brake tubing be-

comes damaged, the entire section
should be replaced with tubing of the
same type, size, shape and length.
Copper tubing should not be used in a
JUST SET TO DRUM FIND CORRECT BRAKE hydraulic s y s t e m . When bending
DIAMETER HERE . . . SHOE DIAMETER HERE brake tubing to fit underbody or rear
axle contours, be careful not to kink
H1416-A
or crack the tube.
All brake tubing should be double
FIG. 7 7—Adjusting Brake Shoes Using Tool HRE-8650 flared properly to provide good leak-
proof connections. Clean the brake
tubing by flushing with clean brake
fluid before installation.
BOOT BOOT When connecting a tube to a hose,
tube connector, or brake cylinder,
tighten the tube fitting nut to specified
torque with Milbar tool 1112-144 or
equivalent.
. BLEEDER .
BRAKE HOSE
PISTON
CYLINDER SCREW RETURN SPRING PIST0N
REPLACEMENT
A flexible brake hose should be re-

H1385-B placed if it shows signs of softening,
cracking, or other damage.
FIG. 72—Brake Wheel Cylinder—Typical
When installing a new front brake
hose, position the hose to avoid con-
DISASSEMBLY 3. Inspect the cylinder bore for tact with other chassis parts. Place a
score marks or rust. If either condi- new copper gasket over the hose fit-
1. Remove the links and the rubber tion is present the cylinder bore must ting and thread the hose assembly into
boots from the ends of the brake cyl- be h o n e d . However, the cylinder the front wheel cylinder. Engage the
inder. Remove the pistons, cups, and should not be honed more than 0.003 opposite end of the hose to the brack-
return spring from the cylinder bore inch beyond its original diameter. et on the frame. Install the horsesho-
(Fig. 12). 4. Check the bleeder hole to be sure e-type retaining clip, and connect the
2. Remove the bleeder screw from that it is open. tube to the hose with the tube fitting
the cylinder. nut (Figs. 17 thru 21).
ASSEMBLY A rear brake hose should be in-
stalled so that it does not touch the
INSPECTION 1. Apply a light coating of heavy- muffler outlet pipe or shock absorber.
duty brake fluip! to all internal parts. Thread the hose into the rear brake
1. Wash all parts in clean brake 2. Thread the bleeder screw into the tube connector. Engage the front end
fluid. Dry with compressed air. cylinder and tighten securely. of the hose to the bracket on the
2. Replace scored pistons. Always 3. Insert the return spring, cups, frame. Install the horseshoe-type re-
replace the rubber cups and dust and pistons into their respective posi- taining clip, and connect the tube to
boots. tions in the cylinder bore (Fig. 12). the hose with the tube fitting nut.
02-02-09 Brake System 02-02-09
REMOVAL AND INSTALLATION
FRONT BRAKE DRUM in the inner cup, and install the new 2. Adjust the brakes as outlined
grease seal see Part 3-5, Section 4. under Brake Shoe Adjustments in this
If the original drum is being in- section. Place the drum over the brake
REMOVAL stalled, make sure that the grease in assembly and into position.
the hub is clean and adequate. 3. Install the three Tinnerman nuts
1. Raise the vehicle until the wheel 2. Adjust the brakes and install the and tighten securely. Install the wheel
and tire clear the floor. Remove the drum assembly as outlined under on the axle shaft flange studs against
wheel cover or hub cap, and remove Brake Shoe Adjustments in this sec- the drum, and tighten the attaching
the wheel and tire from the drum. tion. nuts to specifications.
2. Remove the grease cap from the 3. Install the outer wheel bearing,
hub. Remove the cotter pin, nut lock, washer and adjusting nut.
4. Adjust the wheel bearing as out- BRAKE SHOES AND
adjusting nut, and flat washer from
the spindle. Remove the outer bearing lined in Part 3-7, Section 2, then in- ADJUSTING SCREW-
cone and roller assembly. stall the grease cap. Install the wheel DRUM BRAKES
3. Pull the drum off the wheel and hub cap.
spindle.
4. If the drum will not come off, REAR BRAKE DRUM REMOVAL
pry the rubber cover from the brake
backing plate. Insert a narrow screw- 1. With the wheel and drum re-
driver through the slot and disengage REMOVAL moved install a clamp over the ends of
the adjusting lever from the adjusting the brake cylinder as shown in Fig.
screw. While holding the adjusting 1. Raise the vehicle so that the tire 14.
lever away from the screw, back off is clear of the floor. 2. Remove the secondary shoe to
the adjusting screw with the brake ad- 2. Remove the hub cap and wheel. anchor spring with the tool shown in
justing tool (Fig. 13). Be very careful Remove the three Tinnerman nuts and Fig. 14. With the same tool remove
not to burr, chip, or damage the remove the brake drum. If the drum the primary shoe to anchor spring and
notches in the adjusting screw; other- will not come off, pry the rubber unhook the cable eye from the anchor
wise the self-adjusting mechanism will cover from the backing plate. Insert a pin.
not function properly. narrow screwdriver through the hole 3. On F o r d , Mercury, Meteor,
in the backing plate, and disengage Thunderbird, Continental Mark III
INSTALLATION the adjusting lever from the adjusting and Lincoln Continental models, re-
screw. While holding the adjusting move the shoe guide (anchor pin)
1. If the drum is being replaced, re- lever away from the adjusting screw, plate (Fig. 8).
move the protective coating from the back off the adjusting screw with the 4. Remove the shoe hold-down
new drum with carburetor degreaser. brake adjusting tool (Fig. 13). Be very springs, shoes, adjusting screw, pivot
Then, use sandpaper to insure that no careful not to burr, chip, or damage nut, socket and automatic adjustment
residue remains. Wipe the drum with the notches in the adjusting screw; parts.
a cloth soaked with denatured alcohol. otherwise, the self-adjusting mecha- 5. On rear brakes, remove the
Install new bearings and grease seal. nism will not function properly. parking brake link and spring. Dis-
Pack the wheel bearings, install the connect the parking brake cable from
inner bearing cone and roller assembly INSTALLATION the parking brake lever.
*>. After removing the rear brake
RUBBER PLUG 1. Remove the protective coating secondary shoe, disassemble the park-
REMOVED from a new drum with carburetor de- ing brake lever from the shoe by re-
greaser; then sand lightly and wipe moving the retaining clip and spring
with a cloth soaked with denatured al- washer (Fig. 8).
cohol.
INSTALLATION
1. Before installing the rear brake

shoes, assemble the parking brake
lever to the secondary shoe and secure
with the spring washer and retaining
clip.
2. Apply a light coating of high-
'MOVE HANDLE UPWARD t e m p e r a t u r e grease at the points
TO RETRACT BRAKE SHOES
where the brake shoes contact the
backing plate.
3. Position the brake shoes on the
HI 590-A H1390-A backing plate and secure the assembly
with the hold down springs. On the
FIG. 73—Backing Off Brake FIG. 14—Retracting Spring rear brake, install the parking brake
Adjustment Removal link and spring, back off the parking
02-02-10 Brake System 02-02-10
brake adjustment then connect the 10. Place the adjusting socket on as the lever is actuated by the cable.
parking brake cable to the parking the screw and install this assembly be- To determine the cause of this con-
brake lever (Fig. 8). tween the shoe ends with the adjusting dition:
4. Install the shoe guide (anchor screw toothed wheel nearest the sec- a. Check the cable end fittings. The
pin) plate on the anchor pin when so ondary shoe. cable should completely fill or extend
equipped. 11. Hook the cable hook into the slightly beyond the crimped section of
5. Place the cable eye over the an- hole in the adjusting lever. The adjust- the fittings. If it does not meet this
chor pin with the crimped side toward ing levers are stamped with an R or L specification, possible damage is indi-
the backing plate. to indicate their installation on right cated and the cable assembly should
6. Install the primary shoe to an- or left brake assembly (Fig. 16). be replaced.
chor spring (Fig. 15). 12. Position the hooked end of the b. Check the cable length. On
Ford, Mercury, Meteor, Thunderbird,
ADJUSTING LEVER Continental Mark III, and Lincoln
Continental models, the cable should
measure 11 1/8 inches (plus or minus
1/64 inch) from the end of the cable
anchor to the end of the cable hook.
On F a i r l a n e , M o n t e g o , F a l c o n ,
Mustang, and Cougar models the
cable should measure 8 13/32 inches
on 9 inch brakes or 9 3/4 inches on
10 inch brakes from the end of the
cable anchor to the end of the cable
IDENTIFICATION LINES hook.
H1391-A H1143-C c. Check the cable guide for dam-
age. The cable groove should be paral-
FIG. 75—Retracting Spring FIG. 16—Adjusting Screw and lel to the shoe web, and the body of
Installation Lever Identification the guide should lie flat against the
web. Replace the guide if it shows
7. Install the cable guide on the adjuster spring completely into the damage.
secondary shoe web with the flanged large hole in the primary shoe web. d. Check the pivot hook on the
hole fitted into the hole in the second- The last coil of the spring should be at lever. The hook surfaces should be
ary shoe web. Thread the cable the edge of the hole. Connect the loop square with the body of the lever for
around the cable guide groove (Fig. end of the spring to the adjuster lever proper pivoting. Replace the lever if
8). hole. the hook shows damage.
It is imperative that the cable be 13. Pull the adjuster lever, cable e. See that the adjusting; screw
positioned in this groove and not be- and automatic adjuster spring down socket is properly seated in the notch
tween the guide and the shoe web. and toward the rear to engage the in the shoe web.
8. Install the secondary shoe to an- pivot hook in the large hole in the sec-
chor spring with the tool shown in ondary shoe web (Fig. 8). WHEEL CYLINDER
Fig. 15. 14. After installation, check the ac-
Be certain that the cable eye is not tion of the adjuster by pulling the sec- DRUM BRAKE
cocked or binding on the anchor pin tion of the cable between the cable
when installed. All parts should be flat guide and the anchor pin toward the
on the anchor pin. Remove the brake secondary shoe web far enough to lift REMOVAL '
cylinder clamp. the lever past a tooth on the adjusting
9. Apply high-temperature grease screw wheel. The lever should snap 1. Remove the wheel and the drum.
(MIC-100-A) to the threads and the into position behind the next tooth, 2. Remove the brake shoe assem-
socket end of the adjusting screw. and release of the cable should cause blies, following procedures outlined in
Turn the adjusting screw into the ad- the adjuster spring to return the lever this section.
justing pivot nut to the limit of the to its original position. This return ac- 3. Disconnect the brake line from
threads and then back off 1/2 turn. tion of the lever will turn the adjusting the brake cylinder Figs. 17 thru 21.
Interchanging the brake shoe ad- screw.one tooth. On a vehicle with a vacuum brake
justing screw assemblies from one side If pulling the cable does not pro- booster, be sure the engine is stopped
of the vehicle to the other would cause duce the action described, or if the and there is no vacuum in the booster
the brake shoes to retract rather than lever action is sluggish instead of posi- system before disconnecting the hy-
expand each time the automatic ad- tive and sharp, check the position of draulic lines.
justing mechanism operated. To pre- the lever on the adjusting screw To disconnect the hose at a front
vent installation on the wrong side of toothed wheel. With the brake in a cylinder, loosen the tube fitting that
the vehicle, the socket end of the ad- vertical position (anchor at the top), connects the opposite end of the hose
justing screw is stamped with an R or the lever should contact the adjusting to the brake tube at a bracket on the
L (Fig. 16). The adjusting pivot nuts wheel 3/16 inch (plus or minus 1/32 frame. Remove the horseshoe-type re-
can be distinguished by the number of inch) above the centerline of the taining clip from the hose and brack-
grooves machined around the body of screw. If the contact point is below et, disengage the hose from the brack-
the nut. Two grooves on the nut indi- this centerline, the lever will not lock et, then unscrew the entire hose as-
cate a right thread; one groove indi- on the teeth in the adjusting screw sembly from the front wheel cylinder.
cates a left thread. wheel, and the screw will not be turned At a rear cylinder, unscrew the tube
TUBE 2B253 TUBE 2263
SWITCH 2B264
TUBE 2265
VIEWZ VIEWY
DRUM BRAKE VIEW Y
DISC BRAKE
TYPICAL 2 PLACES VIEW IN CIRCLE K
VIEW IN CIRCLE M DRUM BRAKE H 1639-A
FIG. 17—Service Brake System—Ford, Mercury and Meteor

02-02-12 Brake System 02-02-12
TUBE ASSY. REF. TUBE

2 A 040 2B253 ASSY>Y. REF TUBE
/ W W
' K t h # 2263 ASSY. R.H. REF.
TUBE ASSY. REF. TUBE 2264 ASSY. L.H. REF.
2B113-B 2B112-E
-TUBE
2B329
PRESSURE ASSY. REF.
IMPULSE VALVE
HOSE
PROPORTIONING C8OA-2B218-C ASSY.L.H.
C80A-26171-D ASSY.R.H. VIEW IN CIRCLE T
BEND CLIP TO RETAIN
TUBE AS SHOWN
2B269 ASSY. REF.
382365-S36 WASHER
VIEWZ 8M-2149
INSTALLATION-DISC BRAKE ONLY
INSTALLATION-DISC BRAKES SAME AS
DRUM BRAKES AND MAIN VIEW TUBE-2267 R.H.
EXCEPT AS SHOWN
TUBE-2A040
TUBE-2B253
TUBE 2B329
PRESSURE DIFFERENTIAL WASHER
VALVE 34808-S8
TUBE 2B329 PART OF AXLE
VIEW IN CLI VENT ON STATION
CIRCLE U WAGON ONLY
TYPICAL ^ ,
BOLT-
C E S ^ ^
VENT ASSEMBLY
VIEW IN CIRCLE N
TUBE-2267 VIEW P
3 REQUIRED
ARMOR-390, 428 ENGINES ONLY
BOLT- 3 REQUIRED
8 CYLINDER ENGINE REAR AXLE ONLY
CHECK BRAKE HOSE CLEARANCE „ TUBE ASSEMBLY-2268 L.H.
2A448
TO A L L COMPONENTS IN "
METAL/METAL JOUNCE AND
METAL/METAL REBOUND-
TUBE ASSEMBLY-2265
STANDARD AND POWER DRUM
3RAKES TUBE ASSEMBLY-2B1T2
POWER DISC BRAKES
MANUAL DISC
ROUTING FOR STATION WAGON ONLY

TUBE-2263 R.H.
PRESSURE DIFFERENTIAL TUBE-22.S5
VALVE
- GROMMET- 2
jl^REQUIRED
EWYN
TUBE
CHECK BRAKE HOSE CLEARANCE TO A L L VIEW IN CIRCLE U

COMPONENTS IN METAL/METAL JOUNCE,
TYPICAL 4 PLACES
METAL/METAL REBOUND AND FULL
INSIDE AND OUTSIDE TURNS HOSE-2A448
BRAKE HOSE-2078
VIEWX
TUBE-2263 R.H. 2264 L.H. TYPICAL 2 PLACES
DRUM BRAKES
VIEW I N CIRCLE Y TUBE-2263 R.H
TYPICAL 2 PLACES 2264 L.H.
REINFORCEMENT ASSEMBLY-2B222
LIP APPLY ESB-M4632-A SEALER AROUND
STUDS AND SCREW HOLE ON
TUBE ASSEMBLY-226J)
FLOOR PAN SIDE
GASKET-2149 2 REQUIRED
VIEW IN CIRCLE W VIEW R
TYPICAL 2 PLACES TUBE TUBE
DRUM BRAKES VIEW IN CIRCLE M
POWER DISC BRAKES
BRAKE HOSE MUST BE ASSEMBLED

WITH WHEELS STRAIGHT AHEAD.
STRIPE ON HOLE HOSE ASSEMBLY
MUST SHOW NO EVIDENCE OF TWIST. H 1559-C
—Service Brake System—Fairlane, Montego and Falcon

TUBE-2263 ASSY R.H.
PRESSURE IMPULSE 2264 ASSY L.H.
VALVE
TUBE-2A040 TUBE-2267
TUBE-2B253
PRESSURE
DIFFERENTIAL VIEWX
VALVE 427 & 428 ENGINES 382410-S2
ALL EXCEPT
TUBE-2265
200 ENGINE
PROPORTIONING
VALVE TUBE-2267
TUBE-2B112 \ TUBE-2263
L.H. FENDER APRON REF.
VIEWP
FOR POWER DISC BRAKES
TUBJ,-2268
HOSE-2A448
VIEWY
ALL EXCEPT 200 ENGINE
TUBE-2B253
TUBE-
TUBE-2265
TUBE-22 64 PRESSURE DIFFERENTIAL

VALVE -2B257
VIEWS L&M //
TUBE-2B269 BODY CROSSMEMBER
VIEW IN CIRCLE V
TUBE-2265 TYPICAL 4 PLACES HOSE-2A448
L.H. FENDER APRON REF.

VIEWW
VIEWR
FOR DRUM BRAKES VIEW IN CIRCLE U
VIEW IN CIRCLE T
VIEW IN CIRCLE S VIEWN

TYPICAL 4 PLACES
H1640-A
FIG. 19—Service Brake System—Mustang and Cougar

TUBE ASSEMBLY-2B255
PART OF AXLE ASSEMBLY
6
HOSE ASSEMBLY-2A448
FRAME
VIEW IN CIRCLES V
FUEL LINE TUBE ASSEMBLY-2267
CLIP (4 REQUfRED)
CHECK BRAKE HOSE

CLIP (3 REQUIRED) CLEARANCE TO ALL
COMPONENTS IN
TUBE ASSEMBLY-2267 METAL/METAL JOUNCE
AND METAL/METAL
REBOUND.
BRAKE BOOSTER-2B195 TUBE ASSEMBLY-2B255
TUBE ASSEM3LY-2420 HOSE-2A047
TUBE ASSEMBLY BRAKE TUBE
[ 2268 ASSEMBLY
TUBE ASSEMBLY 2267 R.R. BRAKE TUBE
2263 TUBE-2263-C * ASSEMBLY
VIEW IN CIRCLES X w
Q
7T
COVER-2A487
PEDAL PAD-2457
BRAKE PEDAL-2455
USE EXISTING NUTS

3
CHECK BRAKE HOSE
CLEARANCE TO ALL COMPONENTS
IN METAL/METAL JOUNCE
METAL/METAL REBOUND AND FULL
INSIDE AND OUTSIDE TURNS.
TUBE ASSEMBLY
TUBE ASSEMBLY 2325r
2264 L.H. 2263 R.H. TUBE ASSEMBLY BOLT-381877-S2
2B171-C R.H. CLIP-382088-S2 (3REQUIRED)
23218-C L.H. (3 REQUIRED)
ALL CONNECTIONS, TUBES, MASTER

TUBE ASSY.-2A040 CYLINDER AND FITTINGS MUST BE
PRESSURE IMPULSE FREE OF FLUID LEAKAGE WHEN
VALVE CHECKED AFTER ROAD TEST.
TUBE ASSY.-2B253
ALL BRAKE LINES, FITTINGS AND
TUBE ASSEMBLY FLEXIBLE HOSES MUST BE KEPT FREE
2B255 OF FOREIGN MATERIAL BEFORE
GASKET-2149 PROPORTIONING AND DURING ASSEMBLY OPERATIONS.
(4 REQUIRED) VALVE-2B328
#LUBRICATE PIVOTS
CLIP-381799-S2 BE LEAKPROOF
2REQUIRED
180°APART TUBE ASSEMBLY-2B255
O
BOLT
2 REQUIRED
TUBE ASSY. -2264
6
BRACKET ASSY.-2B328
H 1540-C
FIG. 20—Service Brake System—Thunderbird, Continental Mark

BOLT-381877
TUBE-2267
BRACKET-2A448
TUBE-2268
VIEW IN CIRCLE X
TYPICAL 3 PLACES BEND CLIPS TO RETAIN
TUBE ASSEMBLY-2263 TUBE-2267 TUBES AT ASSEMBLY
TUBE ASSEMBLY-2B162 5 PLACES
VIEWN
TUBE ASSEMBLY-2264 CHECK BRAKE HOSE CLEARANCE
TO A L L COMPONENTS IN METAL/METAL
JOUNCE AND METAL/METAL REBOUND
BOOSTER ASSEMBLY-2B195
TUBE-2268 HOSE-2A448
PULLOUT WHILE BLEEDING

BRAKE SYSTEM-USE CARE TUBE-2A280
NOT TO BEND PIN
TUBE-2420
VIEWP
DIFFERENTIAL VALVE-C8VA
VIEW IN CIRCLE M
SHIELD-2A337
TUBE-2A280
PRESSURE DIFFERENTIAL TUBE-2A280

VALVE ASSEMBLY-C8VA-2B328-C
TUBE-2A280
TUBE ASSEMBLY-2264 VIEW IN CIRCLE S
BRACKET-2082 R.H. TYPICAL 4 PLACES VIEWR
-2AO56 L.H.
CLIP-97502
2 REQUIRED
PROPORTIONING
VALVE ASSEMBLY
357444-S 2 REQUIRED
TO CALIPER ASSEMBLY STOP LAMPS MUST LIGHT WITH MAXIMUM FOOT
PEDAL EFFORT OF 4 POUNDS AND WITHOUT AUDIBLE
SOUND FROM THE SWITCH UNDER NORMAL OPERATION.
ALL BRAKE LINES, FITTINGS AND FLEXIBLE HOSES
HOSE-2B171 R.H. WASHER-2149 2 REQUIRED
MUST BE KEPT FREE OF FOREIGN MATERIAL BEFORE
-2B218 L.H. AND DURING ASSEMBLY OPERATIONS.
BRACKET-2B266
TUBE-2B166 R.H. A L L CONNECT IONS, TUBES, MASTER CYLINDER AND
V1EWU -2B168 L.H. FITTINGS MUST BE FREE OF FLUID LEAKAGE.
VIEWV
H 1528-C
FIG. 21—Service Brake System—Lincoln Continental

02-02-16 Brake System 02-02-16
fitting that connects the tube to the BRAKE BACKING PLATE BLEEDER SCREW FACING THIS DIRECTION^
cylinder. Do not pull the metal tube DRUM BRAKE BLEEDER SCREW
away from the cylinder. Pulling the
tube out of the cylinder connection
will bend the metal tube and make in-
stallation difficult. The tube will sepa- REMOVAL
rate from the cylinder when the cylin-
der is removed from the backing 1. Remove the wheel and brake
plate. drum. Disconnect the brake line from
4. On all except the front wheels on the brake cylinder.
Ford, Mercury, and Meteor models, 2. Remove the brake shoe and ad-
remove the wheel cylinder attaching juster assemblies and the wheel cylin-
bolts and lock washers and remove the der as outlined in this section. On the
cylinder. On the front wheel of Ford, rear wheels, disconnect the parking
Mercury and Meteor models, remove brake lever from the cable.
the nut and washer that attaches the 3. If the rear backing plate is being
cylinder to the anchor pin. Remove replaced, remove the axle shaft from
the cylinder from the anchor pin. the applicable rear axle as outlined in
H 1641-A
Group 4, Part 4-2— Rear Axle, Sec-
INSTALLATION tion 2, disengage parking brake cable FIG. 22—Floating Caliper
retainer from backing plate. Remove
Wipe the end(s) of the hydraulic Installed
the backing plate and gasket.
line to remove any foreign matter be- If the front backing plate is being 1. Remove the front wheel cover.
fore making connections. replaced, remove the bolts and nuts Remove the wheel and tire assembly
1. On all models except Ford, Mer- that secure the backing plate to the from the hub and rotor assembly. Be
cury and Meteor, to install a front front wheel spindle and remove the careful to avoid damage or interfer-
wheel cylinder, position the cylinder to plate and gasket. ence with the caliper splash shield or
the backing plate. Install the two lock bleeder screw fitting.
washers and attaching bolts. Torque INSTALLATION 2. Disconnect the brake line from
them to specifications. the caliper. Cap the hose to prevent
On Ford, Mercury and Meteor If a rear backing plate is to be re-
placed, position a new rear backing *he brake fluid from leaking from the
models, to install a front wheel cylin- master cylinder.
der, position the cylinder on the an- plate and gasket on the attaching
bolts in the axle housing flange. Insert 3. Remove the safety wire and the
chor pin against the backing plate. In- two bolts that attach the caliper as-
stall the washer and cylinder attaching parking brake cable into backing plate
and secure retaining fingers. Install sembly to the spindle.
nut on the anchor pin, and torque it 4. Lift the caliper assembly off the
to specification. Lock the washer re- the rear axle shaft for applicable rear
axle. Refer to Group 4, Part 4-2 — rotor and place it on the bench.
tainer securely.
2. Install a new copper gasket over Rear Axle, Section 2 for the proper
the hose fitting. Thread the hose into installation procedure. Installation
the cylinder and tighten it to specified 1. If the front brake backing plate
torque. is to be replaced, position a new front 1. Position the caliper assembly on
3. Engage the opposite end of the backing plate and gasket to the wheel the rotor, and mate the mounting bolt
hose to the bracket on the frame. In- spindle and install the attaching bolts holes in the caliper with those in the
stall the horseshoe-type retaining clip, and nuts. spindle. It may be necessary to push
and connect the brake tube to the 2. Install the wheel cylinder and the caliper piston into the cylinder
hose with the tube fitting nut. Tighten connect the brake line as outlined in bore to obtain clearance between the
the nut to specification with tool this section. shoe and lining assembly and the
1112-144. 3. Install the brake shoe and ad- rotor.
4. To install a rear wheel cylinder, juster assemblies as outlined in this 2. Install the caliper to spindle at-
place the rear wheel cylinder into po- section. On a rear brake, connect the taching bolts and torque them to spe-
sition. Enter the tubing into the cylin- parking brake cable to the lever. cification. The upper bolt must be
der, and start the tube fitting nut into 4. Adjust the brake shoes (Section tightened first. Install the safety wire
the threads of the cylinder. 2), and install the brake drums and on the bolts and twist the wire ends at
5. Secure the cylinder to the back- wheels. Bleed the brake system and least five turns. Push the wire ends
ing plate by installing the attaching centralize the differential valve as out- against the spindle to avoid interfer-
bolts and lock washers. lined in Part 2-1, Section 2. ence with the brake hose and the
6. Tighten the tube fitting nut to steering stop. Check to insure that the
specification with tool 1112-144. DISC BRAKE CALIPER rotor runs squarely and centrally be-
7. Install the links in the ends of ASSEMBLY tween the two brake shoes.
the wheel cylinder, install the shoes 3. Position the brake hose fitting
and adjuster assemblies, and adjust with a new copper washer on each
the shoes as outlined in this section. ALL MODELS EXCEPT side of the fitting on the caliper as-
8. Adjust the brakes (Part 2-2, Sec- LINCOLN CONTINENTAL sembly. Install the bolts and torque to
tion 2). Install the brake drum and specification.
wheel. Bleed the brakes and centralize Removal 4. Bleed the brake system and cen-
the differential valve as outlined in tralize the differential valve as out-
Part 2-1, Section 2. Refer to Figs. 22 and 23. lined in Part 2-1. Check the master
02-02-17 Brake System 02-02-17
CALIPER PARTS
2B120 R.H.
2B121 L.H.
STABILIZER CALIPER ASS'Y

2B295 2B118 R.H.
2BU9L.H.
FAIRLANE, MONTEGO, FALCON,
INSULATOR SEAL
MUSTANG AND COUGAR
2B2 2B115
CUP " 2207
20310-S 2B164 BOOT
INNER
34806 S \ BEARING
w ANCHOR PLATE
CONE AND ROLLER 2B293 L.H.
1201 2B292 R.H.
CUP CONE AND ROLLER
1216
3105-R.H.
3106-L.H.
ROTOR SPLASH SHI

2K004-R.H.
2K005-L.H. GREASE SEAL
1190
ADJUSTING NUT
374504-S
COVER-1130
1102 H 1670-A
FIG. 23—Disc Brake—Disassembled—All Models Except Lincoln
cylinder fluid level and add the speci- LINCOLN CONTINENTAL Remove the wheel and tire assembly
fied fluid, as required. Pump the from the hub and rotor assembly. Be
brake pedal several times to actuate careful to avoid damage or interfer-
the piston seals and to position the Removal ence with the caliper splash shield,
shoe and lining assemblies. bleeder screw fitting or transfer tube.
5. Install the wheel and tire assem- Refer to Fig. 24. 2. Disconnect the steel brake line
bly and the wheel cover. transfer tube from the caliper (Fig.
6. Road test the vehicle. 1. Remove the front wheel cover. 21). Leave the steel tube connected to
CALI PER PARTS-2B120-R.H. -2B121-L.H.
INBOARD HOUSING
CLIP
PISTON SEALS (4)-2B115
CALIPER ASSEMBLY 34811-S

/ P I S T O N S ( 4 ) -2196 OUTBOARD HOUSING
*2B118-R.H.
•2B119-L.H. T BOOTS (4) 2207
SPINDLE 379726-S
34806-S INNER BEARING SHOE AND LINING

CONE AND ROLLER ASSEMBLIES -2018
1201
GASKET
2B16
3105-R.H. °
3106-L.H.
ROTOR SPLASH SHI EL
COVER-US'!
1102 H 1650-A
FIG. 24—Disc Brake Disassembled—Lincoln Continental

02-02-18 Brake System 02-02-18
the brake hose connector and bracket the hub and rotor assembly. at least five turns. Push the wire ends
assembly. 2. Remove the caliper from the ve- against the spindle to avoid interfer-
3. Remove the two bolts retaining hicle following the procedures outlined ence with the brake hose and the
the brake hose bracket and caliper as- under Disc Brake Caliper Assembly. steering stop.
sembly to the spindle. Take care to 3. To facilitate removal of the cali- 8. With moderate pressure applied
avoid loosening the bridge bolts that per assemblies, the piston may have to to the brake pedal, torque the stabiliz-
hold the two halves of the caliper to- be pushed into its bore. Apply a er attaching screws and caliper locat-
gether. steady inward pressure against the ing pins to specification.
4. Lift the caliper assembly off the inner shoe and lining assembly. Main-
rotor and place it on the bench. tain the pressure for at least a minute. LINCOLN CONTINENTAL
4. Slide the two outer shoe retain-
Installation ing clips off the retaining pins (Fig.
23). Removal
1. If the caliper assembly is to be
5. Remove the two retaining pins
replaced, transfer the steel tubing and
from the outer shoe, then remove the
the bleeder screw to the new caliper. 1. Remove the wheel and tire as-
shoe from the stationary caliper.
2. Position the caliper assembly on sembly from the hub and rotor assem-
6. Slide the inner brake shoe out-
the rotor, and mate the mounting bolt bly. Be careful to avoid damage or in-
holes in the caliper with those in the ward until it is free of the hold-down
springs, then remove the brake shoe. terference with the caliper splash
spindle. It may be necessary to push shield, bleeder screw fitting or transfer
the caliper pistons into the cylinder 7. Remove the caliper locating pins
and stabilizer attaching bolts, then re- tube.
bores to obtain clearance between the 2. Remove the two bolts that retain
shoe and lining assembly and the move and discard the stabilizer or sta-
bilizers. the caliper splash shield, and remove
rotor. The shoe and lining assemblies the shield (Fig. 4).
should be seated properly on the 8. Remove the locating pin insula-
tors from the anchor plate. 3. To facilitate removal and instal-
bridges. lation of the shoe and lining assem-
3. Install the caliper to spindle re- Installation blies, the pistons must be pushed into
taining bolts and torque them to spec- their bores. Apply a steady inward
ification. Check to insure that the pressure against each shoe and lining
rotor runs squarely and centrally be- When installing new shoes and lin- assembly toward its respective caliper
tween the two halves of the caliper. ings it will be necessary to force the
housing on each side of the rotor (Fig.
These should be approximately 0.090- piston to the bottom of its bore.
6). Maintain the pressure for at least
0.120 inch clearance between the cali- Apply sufficient pressure to overcome
a minute. If the pistons will not go ifi
per and the rotor outside diameter the grip of the piston seal on the pis-
easily, force them in with water pump
(Fig. 6). ton.
pliers.
4. Position the steel transfer tube 1. Install new caliper locating pin
4. Grasp the metal flange on the
brake hose bracket and caliper assem- insulators in the anchor plate.
outer end of the shoe with two pairs
bly to the spindle. Install the retaining 2. Position the caliper assembly in
of pliers and pull the shoe out of the
bolts then torque them to specifica- the anchor plate.
caliper (Fig. 25).
tion. 3. Position the new stabilizer or
5. Connect the front wheel steel stabilizers and install the caliper locat-
ing pins to engage approximately four Installation
transfer tube from the caliper to the
front brake hose connector. Check the threads. 1. Position a new shoe and lining
hose for proper installation (Fig. 21). If the caliper locating pins are rust- assembly on each side of the rotor so
6. Bleed the brake system and cen- ed or corroded they should be re- that the lining faces the rotor. Be sure
tralize the differential valve as out- placed.
lined in Part 2-1. Check the master Apply water or isopropyl alcohol to
cylinder fluid level and add the speci- the caliper locating pins before instal-
fied fluid, as required. Pump the lation. Oil or grease must not be used
brake pedal several times to actuate on the locating pins. AB
the piston seals and to position the 4. Position the outer brake shoe on
shoe and lining assemblies. the caliper and install the two retain-
7. Install the wheel and tire assem- ing pins and clips.
bly and the wheel cover. 5. Install the inner brake shoe so
8. Road test the vehicle. that the ears of shoe are on top of the
anchor plate bosses and under the
shoe hold-down springs.
DISC BRAKE SHOE AND 6. Position the shoe and lining
LINING assemblies so that the caliper assem-
bly can be placed over the rotor. Ro- AB
ALL MODELS EXCEPT tate a hammer handle between the lin-

LINCOLN CONTINENTAL ings to reset the stabilizers. USE S E C O N D
7. Install the caliper assembly over P A I R OF
PLIERS HERE
the rotor and on the spindle. Install H 1651 A
the two caliper attaching bolts, and
Removal torque them to specifications. The FIG. 25—Removing Disc Brake
upper bolt must be tightened first. In- Shoe and Lining Assembly—
1. Remove the wheel and tire from stall the safety wire and twist the ends Lincoln Continental
02-02-19 Brake System 02-02-19
that the tabs on the shoe flanges seat fied grease (M-1C75B), and install the Removal in the foregoing procedure
fully against the caliper bridges (Fig. inner bearing cone and roller assembly (it is not necessary to disconnect hy-
25). in the inner cup. Pack grease lightly draulic connections).
2. Install the caliper splash shield between the lips of a new grease seal 2. Remove the three bolts that at-
and secure the shield to the caliper and install the seal (Figs. 23 and 24). tach the splash shield to the spindle,
with two retaining bolts (Fig. 4). If the original rotor is being in- and remove the shield (Figs. 23 and
3. Pump the brake pedal several stalled, make sure that the grease in 24).
times until a firm pedal is obtained the hub is clean and adequate, that 3. Remove and discard the splash
and the shoe and lining assemblies are the inner bearing and grease seal are shield to spindle gasket.
properly seated. lubricated and in good condition, and
4. Install the wheel and tire assem- that the rotor braking surfaces are INSTALLATION
bly on the hub and rotor assembly. clean.
5. Check and refill the master cyl- 2. Install the hub and rotor assem- 1. Install a new splash shield to
inder reservoir with specified brake bly on the spindle. spindle gasket.
fluid as required. 3. Lubricate and install the outer 2. If the shield is bent, straighten it
6. Road test the car. wheel bearing, washer and adjusting out before installation. Position the
It should not be necessary to bleed nut. shield to the mounting bracket, install
the system after a shoe and lining re- 4. Adjust the wheel bearings to the attaching bolts, nuts and torque
placement. specification, and then install the nut them to specification.
lock, cotter pin, and grease cap. The 3. Install the hub and rotor assem-
FRONT WHEEL HUB AND wheel bearing adjustment is especially bly and the caliper as outlined under
ROTOR A S S E M B L Y -
important with disc brakes. Installation in the foregoing proce-
5. Mount the caliper assembly on dure.
DISC BRAKES the spindle following the Disc Brake
Caliper Assembly Installation proce-
DUAL MASTER CYLINDER—
dure in this section.
REMOVAL N O N POWER BRAKES
DISC BRAKE ROTOR

1. Remove the wheel and tire from FORD, MERCURY
SPLASH SHIELD
the hub (Figs. 23 and 24). Be careful AND METEOR
to avoid damage or interference with
the bleeder screw fitting. On Lincoln REMOVAL
Removal
Continental models be careful to avoid
damage to the caliper splash shield or 1. Remove the caliper and the hub
transfer tube. and rotor assembly as outlined under Refer to Fig. 26.
2. Remove the caliper assembly
from the spindle and the rotor. If the
caliper does not require servicing, it is
not necessary to disconnect the brake BUSHING
hose or remove the caliper from the
vehicle. Position the caliper out of the
way, and support it with a wire to
avoid damaging the caliper or stretch-
ing the hose. Insert a clean cardboard
spacer between the linings to prevent
the piston from coming out of the cyl-
inder bore while the caliper is re-
moved.
Handle the rotor and caliper assem-
blies in such a way as to avoid defor-
mation of the rotor and nicking,
scratching or contamination of the
brake linings.
3. Remove the grease cap from the
hub. Remove the cotter pin, nut lock,
the spindle. Remove the outer bearing
cone and roller assembly.
4. Remove the hub and rotor as-
sembly from the spindle.
HAIRPIN
RETAINER
INSTALLATION BUSHING
STOPLIGHT SWITCH
13480 HI 637-A
1. If the rotor is being replaced, re-
move the protective coating from the
new rotor with carburetor degreaser. FIG. 26—Dual Master Cylinder Installation— Non Power Brakes
Pack a new set of bearings with speci- Ford, Mercury, and Meteor
02-02-20 Brake System 02-02-20
1. Disconnect the stoplight switch FAIRLANE, MONTEGO, Installation

wires at the connector. Remove the FALCON, MUSTANG AND
spring retainer. Slide the stop light COUGAR Refer to Figs. 27 and 28.
switch off the brake pedal pin just far 1. Position the boot on tie push
enough to clear the end of the pin, rod and secure the boot to the master
then liftfthe switch straight upward Removal
cylinder. Carefully insert the master
from the pin. Use care to avoid switch cylinder push rod and boot through
damage during removal. Refer to Figs. 27 and 28.
the dash panel opening.
2. Slide the master cylinder push 2. On Fairlane, Falcon or Montego
1. Working from inside the vehicle
rod and the nylon washers and bush- models, position the gasket and mas-
below the instrument panel, disconnect
ings off the brake pedal pin. ter cylinder on the mounting studs on
the master cylinder push rod from the
3. Remove the brake tube from the the dash panel. Install the lock nuts
brake pedal assembly. The push rod
primary and secondary outlet ports of on the studs at the dash panel and
cannot be removed from the master
the master cylinder. torque them to specification.
cylinder.
4. Remove the cap screws and lock-
2. Disconnect the stoplight switch 3. On Mustang or Cougar models,
washers that secure the master cylin-
wires at the connector. Remove the position the gasket and master cylin-
der to the dirSh panel and lift the cyl-
hairpin retainer. Slide the stop light der on the dash panel. Install the re-
inder forward and upward from the
switch off the brake pedal pin just far taining screws and torque them to
vehicle.
enough to clear the end of the pin, specification. Coat the nylon bushings
then lift the switch straight upward with SAE 10W oil. Install the nylon
from the pin. Use care to avoid switch washer and bushing on the brake
Installation damage during removal. pedal pin.
3. Slide the master cylinder push 4. Position the stop light switch on
rod and the nylon washers and bush- the brake pedal pin, install the nylon
1. Position the boot on the push ings off the brake pedal pin. bushing and washer and secure them
rod and secure the boot to the master 4. Remove the brake tubes from in position with the spring retainer.
cylinder. Carefully insert the master the primary and secondary outlet 5. Connect the wires at the stop
cylinder push rod and boot through ports of the master cylinder. light switch connector.
the dash panel opening and position 5. Remove the lock nuts or cap 6. Connect the brake lines to the
the master cylinder on the panel. screw and lockwashers that secure the master cylinder and tighten to speci-
2. Install the cap screws at the dash master cylinder to the dash panel and fied torque.
panel and torque them to specifica- lift the cylinder forward and upward 7. Fill the master cylinder with the
tion. from the car. specified brake fluid to within 1/4
3. Coat the nylon bushings with
SAE 10W oil. Install the nylon wash-
er and bushing on the brake pedal pin.
4. Position the stop light switch on
the brake pedal pin, install the nylon
bushing and washer and secure them
in position with the spring retainer.
5. Connect the wires at the stop UPPER STUD SHAFT (AUTOf/lATIC
MASTER CYLINDER TRANSMISSION)
light switch connector. IDENTIFICATION CLIP
6. Connect the brake lines to the BRAKE PEDAL
BUSHING SUPPORT
master cylinder leaving the brake line
fittings loose.
7. Fill the master cylinder with the
specified brake fluid to within 1/4
inch of the top of the dual reservoirs.
Use Ford Brake Fluid— Extra Heavy
D u t y - P a r t Number C6AZ-19542-A
(ESA-M6C25-A) or equivalent for all
drum brake applications. The extra
heavy duty brake system fluid is col-
ored blue for identification. Do not
mix low temperature brake fluids with TUBE-2B253 CLUTCH
PEDA_
the specified fluid for the power disc
TUBE-2A040
brake system.
8. Bleed the dual-master cylinder STOP LITE BRAKE PEDAL
SWITCH
and the primary and secondary brake / 13480
LOWER STUD
systems. Centralize the pressure dif- MASTER CYLINDER
PUSH ROD
ferential valve. Refer to Hydraulic
System Bleeding and Centralizing of
the Differential Valve, Part 2-1, Sec-
tion 2 for proper procedure.
9. Operate the brakes several times, H 1556-C
then check for external hydraulic FIG. 27—Dual Master Cylinder Installation—Non Power Brake
leaks. Fairlane, Montego, and Falcon
02-02-21 Brake System 02-02-21
INSTALLATION
1. Before installing the m a t e r cyl-

inder, check the distance t; m the
outer end of the booster ass;. ,ihi\
push rod to the master .>',nder
mounting surface. Turn the nu->h rod
adjusting screw in or out as required
to obtain the specified length. Refer to
CLUTCH ASSIST Part 2-1, Section 2. Power Brake
SPRING
Master Cylinder Push Rod Adjust-
ment for the proper procedure.
2. Position the master cylinder as-
sembly over the booster push rod and
onto the two studs on the booster as-
sembly (Figs. 29 thru 3 7 ).
3. Install the attaching nuts and
lock washers and torque them to spec-
ifications.
4. Install the front and rear brake
tubes to the master cylinder outlet fit-
tings.
5. Fill the master cylinder with the
specified brake fluid to within 1/4
inch of the top o\ the dual reservoirs.
SHAFT
AUTOMATIC Use Ford Brake Fluid Fxtra Heavy
MASTER CYLINDER TRANSMISSION
2140
Duty Part Number C6AZ-19542-A
CLUTCH PEDAL (ESA-M6C25-A) for all brake appli-
BUMPER STOP H1638-A
cations. The extra htaw duty brake
fluid is colored blue for identification.
Do not mix low temperature brake
FIG. 28 —Dual Master Cylinder Installation—
fluids with the specified fluids for the
Non Power Brake—Mustang and Cougar disc brake svstem.
inch of the top of the dual reservoirs.
Use Ford Brake Fluid- Extra Heavy
Duty-Part Number C6AZ-19542-A
for all brake applications. The brake
fluid is colored blue for identification.
Do not mix low temperature brake CLIP
fluids with the specified fluid for the
brake system. W '0 AIR CONDITIONING
BUSHING
8. Bleed the dual-master cylinder
and the primary and secondary brake SHAFT
systems. Centralize the pressure dif-
ferential valve. Refer to Hydraulic
tion 2 for the proper procedure.
9. Operate the brakes several times,
then check for external hydraulic
leaks.
DUAL MASTER C Y L I N D E R -
POWER BRAKES
BUSHING
BRAKE PEDAL
REMOVAL
1. Remove the brake tubes from

the primary and secondary outlet SPACER
ports of the master cylinder (Figs. 29
thru 33).
2. Remove the two nuts and two
lock washers attaching the master cyl- H 1642-A
inder to the brake booster assembly.
3. Slide the master cylinder forward FIG. 29—Master Cylinder Installation- -Power Brake-
and upward from the vehicle. Ford, Mercury and Meteor
02-02-22 Brake System 02-02-22
6. Bleed the dual-master cylinder

BRAKE VACUUM BOOSTER -2005 and the primary and secondary brake
systems. Centralize the pressure dif-
ferential valve. Refer to H>draulic
tion 2 for the proper procedure.
7. Operate the brakes several times,
then check for external hydraulic
leaks.
PRESSURE DIFFERENTIAL
VALVE A N D PROPORTIONING
VALVE ASSEMBLY
REMOVAL
1. Disconnect the brake warning

AUTOMATIC I
TRANSMISSION light wire from the pressure differen-
HAIR PIN RETAINER tial valve assembly switch (Figs. 17
330699-S2 thru 21). To prevent damage to the
SPACER brake warning switch wire connector,
STOP LIGHT SWITCH-13480 CLUTCH
PEDAL expand the plastic lugs to allow re-
BUSHING ASSEMBLY
moval of the shellwire connector from
BUSHING
STANDARD PUSH ROD the switch body.
TRANSMISSION
BRAKE PEDAL ASSEMBLY
2. Loosen the tube nuts connecting
the primary and secondary inlet and
H 1557-C
outlet tubes at the pressure differential
valve assembly and remove the tubes.
FIG. 30—Master Cylinder Installation—Power Brake- 3. Remove the screw or screws re-
Fairlane, Montego and Falcon taining the pressure differential valve
assembly to the chassis and remove
the valve assembly.
4. On disc brake equipped vehicles,
place the pressure differential valve
assembly and mounting bracket in a
vise. Loosen the proportioning valve
ASSIST tube nuts at the differential valve and
SPRING BRACKET CLUTCH ASSIST
\ SPRING at the proportioning valve. Remove
BRAKE PEDAL the proportioning valve from the
SHAFT mounting bracket.
5. If the differential valve is to be
CLUTCH replaced, remove the brake warning
PEDAL lamp switch and install the switch in
the new differential valve. The pres-
sure differential valve assembly, the
brake warning lamp switch, and the
proportioning valve are separate units
and each is serviced as a separate as-
sembly only.
INSTALLATION
CLUTCH PEDAL 1. On disc brake equipped vehicles,

TO EQUALIZER ROD connect the proportioning valve inlet
and outlet tubes to the proportioning
valve and differential valve bodies.
HI643- A
Tighten the tube nuts to specification.
2. Mount the pressure differential
valve assembly on the chassis and in-
stall the attaching screw or screws.
3. Connect the primary and second-
ary inlet and outlet tubes to the pres-
FIG. 31—Master Cylinder Installation- sure differential valve assembly and
Power Brake—Mustang and Cougar tighten the tube nuts to specifications.
02-02-23 Brake System 02-02-23
4. Connect the shell-wire connector

to the brake warning lamp switch.
Make sure the plastic lugs on the con-
BOOSTER ASSEMBLY- 2005 nector hold the connector securely to
NUT-34444-S7
the switch.
HOSE 2A047 5. Bleed the brakes and centralize
the pressure differential valve.
PROPORTIONING VALVE
FORD, MERCURY
AND METEOR
On Ford, Mercury and Meteor

models, the proportioning valve must
be removed with the pressure differen-
tial valve. Use the procedure shown
above for replacement of the propor-
MASTER CYLINDER tioning valve.
IDENTIFICATION
BRAKE TUBE-2263 FAIRLANE, MONTEGO
AND FALCON
BRAKE TUBE -2264

Removal
PRESSURE DIFFERENTIAL BRAKE TUBE-2B255

VALVE ASSEMBLY-2B257
Refer to Fig. 18.
H 15S3-B 1. Disconnect the two brake lines at
FIG. 32—Master Cylinder Installation- the proportioning valve.
2. Remove the bolt retaining the
Thunderbird and Continental Mark III pressure differential valve bracket to
the fender apron.
3. Lift the proportioning valve
FLUID LEVEL IN MASTER
bracket from behind the pressure dif-
BUSH
CYLINDER MUST 3E FULL SLEEVE ferential valve bracket and remove the
TO 1/4 INCH FROM TOP
BOLT proportioning valve from the vehicle.
BRAKE SWITCH
13480
Installation
NUT (4 REQUIRED) -55768-S2
WASHER"(4 REQUIRED) -44726-S8
1. Position the proportioning valve
BOOSTER and bracket to the fender apron with
ASSEMBLY 2005
the proportioning valve bracket be-
MASTER CYLINDER 2WO tween the pressure differential valve
HOSE-2A047 BUSHING DIP IN bracket and the fender apron.
S.A.E. 10W MOTOR OIL
BEFORE ASSEMBLY 2. Connect the two brake lines at
the proportioning valve. Do not tight-
en.
3. Install the bolt retaining the two
PEDAL ASSEM6LY-2455
valve brackets to the fender apron.
COVER
4. Tighten the two brake line tube
BRAKE TUBE-2A040 nuts at the proportioning valve to
specifications.
REAR BRAKE TUBE -2B329
5. Bleed the brakes and centralize
PRESSURE DIFFERENTIAL the pressure differential valve.
VALVE ASSEMBLY-2B328
MUSTANG AND COUGAR

FRONT BRAKE TUBE-2B162
PROPORTIONING VALVE
MASTER CYLINDER Removal
IDENTIFICATION
Refer to Fig. 19.

H 1530-C
1. Disconnect the two brake lines at
the proportioning valve.
FIG. 33—Master Cylinder Installation—Lincoln Continental 2. Remove the bolt retaining the
02-02-24 Brake System 02-02-24
proportioning valve to the fender LINCOLN CONTINENTAL switch off from the brake pedal pin
apron and remove the proportioning just far enough for the switch outer
valve. hole to clear the pin, and then remove
Removal the switch from the pin and booster
Installation push rod. Be careful not to damage
the switch during removal. Slide the
Refer to Fig. 21. booster push rod and the nylon wash-
1. Position the proportioning valve 1. Disconnect the two brake lines at ers and bushing off the brake pedal
to the fender apron. the proportioning valve. pin (Figs. 29 thru 33).
2. Connect the two brake lines at 2. Loosen the bolt and nut on the 2. Open the hood and remove the
the proportioning valve. Do not tight- bracket retaining the proportioning master cylinder from the booster. Se-
en. valve to the chassis. cure it to one side without disturbing
3. Install the bolt retaining the pro- 3. Remove the proportioning valve the hydraulic lines. It is not necessary
portioning valve to the fender apron. from the bracket. to disconnect the brake lines, but care
4. Tighten the brake line tube nuts should be taken that the brake lines
at the proportioning valve to specifica- Installation are not deformed. Permanent defor-
tions. mation of brake lines can lead to tube
5. Bleed the brakes and centralize failure.
pressure differential valve. - 1. Position the proportioning valve
in the bracket and connect the two 3. Disconnect the manifold vacuum
brake lines. Do not tighten. hose or hoses from the booster unit.
2. Tighten the bolt and nut on the 4. R e m o v e the booster-to-dash
THUNDERBIRD AND bracket. panel attaching nuts or bolts (Figs. 29
CONTINENTAL MARK III 3. Tighten the tube nuts on the thru 33). Remove the booster and
brake lines at the proportioning valve bracket assembly from the dash panel,
to specifications. sliding the push rod link out from the
4. Bleed the brakes and centralize engine side of the dash panel.
Removal 5. On Fairlane, Montego, and Fal-
the pressure differential valve.
con models, remove the push rod link
Refer to Fig. 20. boot from the dash panel.
1. Disconnect the two hydraulic PRESSURE METERING VALVE—
brake lines at the master cylinder. LINCOLN CONTINENTAL
INSTALLATION
2. Remove the two nuts retaining
the master cylinder to the booster and
1. On Fairlane, Montego and Fal-
remove the master cylinder for clear- REMOVAL con models, install the push rod link
ance.
boot in the hole in the dash panel as
3. Disconnect the two brake lines at Refer to Fig. 21. shown in Fig. 23. Install the four
the proportioning valve. 1. Loosen the tube nuts connecting spacers on the mounting studs.
4. Remove the bolt and nut retain- the inlet and outlet tubes at the me- 2. Mount the booster and bracket
ing the proportioning valve to the tering valve, and remove the tubes.
pressure differential valve bracket and assembly to the dash panel by insert-
2. Remove the two screws retaining ing the push rod or push rod link in
remove the proportioning valve assem- the metering valve to the frame
bly. through the hole and boot in the dash
crossmember, and remove the me- p a n e l . Install the bracket-to-dash
tering valve. The metering valve is ser- panel attaching lock nuts or bolts
Installation viced as an assembly only. (Figs. 29 thru 33).
3. Connect the manifold vacuum
1. Transfer the bracket to the new INSTALLATION hose or hoses to the booster.
proportioning valve. 4. Before installing the master cyl-
2. Position the proportioning valve 1. Position the metering valve to inder, check the distance from the
assembly to the pressure differential the frame crossmember, and install outer end of the booster assembly
valve bracket. the retaining screws. push rod to master cylinder surface.
3. Connect the two brake lines to 2. Connect the inlet and outlet Turn the screw in or out to obtain the
the proportioning valve. Do not tight- tubes to the metering valve, and tight- specified length. Refer to Part 2-1,
en. en the tube nuts to specification. Section 2, Power Brake Master Cylin-
4. Install the bolt and nut retaining der Push Rod Adjustment. Install the
the proportioning valve to the pressure BRAKE BOOSTER master cylinder and torque the attach-
differential valve bracket. ing nuts to specifications.
5. Tighten the two brake line tube 5. Working from inside the vehicle
nuts at the proportioning valve to REMOVAL below the instrument panel, connect
specifications. the booster push rod link to the brake
6. Position the master cylinder to 1. Working from inside the\ vehicle pedal assembly. To do this, proceed as
the booster and install the nuts retain- below the instrument panel, disconnect follows:
ing the master cylinder to the booster. the booster push rod from the brake Install the inner nylon washer, the
7. Connect the two brake lines at pedal assembly. To do this, proceed as booster push rod, and the bushing on
the master cylinder and tighten the follows: the brake pedal pin. Position the
tube nuts to specifications. Disconnect the stop light switch switch so that it straddles the push
8. Bleed the brakes and centralize wires at the connector. Remove the rod with the switch slot on the pedal
the pressure differential valve. hairpin retainer. Slide the stop light pin and the switch outer hole just
02-02-25 Brake System 02-02-25
clearing the pin. Slide the switch com- 5. Check the Brake Pedal Free 6. Connect the stop light switch
pletely onto the pin, and install the Height and Travel Measurements, wires to the connector, and install the
nylon washer as shown in Figs. 29 Part 2-1, Section 1. wires to the retaining clip.
thru 33. Be careful not to bend or de- 7. Adjust the clutch pedal free play
form the switch. Secure these parts to FAIRLANE, MONTEGO AND (Group 5) to specification, if required.
the pin with the hairpin retainer. Con- FALCON—MANUAL-SHIFT 8. Check the Brake Pedal Free
nect the stop light switch wires to the TRANSMISSION Height and Travel Measurements
connector, and install the wires in the (Part 2-1, Section 1).
retaining clip.
Removal
MUSTANG AND COUGAR—
BRAKE PEDAL MANUAL-SHIFT
1. Remove the clutch pedal assist TRANSMISSION
spring.
2. D i s c o n n e c t the clutch pedal-
FORD, MERCURY to-equalizer rod at the clutch pedal by Removal
AND METEOR removing the retainer and bushing.
3. Disconnect the stop light switch
wires at the connector. 1. Disconnect the battery ground
Removal 4. Remove the switch retainer, and cable from the battery.
slide the stop light switch off the 2. Remove the steering column.
brake pedal pin just far enough for Refer to Part 3-4, Section 2 for pro-
the switch outer hole to clear the pin. cedure.
wires at the connector.
Then lower the switch away from the 3. On non-power brakes, remove
2. Remove the hairpin retainer.
pin. the two cap screws retaining the mas-
Slide the stop light switch off the
5. Slide the master cylinder or ter cylinder to the dash panel and re-
brake pedal pin just far enough for
booster push rod and the nylon wash- move the two cap screws retaining the
the switch outer hole to clear the pin,
ers and bushing off from the brake brake pedal support bracket to the
and then lift the switch straight up-
pedal pin (Figs. 27 and 30). dash panel. On power brakes remove
ward from the pin. Be careful not to
6. Remove the self-locking pin and the two cap screws retaining the
damage the switch during removal.
washer from the clutch and brake booster to the dash panel.
Slide the master cylinder or booster
push rod and the nylon washers and pedal shaft, then remove the clutch 4. Working inside the vehicle, se-
bushing off the brake pedal pin (Figs. pedal and shaft assembly, the brake cure the clutch pedal against the
26 and 29). pedal assembly, and the bushings from bumper stop with a small C-clamp as
the pedal support bracket (Figs. 27 shown in Figs. 28 and 31.
3. Remove the hairpin type retainer
and 30). 5. D i s c o n n e c t the clutch pedal-
and washer from the brake pedal
to-equalizer rod at the clutch pedal by
shaft, then remove the shaft, the brake
removing the retainer and bushing.
pedal and the bushings from the pedal Installation
support bracket. 6. Disconnect the stop light switch
1. Apply a coating of SAE 10 en- 7. Remove the switch retainer and
Installation gine oil to the bushings and locate all slide the stop light switch off the
bushings in their proper places on the brake pedal pin just far enough for
1. Apply a coating of SAE 10 En- clutch and brake pedal assemblies. the switch outer hole to clear the pin.
gine oil to the bushings and locate 2. Position the brake pedal to the Then lower the switch away from the
bushings in their proper places on the support bracket, then install the clutch pin. Remove the master cylinder or
pedal assembly and pedal support pedal and shaft assembly through the booster push rod, bushing and nylon
bracket (Figs. 26 and 29). support bracket and brake pedal as- washer from the brake pedal pin.
2. Position the brake pedal assem- sembly. Install the spring clip (Figs. 8. Remove the screw retaining the
bly to the support bracket, then install 27 and 30). pedal support bracket to the top inner
the pedal shaft through the support 3. Install the clutch pedal assist cowl bracket (Figs. 28 and 31).
bracket and brake pedal assembly. In- spring. 9. Remove the two sheet metal
stall the retainer. 4 . C o n n e c t t h e clutch pedal- screws retaining the pedal support
3. Install the inner nylon washer, to-equalizer rod to the clutch pedal bracket to the dash panel. On power
the master cylinder or booster push assembly with the bushing and the brakes remove the nuts from the
rod, and the bushing on the brake spring clip retainer. Apply SAE 10 brake booster studs.
pedal pin. Position the switch so that engine oil to the bushing. 10. Remove the two screws retain-
it straddles the push rod with the 5. Install the inner nylon washer, ing the pedal support bracket to the
switch slot on the pedal pin and the the master cylinder or booster push upper cowl brace and lower the pedal
switch outer hole just clearing the pin. rod, and the bushing on the brake support bracket away from the steer-
Slide the switch completely onto the pedal pin. Position the switch so that ing column studs.
pin, and install the nylon washer as it straddles the push rod with the 11. Remove the pedal support
shown in Figs. 26 and 29. Be careful switch slot on the pedal pin and the bracket assembly from the vehicle.
not to bend or deform the switch. Se- switch outer hole just clearing the pin. 12. Position the pedal and support
cure these parts to the pin with the Slide the switch completely onto the bracket assembly in a vise.
hairpin retainer. pin, and install the outer nylon washer 13. Remove the C-clamp to release
4. Connect the stop light switch as shown in Figs. 27 and 30. Secure the clutch pedal from its bumper stop
wires to the connector, and install the these parts to the pin with the self- and pivot the pedal away from the
wires in the retaining clip. locking pin. bumper.
02-02-26 Brake System 02-02-26
14. Remove the clutch pedal assist engine oil to the bushing. Remove the 3. Install the inner nylon washer,
spring. C-clamp from the clutch pedal. the master cylinder or booster push
15. On non-power brakes, remove 11. Working from the engine side rod, and the bushing on the brake
the retainer clip from the clutch and of the dash panel, on non-power pedal pin. Position the switch so that
brake pedal shaft, then remove the brakes, install the two cap screws at- it straddles the push rod with the
clutch pedal and shaft assembly, the taching the pedal support bracket to switch slot on the pedal pin, and the
brake pedal assembly, and the bush- the dash panel. Then install the two switch outer hole just clearing the pin.
ings from the pedal support bracket. screws attaching the master cylinder Slide the switch completely onto the
On power brakes, remove the retainer to the dash panel. On power brakes pin, and install the outer nylon washer
nut from the brake pedal shaft then install the cap screws retaining the as shown in Figs. 27, 28, 30 and 31.
remove the pedal shaft, the brake brake booster to the dash panel. Secure these parts to the pin with the
pedal assembly and the bushings from 12. Install the steering column. self-locking pin.
the pedal support bracket. Refer to Part 3-4, Section 2 for pro- 4. Connect the stop light switch
cedure. wires to the connector, and install the
Installation 13. Adjust the clutch pedal free wires in the retaining clip.
play (Group 5) to specification, if re- Check the Brake Pedal Free Height
quired. and Travel Measurements, Part 2,
1. Apply a coating of SAE 10 en- 14. Check the Brake Pedal Free Section 1.
gine oil to the bushings and locate all Height and Travel Measurements
bushings in their proper places on the (Part 2-1, Section 1). THUNDERBIRD AND
clutch and brake pedal assemblies.
15. Connect the ground cable to the C O N T I N E N T A L M A R K III
2. On non-power brakes, position battery.
the brake pedal to the pedal support
bracket, then install the clutch pedal FAIRLANE, MONTEGO, Removal
and shaft assembly through the sup-
FALCON, MUSTANG
port bracket and brake pedal assem- 1. Loosen the booster mounting
AND COUGAR-
bly. On power brakes position the nuts.
AUTOMATIC TRANSMISSION
brake pedal to the pedal support
bracket, then install the pedal shaft
and nut. Removal 3. Remove the hairpin retainer.
3. Install the clutch pedal assist Slide the stop light switch off from
spring and pivot the clutch pedal 1. Disconnect the stop light switch the brake pedal pin just far enough
against its bumper stop. Secure the for the switch outer hole to clear the
pedal to the stop with a small C- pin, and then lift the switch straight
2. Remove the self-locking pin and
clamp as shown in Figs. 28 and 31. upward from the pin. Slide the master
slide the stop light switch off the
4. Position the pedal support cylinder push rod and the nylon wash-
brake pedal pin just far enough for
bracket assembly to the dash panel, ers and bushing off from the brake
the switch outer hole to clear the pin.
and to the steering column retainer pedal pin (Fig. 32).
Then lower the switch away from the
studs. 4. Remove the pivot bolt and nut
pin. Slide the master cylinder or
5. Align the pedal support bracket that holds the pedal to the pedal sup-
booster push rod and the nylon wash-
holes with the holes in the dash panel port bracket. Remove the brake pedal
ers and bushing off from the brake
and install the two attaching sheet assembly from the pedal support
pedal pin (Figs. 27, 28, 30 and 31).
metal screws. On power brakes install bracket, and remove the bushings.
3. On all vehicles except Mustang
the nuts on the brake booster studs.
and Cougar with power brakes, re-
6. Install the two cap screws at-
move the self-locking pin and washer Installation
taching the pedal support bracket to
from the brake pedal shaft, then re-
the upper cowl bracket.
move the shaft, the brake pedal as-
7. Install the cap screw attaching sembly and the bushings from the 1. Apply a coating of SAE 10 en-
the pedal support bracket to the top gine oil to the bushings and locate all
pedal support bracket. On Mustang
inner cowl bracket (Figs. 28 and 31). the bushings in their proper places on
and C o u g a r vehicles with power
8. Install the inner nylon washer, the pedal assembly (Fig. 32).
brakes, remove the locknut and bolt
the master cylinder push rod, and the 2. Install the brake pedal assembly
from the pedal. Remove the pedal as-
bushing on the brake pedal pin. Posi- and bushings to the support bracket,
sembly from the support bracket (Fig.
tion the stop light switch so that it and then install the pivot bolt through
3).
straddles the push rod with the switch the support bracket and brake pedal
slot on the pedal pin and the switch assembly. Install the pivot bolt nut
outer hole just clearing the pin. Slide Installation and torque to specifications.
the switch completely onto the pin, 3. Install the inner nylon washer,
and install the outer nylon washer as 1. Apply a coating of SAE 10 en- the master cylinder push rod, and the
shown in Figs. 28 and 31. Secure gine oil to the bushings and locate all bushing on the brake pedal pin. Posi-
these parts to the pin with the self- the bushings in their proper places on tion the switch so that it straddles the
locking retainer. the pedal assembly and pedal support push rod with the switch slot on the
9. Connect the stop light switch bracket (Figs. 27, 28, 30 and 31). pedal pin and the switch outer hole
wires to the connector. 2. Position the brake pedal assem- just clearing the pin. Slide the switch
10. Connect the clutch pedal- bly to the support bracket, then install completely onto the pin, install the
to-equalizer rod to the clutch pedal the pedal shaft or bolt through the outer nylon washer as shown in Fig.
assembly with the bushing and the support bracket and brake pedal as- 32. Secure these parts to the pin with
spring clip retainer. Apply SAE 10 sembly. Install the retainer or locknut. the hairpin retainer.
02-02-27 Brake System 02-02-27
4. Connect the stop light switch the support bracket and pedal assem- and remove the cable from the rear of
wires to the connector, and install the bly. Install the pivot bolt nut and tor- the instrument panel.
wires in the retaining clip. que it to specification. 5. Remove the two nuts attaching
5. Torque the booster mounting 4. Install the inner nylon washer,the the control assembly to the dash
nuts to specifications. master cylinder push rod link, and the panel.
bushing on the brake pedal pin. Posi- 6. Remove the cap screw attaching
LINCOLN CONTINENTAL tion the switch so that it straddles the the control assembly to the cowl side
push rod link with the switch slot on bracket.
the pedal and the switch outer hole 7. Disconnect the hose to the park-
Removal just clearing the pin. Install the outer ing brake vacuum unit, if so equipped.
nylon washer as shown in Fig. 33. In- 8. Remove the front cable assembly
stall the hair-pin type retainer on the retainer clip from the cable assembly
1. Disconnect the battery ground brake pedal pin. and disconnect the cable ball from the
cable from the battery. 5. Connect the stop light switch control clevis.
2. It is necessary to obtain clear- wires to the connector, and install the 9. Remove the control assembly
ance to remove vacuum hoses and the wires in the retaining clip. from the vehicle.
electrical connector to the temperature 6. Position the wire harness and
heat control box. Remove the two clip on the temperature control box
screws retaining the relay to the fend- Installation
and install the retaining screw. Posi-
er and push the relay aside. Discon- tion the temperature control box to
nect the vacuum hoses and connector the dash panel and install the two re- 1. Position the control assembly in
at the heat control box. taining bolts. the vehicle.
3. Working under the instrument 7. Connect the vacuum lines and 2. Fit the cable assembly through
panel, disconnect the vacuum hoses, the electrical connector to the control its mounting hole and install the re-
wires and retaining clip from the tem- box. Position the wire harness to the taining clip. Connect the cable ball to
perature heat control box. Remove the control box and install the retaining the control clevis.
two screws securing the temperature clip. 3. Connect the vacuum hose to the
control box to the dash panel. 8. Position the wire harness shield parking brake unit, if so equipped.
4. Remove the lower control hous- and install two retaining bolts. 4. Install the attaching cap screw to
ing retaining screws (6). Disconnect 9. Connect the wire harnesses to the cowl side bracket. Do not tighten.
the wire harnesses at the lower control the lower control panel and install the 5. Install the two control assemb-
panel and place the panel aside. Re- retaining screws. ly-to-dash panel nuts. Tighten the nuts
move the wire harness shield. Remove 10. W o r k i n g within the engine and the cap screw to specifications.
the wire harness clip. Position the compartment, connect the wire con- 6. Insert the release cable into the
wire harness aside. Remove the tem- nector to the temperature heat control instrument panel and install the re-
perature control box and position it box. taining nut.
aside. 11. Position the relay to the fender 7. Install the release knob on the
5. Remove the hair-pin type retain- apron and install the retaining bolts. cable with the roll pin.
er. Slide the stop light switch off the 12. Connect the ground cable to the 8. Check the operation of the park-
brake pedal pin just far enough for battery. ing brake. Adjust the parking brake
the switch outer hole to clear the pin. 13. Check the brakes and light as required.
Lift the switch upward from the pin. switch for proper operation. Close the
Slide the master cylinder push rod, hood. FAIRLANE, MONTEGO
nylon washers and bushing off the AND FALCON
brake pedal pin.
6. Remove the pivot bolt and nut PARKING BRAKE CONTROL
that holds the pedal to the pedal sup- ASSEMBLY Removal
port bracket. Remove the brake pedal
assembly from the support bracket
Refer to Fig. 35.
and remove the bushings. FORD, MERCURY
7. If required, remove the brake 1. Make sure the parking brake is
AND METEOR
pedal pad retaining nuts and remove completely released.
the brake pedal pad. 2. Remove all tension from the rear
cables by backing off the jam nut and
Removal adjusting nut from the equalizer.
Installation 3. Working inside the vehicle, re-
Refer to Fig. 34. move the four bolts and one nut re-
1. If the brake pedal pad was retaining the left air vent and cable as-
moved, position the pad on the pedal. 1. Make sure the parking brake is sembly to the dash and instrument
Install the pad retaining nuts and tor- fully released. panels. Remove the vent assembly.
que them to specification. 2. Remove all tension from the rear 4. Remove the parking brake front
2. Apply SAE 10 engine oil to the cables by backing off the adjusting nut cable ball retaining clip from the clev-
bushings and locate all the bushings in from the equalizer. is.
their proper places on the pedal as- 3. Remove the roll pin that secures 5. Disconnect the cable ball from
sembly. the release knob to the cable and re- the notch in the brake clevis.
3. Install the brake pedal assembly move the knob. 6. Remove the three screws that at-
and bushings to the support bracket, 4. Remove the nut that secures the tach the control assembly to the left
and then install the pivot bolt through release cable to the instrument panel cowl inner side panel.
BRAKE PEDAL BRACKET CABLE MUST BE TIGHT
ON - 4 CROSSMEMBER
INSTRUMENT PANEL
.25 INSULATOR
.00 TO CLIP
VIEWZ CABLE AND HOUSING R.H.
VACUUM RELEASE
VIEWX
CABLE AND HOUSING L.H.
CLIP
CABLE AND HOUSING R.H.
INSTRUMENT PANEL CROSSMEMBER

LOWER SUSPENSION ARM
INTERMEDIATE CABLE
CONTROL CABLE
CONVERTIBLE ONLY
EQUALIZER PRONGS MUST BE SECURELY
LOCKED IN PLACE WITHIN
BRAKE DRUM
L.H. SHOWN R.H. TYPICAL
VIEWY
VIEWZ
MANUAL RELEASE
H1645-A
FIG. 34—Parking Brake System—Ford, Mercury and Meteor

02-02-29 Brake System 02-02-29
RETAINER-74277-S 2 REQUIRED
CONNECTOR-2A790
FAIRLANE, MONTEGO
SEDAN, HARD TOP AND
CONVERTIBLE
PARKING BRAKE
CONTROL ASSEMBLY-2780
STATION WAGON AND RANCHERO

ALL EXCEPT 390 ENGINE
H 1564-C
FIG. 35 — Parking Brake System—Fairlane, Montego and Falcon

02-02-30 Brake System 02-02-30
7. Disconnect the wire lead at the 3. Position the parking brake warn- LINCOLN CONTINENTAL
parking brake warning light switch ing light switch and install the attach-
and remove the control assembly. ing screw. Connect the parking brake
warning light switch wire lead (if vehi- Removal
Installation cle is so equipped).
4. Position the cable ball in the
notch in the brake clevis. Refer to Fig. 38.
1. Connect the wire lead to the
5. Check the operation of the park 1. Raise the vehicle on a hoist.
parking brake warning light switch.
ing brake. Adjust the parking brake. 2. Loosen the parking brake cable
2. Position the control assembly to
the cowl inner side panel and install a d j u s t i n g n u t , remove the return
the three attaching screws. spring and remove the cable ball end
3. Connect the ball-end of the park- from the equalizer.
THUNDERBIRD AND 3. Lower the vehicle.
ing brake front cable assembly to the CONTINENTAL MARK III
control assembly, and install the hair- 4. Disconnect the battery.
pin retainer. 5. Disconnect the wire harness con-
4. Position the cable ball in the nector and two vacuum hoses at the
notch in the brake clevis. Removal Automatic Temperature Control box.
5. Position the left air vent assem- 6. Working inside the vehicle, re-
bly to the dash and instrument panels. Refer to Fig. 37. move the windshield wiper control
Install the four bolts and one nut re- knob and bezel from the lower control
taining the air vent to the panels. 1. Remove the two nuts retaining panel.
6. Check the operation of the park- the control to the dash panel. 7. Remove the screws retaining the
ing brake. Adjust the parking brake. 2. Remove two screws from the left lower control panel. Lower the control
scuff plate. panel and disconnect wire harnesses
MUSTANG AND COUGAR 3. Remove one screw retaining the and vacuum hoses. Position the con-
left cowl trim panel and remove the trol panel aside.
panel. 8. Remove the screw retaining the
Removal 4. Remove the two screws retaining plastic wire cover and place 'the cover
the left air duct and remove the air aside.
duct. 9. Disconnect three vacuum hoses
Refer to Fig. 36. 5. Remove the two screws retaining and the wiring harness at the Auto-
the dimmer switch and position the matic Temperature Control box.
1. Make sure the parking brake is switch out of the way. 10. Remove the two screws retain-
completely released, 6. Remove the clip retaining the ing the Automatic Temperature Con-
2. Remove all tension from the rear cable assembly to the control. trol box to the dash panel and remove
cables by backing off the jam nut and 7. Disconnect the cable ball from the box for clearance.
adjusting nut from the equalizer. the control clevis. 11. Disconnect the ball end of the
3. Disconnect the wire lead at the 8. Disconnect the vacuum hose at cable from the control clevis.
parking brake warning light switch (if the brake release. 12. Remove the four bolts retaining
so equipped). 9. Remove the bolt retaining the the control to the dash panel and
4. Remove the parking brake front control to the cowl side bracket and lower instrument panel flange.
cable ball retaining clip from the clev- remove the control. 13. Disconnect the vacuum release
is. hose from the control and remove the
5. Remove the parking brake warn- Installation control assembly from the vehicle.
ing light switch and attaching screw (if
so equipped). Installation
6. Disconnect the cable ball from 1. Position the parking brake con-
the notch in the brake clevis. trol in the vehicle.
7. Remove the three screws that at- 2. Install the cable assembly in the 1. Position the control assembly to
tach the control assembly to the left control and connect the cable ball to the dash panel and instrument panel
cowl inner side panel. the control clevis. flange and install the four retaining
8. Pull the control away from the 3. Install the clip retaining the screws.
cowl, panel. Remove the hair-pin re- cable to the control. 2. Connect the vacuum release hose
tainer securing the front cable assem- 4. Install the bolt retaining the con- to the control assembly.
bly to the control assembly. Remove trol to the cowl side bracket. 3. Connect the cable ball to the
the control assembly 5. Connect the vacuum hose to the control clevis.
parking brake release vacuum motor. 4. Position the Automatic Temper-
6. Position the dimmer switch and ature Control box to the dash panel
Installation install the retaining screws. and install the retaining screws.
7. Position the air duct and install 5. Connect the wiring harness and
1. Connect the ball-end of the park- the retaining screws. vacuum hoses to the Automatic Tem-
ing brake front cable assembly to the 8. Position the cowl trim panel and perature Control box.
control assembly, and install the hair- install the retaining screw. 6. Position the plastic wire covei
pin retainer. 9. Install the two scuff plate screws. and install the retaining screw.
2. Position the control assembly to 10. Install the two nuts retaining 7. Connect the wire harnesses and
the cowl inner side panel and install the control to the dash panel. vacuum lines to the lower control
the three attaching screws. 11. Adjust the parking brakf panel and position the panel to the in
CABLE ASSEMBLY
2A635 R.H.
DUAL EXHAUST PRONGS MUST BE SECURELY

LOCKED IN PLACE
EXTENSION SIDE MEMBER
VIEW IN CIRCLE R
EQUALIZER TYPICAL 2 PLACES
2A602 CONVERTIBLE ONLY
VIEWY
VIEWZ
HI646-A
36—Parking Brake System—Mustang and Cougar

BOLT PARKING BRAKE PARKING BRAKE REAR
I A RKING RRAKE
2-REQUIRED CONTROL ASSEMBLY HONT CABLE-2853 CABLE-2A635 2 REQUIRED
2780 2.00 ARMOR
ADJUSTING NUT
EQUALIZER-2A602 BRACKET-2A813
2628
SCREW
CLIP 4 REQUIRED
VIEWY 2A814 ASSEMBLY
BOLT-2 REQUIRED 2A706
2853 ASSEMBLY VIEWX
VIEWZ 8~- HAIRPIN RETAINER-74277-S
PARKING BRAKE
PARKING BRAKE FRONT CABLE-2853 REAR CABLE-2A635
BOLT-374032-S 2 REQUIRED
7-12 LB. FT. APPLY CAULKING CORD
(AB19560-A) OVER HEADS OF SCREWS
AFTER ASSEMBLY.
PARKING BRAKE
REAR CABLE-2A635 HAIRPIN RETAINER
( 2 REQUIRED
WIRING HARNESS
V1EWW
HOSE
BRAKE SUPPORT
PARKING BRAKE
REAR CABLE-2A635
CLIP 2 REQUIRED
PARKING BRAKE PRONGS MUST BE SECURELY VtEWU

REAR CABLE-2A635 LOCKED IN PLACE
BOLT 2 REQUIRED
VIEWY
VIEWT
CABLE WllHIN BRAKE DRUM

H 1529-B
FIG. 38 Parking Brake System—Lincoln Continental

PARKING BRAKE CONTROL PARKING BRAKE CABLE ASSEMBLY-2A635 R.H.
TO-ACTUATOR CABLE AND 2A635 PARKING BRAKE CABLE
CONDUIT ASSEMBLY-2853 NO. 4 CROSSMEMBER ASSEMBLY R.H. TO BE POSITIONED
NO. 4 CROSSMEMBER WITH RUBBER LOCATERS CENTERED
IN 2649 AND 2A 720 BRACKETS
BRACKET
(2 REQUIRED)
PARKING BRAKE
CABLE ASSEMBLY
2A635 R.H.
BOLT-382062-S2
(2 REQUIRED)
EQUALIZER.TO-ACTUATOR
CABLE ASSEMBLY-2A815
2A635 ASSEMBLY R.H.
ACTUATOR ASSEMBLY-2A7U
CABLE WITHIN BRAKE DRUM

L.H. SHOWN (R.H. TYPICAL)
PARKING BRAKE
CABLE ASSEMBLY
2780 ASSEMBLY 2A809 U H .
2795
2A809
ASSEMBLY
L.H.
PRONGS MUST BE
SECURELY LOCKED IN PLACE
PARKING BRAKE CABLE

PARKING BRAKE
NUT-379930-S2 ASSEMBLY-2A809 L.H.
CONTROL ASSEMBLY-2780
(2 REQUIRED)
12-18 LB. FT.
BOLT-378735-S2
(2 REQUIRED)
LB. FT.
2A791 (2 REQUIRED)
PARKING BRAKE
CABLE ASSEMBLY NUT-2A812
2A809 L.H.
EQUALIZER-2A602
CONTROL-TO-ACTUATOR PARKING BRAKE 381877-S2

CABLE AND CONDUIT CABLE ASSEMBLY
ASSEMBLY-2853 2A635 R.H.
BOLT-378180-S
12-18 LB. FT. EQUALIZER.TO-ACTUATOR
RETAINER-74277-S CABLE ASSEMBLY-2A815 H1542-C
FIG. 37—Parking Brake System—Thunderbird and Continental Mark III

02-02-34 Brake System 02-02-34
strument panel. Install the lower con- THUNDERBIRD AND PARKING BRAKE
trol panel retaining screws. CONTINENTAL MARK III EQUALIZER TO CONTROL
8. Install the windshield wiper con- CABLE
trol bezel and knob.
9. Working in the engine compart-
FAIRLANE, MONTEGO
ment connect the wire harness and Removal AND FALCON
vacuum hoses to the Automatic Tem-
perature Control box.
Removal
10. Connect the battery cable. Refer to Fig. 37.
11. Raise the vehicle on a hoist. 1. Partially raise the vehicle.
12. Connect the cable ball to the 2. Back off the adjusting nut at the Refer to Fig. 35.
equalizer and install the equalizer equalizer to relieve the tension on the 1. Make certain the parking brake
lever return ^spring. cable. is fully released.
13. Adjust the parking brake cable 2. Raise the vehicle on a hoist. Re-
3. Remove the spring at the actua-
tension. move the two nuts that attach the
tor lever and disconnect the control
14. Lower the vehicle. cable to the equalizer. Remove the
cable from the clevis on the lever.
equalizer, spring seat and spring.
4. Remove the clip retaining the
3. Remove the hairpin retainer
control cable assembly to thq*. frame
holding the cable assembly to i:he body
PARKING BRAKE ACTUATOR— bracket. B
bracket and remove the cable from
5. Attach a length of wire to the
TO CONTROL CABLE the slot in the bracket.
control cable.
4. Lower the vehicle partially.
6. Working inside the vehicle re-
5. Remove the hairpin retainer
move two screws retaining the left
FORD, MERCURY which retains the cable assembly to
scuff plate.
AND METEOR the control.
7. Remove one screw and remove
6. Remove the cable bolt retaining
the left cowl side trim panel.
clip from the control clevis and dis-
8. Remove the two screws retaining
connect the cable ball from the clevis.
Removed the left air duct to the inner panel and
7. Pull the cable down through the
remove the air duct.
opening in the floor pan and frame
1. Raise the vehicle on a hoist. 9. Remove the two screws retaining
side rail.
2. Loosen the actuator lever to the dimmer switch and position the
equalizer cable adjusting nut at the dimmer switch back out of the way.
10. Remove the clip retaining the Installation
equalizer (Fig. 34).
3. Disconnect the cable ball from cable assembly to the control and re-
move the cable ball from the control 1. Route the new cable through
the clevis on the actuator lever. the frame side rail and up through
4. Remove spring clip that retains clevis.
11. Pull the cable up through the the opening in the floor pan. Pull the
the cable to the frame. cable up into position.
5. From inside of passenger com- opening in the dash panel and remove
the cable from the length of wire. 2. Connect the cable ball in the con-
partment, remove spring clip that re- trol clevis.
tains the cable to the parking brake 3. Insert the cable housing into
control. Disconnect the cable ball the control and install the hairpin re-
from the control assembly. Installation
tainer.
6. Remove the cable assembly from 4. Raise the vehicle.
the vehicle. 1. Attach the cable to the length of
5. Position the cable in the body
wire and pull the cable down through
bracket and install the hairpin re-
the opening in the dash panel.
tainer.
2. Position the upper end of the
Installation 6. Position the spring, spring re-
control cable to the control. Connect
tainer and equalizer on the cable and
the cable ball to the control clevis and
install the two nuts.
1. Position the cable through the install the clip retaining the cable
7. Adjust the parking brake.
provided openings and in the approxi- housing to the control.
mate final installation position. 3. Remove the length of wire from
2. Install the hairpin retainer on the the cable assembly and position the MUSTANG AND COUGAR
cable at the frame crossmember. cable in the frame bracket. Install the
3. Connect the ball end of the cable retainer, Removal
to the parking brake control. Install 4. Connect the cable ball to the
the cable-to-control hairpin retaining clevis on the actuator lever and install Refer to Fig. 36.
clip. the actuator lever spring. 1. Make certain the parking brake
4. Position the cable seal at the 5. Adjust the parking brake. is fully released.
dash panel, and slide the retaining clip 6. Reposition the dimmer switch 2. Raise the vehicle on a hoist. Re-
upward to seal the cable at the dash and install the retaining screws. move the two nuts that attach the
opening. 7. Position the air duct to the inner cable to the equalizer. Remove the
5. Connect the ball end of the cable panel and install the retaining screws. equalizer spring seat and spring.
to the clevis on the actuator lever. & Position the cowl side trim panel 3. Remove the hairpin retainer
6. Adjust the parking brake (Part and install the retaining screw. holding the cable assembly to the
2-1, Section 2). 9. Install the two screws in the body bracket and pull the cable out
7. Lower vehicle on hoist. scuff plate. of the side rail access holes.
02-02-35 Brake System 02-02-35
4. Attach a wire to the end of the Installation PARKING BRAKE EQUALIZER

cable to assist in routing new cable. TO REAR WHEEL CABLE
5. Lower the vehicle. 1. Route the parking brake control
6. Remove the parking brake front to equalizer cable to the control as-
cable ball retaining clip from the sembly and the equalizer, and install FORD, MERCURY,
clevis. the two bolts that retain the cable METEOR, THUNDERBIRD
7. Disconnect the cable ball from to the dash panel (Fig. 38). AND CONTINENTAL
the notch in the brake clevis. 2. Install the left fror%/ender apron MARK III
8.. Remove the hairpin retainer and splash shield and the ^ u attaching
remove the cable assembly from the bolts.
brake control assembly. 3. Lower the vehicle. Removal
9. Pull the cable assembly up through 4. Connect the control cable to the
the opening in the floor and remove clevis on the control assembly.
the wire from the end of the cable. 1. Raise the vehicle and tffosen the
5. Raise the car on a hoist. parking brake equalizer rod" adjusting
6. Position the supporting clip and nut. Disconnect the equalizer from the
Installation cable on the vehicle and install the rear cables (Figs. 34 and 37).
retaining bolts. Do not tighten the 2. Compress the prongs on the left
Refer to Fig. 36. bolts. Position the cable armor ap- cable-to-frame side member retainer
1. Connect the wire to the end of proximately 1/2 inch to the right of so the prong can pass through the
the cable assembly and pull the cable the clip (looking toward the rear of side-member. Remove the clip that at-
down through the opening in the the car) and tighten the retaining taches the left cable to the left lower
floor. Remove the wire. bolts. arm. Pull the cable thru the frame left
2. Connect the cable assembly to 7. Position the equalizer control side member.
the brake control assembly and in- cable to the support bracket and in-
stall the hairpin retainer. 3. Compress the prongs on the
stall the retaining hairpin clip. right cable-to-frame side member re-
3. Position the ball end of the 8. Connect the ball end of the container bracket so the prong can pass
cable in the notch of the brake clevis. trol cable to the equalizer lever. through the bracket. Remove the clips
4. Raise the vehicle on a hoist. 9. Adjust the parking brake linkage retaining the right cable to the frame
5. Pull the cable grommet into po- (Part 2-1, Section 2). crossmember.
sition and route the cable through 10. Check the operation of the auto- 4. Remove the rear wheel cover and
the access holes in the side rail and matic release mechanism. wheel. Remove the three Tinnerman
under the fuel line.
nuts that hold the brake drum in place
6. Insert the cable into the body
PARKING BRAKE and remove the drum.
bracket and install the hairpin re-
ACTUATOR-TO-EQUALIZER 5. Working on the wheel side of the
tainer.
rear brake, remove the automatic
7. Position the spring, spring seat, CABLE
brake adjuster spring. Compress the
and equalizer on the cable and install
prongs on the parking brake cable re-
the two nuts. FORD, MERCURY, tainer so that they can pass through
8. Adjust the parking brake. METEOR, THUNDERBIRD the hole in the brake backing plate.
AND CONTINENTAL Draw the cable retainer through the
MARK III hole.
LINCOLN CONTINENTAL
6. With the spring tension off the
Removal parking brake lever, lift the cable out
Removal of the slot in the lever and remove the
cable through the backing plate hole.
1. Raise the car on a hoist. Dis- Refer to Figs. 34 and 37.
connect the parking brake cable from 1. Raise the vehicle on a hoist.
the equalizer lever underneath the Installation
2. Remove the lock and adjusting
car (Fig. 38). nut which retains the cable to the
2. Remove the retaining clip at the equalizer. 1. Pull enough of the parking brake
cable bracket, and disengage the cable 3. Remove the cable end from the cable through the housing so that the
from the bracket (Fig. 38). equalizer. end of the cable may be inserted over
3. Remove the supporting clip re- 4. Unhook the cable from the act- the slot in the parking brake lever on
taining bolts and remove the support uator, and remove from the vehicle. * the rear brake shoe.
plate from the underbody. 2. Pull the excess slack from the
4. Lower the car on a hoist. cable, and insert the cable housing
5. With the parking brake in the Installation into the brake backing plate access
fully released position, disconnect the hole so that the retainer prongs ex-
cable at the control assembly. 1. Insert new cable end into act- pand. The prongs must be securely
6. Raise the vehicle on a hoist. Re- uator. locked in place. Install the automatic
move the left front fender apron 2. Insert cable end into equalizer brake adjuster spring.
splash shield retaining bolts and the and tighten the adjusting nut snug. 3. Position the right hand cable and
splash shield. Install the lock nut. the two retaining clips and screws on
7. Remove the two bolts securing 3. Adjust the parking brake cable the rear crossmember. Compress the
the parking brake control to equaliz- tension and check operation as out- prongs on the right cable and position
er cable bracket to the dash panel lined in Part 2-1, Section 2. the cable in the retaining bracket on
and remove the cable from the vehicle. 4. Lower the vehicle. the frame side member. Be sure the
02-02-36 Brake System 02-02-36
locating stripe on the cable is midway brake lever on the brake shoe and in- 7. Working on the wheel side of the
between the retaining clips and tighten stall the cable housing retaining grom- backing plate (Fig. 38), compress the
all retaining clip screws. met or steel-pronged Hi-Hat in the prongs on the cable retainer so that it
4. Position the left cable, retaining backing plate. can pass through the hole in the back-
clip and screw on the left lower sus- 4. Install the self-adjuster springs. ing plate. Draw the cable retainer out
pension arm. Compress the prongs on Position the cable housing in the side of the hole.
the left cable and position the cable rail bracket and install the hairpin 8. With the spring tension off the
through the frame side-member. The type retainer. parking brake lever, lift the cable out
prongs must be securely locked in 5. Install rear hub and drum as- of the slot in the lever and remove it
place. sembly, wheel and tire assemblies and through the backing plate hols.
5. Insert the ball ends of the cables wheel cover as outlined in Section 2.
into the equalizer assembly. 6. Position the cable retainer hooks Installation
6. Install the rear drum(s) and (station wagon models) in the under-
tighten the three Tinnerman nuts and body guide (convertible models) and
1. Pull enough of the cable through
secure the drum. Install the wheel and install the connector, thus hooking the
the cable housing so that the end of
tire and the wheel cover. two cables together.
the cable may be inserted through the
7. Adjust the parking brake linkage 7. Insert the cable into the equaliz-
backing plate hole from the inner side
as outlined in Part 2-1, Section 2. Ad- er and install the equalizer, spring
and engage the cable end with the slot
just the rear brakes, as required (Part seat, spring, adjusting nut and lock
in the parking brake lever.
2-1, Section 2). nut to the front, parking brake control
cable. 2. Pull the excess slack from the
cable and insert the cable housing into
FAIRLANE, MONTEGO, 8. Adjust the parking brakeâs di-
the backing plate access hole (Fig.
MUSTANG AND COUGAR— rected in Part 2-1, Section 2.
38). The prongs must be securely
EXCEPT STATION WAGON
locked in place.
FAIRLANE AND MONTEGO
STATION WAGONS AND 3. Install the brake shoe retracting
FALCON PASSENGER springs.
Removal 4. Position the cable to the under-
MODELS
body and install the retaining clamp
1. Remove the equalizer lock nut so that the cable conduit armor ex-
and adjusting nut, equalizer, spring Removal and Installation tends forward of the clamp as shown
and spring seat. in Fig. 38. Install the clamp retaining
2. With the cables slack, discon- Refer to Fig. 35. nuts.
nect the ball-ends from the connector G e n e r a l l y follow the procedure 5. Hook the cable housing to the
(Figs. 35 and 36). given above, omitting separation of retainer at the spring U-bolt.
3. Remove the cable from the re- the cables, since the parking brake 6. Engage the forward end of the
tainer hooks (station wagon models) rear cable assemblies supplied for cable housing with the frame bracket
and the underbody guide (convertible these models is in one piece. Removal and secure it with the hairpin-type
models) if required. and installation of both rear wheels, clip.
4. Remove the hairpin lock retain- tires and drums will also be required. 7. Insert the ball end of the cable
ing the cable housing to the side rail into the equalizer.
bracket. LINCOLN CONTINENTAL 8. Make a preliminary brake ad-
5. Remove the wheel cover, wheel justment with the use of Tool HRA-
and tire and the rear brake drum as 8650 (Fig. 11).
outlined in Section 2. Removal 9. Install the rear drum. Tighten
6. Remove self-adjuster springs to the three Tinnerman nuts that secure
allow clearance to remove cable re- the drum. Install the wheel and wheel
tainer from the backing plate. Discon- 1. Raise the car. Remove the rear cover.
nect the rear end of the cable from the wheel cover. Remove the wheel and 10. Adjust the parking brake link-
parking brake lever on the brake shoe. tire as an assembly. age.
Disengage the cable housing retaining 2. Remove the three Tinnerman 11. Lower the vehicle.
grommet or steel-pronged Hi-Hat nuts that hold the brake drum in
from the backing plate and withdraw place, and remove the drum.
3. Remove the brake shoe retract- ANTI-SKID CONTROL
the cable and housing from the in-
ing springs. ACTUATOR
board side of the backing plate.
7. Slide the cable and housing out 4. Loosen the equalizer rod adjust-
of the side rail bracket. ing nut and disconnect the cable from REMOVAL
the equalizer (Fig. 38).
5. Remove the hairpin-type retainer Refer to Fig. 39.
Installation clip that secures the cable housing to
the body bracket, and pull the cable 1. Working in the passenger com-
1. Insert the rear end of the cable and housing out of the bracket (Fig. partment, under the glove box, remove
through the side rail bracket and pull 38). the screw that attaches the forward
the cable and housing into position. 6. Remove the cable to underbody end of the control module retainer to
2. Insert the rear end of the cable clamp attaching nuts and the clamp. the support assembly. Lower the for-
and housing through the hole in the Disengage the cable housing from the ward end of the control module re-
backing plate from the inboard side. hook-type retainer at the spring U- tainer and remove the module assem-
3. Connect the cable to the parking bolt. bly.
FROM MASTER CYLINDER ACTUATOR AIR FILTER
EXISTING SCREW
VIEW IN CIRCLE W
SOLENOID
GLOVE BOX
ACTUATOR TO REA
BRAKE TUBE
DIFFERENTIAL VALVE
UATORTUBE
FROM ACTUATOR
VIEW IN CIRCLE T TO REAR BRAKES CONTROL MODULE
VIEW V
VIEW U
H1653-A
FIG. 39—Anti-Skid Control System

02-02-38 Brake System 02-02-38
2. Disconnect the actuator solenoid through the two holes in the dash 5.- Secure the wiring to the module
and warning switch harness connectors panel from inside the car. Seat the support extension with the retaining
from the control module. wiring harness grommets in the dash strap.
3. Remove the two wiring harness panel.
grommets from the dash panel and 10. Connect the actuator solenoid
push the wiring harness and connec- and brake warning switch wiring har-
tors through the openings in the dash ness connectors to the control mo- ANTI-SKID CONTROL SENSOR
panel. dules. '
4. Working in the engine compart- 11. Position the control module in
ment loosen the hose clamp and re- the bracket under the glove box and REMOVAL
move the air hose from the air filter. install the retaining screw.
5. Remove the engine air cleaner- 12. In the engine compartment con- Refer to Fig. 39.
Loosen the hose clamp and remove nect the air hose to the air filter and 1. Raise the vehicle on a hoist.
the vacuum hose from the vacuum position the hose clamp. 2. Remove the rear wheel and tire
manifold fitting. 13. Connect the vacuum hose to the assembly.
6. Raise the vehicle on a hoist. engine vacuum manifold fitting. In- 3. Remove the three Tinnerman
7. Disconnect the exhaust pipes stall the engine air cleaner. nuts (3) and remove the brake drum.
from the exhaust manifold and sup- 14. Bleed the rear brake system and 4. Disconnect the sensor lead from
port with wire to provide access to the centralize the pressure differential the rear wiring harness.
actuator assembly. valve. 5. Unseat the sensor lead grommet
8. Remove the bolt retaining the 15. Raise the rear wheels. Apply pushing it to the inside of the brake
actuator ground wire to the rear outer the brakes with the rear wheels turn- assembly.
corner of the engine right bank. ing to verify proper operation of the 6. Remove the four nuts that retain
9. Loosen the tube nuts and discon- anti-skid control system. the sensor to the backing plate and
nect the brake system hydraulic tubes pull the axle shaft, sensor assembly
from the hydraulic valve housing. and wheel bearing assembly from the
10. Remove the three nuts retaining ANTI-SKID CONTROL MODULE axle housing.
the actuator assembly to the actuator 7. Press the wheel bearing retainer
support bracket. and wheel bearing off the axle shaft
11. Remove the three bolts that re- REMOVAL (Refer to Part 4-2).
tain the actuator mounting bracket to 8. Remove the sensor assembly and
the side rail and remove the mounting Refer to Fig. 39. press the rotor off the shaft with tool
bracket. 1. Remove the retaining strap hold- T69P-2B384-A Detail 2 and TOOL
12. Remove the actuator assembly ing the harnesses. 1225-DA.
from the vehicle and place it on a 2. Remove the screw that attaches
bench. the forward end of the control module INSTALLATION
13. Remove the air and vacuum retainer to the support assembly.
hoses from the actuator. 3. Lower the forward end of the 1. Press a new rotor onto the axle
control module and retainer from the shaft. Install a new sensor assembly
INSTALLATION support assembly; move the module on t h e s h a f t w i t h t o o l T 6 9 P -
and retainer forward slightly until the 2B384-ADetail 1 and TOOL 1225-
1. Install the air and vacuum hoses flange clears the slot in the support DA, and press the bearing and bear-
on the new actuator. assembly. ing retainer onto the shaft (Refer to
2. Place the actuator assembly into 4. Disconnect the five wiring har- Part 4-2).
position under the vehicle, routing the ness plugs from the control module. 2. Insert the axle shaft assembly in
air and vacuum hoses up between the 5. Remove the control module from the rear axle housing onto the four
engine and fender apron and inserting the vehicle. backing plate retaining bolts, feeding
the solenoid leads through the holes in the sensor lead through the hole in the
the firewall. INSTALLATION backing plate.
3. Position the ground wire to the 3. Seat the sensor lead grommet in
rear of the engine block and install re- 1. Connect the five wiring harness the backing plate.
taining bolt. plugs to the control module. Only one 4. Install the four nuts on the re-
4. Position the actuator mounting arrangement is possible. taining bolts and tighten to specifica-
bracket to the frame side rail and in- 2. Position the control module in tions.
stall the three retaining bolts. the retainer, orienting the module per 5. Connect the sensor lead to the
5. Position the actuator assembly the markings on it, and insert the re- rear wiring harness and install two re-
to the mounting bracket and install tainer flange into the slot at the rear taining straps.
the three retaining nuts. of the support assembly. 6. Install the rear brake drum and
6. Connect the hydraulic tubes to 3. Pivot the retainer and control retain with the Tinnerrhan drum re-
the hydraulic valve assembly and module upward and align the screw taining nuts.
tighten the tube nuts to specifications. hole in the forward end of the retainer 7. Install the rear wheel and tire as-
7. Connect the exhaust pipes to the with the hole in the support bracket sembly and tighten the wheel nuts to
exhaust manifolds. assembly. Install the retaining screw. specifications.
8. Lower the vehicle. 4. Test the vehicle on the hoist to 8. Test the vehicle on the hoist to
9. Pull the actuator solenoid and verify correct operation of the skid verify proper operation of the skid
brake warning switch wiring harness control system. control system.
02-02-39 Brake System 02-02-39
MAJOR REPAIR OPERATIONS
BRAKE DRUM REFINISHING is necessary to replace linings, they DUAL MASTER CYLINDER
must also be replaced on the wheel on
Minor scores on a brake drum can the opposite side of the vehicle.
be removed with sandpaper. A drum Inspect brake shoes for distortion, DISASSEMBLY
that is excessively scored or shows a cracks, or looseness. If this condition
total indicator runout of over 0.007 exists, the shoe must be discarded. Do 1. Clean the outside of the master
inch should be turned down. Remove not attempt to repair a defective brake cylinder and remove the filler cover
only enough stock to eliminate the shoe. and diaphragm. Pour out any brake
scores and true up the drum. The refi- 1. Wash the brake shoes thoroughly fluid that remains in the cylinder. Dis-
nished diameter must not exceed 0.060 in a clean solvent. Remove all burrs card the old brake fluid.
inch oversize. or rough spots from the shoes. 2.* Remove the secondary piston
Check the inside diameter of the 2. Check the inside diameter of the stop bolt from the bottom of the cyl-
brake drum with a brake drum mi- brake drum with a brake drum mi- inder (Figs. 40 and 41).
crometer (Tool FRE-14^1). crometer (tool FRE-1431). If the di- 3. Remove the bleed screw, iL re-
If the drum diameter is less than ameter is less than 0.030 inches over- quired.
0.030 inch oversize after refinishing^ size, standard lining may be installed. 4. Depress the primary piston and
standard lining may be installed. If If the diameter is 0.030—0.060 inches remove the snap ring from the retain-
the drum diameter is 0.030—0.060 oversize, oversize lining should be in- ing groove at the rear of the master
inch oversize after refinishing, oversize stalled. cylinder bore (Fig. 42). Remove the
lining must be installed. 3. Position the new lining on the push rod and the primary piston as-
After a drum is turned down, wipe shoe. Starting in the center, insert and sembly from the master cylinder bore.
the refinished surface with a cloth secure the rivets, working alternately Do not remove the screw that retains
soaked in clean denatured alcohol. If towards each end. Replacement lin- the primary return spring retainer, re-
one drum is turned down, the opposite ings are ground and no further grind- turn spring, primary cup and protec-
drum on the same axle should also be ing is required. tor on the primary piston. This assem-
cut down to the same size. 4. Check the clearance between the bly is factory pre-adjusted and should
shoe and lining. The lining must seat not be disassembled.
tightly against the shoe with not more 5. Remove the secondary piston as-
ROTOR REFINISHING than 0.008 inch clearance between any sembly. Do not remove the outlet tube
two rivets. seats, outlet check valves and outlet
Rotunda Disc Brake Attachment,
FRE-2249-2, is the only recommended
tool to refinish the disc brake rotors.
The step-by-step resurfacing procedure RETAINER - 2B245
provided with the tool must be ad-
hered to.
The finished braking surfaces of the
rotor must be flat and parallel within COVER - 2 1 6 6
0.0007 inch; lateral runout must not GASKET-2167
exceed 0.003 inch total indicator read- SECONDARY SYSTEM MASTER CYLINDER -2155
BRAKE OUTLET
ing, and the surface finish of the brak- SNAP RING - 7 8 2 1
ing surfaces are to be 80/15 micro BOOT
inches. The minimum limiting dimen- PUSH ROD
sions (Figs. 11 and 12, Part 2-1) from
the inboard bearing cup to the out-
board rotor face and from the inboard
bearing cup to the inboard rotor face
must be observed when removing ma-
terial from the rotor braking surfaces.
On all models except Lincoln Con-
tinental, the limiting dimensions are to
be measured with a ball and gage bar
(Rotunda Kit FRE-70160). PRIMARY PISTON
ASSEMBLY - 2169
* SECONDARY PISTON
ASSEMBLY - 2A502
BRAKE SHOE RELINING
tTUBE S E A T -
2B220 • NOT USED ON POWER BRAKE EQUIPPED VEHICLES
Brake linings that are worn to with- fNOT SERVICED
in 1/32 inch of the rivet head or are •REPLACE AS AN ASSEMBLY ONLY
less than 0.030 inch thick (bonded lin-
ing) or have been contaminated with
brake fluid, grease or oil must be re- H 1499-B
placed. Failure to replace worn linings
will result in a scored drum. When it FIG. 40— Dual Master Cylinder Disassembled—Except Disc Brakes
02-02-40 Brake System 02-02-40
open and free of foreign matter. Use

an air hose to blow out dirt and clean-
ing solvent. Place all parts on a clean
RETAINER - 2B245 pan or paper.
3. Inspect the master cylinder bore
for signs of etching, pitting, scoring or
PRIMARY PISTON
ASSEMBLY-2169 rust. If it is necessary to hone the
master cylinder bore to repair dam-
age, do not exceed allowable hone
GASKET-2167
specifications.
ASSEMBLY
1. Dip all parts except the master

cylinder body in clean Rotunda Extra
Heavy Duty Brake Fluid.
2. Carefully insert the complete
secondary piston and return spring as-
sembly in the master cylinder bore.
RETURN SPRING 3. Install the primary piston assem-
RETAINER fNOT SERVICED
bly in the master cylinder bore.
\ CUP * REPLACE AS 4. Depress the primary piston and
ASSEMBLY ONLY
\\PROTECTOR install the snap ring in the cylinder
*O-RING
^ \ i # PISTON
PUMPING CUP bore groove.
5. Install the push rod, boot and re-
tVALVE tainer on the push rod, if so equipped.
2175 Install the push rod assembly into the
SECONDARY primary piston. Make sure the retain-
BRAKE SYSTEM *SECONDARY PISTON
OUTLET ASSEMBLY-2A502 er is properly seated and holding the
H 1550-B push rod securely.
6. Position the inner end of the
FIG. 41—Dual Master Cylinder Disassembled—Disc Brakes
push rod boot (if so equipped) in the
check valve springs from the master master cylinder body retaining groove.
cylinder body. 7. Install the secondary piston stop
INSPECTION AND REPAIR OUTER SHOE

INNER BRAKE RETAINING CLIPS
SHOE AND LINING 2066
ASSEMBLY-2019
1. Clean all parts in clean isopropyl

alcohol, and inspect the parts for
chipping, excessive wear or damage.
When using a master cylinder repair
kit, install all the parts supplied.
2. Check all recesses, openings and STABILIZER
internal passages to be sure they are 2B295
Snap Ring Pliers
LOCATING PIN
2B296
SNAP RING
MOVABLE CALIPER
2B119(L.H.)
2B118(R.H.)
ANCHOR PLATE
2B293(L.H.)
2B292 (R.H.)
H1477-C H 1573-C
FIG. 42—Removing Snap FIG. 43—Caliper Assembly—Disassembled-

Ring—Typical All Models Except Lincoln Continental
02-02-41 Brake System 02-02-41
bolt and G-ring in the bottom of the caliper, tap lightly around the piston 1. Remove the caliper assembly
master cylinder. while applying air pressure. Care from the car as outlined in Section 2.
8. Install the bleed screw (if so should be taken because the piston 2. Remove the two attaching bolts
equipped). Install the gasket (dia- can develop considerable force due to and the caliper splash shield (Fig. 46).
phragm) in the master cylinder filler pressure build-up. 3. Remove the two shoe and lining
cover. Position the gasket as shown in 7. Remove the dust boot from the assemblies.
Figs. 40 and 41. Make sure the gasket caliper assembly. 4. Remove the flexible brake hose
is securely seated. 8. Remove the rubber piston seal from the caliper.
9. Install the cover and gasket on from the cylinder and discard it. 5. Remove the external transfer
the master cylinder and secure the tube.
cover into position with the retainer. Cleaning and Inspection 6. Remove the four dust boots from
the caliper housings and piston
DISC BRAKE CALIPER
grooves.
Clean all metal parts with isopropyl 7. Clamp the caliper in a vise and
alcohol or a suitable solvent. Use secure it by the mounting flanges on
clean, dry, compressed air to clean out the inboard housing (Fig. 45).
ALL MODELS EXCEPT and dry the grooves and passage ways. 8. Remove the four pistons from
LINCOLN CONTINENTAL Be sure that the caliper bore and com- the cylinder bores with the special tool
ponent parts are completely free of shown in Fig. 45. To prevent cocking
any foreign material. with consequent damage to the piston
Disassembly Check the cylinder bore and piston or bore, rotate the piston with the tool
for damage or excessive wear. Replace while pulling it outward at the same
the piston if it is pitted, scored, or the time. Be careful to avoid scratching or
1. Remove the caliper assembly chrome plating is worn off. damaging the outside diameter surface
from the vehicle as outlined in Section
or dust boot retaining groove of the
2.
Assembly piston. Such damage causes poor seal-
2. Remove the caliper locating pins
ing.
from the caliper assembly and lift the
anchor plate from the caliper. 1. Apply a film of clean brake fluid If a piston is so completely seized in
3. Slide the two outer shoe retain- to the new caliper piston seal and in- the cylinder bore that it can not be re-
ing clips off the retaining pins (Fig. moved with the special tool, the cali-
stall it in the cylinder bore. Be sure
43). per housing must be replaced, by posi-
the seal does not become twisted and
tioning two screwdrivers in the piston
4. Remove the two retaining pins, that it is seated fully in the groove.
dust boot retaining groove and prying
then remove the outer brake shoe 2. Install a new dust boot by setting
outward. To prevent cocking, tap the
from the caliper. the flange squarely in the outer groove
end of the piston lightly around the
5. Slide the inner brake shoe out- of the caliper bore.
circumference with a hammer, while
ward until it is free of the hold-down 3. Coat the piston with the speci- the prying force is being applied. Be
springs, then remove the brake shoe. fied fluid and install the piston in the careful to avoid damaging the dust
6. Apply air pressure to the fluid cylinder bore. Spread the dust boot boot retainer in the caliper housing
port in the caliper with a rubber over the piston as it is installed. Seat (Fig. 46). If this method of removal is
tipped nozzle (Tool 7000-DD) as the dust boot in the piston groove. used, the pistons must be replaced.
shown in Fig. 44 to remove the piston. 4. Position the inner brake shoe so
Place a cloth over the piston before that the ears of the shoe rests on the If the caliper dust boot retainer or
applying air pressure to prevent dam- top of the anchor plate bosses and be- r e t a i n i n g groove is d a m a g e d or
age to the piston. If the piston is neath the hold-down springs. scratched, pry the retainer out of the
seized and cannot be forced from the caliper housing with screwdrivers.
5. Install new caliper locating pin
insulators in the anchor plate.
6. Position the caliper on the an-
chor plate.
7. Apply water or isopropyl alcohol T o o / - T 6 5 P - 2 J 18- A
to the caliper locating pins and install
them loosely in the anchor plate. Be
sure the guide pins are free of oil,
grease or dirt.
FIBER 8. Install the caliper on the spindle
BLOCK
as outlined under Disc Brake Caliper
Assembly.
LINCOLN CONTINENTAL
CALIPER
Disassembly
PISTON
H 1574-B Do not remove the bridge bolts that H 1652-A

hold the two halves of the caliper to-
FIG. 44 —Removing Piston From gether. The two caliper housings are
Caliper — All Models Except shown separated in Fig. 46 for illus- FIG. 45—Removing or Installing
Lincoln Continental tration purposes only. Pistons — Lincoln Continental
02-02-42 Brake System 02-02-42
CALIPER ABUTMENTS to new caliper piston seals and install

them in the grooves of the cylinder
OUTBOARD CALIPER HOUSING
bore. The seal should be positioned at
one area in the groove and gently
PISTON SEAL (4)
DUST BOOT RETAINING GROOVE worked around. Do not use the origi-
EXTERNAL nal seals.
DUST BOOT (4)
TRANSFER TUBE 3. Install the new dust boots by set-
SCREW
ting the flanges squarely in the outer
grooves of the caliper bores.
4. Coat the pistons with the speci-
fied fluid and install the pistons inPthe
cylinder bores. Spread the dust boots
over the pistons as they are installed.
Seat the dust boots in the piston
grooves.
5. Coat the outside diameter of the
pistons with brake fluid and install
them in the cylinder bores so that the
open end of the piston and ihe boot
retaining groove face out of the bore.
To avoid cocking, locate the piston
squarely in the bore and apply a slow
steady pressure. If a piston will not
INBOARD CALIPER HOUSING
easily go all the way into the bore, re-
move it and thoroughly inspect the
cylinder bore, the piston seal and the
installation of the seal. If the piston
still will not go in with bore in good
condition and the piston seal properly
FLEXIBLE HOSE-^ H1367-C installed, use the tool shown in Fig.
45. Rotate the piston with the tool
FIG. 46—Caliper Assembly — Disassembled—Lincoln Continental
while pushing it inward at the same
time.
9. Remove the rubber piston seals bore and component parts are com- 6. Carefully install four new dust
from the grooves in the cylinder bores pletely free of any foreign material. boots on the caliper housings and pis-
by carefully inserting the point of a Check the cylinder bores and pistons. Be sure that each boot is fully
small knife or other pointed instru- tons for damage or excessive wear. seated in the groove of its respective
ment under the seal and raising the Replace the piston if it is pitted, caliper housing and piston (Fig. 46).
seal up far enough to be pulled out scored, or the chrome plating is worn Do not use the original dust boots.
with the fingers. off. Check the caliper dust boot re- 7. Install the external transfer tube.
tainer for wear or damage. 8. Install the flexible brake hose to
the caliper.
Cleaning and Inspection 9. Install the caliper assembly on
Assembly the spindle, and install the shoe and
Clean all metal parts with isopropyl lining assemblies and the splash shield
alcohol or a suitable solvent (Fig. 46). 1. Clamp the caliper in a vise and as outlined in Section 2. Check the
Use clean, dry, compressed air to secure it by the mounting flange on caliper for fluid leaks under maximum
clean out and dry the grooves and the inboard housing. pedal pressures. Do not move the car
passage ways. Be sure that the caliper 2. Apply a film of clean brake fluid until a firm brake pedal is obtained.
02-03-01 Specifications 02-03-01
PART 2-3 Specifications
LINING DIMENSIONS-DRUM BRAKES-INCHES

Vehicle Position Front Rear
FORD, MERCURY, METEOR
Ford, Meteor Passenger (Rivetet1 Primary 2.50x9.34 2.25x9.34
Lining) Except 390, 429 CID
Galaxie500XL, Ford LTD, LeMoyne. Secondary 2.50x12.12 2.25x12.12 .
Ford, Mercury, Meteor with Disc Primary N/A 2.25x9.34
Brakes. Secondary N/A 2.25x12.12
Mercury Passenger, Sta. Wag. and
Conv. Ford Meteor Station Wagon Primary 3.00x9.34 2.25x9.34
and Convertible. 390, 429 CID
Galaxie500XL, Ford LTD, LeMoyne. Secondary 3.00x12.12 2.25 x 12.12
Ford, Meteor 240, 302 CID Taxi
Only (Bonded Lining) Max. Wear Primary 3.00x9.34 2.50 x 9.34
Resistance. Secondary 3.00x12.12 2.50x12.12
MONTEGO, FAIR LANE
Passenger 250, 302 CID Except Primary 2.25 x 8.43 2.00 x 8.43
Convertible Secondary 2.25x10.82 2.00 x 10.82
Station Wagon, Ranchero and
Convertible250, 302 CID. Primary 2.50x8.43 2.00x8.43
Passenger and Convertible
351,390, 428 CID. Secondary 2.50x10.82 2.00 x 10.82
Station Wagon and Ranchero 351, Primary 2.50x8.43 2.50 x 8.43
390, 428 CID. Secondary 2.50 x 10.82 2.50 x 10.82
FALCON
Sedan 6-Cylinder. Primary 2.25 x 7.62 1.50 x 7.62
Secondary 2.25x9.77 1.50x9.77
Station Wagon 6-Cylinder. Primary 2.50 x 8.43 2.00 x 8.43
Secondary 2.50x10.82 2.00 x 10.82
Sedan 8- Cylinder. Primary 2.25 x 8.43 2.00 x 8.43
Secondary 2.25x10.82 2.00x10.82
Station Wagon 8-Cylinder. Primary 2.50 x 8.43 2.00x8.43
Secondary 2.50x10.82 2.00 x 10.75
MUSTANG, COUGAR
200CID Engine. Primary 2.25 x 7.62 1.50 x 7.62
Secondary 2.25x9.77 1.50 x 9.77
250, 302 CID Engines. Primary 2.25 x 8.43 1.75 x 8.43
Secondary 2.25x10.82 1.75x10.82
351,390, 428 CID Engines. Primary 2.50 x 8.43 2.00 x 8.43
Secondary 2.50x10.82 2.00 x 10.82
IHUNDERBIRD, CONTINENTAL MARK III
Primary N/A 2.25x9.34
Secondary N/A 2.25x12.12
LINCOLN CONTINENTAL
Primary N/A 3.00x9.39
Secondary N/A 3.00 x 12.21
Wear Limits Riveted: 1/32 inch from top of rivets.
Bonded: 0.030 inch total lining thickness
BORE DIAMETERS-BRAKE DRUM, WHEEL CYLINDER AND MASTER CYLINDER

Brake Drum Wheel Cylinder Bore Dia. Master Cylinder Bore Dia.
Models Inside Boring Umit With Power Less Power
Diameter (Max.) ® Front 0 Rear ® Brake ® Brake ®
Ford, Taxi and Station Wagon 11.030 11.090 1.094 0.938 1.000 1.000
Mercury
and
Meteor Other 11.030 11.090 L_ U 2 5 0.938 1.000 1.000
Pass, except Conv. 250, 302 CID Engines 10.000 10.060 1.125 0.875 0.9375 1.000
Mont ego
Pass, and Conv. 351, 390, 428 CID Eng. 10.000 10.060 1.094 0.875 0.9375 1.000
and
Convertible 250, 302 CID Engines 10.000 10.060 1.094 0.875 0.9375 1.000
Fairlane
Station and Ranchero 10.000 10.060 1.094 0.938 0.9375 1.000
9 Inch Brake - Passenger Car 9.000 9.060 1.062 0 0.844® 0.9375 1.000
Falcon 10 Inch Brake • Station Wagon 10.000 10.060 1.094 0.938 0.9375 1.000
10 Inch Brake • Passenger Car 10.000 10.060 1.125 0.875 0.9375 1.000
200 CID Engine 9.000 9.060 1.062 ® 0.844® 1.000 1.000
Mustang
351, 390, 428 CID Engine 10.000 10.060 1.094 0.875 1.000 1.000
and Cougar
250, 302, CID Engine 10.000 10.060 1.125 0.875 1.000 1.000
Thunderbird 11.030 11.090 N/A 0.938 1.000 N/A
Continental Mark III 11.030 11.090 N/A 0.938 1.000 N/A
Lincoln Continental 11.090 11.130 N/A 0.938 1.000 N/A
©Max. Runout 0.007 ® Front Wheel Cylinder cannot be honed on Falcon or Mustang with 9 inch Brakes.
(DMax. Allowable Hone 0.003
CD2.755 For Ford, Mercury, Meteor with Disc Brakes.
2.381 For Fairlane, Montego, Falcon, Mustang, Cougar with Disc Brakes.
SHOE AND LINING DIMENSIONS-

DISC BRAKES-INCHES
Ford, Mercury, Meteor Fairlane, Montego
Thunderbird, Continen- Falcon, Mustang,
tal Mark III Cougar Lincoln Continental
Lining Material Bonded Bonded Lining Material Riveted Fomoco
7.38x2.27 Outer 6.82 x 1.80 Outer Lining Size 5.36x1.90
Lining Size 5.36x2.03 Inner 4.90x1.84 Inner Lining Area 10.03 Sq. In/segment
Lining Area - Square Inches 12.25 Outer 11.30 Outer Shoe and Lining Thickness 0.600 nominal
per Segment 8.44 Inner 8.80 Inner
Lining Thickness 0.436 nominal
0.333 Outer
Lining Thickness • Nominal 0.394 0.362 Inner Shoe and Lining Maximum
Wear Limit 0.231
Lining Wear Limit (Front
Surface of Shoe) • Max. 0.030 0.030 Lining Maximum Wear Limit
(from front surface of shoe) 0.066
Lining Taper - M a x . 0.125 0.125
Lining to Rotor Clearance
Lining to Rotor Clearance (brakes released) 0.000-0.010
(Brakes Released) 0.000-0.010 0.000 • 0.010
CALIPER CYLINDER BORE DIAMETER -INCHES TORQUE LIMITS-HUB TO SPINDLE

Ford, Mercury, Meteor, Thunderbird, Continental Mark 2.755 Description Ft-Lbs
Mustang, Cougar, Falcon, Fairlane and Montego 2.381 Hub and Drum or Rotor Assembly to Rotate hub while torquing
Lincoln Continental 1.938 Front Wheel Spindle to 17-25 ft-lbs. Backoff
the adjusting nut 1/2 turn
and retighten to 10-15
inch pounds while rotat-
ing wheel Selectively posi-
tion nut retainer on ad-
justing nut so that a set
ROTOR DIMENSIONS of slots are in line with
Norn. Diameter cotter pin hole. Adjusting
nut should not be rotated
Car Line Thickness Outside Inside in this operation. Lock ad-
Ford, Mercury, Meteor 1.180 11.72 7.785 justing nut and nut retain-
Thunderbird, Continental Mark III 1.180 11.72 7.785 er with cotter pin so that
the cotter pin end does
Fairlane, Falcon, Montego, Mustang not interfere with seating
and Cougar 0.935 11.29 7.355 of wheel static collector
Lincoln Continental 1.240 11.960 7.785 in spindle hole.
ROTOR REFINISH
The following requirements must be met when resurfacing disc On all models except Lincoln Continental the limiting dimen-
brake rotors: sion from the inner bearing cup to the inner rotor face must be
Rotunda Disc Brake Attachment FRE-2249-2 is the only approv- measured with a ball and gage bar (Rotunda FRE-70160).
ed tool to be used to ref inish the disc brake rotors. The step-by- On Lincoln Continental models the limiting dimension from the
step resurfacing procedure provided with the tool must be adhered inboard bearing cup to the inboard rotor face of 0.755 inch mini-
mum and from the inboard bearing cup to the outboard rotor face
t0
" The finished braking surfaces of the rotor must be flat and of 0.395 inch minimum must be observed.
parallel within 0.0007 inch; lateral runout must not exceed 0.003
inch total indicator reading, and the surface finish of the braking
surfaces are to be 15-80 micro inches.
TORQUE LIMITS -GENERAL -FT-LBS.

Fair lane- Thunderbird
Ford-Mercury Montego Mustang- Continental Lincoln
Meteor Falcon Cougar Mark III Continental
Parking Brake Control Assembly Cap Screw 12-25 12-25 1218 Dash Panel
Mounting Nuts and Bolts 12-19 10-20
Inst. Panel
Nuts 7-11 712
Master Cylinder to Dash Panel Screw 13-20 13-20 13-20
Master Cylinder to Booster 13-?0 13-20 13-20 13-20 13-20
Booster to Dash Panel 13-20 13-20 13-20 13-20 13-20
Upper © Upper CD Upper © Upper ©
Disc Brake Caliper to Spindle Bolts 110-140 100-140 100-140 110-140 100-140
Lower Lower Lower Lower
90-120 55-75 55-75 90-120
Disc Brake Rotor Splash Shield
to Spindle 9-14 9-14 9-14 9-14 9-14
Brake Hose to Caliper Connection Bolt 17-25 17-25 17-25 17-25
Caliper Locating Pins 25-35 25-35 25-35 25-35
Caliper Stabilizer to Anchor Plate
Bolt 8-11 8-11 8-11 8-11
Caliper Brake Shoe Clips 6-10 6-10 6-10 6-10 7-9
Caliper Bleeder Screws 6-15 6-15 6-15 6-15 6-15
10 in. Brake 10 in. Brake
Wheel Cylinder to Backing Plate Screws 10-20 10-20 10-20 10-20 10-20
9 in. Brake 9 in. Brake
5-7 5-7
Wheel Cylinder & Backing Plate
Anchor Pin Nut 20-30
Rear Brake Backing Plate to Axle
Housing: Removable Carrier 50-70 50-70 50-70 50-70 30-35
Integral Type IPo 20-40 20-40
Front Brake Backing Plate to Spindle 25-40 28-35 28-35
32-65 ® 32-65 ®
Wheel Cylinder Bleeder Screw 6-15 Inch-lb. Inch-lb. 6-15 6-15
Brake Hose Connection to Front
Wheel Cylinder 12-20 12-20 12-20
Brake Line Connection to Rear Axle
Housing: Removable Carrier 30-40 12-19 12-19 30-40
Integral Type 25-35 12-19 12-19
Hydraulic Tube Connections ®
3/8 x 24 10-15 10-15 10-15 10-15 10-15
7/16 x 24 10-15 10-15 10-15 10-15 10-15
1/2 x 20 10-17 10-17 10-17 10-17 10-17
9/16 x 18 10-17 10-17 10-17 10-17 10-17
4 lug 4 lug
Wheel to Hub and Drum or Hub and 55-85 55-85
Rotor Nuts 70-115 5 lug 5 lug 70-115 70-115
70-115 70-115
® The upper bolt must be tightened f i r s t .
® On front disc brake calipers 6-15 ft-lbs.
® All hydraulic lines must be tightened to the specified torque value and be free of fluid leakage.
SERVICE TOOLS
Ford Tool No. Former No. Description
Rotunda HRE 8650 Brake Adjusting Gage
LM 119 Brake Cylinder Retaining
Clamp
2018-A Brake Adjusting Tool
2162 Adapter Cap
2035N Brake Shoe R & R Spring
Tool 7000-00 Rubber Tipped Air Nozzle
Rotunda 70160 Ball and Gage Bar
Tool 33621 33621 Internal Snap Ring PMers
Milbar
1112-144 Inch Pound Torque Wrench
Tool 4235-C 4235-C Axle Shaft Remover
Rotunda FRE 1431 Brake Drum Micrometer
J 22742 (Kent Moore) Bleeder Valve Clip Spring
Rotunda FRE 22492 Disc Brake Rotor Attachment
03-01-01

Suspension, Steering, Wheels and Ford Design Integral Power
Tires, General Service 03-01-01 Steering Gear 03-08-01
PART 3-2 PART 3-9
Suspension 03-02-01 Saginaw Design Integral Power
PART 3-3 Steering Gear 03-09-01
Automatic Air Leveling System ....03-03-01 PART 3-10
PART 3-4 Ford-Thompson Power Steering
Automatic Air Leveling System Pump 03-10-01
Lincoln Continental 03-04-01 PART 3-11
PART 3-5 Eaton Power Steering Pump 03-1 1-01
Steering Columns and Linkage ... 03-05-01 PART 3-12
PART 3-6 Wheels and Tires 03-1 2-01
Manual Steering 03-06-01 PART 3-13
PART 3-7 Specifications 03-13-01
Ford Design Non-Integral Power
Steering System 03-07-01
PART 3-1 Suspension,Steering, Wheels and

Tires—General Service
MODEL APPLICATION
Continental-
Thunderbird
Continental
All Models
COMPONENT INDEX Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
CASTER AND CAMBER ADJUSTMENTS 01-05 01-05 01-05 01-06 01-06 01-06 01-06 01-06 01-06 01-05 01-05
FRONT END INSPECTION 01-08
FRONT WHEEL ALIGNMENT CHECKS 01-03
LUBRICANT CHECKING PROCEDURE 01-07
POWER STEERING GEAR CLEANING
AND INSPECTION 01-09
POWER STEERING PRELIMINARY TESTS 01-02
POWER STEERING PUMP
Cleaning and Inspection 01-09 01-09 01-09 01-09 01-09 01-09 01-09 01-09 01-09 01-09 01-10
Flow and Pressure Tests 01-02 01-02 01-02 01-02 01-02 01-02 01-02 01-02 01-03 01-02 01-03
POWER STEERING SYSTEM FLUSHING 01-09 01-09 01-09 01-09 01-09 01-09 Gl-09 01-09 N/A 01-09 N/A
SHOCK ABSORBER CHECKS 01-11
STEERING WHEEL SPOKE POSITION
Adjustment 01-07
TOE-IN ADJUSTMENT 01-07
WHEEL BALANCING 01-07
03-01-02 Suspension — Steering, Wheels And Tires — General Service 03-01-02
1 TESTING
POWER STEERING- valve is causing the trouble. Steps out-

PRELIMINARY TESTS lined below should be followed to de-
termine the cause of the trouble.
The following preliminary checks PUMP FLOW TEST
should always be made before per-
forming any operations.
1. Depending on the equipment
present on the vehicle (air condition-
AIR BLEEDING ing, power brakes, standard transmis-
sion), one of the following options
Air in the power steering system may be used to connect the pump
(shown by bubbles in the fluid) should pressure and return hoses to the test
be bled. After making sure that the G 1508- A
tool (T56L-3361O-D and T68L-
reservoir is filled to specification (the 33610-A):
fluid must be at normal operating FIG. 1—Power Steering Pump a. Disconnect the pressure and re-
temperature when the check is made), turn lines at the power steering pump
turn the steering wheel through its full Dipstick
(Fig. 2). Obtain a power steering re-
travel three or four times. Do not hold turn hose from stock and connect the
the wheels against their stops. Re- 1. With the vehicle on dry concrete,
set the parking brakes. end with the fitting to the output fit-
check the fluid level. ting of the tool using the 5/8-18 SAE
2. With the engine warmed up and
running at idle speed, turn the steering female, 1/4 N.P. thread male fitting
CHECK FLUID LEVEL provided. The end of the stock hose
wheel to the left and right several
times to warm the fluid. (without the fitting) should be con-
Run the engine until the fluid is at nected to the return tube of the pump.
normal operating temperature. Then 3. Attach a pull scale to the rim of
Connect the pressure hose from the
turn the steering wheel all the way to the steering wheel. Measure the pull
tool to the outlet fitting of the pump.
the left and right several times, and required to turn the wheel one com-
shut off the engine. plete revolution in each direction. The
effort required to rotate the steering b. Disconnect the pressure line at
Check the fluid level in the power
wheel should not exceed specifications the pump and connect the pressure
steering reservoir. The level must show
given in Part 3-13. line from the test tool to the outlet fit-
on the cross hatching between the bot-
ting of the pump. Disconnect the re-
tom of the dipstick and the full mark
turn line at the gear and connect it to
(Fig. 1). If the level is low, add POWER STEERING PUMP FLOW the output fitting of the tool, using the
enough automatic transmission fluid AND PRESSURE TESTS— 5/8-18 SAE female, 1/4 N.P. thread
C1AZ-19582-A to raise the level to
EXCEPT LINCOLN CONTINENTAL male fitting provided.
the F mark on the dipstick. Do not
overfill the reservoir. AND CONTINENTAL MARK III 2. After installing the lines by the
most advantageous method, proceed
CHECK PUMP BELT The power steering flow and pres- as follows:
sure tests will show whether the pump, 3. Open the manual valves A and B
If the pump belt is broken, glazed, steering gear or power assist control fully (Fig. 2).
or worn, replace it with a new belt. CALIBRATED FLOW
RETURN LINE
Use only the specified type of belt. DETERMINING ORIFICE
Refer to Part 3-13 for belt adjustment
procedure.
CHECK FOR FLUID

LEAKS
With the engine idling, turn the

steering wheel from stop to stop sever-
al times. Check all possible leakage
points. Tighten all loose fittings, and
replace any damaged lines or defective
seats. POWER
STEERING PUMP
CHECK TURNING EFFORT
With the front wheels properly al-

igned and tire pressures correct, check
the effort required to turn the steering
Sr PRESSURE LINE PRESSURE GAGE
G1611-A
wheel. FIG. 2—Power Steering Pump Test Circuit Diagram

4. Connect a tachometer, start the less than 1120 psi, close the valve at
engine and operate it at idle speed the gauge and note the pump pressure.
until the reservoir fluid temperature If it is low with the valve closed, it in-
reaches 165 to 175. This temperature dicates that the pump is not operating
must be maintained throughout the OWER STEERING
properly. If the pressure goes up with
test. Valve B may be partially closed PRESSURE LINE the valve closed, it indicates that the
to create a back pressure up to 350 low pressure in the system must be
psi to hasten the temperature rise. The due to internal leakage in the power
reservoir fluid must be at the proper unit, providing all connections are
INVERTED FLARE
level. CONNECTOR
tight.
5. With the engine operating at rec- % * TUBE x VA" PIPE 4. R e m o v e the pressure testing
ommended idle rpm and fluid temper- gauge set, and connect the pressure
ature noted in Step 4, close the manu- line at the steering gear. Fill and bleed
al valve B. The minimum acceptable the system.
pressure reading is 620 psi. FLARED FEMALE COUPW
% ' TUBE x VA" PIPE
6. If the pressure gauge reading is FRONT WHEEL ALIGNMENT
below the minimum specification, the CHECKS
pump is at fault and should be re- G1544.A
paired with necessary parts.
FIG. 3—Modified Pressure Gauge Do not attempt to check and adjust
7. If the reading is at or above the
Assembly front wheel alignment without first
minimum specification, the pump flow
making a preliminary inspection of
is normal. Open manual valve B and a. Power Steering Pressure Line the front-end parts. Refer to Section
proceed to the Pump Fluid Pressure (refer to the appropriate Parts Catal- 3.
Test. og). Check all the factors of front wheel
b. Inverted Flare Connector (3/8 alignment except the turning angle
PUMP FLUID inch OD Tube x 1/4 inch Pipe before making any adjustments. The
PRESSURE TEST Thread). turning angle should be checked only
c. Inverted Flare Connector (5/16 after caster, camber, and toe-in have
1. Keep the lines and tools con- inch OD Tube x 1/4 inch Pipe been adjusted to specifications.
nected as in the Pump Flow Test. Thread). The front wheel alignment specifica-
2. With manual valves A and B d. Flared Tube Female Coupling tions given in Part 3-13, are correct
opened fully, operate the engine at (3/8 inch OD Tube x 1/4 inch Pipe only when the vehicle is at curb load.
recommended idle speed (Fig. 2). Thread). Before checking or adjusting the
Close manual valve A, then manual The connectors and the coupling are a l i g n m e n t factors, the suspension
valve B. Do not keep both valves standard-type fittings and can be pur- alignment spacers must be installed to
closed for more than 5 seconds as this chased locally. obtain the curb Height.
would abnormally increase the fluid e. To modify tool T56L-33610-D,
temperature and cause undue pump remove the hose from the hand shut- EQUIPMENT INSTALLATION
and/or gear wear. off valve block. Install the 3/8 inch x
3. With the valves fully closed, the 1/4 inch inverted flare connector in Equipment used for front wheel
pressure gauge should read 1000 psi the valve block, and assemble the alignment inspection must be accu-
minimum for Ford, Mercury, Meteor pressure line to the connector (Fig. 3). rate. Whenever possible, front wheel
or Thunderbird and 750 psi minimum Assemble the 3/8 x 1/4 inch coupling alignment checks should be performed
for Cougar, Fairlane, Falcon, Monte- and the 5/16-inch connector to the on stationary wheel aligning equip-
go or Mustang. free end of the hose leading to the.
4. If the pressure gauge reading is pressure gauge. Too/ - T65P3000-A or S
below the minimum specification, the 1. To check the pump pressure, dis-
pump is at fault and should be reconnect the front and rear sections of
paired with necessary parts. the pressure line over the number 6
cylinder. Connect the modified pres-
5. If the pressure gauge reading is
s u r e - t e s t i n g gauge assembly, tool
at or above the minimum specifica-
T56L-3361O-D, between the two sec-
tions, the pump is normal and the
tions.
power steering gear or power assist
control valve is at fault. 2. Make sure the hand-valve at the
gauge is fully opened. Start the engine
and cycle the steering gear from stop
FLUID PRESSURE TEST- to stop to warm up the fluid. Check
the fluid level in the reservoir and add
LINCOLN CONTINENTAL AND fluid, if necessary.
CONTINENTAL MARK III 3. Turn the steering wheel to the
full right and full left turn positions
The pressure testing gauge set, tool and observe the gauge readings.
T56L-33610-D, requires modification Hold the wheels in this position
to make it adaptable for installation only long enough to obtain an accu-
in the power steering hydraulic sys- rate reading. Do not exceed 5 seconds. FIG. 4—Typical Front Alignment
tem. The parts required and the modi- The gauge should read between Spacer Installation—Cougar,
fication procedure are as follows: 1120 and 1250 psi. If the pressure is Fairlane, Falcon, Montego, Mustang
Tool - T 65 P - 3000 B or C
1266-B
F1432-A F 1499-A
FIG. 5—Typical Rear Alignment FIG. 6—Alignment Spacer FIG. 9—Alignment Spacer
Spacer Installation—Cougar, Installation—Rear—Ford, Installation—Front—Lincoln
Mercury, Meteor, Thunderbird, Continental
Fairlane, Falcon, Montego,
Mustang Continental Mark III
CHALK MARK IN THIS POSITION
WHEN CHECKING TOE-IN AND TOE-OUT
ment. In the absence of such equip- ON TURNS
ment, portable equipment may be
used and the work may be performed
on a level floor. The floor area should
be level within 1/4 inch from front to
rear of the vehicle and within 1/8 inch
from side to side. Alignment height
spacers (Figs. 4, 8 and 9) are used to
check caster and camber. The spacers
should be omitted when checking toe-
in.
1. Check the runout of each front
wheel and tire using a dial indicator
against the rim outer band. If the ru-
nout exceeds 1/8 inch, correction may
be made by rotating the wheel on the
drum. When the minimum runout has CHALK MARK IN THIS POSITION
|F1258-Af WHEN CHECKING CASTER AND CAMBER
been obtained, mark the point of
FIG. 7— Alignment Spacer
greatest runout so the wheels can be LOCATION OF POINT OF GREATEST
positioned as shown in Fig. 10 when Installation — Rear Lincoln Continental LATERAL RUN-OUT ON FRONT
WHEaS WHEN CHECKING
checking the front end alignment. Tool-T65P-3000-B or -C ALIGNMENT FACTORS
Hold a piece of chalk against the
wheel rim or the tire sidewall while F1215-A
spinning the wheels. The chalk will FIG. 70—Front Wheel Position
mark the rim or tire at the point of For Checking Alignment
greatest runout.
2. Drive the vehicle in a straight Lift the front of the vehicle and
line far enough to establish the position the alignment spacers be-
straight ahead position of the front tween the suspension lower arm and
wheels, and then mark the steering the frame spring pocket as shown in
wheel hub and the steering column Figs. 4, 8 and 9. Be sure the spacer
collar (Fig. ll).Do not adjust the pin is placed in the correct hole for
steering wheel spoke position at this the vehicle being checked. The lower
time. If the front wheels are turned at end of the alignment spacers should
any time during the inspection, align be placed over the head of the strut
the marks to bring the wheels back to front attaching bolt. Remove the
the straight-ahead position. bumpers from the right and left rear
F1431-A side rails. Position the rear alignment
3. With the vehicle in position for FIG. 8—Alignment Spacer spacers between the rear axle and the
the front end alignment inspection and rear side rails as shown in Figs. 5, 6
adjustment, install the suspension Installation—Front—Ford, and 7.
alignment spacers as follows to esta- Mercury, Meteor, Thunderbird, 4. Install the wheel alignment
blish the curb height. Continental Mark III equipment on the vehicle. Whichever
type of equipment is used, follow the then the maximum difference must
installation and inspection instructions not exceed 1/2 degree. On all other
provided by the equipment manufactu- vehicles, the maximum camber differ-
rer. ence must never exceed 1/2 degree.
CASTER TOE-IN
Check the caster angle at each front Alignment height spacers should not
wheel. be used to check and adjust toe-in.
The caster is the forward or rear- Toe-in should only be checked and ad-
ward tilt of the top of the wheel justed after the caster and camber
spindle (Fig. 12). If the spindle tilts to have been adjusted to specifications.
the rear, caster is positive. If the Check the toe-in with the front
spindle tilts to the front, caster is neg- wheels in the straight-ahead position.
ative. The correct caster angle, or tilt, Run the engine so that the power
is specified in Part 3-13. steering control valve will be in the
On Mustang, Cougar, Fairlane, c e n t e r ( n e u t r a l ) p o s i t i o n (if so
Falcon and Montego vehicles, the equipped). Measure the distance be-
maximum caster difference for check- tween the extreme front and also be- ALIGNMENT MARKS G-1496-A
ing purposes must not exceed one de- tween the extreme rear of both front
wheels. The difference between these FIG. I?—Straight Ahead Position
gree. If setting is necessary, then the
maximum difference must not exceed two distances is the toe-in or toe-out. Marks—Typical
1/2 degree. On all other vehicles, the Correct toe-in, or inward pointing
maximum caster difference must never of both front wheels at the front is
exceed 1/2 degree. specified in Part 3-13.
CAMBER FRONT WHEEL

POSITIVE
TURNING ANGLE
CAMBER
Check the camber angle at each
• N E G A T I V E - * ! | ^*— POSITIVE
•
front wheel. When the inside wheel is turned 20 CASTER CASTER
Camber is the amount the front degrees, the turning angle of the out- ICL OF TIRE
wheels are tilted at the top (Fig. 12). side wheel should be as specified in
If a wheel tilts outward, camber is
positive. If a wheel tilts inward, cam-
Part 3-13. The turning angle cannot
be adjusted directly, because it is a re-
5r\
ber is negative. The correct camber sult of the combination of caster,
angle, or outward (positive) tilt is camber, and toe-in adjustments and
specified in Part 3-13. should, therefore, be measured only
On Mustang, Cougar, Fairlane, after these adjustments have been CA&U
Falcon and Montego vehicles, the made. If the turning angle does not A N G l E
F1216-A
m a x i m u m c a m b e r difference for measure to specifications, check the
checking purposes must not exceed spindle or other suspension parts for a FIG. 72—Caster and Camber
one degree. If setting is necessary, bent condition. Angles

After front wheel alignment factors 13. The tool should be installed with
have been checked, make the neces- the tool pins in the frame holes and
sary adjustments. Do not attempt to the hooks over the upper arm inner
adjust front wheel alignment by bend- shaft. Then, tighten the tool hook nuts
ing the suspension or steering parts. snug before loosening the upper arm
inner shaft attaching bolts.
CASTER AND CAMBER

Caster
ADJUSTMENTS
To adjust the caster angle, tighten
the tool front hook nut or loosen the
FORD, MERCURY, METEOR, rear hook nut (Fig. 14) as required to
THUNDERBIRDAND increase caster to the desired angle.
CONTINENTAL MARK III To decrease caster, tighten the tool
rear hook nut or loosen the front
Caster and camber is adjusted by hook nut as required (Fig. 14). The
loosening the bolts that attach the caster angle can be checked without
upper suspension arm inner shaft to tightening the inner shaft attaching
the frame side rail, and moving the bolts. Check the camber adjustment to
be sure it did not change during the FIG. 73—Camber and Caster
inner shaft in or out in the elongated
bolt holes with the tool shown in Fig. caster adjustment and adjust if neces- Adjusting Tool
SUSPENSION UPPER CASTER CHANGE CAMBER CHANGE

ARM MOVEMENT
Front Bolt Outboard Tilt Backward Tilt Outward
Increase Positive Caster Increase Positive Camber
or or
Decrease Negative Caster Decrease Negative Camber
Rear Bolt Outboard Tilt Forward
Decrease Positive Caster
or
Increase Negative Caster
Front Bolt Inboard Tilt Forward Tilt Inward
Decrease Positive Caster Decrease Positive Camber
or or
Increase Negative Caster Increase Negative Camber
Rear Bolt Inboard Tilt Backward
Increase Positive Caster
or
Decrease Negative Caster
FIG. 14—Caster and Camber Adjustments
sary. Then, tighten the upper arm TER ADJUSTMENT NUTS

inner shaft attaching bolts to specifi-
cation. Remove the adjusting bar FRONT ADJUSTMENT NUT EAR INSULATOR
(Tool T65P-3OOO-D) and the align- INNER SLEEVE WASHER
ment spacers (Tool T65P-3O00-E or
TURN NUTS
F). REARWARD
TO OBTAIN
POSITIVE OUTER SLEEVE
Camber CASTER RONT INSULATOR
CASTELLATED WASHER
To adjust the camber angle, install NUT
the tool as outlined above (Fig. 13).
Loosen both inner shaft attaching
TURN NUTS
bolts and tighten or loosen the hook FORWARD
nuts to move the inner shaft inboard TO OBTAIN
NEGATIVE
or outboard as necessary with Tool CASTER
T65P-3OOO-D to increase or decrease
camber (Fig. 13). The camber angle
can be checked without tightening the
inner shaft attaching bolts.
COUGAR, FAIRLANE, FALCON, NEGATIVE

CAMBER
MONTEGO, MUSTANG
Be sure all the equipment listed in

Equipment Installation is installed be- SPREAD THIS MEMBER AT
LOWER ARM PIVOT
fore adjusting the caster and camber. BUSHING
Caster is controlled by the front
suspension strut (Fig. 15). To obtain PRY AT THESE POINTS'
F1371-A
positive caster, loosen the strut rear
nut and tighten the strut front nut FIG. J5—Caster and Camber Adjustments
against the bushing. To obtain nega-
tive caster, loosen the strut front nut ment bolt area just enough to permit LINCOLN CONTINENTAL
and tighten the strut rear nut against lateral travel of the arm when the ad-
the bushing. justment bolt is turned. Rotate the
Camber is controlled by the eccen- bolt and eccentric clockwise from the Preliminary Steps
tric cam located at the lower arm at- high position to increase camber or
tachment to the side rail (Fig. 13). counterclockwise to decrease camber. 1. With the car properly positioned
To adjust the camber, loosen the After the caster and camber has and wheel alignment measuring equip-
camber adjustment bolt nut at the been adjusted to specification, torque ment properly installed, raise the hood
rear of the body bracket. Spread the the lower arm eccentric bolt nut and and scribe chalk marks around the
body bracket at the camber adjust- the strut front nut to specification. bolts and lock washers that secure the
upper arm shaft to the frame member

(Fig. 3, Part 3-2).
2. Loosen the arm shaft attaching TURN D O W N W A R D TO TURN TURN UPWARD TO
bolts, raise the front end of the vehicle INCREASE ROD LENGTH TURN UPWARD DOWNWARD INCREASE ROD LENGTH
and lower it again. This will break the TO DECREASE TO DECREASE
ROD LENGTH ROD LENGTH
arm shaft loose from the frame mem-
ber.
3. With a pry bar, move the arm
shaft back into alignment with the
chalk marks made in Step 1, and
tighten the shaft attaching bolts. The LEFT-HAND SLEEVE RIGHT-HAND SLEEVE
bolts should be tightened just enough
to hold the shaft in position without F1433-A
preventing its being moved with the
pry bar. FIG. 16—Spindle Connecting Rod Adjustment
Caster
WHEN TOE-IN IS CORRECT i URN BOTH CONNECTING ROD
TURN BOTH CONNECTING ROD SLEEVES DOWNWARD TO
1. With the aid of a pry bar, move SLEEVES UPWARD TO ADJUST ADJUST SPOKE POSITION
the shaft in or out, as required, to SPOKE POSITION
meet specifications. A movement of
approximately 3 /32 inch at either the
front or rear bolt location will change
the caster 1/2 degree. Inboard move-
ment of the front bolt, or outboard
movement of the rear bolt, will change
caster in the negative direction. Out-
board movement of the front bolt, or
inboard movement of the rear bolt,
will change caster in the positive di-
rection. SHORTEN LEFT ROD
WHEN TOE-IN IS
2. When the caster is correct, tor- NOT CORRECT TO DECREASE TOE-IN
que the shaft attaching bolts to speci- LENGTHEN LEFT ROD TO
LENGHTEN RIGHT ROD
fication and recheck the caster and INCREASE TOE-IN
TO INCREASE TOE-IN
camber to insure that the readings SHORTEN RIGHT ROD
have not changed. TO DECREASE TOE-IN
ADJUST BOTH RODS EQUALLY TO MAINTAIN NORMAL SPOKE POSITION

Camber
1. With the aid of a pry bar, move F1434- A

the shaft in or out, as required, to
meet specifications. A movement of f/G.77—Toe-in and Steering Wheel Spoke Alignment Adjustment—Typical
approximately 3/64 inch of the entire
shaft will change the camber 1/4 de- 1. Loosen the two ciamp bolts or (Part 3-13). Lubricate clamp, bolts
gree. Inboard movement will change each spindle connecting rod sleeve and nuts prior to torquing to specifi-
the camber in the negative direction. (Fig. 16). cation. The sleeve position should not
Outboard movement will change the 2. Adjust toe-in. If the steering be changed when the clamp bolts are
camber in the positive direction. wheel spokes are in their normal posi- tightened.
2. When the camber is correct, tortion, lengthen or shorten both rods
que the shaft attaching bolts to speci- equally to obtain correct toe-in (Fig. WHEEL BALANCING
fication and recheck the camber and 16). If the steering wheel spokes are
caster to insure that the readings have not in their normal position, make the
See the instructions provided with
not changed. Remove all alignment necessary rod adjustments to obtain
the Rotunda Wheel Balancer.
equipment and alignment spacers and correct toe-in and steering wheel
Make certain that the brakes are
install the right and left side rail spoke alignment (Fig. 17).
not dragging before attempting to spin
bumpers. 3. Recheck toe-in and the steering the wheels. Push the brake shoes into
wheel spoke position. If toe-in is cor- the caliper to free the rotor.
TOE-IN AND STEERING rect and the steering wheel spokes are
WHEEL SPOKE still not in their normal position, turn
both connecting rod sleeves upward or LUBRICANT CHECKING
POSITION ADJUSTMENTS
downward same number of turns to PROCEDURE
Check the steering wheel spoke po- move the steering wheel spokes (Fig.
sition when the front wheels are in the 16). MANUAL STEERING GEAR
straight-ahead position. If the spokes 4. When toe-in and the steering
are not in their normal position, they wheel spoke position are both correct, 1. Center the steering wheel.
can be properly adjusted while toe-in torque the clamp bolts on both con- 2. Remove the steering gear hous-
is being adjusted. necting rod sleeves to specification ing filler plug.
3. Remove the lower (upper on 5. Slowly turn the steering wheel to and the filler plug hole, add lubricant
M u s t a n g and C o u g a r ) cover- to- the left stop, lubricant should rise until it comes out both holes during
housing attaching bolt. within the lower cover bolt hole; then this check.
4. With a clean punch or like in- slowly turn the steering wheel to the 6. I n s t a l l the lower (upper on
strument, clean out or push inward right stop, lubricant should rise within M u s t a n g and C o u g a r ) cover- to-
the loose lubricant in the filler plug the filler plug hole. If lubricant does housing attaching bolt and the filler
hole and cover to housing attaching not rise in both the cover bolt hole plug.
bolt hole.
FRONT END GENERAL Check for damage that would affect so that the plunger rests against the
INSPECTION the runout of the wheels. Wobble or inner side of the wheel rim adjacent to
shimmy caused by a damaged wheel the upper arm ball joint.
Do not check and adjust front will eventually damage the wheel bear- 4. Grasp the tire at the top and
wheel alignment without first making ings. Inspect the wheel rims for dents bottom, and slowly move the tire in
the following inspection for front-end that could permit air to leak from the and out (Fig. 18). Note the reading
damage, or wear. tires. (radial play) on the dial indicator. If
1. Check for specified air pressures
in all four tires. UPPER BALL JOINT
2. Raise the front of the vehicle off INSPECTION
the floor. Shake each front wheel
grasping the upper and lower surfaces MAXIMUM TOLERANCE
of the tire. Check the front suspension
Ford, Mercury, Meteor,
ball joints and mountings for loose-
ness, wear, and damage. Check the Thunderbird,
brake backing plate mountings. Tor- Lincoln Continental and
que all loose nuts and bolts to specifi- Continental Mark III
cation. Replace all worn parts as out-
lined in Part 3-2. 1. Raise the vehicle and place floor
3. Check the steering gear mount- jacks beneath the lower arms.
ings and all steering linkage connec- 2. Ask an assistant to grasp the
tions for looseness. Torque all mount- lower edge of the tire and move the
ings to specifications. If any of the wheel in and out.
linkage is worn or bent, replace the 3. As the wheel is being moved in
parts as outlined in Part 3-5. and out, observe the upper end of the
4. Check the front wheel bearings. spindle and the upper arm.
If any in-and-out free play is noticed, 4. Any movement between the F 1500-A
adjust the bearings to specifications. upper end of the spindle and the upper
Replace worn or damaged bearings as arm indicates ball joint wear and loss FIG. T8—Measuring Upper Ball
outlined in Part 3-12. of preload. If any such movement is Joint Radial Play
5. Spin each front wheel with a observed, replace the upper ball joint.
wheel spinner, and check and balance During the foregoing check, the
each wheel as required. lower ball joint will be unloaded and
6. Check the action of the shock may move. Disregard all such move-
absorbers. If the shock absorbers are ment of the lower ball joint. Also, do
not in good condition, the vehicle may not mistake loose wheel bearings for a
not settle in a normal, level position, worn ball joint.
and front wheel alignment may be af-
fected.
Cougar, Fairlane, Falcon,
WHEEL INSPECTION Montego and Mustang
Wheel hub nuts should be inspected 1. Raise the vehicle on a frame

and tightened to specification at pre- contact hoist or by floor jacks placed
delivery. Loose wheel hub nuts may beneath the underbody until the wheel
cause shimmy and vibration. Elongat- falls to the full down position as MAXIMUM TOLERANCE
ed stud holes in the wheels may also shown in Fig. 18. This will unload the
result from loose hub nuts. upper ball joint.
F14 35-A
Keep the wheels and hubs clean. 2. Adjust the wheel bearings as de-
Stones wedged between the wheel and scribed in Part 3-12.
drum and lumps of mud or grease can 3. Attach a dial indicator to the FIG. 79—Measuring Lower Ball
unbalance a wheel and tire. upper arm and position the indicator Joint Radial Play
the reading exceeds specifications importance. The bench, tools, and 1. Remove the power steering pump
(Part 3-13), replace the upper ball parts must be kept clean at all times. and remove the pulley as outlined in
joint. Thoroughly clean the exterior of the Part 3-10.
unit with a suitable solvent and, when 2. Install the pulley on a new
necessary drain as much of the hy- pump. Install the pump and connect
draulic fluid as possible. Handle all only the pressure hose to the pump
LOWER BALL JOINT parts very carefully to avoid nicks, (Part 3-10).
INSPECTION burrs, scratches and dirt, which could 3. Place the fluid return line in a
make the parts unfit for use. suitable container and plug the reser-
Ford, Mercury, Meteor, Do not clean, wash or soak seals in voir return pipe.
Thunderbird, Lincoln Continental cleaning solvent. 4. Fill the reservoir with lubricant
and Continental Mark III (C1AZ-19582-A).
5. Disconnect the coil wire to pre-
INSPECTION
1. Raise the vehicle and place vent the engine from starting and raise
jacks under the lower arms as shown the front wheels off the ground.
1. Check the sector shaft contact
in Fig. 12. This will unload the lower 6. While approximately two quarts
surface in the cover for wear. If worn,
ball joints. of steering gear fluid are being poured
replace the cover.
2. Adjust the wheel bearings as des- into the reservoir, turn the engine over
2. Inspect the input shaft bearing
cribed in Part 3-12. using the ignition key, at the same
for cracked races and the balls for
3. Attach a dial indicator to the time cycle the steering wheel from
looseness, wear, pitting, end play or
lower arm and position the indicator stop to stop.
other damage. Check the fit of the
so that the plunger rests against the 7. As soon as all of the lubricant
bearing on the input shaft. Replace
inner side of the wheel rim adjacent to has been poured in, turn off the igni-
the bearing, if required.
the lower ball joint. tion key, and attach the coil wire.
3. Inspect the valve housing for
4. Grasp the tire at the top and 8. Remove the plug from the reser-
wear, scoring or burrs.
bottom and slowly move the tire in voir return pipe, and attach the return
4. Inspect the tube seats in the
and out (Fig. 19). Note the reading hose to the reservoir.
pressure and return ports in the valve
(radial play) on the dial indicator. If 9. Check the reservoir fluid level; if
body for nicks, etc. If necessary, re-
the reading exceeds specifications low, add fluid to the proper level. Do
move and replace.
(Part 3-13), replace the lower ball not overfill.
5. Check the sector shaft contact
joint. 10. Lower the vehicle.
surface in the housing for wear. If
11. Start the engine and cycle the
worn, replace the bushing or the hous-
Cougar, Fairlane, Falcon, steering from stop to stop to expel
ing.
any trapped air from the system.
Montego, Mustang 6. Check all fluid passages for ob-
struction or leakage.
7. Inspect the steering gear housing POWER STEERING PUMP—ALL
1. Raise the vehicle on a frame
for cracks, stripped threads, and mat- EXCEPT LINCOLN
contact hoist or by floor jacks placed
beneath the underbody until the wheel ing surfaces for burrs. Inspect the pis- CONTINENTAL AND
falls to the full down position. ton bore of the housing for scoring or CONTINENTAL MARK III
2. Ask an assistant to grasp the wear. If necessary, replace the hous-
lower edge of the tire and move the ing.
wheel in and out. 8. Check the input shaft bearing CLEANING
3. As the wheel is being moved in after installation to be sure that it ro-
tates freely. Wash all parts (except seals) in a
and out, observe the lower end of the
9. If the valve spool is not free in Naptha or Chlorinated-type solvent
spindle and the lower arm.
the valve housing, check for burrs at and dry with compressed air.
4. Any m o v e m e n t between the
the outward edges of the working
lower end of the spindle and the lower
lands in the housing and remove with
arm indicates ball joint wear and loss Punch or Rod
a hard stone. Check the valve spool
of preload. If any such movement is
for burrs and if burrs are found, stone
observed, replace the lower arm.
the valve in a radial direction only.
During the foregoing check, the
Check for freedom of the valve again.
upper ball joint will be unloaded and
may move. Disregard all such move- 10. Check the piston rack teeth and
ment of the upper ball joint. Also, do sector shaft teeth for nicks and burrs.
not mistake loose wheel bearings for a
worn ball joint.
FLUSHING THE POWER
STEERING SYSTEM—ALL EXCEPT
POWER STEERING GEAR
LINCOLN CONTINENTAL AND
CLEANING CONTINENTAL MARK III
Disassembly and assembly of the Should it be necessary to replace an

steering gear and. the sub-assemblies inoperative power steering pump, the RELIEF VALVE PLUNGER
must be made on a clean workbench. need for flushing the steering system G1607-A
As in repairing any hydraulically op- is required when installing the new
erated unit, cleanliness is of utmost pump. FIG. 20—Cleaning Pump Relief Valve
The following procedure should be The rotor and cam assembly can be 1. Hold the plate assembly in a
followed when cleaning the relief valve reused if there is no wear other than horizontal position and grip at least
which is a part of the pump valve as- the removal of the phosphate coating an inch of the dowel pin in a vise. Tap
sembly. on the cam contour. Do not disas- the plate with a plastic or a rubber
1. Using a punch or rod of suitable semble the rotor and cam assembly. hammer to pull the pin from the
diameter, apply an even pressure in a Push the rotor part way out the cam plate.
straight line to the tip of the relief insert taking care not to let the slip- 2. Insert the support guide (Tool
valve pin (Fig. 20). Depress the valve pers and springs fall out. Check the T69P-3D608-B) over a dowel pin (Fig.
two or three times to exhaust the oil cam ID for scoring and burning. 22) and press the pin into the plate to
which is trapped in the assembly. Do Check the rotor faces and OD for a height of 1.68 inch (See Fig. 23).
not hammer on the valve pin or hous- scoring and chipping. Do not attempt The support guide tool will serve as a
ing. to repair or refinish the lower and stop guide. Be careful not to bend the
2. Submerge the assembly in a con- upper pressure plates, cam or rotor new dowel pin during installation.
tainer of clean solvent. Again applying assembly. When wear or burning is 3. Again use Tool T69P-3D608-A
an even pressure to the tip of the relief encountered, replace, them with new (with a dial indicaator) to check the
valve pin, (a sudden strong force could components. dowel pin squareness as outlined
push the pin through the relief valve Install a new rotor and cam assem- above.
spool) move the valve in and out sev- bly if the slippers are worn. Replace
eral times, thereby thoroughly flushing the springs if they are bent or broken. POWER STEERING PUMP
the assembly. Pressure created within Polishing the phosphate coating of the INSPECTION—LINCOLN
the valve bore when the valve is moved slipper sealing surface is permissable. CONTINENTAL AND
inward should force the cleaning fluid The rotor shaft can be reused if the CONTINENTAL MARK III
out through the sensing orifice. If this front and rear thrust faces, the bush-
does not occur, the sensing orifice ing diameter and the shaft seal diame- 1. Wash all parts in clean solvent
should be cleaned with a piece of wire. ter are not excessively worn or scored. and dry them with clean cloths or
The valve must move freely and even- The housing plate and bushing as- compressed air.
ly. If the pin is bent or damaged, or if sembly may be reused if all of the 2. Inspect the rotor shaft for wear,
the valve binds, the pump valve must t h r e a d e d holes are not damaged scoring, nicks, or burrs. Replace the
be replaced. beyond repair and the bushing diame- shaft if it is damaged or if the inner
ter is not scored or worn .0005 inch keyway is damaged.
INSPECTION over the maximum dimension of .6897
inch. Threaded holes can be repaired
Tool T69P-3D608-B
The following describes the compo- by drilling out the damaged threads
nents of the power steering pump and installing a helicoil insert. If the
which must be replaced regardless of bushing is scored or excessively worn,
condition and how to determine when a new plate and bushing assembly
other components should be replaced. must be installed.
The outlet fitting hex nut may be With Tool T69P-3D608-A (using a
reused if the corners of the hex are dial indicator) check the squareness of
not rounded. The housing bolts may the fixed dowel pin in the plate (Fig.
be reused if the threads are not dam- 21). The pin must be square with the
aged. adjacent surface within .001 inch per
All gaskets and seals must be re- inch through a 180 degree arch.
placed with new components except A bent or broken dowel pin can be G1609-A
the rotor shaft seal which should be replaced as follows: FIG. 22—Dowel Pin Insertion
reused unless it was leaking.
The reservoir assembly may be
reused if the reservoir seal and gasket
areas are not damaged (dents, scratch-
es, etc.). The soldered joints of the re-
turn and fill tubes must not be loose
or bent. Be sure to check for a broken
baffle.
The housing or housing assembly
may be reused if there is no damage
(scratches, etc.) at reservoir gasket,
outlet fitting or cover seal areas.
If the outlet fitting is damaged, the
pump housing must be replaced. The
pressure plate springs may be reused
providing they are not bent, broken or
have not taken a set.
Do not reuse the retainer end plate
if it is burred or damaged. The upper Tool T69P-3D608-A
G1608-A
pressure plate may be reused if there
is no scoring on the wear surface. It is FIG. 21—Dowel Pin Squareness
acceptable to polish the phosphate Check FIG. 23 — Replacing Dowel Pin
coating.
3. Inspect the rotor, rollers, cam Before replacing a shock absorber, action is smooth, but the shock absor-
ring, pressure plate, cover, and bush- check the action of the shock absorbers are suspected of being weak fol-
ing in the pressure plate for wear or bers as follows: low step 4:
scoring. If damaged, replacement of 4. Repeat step 3 on the mating
the pump (less housing) is required. ON VEHICLE TESTS shock absorber installed on the oppo-
4. Make sure the inner faces of the site side of the vehicle, and compare
cover and the housing are free of 1. Check the shock absorber to be results of both tests. If the action is
paint, nicks, or burrs. Check all fluid sure it is securely and properly in- similar, it is unlikely that either shock
passages for restrictions. stalled. Check the shock absorber in- absorber is defective. Reconnect both
5. I n s p e c t the valving surfaces sulators for damage and wear. shock absorbers.
(areas where the rotor and rollers con- Replace any defective insulators and Replace the shock absorber having
tact) for wear or scoring. Replace the tighten attachments to the specified the lower resistance. Ensure that the
pressure plate or the cover if worn or torque (on a shock absorber which in- part number of the replacement is the
scored. Inspect the bushing in the corporates integral insulators, replace same as that of the original shock ab-
pressure plate for wear or scoring, and the shock absorbers). sorber. The replacement shock absor-
replace the plate if necessary. 2. Inspect the shock absorber for ber resistance will appear to be higher
6. Inspect the control valve for evidence of fluid leakage. A light film than either original due to initial fric-
scores, nicks, or burred edges. Re- of fluid is permissible. Be sure any tion of the rod seal.
place the valve if damaged. Do not dis- fluid observed is not from sources
assemble the valve. Check the valve other than the shock absorber. BENCH TEST
for free movement in the housing Replace the shock absorber if leak-
bore. age is severe. With the shock absorber right side
7. Inspect the tube seat in the hous- 3. Disconnect the lower end of the up (as installed in vehicle), extend it
ing. If damaged, remove it with an shock absorber. Extend and compress fully. Then turn the shock absorber
E-Z-Out and install a new seat. the shock absorber as fast as possible, upside down and fully compress it.
using as much travel as possible. Repeat this procedure at least three
Action should become smooth and times to ensure that any entrapped air
SHOCK ABSORBER CHECKS u n i f o r m t h r o u g h o u t each stroke. has been expelled. Now place the
Higher resistance on extension than shock absorber right side up in a vise,
All vehicles are equipped with hy- on compression is a normal condition. and hand stroke the shock absorber as
draulic shock absorbers of the direct- Faint swish noises are also normal. described in On Vehicle Tests, step 3.
acting type and are nonadjustable and Remove the shock absorber for a If action is not now smooth and uni-
nonrefillable. They cannot be repaired. bench test if action is erratic. If the form, install a new shock absorber.
03-02-01 Suspension 03-02-01
PART 3-2 Suspension

MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
COMPONENT INDEX
Mustang
Montego
Mercury
Mark III
Fairlane
Lincoln-
Cougar
Meteor
Falcon
Ford
1
BALL JOINT
BUSHING
DRIVE SHAFT PINION ANGLE
Adjustment 02-11 02-11 02-11 N/A N/A N/A N/A N/A N/A 02-11 02-11
FRONT SHOCK ABSORBER
FRONT SPRING
Removal and Installation 02-12 02-12 02-12 02-13 02-13 02-13 02-13 02-13 N/A 02-12 02-12
FRONT SPRING AND LOWER ARM
FRONT SUSPENSION
Description 02-02
FRONT SUSPENSION LOWER ARM
FRONT SUSPENSION LOWER ARM STRUT
AND/OR BUSHING
Adjustment and Repair 02-11 02-11 02-11 N/A N/A N/A N/A N/A N/A 02-11 02-11
FRONT SUSPENSION UPPER ARM
FRONT SUSPENSION UPPER ARM
BUSHING - ARM REMOVED
Disassembly and Overhaul 02-27 02-27 02-27 N/A N/A N/A N/A N/A N/A 02-27 02-27
FRONT WHEEL SPINDLE
HOISTING INSTRUCTIONS 02-08
INNER SHAFT
LOWER ARM - REMOVED
Disassembly and Overhaul N/A N/A N/A N/A N/A N/A N/A N/A 02-27 N/A N/A
LOWER ARM STRUT AND/OR BUSHING •
Removal and Installation N/A N/A N/A 02-11 02-11 02-11 02-11 02-11 N/A N/A N/A
LOWER BALL JOINT - ARM IN VEHICLE
REAR SHACKLE AND HANGER ASSEMBLY
REAR SHOCK ABSORBER
REAR SHOCK ABSORBER LOWER
MOUNTING STUD
Removal ancl Installation N/A N/A N/A N/A N/A N/A N/A N/A 02-23 N/A N/A
03-02-02 Suspension 03-02-02
MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
REAR SPRING
Disassembly and Overhaul N/A N/A N/A N/A N/A N/A N/A N/A 02-28 N/A N/A
REAR SUSPENSION
Description 02-02 02-02 02-02 02-04 02-04 02-04 02-04 02-04 02-04 02-02 02-02
REAR SUSPENSION LOWER ARM
REAR SUSPENSION UPPER ARM
SPRING LEAVES AND TIE-BOLT
STABILIZER
TRACK BAR
UPPER ARM - REMOVED
UPPER ARM SHAFT A N D / O R BUSHING
UPPER BALL JOINT
DESCRIPTION
FRONT SUSPENSION REAR SUSPENSION The upper end of the rear shock ab-
sorber is attached to the spring upper
seat; the lower end is bolted to a
FORD, MERCURY, bracket on the axle housing.
METEOR, THUNDERBIRD AND The upper suspension arm attaches
CONTINENTAL MARK III to the right side of the axle housing
Each front wheel rotates on a through an eccentric pivot bolt and a
Each rear wheel, hub, and brake
spindle. The upper and lower ends of bracket which is welded to the top of
drum assembly is bolted to the rear
the spindle are attached to upper and the housing. The forward end of the
axle shaft flange. The axle shaft as-
lower ball joints which are mounted to arm is connected by a pivot bolt to
sembly rotates in the rear axle hous-
an upper and lower arm respectively. the frame crossmember.
ing.
The upper arm pivots on a bushing Each lower suspension arm attaches
The rear axle housing is suspended
and shaft assembly which is bolted to to one end of the axle housing
from the frame by a coil spring and
the frame. The lower arm pivots on a through a pivot bolt and a bracket
shock absorber at each side of the ve-
bolt in the front crossmember (Figs. 1, which is welded to the underside of
hicle and by three arms (one upper
2 and 3). A coil spring seats between the housing. The forward end of the
and two lower) which pivot in the
the lower (upper on Cougar, Fairlane, arm is connected by a pivot bolt to
frame members (Fig. 4).
Falcon, Montego and Mustang) arm the frame side member.
and the top of the spring housing. A Each coil spring is mounted be- A track bar is connected between
double action shock absorber is bolted tween a lower seat, which is welded to the upper arm bracket on the axle
to the arm and the top of the spring the axle housing, and an upper seat housing and a mounting bracket on
housing. which is integral with the frame. the left frame side rail.
BALL JOINT
3263
BUSHING
INNER SHAFT
3068
BOLT MUST BE INSTALLED FROM UPPER ARM
TOP OF STABILIZER BAR (HEAD UP)
3082
STABILIZER BAR
5482
SPRING INSULATOR
5415
BUSHING
3A187
F1246-C
FIG. 1 — Front Suspension Disassembled—Typical—Ford, Mercury, Thunderbird, Continental Mark

03-02-04 Suspension 03-02-04
COUGAR, FAIRLANE, SHOCK ABSORBER SHOCK ABSORBER

FALCON, MONTEGO, UPPER MOUNTING
MUSTANG BRACKET
LINCOLN CONTINENTAL
Each rear wheel, hub and brake SPRING

drum assembly is bolted to the rear
axle shaft flange. The wheel and axle
shaft assembly rotates in the rear axle
housing. Two spring pads, integral
with the axle housing, rest on two leaf
spring assemblies. The axle housing is
UPPER ARM
fastened to the center of the springs
by spring clips (U-bolts), retainers,
and nuts (Figs. 5 and 6). Each spring
assembly is suspended from the under-
body side rail by hanger and shackle
assemblies at the front and rear. The
integral mounting stud at the upper
end of each shock absorber is attached
to the crossmember by a mounting
plate. The lower end is mounted to a
stud which is integral with a bracket
welded to the axle housing.
FIG. 2—Front Suspension—Typical—Cougar, Fairlane, Falcon,

Montego, Mustang
F 1497. A
3—Front Suspension—Lincoln Continental

o
CO
REAR SPRING
5560
CD
!c€raMi~z'
VENT
TUBE
UPPER ARM
5500
INDENT TOWARD
FRONT OF VEHICLE
LEFT ARM INDENTED O
BY 2 NOTCHES IN BUSHING FLANGE CO
F J353-A
6
Pin. ^—Rear Suspension—Disassembled—Ford, Mercury, Thunderbird, Continental Mark 6
Cn
03-02-06 Suspension 03-02-06
F1085-D
FIG. 5—Rear Suspension—Typical—Cougar, Fairlane, Falcon,

Montego, Mustang
03-02-07 Suspension 03-02-07
BUSHING
5791
SPRING HANGER
5987
RETAINER
5A631
INSULATOR
5732
BUSHING
RETAINER
F 1220-C
FIG. 6—Rear Suspension Components—Lincoln Continental

03-02-08 Suspension 03-02-08
HOISTING INSTRUCTIONS 11. Position the ball joint stud in

the spindle bore, and torque the at-
Damage to steering linkage compo- taching nut to specification. Install a
nents and front suspension struts may new cotter pin.
occur if care is not exercised when po- 12. Install the wheel and tire.
sitioning the hoist adapters of 2 post 13. Remove the safety stands, and
hoists prior to lifting the vehicle. lower the vehicle.
If a 2 post hoist is used to lift the 14. Check and, if necessary, adjust
vehicle, place the adapters under the caster, camber, and toe-in. Whenever
lower arms or the No. 1 crossmember. any part of the front suspension has
Do not allow the adapters to contact been removed and installed, front
the steering linkage. If the adapters wheel alignment must be checked.
are placed under the crossmember, a
piece of wood (2 x 4 x 16 inches) COUGAR, FAIRLANE,
should be placed on the hoist channel FALCON, MONTEGO,
between the adapters. This will pre- MUSTANG
vent the adapters from damaging the
front suspension struts. 1. Position a support between the
upper arm and frame side rail as
shown in Figs. 8 and 9; then, raise the
UPPER BALL JOINT
vehicle and position safety stands.
REPLACEMENT 2. Remove the wheel and tire.
3. Remove the cotter pin and nut
FORD, MERCURY, from the upper ball joint stud.
METEOR, THUNDERBIRD, F1436-A
4. Position the ball joint remover
CONTINENTAL MARK III tool as shown in Fig. 10. The tool
FIG. 7—Disconnecting Ball
should seat firmly against the ends of
Joints—Typical both studs, and not against the lower
1. Raise the vehicle high enough to
provide working space, and place a 9. Attach the new ball joint to the stud nut. It may be necessary to re-
support under the lower arm. If a upper arm. Use only the specified move the lower ball joint cotter pin if
chain hoist or a jack that has a nar- bolts, and nuts. Do not rivet the new it prevents the tool from seating on
row contact pad is to be used on the ball joints to the arm. Torque the nuts the lower stud.
bumper to raise the vehicle, distribute to specification. 5. Turn the tool with a wrench until
the load along the bumper by using a 10 Install the upper arm suspension both studs are under tension, and
steel plate 3 or 4 inches long as a con- bumper. Torque the nut to specifica- then, with a hammer, tap the spindle
tact pad to prevent damaging the tion. near the upper stud to loosen the stud
bumper.
2. Remove the wheel and tire.
3. Drill a 1/8-inch hole through
each upper ball joint retaining rivet.
Using a large chisel, cut off the rivets.
4. Remove the upper arm suspen-
sion bumper.
from the upper ball joint stud.
6. Place a box wrench over the
lower end of the ball joint remover
tool, and position the tool as in Fig. 7.
The tools should seat firmly against
the ends of both studs, and not
against the lower stud nut.
7. Turn the wrench until both studs
are under tension, and then, with a
hammer, tap the spindle near the
upper stud to loosen the stud from the
spindle. Do not loosen the stud with
tool pressure alone. Remove the ball
joint.
8. Clean the end of the arm, and
remove all burrs from the hole edges.
F 1496-A
Check for cracks in the metal at the
holes, and replace the arm if it is
cracked. FIG. 8—Upper arm Support—Mustang
03-02-09 Suspension 03-02-09
5. Install the spring compressor

tool (Figs. 20, 21 and 22).
6. Remove 2 upper arm-to-spring
tower attaching nuts and swing the
upper arm outboard from the spring
tower.
7. Rotate the inner shaft so that the
studs can be removed. Remove the
studs with a soft mallet.
8. Unscrew the bushings from the
shaft and suspension arm; then, re-
move the shaft from the arm.
1495-A 9. Position the shaft in the. arm,
FIG. 11 —Shaft Centered in apply grease to the new bushings and
Arm—Typical O-rings, and install the bushings loose
on the shaft and arm. Turn the bush-
ings so that the shaft is exactly cen-
WOOD BLOCK F 1287-A
tered. The shaft will be properly cen-
FIG. 9—Upper Arm Support— tered when dimensions A and B in
Fig. 11 are equal.
Montego, Falcon and Fairlane
10. Fabricate a spacer from a sec-
tion of 3/4-inch diameter pipe or
Tool-T62F-3006-A m e t a l of c o m p a r a b l e size and
ARM SUPPORT
strength. The spacer should be 6
15/16 inches long.
11. Position the spacer parallel with
the inner shaft, and force the spacer
between the flanges of the upper arm
(Fig. 12).
If the spacer cannot be forced be-
tween the arm flanges due to excessive
distortion, replace the upper arm as-
sembly.
F 1494- A
12. With the spacer positioned in
FIG. 12—Torque Upper Arm the arm, torque the bushings to speci-
Inner Shaft Bushings—Typical fication. Move the arm on the shaft to
SLEEVE
be sure that no binding exists, then re-
10. Lubricate the ball joint, and in- move the spacer.
Too/-T57P-3006-A
stall the wheel and tire. Torque the 13. Attach the suspension upper
LOWER BALL JOINT F 1157-C lug nuts to specification (Part 3-13). arm to the underbody. Release the
11. Remove the safety stands, and front spring.
FIG. TO—Loosening Ball Joint lower the vehicle.
Studs in Spindle—Typical 14. Remove the spring compressor
12. Remove the support from be- and position the wheel, tire, and hub
tween the upper arm and frame. and drum on the spindle.
13. Check and, if necessary, adjust 15. Install the bearing, washer, ad-
from the spindle. Do not loosen the
caster, camber, and toe-in.
stud with tool pressure alone. Raise justing nut and nut lock. Adjust the
the stud out of the spindle bore. wheel bearing as outlined in Part 3-12
6. Using a large chisel, cut off the UPPER ARM SHAFT AND/OR and install the cotter pin, grease cap
three upper ball joint retaining rivets BUSHING REPLACEMENT and hub cap or wheel cover.
and remove the ball joint. 16. Lower the vehicle and install
7. Clean the end of the arm, and COUGAR, FAIRLANE, the shock absorber and upper mount-
remove all burrs from the hole edges. FALCON, MONTEGO, ing bracket.
Check for cracks in the metal at the MUSTANG 17. Check caster, camber, and toe-
holes, and replace the arm if it is in, and adjust as necessary (Part 3-1).
cracked. 1. Remove the shock absorber and
8. Attach the new ball joint to the upper mounting bracket as an assem- LOWER BALL JOINT
upper arm. Use only the specified bly.
REPLACEMENT-
bolts, nuts, and washers. Do not rivet 2. Raise the vehicle on a hoist, in-
the new ball joint to the arm. Torque stall safety stands, and remove the ARM IN VEHICLE
the nuts to specification (Part 3-13). wheel cover or hub cap.
9. Position the lower ball joint stud 3. Remove the grease cap from the
in the spindle bore, and torque the at- hub; then, remove the cotter pin, nut FORD, MERCURY,
taching nut to specification. Install a lock, adjusting nut and outer bearing METEOR, THUNDERBIRD,
new cotter pin and tighten the nut if from the hub. CONTINENTAL MARK III
necessary to line up the cotter pin 4. Pull the wheel, tire, and the hub
hole. Install a new cotter pin in the and drum off the spindle as an assem- 1. Raise the vehicle high enough to
lower ball joint if it was removed. bly. provide working space, leaving the
03-02-10 Suspension 03-02-10
lower arm free to drop as coil spring T57P-3006-A UPPER ARM arm slightly. Place a support stand
tension is eased. If a chain hoist or a UPPER BALL JOINT under the lower arm as a safety pre-
jack that has a narrow contact pad is caution.
to be used on the bumper to raise the 10. Remove the nut from the ball
car, distribute the load along the joint stud. Raise the upper arm and
bumper by using a steel plate 3 or 4 spindle until the spindle clears the ball
inches long as a contact pad to pre- stud. Prop the upper arm in a raised
vent damaging the bumper. position.
2. If the ball joint is riveted to the 11. Remove the ball -joint rivet
arm, drill a 1/8-inch pilot hole com- heads with a chisel. Punch the remain-
pletely through each rivet. Then drill ing portion of the rivets from the
off the rivet head through the pilot holes, and remove the joint.
hole with a 3/8-inch drill, and drive 12. Install the new joint using the
out both rivets. parts supplied in the kit. Torque the
3. Position a jack or safety stand nuts to specification. Make sure the
under the lower arm, and lower the joint is completely filled with the spec-
vehicle about 6 inches to offset the ified lubricant.
coil spring tension. 13. Lower the upper arm while
4. Remove the cotter pin from the guiding the spindle over the ball stud.
ball joint stud, and remove the nut. Install the stud nut and tighten it to
5. Place a box wrench over the specification. Continue to tighten the
lower end of the tool shown in Fig. 7, nut to line up the cotter pin hole. In-
and position the tool. The tool should stall the cotter pin.
seat firmly against the end of both 14. Install the gasket and shield on
studs, and not against the upper stud the spindle. Tighten the attaching
nut. bolts to specifications.
6. Turn the wrench until both studs 15. Install the hub and rotor on the
are under tension, and then, with a spindle and adjust the wheel bearings.
hammer, tap the spindle near the LOWER BALL JOINT \ LOWER ARM 16. Install the caliper to the spindle
lower stud to loosen the stud from the T62F.3006-A F 1493-A and tighten the attaching bolts to
spindle. Do not loosen the stud with specifications. Check for the correct
FIG. 13— Loosening Ball Joint
tool pressure alone. Remove the ball flexible hose routing (Part 2-2).
Stud 17. Install the wheel and tire. Tor-
joint.
7. Clean the end of the arm, and que the wheel nuts to specification and
remove all burrs from the hole edges. Lower Arm lower the vehicle.
Check for cracks in the metal at the
holes, and replace the arm if it is 1. Raise the vehicle. Place a sup- Upper Arm
cracked. port under each rail to the rear of the
8. Position the stud of the ball joint lower arm in the lifting pad area. 1. Place a jack under the outer end
to the spindle bore, and install the at- 2. Remove the wheel and tire from of the lower arm, and raise the arm.
taching nut finger-tight. the hub. Place a support stand under the side
9. Attach the ball joint to the lower 3. Remove 2 bolts and washers that rail in the lifting pad area.
arm. Use only the specified bolts and attach the caliper to the spindle. Re- 2. Remove the wheel and tire.
nuts. Do not rivet the new ball joint to move the caliper from the rotor and 3. Remove the cotter pin from the
the arm. Torque nuts to specification. wire it to the underbody to prevent upper ball stud, and loosen the nut
10. Torque the ball joint stud nut damage to the brake hose. one to two turns.
to specification, and install a new cot- 4. Remove the hub and rotor from % 4. Place a box wrench over the
ter pin. the spindle. lower end of the ball joint remover
11. Remove the jack. 5. Remove the splash shield and tool, and position the tool as in Fig.
12. Check and, if necessary, adjust gasket from the spindle. 13). The tool should seat firmly
caster, camber, and toe-in. Whenever 6. Remove the cotter pin from the against the ends of both studs, and
any part of the front suspension has lower ball stud, and loosen the nut not against the upper stud nut.
been removed and installed, front one to two turns. 5. Turn the wrench until both studs
wheel alignment must be checked. 7. Place a box wrench over the are under tension, and then, with a
lower end of the ball joint remover hammer, tap the spindle near the
tool, and position the tool as in Fig. upper stud to loosen the stud from the
13. The tool should seat firmly against spindle. Do not loosen the stud with
BALL JOINT REPLACEMENT the ends of both studs, and not tool pressure alone.
against the lower stud nut. 6. Raise the upper arm to free the
8. Turn the wrench until both studs ball stud from the spindle. Wire the
LINCOLN CONTINENTAL are under tension, and then, with a upper end of the spindle to the under-
hammer, tap the spindle near the body to prevent damage to the brake
The lower ball joint is riveted to the lower stud to loosen the stud from the hose.
lower arm wheras the upper ball joint spindle. Do not loosen the stud with 7. Remove the ball joint retaining
is bolted to the upper arm. When re- tool pressure alone. nuts and bolts, and remove the joint.
placing a ball joint, use all the parts 9. Place a jack under the spring 8. Install the new joint using the
supplied in the kit. pocket in the lower arm, and raise the parts supplied in the kit. Torque the
03-02-11 Suspension 03-02-11
nuts to specification. Make sure that FRONT SUSPENSION LOWER 2. Raise the vehicle, position safety
the joint is completely filled with the ARM STRUT AND/OR stands, and remove the wheel and tire.
specified lubricant. 3. Remove the cotter pin, castelated
BUSHING
9. Guide the ball joint stud into the nut and the adjustment nut from the
spindle. Install the stud nut and tor- front of the strut.
FORD, MERCURY,
que it to specification. Continue to 4. With two pry bars approximately
METEOR, THUNDERBIRD,
tighten the nut to line up the cotter 18 inches long, one at each side and at
pin hole. Install the cotter pin. the rear of the front washer, pry it
10. Install the wheel and tire. Tor- forward to separate the inner sleeve
que the wheel nuts to specification. 1. Remove the cotter pin from the
lower arm strut at the frame front from the outer sleeve. Remove the
crossmember and remove the nut, front insulator from the strut (Fig.
washer, and bushing from the strut. 26).
2. Remove nuts, washers, and bolts 5. Install the new rear washer
STABILIZER REPAIR attaching the strut and rubber bumper (large ID), outer sleeve and insulator
to the lower arm (Fig. 1). bushing on the forward end of the
3. Pull the strut from the frame strut rod.
FORD, MERCURY, crossmember. 6. P o s i t i o n the s t r u t i n t o the
METEOR, THUNDERBIRD, 4. Remove the crossmember rear crossmember and to the lower suspen-
CONTINENTAL MARK III side bushing and washer from the sion arm. Install the strut-to-arm at-
strut. taching bolts and nuts, and torque
To replace the end bushings on each 5. Place the crossmember rear side them to specification.
stabilizer link, use the following pro- washer and bushing on the strut and 7. Install the forward insulator
cedure. position the strut to the frame and washer (small ID), inner sleeve and
1. Raise the vehicle on a hoist. lower arm. adjustment nut on the forward end of
the strut. The inner sleeve need not be
2. Remove the nut, washer and in- 6. Position the rubber bumper on
crimped to the outer sleeve.
sulator from the lower end of the sta- the strut and install the bolts, washer,
bilizer bar attaching bolt. and nuts attaching the strut to the 8. Install the wheel and tire, re-
3. Remove the bolt and the remain- lower arm. Torque the nuts and bolts move the safety stands and lower the
ing washers(3) insulators (3) and the to specification. vehicle. Remove the tool supporting
spacer. 7. Install the bushing, washer, and the upper arm.
4. Assemble a flat washer and a nut on the strut at the front cross- 9. Adjust the caster and camber to
new insulator on the bolt. member. Tighten the nut and install specification.
5. Insert the bolt through the stabi- the cotter pin. 10. Install the castellated nut and
lizer bar then install a new insulator 8. Check caster, camber, and toe-in cotter pin.
and a flat washer on it. and adjust if necessary.
6. Install the spacer, flat washer DRIVE SHAFT PINION
and another new insulator on the bolt LOWER ARM STRUT AND/OR ANGLE ADJUSTMENT
(Fig. 1). BUSHING REPLACEMENT
7. Insert the bolt through the lower
arm and install a new insulator and a COUGAR, FAIRLANE, FORD, MERCURY,
flat washer. Install and torque the at- FALCON, MONTEGO, METEOR, THUNDERBIRD,
taching nut to specification. MUSTANG CONTINENTAL MARK III
1. Position the support as shown in The pinion-drive shaft working

Figs. 8 and 9 under the upper arm. angle must be checked and adjusted to
COUGAR, FAIRLANE,
FALCON, MONTEGO,
MUSTANG
1. Raise the vehicle high enough to

provide working space, and place sup-
ports under both front wheels.
2. Disconnect the stabilizer from
each link. Disconnect both stabilizer
attaching brackets, and remove the
stabilizer.
3. Coat the necessary parts of the
stabilizer with RUGLYDE or a com-
parable lubricant, and slide new insu-
lators onto the stabilizer. ADJUSTING
4. Secure each end of the stabilizer SCREW
bar to the lower arm making sure that
the bolt head is at the top (Fig. 2) to F1503-A
eliminate interference with the brake F1432- A
hose.
5. Remove the supports and lower FIG. 14—Alignment Spacer FIG. 75—Positioning Tool On
the vehicle. Installation U-Joint
03-02-12 Suspension 03-02-12
degree on Ford, Mercury or Meteor

models, 7 1/4 degrees plus 3/4 degree
ECCENTRIC UPPER ARM on Thunderbird or Continental Mark
WASHER KET III models.
ECCENTRIC
WASHER
Adjustment
If the pinion angle is not within

AXLE HOUSING specifications, adjust the pinion angle
E1761-A as follows:
The upper arm-to-axle housing bolt
FIG. 17 — Pinion Angle Adjustment and two eccentric washers form an ad-
1. Position the magnetized Tool justing cam mechanism (Fig. 17)
T68P-4602-A on a U-joint bearing which will tilt the axle housing to the
F1504-A cap as shown in Fig. 15. required angle.
2. With the tool suspended straight 1. Loosen the upper arm pivot bolt
FIG. 76 —Measuring Pinion Angle down and the adjusting screw to the nuts.
left, adjust the dial on the tool until 2. If the angle is less than specifica-
specification whenever the rear axle the left-hand edge of the bubble is ex- tions, rotate the adjusting cam for-
has been removed. actly on the zero line. ward and recheck the angle. If the
Before checking the drive shaft pin- 3. Position the vee magnet on the angle is more than specification, ro-
ion angle, alignment height spacer drive shaft away from welds and bal- tate the adjusting cam rearward and
(Tool T65P-3OOO-B or C) must be in- ance weights (Fig. 15). recheck the angle.
stalled at a height of 4.30 inches (Fig. 4. Position the magnetized tool 3. When the axle housing is adjust-
14). (T68P-4602-A) on the vee magnet ed in such a way that the drive shaft
with the adjusting screw to the left in angle reading is within specification,
Checking Procedure the same relative position as it was on install new pivot bolt nuts and torque
the bearing cap (Fig. 16). to specification (Fig. 17).
The checking and adjusting proce- 5. Read the position of the bubbles 4. Lower the vehicle and road test
dure must be done with the weight of left-hand edge on the scale to deter- for proper axle operation.
the vehicle on the front and rear sus- mine the drive shaft pinion angle. The
pension. reading should be 3 1/2 degrees plus 1
HOISTING INSTRUCTIONS FRONT SPRING 5. Disconnect the lower end of the

REPLACEMENT sway bar stud from the lower arm.
6. Remove the nut and bolt that se-
cures the inner end of the lower arm
FORD, MERCURY,
Damage to steering linkage compo- to the crossmember.
nents and front suspension struts may 7. Carefully lower the jack slowly
CONTINENTAL MARK HI
occur if care is not exercised when po- to relieve the spring pressure on the
sitioning the hoist adapters of 2 post lower arm, then remove the spring
hoists prior to lifting the vehicle. Removal (Fig. 18).
If a 2 post hoist is used to lift the
1. Raise the vehicle and support the Installation
vehicle, place the adapters under the
lower arms or the No. 1 crossmember. front end of the frame with jack
Do not allow the adapters to contact stands. 1. Position the spring on the lower
the steering linkage. If the adapters 2. Place a jack under the lower arm arm so that the lower end properly
are placed under the crossmember, a to support it. engages the seat.
piece of wood (2 x 4 x 16 inches) 3. Disconnect the lower end of the 2. Raise the lower arm carefully
should be placed on the hoist channel shock absorber from the lower arm. with a jack while guiding the inner
between the adapters. This will pre- 4. Remove the bolts that attach the end to align with the bolt hole in the
vent the adapters from damaging the strut and the rebound bumper to the crossmember. Insert the attaching bolt
front suspension struts. lower arm. in the rear of the crossmember and
03-02-13 Suspension 03-02-13
BALL JOINT BOLT HEAD STABILIZER

and adjust it to the recommended
specifications if required.
COUGAR, FAIRLANE,
FALCON, MONTEGO,
MUSTANG
Removal
1. Remove the shock absorber and

upper mounting bracket as an assem-
bly.
2. Raise the vehicle on a hoist, in-
stall safety stands, and remove the
wheel cover or hub cap.
hub; then, remove the cotter pin, nut
lock, adjusting nut and outer bearing
from the hub.
4. Pull the wheel, tire and the hub
and drum off the spindle as an assem-
bly.
tool as shown in Figs. 19, 20 and 21.
6. Remove 2 upper arm-to-spring
tower attaching nuts and swing the
upper arm outboard from the spring
F1370-A
tower (Fig. 21).
7. Release the spring compressor
FIG. 18 —Removing or Installing Front Spring tool and remove the tool from the
spring. Then, remove the spring from
TURN TO COMPRESS the vehicle.
NUT •
Installation
Tool T 63 P-53J0-A
1. Place the spring upper insulator
on the spring and secure in place with
Upper Adapter Plate
tape.
T67P-5370-A 2. Position the spring in the spring
SHAFT SCREW
tower. Install the spring compressor,
(Fig. 19) and compress the spring.
3. Swing the upper arm inboard
and insert the bolts through the holes
in the side of the spring tower. Then,
install the attaching nuts and torque
them to specification.
4. Release the spring pressure and
Lower Adapter Plate guide the spring into the upper arm
spring seat. The end o! the spring
CAVITY
must seat against the tab on the
spring seat.
5. Remove the spring compressor
and position the wheel, tire, and hub
F 1492. A and drum on the spindle.
6. Install the bearing, washer, ad-
FIG. 79—Spring Tool Installation justing nut and lock nut. Adjust the
wheel bearing as outlined in Part 3-12
through the lower arm. Install and attaching bolts. Torque the bolts to and install the cotter pin, grease cap,
torque the nut to specification. specification and hub cap or wheel cover.
3. Secure the lower end of the 5. Connect the sway bar to the 7. Lower the vehicle and install the
shock absorber to the lower arm with lower arm with the attaching washer shock absorber and upper mounting
the two attaching bolts. and insulators as shown in Fig. 1. bracket.
4. Secure the strut and the rebound Torque the nut to specification. 8. Check caster, camber, and toe-in
bumper to the lower arm with the two 6. Check the front end alignment and adjust as necessary (Part 3-1).
03-02-14 Suspension 03-02-14
FRONT SPRING AND

LOWER ARM
LINCOLN CONTINENTAL
Removal
1. Raise the vehicle. Place a sup-

port under each underbody side rail to
the rear of the lower arm in the lifting
pad area.
2. Remove the wheel and tire from
the hub.
3. Remove 2 bolts and washers that
attach the caliper to the spindle. Re-
move the caliper from the rotor and
wire it to the underbody to prevent
damage to the brake hose.
4. Remove the hub and rotor from
the spindle.
5. Loosen the splash shield to pro-
vide clearance at the end of the arm
when it is lowered.
6. Remove the shock absorber.
7. Disconnect the stabilizing strut
(drag strut) from the lower arm.
8. Disconnect the stabilizer bar
from the suspension bar. Basic Tool Adapter F 1288-B
9. Remove the cotter pin from the
slotted nut attaching the lower ball FIG. 20—Spring Compressor Tool Installed—Upper View—Typical
joint to the end of the spindle boss.
Loosen the nut one to two turns.
10. Place a box wrench over the
lower end of the ball joint remover DETAIL NO 3 T63P-5310-A DETAIL NO.4 DETAIL NO. I
tool, and position the tool as in Fig.
13. The tool should seat firmly against
the ends of both studs, and not
against the lower stud nut.
11. Turn the wrench until both
studs are under tension, then, tap the
spindle with a hammer near the lower
stud to loosen it from the spindle. Do
not loosen the stud with tool pressure
alone.
12. Place a jack under the outer
end of the lower arm and raise the
arm several inches.
Tool 5310-A (Fig. 23) inside the
spring with the jaws of the tool
toward the center of the vehicle.
14. Remove the nut from the ball
joint stud. Lower the jack until the
spindle and spring are free, and re-
move the spring and insulators.
15. R e m o v e the lower arm- to-
crossmember nut, bolt, washers, and
spacer, then remove the arm.
Installation
1. Connect the inner end of the

lower arm to the underbody
crossmember. Do not tighten the at- 21 —Compressing Spring—Lower View—Montego, Falcon
taching nut at this time. Refer to Fig.
22. and Fairlane
03-02-15 Suspension 03-02-15
BUSHING
BUSHING
WASHER
BOLT K5s»
LOCKWASHER
STRUT
SLOWER ARM ASSY.

; 0lT
'
Y'
N
-£ii *
WASHER > * V © " *
« ^PLUG
INSULATOR
WASHER
NUT
LOCKWASHER
SHER/# ©^— NUT
NUT
NUT
F1221-B
FIG. 22—Front Suspension Components

03-02-16 Suspension 03-02-16
2. Place a jack under the outer end en the stud in the spindle. Do not
of the arm. loosen the stud from the spindle with
3. Tape the upper and lower spring tool pressure only.
insulators to the spring. 12. Position a floor jack under the
4. Compress the coil spring with lower arm (Fig. 24) and remove the
Tool 5310-A (Fig. 23) and place the lower ball joint stud nut.
spring and insulators in position. Be •Tool—5310-A
13. Lower the floor jack and re-
sure both ends of the spring are prop- F 1491-A move the sprina and insulator (Fie.
erly seated, and raise the arm. Guide FIG. 23—Coil Spring Compressed 25).
the spindle boss over the ball joint for Installation 14. Remove one nut and bolt at-
stud. taching the lower control arm to the
5. Install the ball joint stud retain- No. 2 crossmember and remove the
ing nut and torque it to specification. lower arm (Fig. 24).
Continue tightening the nut to line up
the cotter pin hole. Install a new cot-
ter pin. Installation
6. Connect the stabilizer bar to the
lower arm. Torque the nut to specifi- 1. Position the lower arm to the
cation. No. 2 crossmember and loosely install
7. Connect the drag strut to the the attaching bolt and nut (Fig. 1).
lower arm. Torque the nuts to specifi- 2. Position the spring and insulator
cation. to the upper spring pad and lower
8. Install the shock absorber. arm. Using a floor jack, compress the
9. Tighten the splash shield attach- spring and guide the lower ball joint
ing bolts to specifications. stud into the spindle hole.
10. Install the hub and rotor on the 3. Install the ball joint stud attach-
spindle and adjust the wheel bearings. ing nut and torque to specification.
11. Install the caliper to the spindle Continue to tighten the nut until the
and tighten the attaching bolts to cotter pin hole is in line with the nut
specifications. Check for the correct slots. Install a cotter pin in the upper
flexible hose routing (Part 2-2). and lower ball joint studs.
12. Install the wheel and tire on the 4. Pull the shock absorber down
hub. Torque the wheel lug nuts to and connect it to the lower arm.
specifications and remove the support 5. Position the strut and bumper to
stands. the lower arm. Install the attaching
13. With the front end weight of F1437-A bolts and nuts and torque to specifica-
the car on the wheels, torque the tion.
lower arm-to-crossmember bolt at- FIG. 24—Removing Front Spring 6. Torque the lower arm to No. 2
taching nut to specification. —Lower Arm Replacement crossmember attaching bolt and nut to
hub. Remove 2 bolts and washers that specifications.
attach the caliper and brake hose to 7. Position the stabilizer bar link to
FRONT SUSPENSION the spindle. Remove the caliper from the lower arm and install the attach-
LOWER ARM the rotor and wire it to the underbody ing nuts.
to prevent damage to the brake hose. 8. If equipped with drum type
FORD, MERCURY, Then, remove the hub and rotor from brakes—Position the brake backing
METEOR, THUNDERBIRD, the spindle. plate to the spindle and install the at-
CONTINENTAL MARK III 5. Disconnect the lower end of the taching bolts. Torque the bolts to spe-
shock absorber, and push it up to the cification. Adjust the brakes as out-
retracted position. lined in Group 2. Install the wheel,
Removal 6. Disconnect the stabilizer bar link tire, and drum to the spindle and ad-
from the lower arm. just the wheel bearings as outlined in
1. Raise the front of the vehicle and 7. Remove the cotter pins from the Part 3-12.
position safety stands under both sides upper and lower ball joint stud nuts. If equipped with disc brakes-Install
of the frame just back of the lower 8. Remove 2 bolts and nuts attach- the hub and rotor on the spindle.
arms. ing the strut to the lower arm. Position the caliper over the rotor and
2. Remove the hub cap or wheel 9. Loosen the lower ball joint stud install the attaching bolts. Torque the
cover. nut one or two turns. Do not remove bolts to specification. Install the
3. If equipped with drum type the nut from the stud at this time. wheel and tire on the wheel hub and
brakes—Remove the wheel and tire 10. Install Tool T57P-3OO6-A bet- adjust the wheel bearings as outlined in
and brake drum as an assembly. Re- ween the upper and lower ball joint Part 3-12.
move the brake backing plate attach- studs (Fig. 7). The tool should be 9. Install the hub cap or wheel
ing bolts and remove the backing seated firmly against the ends of both cover.
plate from the spindle. Wire the back- studs and not against the stud nuts. 10. Remove the safety stands and'
ing plate to the underbody to prevent 11. With a wrench, turn the adapter lower the vehicle.
damage to the brake hose. screw until the tool places the stud 11. Check the caster, camber, and
4. If equipped with disc brakes- under tension. Tap the spindle near toe-in and adjust as required (Section
—Remove the wheel and tire from the the lower stud with a hammer to loos- 2, Part 3-1).
03-02-17 Suspension 03-02-17
BOLT
REAR ADJUSTMENT 5A486
NUT
BUSHING OUTER SLEEVE
3A187 3B282
LOWER BALL JOINT

CASTELLATED FRONT ADJUSTMENT 3042
NUT NUT
F 1152- E
FIG. 25— Front Suspension Assembly
COUGAR, FAIRLANE, near the lower stud smartly with a 6. T o r q u e the lower a r m - to
FALCON, MONTEGO, hammer to break the stud loose in the underbody pivot bolt and nut to speci-
MUSTANG spindle. Do not loosen the stud in the fication.
spindle with tool pressure only. If 7. Remove the safety stands and
both arms are being removed, loosen lower the vehicle.
Removal the upper stud in the same manner as 8. Remove the support from be-
the lower stud. tween the upper arm and frame.
8. Remove the nut from the lower 9. Check and, if necessary, adjust
1. Position a support between the ball joint stud, and lower the arm. caster, camber, and toe-in.
upper arm and side rail as shown in 9. Remove the lower arm to under-
Figs. 8 and 9). body pivot bolt, nut and washer. Re-
2. Raise the vehicle, position safety FRONT SUSPENSION
move the lower arm.
stands, and remove the wheel and tire. UPPER ARM
3. Remove the stabilizer bar and Installation
link attaching nut. Disconnect the bar
from the link, and remove the link 1. Position the lower arm to the FORD, MERCURY,
bolt underbody bracket and install the METEOR, THUNDERBIRD,
4. Remove the strut to lower arm pivot bolt, washer, and nut loosely. CONTINENTAL MARK III
attaching nuts and bolts. 2. Raise the lower arm, guide the
5. Remove the cotter pin from the lower ball joint stud into the spindle
nut on the lower ball joint stud, and bore, and install the stud attaching
loosen the nut one or two turns. Do nut loosely. Removal
not remove the nut from the stud at 3. Install the stabilizer link bolt,
this time. washers, bushings and spacer. Connect 1. Raise the front of the vehicle and
6. Straighten the cotter pin on the the stabilizer bar to the link. Install position safety stands under both sides
upper ball joint stud nut. Position the the attaching nut and torque to speci- of the frame just back of the lower
ball joint remover tool between the fications (Fig. 25). arm.
upper and lower ball joint studs in the 4. Position the strut to the lower 2. Remove the hub cap or wheel
reverse position from that shown in arm. Install the attaching bolts and cover.
Fig. 10. The tool should seat firmly nuts, and torque to specification. 3. If equipped with drum type
against the ends of both studs and not 5. Torque the lower ball joint stud brakes—remove the wheel and tire
against the stud nuts. nut to specification, continue to tight- and brake drum as an assembly (Part
7. Turn the tool with a wrench until en the nut until the cotter pin hole 3-12).
the tool places the studs under consid- and slots are aligned, and install a 4. If equipped with disc brakes—re-
erable tension, and hit the spindle new cotter pin. move the wheel and tire from the hub.
03-02-18 Suspension 03-02-18
5. Remove the cotter pin from the COUGAR, FAIRLANE, 2. Position the upper ball joint stud
upper ball joint stud nut. FALCON, MONTEGO, in the top of the wheel spindle, and in-
6. Loosen the upper ball joint stud MUSTANG stall the stud nut. Torque the nut to
nut one or two turns. Do not remove specification, and continue to tighten
the nut from the stud at this time. it until the cotter pin hole and slots
7. Install tool T57P-3006-A be- Removal line up. Install a new cotter pin.
tween the upper and lower ball joint 3. Release the coil spring, remove
studs with the adapter screw on top the tool, and install the front shock
1. Raise the front of the vehicle, absorber and the wheel and tire.
(Fig. 13). The tool should be seated
p o s i t i o n safety s t a n d s under the
firmly against the ends of both studs
frame, and lower the vehicle slightly. LINCOLN CONTINENTAL
and not against the nuts or lower stud
2. Remove the wheel and tire.
cotter pin.
3 . R e m o v e the shock absorber
8. With a wrench, turn the adapter
lower attaching nuts and washers. Removal
screw until the tool places the stua
4. R e m o v e the shock absorber
under tension. Tap the spindle near
upper mounting bracket attaching
the upper stud with a hammer to loos- 1. Place a jack under the outer end
nuts, and remove the shock absorber
en the stud in the spindle. Do not of the suspension lower arm and raise
and bracket as an assembly (Fig. 26).
loosen the stud from the spindle with the arm. Refer to Fig. 22.
On all 8-cylinder vehicles, remove
tool pressure only. 2. Remove the wheel and tire.
the air cleaner to obtain access for
9. Remove the tool from between 3. Remove the cotter pin from the
tool installation.
the ball joint studs and place a floor upper ball joint stud. Loosen the nut
jack under the lower arm. one or two turns.
tool and compress the spring (Figs.
10. Raise the floor jack to relieve 4. Place a box wrench over the
19, 20 and 21).
the pressure from the upper ball joint lower end of the ball joint remover
6. Position a safety stand under the
stud nut and remove the nut. tool, and position the tool as in Fig.
lower arm.
11. Remove the upper arm inner 13. The tool should seat firmly against
7. Remove the cotter pin from the
shaft attaching bolts. Remove the the ends of both studs, and not
nut on the upper ball joint stud, and
upper arm and inner shaft as an as- against the upper stud nut.
loosen the nut one or two turns. Do
sembly (Fig. 1). 5. Turn the wrench until both studs
not remove the nut from the stud at
12. Remove the bumpei from the are under tension, and then, tap the
this time.
upper arm. spindle with a hammer near the upper
tool between the upper and lower ball stud to loosen it from the spindle. Do
joint studs as shown in Fig. 10. The not loosen the stud with tool pressure
tool should seat firmly against the alone. Remove the nut.
Installation UPPER MOUNTING BRACKET
ends of both studs and not against the
stud nuts.
1. Position the bumper to the upper 9. Turn the tool with a wrench until
arm and install the nut and washer. the tool places the studs under consid-
Torque the nut to specifications. erable tension; then, hit the spindle
2. Position the upper arm inner smartly near the upper stud with a
shaft to the frame side rail and install hammer to break the stud loose in the
the 2 attaching bolts and washers spindle. Do not loosen the stud in the
snug. spindle with tool pressure only. If
3. Connect the upper ball joint stud both arms are being removed, loosen
to the spindle and install the attaching the lower stud in the same manner as
nut. Torque the nut to specification the upper stud.
and continue to tighten the nut until 10. Remove the nut from the upper
the cotter pin hole in the stud is in stud and lift the stud out of the
line with the nut slots. Then, install spindle.
the cotter pin. 11. Remove the upper arm inner
4. If equipped with drum type bra- shaft attaching nuts from the engine
kes—Adjust the brakes as outlined in compartment, and remove the upper
Part 2-2. Install the wheel, tire, and arm.
drum to the spindle and adjust the 12. Wipe off all loose dirt from the
wheel bearings as outlined in Part upper arm parts. Do not wash the ball
3-12. joint with a solvent.
5. If e q u i p p e d with disc brak-
es—Install the wheel and tire on the
hub and adjust the wheel bearings as Installation
outlined in Part 3-12.
6. Install the hub cap or wheel 1. Position the upper arm on the
cover. underbody mounting bracket, and in-
7. Remove the safety stands and stall the nuts and lock washers on the
lower the front of the vehicle. two inner shaft attaching bolts. The LOWER RETAINING BOLTS F 1490-A
8. Check caster, camber, and toe-in specified keystone-type lock washers FIG. 26—Removing or Installing
and adjust as required (Section 2, Part must be used. Torque the nuts to
3-D. soecification. Front Shock Absorber—Typical
03-02-19 Suspension 03-02-19
6. Raise the upper arm to free the

ball joint stud from the spindle. Wire
the upper end of the spindle to the un- 3/8'
derbody to prevent damage to the
brake hose.
7. Mark the position of the upper
1/16" GAUGE - * .
arm shaft on the underbody member STEEL (REFERENCE)
to facilitate making caster and camber
adjustments after installation of the
upper arm.
8. Remove the suspension upper
arm-to-underbody attaching bolts,
lock washers, and attaching nuts. —3/16'
Then, remove the upper arm.
Installation
1 / 2 " DIAMETER PLUG WELD
1. Position the upper arm shaft on
the underbody member. Line up the
shaft with the marks made before re-
moval of the arm.
2. Install the attaching bolts and
lock w a s h e r s . F A B R I C A T E A
TOOL, AS SHOWN IN Fig. 27, to
hold the nut in place while starting the
attaching bolt into the nut. Remove
the tool; then, tighten the attaching
bolts to specification.
3. Guide the ball joint stud into the F 1501-A
spindle. Install the attaching nut and
torque it to specification. Continue FIG. 27 - U p p e r Arm Shaft Installing Tool
tightening the nut to line up the cotter
pin hole. Install a new cotter pin. 4. If equipped with disc brakes—re- Installation
4. Install the wheel and tire, and move the wheel and tire from the hub.
torque the wheel lug nuts to specifica- Remove 2 bolts and washers retaining 1. Position the spindle to the lower
tion. the caliper and brake hose to the ball joint stud and install the attaching
5. With the front end weight of the spindle. Remove the caliper from the nut. Torque the nut to specification.
car on the wheels, torque the bolts at rotor and wire it to the underbody to Continue to tighten the nut until the
the ends of the upper arm shaft to prevent damage to the brake hose. cotter pin hole is in line with the slots
specification if the bushings were re- Then, remove the hub and rotor from in the nut. Then, install the cotter pin.
placed. the spindle (Part 3-12). Remove 3 2. Position the spring and raise the
6. Check the front wheel alignment. bolts attaching the splash shield to the lower arm and guide and upper ball
spindle and remove the splash shield. joint stud into the spindle hole and in-
FRONT WHEEL SPINDLE 5. Remove the steering connecting stall the attaching nut. Torque the nut
rod from the spindle arm with tool to specification and install the cotter
OTC462. pin as outlined in the preceeding step.
6. Remove the cotter pins from 3. Remove the floor jack from
FORD, MERCURY, both ball joint stud nuts, and loosen under the lower arm.
METEOR, THUNDERBIRD, the nuts one or two turns. Do not re- 4. Attach the steering connecting
CONTINENTAL MARK III move the nuts from the studs at this rod to the spindle and install the nut.
time. Torque the nut to specification. Con-
Removal 7. Install the ball joint remover tool tinue to tighten the nut until the cotter
between the upper and lower ball joint pin hole is in line with the slots in the
studs (Fig. 7). The tool sho.uld seat nut. Then, install the cotter pin.
1. Raise the vehicle until the front firmly against the ends of both studs 5. If equipped with drum type
wheel clears the floor, and place a and not against the stud nuts. brakes—Position the brake backing
support under the frame. 8. Turn the tool nut with a wrench plate to the spindle and install the at-
2. Remove the hub cap or wheel until the tool places the studs under taching bolts. Torque the bolts to spe-
cover. tension, and, with a hammer, tap the cification. Adjust the brakes as out-
3. If equipped with drum type spindle near the stud to loosen them lined in Part 2-2. Install the wheel,
brakes—remove the wheel and tire in the spindle. Do not loosen the studs tire, and drum to the spindle and ad-
and brake drum as an assembly (Part in the spindle with tool pressure only. just the wheel bearings as outlined in
3-12). Remove the brake backing 9. Position a floor jack under the Part 3-12).
plate attaching bolts and remove the lower control arm. 6. If e q u i p p e d with disc brak-
backing plate from the spindle. Wire 10. Remove the ball joint stud nuts es—Install the splash shield on the
the backing plate to the underbody to and lower the lower arm enough to re- spindle and torque the attaching bolts
prevent damage to the brake hose. move the spring and the spindle. to specification (Part 3-13). Install the
03-02-20 Suspension 03-02-20
hub and rotor on the spindle. Position 2. Raise the lower suspension arm 11. Remove the upper and lower
the caliper over the rotor and install and guide the upper ball joint stud ball joint stud nuts; lower the jack
the attaching bolts. Torque the bolts into the spindle. Install the stud nut. and remove the spindle.
to specification (Part 3-13). Install the 3. Torque the upper stud nut and
wheel and tire on the hub and adjust then the lower stud nut to specifica- Installation
the wheel bearings as outlined in Part tion. Continue to tighten both nuts
3-12 . until the cotter pin holes and slots line
7. Install the hub cap or wheel up. Install new cotter pins. 1. Position the spindle on the lower
cover. Then, remove the support stand 4. Connect the spindle connecting ball joint stud and install the stud nut
and lower the vehicle. rod end to the spindle arm. (Fig. 25). Torque the nut to specifica-
8. Check caster, camber, and toe-in 5. Install the brake backing plate tion and install the cotter pin.
(Part 3-1) and adjust as necessary. on the spindle, and torque the bolts to 2. Raise the lower suspension arm,
specification. and guide the upper ball joint stud
6. Install the wntel and drum and into the spindle. Install the stud nut.
COUGAR, FAIRLANE, 3. Torque the nut to specifications
adjust the wheel bearing (Part 3-12).
FALCON, MONTEGO, and install the cotter pin. Then, re-
7. Remove the safety stands, and
MUSTANG move the floor jack.
lower the vehicle.
8. Remove the support from be- 4. Connect the spindle connecting
tween the upper arm and frame. rod end to the spindle arm and install
Drum Brakes the attaching nut. Torque the nut to
9. Check and, if necessary, adjust
caster, camber, and toe-in. specification and install the cotter pin.
5. Position the caliper splash shield
Removal to the spindle and install the attaching
bolts and nuts. Torque the nuts and
1. Position a support between the Disc Brakes bolts to specification.
upper arm and frame as shown in 6. Install the hub and rotor on the
Figs. 8 and 9; then, raise the vehicle spindle.
and position safety stands. Removal
7. Position the caliper to the rotor
2. Remove the hub cap or wheel and spindle and install the attaching
cover. bolts. Torque the bolts to specification
3. Remove the grease cap from the 1. Remove the hub cap or wheel and install the safety wire.
hub; then, remove the adjusting nut, cover, and remove the wheel and tire 8. Install the wheel and tire on the
washer, and outer bearing cone and from the hub. hub and adjust the wheel bearing
roller assembly. 2. Remove two bolts attaching the (Part 3-12).
4. Pull the wheel, hub, and drum caliper to the spindle. Remove the cal- 9. Install the hub cap or wheel
assembly off the wheel spindle. iper from the rotor and wire it to the cover.
5. Remove the brake backing plate underbody to prevent damage to the 10. Before driving the vehicle,
from the spindle. Support the plate to brake hose. pump the brake pedal several times to
prevent damage to the brake hose. 3. Remove the grease cap from the obtain normal brake lining-to-rotor
6. Disconnect the spindle connect- hub, then, remove the adjusting nut, clearance and restore normal brake
ing rod end from the spindle arm washer, and outer bearing cone and pedal travel.
using Tool 3290-C. roller assembly.
7. Remove the cotter pins from 4. Pull the hub and rotor assembly LINCOLN CONTINENTAL
both ball joint stud nuts, and loosen off the wheel spindle.
the nuts one or two turns. Do not re- 5. Remove the three caliper shield
move the nuts from the studs at this attaching bolts and remove the shield.
6. Disconnect the spindle connect- Removal
time.
ing rod end from the spindle arm
using Tool-3290-C. 1. Raise the vehicle. Place a sup-
tool between the upper and lower ball
joint studs (Fig. 10). The tool should 7. Remove the cotter pins from port under each side rail to the rear of
seat firmly against the ends of both both ball joint stud nuts, and loosen the lower arm in the lifting pad area.
studs and not against the stud nuts. the nuts one or two turns. Do not re- 2. Remove the wheel and tire from
9. Turn the tool with a wrench until move the nuts from the studs at this the hub.
the tool places the studs under consid- time. 3. Remove 2 bolts and washers that
erable tension, and, with a hammer, 8. Position the ball joint remover attach the caliper to the spindle. Re-
hit the spindle smartly near the studs tool between the upper and lower ball move the caliper from the rotor and
to break them loose in the spindle. Do joint studs (Fig. 10). The tool should wire it to the underbody to prevent
not loosen the studs in the spindle seat firmly against the ends of both damage to the brake hose.
with tool pressure alone. studs and not against the stud nuts. 4. Remove the hub and rotor from
10. Remove the stud nuts and re- 9. Turn the tool with a wrench until the spindle.
move the spindle from both studs. the tool places the studs under consid- 5. Remove the splash shield and
erable tension, and, with a hammer, gasket from the spindle.
hit the spindle smartly near the studs 6. Disconnect the spindle arm con-
Installation to break them loose in the spindle. Do necting rod from the spindle arm with
not loosen the studs in the spindle Tool 3290-C. See Fig. 23.
1. Position the spindle on the lower with tool pressure alone. 7. Remove the cotter pins from
ball joint stud and install the stud nut 10. Position a floor jack under the both ball joint stud nuts. Loosen the
(Fig. 25). lower suspension arm. nuts one to two turns.
03-02-21 Suspension 03-02-21
8. Place a box wrench over the 3. Remove 2 bolts attaching the 2. Remove the bolts which attach
lower end of the ball joint remover shock absorber to the lower arm and the shock absorber to the suspension
tool, and position the tool as in Fig. remove the shock absorber. lower arm. Lower, and remove the
13. The tool should seat firmly against 4. Place a washer and bushing on shock absorber.
the ends of both studs, and not the shock absorber top stud and posi- 3. Examine the shock absorber unit
against the stud nuts. tion the shock absorber inside the and rubber bushings. Replace parts
9. Turn the wrench until both studs front spring. Install the 2 lower at- that are defective, deteriorated, or
are under tension, and then, tap the taching bolts and torque them to spe- worn.
spindle with a hammer near the studs cifications.
to loosen them from the spindle. Do 5. Remove the safety stands and Installation
not loosen the studs with tool pressure lower the vehicle.
alone. 6. Place a bushing and washer on
10. Place a jack under the outer the shock absorber top stud and in- 1. Fully extend the shock absorber
end of the lower arm, and raise the stall the attaching nut. Torque it to and position it inside the coil spring.
arm several inches. Remove both ball specification. Connect the lower end of the shock
stud nuts, and remove tê spindle. absorber to the suspension lower arm.
COUGAR, FAIRLANE, Torque the attaching nuts to specifica-
FALCON, MONTEGO, tion.
Installation 2. Insert the upper bracket stud
MUSTANG
through the bushing in the shock ab-
1. Position the new spindle onto the sorber upper eye. Install the stud
upper and lower ball joint studs, in- bracket to crossmember attaching
stall the stud nuts and tighten the nuts Removal bolt. Do not tighten the bolt: at this
to specifications. Continue to tighten time.
both nuts until the cotter pin holes 1. Raise the hood and remove 3 3. Install the upper eye bracket
line up with the slots, then install new shock absorber upper mounting stud nut. Torque the nut to specifica-
cotter pines. bracket-to-spring tower attaching tion.
2. Connect the spindle connecting nuts. 4. T o r q u e the stud bracket- to-
rod to the spindle arm. Install the re- 2. Raise the front of the vehicle and crossmember attaching bolt to specifi-
taining nut and tighten the nut to place safety stands under the lower cation. The shock absorber upper eye
specification. Continue to tighten the arms. stud nut must be tightened to com-
nut until the cotter pin hole lines up 3. Remove 2 shock absorber lower press the rubber bushing before the
with the slot, then install a new cotter attaching nuts and washers. s t u d b r a c k e t is b o l t e d t o the
pin. 4. Lift the shock absorber and crossmember; otherwise, the upper at-
3. Install the gasket and splash upper bracket from the spring tower tachment could be loose and noisy.
shield on the spindle. Tighten the at- (Fig. 26) and remove the bracket from
taching bolts to specifications. the shock absorber. REAR SHOCK ABSORBER
4. Install the hub and rotor on the
REPLACEMENT
spindle. Installation
5. Install the caliper to the spindle
and tighten the attaching bolts to spe-
cifications. Check for the correct flex- 1. Install the upper mounting FORD, MERCURY,
ible hose routing (Part 2-2). bracket on the shock absorber and METEOR, THUNDERBIRD,
6. Install the wheel and tire and ad- torque to specification. CONTINENTAL MARK 1(11
just the wheel bearings (Part 3-12). 2. Position the shock absorber and
7. Lubricate the steering stop on upper mounting bracket in the spring 1. Raise the vehicle on a hoist.
the lower arm and the mating flat on tower, making sure the shock absor- 2. Remove the shock absorber at-
the spindle with the specified lubri- ber lower studs are in the pivot plate taching nut, washer and insulator
cant. holes. from the upper stud at the upper side
8. Remove the safety stands, lower 3. Install the 2 washers and attach- of the spring upper seat. Compress the
the car and check camber, caster and ing nuts on the shock absorber lower shock absorber to clear the hole in the
toe-in. studs and torque to specification. spring seat, and remove the inner in-
4. Install the 3 shock absorber sulator and washer from the upper at-
upper mounting bracket-to-spring taching stud.
tower attaching nuts and torque to 3. Remove the self-locking attach-
FRONT SHOCK ABSORBER
specification. Then, remove the safety ing nut, and disconnect the shock ab-
REPLACEMENT stands and lower the vehicle. sorber lower stud from the mounting
bracket on the rear axle housing (Fig.
LINCOLN CONTINENTAL 4).
FORD, MERCURY, 4. Expel all air by performing step
METEOR, THUNDERBIRD, Removal 3 On Vehicle Tests in Part 3-1.
CONTINENTAL MARK III 5. Place the inner washer and insu-
1. Remove the stud nut at the lator on the upper attaching stud, and
1. Remove the nut, washer, and upper eye of the shock absorber. Re- position the shock absorber so that
bushing from the shock absorber move the upper eye stud bracket to the upper attaching stud enters the
upper end. crossmember attaching bolt and re- hole in the spring upper seat. While
2. Raise the vehicle on a hoist and move the stud bracket. Refer to Fig. holding the shock absorber in this po-
install safety stands. 22. sition, install the outer insulator and
03-02-22 Suspension 03-02-22
washer and the nut on the upper stud 2. Expand the shock absorber and
from the upper side of the spring SHOCK ABSORBER UPPER ATTACHING NUT position it to the spring clip plate and
upper seat. Torque the nut to specifi- to the mounting in the floor pan.
cations. 3. Connect the lower stud to the
6. Extend the shock absorber and spring clip plate, and install the bush-
locate the lower stud in the hole in ing, outer washer, and new nut on the
mounting bracket on the rear axle stud (Fig. 30). Be sure the spring clip
housing. Install a new self-locking at- plate is free of burrs.
taching nut and torque to specifica- On the Ranchero, after tightening
tion. the nut to specification, install the for-
ward half of the floor panel.
MUSTANG AND COUGAR ACCESS COVER 4. From the luggage compartment,
F 1488-A install the bushing outer washer and
new attaching nut to the upper mount-
FIG. 29—Rear Shock Absorber ing stud (Fig. 29). Torque to specifica-
Removal
Upper Mounting tion. On a station wagon, replace the
floor bed panel (14 screws).
1. Disconnect the shock absorber outer washer, and new nut on the 5. Place the spare wheel and tire in
from the spring clip plate (Fig. 30). stud. Torque the nut to specification, the luggage compartment, and secure
2. Remove the shock absorber ac- and install the cover. it in the storage position.
cess cover from the luggage compart- 3. Connect the lower stud to the
ment (Fig. 28).-(On convertible mod- spring clip plate, and install the bush- MONTEGO AND FAIRLANE
els, remove the rear seat and seat ing, outer washer, and new nut on the CONVERTIBLE
back to reach the access cover.) stud. Be sure that spring clip plate is
free of burrs. Tighten the nut to speci-
fication. Removal
SHOCK ABSORBER ACCESS COVER
MONTEGO, FALCON, AND 1. Remove the rear seat cushion
FAIRLANE (EXCEPT and seat back.
CONVERTIBLE) 2. Partially raise the vehicle on a
hoist. With an assistant under the ve-
hicle holding the shock absorber, re-
Removal move the nut from the top of the
shock absorber.
3. Remove the lower shock absor-
1. Open the luggage compartment
ber attaching nut and remove the
door, and remove the spare wheel and
shock absorber.
tire.
On the Ranchero, remove the at-
taching screws, and lift the forward Installation
half of the floor panel from the body;
then, remove the access cover from 1. Position the washers and bush-
the opening in the floor pan over the ings on the shock absorber and posi-
shock absorber. tion the shock absorber to the lower
On station wagons, remove the ac- attachment. Install the bushing, outer
cess cover from the opening in the washer, and new attaching nut and
seat riser over the shock absorber. torque the nut to specification (Part
LUGGAGE COMPARTMENT 2. Fold back the floor mat and re- 3-13).
FLOOR PANEL move the shock absorber access cover 2. Lower the vehicle and install the
from the floor pan. Remove the nut, bushing, outer washer, and new at-
F 1489-A
outer washer, and rubber bushing that taching nut on the top of the shock
FIG. 28—Rear Shock Absorber attach the shock absorber to the upper absorber. Torque the nut to specifica-
mounting in the floor pan (Fig. 29). tion.
Access Cover
3. Raise the vehicle and remove the 3. Install the rear seat back and
3. R e m o v e the shock absorber attaching nut, outer washer and bush- seat cushion.
upper attaching nut. ing from the shock absorber at the
4. Compress the shock absorber spring clip plate (Fig. 30). Compress LINCOLN CONTINENTAL
and remove it from the vehicle. Re- the shock absorber and remove it
move the bushings and washers from from the vehicle.
4. If the shock absorber is service- Removal
the shock absorber studs.
able and requires new bushings, remove
the inner bushings and washers from 1. Lift the vehicle and place support
Installation the shock absorber studs. stands under the axle housing. Posi-
tion the vehicle with a hoist to relieve
1. Place the bushing and inner Installation tension on the shock absorbers.
washer on the shock absorber stud. 2. Remove the screws that attach
2. Connect the upper stud to the 1. Place the inner washer and bush- the shock absorber mounting plate to
mounting, and install the bushing, ing on each shock absorber stud. the crossmember (Fig. 31).
03-02-23 Suspension 03-02-23
SEDAN MODELS ONLY-
SPRING CLIPS 5705 ,^-::^^^^SSSS^

^CS^.-''' .--'""-.'.'""'"* D D A f~ V C T
BRACKET
(STATION WAGON-
AND RANCHERO
ONLY) 5610
INSULATOR RETAINER
5736
INBOARD
SHACKLE
REAR
BUSHING SHACKLE
5791
. . . ».IA- ASSEMBLY
5776
vae.
OUTBOARD SHACKLE
BUSHING
5791
FRONT HANGER LOWER INSULATOR 5732

INBOARD BUSHING INSULATOR PLATES
(H.D. STATION WAGON
AND RANCHERO) 5A584
SPRING CLIP PLATE
(STATION WAGON
AND RANCHERO
ONLY) 5798-99
FRONT HANGER
SPRING HANGER
OUTBOARD BUSHING
MOUNTING BOLT
HANGER
F 1487-A
FIG. 30—Rear Spring and Shock Absorber—Typical

3. Remove the attaching nut and 2. Install the mounting plate, outer 1. Cut off the old stud as close to
washers from the lower end of the insulator, washer and nut on the stud. the bracket as possible.
shock absorber. Torque the nut to specification. 2. Grind off the weld at both ends
4. Remove the shock absorber. 3. Attach the mounting plate and of the stud and bracket face.
5. Remove the nut, outer washer, shock absorber to the crossmember 3. Drive out the balance of the stud
and insulator that attach the shock with the attaching screws and washers. with a brass drift. Do not enlarge the
absorber to the mounting plate; then Torque the screws to specifications. hole in the bracket.
remove the plate. 4. Connect the lower end of the 4. Remove any weld remaining on
6. Inspect the shock absorber for shock absorber to the mounting stud the sides of the bracket.
damage or leaks. If the bushing must with the washers and attaching nut. 5. Attach the service stud to the
be replaced, the operation may be per- Torque the nut to specification. axle housing bracket with a nut. Tor-
formed without the use of special que the nut to specification.
tools. Wet the rubber bushing with a REAR SHOCK ABSORBER 6. Stake the nut to prevent loos-
soap solution and press it into the ening.
LOWER MOUNTING STUD
shock absorber eye by hand. Repla-
REPLACEMENT REAR SPRING
cethe insulators if they appear worn or
damaged. FORD, MERCURY,
LINCOLN CONTINENTAL METEOR, THUNDERBIRD,
Installation CONTINENTAL MARK III
1. Place the inner washer and insu- If the shock absorber mounting stud Removal
lator on the upper (stud) end of the is damaged, replace the stud as fol- 1. Raise the vehicle on a hoist with
shock absorber (Fig. 31). lows: the hoist under the rear axle housing.
03-02-24 Suspension 03-02-24
Installation
LOCK NUT
INSULATOR 1. Position the spring in the upper

and lower seats with an insulator be-
tween each seat and the spring.
2. Raise the hoist and axle housing
with the spring in position and con-
nect the lower studs of the rear shock
absorbers to the mounting brackets on
the axle housing. Install the attaching
nuts, and torque to specifications.
3. Remove the jack stands and
lower the vehicle.
NG
REAR SUSPENSION
LOWER ARM
FORD, MERCURY,
Removal
NUT M O U N T I N G STUD
1. Raise the vehicle on a hoist and
WASHER place jack stands under the frame side
LOCK WASHER rails.
F1486-A
2. Remove the attaching nut and
FIG. 31—Rear Shock Absorber Mounting bolt from the frame track bar mount-
ing bracket and disconnect the bar
from the stud (Fig. 4).
3. Lower the axle enough to relieve
spring pressure.
4. Support axle under differential
pinion nose as well as under axle.
5. Remove the lower arm pivot bolt
and nut from the axle bracket. Then,
disengage the lower arm from the
bracket.
6. Remove the pivot bolt and nut
from the frame bracket and remove
the lower arm from the vehicle.
Installation
The rear suspension lower arms are

not interchangeable. The lower arm
for the left side can be identified by
notches in the bushing flange (Fig. 4).
The right arm does not have the
SHOCK
TRACK BAR SHOCK notches.
MOUNTING ABSORBER
ABSORBER STUD AXLE 1. Position the lower arm in the
MOUNTING
MOUNTING VENT
BRACKET
bracket on the frame side rail. Install
BRACKET
a new pivot bolt and new nut (Fig.
COIL SPRING F1438-A
V-V.
33). Do not tighten the nut at this
FIG. 32—Removing or Installing Rear Spring—Typical time.
2. Position the lower arm to the
axle bracket and install a new bolt
Place jack stands under the frame side 3. Lower the hoist and axle housing and new nut (Fig. 33). Do not tighten
rails. until the coil springs are released (Fig. the nut at this time.
32). 3. Raise the axle.
2. Disconnect the lower studs of the 4. Install alignment spacers be-
two rear shock absorbers from the 4. Remove the springs and the insu- tween the rear axle and frame (Fig. 3,
mounting brackets on axle housing. lators from the vehicle. Part 3-1). Then, torque the lower arm
03-02-25 Suspension 03-02-25
pivot bolts and nuts to specification

(Part 3-13).
5. Connect the track bar to the REAR PIVOT BOLT NUT
FRONT PIVOT BOLT LOWER ARM
frame bracket with a new nut and
bolt. Torque the nut to specification
(Part 3-13).
6. Remove the alignment spacers
and jack stands and lower the vehicle.
REAR S U S P E N S I O N -
UPPER ARM
FORD, MERCURY,
CONTINENTAL MARK HI
Removal F1439-A
1. Raise the vehicle and support the FIG. 33—Rear Suspension Lower Arm Installed
frame side rails with jack stands.
2. Support the rear axle, then dis
connect the track bar from the frame
bracket.
3. Lower the axle and support axle
under differential pinion nose, as well
as under axle.
4. Remove the nut, bolt and two
washers that attach the upper arm to
the axle housing. Disconnect the arm
from the housing.
5. Remove the nut and bolt that se-
cures the upper arm to the crossmem-
ber and remove the arm.
Installation
1. Hold the upper arm in place on Tool-T64K-5781-B4 (Thrust Washer) F 1485. A

the crossmember and install a new at-
taching bolt, a new lockwasher and a FIG. 34—Rear Spring Front Bushing Removal—Typical
new nut. Do not tighten the nut at this
time.
2. Secure the upper arm to the axle 2. Remove rubber cover at axle at- REAR SPRING AND/OR BUSHING
housing with a new attaching bolt, tachment on track bar.
two washers and a new nut. Do not COUGAR, FAIRLANE,
tighten the nut at this time. 3. Remove the nut and washer at- FALCON, MONTEGO,
3 . Install alignment spacers be- taching the track bar to the upper arm MUSTANG
tween the rear axle housing and bracket and disengage the track bar
frame. from the mounting stud (Fig. 33).
4. Connect the track bar to the Removal
frame bracket with a new nut and 4. Remove the nut and bolt attach-
bolt. Torque the nut to specifications. ing the track bar to the frame side rail 1. Raise the vehicle on a hoist and
5. Torque the upper arm front nut and remove the track bar. place supports beneath the underbody
to specification. Remove the align- and under the axle.
ment spacers and the jack stands. 5. Position the track bar to the 2. Disconnect the lower end of the
6. Adjust the pinion angle and tor- frame side rail and install a new at- shock absorber from the spring clip
que the rear nut to specification. taching bolt and new nut. plate and push the shock out of the
7. Lower the vehicle. way. Remove the supports from under
6. Position the track bar on the the axle.
TRACK BAR upper arm bracket mounting stud and 3. Remove the spring clip plate
install a new washer and a new at- nuts from the U-bolts; then, remove
FORD, MERCURY, taching nut. Torque the track bar at- the plate (Fig. 31). Raise the rear axle
METEOR, THUNDERBIRD, taching bolt and nuts to specification just enough to remove the weight from
CONTINENTAL MARK HI (Part 3-13). Lubricate rubber cover the spring.
with synthetic rubber lubricant and in- 4. Remove the two attaching nuts,
1. Raise the vehicle on an axle con- sert over end of stud onto washer. and rear shackle bar, and the two
tact hoist. Then, lower the vehicle. shackle inner bushings.
03-02-26 Suspension 03-02-26
the rear of each rear spring hanger.

T64K-578 7-B2 (Adapter) 2. Lower the rear axle slightly to
-83 (Nut)
(Bolt)
reduce some of the spring load; then,
remove the spring U-bolts.
3. Remove the nuts, lock washers
and front mounting stud. Refer to
Fig. 6.
4. Remove the rear shackle nuts
and mounting plate. Remove the
lower inner insulator. Remove the
spring. If the rear shackle insulators
are to be replaced, it will be necessary
to remove the rear hanger assembly.
(Hanger attaching bolts must be tor-
qued to specification when rein-
stalled.)
5. Remove the insulators from the
spring.
6. Examine all parts for wear or
SPRING FRONT EYE damage. Note the condition of the
spring center bolt.
BUSHING
Tool-T64K-5781-B2 (Adapter) 7. The spring center bolt can be re-
F 1484-A
placed by clamping the spring in a
vise, thus keeping the spring com-
FIG. 35—Rear Spring Front Bushing Installation—Typical pressed during bolt removal and in-
stallation.
5. Remove the rear shackle assem- 4. Install the shackle inner bush-
bly and the two outer bushings. ings, the shackle plate, and the lock-
6. Remove the front hanger bolt, nuts. Tighten the locknuts finger-tight.
nut, and washer from the eye at the 5. Position the spring front eye in Installation
forward end of the spring. Lift out the the front hanger, slip the washer on
spring assembly. the front hanger bolt, and (from the 1. Attach the spring and bushing to
7. If the front bushing is being re- inboard side) insert the bolt through the front hanger. Torque the outboard
placed, assemble the special tool com- the hanger and eye. Install the locknut nut to specifications. Do not tighten
bination to the bushing in the spring on the hanger bolt and tighten finger- the inboard nut at this time.
front eye as shown in Fig. 34. tight.
2. Install the spring to the rear
8. While holding the tool nut, tight- 6. Lower the rear axle until it rests
shackle assembly with the insulators
en the tool bolt against the tool thrust on the spring. Position the spring clip
in position. Do not tighten the nuts at
washer, the adapter, and detail A l . plate on the clips (U-bolts). Install the
this time. Refer to Fig. 6.
This operation will force the bushing U-bolt nuts and torque to specifica-
out of the spring eye into detail A4 of tion. 3. Place the insulator and retainers
the tool as shown. 7. Connect the lower end of the in position on the spring.
shock absorber to the spring clip plate 4. Lower the axle housing onto the
using a new nut if working on a sta- insulator and retainer assembly.
tion wagon or Ranchero. If a wedge was located between the
8. Place safety stands under the upper retainer and mounting pad,
Installation rear axle, lower the vehicle until the reinstall the same thickness wedge
spring is in the approximate curb load with the taper in the original direc-
During rear suspension leaf spring position, and then torque the front tion. Raise the axle until the spring is
assembly replacement in service, all hanger stud locknut to specification. approximately horizontal with the
used attaching components must be 9. Torque the rear shackle locknuts floor.
discarded and replaced with new com- to specification.
ponents. 10. Remove the safety stands and 5. Install the lower insulator retain-
1. Assemble the bushing and the lower the vehicle. er and U-bolts. Do not tighten the U-
special tool combination to the spring bolt nuts at this time. Torque the rear
front eye as shown in Fig. 35. REAR SPRING shackle nuts to specifications.
2. While holding the tool nut, tight- 6. Torque the inboard nut at the
en the tool bolt against the tool thrust front eye to specification.
washer, adapter, and detail A4 to LINCOLN CONTINENTAL
force the bushing into the spring eye 7. Tighten the U-bolt nuts evenly to
as shown. the specified torque.
3. Position the spring under the Removal
8. Make sure the lower insulator
rear axle and insert the shackle as- retainer contacts the upper retainer.
sembly into the rear hanger bracket 1. Raise the vehicle and place sup-
and the rear eye of the spring. port stands under the sidemembers on
03-02-27 Suspension 03-02-27
FRONT SUSPENSION UPPER ings and inner shaft in the upper arm
ARM BUSHINGS—ARM as shown in Fig. 37. PRESS RAM
REMOVED 6. Install a washer and new nut on Tool—3069-AA
each end of the inner shaft.
FORD, MERCURY,
METEOR, THUNDERBIRD, Tool - T65P Tool - T65P
3044 - A3
CONTINENTAL MARK III 3044 - A2
1. Remove the nuts and washers

from both ends of the upper arm inner
shaft.
2. Install Tool T65P-3044-A1 on
the inner shaft and place Tool T65P-
3044-A3 inside the upper arm around
the inner shaft (Fig. 36).
F 1483-A
FIG. 38—Removing Lower Arm

Bushing
PRESS
RAM
F1441-A
FIG. 37—Installing Upper Arm

Shaft Bushings
LOWER ARM OVERHAUL-
ARM REMOVED
LINCOLN CONTINENTAL
Inspect the lower arm, bushings and

1482-A
pivot bolt for cracks, bends, wear or
other damage. Replace the arm if nec- FIG. 39—Installing Lower Arm
essary. Bushing
F1440-A 1. If the ball joint requires replace-
ment, remove the rivet heads with a 5. If the ball joint was removed, in-
FIG. 36—Removing Upper Arm chisel. Punch the remaining portion of stall the new joint using the parts sup-
Bushings the rivets from the holes. plied in the ball joint kit. Torque the
Do not wash the ball joint with sol- nuts to specification. Make sure the
3. Position the upper arm in an vent. The solvent may attack parts joint is completely filled with the spec-
arbor press on Tool T65P-3044-A4 within the joint. ified lubricant.
(Fig. 36), and press the lower bushing 2. If the bushing requires replace-
out of the upper arm. ment, press it out of the arm with
4. Remove the bushing from the Tool 3069—details H, AA, and AA2 UPPER ARM OVERHAUL-
inner shaft; turn the assembly over (Fig. 38). ARM REMOVED
and remove the bushing from the 3. Apply silicone or liquid soap to
other side of the arm. It may be nec- the shell of the new bushing. Place the
essary to remove Tool T65P-3044-A1 bushing in the arm with the flange end LINCOLN CONTINENTAL
from the inner shaft and remove the (large end) of the bushing at the front
shaft from the arm to remove the of the arm. Inspect the upper arm and the inner
bushing from the shaft. Then, install 4. Press the bushing into the arm shaft for cracks, bends or other dam-
the tool on the shaft and remove the until the shoulder on the bushing shell age. Replace the parts as required.
other bushing. seats a g a i n s t the a r m . Use tool Replacement arms come with the
5. Position the shaft and bushings 3069—details H, AA2, and M5 (Fig. bushings, inner shaft, and ball joint
to the upper arm and install the bush- 39). installed. If the original arm is to be
03-02-28 Suspension 03-02-28
used, these components should be re- Bottom the bushing flange against the
placed on the bench. flange in the arm.
Do not wash the ball joint with sol- 8. Install the flat washers, lock-
vent. The solvent may attack parts PRESS RAM washers, and bolts at the ends of the
within the joint. upper arm shaft. Do not tighten the
Tool-3069-H bolts at this time. These must be
BUSHING AND INNER tightened after the arm assembly has
been installed, and when the front end
SHAFT REPLACEMENT
weight of the vehicle is on the wheels.
These bolts are made of a special
material. Use only the specified bolt if
LINCOLN CONTINENTAL replacement is necessary.
Always replace both upper arm

bushings, if either bushing is worn or PRESS RAM
damaged. Install only new bushings
when replacing the inner shaft. Refer
to Section 3 for the upper arm remov-
F 1480-A
al procedure.
1. Remove the bolts, lock washers, FIG. 41—Removing Upper Arm
and flat washers from the ends of the Rear Bushing
upper arm shaft.
2. A s s e m b l e the remover, tool
3044-LA, to the shaft at the front proper assembly of the shaft and
bushing. Press the bushing out of the bushings.
arm using the support cup, tool 6069- 6. Press the upper arm rear bushing
H, and the remover tool 3044-AB3 into the arm using the support cup,
(Fig. 40). tool 3069-H, and the replacer, tool
3068 (Fig. 43). Press the bushing in FIG. 44—Installing Upper Arm
until the shoulder stop is reached. Front Bushing
7. Insert the end of the shaft into
the rear bushing. Press the front bush- REAR SPRING OVERHAUL-
PRESS RAM ing onto the shaft and into the arm SPRING REMOVED
using the replacer, tool 3068 (Fig. 44).
REAR BUSHING FRONT BUSHING LINCOLN CONTINENTAL
Front Hanger Assembly
If the front hanger or bushings are

to be replaced, proceed as follows:
1. Remove the nuts and lock wash-

ers from the spring front mounting
bolt (Fig. 6).
F 1479-A
FIG. 42— Upper Arm, Shaft, and 2. Tap the spring mounting stud
Bushing Assembly out of the bushing and hanger, then
separate the hanger from the spring.
3. Remove the front bushing from

PRESS RAM the spring with tool T64N-5781-A.
Tool— 3068
FIG. 40 —Removing Upper Arm 4. Install the bushing in the spring
Front Bushing with tool T64N-5781-A.
5. Assemble the front hanger to the
3. Remove the shaft. spring eye and install the spring
4. Remove the upper arm rear mounting stud through the hanger,
bushing using the support cup, tool bushings, and spring eye as shown in
3069-H, and the remover, tool 3069-L Fig. 6.
(Fig. 41).
5. Both upper arm bushings are 6. Install the lock washers and nuts
pressed into the arm from the outside JF 1478-A
on the mounting stud and tighten the
toward the inside of the arm. To facil- outboard nut to specification. Tighten
itate installation, use silicone or liquid FIG. 43—Installing Upper Arm the inboard nut to specification with
oap as a lubricant. See Fig. 41 for Rear Bushing the vehicle at curb riding height.
03-02-29 Suspension 03-02-29
SPRING LEAVES If the spring center tie-bolt requires If the rear shackle bushings are to
AND TIE-BOLT replacement, clamp the spring in a be replaced, it will be necessary to re-
vise to keep the spring compressed move the rear hanger assembly. Tor-
during bolt removal and installation. que the hanger attaching bolts to
LINCOLN CONTINENTAL specification when installed.
REAR SHACKLE AND
Check for broken spring leaves. In- HANGER ASSEMBLY
spect the anti-squeak inserts between
the leaves, and replace them if they LINCOLN CONTINENTAL
are worn. The spring leaves must be Inspect the rear shackle, bushings,
dry and free of oil and dirt before new and studs for wear or damage. Re-
inserts are installed. place parts where necessary (Fig. 6).
03-03-01 Automatic Air Leveling System 03-03-01
PART 3-3 Automatic Air Leveling System

MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
AIR COMPRESSOR
Disassembly and Overhaul 03-03 03-03 03-03 N / A N / A N / A N / A N / A N / A N / A N/A
Removal and Installation 03-02 03-02 03-02 N / A N / A N / A N / A N / A N / A N / A N/A
AIR CYLINDER
Removal and Installation 03-02 03-02 03-02 N / A N / A N / A N / A N / A N / A N / A N / A
DESCRIPTION 03-01 03-01 03-01 N / A N / A N / A N / A N / A N / A N / A N / A
HEIGHT CONTROL VALVE
Disassembly and Overhaul 03-03 03-03 03-03 N / A N / A N / A N/A N/A N/A N/A N/A
Removal and Installation 03-02 03-02 03-02 N / A N / A N / A N/A N/A N/A N/A N/A
DESCRIPTION
The automatic level control is an cally maintain the rear standing height pressor, control valve, air cylinders
accessory item on the Ford, Mercury of the vehicle at an approximate con- and the connecting lines and fittings.
and Meteor vehicles (Fig. 1). This de- stant position compensating for vary- In the event of accidental air loss, the
vice is a supplement to the rear coil ing loaded conditions. The system conventional coil springs will support
spring suspension, and will automati- consists of a vacuum operated com- the vehicle.
RUBBER AIR CYLINDER HEIGHT CONTROL RUBBER AIR CYLINDER

WITHIN COIL SPRING VALVE WITHIN COIL SPRING
RUBBER VACUUM LINE TO VACUUM

DISTRIBUTION CONNECTOR
RED CLAMP STATION WAGON ONLY
COMPRESSOR
NYLON AND STEEL LINES

FROM VALVE TO CYLINDERS
FT475-A
FIG. 1 — Air Leveling System

AIR COMPRESSOR may be more convenient to support height, check the operation of the air
the rear of the frame with two jack leveling system.
REMOVAL stands and lower the, axle to provide
1. Slip the vacuum line off the in- greater accessability to the valve. AIR CYLINDER
take fitting on the side of the com- 2. Disconnect the compressor line
pressor (Fig. 2). from the intake port of the height REMOVAL
2. Disconnect the output line from control valve (Fig. 3).
the rear of compressor. 3. Disconnect the air cylinder line 1. Raise the vehicle on a hoist with
3. Remove the three compressor at- from the rear of the height control the hoist under the rear axle housing.
taching nuts from the bracket. Lift the valve. Place jack stands under the frame side
compressor from the mounting brack- 4. Disconnect the link from the rails.
et. height control valve lever. 2. Disconnect the air cylinder line
5. Remove the two control valve- from the fitting on the lower end of
INSTALLATION to-mounting bracket attaching screws the cylinder (Fig. 4).
1. Place the star washer on each in- and remove the valve. 3. Lower the hoist and axle housing
sulator. Position the compressor on until the rear shock is fully extended.
the mounting bracket and install and INSTALLATION 4. Squeeze all air from the bag and
torque the three attaching nuts to install the valve cap.
specifications. 1. Position the height control valve 5. Remove the air cylinder from the
2. Connect the vacuum line to the to the mounting bracket and install rear spring.
intake fitting at the side of the com- the two attaching screws. Torque the
pression. screws to specification. INSTALLATION
3. Start the engine and check the 2. Connect the link to the height
compressor output. control valve lever. 1. Make sure all the air is out of
4. Connect the output line to the 3. Connect the compressor line to the bag and the valve cap is on.
nylon fitting at the rear of the com- the height control valve. 2. Position the air cylinder in the
pressor (Fig. 2). 4. Connect the air cylinder line to spring with the inlet at the lower end.
the height control valve. 3. Remove the valve cap and con-
HEIGHT CONTROL VALVE 5. Set the height control valve lever nect the air cylinder line to the cylin-
REMOVAL as required to obtain the correct trim der.
height. 4. Remove the jack stands and
1. Raise the vehicle on a hoist. It 6. After obtaining the correct trim lower the vehicle.
VACUUM INTAKE LINE INSULATORS NYLON FITTING
MOUNTING BRACKET STAR WASHERS COMPRESSOR F 1364-A

FIG. 2—Compressor Installed
COMPRESSOR LINE AIR CYLINDER LINE INTAKE PORT EXHAUSTPORT ADJUSTMENT SCREW
MOUNTING BRACKET HEIGHT CONTROL VALVE REAR SUSPENSION UPPER ARM F 1365-A
FIG. 3—Height Control Valve Installation
Al R CYLINDER
FIG. 4—Air Cylinder Installation
3 MAJOR REPAIRS
AIR COMPRESSOR 2. Remove the filter and cover 2. Install the three attaching
gasket. screws.
Compressor repair should be limit- 3. Wash the filter in solvent, blow
ed to the cleaning of the micro-bon it dry with compressed air working HEIGHT CONTROL VALVE
filter. from the inside outward.
O t h e r t h a n a d j u s t i n g the trim
REMOVAL INSTALLATION height, no repairs should be made to
the height control valve.
1. Remove the three cover filter at- 1. Position a new gasket and the 1. Thoroughly clean exterior of the
taching screws. cover on the compressor. height control valve.
03-04-02 Automatic Air Leveling System — Lincoln Continental 03-04-02

the three shield attaching screws (Fig. INSTALLATION
COMPRESSOR
2).
3. Disconnect the one vacuum line, 1. Assemble the compressor and in-
clean air intake line and the two pres- sulators to the mounting bracket. In-
REMOVAL sure lines from the compressor. stall and torque the three nuts to spec-
4. Remove the two compressor ification.
1. Raise the front of the vehicle and mounting bracket attaching bolts. Re- 2. Position the compressor mount-
place jack stands under frame side move the bracket and compressor as ing bracket and compressor and se-
rails. an assembly. cure with the two attaching nuts. Tor-
2. Turn the front wheels all the way 5. Remove the three compressor to que the nuts to specification.
to the right. Working from the und- bracket attaching nuts. Separate the 3. Connect the vacuum line (coded
erside of the left front fender, remove compressor from the bracket. with a red stripe), clean air intake line
BRACKET AND COMPRESSOR MUST BE

BOLT MUST BE IN PLACE ASSEMBLED TOGETHER PRIOR TO
PRIOR TO INSTALLATION INSTALLATION IN VEHICLE
OF SUPPORT INTO VEHICLE
F1420-A
FIG. 2—Compressor Installation
CROSSMEMBER and the two pressure lines (Fig. 2) to

the compressor.
4. Install the shield and three at-
taching screws.
5. Remove the jack stands and
lower the vehicle.
HEIGHT CONTROL VALVE
REMOVAL
EXHAUST VALVE PORT 1. Exhaust all air from system.

OVER TRAVEL LEVER
2. Raise the rear of the vehicle and
support it with jack stands.
REAR AXLE HOUSING
3. Disconnect the link from the
height control valve arm.
4. Disconnect the air inlet and the
outlet line from the valve.
5. Remove the two control valve
mounting bracket attaching bolts (Fig.
3) and remove the valve.
INSTALLATION
1. Position the height control valve

F1400-A and install the two attaching bolts.
Torque the bolts to specification.
2. Connect the air inlet and the
3—Height Control Valve
outlet lines to their respective parts. from the system. Then, disconnect the nut on the stud at the upper end of
3. Adjust the trim height as de- line or lines. the super lift. Torque the nut to speci-
tailed in Section 4. 3. Remove the three mounting plate fication.
4. Connect the link to the arm. attaching screws from the upper end 2. Install the mounting plate, outer
5. Remove the jack stands and of the super lift. insulator, washer and nut on the stud.
lower the vehicle. 4. Remove the attaching nut and Torque the nut to specification.
washer from the lower end of the 3. Attach the mounting plate and
super lift and remove it from the vehi- shock absorber to the crossmember
SUPER LIFT SHOCK ABSORBER cle. with the attaching screws to specifica-
5. Remove the nut, outer washer tions.
and the insulator that attach the super 4. Connect the lower end of the
REMOVAL lift to the mounting plate. Remove the super lift to the mounting stud with
plate, remaining insulator and washer. the washers and attaching nut. Torque
1. Raise the vehicle and place jack the nut to specification.
stands under the axle to compress the INSTALLATION 5. Connect the air line or lines
super lift. (right super lift) to the super lift.
2. Loosen the air line or lines (right 1. Position a washer, insulator, 6. Start the engine and check for
super lift) slowly to release the air mounting plate, insulator, washer and leaks.
3 IN-VEHICLE ADJUSTMENTS AND REPAIRS
REGULATOR ADJUSTMENT HEIGHT CONTROL VALVE the exterior of the valve thoroughly.
2. Position the valve with delay
plug on top. Remove delay plug and
The regulator may be adjusted if
drain silicone fluid from the chamber.
the regulator pressure is under 100 psi SILICONE FLUID
Remove the O-ring from the chamber
with the reservoir pressure at a mini- REPLACEMENT
(Fig. 5), and discard the O-ring.
mum of 140 psi. If the regulated pres-
3. Remove the cover plate retaining
sure exceeds 130 psi, the regulator If the height control valve time
ring, using snap ring pliers. Remove
must be replaced. delay does not fall within specifica-
the delay cover from the valve body.
To adjust the regulator, remove the tion, the silicone fluid must be re-
Remove the O-ring from the chamber,
boot and reposition the sleeve and replaced. Then repeat the time delay
and discard the O-ring.
tainer deeper into the body of the re- test. If delay is still not within specifi-
cations, replace the height control 4. Place a new O-ring over the
gulator, using a deep well socket (Fig.
valve. delay plug and install the plug. Tor-
4). If the regulator pressure remains
1. Remove control valve and clean que the plug to 20-30 in-lbs. .
under 100 psi, replace regulator.
5. Pour silicone fluid into the delay
piston chamber until fluid level is 5/16
inch below the top edge of the body.
Add or remove fluid with an eye drop-
per until the proper fluid level is
reached.
6. Hold the control valve body in a
vise with the delay chamber elevated
slightly. Carefully operate the lever to
purge trapped air from the fluid.
7. Place a new O-ring in the groove
around the delay piston bore. Install
5/16" TO
FLUID LEVEL
F1406 A
F 1405 A
FIG. 4—Adjusting Regulator FIG. 5—Replacing Silicone Fluid

the cover and secure it with a snap down. Move the overtravel lever up vehicle. If delay is not within 4-18 sec-
ring, using snap ring pliers. and down for one minute to vent air onds, recheck the fluid level in the
8. Place the control valve vertically from the delay piston pin chamber. delay chamber. If the level is within
in a vise with the delay chamber Perform a time delay check off the specifications, replace the valve.
9. Install the height control valve.
03-05-01 Steering Columns And Linkage 03-05-01
PART 3-5 Steering Columns and Linkage

MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
ADJUSTING SLEEVE (LINKAGE)
CENTER LINK (LINKAGE)
LOCKING LEVER (TILT-AWAY COLUMN)
Removal and Installation N/A N/A N/A 05-06 N / A N/A N / A 05-06 N / A 05-06 N / A
PITMAN ARM (LINKAGE)
SPINDLE CONNECTING ROD ASSEMBLY
(Inner and Outer Ends)
STATIONARY STEERING COLUMNS
Description 05-01
STEERING COLUMN
Alignment N / A N / A N / A N / A N / A N / A N / A N / A 05-06 05-07 05-06
STEERING COLUMN SHIFT TUBE
STEERING COLUMN UPPER BEARING
STEERING IDLER ARM AND BRACKET
ASSEMBLY
STEERING WHEEL
Spoke Position Adjustment 05-02
TILT-AWAY STEERING COLUMN
Description N/A N/A N / A 05-02 N / A N/A N / A 05-02 N / A 05-02 N / A
TILT STEERING COLUMN
Description 05-01 05-01 05-01 N / A N/A N/A N/A N/A 05-01 N / A 05-01
TILT WHEEL STEERING COLUMN
STEERING SHAFT
Removal and Installation 05-16 05-16 05-16 N / A N/A N/A N/A N/A 05-16 N / A 05-16
VACUUM MOTOR (TILT-AWAY COLUMN)
Removal and Installation N/A N/A N/A 05-05 N / A N/A N/A 05-05 N / A 05-05 N / A
VACUUM RELEASE VALVE (TILT-AWAY
COLUMN)
Removal and Installation N/A N / A N / A 05-05 N / A N/A N/A 05-05 N / A 05-05 N / A
1 DESCRIPTION
STATIONARY STEERING COLUMNS dent. The lower end of the steering will shear and allow them to collapse
column tube at the bellows area will in proportion to the outer tube upon
The steering column is of the col- c o l l a p s e approximately six inches impact.
lapsible type to lessen the possibility upon a hard impact. Once the steering column has been
of injury to the driver of the vehicle The shift tube and the steering shaft collapsed, a complete new column
should he become involved in an acci- are provided with plastic dowels and must be installed with new brackets
which also will shear away during im- must be installed. the shift lever is placed in PARK and
pact. The tilt column features nine driv- the driverns door is opened.
ing positions (four up and four down The steering column is of the col-
from a center position). The .column lapsible type to lessen the possibility
TILT STEERING COLUMNS
also features a turn signal switch with of injury to the driver of the vehicle
The steering column is of the col- a lane-changer position turn indicating should he become involved in an acci-
lapsible type to lessen the possibility position and emergency warning flash- dent. The lower end of the steering
of injury to the driver of the vehicle er control. column tube at the bellows area will
should he become involved in an acci- c o l l a p s e approximately six inches
dent. The lower end of the steering TILT-AWAY STEERING COLUMNS upon a hard impact.
column tube at the bellows area will The shift tube and the steering shaft
c o l l a p s e approximately six inches The tilt-away steering column fea- are provided with plastic dowels and
upon a hard impact. tures nine driving positions (four up will shear and allow them to collapse
The shift tube and the steering shaft and four down from a center position) in proportion to the outer tube upon
are provided with plastic dowels and and a tilt-away position that is auto- impact.
will shear and allow them to collapse matically accomplished on Mustang Once the steering column has been
in proportion to the outer tube upon and Cougar models when the ignition collapsed, a complete new column
impact. key is turned to the OFF position and must be installed along with mounting
Once the steering column has been the left door is opened. On Thunder- brackets which will also shear away
collapsed, a complete new column bird models, the tilt-away occurs when during impact.

STEERING WHEEL SPOKE on the hub of the wheel is adjacent to removal instructions). Remove the
POSITION ADJUSTMENT the one on the shaft. Install a new horn ring (if so equipped) by turning
When the steering gear is on the locknut and torque it to specifications. it counterclockwise.
high point, the front wheels should be 6. Install the horn ring (if so 3. Remove the steering wheel at-
in the straight-ahead position and the equipped) and crash pad. taching nut. Remove the steering
steering wheel spokes should be in wheel using tool T67L-3600-A (Fig.
STEERING COLUMN UPPER
their normal position with the Pitman 1). Do not use a knock-off type steer-
arm pointing directly forward. If the BEARING REPLACEMENT ing wheel puller or strike the end of
spokes are not in their normal posi- STATIONARY COLUMNS the steering shaft with a hammer.
tion, they can be adjusted without dis- Striking the puller or shaft will dam-
turbing the toe-in adjustment (Part Removal age the bearing or the collapsible col-
3-1). 1. Disconnect the horn wire and the umn.
turn indicator wires at the connector. 4. Remove the turn indicator lever.
STEERING WHEEL 2. Working from the underside of 5. Remove the turn signal switch
REPLACEMENT the steering wheel spoke, remove the attaching screws. Lift the switch over
two crash pad attaching screws. Lift the end of the steering shaft and place
1. Disconnect the negative cable the crash pad from the wheel. (On it to one side.
from the battery. Continental Mark III models, pry out 6. Remove the snap ring from the
2. Working from the underside of the crash pad insert and remove the top of the steering shaft.
the steering wheel spoke, remove the two screws that secure the crash pad. 7. Loosen the two flange-to-steering
crash pad attaching screws. Lift the Remove the crash pad. On models column tube attaching bolts to disen-
crash pad from the wheel. (On Conti- equipped with steering wheel mounted gage them from the tube.
nental Mark III models, pry out the speed controls, refer to Group 16 for 8. Raise the flange upward while
crash pad insert and remove the two BEARING AND
INSULATOR
screws that secure the crash pad. Re- 7oo/-T67L-3600-A
move the crash pad. On models
equipped with steering wheel mounted
speed controls, refer to Group 16 for
removal instructions). Remove the
horn ring (if so equipped) by turning
it counterclockwise.
3. Remove the steering wheel nut,
and then remove the steering wheel
with tool T67L-3600-A (Fig. 1). Do
not use a knock-off type steering
wheel puller or strike the end of the
steering shaft with a hammer. Striking
the puller or shaft will damage the
bearing or the collapsible column.
4. Transfer all serviceable parts to
G 1497-A
the new steering wheel. Spacer
G 1502 - B
5. Position the steering wheel on
the shaft so that the alignment mark FIG. 1—Removing Steering Wheel FIG. 2—Installing Upper Bearing
tapping the steering shaft lightly with position. Install and torque the attach- 5. Loosen the screw on the bottom
a plastic hammer to free the bearing ing nut to specification. side and slide the lower cover down-
and flange from the shaft. 8. Secure the crash pad to the ward on the column (on Ford and
9. Remove the bearing and insula- steering wheel with the two attaching Mercury models, remove the shroud.)
tor from the flange. screws. 6. Remove the screw that secures
9. Connect the horn and turn signal the turn signal wire retaining clip to
Installation wires. the column and remove the clip.
10. Install the turn signal lever. 7. Remove the two screws that at-
1. Install flange bolts (square head) tach the turn signal switch to the
in flange if they were removed. Turn TILT WHEEL COLUMNS steering column. Move the switch
the nuts onto the bolts one complete wires upward enough to permit lifting
turn only. the switch over the end of the steering
2. Position the flange onto the Removal shaft and lay the switch to one side.
steering column tube. Be careful not to lose the turn signal
3. Engage the two flange bolt heads 1. Disconnect the negative cable lever pivot from the switch.
with the square holes in the column from the battery. 8. Compress the steering column
tube, then tighten the two attaching 2. Remove the steering wheel with locking clamp with vise grip pliers
nuts to specification. tool T67L-3600-A (Fig. 1). Install the (Fig. 4) and move the steering shaft to
4. Position the bearing and insula- spring, shipping spacer (3/4 x 1 1/8- the full up position.
tor on the shaft. Work it down onto inch pipe) and a steering wheel attach- 9. Hold the column position spring
the shaft as far as possible, then place ing nut on the shaft. Do not use a rod with vise grip pliers to prevent flo-
a piece of 3/4 ID x 2 1/8 inch pipe knock-off type steering wheel puller or tation then compress the spring and
over the end of the shaft and install strike the end of the steering shaft remove the retainer. Remove the plas-
the steering wheel attaching nut (Fig. with a hammer. Striking the puller or tic cover and spring.
2). shaft will damage the bearing or the 10. Install tool T67P-3D739-B as
5. Tighten the nut until the bearing collapsible column. shown in Fig. 4. Thread the bolt in-
is seated in the flange, then remove 3. Remove the turn indicator lever ward finger tight until it bottoms, then
the nut and pipe from the shaft. (Fig. 3). back it out one full turn. Make sure
6. Position the turn signal switch 4. Remove the three screws that at- that the handle is centered over the
on the flange and install the three attach the upper cover to the column pivot pin to prevent bolt breakage.
taching screws. and remove the cover. It may be nec- Hold the 3/8 inch bolt head station-
7. Make certain that the wheels are essary to rotate the cover approxi- ary, then tighten the nut to extract the
in the straight ahead position. Place mately 1/4—1/2 inch to engage the pin. Repeat this operation on the op-
the steering wheel on the steering cover lip in the slot of turn signal posite pin.
shaft with the spokes in the horizontal switch to permit clearance. 11. Remove the nut, shipping spa-
UPPER
COVER
G 1498-B
FIG. 3—Typical Steering Column—Disassembled

Shipping Spacer
(3/4 X 1-1/3 inch
Pipe)
TURN SIGNAL SWITCH
Too/-T65P-3D739-A
G 1468-3
FIG. 4—Removing Pivot Pin
cer and spring from the steering shaft. satisfactory press-fit as shown in Fig. column and install the two attaching
12. With the steering column lock- 6 with a C-clamp. The pivot pins screws.
ing clamp still compressed, lift the should have a clearance of 0.005 inch 12. Install the combination turn
upper flange from the column by between the shoulder and casting signal and tilt mechanism lever.
working against the lower bearing when properly installed. A clearance 13. Install the steering v/heel and
inner race. of less than 0.005 inch may create a the crash pad.
13. Place the flange on the bench bind in the tilt mechanism. If one pin 14. Connect the negative cable to
with the smaller bearing toward the presses in before the other, place a the battery. Check the turn signal and
bench (Fig. 5). Drive lightly on the spacer washer over the head of the pin tilt mechanism for proper operation.
outer race at each slot with a small that has already positioned to prevent
pick. To remove the upper bearing in- over pressing while still pressing the
vert the flange and remove the larger other one into position.
bearing in the same manner. Never 5. Move the tilt mechanism to the
drive or apply pressure to the inner uppermost position and remove the
race. vise grip pliers to lock it in place.
6. Position the release spring rod BEARING OUTER
RACE
and hold it up as high as possible with
Installation vise grip pliers. Place the spring and
cover in place on the upper flange.
1. Select a socket wrench that is Compress the spring and install the
the same diameter of each bearing retainer. Remove the vise grip pliers.
outer race. Position the bearing on the 7. Depress the column release lever
upper flange with the open side facing with pliers and place the tilt mecha-
inward. Place the socket on the outer nism in the center position.
race and tap the bearing into place. 8. Position the turn signal switch
Be careful not to contact the bearing and install the two attaching screws.
inner race as damage will result. 9. Pull the wires into place and in-
2. Compress the column release stall the plastic retaining clip.
SLOT
lever with vise grips to place the lock- 10. Slide the lower cover into place.
ing levers in the release position. Tighten the screw attaching the lower
3. Position the flange on the upper cover to the column. Make sure the
end of the shaft being careful to apply rotating socket casting does not rub G 1448-A
pressure only on the upper bearing on the lower cover. (On Ford and
inner race to prevent bearing damage. Mercury models, replace the shroud.)
4. Install new pivot pins to assure a 11. Position the upper cover on the FIG. 5—Removing Ball Bearings
TILT-AWAY STEERING 4. Connect the hose from the vacu- mounting bracket and the attaching
COLUMN REPAIRS um dash panel junction block to the screws.
connector on the vacuum release valve 2. Connect the control cable to the
that points downward and forward. vacuum motor rod with the clevis pin.
VACUUM RELEASE VALVE- Connect the hose from the vacuum 3. Position the bracket to the in-
COUGAR AND MUSTANG motor to the other connector on the strument panel and install the attach-
release valve. ing bolt. Make all electrical and vacu-
5. Install the lower finish panel. um connections.
4. Readjust the cable bracket to as-
Removal VACUUM MOTOR- sure full engagement of the locking
COUGAR AND MUSTANG pawl when in driving position.
1. Working from the underside of 5. Connect the hose to the vacuum
the instrument panel disconnect the Removal motor.
hose from the valve.
2. Disconnect the wire from the
1. Working from the underside of
connector on the valve and the con- VACUUM MOTOR—
the instrument panel, disconnect the
nector from the relay. THUNDERBIRD
hose to the valve and the wires to the
3. Remove the b r a c k e t - relay and valve.
to-instrument panel attaching bolt and
let the bracket swing down. 2. R e m o v e the b r a c k e t -
to-instrument panel attaching bolt and
4. Remove the two screws that se- Removal
swing the bracket downward.
cure the valve to the mounting bracket
and remove the valve. 3. Remove the clevis pin that se-
cures the cable to the vacuum motor 1. Remove the lower finish panel.
rod. 2. Disconnect the vacuum hose
Installation 4. Disconnect the starter safety from the solenoid valve. Disconnect
switch wire at the connector. the electrical lead.
1. Secure the valve to the mounting 5. R e m o v e t h e two motor- 3. Loosen the screws that attach
bracket with the two attaching screws. to-bracket attaching screws and re- the bracket to the dash and lift the
2. Position the bracket to the in- move the motor, disconnecting the bracket up; then, swing it down.
strument panel and install the attach- hose to the solenoid. 4. Remove the clevis pin holding
ing bolt. the motor to the cable.
3. Connect the wire to the terminal Installation 5. Remove the two attaching
on the valve. screws, then lift the motor from the
4. Connect the hose from the vacu- 1. Position the motor on the bracket.
um motor to the horizontal connector
on the valve and the hose from the
reservoir to the vertical connector. C-CLAMP
VACUUM RELEASE VALVE—

THUNDERBIRD
Removal
1. Remove the lower finish panel.

2. Disconnect the vacuum hose
from the vacuum release valve.
3. Disconnect the vacuum release
valve electrical leads at the connector.
4. Loosen the two attaching screws
holding the bracket to the dash. Lift
up the bracket to clear the screws and
swing it down below the panel. PIVOT PIN
5. Remove the screws attaching the
valve to the panel and remove the
valve.
Installation
1. Position the vacuum release

valve on the bracket.
2. Install the two attaching screws
and swing the bracket up and over the
G 1462-A
screws. Tighten the screws.
3. Connect the electrical leads to
the wiring harness. FIG. 6—Installing Pivot Pins
Installation. 7. Remove the levers, spring caps efforts may be experienced caused by
and springs from the flange. improper alignment of the energy ab-
s o r b i n g steering column. The fol-
1. Position the vacuum motor on
Installation lowing procedures outline the steps
the bracket. Tighten the two attaching
necessary to correctly re-align either
screws. 1. Make sure that the rubber insu- fixed or tilt columns.
2. Connect the cable to the motor lators are in place in the upper flange.
with the clevis pin. Adjust the cable It is recommended that before at-
2. Position the springs, spring caps tempting realignment, the toe plate
bracket so the motor rod is fully ex- and locking levers in the upper flange.
tended, but not tight. (column retainer) to dash panel fas-
3. Place the assembly in a vise and tener holes be inspected for a binding
3. Slide the vacuum motor as re- compress the springs. Install new lever
quired to align the locking pawl rod or misaligned condition.
retaining pins in the upper flange. The If the conditions described above
and vacuum motor. Retighten the two pins should protrude from the sides of
vacuum motor attaching screws. could be attributed to this area, file or
the flange by .03 to .09 inch. ream the dash panel holes for greater
4. Connect the vacuum hose to the 4. Install a 3 1/8-inch bolt between clearance.
vacuum motor. the lower ends of the locking levers as The column alignment procedures:
5. Install the lower finish panel. shown in Fig. 7. 1. Loosen the nuts retaining the toe
5. Make sure that the column re- plate (column retainer) to the dash
LOCKING LEVER lease lever stop and spring is in place panel (B in Fig. 8).
REPLACEMENT in the upper flange, then position the 2. Loosen to fingertight the bolt
column release lever on the flange. In- and nut located on the toe plate re-
Removal stall the two retainers. taining clamp (C in Fig. 8).
6. Remove the 3 1/8-inch bolt from 3. Remove trim at instrument panel
1. Remove the upper flange and between the levers. to steering column mounting to ex-
bearings from the column. 7. Install the upper flange and pose retaining bolts.
2. Insert a 3 1/8-inch bolt between bearings in the steering column. 4. Loosen to fingertight {.he bolts
the lower ends of the locking levers that support the column and bracket
(Fig. 7) to relieve the tension from the STEERING COLUMN against the instrument panel (D in
column release lever. ALIGNMENT Fig. 8).
3. Place the flange in a vise as 5. Loosen to fingertight the bolts or
shown (Fig. 7) and remove the two re- nuts which retain the column brackets
tainers with a screwdriver. THUNDERBIRD AND to the brake pedal support bracket
4. Lift the column release lever CONTINENTAL MARK III (E).
from the flange. 6. Loosen to fingertight the bolt
5. Drive the locking lever retaining A condition of high shift or steering which controls lateral adjustment of
pins from the flange with a small
drift.
6. Release the vise slowly to pre-
vent the levers from flying out.
LEVER RETAINING
PINS
3-1/8'
RETAINER TORQUE VALUE
B 8-12 FT. LB.

c 3-5 FT. LB.
D 7.12 FT. LB.
E 7.12 FT. LB.
F 28-42 FT. LB.
G1536-A
FIG. 7—Removing or Installing

Locking Levers FIG. 8—Steering Column Alignment Locations and Torque Specifications
the steering column (F in Fig. 8).

7. Disconnect the transmission shift
rod at the shift tube. -HANDLE PORTION
8. Working under the hood, install
- * - 3/4"
the aligning spacer (Fig. 9) around the
visible portion of the steering shaft
and slide it up the shaft into the steer- DIMENSION A:
ing column. It may be necessary to BEND AROUND
STANDARD COLUMN 7/16"
TILT WHEEL COLUMN 1-1/8"
move the shaft back and forth to com- STEERING SHAFT
pletely install the spacer. 2-3/4"
9. At this point the steering column

assembly, being loose, may have
dropped toward the steering gear
grounding the steering shaft on the
steering gear input shaft. To properly •2-3/4
establish the steering shaft to steering
FABRICATE ALIGNING SPACER OUT OF
gear clearance, insert a 1/8 diameter PLASTIC SHIPPING COLLAR PROVIDED STEERING SHAFT
rod or drill through the opening in the ON SERVICE DRIVESHAFTS, OR OUT OF
1/32"—1/16" CARDBOARD
upper half of the flex coupling.
10. Tighten to a snug fit (approxi-
mately 2-3 ft-lb) the nuts retaining the
toe plates to the dash panel (B in Fig.
8).
11. If the aligning spacer cannot be
rotated freely, the dash panel holes
must be filed or reamed for greater ALIGNMENT SPACER-BEND AROUND
STEERING SHAFT (DIMENSION A) AND
travel (as mentioned in the second SLIDE UP THE SHAFT INTO COLUMN
paragraph at the beginning of this
procedure).
G1537-A
12. T i g h t e n all nuts and bolts
(noted as C, D and E in Fig. 8) in the
passenger compartment to a snug fit FIG. 9—Aligning Spacer Fabrication and Insertion
(approximately 2-3 ft-lb). Again check
aligning spacer for looseness. Perform
these tightening operations in alpha-
betical order.
13. Tighten the lateral adjustment
bolt (F in Fig. 8) to snug fit. Again
check the aligning spacer for loose-
ness.
14. Tighten all bolts and nuts to the
proper torque value (listed in Fig. 8)
in alphabetical order.
15. Remove the steering shaft al-
igning spacer.
16. Remove the 1/8 diameter rod or
drill previously inserted in the flex
coupling.
17. Reinstall the trim at the instru-
ment panel to steering column mount- BRAKE PEDAL
ing. SUPPORT BRACKET
LINCOLN CONTINENTAL
If a condition of high shift or steer-

ing effort is experienced it may be
caused by improper alignment of the
energy absorbing steering column. The
following procedures outline the steps
PART TORQUE VALUE
necessary to correctly realign either
fixed or tilt columns: A-TOE PLATE 8-12 FT. LB.
B-CLAMP 3-5 FT. LB.
1. Disconnect the battery. C-C0LUMN BRACKET 10-15 FT. LB.
2. Loosen four toe plate attaching D-BRAKE PEDAL
8-12 FT. LB.
nuts (Fig. 10). SUPPORT BRACKET
G1541-A
3. Loosen one toe plate to steering
column clamp bolt and nut. Check FIG. 10—Steering Column Alignment Locations and Torque
alignment of steering shaft to shift Specifications—Lincoln Continental
tube. In some instances the column 6. Install a 3/16 inch diameter rod some instances it may be necessary to
will shift into proper alignment when spacer in the flex coupling to assure enlarge the holes in the dash panel in
the toe plate attaching nuts are loos- proper clearance between upper and order to obtain proper column align-
ened. (Alignment is acceptable if a lower steering shaft. ment.
.010 inch feeler blade can be passed 7. Raise the vehicle, remove the 11. With the column properly al-
freely, completely around the area be- transmission splash shield, and visual- igned, torque the four toe plate at-
tween the outer diameter of the steer- ly align the column to center the taching nuts to 4-9 ft-lbs.
ing shaft and the shift tube.) if the steering shaft in the column. Tighten 12. Torque the toe plate to steering
misalignment condition can be attrib- two toe plate attaching nuts sufficient- column clamp bolt to 3-5 ft-lbs.
uted to this area, file or ream the dash ly to hold the column alignment (two 13. Recheck steering shaft to shift
panel holes for greater clearance. If persons may be required for this oper- tube alignment. A 0.10 inch feeler
the alignment is maintained after the ation). blade should pass freely, completely
toe plate nuts and toe plate to column 8. Lower the vehicle. around the area between the outer di-
clamp bolt and nut are torqued to the 9. Check the clearance between the ameter of the steering shaft and shift-
8-12 ft-lb specification, no further ad- steering column support bracket and er tube.
justment is necessary. the instrument panel bracket. It may 14. Raise the vehicle.
4. Remove instrument panel lower be necessary to add shims (Part Num- 15. Adjust transmission shift link-
trim panel. Vehicles equipped with a ber MK-3054-A .060 inch thick, or age.
combination radio stereo tape player C3AZ-3054-A, .113 inch thick) be- 16. Install transmission splash
will require removal of the radio and tween the support bracket and the in- shield.
tape player assembly in order to gain strument panel bracket to prevent 17. Lower the vehicle.
access to the upper R.H. steering col- movement of the column when the 18. Install the radio stereo tape
umn support bracket bolt. support bracket bolts are tightened. player if so equipped.
5. Loosen the seven bolts at the 10. Loosen the two toe plate at- 19. Install instrument panel lower
steering column support bracket and taching nuts previously tightened. Re- trim panel.
brake pedal support bracket. check steering column alignment. In 20. Connect the battery.
STEERING COLUMN nect the light switch electrical connec- 5. Tighten the four attaching nuts
tor block. at the upper and lower brackets and
FORD, MERCURY, METEOR 8. Remove the two screws that se- the two nuts at the upper bracket to
cure the intermediate bracket to the instrument panel. The dial pointer (if
column lower bracket. so equipped) should be adjusted to
9. While supporting the steering coincide with the selector lever.
Removal column, remove the two nuts that se- 6. Install and tighten the nuts and
cure the column lower bracket to the bolts that secure the column retainer
1. Disconnect the battery cable instrument panel. Remove the brack- and seal at the toe plate. Make sure
from the negative post. ets. the steering shaft is centered in the
2. Disconnect the turn signal switch 10. Lift the steering column and column before tightening the nuts.
wires at the connector. wheel from the vehicle. 7. Ford, Meteor: Install and tighten
3. Disconnect the neutral start the two screws that secure the lower
switch and back-up light switch wires Installation trim shroud to the upper trim shroud.
from the switches. Mercury: Connect the light switch
4. Disconnect the transmission con- 1. Position the steering column in harness block. Install the ignition and
trol rod(s) from the lever(s) at the the vehicle. Index the block tooth on light switch bezels. Connect the igni-
lower end of the column. the steering gear shaft with the corre- tion switch light bulb. Install the top
5. Remove the bolt that secures the sponding slot on the flex coupling. In- shroud and the two screws that secure
flex coupling to the steering gear. stall and tighten the flex coupling- the lower trim shroud to the upper
6. Remove the nuts that secure the to-steering gear attaching bolt. shroud.
column retainer and seal at the toe 2. Place the column upper bracket 8. Connect the transmission control
plate (Fig. 11). and column lower bracket in position rod(s) to the lever(s) at the lower end
7. Ford, Meteor: Remove the two on the column and install but do not of the column.
screws that secure the lower trim tighten the four attaching nuts. 9. Connect the neutral start switch
shroud to the upper trim shroud. Re- 3. Install and tighten the two nuts and back-up light switch to their re-
move the two shrouds. that secure the column lower bracket spective terminals.
Mercury: Remove the two screws to the instrument panel. Make certain 10. Connect the turn signal switch
that secure the lower trim shroud to the column is properly positioned rela- wires.
the upper trim shroud. Remove the tive to the flex coupling input shaft 11. Connect the negative battery
top shroud Disconnect the ignition connection. cable to the battery.
switch light bulb. Remove the ignition 4. Install and tighten the screws 12. Check the operation of the
and light switch bezels and spring clip that secure the intermediate bracket to steering tilt mechanism if so equipped
and remove the lower shroud. Discon- the column lower bracket. and the switches.
FAIRLANE, FALCON 6. Remove the nuts and bolts that port bracket and the dash panel.
AND MONTEGO secure the column retainer and seal at Make certain the column is properly
the toe plate. positioned relative to the flex coupling
7. Disconnect the nuts that secure inpui shaft connection.
Removal the column upper and lower brackets 3. Install and tighten the flex cou-
to the brake pedal support bracket pling-to-steering gear attaching bolt.
1. Disconnect the battery cable and the dash panel. 4. Tighten the nuts at the brake
from the negative post. 8. Lift the column from the vehicle. pedal support bracket and the dash
2. Disconnect the turn signal switch panel.
wires at the connector. Installation 5. Install and tighten the nuts and
3. Disconnect the neutral start bolts that secure the column retainer
siwtch (with automatic transmission) 1. Position the steering column in and seal at the toe plate.
and back-up light switch wires from the vehicle. Make sure that the wheels 6. Connect the transmission control
the switches. are in the straight ahead position and rod(s) to the lever(s) at the lower end
4. Disconnect the transmission con- that the steering wheel spokes are in a of the column.
trol rod(s) from the lever(s) at the horizontal position when the flex cou- 7. Connect the neutral start switch
lower end of the column. pling engages the input shaft splines. (if so equipped) and back-up light
5. Remove the bolt that secures the 2. Install but do not tighten the switch to their respective terminals.
flex coupling to the steering gear (Fig. nuts that secure the column upper and 8. Connect the turn signal switch
12). lower brackets to the brake pedal sup- wires.
COLUMN UPPER \
BRACKET-3506 V
BRAKE PEDAL
SUPPORT BRACKET
TRIMSHROUD-3530
UPPER CLAMP-3507,
COLUMN LOWER
BRACKET-3R547
ÎNTERMEDIATE
BRACKET-3676 VIEW AA
• FLEXCOUPLING-3A525
G1616-A
FIG. 11—Steering Column Installation—Ford, Mercury, Meteor

9. Connect the battery cable to the secure the column retainer and seal at positioned relative to the flex coupling
negative post. the toe plate. input shaft connection.
10. Check the operation of the 6. Remove the nuts that secure the 3. Tighten the two rearward nuts at
switches. column lower bracket to the brake the brake pedal support bracket and
pedal support (Fig. 13). column lower bracket to the brake
COUGAR, MUSTANG 7. Lift the column from the vehicle. pedal support.
4. Install and tighten the nuts and
bolts that secure the column retainer
Removal Installation and seal at the toe plate. Tighten the
forward nuts securing the column to
1. Disconnect the battery cable 1. Position the steering column in the brake pedal support.
from the negative post. the vehicle. Make sure that the wheels 5. Install and tighten the flex cou-
2. Disconnect the turn signal switch are in the straight ahead position and pling-to-steering gear attaching bolt.
wires at the connector. that the steering wheel spokes are in a 6. On tilt-away columns, connect
3. On tilt-away columns, disconnect horizontal position when the flex cou- the tilt-control cable to the vacuum
the tilt-control cable from the vacuum pling engages the input shaft splines. motor and mounting bracket. Adjust
motor and mounting bracket. 2. Install but do not tighten the the cable for proper operation.
4. Remove the bolt that secures the nuts that secure the column lower 7. Connect the turn signal switch
flex coupling to the steering gear. bracket to the brake pedal support. wires.
5. Remove the nuts and bolts that Make certain the column is properly 8. Connect the battery cable to the
negative post.
STEERING WHEEL-3600
BRAKE PEDAL SUPPORT

BRACKET-3B139
TOE PLATE
COLUMN LOWER
BRACKET-3R547
FLEXCOUPLING-3A525
G1617-A
FIG. 72—Steering Column Installation—Fairlane, Falcon, Montego

9. Check the operation of the steer- 5. Remove the four screws that at- cle making sure that the steering shaft
ing tilt mechanism (if so equipped) tach the column retainer to the dash engages the flex coupling.
and the switches. panel. 1. I n s t a l l the column retainer-
6. Working from the underside of to-dash panel attaching screws, but do
THUNDERBIRD AND the instrument panel disconnect the not tighten them.
CONTINENTAL MARK III steering column tilt-control cable from 3. Install the lower clamp and the
the vacuum motor and mounting attaching nuts. Tighten the nuts fing-
bracket (if so equipped) (Fig. 14). ertight.
Removal 7. D i s c o n n e c t the turn signal 4. Move the lower flange as re-
switch, and emergency flasher wires at quired to center the steering shaft in
1. Remove the instrument panel the connectors. Disconnect the wires the tube. Aligning procedures are de-
lower outer finish panel, instrument from the neutral start switch. tailed in Part 3-1. Tighten the lower
panel steering column plate and cover. 8. While supporting the steering flange attaching nuts when the shaft is
2. Disconnect the negative cable column, remove the four bolts that at- centered.
from the battery. tach the lower clamp to the upper 5. Connect the shift rod to the shift
3. Remove the bolt that attaches clamp (Fig. 14). Lift the column from lever at the lower end of the column.
the flexible coupling to the steering the vehicle. 6. Install and tighten the flex cou-
shaft. pling attaching bolt.
Installation 7. Tighten the instrument panel-
4. Disconnect the shift rod from the
lever at the lower end of the column. 1. Position the column in the vehi- to-clamp attaching nuts.
STEERING WHEEL-3600
BRAKE PEDAL SUPPORT
TURN SIGNAL LEVER-13305
COLUMN TUBE-3514
COLUMN LOWER BRACKET-3R547
•TOE PLATE
FLEX COUPLING-3A525
G1618-A
f/G. 73—Steering Column Installation—Cougar, Mustang

SPRING-3D655
BRACKET-3678
RELEASE-3D544
UPPER CLAMP-3506
WIRE RETAINING CLIP-13377

SPRING-3520 COVER-3D505
TURN SIGNAL SWITCH-13341

TURN SIGNAL AND TILT
CONTROL LEVER-13305
FLEX COUPLING-3A525
BEARING-7347
INSULATOR-7C102
SEAL-3E629
BEARING-3576
G1539-A
flG. 14—Steering Column Installation—Thwderibird cmd Corrttnettfd Mark

STEERING WHEEL-3600
STEERING SHAFT-3525
LOWER CLAMP
3668
CENTERING WASHER-3C708
G1542-A
:
/G. 15—Steering Column (Fixed)—Disassembled—Lincoln Continental
8. Connect the turn signal and lever at the lower end of the selector cle, making sure that the steering
emergency flasher switch wires at the tube. shaft engages the flex coupling.
multiple connectors. Connect the wires Loosen the clamp bolt that locks 2. I n s t a l l the c o l u m n retainer-
to the neutral start switch. Adjust- the flexible coupling to the steering to-dash panel attaching screws, but do
ments for the neutral start switch are shaft. not tighten them.
detailed in Group 7 of this manual. 3. Working from the underside of 3. Install the lower clamp and the
9. Connect the tilt-column control the steering wheel spoke, remove the attaching nuts. Tighten the nuts fing-
cable to the release cable retainer and two screws that secure the crash pad. ertight.
vacuum motor (if so equipped). To re- Remove the pad. Do not use a ham- 4. Move the lower flange as re-
move cable slack, loosen the bracket mer or knock-off type wheel puller. quired to center the steering shaft in
attaching screw and pull it slightly Striking the puller or shaft may cause the tube. Aligning procedures are de-
toward the column, then tighten the damage to the bearings and/or col- tailed in Part 3-1. Tighten the lower
screw. If difficulty in adjusting this lapsible column. Remove the steering flange attaching nuts when the shaft is
control is experienced, the retainer wheel as shown in Fig. 15. centered.
slot may be filed to gain additional 4. Remove the instrument panel 5. Connect the shift rod to the shift
travel. steering column finish plate. lever at the lower end of the column.
10. Install the instrument panel 5. Remove the four screws that at- 6. Install and tighten the flex cou-
steering column plate and cover and tach the lower retainer to the dash pling attaching bolt.
the instrument panel lower outer fin- panel. 7. Tighten the instrument panel-
ish panel. 6. Disconnect the turn signal switch to-clamp attaching nuts.
11. Connect the negative cable to and emergency flasher wires at the 8. Connect the turn signal and
the battery. connectors. Disconnect the wires from emergency flasher switch wirss at the
12. Start the engine and check the the neutral start switch. multiple connectors. Connect the wires
operation of the steering column and 7. While supporting the steering to the neutral start switch. Adjust-
switches. column, remove the bolts that attach ments for the neutral start switch are
the lower clamp to the upper bracket detailed in Group 7 of this manual.
LINCOLN CONTINENTAL (Fig. 15). Lift the column from the ve- 9. I n s t a l l the instrument panel
hicle. steering column finish plate.
Removal 10. Install the steering wheel and
Installation crash pad.
1. Disconnect the battery.
2. Disconnect the rod from the 1. Position the column in the vehi-
STEERING COLUMN ing or the collapsible column. (Fig. 16) on the tube and insert the
SHIFT TUBE REPLACEMENT 3. Remove the steering column steering shaft in the shift tube.
from the vehicle. 2. Install the C-washer on the
4. Remove the selector lever from upper end of the steering shaft.
STATIONARY COLUMN the hub (Fig. 16). 3. Insert the shift tube and steering
WITH STANDARD 5. Remove the bearing upper snap shaft into the steerint column tube
TRANSMISSION ring. It may be necessary to pull the and install the three attaching screws
turn signal switch out to remove the at the lower end of the steering col-
Removal snap ring. umn tube.
6. Remove the screws that attach 4. Position the bearing and insula-
1. Working from the underside of the shift tube bearing, shift arms, and tor on the shaft if it was disturbed
the steering wheel spoke, remove the shift tube to the lower end of the during removal. Work it down onto
two screws that secure the crash pad. steering column. the shaft as far as possible, then place
Remove the pad. (On Continental 7. Slip the shift tube and steering a piece of 3/4 ID x 2 1/8 inch pipe
Mark III models, pry out the crash shaft from the lower end of the steer- over the end of shaft and install the
pad insert and remove the two screws ing column tube. The upper bearing steering wheel attaching nut (Fig. 2).
that secure the crash pad. Remove the has a slight press fit on the steering 5. Tighten the nut until the bearing
crash pad. On models equipped with shaft. is seated in the flange, then remove
steering wheel mounted speed con- 8. Remove the C-washer from the the nut and pipe from the shaft.
trols, refer to Group 16 for removal upper end of the steering shaft, and 6. Position the turn signal switch
instructions). pull the shift tube from the steering on the flange and install the three at-
2. Remove the steering wheel from shaft. taching screws. Install the upper snap
the steering shaft with tool T67L- 9. Remove the shift tube bearing ring.
3600-A (Fig. 1). Then, remove the from the lower end of the tube 7. Install the selector lever and the
tool from the steering wheel. Do not turn signal lever in the column.
use a knock-off type steering Wheel 8. Adjust and install the neutral
puller or strike the end of the steering Installation start switch as detailed in Group 7.
shaft with a hammer. Striking the 9. Install the steering column in the
puller or shaft will damage the bear- 1. Position the shift tube bearing vehicle.
STEERING
QUADRANT
COLUMN TUBE SELECTOR
BEARING
I LEVER HUB
UPPER
SNAP RING
SHIFT
TUBE \ CENTERING
I WASHER
TURN SIGNAL AND

EMERGENCY FLASHER
SWITCH
PLASTIC
CONDUIT
STEERING
SHAFT
CONNECTOR
G 1494-A
FIG. 16—Typical Stationary Steering Column Disassembled—Standard Transmission
SNAP RING STEERING WHEEL-3600 SEAL - 7C102
BEARING -3517
SNAP RING
FLANGE -3511
SELECTOR BEZEL-
Z t L
LEVER- 7210
GEAR SHIFT LEVER

(FIRST &
REVERSE) / <P
7303 / 9
WASHER - 7242
BUSHING - 733 - 7347
GEARSHIFT LEVER
UPPER CLAMP-01698 (SECOND & THIRD) - 7302
SEAL-
LOWER CLAMP - 01699 ^ ^ r * * — — FLEX JOINT - 3A525 G1501-A

FIG. 17—Typical Stationary Steering Column Disassembled—Automatic Transmission
placed if it becomes worn or damaged spindle connecting rod ends, if re- prevent bushing damage after the at-
(Figs. 18 through 21). Do not attempt quired. taching nut has been torqued. Insert
to straighten the sleeve if damaged. 2. Position the center link to the the center link stud through the hole
1. Remove the spindle connecting Pitman arm and idler arm and install in the end of the idler arm and install
rod end assemblies as described in the the attaching nuts loosely. On all ve- the nut and washer.
previous sub-section. hicles except Lincoln Continental On Lincoln Continental models, in-
2. Screw the spindle rod end assem- models, place the idler arm and the sert the center link stud through the
blies into the new sleeve the same front wheels in the straight ahead po- hole in the end of the idler arm insur-
number of turns as the ends that were sition to insure keeping the steering ing that the seal is properly installed
removed. Do not tighten the clamp wheel aligned and to prevent bushing on the center link.
bolts at this time. damage after the attaching nuts have 3. Torque the idler arm rod nut to
3. Position the sleeve and end as- been torqued. On Lincoln Continental specification and install a new cotter
sembly on the center link and the models, insure that the seal is properly pin.
spindle arm. Install the attaching nut, installed on the center link. Torque
torque it to specification, and install the nuts to the low end of the specifi- PITMAN ARM
the cotter pin. cation. Continue to tighten each nut REPLACEMENT
4. Check and, if necessary, adjust until the slots in the nut align with the
toe-in (Part 3-1). After toe-in is hole in the stud. Then install a new
checked and adjusted, oil the sleeve cotter pin.
clamp bolts then torque them to speci- 3. Position the spindle connecting REMOVAL
fication. The sleeve clamp must be in- rod ends to the center link and install
stalled as shown in Figs. 18 through the attaching nuts. Torque the nuts to 1. Remove the cotter pin from the
21. the low end of the specification. Con- castellated nut that attaches the steer-
tinue to tighten each nut until the ing center link to the Pitman arm.
CENTER LINK slots in the nut align with the hole in Remove the castellated nut.
REPLACEMENT the stud. Then, install a new cotter 2. Disconnect the steering center
pin. link from the Pitman arm with tool
The center link connecting the Pit- 4. Remove the safety stands, lower 3290-C.
man arm and the idler arm is non- the vehicle, check and adjust toe-in to 3. Remove the Pitman arm attaching
adjustable and is provided with ta- specification (Part 3-1). nut and lock washer.
pered holes to accommodate the ball 4. Position the front wheels in the
studs (Figs. 18 through 21). The link straight ahead position. Remove the
STEERING IDLER ARM Pitman arm with tool T64P-3590-F
should be replaced when damaged or
when worn at the ball studs. On Lin- AND BRACKET ASSEMBLY (Fig. 23).
coln Continental models, the link REPLACEMENT
should be replaced if excessive loose-
ness is noticed in either ball stud sock- INSTALLATION
REMOVAL
et.
1. With the front wheels in the
REMOVAL straight ahead position, place the Pit-
If the idler arm bushings are worn
1. Raise the vehicle on a hoist and the complete idler arm assembly must man arm on the sector shaft making
position safety stands. be replaced. In Lincoln Continental sure it is pointing forward.
2. Remove the cotter pins and nuts models, if the socket at the idler 2. Install the nut and lock washer.
that attach both inner connecting rod bracket is excessively loose, replace Torque the nut to specification.
ends to the center link (Figs. 18 the complet assembly.
through 21). 1. Remove the cotter pin and nut
3. Disconnect the inner connecting attaching the steering center link at
rod ends from the center link using the idler arm (Figs. 18 through 21).
Tool 3290-C (Fig. 22). 2. Disconnect the center link from
4. Remove the cotter pin and nut the idler arm (on Lincoln Continental
attaching the idler arm to the center models, use Tool 3290-C).
link. Disconnect the idler arm from 3. Remove the two bolts that attach
the center link using Tool 3290-C for the idler arm and bracket assembly to
Lincoln Continental models only. the frame.
attaching the Pitman arm to the cen- INSTALLATION
ter link. Disconnect the Pitman arm
from the center link (use Tool 3290-C) 1. Secure the new idler arm and
and remove the center link. On ve- bracket assembly to the frame with
hicles equipped with the non-integral the two attaching bolts (nuts and flat
power steering system, remove the washers as shown in Figs. 18, 19 and
center link from the control valve as 21).
detailed in Part 3-7. 2. On all vehicles except Lincoln G1663-A
Continental models, place the idler
INSTALLATION arm and the front wheels in the
straight ahead position to insure keep- FIG. 23— Removing Pitman
1. Replace the rubber seals on the ing the steering wheel aligned and to Arm—Typical
3. Secure the steering center link to insure that the seal is properly in- tighten the nut to the next castellation
the Pitman arm with the castellated stalled. Torque the nut to specification if necessary to install the cotter pin.
nut. On Lincoln Continental models, and install the cotter pin. Always
03-06-01 Manual Steering 03 06-01
PART 3-6 Manual Steering

MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
COMPONENT INDEX
Mustang
Montego
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
STEERING GEAR
Cleaning and Inspection
(See Part 03-01)
Description 06-01 06-01 06-01 06-01 06-01 06-01 06-01 06-01 N/A N/A N/A
Disassembly and Overhaul 06-03 06-03 06-03 06-03 06-03 06-03 06-03 06-03 N/A N/A N/A
Removal and Installation 06-02 06-02 06-02 06-02 06-02 06-02 06-02 06-02 N/A N/A N/A
STEERING WORM AND SECTOR
Adjustment and Repair 06-02 06-02 06-02 06-02 06-02 06-02 06-02 06-02 N/A N/A N/A
DESCRIPTION
STEERING GEAR
The steering gear (Fig. 1) is of the ing a bushing located in the cover The worm bearing preload is con-
worm and recirculating ball type. The above the gear and a roller bearing in trolled by the large adjusting nut
sector shaft is straddle mounted hav- the housing below the gear. which is threaded into the housing.
The sector shaft mesh load is con-
INPUT SHAFT
trolled by an adjusting screw located
in the housing cover.
The steering linkage consists of the
SECTOR SHAFT ADJUSTMENT SCREW Pitman arm, steering-arm-to-idler arm
rod, idler arm and the spindle con-
necting rods (tie rods).
A steering gear identification tag is
LOCK NUT provided under one of the cover at-
taching bolts (Fig. 2).
SERVICE IDENTIFICATION
CODE NUMBER
STEERING GEAR
MODEL
IDENTIFICATION TAG
SECTOR SHAFT COVER
SERIAL NUMBER OR DATE CODE

G 1625-A G 1626-A
FIG. 1—Manual Steering Gear FIG. 2—Steering Gear Identification

03-06-02 Manual Steering 03-06-02
STEERING WORM AND 7. Turn the sector adjusting screw

SECTOR .•ADJUSTER LOCK NUT clockwise until the specified torque
(Part 3-13) is necessary to rotate the
worm past its center (high spot) (Fig.
GEAR ADJUSTMENTS 1).
8. While holding the sector adjust-
The ball nut assembly and the sec- ing screw, tighten the sector adjusting
tor gear must be adjusted properly to screw locknut to specification, and re-
maintain minimum steering shaft end check the backlash adjustment.
play (a factor of preload adjustment) 9. Connect the Pitman arm to the
and minimum backlash between sector steering arm-to-idler arm rod.
gear and ball nut. There are only two
possible adjustments within the recir-
culating ball-type steering gear, and
these should be made in the following
order to avoid damage or gear failure.
1. Disconnect the Pitman arm from
the steering Pitman-to-idler arm rod. SECTOR SHAFT
ADJUSTING SCREW G 1627-A
2. Loosen the nut which locks the
sector adjusting screw (Fig. 3), and FIG. 3—Steering Gear
turn the adjusting screw counterclock- Adjustments—Typical
wise. (On models equipped with the
Cobra Jet engine, it may be necessary 4. Loosen the steering shaft bearing
to use a suitable holding tool with an adjuster lock nut, and tighten or back
extension and a long screwdriver to off the bearing adjuster (Fig. 1) to
make the gear adjustment). bring the preload within the specified
3. Measure the worm bearing pre- limits.
load by attaching an in-lb torque 5. Tighten the steering shaft bear-
wrench to the steering wheel nut (Fig. ing adjuster lock nut, and recheck the
4). With the steering wheel off center, preload.
read the pull required to rotate the 6. Turn the steering wheel slowly to
input shaft approximately 1 1/2 turns either stop. Turn gently against the
either side of center. If the torque or stop to avoid possible damage to the G-1495-A
preload is not within specification ball return guides. Then rotate the
(Part 3-1), adjust as explained in the wheel 2-3/4 turns to center the ball FIG. 4—Checking Steering Gear
next step. nut. Preload—Typical
STEERING GEAR INSTALLATION

Too / - M B STEERING GEAR HOUSING
REMOVAL T64P-3590.F 1. Position the steering gear and
flex coupling in place; then, install
1. Remove the bolt(s) that retains and torque the steering gear-to-side
the flex coupling to the steering shaft. rail bolts to specification (Part 3-13).
2. Remove the nut and lock washer 2. If the clutch linkage has been
that secures the Pitman arm to the disconnected, reposition, install and
sector shaft using Tool T64P-3590-F adjust it. If the exhaust system has
(Fig. 5). been lowered, reinstall it to its proper
3. To obtain clearance on some position.
models equipped with standard trans- 3. Position the Pitman arm and the
mission, it may be necessary to dis- sector shaft and install the attaching
connect the clutch linkage. On some nut and lock washer. Torque the nut
8-cylinder models, it may be necessary to specification.
to lower the exhaust system. 4. Install and connect the flex cou-
4. Remove the steering gear-to-side pling attaching nut(s) and torque it to
rail bolts and remove the gear. specification (Part 3-13).
(PITMAN "APU'^ M - .-. • -" •.:,.17''i.a— r . i M I . A
F
'G. 5—Removing Pitman Arm
STEERING GEAR 6. Turn the ball nut over, and ro-

tate the worm shaft from side to side
DISASSEMBLY until all 50 balls have dropped out of
the nut into a clean pan. With the
1. Rotate the steering shaft 3 turns balls removed, the ball nut will slide
from either stop. off the worm.
2. After removing the sector adjust- 7. Remove the upper bearing cup
ing screw locknut and the housing from the bearing adjuster and the
cover bolts (Fig. 6), remove the sector lower cup from the housing. It may be
shaft with the cover. Remove the necessary to tap the housing or the
cover from the shaft by turning the adjuster on a block of wood to jar the Tool - T62F • 3576 - A
screw clockwise. Keep the shim with bearing cups loose.
the screw. 8. If the preliminary inspection
HOUSING • 3548 GASKET • 3581
SHIM-3A657 COVER AND

BUSHING • 3583
SECTOR SHAFT
ADJUSTING SCREW . 3577
•BEARING-3576
G 1622-A
SEAL - 3591
G 1623-A
FIG. 8—Removing Oil Seal
FIG. 6—Sector Shaft and Housing Disassembled and Bearing
4. Insert the ball guides into the
holes of the ball nut, tapping them
-^-HOUSING-3548 lightly with a wood handle of a screw
BEARING CUP • 3552 driver if necessary to seat them.
LOCK NUT-3707
BALL NUT 5. Insert 25 balls into the hole in
3524 BEARING CUP \ SEAL-3738
the top of each ball guide. It may be
necessary to rotate the shafi: slightly
one way, then in the opposite direc-
BEARING-3571 •GUIDE -3523 tion to distribute the balls in the cir-
cuit.
FILLER PLUG-3556 • BEARINGS • 3647 BEARING • 3571
6. After the 50 balls are installed,
.CLAMP-3544 install the ball guide clamp. Torque
G 1624-A the screws to specification. Check the
worm shaft to make sure that it ro-
FIG. 7—Steering Shaft and Related Parts Disassembled tates freely.
7. Coat the threads of the steering
shaft bearing adjuster, the housing
3. Loosen the worm bearing adjust- shows damage, press the sector shaft cover bolts, and the sector adjusting
er nut, and remove the adjuster as- bearing and the oil seal from the screw with a suitable oil-resisi:ant seal-
sembly and the steering shaft upper housing (Fig. 8). ing compound. Do not apply sealer to
bearing (Fig. 7). female threads and especially avoid
4. Carefully pull the steering shaft ASSEMBLY getting any sealer on the steering shaft
and ball nut from the housing, and i •- bearings.
move the steering shaft lower bearr g. 1. If the sector shaft bearing and 8. Coat the worm bearings, sector
To avoid possible damage to the ball oil seal have been removed, press a shaft bearings, and gear teeth with
return guides, keep the ball nut from new bearing into the housing and in- steering gear lubricant.
running down to either end of the stall a new oil seal. Do not clean, 9. Clamp the housing in a vise, with
worm. wash or soak seals in cleaning solvent the sector shaft axis horizontal, and
Disassemble the ball only if there is (Fig. 7). Apply the recommended position the steering shaft lower bear-
indication of binding or tightness. steering gear lubricant to the bearing ing in its cup.
5. Remove the ball return guide and seals. 10. Position the steering shaft and
clamp and the ball return guides from 2. Install a bearing cup in the lower ball nut assemblies in the housing.
the ball nut. Keep the ball nut clamp- end of the housing and in the adjuster. 11. Position the steering shaft
side up until ready to remove the 3. If the seal in the bearing adjuster upper bearing on the top of the worm,
balls. was removed, install a new seal. and install the steering shaft bearing
adjuster and the adjuster nut and housing so that the ball will tip
bearing cup. Leave the nut loose. toward the housing cover opening.
12. Adjust the worm bearing pre- 17. Lubricate the sector shaft jour-
load, using an in-lb torque wrench In - /b Torque Wrench nal and install the sector shaft and
(Fig. 9). See Part 3-13 for the speci- cover.
fied preload. ADJUSTER NUT 18. With the housing cover turned
13. Position the sector adjusting out of the way fill the gear with 0.97
screw and adjuster shim, and check lbs of gear lubricant. Push the
the end clearance which should not housing cover and sector shaft assem-
exceed 0.002 inch between the screw blies into place, and install the two
head and the end of the sector shaft. top housing cover bolts. Do not tight-
If clearance is greater than 0.002 inch, en the cover bolts until it is certain
add enough shims to reduce the end that there is some lash between ball
play to within the 0.002 inch toler- nut and sector gear teeth. Hold or
ance. push the cover away from the ball nut,
14. Start the sector shaft adjusting then torque the bolts to specification.
screw into the housing cover. 19. After loosely installing the sec-
15. Install a new gasket on the 21-A
tor shaft adjusting screw lock nut, ad-
housing cover. just the sector shaft mesh load. See
16. Rotate the steering shaft until FIG. 9—Checking Steering Shaft Part 3-13 for the specified mesh load;
the ball nut teeth are in position to Bearing Preload then, tighten the adjusting screw lock
mesh with the sector gear, tilting the nut.
03-07-01 Ford Design Non-Integral Power Steering System 03-07-01
PART 3-7 Ford Design Non-Integral Power

Steering System
MODEL APPLICATION
Continental-
Thunderbird
Continental
All Models
COMPONENT INDEX
Mustang
Montego
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
CONTROL VALVE
Disassembly and Overhaul N/A N/A N/A N / A 07-04 07-04 07-04 07-04 07-04 N / A N/A
Removal and Installation N/A N/A N/A N / A 07-03 07-03 07-03 07-03 07-03 N / A N/A
CONTROL VALVE CENTERING SPRING
Adjustment N/A N/A N/A N / A 07-02 07-02 07-02 07-02 07-02 N / A N/A
CONTROL VALVE TO POWER STEERING
CYLINDER HOSE
HOISTING INSTRUCTIONS N/A N/A N/A N / A 07-02 07-02 07-02 07-02 07-02 N / A N/A
POWER CYLINDER
POWER CYLINDER SEAL
POWER STEERING PUMP CLEANING
AND INSPECTION (See Part 03-01)
POWER STEERING PUMP TO CONTROL
VALVE HOSE
STEERING GEAR
Cleaning and Inspection
(See Part 03-01)
DESCRIPTION
The F o r d N o n - I n t e g r a l Power fluid lines, and the steering linkage. valve which governs the pressures
Steering System (Fig. 1) is a hydrauli- The hydraulic pump and belt, driven within the steering system according
cally controlled linkage-type steering from the engine crankshaft, draws to the varying conditions of operation.
system which includes an integral fluid from the reservoir and provides After fluid has passed from the pump
pump and fluid reservoir, a control fluid pressure for the system. Within to the control valve and the power cyl-
valve, a power cylinder, the connecting the pump itself is a pressure-relief inder, it returns to the reservoir.
PUMP AND RESERVOIR
CONTROL VALVE
POWER CYLINDER
G 1651-A
FIG. 7—Non-Integral Power Steering System

HOISTING INSTRUCTIONS turn the wheel in both directions Connect the opposite end to the lower
should not exceed 12 pounds. port in the cylinder. Hold the tube se-
curely while tightening the nut to pre-
Damage to suspension and/or steer-
CONTROL VALVE TO POWER vent twisting the tube. Connect the
ing linkage components may occur if
other tube (9 5/8 in long) to port A,
care is not exercised when positioning STEERING CYLINDER HOSE
the hoist adapters of 2 post hoists making sure that tube is parallel with
prior to lifting the vehicle. the other tube.
1. Raise the vehicle on a hoist and 4. Remove the drain pan and lower
If a 2 post hoist is used to lift the place a drain pan under the power the vehicle.
vehicle, place the adapters under the cylinder. 5. Fill the power steering pump res-
front suspension lower arms. Do not 2. Disconnect the hose from the ervoir with fluid to the proper level
allow the adapters to contact the power cylinder and allow the fluid to (Part 3-1).
steering linkage. drain from the hose. Then, disconnect 6. Start the engine and turn the
the hose from the control valve. steering wheel to each end of its travel
CONTROL VALVE CENTERING 3. Connect the unmarked end of several times to cycle the system.
SPRING ADJUSTMENT the shorter tube (9 7/16 in long) to Then, check for leaks.
valve port C (Fig. 2). Hold the tube so 7. Stop the engine and again check
that the bend parallels the surface of the power steering fluid level. Add
1. Raise the vehicle and remove 2
valve shown in Fig. 2, tighten the nut. fluid as required.
spring cap attaching screws and lock
washers and remove the spring cap.
2. Tighten the adjusting nut snug PLANE OF TUBE BEND IN
3A717 HOSE TO BE PARALLEL
POWER STEERING PUMP
WITH THIS SURFACE ON VALVE.
(90-100 in-lbs); then, loosen the nut TO CONTROL VALVE HOSE
1/4 turn. Make sure that the nut ro-
tates 1/4 turn (90 degrees) on the
threads of the bolt. Do not tighten the REMOVAL
adjusting nut too tight.
3. Position the spring cap to the 1. Remove the fluid from the pump
valve housing. Lubricate and install reservoir with a suction gun.
the two attaching screws and washers. 2. Raise the vehicle on a hoist.
Torque the screws to 72-100 in-lbs. 3. Remove the clamp retaining the
CLEARANCE BETWEEN
4. Lower the vehicle. COUPLING TO BE 1/16- hose tubes to the control valve.
5. Start the engine and check the 1/8 INCH IN THIS AREA G 1503-A 4. Disconnect the fluid return and
turning effort with a spring scale. pressure hoses from the control valve
With the spring scale attached to the FIG. 2—Power Steering Hose and allow the fluid to drain into a
rim of the steering wheel, the effort to Installation pan.
5. Lower the vehicle and disconnect hoses in the insulator and retainer. 4. Raise the vehicle and connect the
the fluid return hose from the reser- Paint stripe on pressure hose must be pressure and return lines to the con-
voir. aligned with slot in insulator. Paint or trol valve.
6. Disconnect the fluid pressure tape band on return hose must be cen- 5. Install the clamp to retain the
hose from the pump outlet fitting. tered in insulator. Position the assem- hose tubes to the control valve.
7. Remove 1 bolt attaching the bly to the frame side rail and install 6. Lower the vehicle and fill the
hoses, insulator, and the retainer to the attaching bolt. power steering pump reservoir with
the frame side rail and remove the 2. Place a hose clamp on the fluid fluid, C1AZ-19582-A, to the proper
hoses, and the insulator and retainer return hose and install the hose on the level (Part 3-1).
as an assembly from the vehicle. power steering pump reservoir return 7. Start the engine and turn the
8. Remove the pressure and return fitting. steering wheel to each end of its travel
hoses from the retainer and insulator. 3. Torque the pump outlet fitting to several times to cycle the system.
specification (Part 3-13). Then, con- Then, check for fluid leaks.
INSTALLATION nect the pressure hose to the outlet fit- 8. Stop the engine and again check
ting and torque the fitting to specifica- the power steering fluid level (Part
1. Install the pressure and return tion. 3-1). Add fluid as required.

HOISTING INSTRUCTIONS VALVE sleeve. Install the roll pin in the rod
Too/-3290-C BALL STUD PITMAN ARM
hole to lock the valve in position on
the rod.
Damage to suspension and/or steer-
5. Torque the valve sleeve clamp
ing linkage components may occur if
bolt to specification.
care is not exercised when positioning
the hoist adapters of 2 post hoists 6. Install the nut on the ball stud,
prior to lifting the vehicle. and torque the nut to specification.
Install a new cotter pin.
If a 2 post hoist is used to lift the 7. Connect the fluid lines to the
vehicle, place the adapters under the control valve, and tighten all fittings
front suspension lower arms. Do not securely. Do not over-tighten.
allow the adapters to contact the
8. Fill the fluid reservoir with the
steering linkage.
specified fluid to the cross hatched
area on the dip stick.
STEERING GEAR FIG. 3—Removing Control Valve 9. Start the engine and run it at
Ball Stud idle speed for about two minutes to
Refer to Group 3-6, Section 3 for warm the fluid in the power steering
6. After turning the front wheels system.
detailed instructions. fully to the left, unthread the control 10. Turn the steering wheel all the
valve from the center link steering way to the left and right several times,
POWER STEERING PUMP arm-to-idler arm rod. and check the system for fluid leaks.
11. Increase the engine speed to
Refer to Group 3-10, Section 3 for INSTALLATION about 1000 rpm, and turn the steering
detailed instructions. wheel all the way to the left and right
1. Thread the valve onto the center several times.
POWER STEERING CONTROL link until about four threads are still
visible on the link. CONTROL VALVE CONNECTING ROD STUD
VALVE
2. Position the ball stud in the sec-
tor shaft arm.
REMOVAL 3. Measure the distance between
the center of the grease plug in the
1. Disconnect the 4 fluid line fit- sleeve and the center of the stud at the
tings at the control valve, and drain inner end of the left spindle connect-
the fluid from the lines. Turn the front ing rod (Fig. 4). The distance should
wheels to the left and right several be 5 5/8 inches for Montego, Falcon
times to force all the fluid from the and Fairlane vehicles. The distance
system. should be 4 7/8 inches for Mustang
2. Loosen the clamping nut and and Cougar models. If the distance is
bolt at the right end of the sleeve. not correct, disconnect the ball stud
3. Remove the roll pin from the from the sector shaft arm and turn the
steering arm-to-idler arm rod -through valve on the center link to increase or
the slot in the sleeve. decrease the distance.
4. Remove the control valve ball 4. When the correct distance is ob-
LUBRICATION PLUG
stud nut. tained and the ball stud is positioned G1653-A
5. Using the tool shown in Fig. 3, in the sector shaft arm, align the hole
remove the ball stud from the sector in the steering arm-to-idler arm rod FIG. 4—Control Valve Installation
shaft arm. with the slot near the end of the valve Measurements—All Models
12. Stop the engine, and check the CENTER LINK 6. Inspect the tube fittings and the
control valve and hose connections for seats in the power cylinder for nicks,
fluid leaks. Correct the cause of any burrs or damage. Replace the seats in
leaks. the cylinder or the tubes as required.
13. Check the fluid level, and refill
the reservoir if necessary. INSTALLATION
14. With the engine running check 1. Install the washer, sleeve and the
the position of the steering wheel insulator on the end of the power cyl-
when the front wheels are in the inder rod.
straight-ahead position.Do not make 2. Extend the rod as far as possible.
any adjustments until toe-in is Insert the rod in the bracket on the
POWER CYLINDER
checked. Tool- T64P-3590-F
frame and compress the rod as neces-
G 1654-A
15. Keep the engine running, and sary to insert the stud in the -center
check toe-in. If either toe-in or steer- link. Secure the stud with a castellat-
ing wheel position is not correct make FIG. 5—Disconnecting Power
ed, nut and a cotter pin.
all necessary adjustments (Part 3-1) at Cylinder Stud
3. Secure the power cylinder rod
the spindle connecting rod sleeves. with an insulator, washer, nut and a
16. Check the effort to turn the pal nut.
wheels in both directions. The effort 4. Connect each of the two fluid
should be about equal in both direc- 2. Remove the 'pal nut, attaching lines to its respective port in the cylin-
tions. nut, washer and the insulator from the der.
end of the power cylinder rod. 5. Fill the reservoir to the correct
3. Remove the cotter pin and cas- level.
POWER CYLINDER tellated nut that secures the power 6. Start the engine and turn the
cylinder stud to the center link. steering wheel to each end of its travel
4. Disconnect the power cylinder several times to cycle the system. Stop
REMOVAL stud from the center link as shown in the engine.
Fig. 5. 7. Check the fluid level and fill as
1. Disconnect the two fluid lines 5. Remove the insulator sleeve and necessary. Install the dipstick and cap.
from the power cylinder and allow washer from the end of the power cyl- 8. Start the engine and check for
them to drain into a container. inder rod. leaks.

CONTROL VALVE 8. Drive the stop pin out of the 1. Tap the existing hole in the hose
travel regulator stop with a punch and seat, using a starting tap of suitable
DISASSEMBLY hammer (Fig. 7). Pull the head of the size. Be sure to remove all metal chips
valve spool bolt tightly against the from the hose seat port after tapping.
1. Wipe all fluid and loose dirt travel regulator stop before driving the 2. Place a nut and large flat washer
from the outside of the control valve. pin out of the stop. on a bolt of the same size as the
2. Remove the centering spring cap 9. Turn the travel regulator stop tapped hole. The washer must be large
from the valve housing (Fig. 6). counterclockwise in the valve sleeve to enough to cover the hose seat port.
When holding the control valve for remove the stop from the sleeve. 3. Insert the bolt in the tapped
disassembly, use a soft-jawed vise, and 10. Remove the valve spool bolt, hole, and using the nut as a puller, re-
clamp the valve only around the sleeve spacer, and rubber washer from the move the hose seat.
flange to prevent damage to the hous- travel regulator stop. 4. Place a new hose seat in the
ing, spool, or sleeve. 11. Remove the rubber boot and port, and thread a bolt of suitable size
3. Remove the nut from the end of clamp from the valve sleeve. into the port. Tighten the bolt enough
the valve spool bolt. Remove the 12. Slide the bumper, spring, and to bottom the seat in the port.
w a s h e r s , spacer, centering spring, ball stud seat out of the valve sleeve,
adapter, and bushing from the bolt and remove the ball stud socket from ASSEMBLY
and the valve housing. the sleeve.
4. Remove the two bolts that hold 13. After removing the return port Before assembling the control valve,
the valve housing and the sleeve to- hose seat, remove the return port re- coat all parts except the seals with
gether, and separate the housing from lief valve. Automatic Transmission Fluid. Coat
the sleeve. 14. After removing the spring plug the seals with lubricant COAZ-
5. Remove the plug from the valve and O-ring, remove the reaction limit- 19553-A.
sleeve. ing valve (Fig. 8). 1. I n s t a l l the reaction limiting
6. Push the valve spool out of the valve, the spring, and the plug.
centering spring end of the valve hous- Tube Seat Replacement 2. Install the return port relief valve
ing, and remove the seal from the and the hose seat.
spool. If a hose seat is worn or damaged it 3. Insert one of the ball stud seats
7. Remove the spacer, bushing, and should be replaced. It can be removed (flat end first) into the ball stud sock-
seal from the sleeve end of the valve with an Easy-Out tool, or by using a et, and insert the threaded end of the
housing. bolt of appropriate size as a puller. ball stud into the socket.
• SPRING REACTION SPRING

SEAT \ REACTION SPRING PLUG
VALVE
\ VALVE HOUSING AND O-RING SPACER
WASHERX CUSHION
STOP PIN
TRAVEL
REGULATOR
CLAMP
FIG. 6—Control Valve Disassembled—Typical
4. Place the socket in the control et, travel regulator stop, and valve er. Do not nick or scratch the seal or
valve sleeve so that the threaded end spool bolt (Fig. 7). the spool during installation.
of the ball stud can be pulled out 7. Install the rubber boot, clamp, 11. Place the sleeve end of the
through the slot in the sleeve (Fig. 9). and the plug on the control valve housing on a flat surface so that the
5. Place the other ball stud seat, sleeve. Make sure that the lubrication seal, bushing, and spacer are at the
and spring, and the bumper (Fig. 6) in fitting is turned on tightly and does bottom end and push down the valve
the socket, and install and securely not bind on the ball stud socket. spool until it stops.
tighten the travel regulator stop. 8. Insert the valve spool in the valve 12. Carefully install the spool seal
6. Loosen the stop just enough to housing. Rotate the spool while insert- and bushing in the centering spring
align the nearest hole in the stop with ing it in the housing (Fig. 10). end of the housing. Press the seal
the slot in the ball stud socket, and in- 9. Move the spool toward the cen- against the end of the spool., guiding
stall the stop pin in the ball stud sock- tering spring end of the housing, and the seal over the spool with a small
place the small seal bushing, and spa- screwdriver. Do not nick or scratch
cer in the sleeve end of the housing. the seal or the spool during installa-
10. Press the valve spool against tion.
the inner lip of the seal and, at the
same time, guide the lip of the seal
over the spool with a small screwdriv-
VAIVE
SPOOL
BOLT
CONTROL
VALVE SLEEVE
BALL STUD
SOCKET TRAVEL BALL STUD SEAT-
REGULATOR
BALL STUD'
STOP
BALL STUD SOCKET'
G 1656-A G 1657-A G 16 58-A

FIG. 8—Removing Reaction Valve FIG. 9—Installing Ball Socket,
FIG. 7—Removing Stop Pin
Plug Seal and Bracket
COAZ-19553-A (silicone) grease at moved in this manner, remove them

the sealing areas. from the cylinder with a sharp pick.
VALVE HOUSING 18. Lubricate the two cap attaching Take care, when using a pick, not to
bolts. Install the centering spring cap damage the shaft or seal seat.
on the valve housing, and torque the
two cap bolts to specification. INSTALLATION
VALVE SPOOL
19. Install the nut on the ball stud
so that the valve can be positioned in When replacing the power cylinder
a vise as shown in Fig. 12. Then push seals, install all of the parts supplied
forward on the cap end of the valve to in the repair kit for the cylinder being
check the valve spool for free move- repaired.
ment. 1. Coat the new seals with lubricant
G 1659- A
20. Turn the valve around in the COAZ-19553-A and place the parts
vise, and push forward on the sleeve (Fig. 13) on the piston rod which has
FIG. 70—Inserting Valve Spool end to check the spool for free move- been coated with the same grease.
ment. 2. Push the rod in all the way, and
13. Pick up the housing, and slide install the parts in the cylinder with a
the spool back and forth in the hous- deep socket slightly smaller than the
ing to check for free movement. PUSH FORWARD TO CHECK cylinder opening (Fig. 14).
VALVE SPOOL MOVEMENT
14. Place the valve sleeve on the
housing so that the ball stud is on the
same side of the housing as the ports 15/16" O.D. X 6 " STEEL
ELECTRICAL CONDUIT
for the two power cylinder lines. In-
stall the two bolts in the sleeve, and
torque them to specifications. POWER
15. Place the adapter on the cen- CYLINDER
tering spring end of the housing, and

install the bushing, washers, spacers,
and centering spring on the valve
spool bolt. G 1660-A
16. Compress the centering spring, FIG. 12—Inspecting Valve Spool
and install the nut on the bolt. Tight- Movement
en the nut snug (90-100 in-lbs); then
G 1662-A
loosen it not more than 1/4 turn (Fig.
11). Make sure that the nut turns (90 POWER CYLINDER SEAL FIG. 14—Installing Power
degrees) on the threads of bolt. Exces- Cylinder Seals
sive tightening of the nut may break REMOVAL
the stop pin at the travel regulator
stop. 1. Clamp the power cylinder in a
vise, and remove the snap ring from
the end of the cylinder. Be careful not POWER STEERING PUMP
TIGHTEN NUT SNUG to distort or crack the cylinder in the
(90-100 IN - L B S ) THEN RESERVOIR REPLACEMENT
LOOSEN % TURN ON vise.
THREADS OF BOLT 2. Pull the piston rod out all the
way to remove the scraper, bushing, Refer to Group 3-10, Section 3 for
and seals. If the seals cannot be re- detailed instructions.
ADJUSTING
NUT
INSERT
CENTERING SPRING RUBBER WIPER
SCRAPER
ADAPTER
G 1034 - C
FIG. 11—Adjusting Centering
Spring
17. Move the ball stud back and

forth in the sleeve slot to check the SNAP RING
spool for free movement. See Part SEATS' G 1661-A
3-13 for the specified travel. Apply FIG. 73—Power Cylinder
03-08-01 Ford Design Integral Power Steering Gear 03-08-01
PART 3-8 Ford Design Integral Power

Steering Gear
MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
COMPONENT INDEX
Mustang
Montego
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
STEERING GEAR
Adjustments 08-02 08-02 08-02 N/A N/A N/A N/A N/A 08-02 08-02 08-02
Cleaning and Inspection (See
Part 03-01)
Description 08-01 08-01 08-01 N/A N/A N/A N/A N/A 08-01 08-01 08-01
Disassembly and Assembly 08-05 08-05 08-05 N/A N/A N/A N/A N/A 08-05 08-05 08-05
Overhaul 08-06 08-06 08-06 N/A N/A N/A N/A N/A 08-06 08-06 08-06
Removal and Installation 08-03 08-03 08-03 N/A N/A N/A N/A N/A 08-03 08-03 08-03
VALVE CENTERING SHIM
Removal and Installation 08-03 08-03 08-03 N/A N/A N/A N/A N/A 08-03 08-03 08-03
VALVE SPOOL CENTERING CHECK 08-02 08-02 08-02 N/A N/A N/A N/A N/A 08-02 08-02 08-02
DESCRIPTION
The Ford integral power steering rack-piston, worm and sector shaft in creasing or decreasing shim thickness
unit (Fig. 1) is a torsion-bar type of one housing and the valve spool in an as follows:
hydraulic assisted system. This system attaching housing (Fig. 1). This makes Efforts heavy to the left—Increase
furnishes power to reduce the amount possible internal fluid passages bet- shim thickness.
of turning effort required at the steer- ween the valve and cylinder, thus eli- Efforts light to the left—Decrease
ing wheel. It also reduces road shock minating all external lines and hoses, shim thickness.
and vibrations. except the pressure and return hoses A change of one shim size will in-
The torsion bar power steering unit between the pump and gear assembly. crease or decrease steering efforts ap-
includes a worm and one-piece rack The power cylinder is an integral proximately 1 1/2 in-lbs.
piston, which is meshed to the gear part of the gear housing. The piston is Shims are available in the following
teeth on the steering sector shaft. The double acting, in that fluid pressure thicknesses and are notched on the
unit also includes a hydraulic valve, may be applied to either side of the outside diameter for identification:
valve actuator, input shaft and torsion piston. 0.0057-0.0063 inch—0 notch
bar assembly which are mounted on A selective metal shim located in 0.0077-0.0083 inch—1 notch
the end of the worm shaft and operat- the valve housing of the gear is for the 0.0097-0.0103 inch—2 notches
ed by the twisting action of the tor- purpose of tailoring steering gear ef- 0.0117-0.0123 inch—3 notches
sion bar. forts. If efforts are not within specifi- 0.0137-0.0143 inch—4 notches
The torsion-bar type of power steer- cations they can be changed by in- Do not use more than one shim.
ing gear is designed with the one piece
-INPUT SHAFT
OUTLET PORT
INLET PORT
CONTROL VALVE HOUSING
SECTOR SHAFT COVER
SECTOR SHAFT ADJUSTMENT SCREW
LOCK NUT
IDENTIFICATION TAG
SECTOR SHAFT
G1545- A
FIG. 1—Power Steering Gear
IN-VEH1CLE ADJUSTMENTS AND REPAIRS
VALVE SPOOL engine and recheck the reservoir. Add shim installed. Only one shim is to be
CENTERING CHECK fluid if necessary. used. If the steering effort is heavy,
5. With the engine running at ap- the shim t h i c k n e s s should be in-
1. Install a 0-2000 psi pressure proximately 1000 rpm and the steer- creased. Shim thickness should be de-
gauge Tool T56L-33610-D in the pres- ing wheel centered, attach an inch- creased if the steering effort is light to
sure line between the power steering pound torque wrench to the steering the left.
pump outlet port and the integral wheel retaining nut. Apply sufficient The out of vehicle procedure for
steering gear inlet port. torque to the torque wrench in each valve centering check is the same as
2. Make sure that the valve on the direction, either side of center, to get for the in vehicle except the torque
gauge is in the fully open position. a gauge reading of 250 psi. and simultaneous pressure reading
3. Check the fluid level in the reser- 6. The torque reading should be the must be made at the right and left
voir and fill it to proper level with the same in both directions when 250 psi stops instead of either side of center.
specified fluid. is reached. If the difference between
4. Start the engine and cycle the the readings exceeds 4 in-lbs, the STEERING GEAR
steering wheel from stop-to-stop, to steering gear must be removed and the ADJUSTMENTS
bring the steering lubricant up to nor- valve centering shim removed from the During the vehicle breaking-in peri-
mal operating temperature. Stop the valve housing and a thicker or thinner od, it is probable that some of the
factory adjustments will change. These 4. Remove the ornamental cover

changes in adjustment do not neces- INPUT SHAFT from the steering wheel hub and turn
sarily affect the satisfactory operation the steering wheel to 45 degrees from
SECTOR SHAFT
of the steering gear assembly, and ADJUSTMENT SCREW
the left stop.
therefore ordinarily do not require 5. Using an in-lb torque wrench on
readjustment unless there is excessive the steering wheel nut, determine the
lash or other malfunctioning. torque required to rotate the shaft
slowly through an approximately 1/8
turn from the 45 degree position.
ADJUSTMENT IN 6. Turn the steering gear back to
VEHICLE center, then determine the torque re-
quired to rotate the shaft back and
forth across the center position. Loos-
The only adjustment which can be en the adjuster nut, and turn the ad-
performed is the total over center juster screw in (Fig. 2) until the read-
position load, to eliminate excessive ing is 8-9 in-lb greater than the torque
lash between the sector and rack 45 degrees from the stop.
teeth. C1547- A Tighten the lock nut while holding
1. Disconnect the pitman arm from the screw in place.
the sector shaft. FIG. 2—Adjusting Mesh Load 7. Recheck the readings and replace
2. Disconnect the fluid return line pitman arm and steering wheel hub
at the reservoir, at the same time cap cover.
the reservoir return line pipe. steering wheel in both directions as re- 8. Connect the fluid return line to
3. Place the end of the return line quired, to discharge the fluid from the the reservoir and fill the reservoir with
in a clean container and cycle the gear. specified lubricant to the proper level.
REMOVAL 6. Support the steering gear then place on the frame side rail. Install
remove the three steering gear attach- the three attaching bolts and torque
1. Disconnect the pressure and the ing bolts. them to specification.
return lines from the steering gear. 7. Work steering gear free of the 4. Make sure that the wheels are in
Plug the lines and the ports in the flex coupling and remove it from the the straight ahead position, then in-
gear to prevent entry of dirt. vehicle. stall the Pitman arm on the sector
2. Remove the two bolts that secure 8. If the flex coupling stayed on the shaft. Install and tighten the sector
the flex coupling to the steering gear input shaft, lift if off the shaft at this shaft and install and tighten the at-
and to the column. time. taching bolts to specification.
3. Raise the vehicle and remove the 5. Move the flex coupling into
sector shaft attaching nut. place on the input and steering co-
4. Remove the Pitman arm from INSTALLATION lumn shaft and install and tighten the
the s e c t o r shaft with Tool T64P- attaching bolts to specification.
3590-F. Remove the tool from the 1. Slide the flex coupling into place 6. Connect and tighten the fluid
Pitman arm. Do not damage the on the steering shaft. Turn the steer- pressure and the return line to the
seals. ing wheel so that the spokes are in the steering gear.
5. If working on a vehicle equipped horizontal position. 7. Fill the power steering pump and
with a standard transmission, remove 2. Center the steering gear input cycle the steering gear. Check for
the clutch release lever retracting shaft. leaks and again check the fluid level.
spring to provide clearance for remov- 3. Slide the steering gear input Add fluid as required.
ing the steering gear. shaft into the flex coupling and into
In most cases, complete disassembly tools, and parts must be kept clean at VALVE CENTERING
of the power steering gear will not be all times. Thoroughly clean the exter- SHIM REPLACEMENT
necessary. It is suggested that only ior of the unit with a suitable solvent
those assemblies that are faulty be dis- and when necessary, drain as much of 1. Hold the steering gear over a
assembled. Disassembly and reassem- the hydraulic oil as possible. Handle drain pan in an inverted position and
bly of the unit and the subassemblies all parts very carefully to avoid nicks, cycle the input shaft several times to
must be made on a clean workbench. burrs, scratches and dirt, which could drain the remaining fluid from the
As in repairing any hydraulically op- make the parts unfit for use. Do not gear.
erated unit, cleanliness is of utmost clean, wash or soak seals in cleaning 2. Mount the gear in a soft-jawed
importance. Therefore, the bench, solvent. vise.
3. Turn the input shaft to either

stop then, turn it back approximately
1 3/4 turns to center the gear.
4. Remove the two sector shaft
cover attaching screws and the identif-
ication tag.
5. Tap the lower end of the sector
shaft with a soft-faced hammer to
loosen it, then lift the cover and shaft
from the housing as an assembly. Dis-
card the O-ring.
6. Remove the four valve housing
attaching bolts. Lift the valve housing
from the steering gear housing while
holding the piston to prevent it from
rotating off the worm shaft.
7. Remove the valve housing and
the lube passage O-ring and discard
them.
8. Place the valve housing, worm
and piston assembly in the bench
mounted holding fixture Tool T57L-
500-A with the piston on the top.
9. Rotate the piston upward (back
off) 3 1/2 turns.
10. Insert Tool T66P-3553-C (with
the arm facing away from the piston)
into a bolt hole in the valve housing.
Rotate the arm into position under
the piston (Fig. 3). G1365-A
11. Using Tool T66P-3553-B, loos- FIG. 3—Removing Worm Bearing Lock Nut
en the worm bearing lock nut.
12. Hold the lock nut up out of the
way and loosen the attaching nut (Fig.
4).
13. Lift the piston-worm assembly
from the valve housing. During remov-
al hold the piston to prevent it.from
spinning off of the shaft.
14. Change the power steering valve
centering shim.
15. Install the piston-worm assem-
bly into the valve housing. Hold the
piston worm to prevent it from spin-
ning off of the shaft.
16. Install the valve housing attach-
ing nut and torque to specification
(Fig. 5).
17. Install the power steering worm
bearing lock nut with Tool T66P-
3553-B and torque to specifications.
18. Rotate the piston upward (back
off) 1/2 turn and remove Tool T66P-
3553-C.
19. Remove the valve housing,
worm, and piston assembly from the
holding fixture.
20. Position a new lube passage O-
ring in the counterbore of the gear
housing.
21. Apply vaseline to the teflon seal
on the piston. Tool-T66P-3553-C
22. Place a new O-ring on the valve
housing.
23. Slide the piston and valve into
the gear housing being careful not to G1367-A
damage the teflon seal. FIG. 4—Removing Valve Housing Attaching Nut
24. Align the lube passage in the

valve housing with the one in the gear
housing, and install but do not tighten
the attaching bolts.
25. Rotate the ball nut so that the
teeth are in the same place as the sec-
tor teeth. Tighten the four valve hous-
ing attaching bolts to specification.
26. Position the sector shaft cover
O-ring in the steering gear housing.
Turn the input shaft as required to
center the piston.
27. Apply vaseline to the sector
shaft journal; then, position the sector
shaft and cover assembly in the gear
housing. Install the steering gear iden-
tification tag and the two sector shaft
cover attaching bolts.
28. Position an in-lb torque wrench
on the gear input shaft and adjust the
rque Wrench
meshload to approximately 4 in-lbs.
Then, torque the sector shaft cover at-
taching bolts to specification (Part
3-13).
29. After the cover attaching bolts
Tool-T66P-3553-C have been tightened to specification,
adjust the meshload to specification
with an in-lb torque wrench.
G1366-A
STEERING GEAR
FIG. 5—Installing Valve Housing Attaching Nut DISASSEMBLY
1. Hold the steering gear over a

drain pan in an inverted position and
cycle the input shaft several times to
CENTERING SHIM
WORM AND VALVE ASSEMBLY
LOCK NUT
PISTON AND BALL NUT VALVE HOUSING
TEFLON RING
•BALL GUIDE CLAMP
0-RING BALL GUIDES G1548-A
FIG. 6 — Ball Nut and Valve Housing Disassembled

VALVE HOUSING
7W-T65P
OIL SEAL
DUST SEAL
C1239 -A
FIG. 7—Removing or Installing Lock INLET TUBE SEAT

Nut OUTLET TUBE SEAT
drain the remaining fluid from the
gear. G1549-A
2. Mount the gear in a soft-jawed FIG. 8—Valve Housing Disassembled
vise.
3. Remove the lock nut and the Too/-T<
brass washer from the adjusting screw.
4. Turn the input shaft to either
Tool-
stop then, turn it back approximately T65P-3524-A7
1 3/4 turns to center the gear. Press Ra
5. Remove the two sector shaft
cover attaching screws and the identif-
ication tag.
6. Tap the lower end of the sector
shaft with a soft-hammer to loosen it,
then lift the cover and shaft from the
housing as an assembly. Discard the
O-ring.
7. Turn the sector shaft cover coun-
terclockwise off the adjuster screw.
8. Remove the four valve housing
attaching bolts. Lift the valve housing Tool-
T57L-500-A ,^^^
from the steering gear housing while
G1364-A G1363-A
holding the piston to prevent it from
rotating off the worm shaft. Remove FIG. 9—Removing Bearing and Oil FIG. 10—Installing Valve Housing
the valve housing and the lube passage Seal Bearing
O-rings and discard them.
9. Stand the valve body and piston PARTS REPAIR 6. Coat the fluid inlet and outlet
on end with the piston end down. Ro- OR REPLACEMENT tube seats with vaseline and position
tate the input shaft counterclockwise them in the housing. Install and tight-
out of the piston allowing the ball en the tube nuts to press the seats to
bearings to drop into the piston. Valve Housing the proper location.
10. Place a cloth over the open end 7. Coat the bearing and seal surface
of the piston and turn it upside down 1. Remove the dust seal (Fig. 8) of the housing with a film of vaseline.
to remove the balls. from the rear of the valve housing 8. Position the bearing in the valve
11. Remove the two screws that at- with Tools T59L-100-B and T58L- housing. Seat the bearing in the valve
tach the ball guide clamp (Fig. 6) to 101-A and discard the seal. housing with the tool shown in Fig.
the ball nut and remove the clamp and 2. Remove the snap ring from the 10. Make sure that the bearing is
the guides. valve housing. free to rotate.
12. Install the valve body assembly 3. Turn the fixture to place the
9. Dip the new oil seal in gear lu-
in the holding fixture (do not clamp valve housing in an inverted position.
bricant; then, place it in the housing
in a vise) and remove the lock nut and 4. Insert special tool in the valve
with the metal side of the seal facing
the attaching nut as shown in Fig. 7. body assembly opposite the seal end
outward. Drive the seal into the hous-
13. Carefully slide the input shaft, and gently tap the bearing and seal
ing until the outer edge of seal does
worm and valve assembly out of the out of the housing as shown in Fig.
not quite clear the snap ring groove
valve housing. Due to the close diame- 9. Discard the seal. Caution must be
trical clearance between the spool and exercised when inserting and removing (Fig. 11).
housing, the slightest cocking of the the tool to prevent damage to the 10. Place the snap ring in the hous-
spool may cause it to jam in the hous- valve bore in the housing. ing; then, drive on the ring with the
ing. 5. Remove the fluid inlet and outlet tool shown in Fig. 11 until the snap
14. Remove the shim from the tube seats with an EZ-out if they are ring seats in its groove to properly lo-
valve housing bore. damaged. cate the seal.
Tool-
T65P.3524-A1 STEERING GEAR HOUSING
Press Ram
J
UPPER SEAL
I LOWER SEAL
SNAP RING
SPACER WASHER
G1362-A
G1550-A
FIG. 17—Installing Oil Seal in FIG. 12—Steering Gear Housing Disassembled
Valve Housing
11. Place the dust seal in the hous- SHORT END
ing with the dished side (rubber side) AWAY Press Rom
FROM SEAL
facing out. Drive the dust seal into
place with the tool shown in Fig. 11. Tool - T59L - 100-B
t h e seal must be located behind the

undercut in the input shaft when it is
installed. Tool T57L-500 - A
Worm and Valve
1. Remove the snap ring from the

end of the actuator.
2. Slide the control valve spool
(Fig. 6) off the actuator.
3. Install the valve spool evenly and
slowly with a slight oscillating motion
into the flanged end of valve housing G1551-A G1374-A
with the Valve identification groove FIG. 13—Removing Lower Seal FIG. 14—Installing Sector Shaft
between the valve spool lands out- Inner Seal
ward, checking for freedom of valve
movement within the housing working Piston and Ball Nut 5. Apply Lubricant to the sector
area. The valve spool should enter the shaft seal bore of the housing and
housing bore freely and fall by its own 1. Remove the teflon ring and the position the sector shaft inner seal
weight. O-ring (Fig. 7) from the piston and into the housing with the lip facing in-
4. If the valve spool is not free, ball nut. ward. Press the seal into place with
check for burrs at the outward edges 2. Dip a new O-ring in gear lubri- the tool shown in Fig. 14. Place a spa-
of the working lands in the housing cant and install it on the piston and cer washer (0.090 inch) on top of the
and remove with a hard stone. ball nut. seal and apply more Lubricant to the
5. Check the valve for burrs and if 3. Install a new teflon ring on the housing bore.
burrs are found, stone the valve in a piston and ball nut being careful not 6. Place the outer seal in the hous-
radial direction only. Check for free- to stretch it any more than necessary. ing with the lip facing inward and
dom of the valve again. press it into place as shown in Fig. 15.
6. Remove the valve spool from the Then, place a 0.090 inch spacer wash-
housing. Steering Gear Housing er on top of the seal.
7. Slide the spool onto the actuator 7. Position the snap ring in the
making, sure that the groove in the 1. Remove the snap ring and the housing. Press the snap ring into the
spool annulus is toward the worm. spacer washer (Fig. 12) from the housing with the tool shown in Fig. 15
8. Install the snap ring to retain the lower end of the steering gear housing. to properly locate the seals and en-
spool. 2. Remove the lower seal from the gage the snap ring in the groove.
9. Check the clearance between the housing as shown in Fig. 13. Lift the
spool and the snap ring. The clearance spacer washer from the housing. STEERING GEAR
should be between 0.002-0.005 inch. If 3. Remove the upper seal in the ASSEMBLY
the clearance is not within these lim- same manner as the lower seal.
its, select a snap ring that will allow a 4. Dip both sector shaft seals in Do not clean, wash, or soak seals in
clearance of 0.003 inch. gear lubricant. cleaning solvent.
LONG END
AWAY FROM Press Ram
SEAL
FIRST GROOVE OF WORM SHOULD BE IN

ALIGNMENT WITH THIS HOLE
G1375-A
G1554-A
FIG. 15— Installing Sector Shaft FIG. 16—Assembling Piston on Worm Shaft
Outer Seal
1. Mount the valve housing in the 10. Apply vaseline to the teflon seal
holding fixture with the flanged end INPUT SHAFT on the piston.
up. 11. Place a new O-ring on the valve
SECTOR SHAFT
2. P l a c e the required thickness ADJUSTMENT SCREW housing.
valve spool centering shim (Fig. 6) in 12. Slide the piston and valve into
the housing. Use one shim only. the gear housing being careful not to
3. Carefully install the worm and damage the teflon seal.
valve in the housing. 13. Align the lube passage in the
4. Install the attaching nut in the valve housing with the one in the gear
housing and torque it to specification housing, and install but do not tighten
(Part 3-13). the attaching bolts.
5. Install the lock nut (Fig. 7) and 14. Rotate the ball nut so that the
torque it to specification (Part 3-13). teeth are in the same plane as the sec-
6. Place the piston on the bench tor teeth. Tighten the four valve hous-
with the ball guide holes facing up. ing attaching bolts to specifications.
Insert 44ie worm shaft into the piston 15. Position the sector shaft cover
so that the first groove is in alignment O-ring in the steering gear housing.
with the hole nearest to the center of G1547-A
Turn the input shaft as required to
the piston (Fig. 16). center the piston.
7. Place the ball guide in the pis- FIG. 77—Adjusting Mesh 16. Apply vaseline to me sector
ton. Place the 27 balls in the ball shaft journal then position the sector
guide (Fig. 16) turning the worm in a shaft and cover assembly in the gear
clockwise direction as viewed from the or the piston more than 3 1/2 turns housing. Install the steering identifica-
input end of the shaft. If all of the off the right stop to prevent the balls tion tag and two sector shaft cover at-
balls have not been fed into the guide from falling out of the circuit. taching bolts. Torque the bolts to spe-
upon reaching the right stop, rotate 8. Secure the guides in the ball nut cifications.
the input shaft in one direction and with the clamp (Fig. 6). 17. Attach an in-lb torque wrench
then in the other while installing the 9. Position a new lube passage O- to the input shaft. Adjust the mesh
balls. After the balls have been in- ring in the counterbore of the gear load to specifications as shown in Fig.
stalled, do not rotate the input shaft housing. 17.
03-09-01 Saginaw Design Integral Power Steering Gear 03-09-01
PART 3-9 Saginaw Design

Integral Power Steering Gear
MODEL APPLICATION
Continental-
Thunderbird
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
STEERING GEAR
Cleaning and Inspection (See Page 03-01) N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Description 09-01 N / A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Disassembly and Assembly 09-03 N / A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Mesh Load Adjustment 09-01 N / A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Removal and Installation 09-02 N / A N/A N/A N/A N/A N/A N/A N/A N/\ N/A
Overhaul 09-04 N / A N/A N/A N/A N/A N/A N/A N/A N/A N/A
DESCRIPTION
The Rotary Valve Safety power to absorb road shocks that may be Response of the steering gear to effort
steering gear operates entirely on dis- transmitted to the driver. All fluid applied to the steering wheel has been
placing fluid to provide hydraulic fluid passages are internal except the pres- greatly increased.
pressure assists only when turning. As sure and return hoses between the The rack-piston nut is one piece and
the entire gear assembly is always full gear and pump. is geared to the sector shaft. Lash be-
of fluid, all internal components of the The rotary valve provides a smooth tween the sector shaft and rack-piston
gear are immersed in fluid making transmission through the driving range nut is maintained by an adjusting
periodic lubrication unnecessary. In of steering wheel effort. A torsion bar screw which is retained in the end o\'
addition, this fluid acts as a cushion transmits the road feel to the driver. the shaft uear (Eiiz.l).
During the breaking in period of the sector shaft and remove the steer- repeating the method of reading tor-
the vehicle, it is probable that some ing wheel hub. que as in Step 4, above, loosen the
of the factory adjustments will change. 2. Disconnect the fluid return line adjuster lock nut, turn the screw in-
These changes in adjustment do not at the reservoir; at the same time cap ward with a 7/32-inch Allen wrench
necessarily affect the satisfactory op- the reservoir return line pipe. until the reading is equal to 6 in-lbs
eration of the steering gear assembly 3. Place the end of the return line in excess of Step 4 above, and retigh-
and ordinarily do not require re-ad- in a clean container and cycle the ten the lock nut while holding the
justment unless there is excessive lash steering wheel in both directions as screw in place.
or other malfunctioning. The only ad- required, to discharge the fluid from 6. Recheck the readings and re-
justment that should be performed in the gear. place the Pitman arm and the steering
the vehicle is the total over center 4. Turn the gear 1/2 turn off cen- wheel hub.
position load (mesh load) to eliminate ter (either direction). Using a 24 in- 7. Connect the fluid return line to
excessive lash between the sector shaft lb torque wrench on the steering wheel the reservoir and fill the reservoir
and rack teeth. nut, determine the torque required to with C1AZ-I9582-A Fluid to the
rotate the shaft slowly through a 20 proper level.
MESH LOAD ADJUSTMENT degree arc.
1. Disconnect the Pitman arm from 5. Turn the sear back to center and
WORM
ADJUSTER PLUG
TORSION BAR
STUB SHAFT
SEAL
NEEDLE BEARINGS
TEFLON RING
TEFLON SEALS
SECTOR SHAFT
G 1650-A
FIG.l — Power Steering Gear—Sectional View
REMOVAL the clutch release lever retracting spring ing wheel so that the spokes are in
to provide clearance for removing the the horizontal position.
1. Disconnect the pressure and the steering gear. 2. Center the steering gear input
return line from the steering gear. 6. Support the steering gear then shaft.
Plug the lines and the ports in the remove the three steering gear attach-
3. Slide the steering gear input shaft
gear to prevent entry of dirt. ing bolts.
into the flex coupling and into place
2. Remove the two bolts that secure 7. Work the steering gear free of
on the frame side rail. Install the three
the flex coupling to the steering gear the flex coupling and remove it from
attaching bolts and torque them to
and to the column. the vehicle.
specification.
3. Raise the vehicle and remove the 8. If the flex coupling stayed on the
Pitman arm attaching nut. input shaft, lift it off the shaft at 4. Make sure that ihe wheels are
4. Remove the Pitman arni from this time. in the straight-ahead position, then
the sector shaft with Tool T64P-3590- install the Pitman arm on the sector
F. Remove the tool from the Pitman INSTALLATION shaft. Install and tighten the sector
arm. shaft attaching nut to specification.
5. If working on a vehicle equipped 1. Slide the flex coupling into place 5. Move the flex coupling into place
with a standard transmission, remove on the steering shaft. Turn the steer- on the input shaft and steering column
shaft and install and tighten the attach- pressure and the return line to the cycle the steering gear. Check for
ing bolts to specification. steering gear. leaks. Check the reservoir fluid level
6. Connect and tighten the fluid 7. Fill the power steering pump and again and add as required.
Disassembly and reassembly of the 3. Working through the hole in the 7. Remove the lock nut from the
unit and the subassemblies must be housing (Fig. 3), unseat the retaining sector shaft adjustment screw. Discard
made on a clean workbench. As in re- ring then work it out of the groove the nut.
pairing any hyldraulically operated with a screwdriver. 8. Remove the four cover attaching
unit, cleanliness is of tftfiiost impor- 4. Rotate the input shaft in a coun- screws. Rotate the sector shaft adjust-
tance. Therefore, the bench, tools, and terclockwise direction using a 3/4 ment screw with an Allen wrench until
parts must be kept clean at all times. inch, 12-point socket wrench to force the cover is free of the housing. Re-
Thoroughly clean the exterior of the the end plug out of the housing. Do move the cover and the O-ring. Dis-
gear with a suitable solvent and, when not rotate the shaft any more than card the O-ring.
necessary, drain as much of the hy- necessary to remove the plug. Further 9. Turn the input shaft as required
draulic fluid from the gear as possible. rotation will allow the balls to fall to center the sector shaft teeth in the
from their circuit and allow the rack- housing.
DISASSEMBLY INTO piston to become disengaged from the 10. Tap the end of the sector shaft
sector shaft. Remove the O-ring from with a soft-faced hammer to free it
SUB-ASSEMBLIES
the housing and discard it. from the housing.
5. Rotate the input shaft 1/2 turn 11. Remove the adjuster plug lock
1, Mount the steering gear in a in a clockwise direction to draw the nut.
vise. (Fig.. 2\ piston inward. 12. Remove the adjuster p>ug with
2. Rotate the end plug retaining 6. Turn the end plug (Fig. 4) count- spanner wrench T65P-3A537-A (Fig.
ring to place one end of the ring erclockwise out of the piston with a 15).
opposite the hole in the housing. 1/2 inch drive extension. 13. Insert the tool shown ir Fig. 6
RETUF P0RT
LOCK NUT ™
INLET PORT
TORSION BAR SECTOR SHAFT

ADJUSTMENT SCREW
STUB SHAFT
ADJUSTER PLUG
HOUSING
SECTOR SHAFT
END PLUG G1648-A
G 1649- A
FIG. 3—Removing End Plug

FIG. 2—Steering Gear Retaining Rina
TEFLON RINGS (3)
VALVE SPOOL
0-RING SPOOL
SEAL
STUB SHAFT
ASSEMBLY FLEXIBLE
INLET PORT SEAT COUPLING
CHECK VALVE
RETURN PORT
SEAT
CLAMP SPRING
BALL RETURN GUIDE

'BEARING LOCK
NUT
GROUND STRAP
RETAINING RING
DUST SEAL
OIL SEAL
ADJUSTER PLUG
O-RING SEAL
THRUST BEARING
SPACER
BEARING RETAINER
SPOOL SPRING
TEFLON RING
RACK-PISTON END PLUG
O-RING RETAINING RING
HOUSING END PLUG
RETAINING RING
G 1647-A
FIG. 4—Steering Gear Disassembled
14. Pull the stub shaft and valve as- that secures the sector shaft seals in
sembly from the housing. the lower end of the housing. Remove
15. Lift the worm, lower thrust the lower spacer washer.
bearing and the races from the hous- 2. Remove the lower seal (double
ing. lip), spacer washer, upper seal (single
lip) with T o o l s T85L-1O1-A and
REPAIR OF S U B -
T59L-100-B (Fig. 8).
ASSEMBLIES
3. Check the housing bearing for
Do not clean, wash, or soak seals in wear and remove the bearing only if
SPANNER WRENCH
cleaning solvent. worn or damaged. Working from the
Tool - T65P- lower end of the housing (Fig. 9) press
STEERING GEAR HOUSING the bearing out of the housing. Dis-
lG 1646-A
1. Remove the snap ring (Fig. 7) card the bearing.
FIG. 5—Removing Adjuster Plug
.HOUSING LOWER SEAL (DOUBLE LIP)
Tool - T 65P-3D517-A
SNAP
G 1645-A RING
FIG. 6—Removing Rack Piston
into the end of the rack-piston until it
contacts the worm shaft. Rotate the
stub shaft in a counterclockwise direc-
tion until the worm is free of the
INLET PORT
rack-piston. Withdraw the rack-piston SEAT
from the housing making sure that the
tool is held all the way in the piston RETUkN PORT
SEAT G 1643-A
to prevent dropping the balls. Do not
disassemble the rack-piston at this
time. FIG. 7—Steering Gear Housing Disassembled
the special tool, drive the seal and 13. Install the outlet port seat in
back-up washer in only far enough to the same manner.
provide clearance for the retaining
ADJUSTER PLUG
ring. Install the sector shaft seal re-
taining ring with snap ring pliers, 1. Lift the adjuster plug off the stub
making certian that the ring is seated shaft (Fig. 4).
properly. 2. Pry the thrust bearing retainer
6. To remove a damaged port seat, off the adjuster plug as shown in Fig.
u s e a 5 / 1 6 - 1 8 inch U . S . t h r e a d 13. Be careful not to score the needle
(coarse) tap and turn it two turns into bearing bore. Discard the retainer.
the seat. 3. Lift the spacer, thrust bearing,
7. Thread a bolt and nut with a flat races and the O-ring, from the plug
washer into the tapped hole (Fig. 11). (Fig. 14). Discard the O-ring.
Tool . T59L -100S
8. Hold the bolt from turning and 4. If necessary to replace the roller
tighten the nut to extract the seat. bearing, remove the dust seal retaining
Discard the seat. ring. Working from the spacer end of
9. Remove the check valve and the adjuster plug, remove the roller
spring from the inlet port. bearing, oil seal and the dust seal as
10. Blow all chips from the hous- shown in Fig. 15.
ing.
11. Position the spring, check valve
and new seat in the inlet port.
12. Use the tool shown in Fig. 12
and drive the seat into place.
. T65P-3D642-A
FIG. 8—Removing Sector

Shaft Seals
G1639-A
FIG. 12 -Installing Inlet Port
BEARING RETAINER
Too/ - T65P -3576-C
G1287- A
G 1641-A
FIG. 10 — Installing Sector
Shaft Seal
FIG. 9—Removing Sector
C1638-A
Shaft Bearings
5/16 • 16x2"
4. Working from the upper end of BOLT FIG. 73—Removing Thrust
the housing, press in a new bearing Bearing Retainer
until the upper end is 0.030 inch below
the housing bore. When installing the If the roller bearing does not need
bearing, make sure it is pressed in replacing do not remove it. Pry the
from the identification end (stamped dust seal and the oil seal from the ad-
end). juster plug with a screwdriver.
5. Lubricate new sector shaft seals 5. Place a new roller bearing on the
(Fig. 7) in C1AZ-19582-A hydraulic tool shown in Fig. 15 with the bearing
fluid. Install the single lip seal first, manufacturer's identification facing
then a back-up washer. Using special toward the tool.
tool (Fig. 10), drive the seal and wash- 6. Position the bearing and tool in
er in far enough to provide clearance the bore. Drive the bearing into the
for the other seal and back-up washer plug until it is flush with the bottom
and the retaining ring. The seal must surface of the stub shaft seal bore.
not bottom on the end of the counter- 7. Lubricate a new oil seal with
G1640-A
bore. Install the double lip seal and C1AZ-19582-A. Install the seal with
the second back-up washer. Again using FIG. 11 —Removing Port Seat Tool T65P-3D536-A pressing it into
than removing the spool to replace the

ADJUSTER PLUG dampener O-ring or replace the three
DUST SEAL
teflon seals or O-rings under the teflon
seals.
1. Remove the cap to worm O-ring
and discard it (Fig. 17).
2. Work the rear coil of spool
spring onto the stub shaft bearing sur-
OIL RETAINING face. Do not pry on the valve body.
SEAL RING
Slide the spring off the shaft.
3. Extreme care must be used when
G 1637-A removing the valve spool. The diame-
tral clearance between the valve body
FIG. 14 —Adjuster Plug Disassembled
and the spool may be as low as 0.0004
the plug far enough to provide clear- 12. Press a new bearing retainer inch. The slightest cocking of the
ance for the dust seal and the snap into the bearing bore. The radial loca- spool may jam it in the valve body.
ring. tion of the dimples is not important. a. To remove the valve spool, hold
8. L u b r i c a t e a new d u s t seal the valve assembly in both hands with
C1AZ-19582-A and install it with STUB SHAFT AND the stub shaft pointing downward.
smooth rubber surface facing outward. VALVE ASSEMBLY Push lightly on the valve spool with a
9. Secure the dust seal with the small rod by inserting the rod through
ring, making sure that the ring is The control valve and spool is a se- the openings in the end cap (Fig. 18)
properly seated. lect fit and cannot be serviced other until the spool is far enough out of the
10. Lubricate a new O-ring seal valve so that it may be grasped by the
with vaseline and install it on the ad- hand. Withdraw the spool with a
juster plug. steady oscillating pull to prevent jam-
11. Assemble the thrust bearing ming. If slight sticking occurs, make a
outer race, thrust bearing, inner race, gentle attempt to reverse the with-
and the thrust bearing spacer on the drawal procedure. If this does not free
adjuster plug (Fig. 16). the spool, it has become cocked in the
valve body bore. Do not attempt to
force the spool in or out if it becomes
cocked. In this case, continue to disas-
semble the valve assembly as follows
and return to the spool as described
later. Remove the stub shaft, torsion
bar, and end cap assembly by holding
the thumbs on the valve body as
BEARING AND
shown in Fig. 18. Tap the torsion bar
RACES lightly against the workbench. This
will dislodge the cap from the valve
body to cap pin. The stub shaft, tor-
sion bar and end cap assembly can
now be removed from the valve body.
b. If the valve spool has become
cocked as described in step 3 above, it
can now be freed. By visual inspection
1636-A
G 1635-A on a flat surface it can be determined
in which direction the spool is cocked.
FIG. 15 —Removing or Installing FIG. 76 —Installing Thrust A few very light taps with a light soft
Roller Rearing from Adjuster Plug Bearing Retainer plastic or raw-hide mallet should align
the spool in the bore and free it. Do
SPOOL SPRING not tap with anything metallic. If
spool can be rotated, it can be re-
moved.
4. Remove O-ring dampener seal
from the spool and discard it.
5. Carefully cut the valve rings and
the ring back-up seals, remove and
BEARING discard them, providing the rings show
RACE evidence of excessive wear. The valve
DOWEL rings are made of filled teflon and it is
very unusual that replacement is re-
G1634-A quired.
6. Remove the dampener O-ring
FIG. 77—Control Valve Disassembled from the valve spool and discard it.
damage. Guide the spool to engage 6. Lubricate a new O-ring and tef-
the notch with the dowel in the body. lon ring. Install the O-ring on the pis-
11. Place the spool spring on the ton being qareful not to twist it. Slide
stub shaft with the larger diameter the teflon ring into place being careful
toward the spool. Work the small end not to stretch it any more than neces-
of the spring down over the shaft until sary.
the small end is seated in the groove 7. Slide worm (Fig. 20) fully into
of the stub shaft. the rack-piston. Load 16 balls into the
12. If, during the assembly of the guide hole nearest the teflon ring
valve, the stub shaft and end cap as- while slowly rotating the worm count-
sembly is allowed to slip out of en- erclockwise to feed the balls through
gagement with the valve body pin, the circuit. Alternate the dark colored
spool will be permitted to enter the balls with the polished balls through
VALVE SPOOL
valve body too far. The dampener O- the circuit.
DAMP EN ERO-RING
ring seal will expand into the valve
body fluid grooves preventing with-
drawal of the spool. Attempt to with-
TORSION BAR draw the spool with a slight pull and
TEFLON RING
G 1633-A much rotary motion. If this does not
FIG. 18 —Removing Spool free the spool after several tries, make
sure that the spool is free to rotate;
from Valve Body place the valve body on a flat surface
7. Dip three new valve body O- with the notched end up, and tap the
rings and teflon rings in C1AZ- spool with a wooden or plastic rod
19582-A lubricant. Install the O-rings until the O-ring seal is cut and the
on the valve body being careful not to spool can be removed. Replace the
twist them. Slide the three teflon rings dampener O-ring seal and proceed
into place over the O-rings being care- with the assembly procedure as be-
ful not to stretch them any more than fore. G 1632-A
necessary. FIG. 20—Assembling Rack Piston
8. Lubricate a new dampener O- RACK-PISTON
ring and install it in the spool groove. Apply Lubriplate liberally to one of
9. Assemble the stub shaft in the 1. Cut the teflon ring and the O- the ball return guides and install the
valve body making sure that the ring from the piston. six remaining balls in the guide. Place
groove in the cap engages the pin in 2. Place the assembly on a clean the other half of the guide in position
the body. Tap the cap lightly with a lint-free cloth and remove the screws and insert them into holes in the
soft-faced hammer to seat it in the that attach the ball return guide clamp rack-piston. Be sure that the dark ball
valve body. to the rack piston and remove the in the guide is installed next to the
10. Dip the valve spool in C1AZ- clamp (Fig. 19). polished ball in the rack-piston. Install
19582-A. With the notch of the spool 3. Lift the ball return guides from the ball return guide clamp with
toward the valve body, carefully slide the rack-piston. screws and lock washers. Tighten the
the spooi over the shaft and into the 4. Remove Tool T65P-3D517-A screws to 8-12 ft-lbs.
body rotating it slightly to permit easy from the piston and remove the re- 8. The worm groove is ground with
entry. Make sure that the dampener maining balls. a high point in the center. V/hen the
O-ring is distributed evenly to prevent 5. Thoroughly clean all parts. rack-piston passes over this high point
there should be a preload of 1-4 in-
lbs. Clamp the rack-piston in a vise
with soft jaws with the worm shaft
TEFLON RING pointing up. To avoid distortion, do
not tighten the vise too tight.
END PLUG RACK PI STON 9. Place the valve assembly on the
worm, engaging the worm drive pins.
Rotate the worm until it extends 1
1/4 inch from the rack-piston to the
DARK COLORED BALLS
(11 REQUIRED) thrust bearing face. This is the center
position.
V
10. Place an in-lb torque wrench
0-RING with a 3/4-inch-deep wall 12-point
POLISHED BALLS
socket on the stub shaft, and rotate
(II REQUIRED) the wrench through an arc of approxi-
mately 60 degrees in both directions
BALL RETURN GUIDE
several times, then take a torque read-
ing. The highest average reading ob-
tained with the worm rotating should
CLAMP
B
G1296. A
be between 1-4 in-lbs.
11. If this reading is too high or
FIG. 19—Rack-Piston Disassembled too low a new set of balls should be
Code Diameter Size Range of Ball just enough to be sure all parts are
Size Mean (Inch) properly seated. Remove Tool T65P-
3A537-B.
6 0.28117 0.28112-0.28122 7. Install the adjuster plug locknut
loosely on the plug.
7 0.28125 0.28120-0.28130 8. Tighten the adjuster plug with
8 0.28133 0.28128-0.28138 wrench J7624 while rotating the input
shaft. As soon as additional drag is
9 0.28141 0.28136-0.28146 noted, back the adjuster plug off 1/8
turn. Measure the input shaft drag
10 0.28149 0.28144-0.28154
with an in-lb torque wrench.
11 0.28157 0.28152-0.28162 9. Tighten the adjuster plug (Fig.
25) to obtain a 1-3 in-lb preload in ex-
FIG. 21 —Worm Ball Sizes cess of the drag that was measured
previously. Tighten the adjuster plug
lock nut and recheck the thrust bear-
installed. Service replacement balls are ASSEMBLY OF ing preload. Total preload must not
available in the sizes shown in (Fig. STEERING GEAR exceed 8 in-lbs.
21). 10. Install Tool T65P-3805-A in
12. Note the ball size stamped on 1. Secure the steering gear housing the steering gear housing. Position the
the rack-piston and install the next in a vise. rack-piston as shown in Fig. 26. Be
size larger balls to increase the pre- 2. Lubricate the worm shaft, lower sure that Tool T65P-3D517-A is con-
load. If no number is stamped on the thrust bearing, and races; then posi- tacting the worm shaft. Push the
rack-piston, the original ball code size tion the thrust bearing and races on rack-piston inward until it contacts
was No. 7. the worm. the worm shaft while keeping pressure
A change of one ball size larger will Align the valve body drive pin on applied to Tool T65P-3D517-A. Turn
increase the preload approximately the worm, with the narrow pin slot in the stub shaft clockwise until the
one in-lb. Final preload on replace- the valve body. Be sure O-Ring seal middle rack groove in the rack-piston
ment balls should be 2-3 in-lbs. between the valve body and the worm is aligned with the center of sector
Remove the valve assembly from head is installed. shaft roller bearing. Remove the tool
the worm and the rack-piston from 3. Position the valve assembly and from the housing.
the vise. the worm shaft in the housing as a
13. Insert Tool T65P-3D517-A into 11. Lubricate a new O-ring with
unit (Fig. 23). Do not push against the C1AZ-19582-A and position it in the
the plug end of the rack and piston to stub shaft as this could cause the stub
contact the worm shaft (Fig. 22). sector shaft cover.
shaft and cap to pull out of the valve 12. Thread the sector shaft cover
Apply pressure on the tool while ro- body, allowing the spool seal to slip
tating the worm shaft out of the pis- on the adjusting screw until it bottoms
into valve body fluid grooves. Install then back it off 1 1/2 turns.
ton and rack. Leave the tool in place the valve assembly by pushing on the
until the piston is installed in the 13. Install the sector shaft so that
outer diameter of the valve body hous- the center gear tooth meshes with the
housing. ing with the finger tips. Be sure that center groove in the rack-piston. Be
the teflon rings are not binding inside sure that the cover O-ring is in place
END OF TOOL MUST BE IN the housing. The valve assembly is before pushing the cover down on the
CONTACT WITH WORM
SHAFT correctly seated when the fluid return housing.
hole in the gear housing is fully vis- 14. Install the cover screws and
ible. lock washers. Tighten to 30-35 ft-lbs.
4. Place the tool shown in Fig. 24 15. Install a new adjuster lock nut
over the end of the stub shaft. halfway on the adjuster screw.
Tool * T65P-3D517-A G 1631-A 5. Lubricate a new adjuster plug 16. Install the end plug in the
O-ring and install it in the adjuster rack-piston. Tighten the plug to 50-
FIG. 22—Installing Tool plug groove. 100 ft-lbs torque.
6. Install the adjuster plug over the 17. Lubricate a new housing end
in Raek-Piston
end of the stub shaft and tighten it plug O-ring and install it in the hous-
ing.
18. Place the end plug in the gear
DRIVE PIN housing and seat it against the O-ring
seal. It may be necessary to tap the
Tool T65P-3A537-B
STUB SHAFT
ADJUSTER
PLUG
G 1629-A
G 1630-A
FIG. 23—Installing Valve and Worm Shaft in Housing FIG. 24 —Installing Adjuster Plug
Tool • T65P-3D517-A
RACK PISTON Tool - T65P.3805-A

jG1302 A
LOCK NUT
ADJUSTER PLUG FIG. 26—Installing Rack-Piston
G1628-A 21. Place an in-lb torque wrench on

the input shaft as shown in Fig. 27.
FIG. 25 — Adjusting Thrust Preload 22. With the gear on center and the
sector shaft adjuster backed off, meas-
end plug lightly with a soft-faced mal- ure the total drag. With the gear on
let to seat it properly. center, adjust the sector shaft thrust
19. Snap the retainer ring in place screw so that preload is 4-8 in-lbs in
with the fingers. Tap lightly on the excess of total preload and drag.
ring to be sure the ring is bottomed Readings are to be made through an
securely in the housing. arc not exceeding 20 degrees with the
20. Turn the input shaft to the full gear on center. Tighten the lock nut.
left or right position then turn it back 23. After obtaining the proper mesh
approximately 1 3/4 turns to center load, tighten the sector shaft adjust-
the worm. ment screw lock nut to 20-30 ft-lbs.
G1303-A
FIG. 27—Adjusting Sector

Shaft Mesh Load
03-10-01 Ford-Thompson Power Steering Pump* 03-10-01
PART 3-10 Ford-Thompsonr Power Steering Pump

MODEL APPLICATION
Continental-
Thunderbird
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
PUMP BELT TENSION ADJUSTMENT 10-01 10-01 10-01 10-01 10-01 10-01 10-01 10-01 N / A 10-01 N / A
PUMP DRIVE BELT
Removal and Installation l5-O2 10-02 10-02 10-02 10-02 10-02 10-02 10-02 N / A 10-02 N / A
POWER STEERING PUMP
Cleaning and Inspection (See Part 03-01)
Description 10-01 10-01 10-01 10-01 10-01 10-01 10-01 10-01 N / A 10-01 N / A
Disassembly and Assembly 10-04 10-04 10-04 10-04 10-04 10-04 10-04 10-04 N / A 10-04 N / A
Removal and Installation 10-02 10-02 10-02 10-02 10-02 10-02 10-02 10-02 N / A 10-02 N / A
POWER STEERING PUMP PULLEY
Removal and Installation 10-03 10-03 10-03 10-03 10-03 10-03 10-03 10-03 N / A 10-03 N / A
POWER STEERING PUMP RESERVOIR
Removal and Installation 10-03 10-03 10-03 10-03 10-03 10-03 10-03 10-03 N / A 10-03 N/A
ROTOR SHAFT SEAL
Removal and Installation 10-04 10-04 10-04 10-04 10-04 10-04 10-04 10-04 N / A 10-04 ' N / A
1 DESCRIPTION
The Ford-Thompson power steering voir (Fig. 1). It is constructed so that and the pump body is encased within
pump is a belt driven slipper type the reservoir is attached to the rear the reservoir (Fig. 2).
pump which is integral with the reser- side of the pump housing front plate

PUMP BELT TENSION
DIPSTICK.
ADJUSTMENT
DRIVE
Pump drive belt tension cannot be PULLEY
checked accurately using the • thumb
pressure or belt deflection methods.
Correct belt adjustment is assured
only with the use of a belt tension
gauge.
1. Check the belt tension with a
belt tension gauge tool T63L-8620-A.
With a new belt, or one that has been
run for less than 15 minutes, the ten-
sion should be within 120-150 lbs.
With a belt that has been run for
RELIEF VALVE
more than 15 minutes, the tension
should be within 90-120 lbs.
2. To adjust the belt, loosen the
mounting bolts incorporated on the
front face of the pump cover plate RESERVOIR
(hub side) and one nut at the rear of
the reservoir. Fix a 9/16 inch open ORIFICE PLUG
end wrench on the nrojecting 1/2 inch
boss on the cover -'plate a"hd pry up- G1479-B
ward to correct tension on 6 cyl. en-
gines. FIG. 1—Power Steering Pump—Sectional View
03-10-02 Ford-Thompson Power Steering Pump 03-10-02
LOWER PRESSURE
PLATE 3D590
SPRING-3D601
UPPER PRESSURE
PLATE -3A645
RETAINER END
PLATE-3D589
CAM AND ROTOR

ASSEMBLY- -3D607
PULLEY-3D673
PUMP SHAFT
SEAL 3B592
PLATE AND BUSHING
ASSEMBLY-3D643
SCREW AND WASHER 0-RING
ASSEMBLY-379376-S
382744-S
HOUSING GASKET
3A760
G1343-B
FIG. 2—Power Steering Pump Disassembled
To adjust the belt on 8 cyl. engines tighten the bolts and the fiut to speci- taching the power steering pump to
loosen the mounting bolt in the ad- fication (Part 3-13). the pump bracket, and remove the
justing slot and the nut directly above pump drive belt.
the adjusting slot. Place a suitable pry POWER STEERING 3. P o s i t i o n the power steering
bar between the cast boss on the pump drive belt on the pulleys.
PUMP DRIVE BELT
pump mounting bracket and the cast 4. Adjust the drive belt tension as
REPLACEMENT outlined in Section 2 to specification
boss on the pump cover plate and pry
upward to correct tension. (Part 3-13) and tighten the pump at-
Do not pry against the reservoir to 1. Loosen the idler pulley attaching taching bolts and one nut to specifica-
obtain proper belt load as it can be bolts and remove the compressor drive tion.
deformed and cause a leak. belt if equipped with an air condition- 5. Install the compressor drive belt
3. Recheck the belt tension. When er. if equipped with an air conditioner
the tension has been correctly adjusted, 2. Loosen 3 bolts and one nut at- and adjust to specification (Part 16).
POWER STEERING
from the pump. Tool T63L-8620-A and tighten the
PUMP REPLACEMENT 3. Remove 3 bolts from the front of bolts and nut to specifications.
the pump and the one nut at the rear 6. Torque the pressure hose fitting
(rear nut on 8 cyl. engines only) that hex nut to specification. Then, connect
EIGHT CYLINDER attach the pump to the mounting the pressure hose to the fitting and
WITHOUT AIR bracket; disconnect the belt from the torque the hose nut to specification.
CONDITIONER AND pulley and remove the pump from the 7. Connect the hose to the pump.
ALL SIX CYLINDER vehicle. Then, tighten the clamp.
4. Position the pump to the mount- 8. Fill the power steering pump res-
1. Remove the power steering fluid ing bracket and install the 3 bolts at ervoir with transmission fluid C1AZ-
from the pump reservoir by discon- the front of pump and (rear nut on 8 19582-A and cycle the system to re-
necting the fluid return hose at the cyl. engines only) the 1 nut at the move air from the steering gear sys-
reservoir, and allow the fluid to drain rear. Torque to specification. tem.
into a suitable container. 5. Place the belt on the pulley and 9. Check for leaks and again check
2. Disconnect the pressure hose adjust the belt tension (Section 2) with the fluid level. Add fluid as necessary.
EIGHT CYLINDER WITH check the fluid level. Add fluid as re- on the shaft to prevent damage to in-
AIR CONDITIONER quired. ternal thrust areas.
3. Remove the tool.
1. Remove the power steering fluid POWER STEERING PUMP
from the pump reservoir by discon- POWER STEERING PUMP
PULLEY REPLACEMENT
necting the fluid return hose from the RESERVOIR REPLACEMENT
reservoir and allow the fluid to drain
in a suitable container.
2. Disconnect the pressure hose REMOVAL Reservoir replacement must be done
from the pump. on a clean workbench. Cleanliness of
3. Remove 3 bolts from the front of 1. Drain as much of the fluid as work area and tools is extremely im-
the pump and the one nut at the rear possible from the pump through filler portant when repairing any hydraulic
that attach the pump to the mounting pipe. unit. Thoroughly clean the exterior of
bracket and remove the drive belt 2. Install a 3/8-16 inch capscrew in the pump with a suitable cleaning sol-
from the pump pulley. the end of the pump shaft to prevent vent. Do not clean, wash or soak the
4. Loosen the upper pump bracket- damage to the shaft end by the tool shaft oil seal in solvent. Plug the inlet
to-engine attaching bolt and remove screw. and outlet openings with plugs or
the bolt in the belt adjusting slot. Re- 3. Install the pulley remover, Tool masking tape before cleaning the
move the pump. T63L-1O3OO-B, on pulley hub, and pump exterior or removing the reser-
5. Position the pump to the bracket place the tool and pump in a vise as voir.
and install the bracket-to-pump at- shown in Fig. 3.
taching bolts and nuts. Tighten to spe- 4. Hold the pump and rotate the REMOVAL
cifications. tool nut counterclockwise to remove
6. Place the belt on the pump pul- the pulley (Fig. 3). The pulley must be 1. Assemble the adapter plate (Tool
ley. Adjust the belt tension as outlined removed without in and out pressure T69P-3A674-A) to the bench mounted
in Section 2 and tighten the bolts and on the pump shaft to prevent damage fixture tool (T57L-5OO-A). Position
nut to specification. to internal thrust areas. the pump and pulley on the adapter
7. Torque the pressure hose fitting plate, pulley facing down.
hex nut to specification. Then, connect INSTALLATION 2. Remove the outlet fitting hex nut
the pressure hose to the fitting and and the service identification tag.
torque the hose nut to specification. 1. Position the pulley to the pump 3. Invert the pump so the pulley is
8. Connect the return hose to the shaft and install Tool T65P-3A733-A facing up and remove the reservoir by
power steering pump and tighten the as shown in Fig. 4. tapping around the flange with a wood
clamp. 2. Hold the pump and rotate the block (Fig. 5).
9. Fill the pump with automatic tool nut clockwise to install the pulley 4. Remove the reservoir O-ring seal
transmission fluid C1AZ-19582-A. on the shaft. The pulley face will be and the outlet fitting gasket from the
Bleed the air from the system (Part flush with end of pump shaft. Install pump.
3-1) and check for leaks and again the pulley without in and out pressure
INSTALLATION
1. Install a new gasket on the outlet

fitting and a new reservoir O-ring seal
on the pump housing plate (Fig. 6).
The old gasket and seal should never
be re-used.
Too/ T57L 500-A
Tool • T 63 L-
10300 -
G1602-A
G 1477 A 1478 A
FIG. 3—Removing Power FIG. 4—Installing Power FIG. 5—Removing Pump

Steering Pump Pulley Steering Pump Pulley Reservoir
OUTLET FITTING Wood Block 2. Apply vaseline to the reservoir

GASKET O-ring seal and to the inside edge of
the new reservoir flange. Do not twist
the O-ring seal.
3. Position the reservoir over the
pump and align the notch in the reser-
voir flange with the notch in the outer
diameter of the plate and bushing as-
sembly.
4. Install the reservoir on the pump
and O-ring seal with a plastic or rub-
ber hammer and a block of wood as
shown in Fig. 7. Tap at the rear of the
reservoir and on the outer edges only.
5. Inspect the assembly to be sure
the reservoir is evenly seated on the
pump housing plate.
-500- A
0-RING SEAL G1345- G1603- A
6. Position the service identification
tag on the outlet fitting and install the
outlet fitting hex nut. Torque the nut
FIG. 6—Gasket Locations FIG. 7—Installing Reservoir to specification (Part 3-13). Do not
on Pump—Typical exceed specification.
DISASSEMBLY 6. If necessary, remove the fol- PARTS REPAIR OR

lowing components from the pump REPLACEMENT
Disassembly of the pump and its housing: the housing cover, the O-ring
subassemblies must be made on a seal and the pressure springs. These
clean work bench. In repairing any components normally will remain in
hydraulically operated unit, cleanliness the pump housing when it is removed. ROTOR SHAFT
is of utmost importance. Clean the ex- 7. Remove and discard the pump SEAL REPLACEMENT
terior of the unit with a suitable sol- cover gasket.
vent and drain as much of the fluid as 8. Remove the retainer end plate
possible. and upper pressure plate (in some Removal
If only the reservoir is to be re- pumps, the end plate and upper pres-
moved, plug the inlet and outlet open- sure plate are integral). 1. Remove the pulley from the
ings with masking tape or plugs. Do 9. Remove the loose fitting dowel rotor shaft as described under Power
not immerse the shaft oil seal in sol- pin. Be careful not to bend the fixed Steering Pump Pulley Removal.
vent. If only the rotor shaft seal is to dowel pin which remains in the hous- 2. Position the pump assembly in
be replace, see Rotor Shaft Seal Re- ing plate assembly.
placement outlined in this section. 10. Remove the rotor assembly
T57L-500-A
1. Assemble the adapter plate (Tool being careful to prevent the springs
T69P-3A674-A) to the bench mount- and slippers from falling out and be-
ed holding fixture Tool T57L-5OO-A coming lost. Do not disassemble fur-
T69P-3A674-A
(Fig. 8). ther unless the lower pressure plate,
2. Position the pump assembly, housing plate, rotor shaft and/or seal
with pulley assembled, on the adapter is to be replaced.
plate, pulley facing down. 11. Invert the pump assembly and,
3. Remove the outlet fitting nut and using Tool T63L-1O3OO-B, remove the
the service identification tag. pulley.
4. Invert the pump assembly and, 12. Clean any rust, road dirt, burrs,
using a block of wood and a rubber or scoring, etc. from the pulley end of
plastic hammer, remove the pump res- the rotor shaft prior to removal of the
ervoir and seal by tapping around the shaft from the housing plate. The
flange of the reservoir and on the und- shaft must come out without restric-
erside of the filler neck. tions to prevent scoring or damage to
5. Again invert the pump assembly, the bushing. Remove the pump rotor
loosen and remove the pump housing shaft.
• G1604-A
retention bolts and remove the pump 13. Remove the lower pressure
housing. plate. FIG. 8—Adapter Plate Installation
the bench mounted holding fixture, 5. Using a sharp tool such as a on the shaft seal protector, Tool
T57L-5OO-A or on the assembled sheet metal punch, carefully pierce the T68P-3B592-B.
adapter plate, T69P-3A674-A, pulley metal seal body face and pry the old 3. Insert the seal protector tool and
end of the shaft up. seal out (Hg. 9). Do not damage the the rotor shaft seal onto the shaft
3. Clean any rust or road dirt from bushing, the housing or the rotor (Fig. 10).
the pulley end of the rotor shaft. shaft. 4. Using" the seal installation Tool
4. To prevent scoring of the shaft, T68P-3B592-A and a rubber or plastic
wrap .005 shim stock (free of burrs) Installation
hammer, tap gently on the end of the
around the rotor shaft and push it into tool until the seal is completely in-
the ID of the seal until it is against 1. Remove the shim stock. stalled (flush with the end of the seal
the bushing. 2. Position the new rotor shaft seal bore).
5. Remove the tools.
6. Install the pulley on the rotor
. * SHARP POINTED TOOL shaft as described under Power Steer-
(PRY OUT SEAL)
ing Pump Pulley Installation.
ASSEMBLY
1. Assemble adapter plate (Tool

T69P-3A674-A) to the bench mounted
holding fixture Tool T57L-5OO-A. Po-
sition the pump assembly on ' the
adapter plate, pulley side facing doVn.
JrM" the lower pressure plate and rotor
shaft have not been disassembled,
omit Steps 2 and 3).
2. Insert the lower pressure plate
on the anchor pin with the wide cham-
fered slots at the center hole facing up
(Fig. 11).
FIXED ROUND NOTCH ON

DOWEL HOLE THIS SIDE WIDE
0NLY
CHAMFERED
SLOTS
FIG. 9—Rotor Shaft Seal Removal
s- •:?
G1347-A
. SHAFT SEAL PROTECTOR
TOOL NO. T68P-3B592-B
FIG. 11—Lower Pressure
Plate Installed
3. Dip the rotor shaft in specified

s t e e r i n g gear lubricant (C1AZ
19582A); then insert the rotor shaft
into the lower pressure plate and
housing plate.
4. If the rotor assembly is disas-
sembled, hold the cam insert with the
notch on the OD of the cam at the
top and the arrow on the OD of the
cam pointing downward.
5. Insert the rotor in the cam with
the double step in the ID of the rotor
facing upward.
6. With the rotor extended upward
approximately one half way out of the
cam, insert a spring into a rotor
spring pocket working in the rotor
FIG. 10—Rotor Shaft Seal Installation cavity directly beneath the cam notch.
7. Use one of the slippers to com- 10. Insert the loose fitting dowel stack of parts must be fully seated. If
press the spring and install the slipper through the cam insert and lower the pump valve has been installed cor-
with the groove in the slipper facing plate into the hole in the housing plate rectly, the relief valve stem will be in
upward (toward the cam notch). The assembly. When the loose dowel is line with the lube return hole in the
flats on the side of the slipper should properly installed the heights of the pump housing plate (Fig. 16).
be on the left (Fig. 12). two dowels must be equal. Squirt the
rotor, springs, slippers and cam insert
with C1AZ-19582-A lubricant. O-RING SEAL
FLATS ON LEFT
11. Place the upper pressure plate
with the face having the tapered notch
down against the cam insert. The
fixed dowel should pass through the
round dowel hole and the loose dowel
through the elongated hole. The slot
between the ears on the pressure plate
OD should match the notch on the
cam insert OD (Fig. 14).
EARS
EARS
G1605-A
DOUBLE STEP
G1350-A
FIG. 16 —Valve and Pressure
FIG. 72—Correct Slipper Spring Installation
Installation
'G 1352-A
Tool 169P-3B586-A
8. Hold the cam stationary and

turn the rotor either to the right or FIG. 74—Upper Pressure Plate
left, one space at a time. Repeat Step Installation
7 until all the rotor cavities have been
filled. Be careful when turning the
rotor that the springs and slippers al- \ EARS
ready inserted do not fall out.
9. Install the cam and rotor assem-
bly onto the pump housing plate with
the fixed dowel passing through the
first hole to the left of the cam notch
when the arrow on the cam OD is
pointing toward the lower pressure
plate (Fig. 13). If the cam and rotor
assembly will not seat, turn the rotor
shaft slightly until the spline teeth
G1353-B G1606-B
mesh, allowing the cam and rotor to
drop down into position. FIG. 17—Pump Housing
Installation
FIG. 75—Retainer End Plate
Installation
FIXED DOWEL D 0 |JBLE STEP
12. Install the retainer end plate so

the slot on the end plate OD matches
the corresponding notches of the
upper pressure plate and cam (Fig
15).
13. Install the pump valve assembly
O-ring seal onto the pump valve as-
sembly being careful not to twist the
seal (Fig. 16).
14. Place the pump valve assembly
ARROW POINTING DOWN G 1351-A on top of the retainer end plate with
the large exhaust slot on the pump
FIG. 13—Cam and Rotor valve in line with the OD notches of FIG. 18 -Checking Pump
Installation the previously assembled parts. The Rotational Torque
15. Place small amounts of vaseline sure plate springs must not be jarred fallen out of their seats and must be
on the pump housing plate to hold the and moved out of position. Remove reinstalled.
cover gasket in place. Install the gas- the guide studs. 26. Install the reservoir O-ring on
ket on the pump housing plate. 21. Install the housing retaining the housing plate being careful not to
16. Insert the pressure plate springs bolts finger tight. twist the O-ring. Apply vaseline to the
into the pockets in the pump valve as- seal and to the ID of the reservoir
22. Remove Tool T69P-3B586-A.
sembly. Vaseline may be placed in the flange.
spring pockets to hold the springs in 23. Torque the retaining bolts even- 27. Install the reservoir, aligning
position (Fig. 17). ly to 28-32 ft-lbs until the housing the notch in the reservoir flange with
17. Using Tool T69P-3B586-A, flange contacts the gasket. the notch in the OD of the pump
plug the intake hole in the housing 24. I n s t a l l a 3 / 8 x 1 6 hex head housing plate and bushing assembly.
(Fig. 17). screw, finger tight, into the end of the Using only a plastic or rubber ham-
18. Lubricate the inside of the rotor shaft. Using a torque wrench, mer, tap at the rear on the outer cor-
housing and the housing cover seal check the input torque of the shaft ners of the reservoir to avoid damage.
with C1AZ-19582-A lubricant. Fabri- (Fig. 18). The torque should not ex- 28. Inspect the assembly to deter-
cate two studs (3/8-16x1.55 ) to be ceed 15 in-lbs. If it does, loosen the mine if the reservoir is seated on the
used as positioning guides. Install one retaining bolts slightly, rotate the housing plate.
in the housing plate bolt hole closest rotor shaft, retorque the bolts evenly 29. Install the service identification
to the drain hole and one in the bolt and again check the shaft torque. The tag on the outlet valve fitting.
hole diametrically opposite. pump must not be used if the shaft 30. Install the outlet valve fitting
19. Align the small diameter lube torque exceeds 15 in-lbs. nut and torque to 43-47 ft-lbs.
hole in the housing rim with the lube 25. Release the pin in the bench 31. Invert the pump assembly.
hole in the housing plate. holding fixture and agitate the pump 32. If the pulley was removed, in-
20. Install the housing, applying an assembly back and forth. If there is a stall the correct pulley using Tool
even, downward pressure. The pres- rattle, the pressure plate springs have T65P-3A733-A.
03-11-01 Eaton Power Steering Pump 03-11-01
PART 3-11 Eaton Power Steering Pump

MODEL APPLICATION
"o
COMPONENT INDEX
3
§>
4
POWER STEERING PUMP
Cleaning and Inspection (See Part 03-01)
Description N/A N/A N/A N/A N/A N/A N/A N/A 11-01 N/A 11-01
Disassembly and Overhaul N/A N/A N/A N/A N/A N/A N/A N/A 11-03 N/A 11-03
Removal and Installation N/A N/A N/A N/A N/A N/A N/A N/A 11-01 N/A 11-01
POWER STEERING PUMP RESERVOIR
Removal and Installation N/A N/A N/A N/A N/A N/A N/A N/A 11-01 N/A 11-01
l DESCRIPTION
The roller-type hydraulic pump, is also provided by the same fluid sures within the steering system ac-
driven by the crankshaft, draws auto- from the reservoir. Within the pump cording to the varying conditions of
matic transmission fluid down the res- itself is a flow-control and pressure- operation. After fluid has passed from
ervoir and provides fluid pressure for relief valve which governs the pres- the gear, it returns to the reservoir.
the system. Steering gear lubrication
POWER STEERING PUMP 8. R e m o v e the pump-to-engine 6. If the vehicle is equipped with air
front cover cap screws, and remove conditioning, install the compressor
the pump. Remove the seal from the drive belt. Adjust the belt tension, and
REMOVAL front cover. tighten the adjusting and support
bracket bolts.
1. Open the hood, and install fend- INSTALLATION 7. Run the engine at idle speed,
er covers. and check the fluid level in the reser-
2. If the vehicle is equipped with air 1. Install a new seal on the engine voir. If required, add the specified au-
conditioning, loosen the compressor front cover. tomatic transmission fluid. Turn on
adjusting and support bracket bolts 2. Align the slot in the pump rotor the windshield wipers. Rotate the
and remove the drive belt. shaft with the drive key in the crank- steering wheel from stop to stop sever-
3. Loosen the generator adjusting shaft, and slide the pump onto the al times to bleed the air from the sys-
and support bracket bolts, and remove shaft. Install the pump-to-engine front tem. Recheck the fluid level.
the drive belts. cover cap screws. Torque the cap
4. Remove the fan, pulley, and spa- screws to specification.
POWER STEERING PUMP
cer. 3. Connect the pump inlet line and
5. Raise the vehicle. the pressure line. RESERVOIR
6. Remove the crankshaft damper 4. Install the damper drive key,
bolt and washer. Remove the damper damper, washer and bolt. Torque the WITHOUT AIR
with Tool 6306-AG. Remove the drive bolt to specification. CONDITIONING
key. 5. Install the fan, pulley, and spa-
7. Disconnect the pump inlet line at cer. Install the generator drive belts.
the pump, and plug the end of the line Adjust the belt tension, and tighten Removal
to prevent the loss of fluid. Disconnect the adjusting and support bracket
the pump pressure line at the pump. bolts. 1. Remove the reservoir cover and
gasket. Withdraw the fluid with a suc- WITH AIR CONDITIONING cover by manipulating them through
tion gun. the opening between the radiator and
2. Remove the reservoir bracket- Removal the compressor drive belt.
to-cylinder block upper cap screw and
the lower cap screw and spacer. Installation
3. Disconnect the reservoir infet line 1. Raise the front of the vehicle.
and the outlet line at the reservoir, Remove the reservoir-to-pump line
and remove the reservoir. (outlet line) clamp at the reservoir, 1. Position the reservoir in the en-
but do not disconnect the line at this gine compartment. Loosely attach the
time. reservoir and bracket to the cylinder
Installation 2. Disconnect the reservoir inlet line block with the upper cap screw.
at the reservoir. 2. Install the fan shroud, then raise
1. Connect the reservoir-to-pump 3. Remove the reservoir bracket to the front of the vehicle.
line (outlet line) at the reservoir, but the cylinder block upper cap screw. 3. Connect the reservoir-to-pump
do not tighten the clamp. Support the reservoir and remove the line (outlet line) at the reservoir.
2. Attach the reservoir and bracket lower cap screw and spacer. 4. I n s t a l l the reservoir bracket-
to the cylinder block with the upper 4. With a drain pan under the res- to-cylinder block lower cap screw and
cap screw and the lower cap screw ervoir, disconnect the outlet line hose spacer. Tighten both the upper and
and spacer. Tighten the cap screws. from the reservoir tube and allow the the lower cap screws.
3. Tighten the outlet line clamp at fluid to drain. 5. Connect the reservoir inlet line at
the reservoir. Connect the reservoir 5. Remove the reservoir cover re- the reservoir. Install the clamps on
inlet line to the reservoir. taining nut and the cover. Position the both lines. Lower the car, and install
4. Fill the reservoir with the speci- cover and the reservoir out of the way the reservoir cover and attaching nut.
fied automatic transmission fluid. Run and allow them to rest in the engine 6. Fill the reservoir with the speci-
the engine, and bleed the system by compartment. fied automatic transmission fluid. Run
cycling the steering gear with the 6. Lower the front of the vehicle. the engine, and bleed the system by
windshield wipers turned on. Check Remove the fan shroud. cycling the steering gear with the
for leaks, and recheck the fluid level. 7. Remove the reservoir and the windshield wipers turned on. Check
for leaks, and recheck the fluid level.
3 MAJOR REPAIR OPERATIONS
PLUG
O RING
INSULATOR (2) VALVE ASSEMBLY
WASHER (2) VALVE SPRING
MOUNTING BOLT (2) INSULATOR
COVER HOUSING
DOWEL PIN (2)
BOLT (7)
ROTOR
ROTOR SHAFT
, PUMP
i HOUSING
SEAL
ROLL
C A M RING PIN
PRESSURE PLATE
INSULATOR
TUBE SEAT
O RING
RETAINER RING
COVER SEAL
SCREW (2)
G12O8-B
FIG. 1 — Power Steering Pump

POWER STEERING PUMP b. Start the seal (metal shell up- cover as shown in Fig. 4 to prevent
ward) square!y into the bore with fin- damage to the seal.
DISASSEMBLY ger pressure. Place the adapter on the 4. Install the dowel pins in the
driver with the square corner of the cover. Place the rotor drive key in the
A clean working area should be shaft. Install the rotor on the shaft
used when overhauling the power with the drive key groove aligned with
steering pump. Foreign matter picked the key and the counterbored side of
up on working parts may cause dam- the rotor toward the cover so that it
age or failure of the unit. Clean con- goes over the snap ring.
tainers should be used for parts. 5. Place the cam ring on the dowel
1. Drain the fluid from the pump. pins with the chamfered edge upward
Remove the pump cover-to-housing (Fig. 5). Place the rollers in the rotor.
cap screws (Fig. 1). Place the pump 6. Place the pressure plate on the
on the bench, cover side down. Lift dowel pins. Install and tighten the
the housing from the cover. screws to 20 in-lbs torque. Install the
2. Remove the large and the small O-ring on the pressure plate hub. In-
O-rings from the pump cover. Remove stall O-rings in the groove at the fluid
the O-ring from the pressure plate bypass hole and around the cam ring
hub. (Fig. 6).
3 . R e m o v e the pressure plate- 7. Place the tool shown in Fig. 6 in
to-cover screws, and remove the plate. the rotor shaft to prevent damage to
Lift the cam ring off the dowel pins. the oil seal, then install the housing on
4. Remove the rollers. Lift the the cover. Install and torque the cap
rotor off the shaft, and remove the screws to 15-20 ft-lbs.
drive key from the shaft. Remove the FIG. 2—Preparation for Installing
dowel pins from the cover. Rotor Shaft Seals
5. Remove the rotor shaft from the
cover. Do not remove the snap ring adapter toward the seal (Fig. 2). Drive
from the shaft unless it, or the shaft, the seal into the cover, as shown in
is damaged. Fig. 3, until it bottoms.
6. Pry the rotor shaft seals out of Driving the seal beyond this point
the cover and the housing. can damage it. Install the seal in the
7. Do not disturb the control valve pump housing in the same manner.
unless diagnosis indicated a control 3. Install the rotor shaft in the
valve problem or foreign matter in the
valve. To remove the valve, drive the
roll pin out of the housing. Remove
the plug and O-ring, control valve,
and the spring. If the plug or valve is
stuck, tap the end of the housing on a
piece of wood or tap it with a soft-
faced hammer. Remove the O-ring
from the plug.
ASSEMBLY
FIG. 5—Cam Ring Installation
Apply automatic transmission fluid
to all parts as they are assembled. Al-
ways use new seals and O-rings.
1. Install the control valve spring in
the housing. Install the valve with the
small sensing hole in the end of the
valve toward the spring. Install a new
O-ring on the plug. The plug O-ring is
1/8 inch smaller in diameter than the
bypass O-ring. Make sure the proper FIG. 3—Installing Rotor
O-ring is used. Install the plug and a Shaft Seals
new roll pin (Fig. 1).
2. The rotor shaft oil seals are in-
stalled in the cover and the housing
with Tool 3583-J, which consists of a
driver and an adapter. The procedure
is as follows:
a. Support the cover on wood
blocks (Fig. 2) to provide tool clear-
ance. Use clean blocks that will not
nick or damage the inner face of the FIG. 4—Installing Rotor Shaft
cover. in Cover FIG. 6—O-Ring Installation
03-12-01 Wheels And Tires 03-12-01
PART 3-12 Wheels And Tires

MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
FRONT HUB AND DRUM ASSEMBLY
FRONT HUB AND ROTOR ASSEMBLY
FRONT WHEEL ASSEMBLY DESCRIPTION 12-01
FRONT WHEEL BEARING ADJUSTMENT 12-02
FRONT WHEEL GREASE SEAL AND
BEARING
Removal, Installation, Repacking 12-05
HOISTING INSTRUCTIONS 12-02
LIFE GUARD TIRE
Balancing N/A N/A N/A N/A N/A N/A N/A N/A 12-03 12-03 12-03
Correcting Vibration and Shake N/A N/A N/A N/A N/A N/A N/A N/A 12-03 12-03 12-03
Description N/A N/A N/A N/A N/A N/A N/A N/A 12-02 12-02 12-02
Repairs N/A N/A N/A N/A N/A N/A N/A N/A 12-08 12-08 12-08
REAR WHEEL ASSEMBLY DESCRIPTION 12-01
WHEELS AND TIRES (Conventional)
DESCRIPTION
FRONT WHEEL ASSEMBLY entire assembly is retained to the rear plate which is bolted to the housing
axle housing by the bearing retainer flange.
Each front wheel and tire is bolted
to its respective front hub and brake
drum or rotor assembly. Two opposed
tapered roller bearings are installed in
each hub. A grease retainer is in- HUB AND BRAKE
stalled at the inner end of the hub to DRUM ASSEMBLY
prevent lubricant from leaking into
the drum or on the rotor. The entire ADJUSTING OUTER
assembly is retained to its spindle by NUT BEARING
CUP
the adjusting nut, nut lock and cotter OUTER
pin (Figs. 1 and 2). BEARING
CONE AND
ROLLER
GREASE
REAR WHEEL ASSEMBLY CAP
INNER BEARING
CONE AND
The rear wheel hub and brake drum ROLLER
assembly is attached to studs on the
rear axle shaft flange by three speed
nuts. The wheel and tire mounts on WHEEL
the same rear axle shaft flange studs NUT ASSEMBLY
and is held against the hub and drum
by the wheel nuts. The rear wheel HUB BOLT' ^£=3^ F1422-A
bearing is pressed onto the axle shaft
just inside the shaft flange, and the FIG. 1 — Front Hub, Bearing and Grease Retainer Drum Brakes
LIFE GUARD TIRE provides a tire within a tire with two allow driving at speeds up to 40 mph
separate air chambers (Fig. 3). If the with good control up to a distance of
The Goodyear Power Cushion Tire outer tire casing should be punctured 40 miles. A Safety-Signal built into
(available on Thunderbird, Lincoln or otherwise damaged causing it to go the Life Guard tread produces a lope
and Continental Mark III models) fit- flat, the Life Guard Safety Spare will or vibration indicating the outer tire
ted with the Life Guard Safety Spare carry the load of the vehicle and will has lost pressure.
HUB AND ROTOR INNER GREASE

ASSEMBLY BEARING RETAINER
CUP
ADJUSTING
NUT
OUTER
BEARING
CONE AND
ROLLER
INNER BEARING
CONE AND
ROLLER
WHEEL
ASSEMBLY
F1416-A F- 1380 • A
FIG. 2—Front Hub and Rotor Bearing and Grease FIG. 3—Life Guard Safety
Retainer Disc Brakes—Typical Tire—Sectional View
HOISTING INSTRUCTIONS 2. Pry off the hub cap or wheel back off the adjusting nut one half
cover and remove the grease cap (Fig. turn. Retighten the adjusting nut to
Damage to steering linkage compo- 1) from the hu6. 10-15 in-lbs with a torque wrench or
nents and front suspension struts may 3. Wipe the excess grease from the finger tight.
occur if care is not exercised when po- end of the spindle, and remove the 7. Position the lock on the adjust-
sitioning the hoist adapters of 2 post cotter pin and nut lock. ing nut and install a new cotter pin.
hoists prior to lifting the vehicle. 4. While rotating the wheel, hub, Bend the ends of the cotter pin around
If a 2 post hoist is used to lift the and drum assembly, torque the adjust- the castellated flange of the nut lock.
vehicle, place the adapters under the ing nut to 17-25 ft-lbs to seat the 8. Check the front wheel rotation.
lower arms or the No. 1 crossmember. bearings (Fig. 4). If the wheel rotates properly, install
Do not allow the adapters to contact 5. Locate the nut lock on the ad- the grease cap and the hub cap or
steering linkage. If the adapters are justing nut so that the castellations on wheel cover. If the wheel still rotates
placed under the crossmember, a piece the lock are aligned with the cotter roughly or noisily, clean, inspect or
of wood (2x4x16 inches) should be pin hole in the spindle. replace the bearings and cups as re-
placed on the hoist channel between 6. Using a 1 1/8-inch box wrench, quired.
the adapters. This will prevent the
adapters from damaging the front sus-
pension struts.
FRONT WHEEL BEARING

ADJUSTMENT
The front wheel bearings should be
adjusted if the wheel is loose on the
spindle or if the wheel does not rotate
freely. The following procedures will
bring the bearing adjustment to speci-
fication. WITH WHEEL ROTATING BACK ADJUSTING TIGHTEN ADJUSTING INSTALL THE LOCK
TORQUE ADJUSTING NUT NUT OFF 1/2 TURN NUT TO 10-15 IN.-LBS. AND A NEW COTTER PIN
TO 17-25 FT. LBS.
DRUM BRAKES
F1417-A
1. Raise the vehicle until the wheel
and tire clear the floor. FIG. 4— Front Wheel Bearing Adjustment
DISC BRAKES pump the brake pedal several times to 4. Rotate tire casing 90 degrees on
obtain normal brake lining to rotor the wheel rim.
1. Raise the vehicle until the wheel clearance and restore normal brake 5. Rotate the tire casing back and
and tire clear the floor. pedal travel. forth on the rim to center the valve.
2. Pry off the wheel cover and re- 6. Inflate both chambers of the tire
move the grease cap (Fig. 2) from the BALANCING LIFE following steps 13 through 15 of the
hub. GUARD TIRE Tire Installation procedure.
3. Wipe the excess grease from the 7. Balance the tire in the normal
end of the spindle, and remove the ad- manner.
Tires fitted with the Life Guard
justing nut cotter pin and nut lock. Safety Spare are balanced in the same
4. Loosen the bearing adjusting nut manner as conventional tires. If an ex- CORRECTING VIBRATION
three turns. Then, rock the wheel, cessive out of balance condition exists AND SHAKE-
hub, and rotor assembly in and out the following procedure can be used to
several times to push the shoe and lin- LIFE GUARD TIRE
correct the condition:
ings away from the rotor.
1. Remove the core housing and de-
5. While rotating the wheel, hub, flate both air chambers. The condition of excessive vibration
and rotor assembly, torque the adjust- 2. Install the core housing. and shake is generally the result of an
ing nut to 17-25 ft-lbs to seat the 3. Unseat the beads of tire with the incorrect pressure relationship between
bearings (Fig. 4). bead breakers away from the valve the inner and outer air chambers that
6. Back the adjusting nut off one stem as shown in Fig. 5. may cause the life guard to shift posi-
half turn. Then, retighten the adjust- tion within the tire. The following
ing nut to 10-15 in-lbs with a torque procedure should be used to correct
wrench or finger tight. vibration and shake conditions:
7. Locate the nut lock on the ad- 1. Check pressure of the inner and
justing nut so that the castellations on outer air chambers on all four tires.
the lock are aligned with the cotter 2. If the inner chamber has at least
pin hole in the spindle. five psi more pressure than the outer
8. Install a new cotter pin, and chamber the pressures should be ad-
bend the ends of the cotter pin around justed and the tires rebalanced if nec-
the castellated flange of the nut lock. essary.
9. Check the front wheel rotation. 3. If the pressures of the inner and
If the wheel rotates properly, install outer air chambers are equal the Air
the grease cap and the hub cap or Container is leaking. To repair the
wheel cover. If the wheel still rotates F 1383
leaking air container the recommend-
roughly or noisily, clean or replace the ed procedures for the removal, repair
bearings and cups as required. FIG. 5—Breaking Top Bead of of air container, mounting, and bal-
10. Before driving the vehicle, Tire From Wheel Rim ancing should be followed.

HOISTING INSTRUCTIONS REMOVING CONVENTIONAL
TIRE FROM WHEEL
Damage to steering linkage compo- wheel cover. Loosen but do not re-
nents and front suspension struts may move the wheel hub nuts. The tire can be demounted on a
occur if care is not exercised when po- 2. Raise the vehicle until the mounting machine. Be sure that the
sitioning the hoist adapters of 2 post wheel and tire clear the floor. outer side of the wheel is positioned
hoists prior to lifting the vehicle. 3. Remove the wheel hub nuts downward. If tire irons are used, fol-
If a 2 post hoist is used to lift the from the bolts, and pull the wheel low the procedure given here.
vehicle, place the adapters under the and tire from hub and drum. 1. Remove the valve cap and core,
lower arms or the No. 1 crossmember. and deflate the tire completely.
Do not allow the adapters to contact 2. With a bead loosening tool,
the steering linkage. If the adapters break loose the tire side walls from
are placed under the crossmember, a the wheel (Fig. 6).
piece of wood (2x4x16 inches) should
3. Position the outer side of the
be placed on the hoist channel be-
tween the adapters. This will prevent wheel downward, and insert two tire
the adapters from damaging the front irons about eight inches apart between
suspension struts. the tire inner bead and the back side
of the wheel rim. Use only tire irons
WHEELS AND TIRES with rounded edges or irons designed
for removing tubeless tires.
WHEEL AND TIRE 4. Leave one tire iron in position,
REMOVAL and pry the rest of the bead over the
F1424- A
rim with the other iron. Take small
1. Pry off the wheel hub cap or FIG. 6—Bead Loosening Tool bites with the iron around the tire in
order to avoid damaging the sealing

surface of the tire bead. RUBBER VALVE HOUSING
5. Stand the wheel and tire upright
with the tire outer bead in the drop
center well at the bottom of the wheel. AIR CONTAINER
Insert the tire iron between the bead VALVE STEM
and the edge of the wheel rim, and
pry the wheel out of the tire.
MOUNTING CONVENTIONAL
TIRE TO WHEEL
Ilk- VALVE GROOVES
1. If a used tire is being installed F 1382 . A

remove all dirt from the tire.
If a tire is being mounted to the FIG. 8—Core Housing Disassembled
original wheel, clean the rim with
emery cloth or fine steel wool. Check REMOVING LIFE GUARD
the rim for dents. TIRE FROM WHEEL
If a new wheel is being installed,
coat a new valve with RUGLYDE or 1. Mark the valve stem location on
similar rubber lubricant and position the tire sidewall.
the valve to the new wheel. Use a rub- 2. Remove the core housing (Fig. 8)
ber hammer or a valve replacing tool and deflate both air chambers.
to seat the valve firmly against the in- 3. Unseat the beads of the tire with
side of the rim. the bead breakers working away from
2. Apply RUGLYDE or a similar the valve stem (Fig. 5).
rubber lubricant to the sealing surface 4. Starting at the valve stem, work
on both tire beads. With the outer the top bead of the tire over the rim
side of the wheel down, pry the beads of the wheel. 1385- A
over the wheel rim with two tire irons. 5. Pull the air container valve stem
Do not use a hammer or mallet to out of the rubber valve housing (Fig. FIG. 70—Folding Life Guard
force the beads over the rim. 9). For Installation In Tire
3. Align the balance mark on the
tire with the valve on the wheel. 3. Insert life guard into tire casing.
4. Hold the beads against the rim 4. Install a new rubber valve hous-
flanges by positioning a tire mounting ing on the air container valve stem
band over the tire (Fig. 7). If a and thread the core housing into
mounting band is not available, tie a place. It is not necessary to install a
tourniquet of heavy cord around the new core housing.
circumference and in the center of the 5. Insert air container into the life
tire. Tighten the cord with a tire iron. guard with the valve grooves to the
Center the tire on the wheel with a outboard side of the tire. Place the
rubber mallet. valve at the valve stem location
marked on the sidewall during remov-
al as shown in Fig. 11.
F 1384- A
FIG. 9—Removing Air Container

Valve Stem
6. Remove the air container before

F1425- A attempting to remove the tire from the
FIG. 7—Tubeless Tire wheel.
Mounting Band 7. Lift the lower bead over the
wheel rim to remove the tire.
5. Give the tire a few quick bursts 8. Remove the rubber valve housing
of air to seat the beads properly, then from the wheel rim.
inflate the tire to 40 psi pressure. F 1386 • A
Check to see that the bead positioning INSTALLING LIFE GUARD
rings (outer rings near the side walls) TIRE ON WHEEL
FIG. 7 7—Aligning Valve With
are evenly visible just above the rim 1. A p p l y S i l i c o n e L u b r i c a n t Reference Mark on Tire
flanges all the way around the tire. If (COAZ-19553-A) as the anti-friction
the rings are not even, deflate the tire treatment uniformly over the crown 6. Apply a soap solution to the
completely and inflate it again. and shoulder area inside the tire or beads and the rubber valve housing.
6. When the rings are properly po- outside the life guard. 7. Place the wheel on the mounting
sitioned, deflate the tire to the recom- 2. Fold the life guard as shown in machine with the valve hole away
mended pressure. Fig. 10. from bead breakers. Remove all burrs
and sharp edges from valve hole in 15. Inflate the inner chamber to 16. Remove t h e I n f l a t e - C h e k
rim. seat the tire beads exercising care not adapter and adjust tire (outer cham-
8. Mount first tire bead exercising to exceed 45 psi pressure. Adjust this ber) pressure to the recommended
care not to pinch air container. inner chamber air pressure to 15 psi pressure.
9. Start valve through hole in rim. higher than the recommended tire 17. Recheck inner chamber pres-
Do not pull valve housing into place pressure. sure.
at this time. 18. Install valve cap.
10. Mount the second bead starting
just past the valve so the last portion WHEEL AND TIRE
of the bead goes over the rim at the INSTALLATION
valve.
11. Rotate the tire back and forth 1. Clean all dirt from the hub and
to center the valve housing. drum.
12. Pull the valve housing into 2. Position the wheel and tire on
place. Make certain that the rubber the hub and drum. Install the wheel
valve ridge is visible around thi valve hub nuts and tighten them alternately
housing (Fig. 12). to draw the wheel evenly against the
13. Tighten the core housing lightly hub and drum.
using pliers. 3. Lower the vehicle to the floor,
F 1387 - A
14. Thread the Inflate-Chek adapt- and torque the hub nuts to specifica-
er onto the core housing. FIG. 12—Valve Installation tion.
HOISTING INSTRUCTIONS cap. Remove the grease cap from the cone and roller assembly from the hub
hub. Remove the cotter pin, nut lock, with Tool 1175AE.
Damage to steering linkage compo- adjusting nut, and flat washer from 5. Clean the lubricant off the inner
nents and front suspension struts may the spindjej, Remove the outer bearing and outer bearing cups with solvent
occur if care is not exercised when po- cone and roller assembly (Fig. 1). and inspect the cups for scratches,
sitioning the hoist adapters of 2 post 3. Pull the wheel, hub, and drum pits, excessive wear, and other dam-
hoists prior to lifting the vehicle. assembly off the wheel spindle. age. If the cups are worn or damaged,
If a 2 post hoist is used to lift the 4. Remove and discard the grease remove them with Tool T69L-1102-A
vehicle, place the adapters under the retainer. Remove the inner bearing (Fig. 13).
lower arms or the No. 1 crossmember. 6. Thoroughly clean the inner and
Do not allow the adapters to contact Too/-T69L-J102-A
outer bearing cone and roller assem-
the steering linkage. If the adapters blies with solvent and dry them thor-
are placed under the crossmember, a oughly. Do not spin the bearings with
piece of wood (2x4x16 inches) should compressed air.
be placed on the hoist channel be- Inspect the cone and roller assem-
tween the adapters. This will prevent blies for wear or damage, and replace
the adapters from damaging the front them if necessary. The cone and roller
suspension struts. assemblies and the bearing cups
should be replaced as a unit if damage
to either is encountered.
FRONT WHEEL GREASE 7. Thoroughly clean the spindle and
SEAL AND BEARING the inside of the hub with solvent to
REPLACEMENT AND/OR remove all old lubricant.
REPACKING Cover the spindle with a clean
cloth, and brush all loose dust and
If bearing adjustment will not elimi- dirt from the brake assembly. To pre-
nate looseness or rough and noisy op- vent getting dirt on the spindle, care-
eration, the hub and bearings should fully remove the cloth from the
be cleaned, inspected, and repacked spindle.
with specified wheel grease. If the 8. If the inner and/or outer bearing
bearing cups or the cone and roller cup(s) were removed, install the re-
assemblies are worn or damaged, they placement cup(s) in the hub with the
should be replaced. tool shown in Fig. 14. Be sure to seat
F1476-A the cups properly in the hub.
DRUM BRAKES 9. Pack the inside of the hub with
specified wheel bearing grease. Add
FIG. 13—Removing Front Wheel lubricant to the hub only until the
1. Raise the vehicle until the wheel
and tire clear the floor. Bearing Cup—Except Lincoln grease is flush with the inside diame-
2. Remove the wheel cover or hub Continental ter of both bearing cups (Fig. 15).
Tool-T56P-1217-A Be sure that the retainer is properly 8. Clean the lubricant off the inner
seated. and outer bearing cups with solvent
12. Adjust the brake shoes as out- and inspect the cups for scratches,
lined in Group 2. pits, excessive wear, and other dam-
13. Install the wheel, hub, and age. If the cups are worn or damaged,
drum assembly on the wheel spindle. remove them with Tool T69L-1102-A
Keep the hub centered on the spindle (Fig. 13).
to prevent damage to the grease re- On Lincoln Continental models, re-
tainer or the spindle threads. move worn or damaged cups with the
INNER CUP OUTER CUP
14. Install the outer bearing cone tools shown in Fig. 16.
INSTALLATION INSTALLATION and roller assembly and the flat wash- 9. Thoroughly clean the inner and
er on the spindle, then install the ad- outer bearing cones and rollers with
F1464-A justing nut (Fig. 1). computer solvent, and dry them
15. Adjust the wheel bearings as thoroughly. Do not spin the bearings
FIG. ^.Installing Front Wheel
outlined in Section 2, and install a dry with compressed air.
Drum Bearing Cups new cotter pin. Bend the ends of the
Inspect the cones and rollers for
cotter pin around the castellations of
wear or damage, and replace them if
the nut lock to prevent interference
necessary. The cone and roller assem-
with the radio static collector in the
blies and the bearing cups should be
grease cap. Install the grease cap.
replaced as a set if damage to either is
16. Install the hub cap or wheel
encountered.
cover.
LUBR 10. Thoroughly clean the spindle
DISC BRAKES and the inside of the hub with solvent
to remove all old lubricant.
1. Raise the vehicle until the wheel Cover the spindle with a clean
and tire clear the floor. cloth, and brush all loose dust and
2. Remove the wheel cover or hub dirt from the dust shield. To prevent
cap from the wheel. getting dirt on the spindle carefully re-
3. Remove the wheel and tire from move the cloth from the spindle.
the hub and rotor. 11. If the inner and/or outer bear-
4. Remove 2 bolts and washers that ing cup(s) were removed, install the
attach the caliper to the spindle. Re- replacement cup(s) in the hub with the
move the caliper from the rotor and tools shown in Fig. 17. Be sure to seat
wire it to the underbody to prevent the cups properly in the hub.
damage to the brake hose. 12. Pack the inside of the hub with
5. Remove the grease cap from the the specified wheel bearing grease.
hub. Remove the cotter pin, nut lock, Add lubricant to the hub only until
adjusting nut, and flat washer from the grease is flush with the inside di-
the spindle. Remove the outer bearing ameter of both bearing cups.
cone and roller assembly (Fig. 2). It is important that all old grease
6. Pull the hub and rotor assembly be removed from the wheel bearings
F1427. A
off the wheel spindle. and surrounding surfaces because the
FIG. 75—Front Wheel Hub 7. Remove and discard the old new Lithium base grease C1AZ-
Lubrication grease retainer and the inner bearing 19590-B is not compatible with Sodi-
cone and roller assembly from the um base grease which may already be
hub. present on the bearing surfaces.
10. All old grease should be com-
pletely cleaned from the bearings and
surrounding surfaces before repacking
t h e m w i t h new g r e a s e ( C 1 A Z -
19590-B). The new lithium base grease
is not compatible with sodium base
grease which may have been present
on the bearing surfaces. Pack the
bearing cone and roller assemblies
with wheel bearing grease. A bearing
packer is desirable for this operation.
If a packer is not available, work as
much lubricant as possible between
the rollers and cages. Lubricate the
cone surfaces with grease.
11. Place the inner bearing cone
and roller assembly in the inner cup,
Apply a light film of grease to the
lip(s) of the grease retainer and install
F 1502-A
the new grease retainer with the rev-
erse end of the tool shown in Fig. 6. FIG. 16—Removing Front Wheel Bearing Cup—Lincoln Continental
8. Place the inner bearing cone and

roller assembly in the inner cup, and
install the new grease retainer with the
reverse end of the tool shown in Fig.
6. Be sure that the retainer is properly
seated.
Tool - 7277- K
9. Adjust the brake shoes as out-
lined in Group 2.
10. Install the new hub and drum
assembly on the wheel spindle. Keep
the hub centered on the spindle to pre-
vent damage to the grease retainer.
11. Install the outer bearing cone
and roller assembly and the flat wash-
er on the spindle; then, install the ad-
justing nut (Fig. 1).
12. Position the wheel and tire on
the new hub and drum assembly. In-
F 1263-A
stall the wheel hub nuts and tighten
them alternately in order to draw the
FIG. 17—Installing Front Wheel Bearing Cup wheel evenly against the hub and
drum.
13. Adjust the wheel bearings as
13. Pack the bearing cone and roll- FRONT HUB AND DRUM outlined in Section 2, and install a
er assemblies with wheel bearing new cotter pin. Bend the ends of the
ASSEMBLY REPLACEMENT
grease. A bearing packer is desirable cotter pin around the castellations of
for this operation. If a packer is not the nut lock to prevent interference
available, work as much lubricant as with the radio static collector in the
possible between the rollers and cages. When the hub and drum assembly
is replaced, new bearings and a grease grease cap. Install the grease cap.
Lubricate the cone surfaces with 14. Install the hub cap or wheel
grease. retainer must be installed in the new
assembly. The new grease retainer cover.
14. Place the inner bearing cone should be soaked in light engine oil at
and roller assembly in the inner cup. least 30 minutes before installation.
Apply a light film of grease to the lips 1. Raise the vehicle until the wheel
of the grease retainer and install the FRONT HUB AND ROTOR
and tire clears the floor. Pry off the
new grease retainer with the tool ASSEMBLY REPLACEMENT
hub cap or wheel cover, and remove
shown in Fig. 18. Be sure the retainer
the wheel and tire from the hub and
is properly seated. When the hub and rotor assembly is
drum assembly.
15. Install the hub and rotor as- 2. Remove the grease cap from the replaced, new bearings and a grease
sembly on the wheel spindle. Keep the hub. Remove the cotter pin, nut lock retainer must be installed in the new
hub centered on the spindle to prevent adjusting nut, and flat washer from assembly.
damage to the grease retainer or the the spindle. Remove the outer bearing 1. Raise the vehicle until the wheel
spindle threads. cone and roller assembly (Fig. 1). and tire clear the floor. Pry off the
16. Install the outer bearing cone 3. Pull the hub and drum assembly hub cap or wheel cover, and remove
and roller assembly and the flat wash- off the wheel spindle. the wheel and tire from the hub and
er on the spindle, then install the ad- 4. Remuve the grease retainer and rotor assembly.
justing nut. the inner bearing cone and roller as- 2. Remove 2 bolts and washers that
17. Adjust the wheel bearings as sembly from the hub with Tool attach the caliper to the spindle. Re-
outlined in Section 2, and install a 1175AE. move the caliper from the rotor and
new cotter pin. Bend the ends of the 5. Remove the protective coating wire it to the underbody to prevent
cotter pin around the castellations of from the new hub and drum with car- damage to the brake hose.
the nut lock to prevent interference buretor degreaser.
with the radio static collector in the 6. Pack the inside of the hub with
hub. Remove the cotter pin, nut lock,
grease cap. Install the grease cap. specified wheel bearing grease. Add
lubricant to the hub only until the
18. Install the caliper to the spindle the spindle; then, remove the outer
grease is flush with the inside diame-
and torque the attaching bolts to spe- bearing cone and roller assembly,
ter of both bearing cups (Fig. 15).
cifications as detailed in Group 2. (Fig. 2).
7. All old grease should be com-
19. Install the wheel and tire on the pletely cleaned from the bearings be- 4. Pull the hub and rotor off the
hub. fore repacking them with new grease. spindle.
20. Install the hub cap or wheel Pack the bearing cone and roller 5. Remove the protective coating
cover. assemblies with wheel bearing grease. from the new hub and rotor with car-
2 1 . Before driving the vehicle, A bearing packer is desirable for this buretor degreaser.
pump the brake pedal several times to operation. If a packer is not available, 6. Grease and install the inner
obtain normal brake lining to rotor work as much lubricant as possible bearing cone and roller assembly in
clearance and restore normal brake between the rollers and cages. Lubri- the inner bearing cup. Apply a light
pedal travel. cate the cone surfaces with grease. film of grease on the grease retainer
and install the grease retainer. LIFE GUARD

7. Install the new hub and rotor as-
TIRE REPAIRS
sembly to the wheel spindle. Keep the
hub centered on the spindle to prevent
damage to the grease retainer. REPAIR OF OUTER TIRE
8. Install the outer bearing cone
Tool - 7 775 - AH and roller assembly and the flat wash- Outside Repairs
er on the spindle; then, install the ad-
justing nut. All outside repairs are made in the
9. Install the caliper to the spindle same manner as on conventional tube-
and tighten the attaching bolts to spe- less tires.
cifications as detailed in Group 2. Inside Repairs
10. Position the wheel and tire on
the new hub and rotor. Install the 1. Remove the anti-friction treat-
wheel hub nuts and tighten them alter- ment on the inside of the tire with
nately in order to draw the wheel rubber solvent.
evenly against the hub and rotor. 2. Buff the inside area of the tire.
F1443-A 11. Adjust the wheel bearings as 3. Apply a hot cure patch only.
outlined in Section 2, and install a
FIG. 18 — Installing Grease new cotter pin. Bend the ends of the REPAIR OF AIR
Retainer cotter pin around the castellations of CONTAINER
the nut lock to prevent interference
with the radio static collector in the Air containers are repaired in the
grease cap. Install the grease cap. same manner as conventional inner
12. Install the hub cap or wheel tubes.
cover.
13. Before driving the vehicle, REPAIR OF LIFE GUARD
pump the brake pedal several times to A damaged life guard that may
obtain normal brake lining to rotor pinch the air container should be re-
clearance and restore normal brake place. No repairs are required for
pedal travel. small punctures in the life guard.
FRONT WHEEL ALIGNMENT

Dimension Dimension
Vehicle "C" "D" Alignment
Model Inches Inches Factors Min. Max. Desired
Mustang, Cougar (I) 6.30 ©5.50 (Mustang) Caster© -3/4° +1 1/4° +1/4°
6.35 (Cougar) Camber© +1/4° +1 3/4° +3/4°
Toe-in-Inches 1/16 5/16 3/16
Fairlane, Falcon ® 6.50 ©6.72 Caster© -1 3/4° +1/4° •3/4°
Mont ego Camber© •1/2° +1° +1/4°
Toe-in-Inches 1/8 3/8 3/16
Ford, Mercury ©4.20 ©6.70 Caster© 0° +2° +1°
Meteor Camber© •1/4° +11/4° +1/2°
Toe-in-Inches 1/16 5/16 3/16
Thunderbird, ® 4.20 ©6.70 Caster© 0° +2° +1°
Mark III Camber® •1/4° +1 1/4° +1/2°
Toe-in-Inches 1/16 5/16 3/16
Lincoln ©5.87 ©8.39 Caster® -1/2° -2 1/2° •11/2°
Continental Camber® •1/4° +11/4° +1/2°
Toe-in-Inches 0 1/4 1/8
©Maximum difference between wheels not to exceed 1/2° (setting). Maximum checking difference not to exceed 1° with caster and camber with-
in specifications.
©Maximum difference between wheels not to exceed 1/2°.
©Vertical distance between bottom surface of spring tower on centerline of rebound bumper bolt and point on flat surface of upper suspension
arm midway between ball joint rivets.
©Shortest vertical distance between point on side member and axle housing.
©Distance from corner of lower flange sidemember front to center of bolt head (strut mounting bolt).
©Vertical distance between bottom of sidemember at center of axle bumper bracket and top of axle housing.
©Vertical distance between point on underside of crossmember pocket and point on top of drag strut.
©Distance from axle housing to surface on sidemember immediatly behind axle bumper.
WHEELBASEAND TREAD WIDTH-INCHES FRONT WHEEL TURNING ANGLE

Tread Width Vehicle Model Turning Angle of Outside Wheel
Vehicle Model Wheelbase
Front Rear With Inside Wheel Turned 20°
Mustang 108.0 58.5 58.5 Mustang, Cougar 18.68°

Cougar 111.1 58.5 58.5 Fairlane, Falcon, Montego With Power Steering 17.88°
Fairlane, Montego 116.0 58.8 5«.5 With Manual Steering 18.1°
Falcon (except Station Wagon) 110.9 58.8 58.5 Ford, Mercury, Meteor With Power Steering 19.14°
Falcon Station Wagon 113.0 58.8 58.5 With Manual Steering 18.96°
Ford 121.0 63.0 64.0
Mercury, Meteor 124.0 63.0 64.0 Thunderbird, Mark III 19.26°
Thunderbird (2-Door) 114.7 62.0 62.0 Lincoln Continental 17.71°
Thunderbird (4-Door), Mark HI 117.2 62.0 62.0
Lincoln Continental 126.0 62.4 61.0
BALL JOINTS -RADIAL PLAY STEERING WHEEL TURNING EFFORT

Vehicle Model Description Radial Play-Max. Allowable Vehicle Model Lbs. Effort
Cougar, Fairlane, Lower Ball Joint Replace if perceptibly loose Ford, Mercury, Meteor 5.0
Falcon, Montego, Upper Ball Joint 0.250 Inch Cougar, Fairlane, Falcon,
Mustang Montego, Mustang 6.5
Ford, Mercury, Lower Ball Joint 0.250 Inch Lincoln Continental, Mark I I I ,
Meteor, Thunderbird, Upper Ball Joint Replace if perceptibly loose Thunderbird 3.75
Mark I I I , Lincoln
Continental
POWER STEERING PUMP

SERVICE SPECIFICATIONS
Description Ford-Thompson Eaton
Pump Rotor Shaft End Play .017 in. Max.-.003 in. Min. —
Max. Torque Allowed to
Rotate Rotor Shaft 15 In-Lb. _
Stamped Housing to Plate
Assy. Screw and Washer Assy. 28-32 Ft.-Lb. -
Reservoir to Stamped Housing
Nut 43-47 Ft.-Lb. —
Cam Ring to Pressure Plate
Screw _ 20 In-Lb.
Housing to Cover Screw - 15-20 Ft,-Lb.
FORD-THOMPSON POWER STEERING

PUMP TORQUE LIMITS (FT-LBS)
Ford, Mercury, Cougar, Falcon,
Description Meteor, Fairlane, Montego,
Thunderbird Mustang
Pump Rear Mounting Nut 14-18 20-30
Pressure Hose Nut 20-30 20-30
Pump Attaching Nuts 25-35 30-40
Bracket to Engine Attaching Nuts 6-Cyl. 1216 7-10
302-351 CID 18-25 18-25
390,427,428,429 CID 30-40 30-40
Bracket to Cylinder Head 25-35 25-35
Belt Adjustment Bolt - 25-35
Rear Support Bracket Attaching Nuts 240 CID 45-60 -
Bracket to Engine Adapter 170-200 CID - 25-35
Engine Adapter to Engine 170-200 CID - 17-25
250 CID - 30-40
Engine Adapter to Pump 250 CID - 25-35
INTEGRAL POWER STEERING GEAR SPECIFICATIONS

Description Ford Design Saginaw
(XR-«0) Design
Type Recirculating Ball Torsion Bar
Ratio 17:1 17.5:1
Turns of Steering Wheel (Lock to Lock-Linkage Disconnected) 4 41/8
Fluid Specifications M-2C33-F
Fluid Capacity (Included in Pump Reservoir Fill) 1.6 Pints (Approx.)
Phosphorescent Dye Additive (For Leak Detection) M99B103-A(4 0z. per quart)
Sector Shaft End Play -Linkage Disconnected None .002" Max.
Sector Shaft Mesh Load. Total Over Mechanical Center 14 In Lb (Max) 14 In Lb (Max)
Position. Must beCDGreater Than Worm (Exc. Lincoln)
Bearing Preload Torque, Shown Below 17 In Lb (Max.)
(Lincoln)
Worm Bearing Preload 2-7 la U) 4-7 In Lb®
Clearance Between Valve Spool & Retaining Ring .0035-.0005"
Preferable .002" _
Pressure Variation Between Right & Left Turn (At 250 P.S.I.) - 4 In Lb Max. —
Check Efforts Each Side of Center Variation
Clearance Between Inner Sector Seal and Housing .025" -
©8-9 In Lb (XR-50 Exc. Lincoln) 11-12 In Lb for Uncoln, 4-8 In Lb for Saginaw Gear.
® 3 In Lb in Excess of Valve Assy. Drag Total Worm Bearing Preload and Seal Drag not to Exceed 8 In Lb.
MANUAL AND POWER ASSIST STEERING GEAR SPECIFICATIONS

Ford, Falcon,
Mercury, Mont ego,
Vehicle Meteor Mustang, Cougar Fairlane
Model SM/VD-1 SMB-D SMBK SMB-F® SMA-F SMA-B
Gear Type Manual Manual Power Assist Manual Manual Power
and Manual® Assist
Gear Ratio 24:1 19.9:1 16:1 16:1 22:1 16:1
Turns of Strg. 6-2/5 4-5/8 3-3/4 3-3/4 5-1/2 4
Gr. (Lock to Lock) ®
Lube Type ESW-M1C87-A
Lube Capacity .97 ± .07 .55 ± .05 .55 ± .05 .55 ± .05 .87 ± .07 .87 ± .07
(Lb.)
Worm Bearing 4-5 4-5 3-4® 4-5 4-5 3-4
Preload (In Lb)®
Total Center 9-10 9-10 8-9® 9-10 9-10 8-9
Meshload(lnLb)®
Adjustments Adjusting screw to bottom of sector shaft T slot clearance:
(All Models) .000 -.002
©Production only - for service, use Model SMB-K.
®When used for improved or competition handling, worm bearing preload must be adjusted to 4-5 In Lb and total center meshload must be
adjusted to 9-10 In Lb.
®Gear only - not attached to Pitman arm.
0Torque required to rotate input shaft at approximately 1-1/2 turns either side of center (gear out of vehicle or Pitman arm disconnected).
©Requiredto rotate input shaft and worm assembly past the center high point.
STEERING GEAR TORQUE UMITS(FT-LB)

Manual and Power Assist
Ford, Mercury, Fairlane, Falcon, Mustang Power steering

Description Meteor Montego Cougar Steering
Sector Shaft Cover Bolts 30-40 17-2? 15-22 55-70 30-35
Mesh Load Adjusting Screw Lock Nut 32-40 32-40 32-40 25-35 20-30
18-42 (In-Lb) Pwr.
Ball Return Guide Clamp Screw 18-42 (In-Lb) 42-60 (In-Lb) Man. 18-42 (In-Lb) 60-120 (In-Lb) 3-6
Preload Adjuster Lock Nut 60-80 60-80 45-60 50-110
Valve Housing to Gear Housing Screw 35-45
Race Retaining Inner Nut (D
Race Lock Nut ®
Piston End Cap 50-75 50-100
Set Screw-Rack Adjustment
Lubricant Fill Plug and Vent 3-9® 3-9® 3-9®
® With tool T66P-3553-B • compute the torque as follows:
Length of Torque Wrench X 60 Lb. Ft.
° r q u e " Length of Torque Wrench + 5.5 Inches
Example: With 13 inch torque wrench
13ln. X 60 Lb. Ft. 13 X 60 Lb. Ft. -0.703 X 6 0 - 42 (Lb. Ft.)
13 In. + 5.5 In. 18.5
®With tool T66P-3553-B • compute the torque as follows:
Length of torque wrench X 25 Lb. Ft.
Length of torque wrench + 5.5 Inches
©Minimum of one thread must remain exposed when installed.
STEERING LINKAGE TORQUE LIMITS (FT-LBS)

Cougar, Fairlane, Ford, Continental
Description Falcon, Mont ego, Mercury, Mark III Lincoln
Mustang Meteor Thunder bird Continental
Cylinder Mounting Bracket to (Side Hole) 28-35 - - -
Underbodyor Frame (Bottom Hole) 35-43 - - -
Power Cylinder to Bracket 18-24 - - -
Power Cylinder to Bracket Lock Nut 3-5 - - -
Steering Tie Rod End to Spindle Arm 30-40 © 35-47® 35-47 © 40-55
Idler Arm Mounting Bracket to
Underbody or Frame 28-35 28-35 28-35 20-30
Pitman Arm to Control Valve (Power Steering) 35-47 © - - -
Steering Gear to Side Rail or Frame 50-65 50-65 50-65 50-65
Pitman Arm to Sector Shaft 150-225 150-225 150-225 150-200
Idler Arm to Pitman Arm-to-ldler Arm Rod 60-80® 60-80 ® 60-80 © 40-55
Spindle Connecting Rod Clamp to Adjusting
Sleeve 10-14 8-13 8-13 19-26
Pitman Arm to Steering Arm-to-ldler Arm Rod 35-47 © 35-47 © 35-47 © 40-55
Steering Spindle Arm Connecting Rod to
Arm-to-ldler Arm Rod 30-40 © 35-47 ® 35-47 © 40-55
CD Torque to low limit of specification; then, tighten the nut to the nearest cotter pin slot and insert the cotter pin.
STEERING COLUMN TORQUE LIMITS (FT-LBS)

Ford, Fairlane, Continental
Description Mercury, Falcon, Cougar, Lincoln Mark III
Meteor Mont ego Mustang Continental Thunder bird
Upper 9-20
Column Lower Bracket to Column Upper Bracket Lower 8-12 10-20 8-15 _ _
Intermediate Bracket to Brake Pedal
Support Bracket 9-20 _ _ _ _
Lower Trim Shroud to Upper Trim Shroud 5-10 - - - -
Flex Coupling to Steering Gear 24-37 24-37 24-37 25-35 25-35
Flex Coupling to Steering Shaft Flange 10-18 12-18 10-18 - -
Flex Coupling to Steering Shaft - - - 25-35 25-35
Tee Plate to Instrument Panel 8-13 3-8 5-15 4-9 4-9
Steering Wheel Attaching Nut 30-40 30-40 30-40 20-30 30-40
Brake Pedal Support Bracket to Brake
Pedal Support _ 28-42 13-25 _ 28-42
Column Upper Bracket to Instrument Panel - 10-16 - 10-15 7-12
Column Upper Bracket to Lower Clamp - - - 8-12 7-1?
TORQUE LIMITS-FRONT SUSPENSION

MONTEGO, FALCON, FAIR LANE, MUSTANG AND COUGAR
Description Ft • Lbs
Montego, Falcon, Fairlane Mustang and Cougar
Shock Absorber Upper Attachment 20-28 10-15
Shock Absorber Upper Bracket to Body 15-25 22-34
Front Suspension Compression Bumper to Body 12-17 12-17
Brake Backing Plate to Spindle 9-14 (Disc) 25-45 (Drum) 9-14 (Disc) 28-45 (Drum)
Upper Arm and Inner Shaft to Body 75-100 75-100
Spring Seat to Upper Arm 30-40 25-40
Shock Absorber to Spring Seat 8-12 8-12
Ball Joint to Spindle (Upper and Lower) 60-90 © 60-90 ©
Wheel Bearing Adjusting Nut 17-25 © 17-25 ©
Strut to Lower Arm 75-105 70-105
Lower Arm to Underbody 75-100 75-100
Stabilizer Bar Mounting Bracket to Underbody 17-25 17-25
Strut to Underbody 60-80 60-80
Stabilizer Bar to Lower Arm 5-10 8-12
Caliper to Spindle (Disc Brake) • Upper 110-140 110-120
- Lower 55-75 55-75
Strut to Underbody Slotted Nut 50-70 | 50-70
©Torquethe adjusting nut to 17-25 ft-lb. Locate nut lock on adjusting nut so ,ctstellations are aligned with cotter pin hole in spindle. Then,
backoff adjusting nut and nut lock so the next castellation aligns with the cotter pin hole.
TORQE LIMITS-fRONT SUSPENSION

Description Ft Lbs Description Ft-Lbs
Lower Arm to No. 2 Crossmember 55-75 Brake Backing Plate to Spindle 25-45
Upper Arm to Frame 100-130 Strut to Lower Arm 70-113
Upper Arm Bumper 15-25 Stabilizer Bar to Frame 18-27
Brake Backing Plate and Cylinder Assembly Strut to Frame 60-90 ©
to Spindle 80-106 Shock Absorber Upper Attachment 20-28
Stabilizer Bar to Lower Arm 5-10 Shock Absorber Lower Arm 8 12
Ball Joint to Spindle (Upper and Lower) 60-90® Caliper to Spindle (Disc Brake) 120-130
©Torque to specification, then tighten the nut to the nearest cotter pin slot and insert the cotter pin.

THUNDERBIRD, CONTINENTAL MARK
Description Torque
Ft-Lbs
Lower Arm to #2 Crossmember 60-90
Upper Arm to Frame 100-150
Upper Arm Bumper 15-25
Stabilizer Bar to Lower Arm 5-10
Ball Joint to Spindle (Upper and Lower) ©60-90
Strut to Lower Arm 70-113
Stabilizer Bar to Mounting Bracket 8-12
Strut to Frame ©60-90
Shock Absorber Upper Attachment 20-23
Shock Absorber to Lower Arm 8-12
Brake Splash Shield (Disc) to Spindle 9-14
Caliper to Spindle (Disc Brake)
Upper Bolt 110-140
Lower Bolt 90-120
©Torque to minimum specification; then, tighten the nut to the nearest cotter pin slot and insert the cotter pin.

LINCOLN CONTINENTAL
Description FtLbs
Brace-Front Suspension to Sidemember (Model 74A Only) 90-110
Drag Strut to Strut Bracket Assembly 70-90
Lower Arm Assembly to Front Crossmember - (Attach Bracket) 55-75
Lower Arm Assembly to No. 2 Crossmember 110-140
Drag Strut to Lower Arm Assembly 70-90
Wheel Spindle to Lower Arm Ball Joint 70-90
Front Wheel Spindle to Upper Arm Ball Joint Assembly 55-75
Upper Arm Inner Shaft to Upper Arm 25-35
Upper Arm and Shaft Assembly to No. 2 Crossmember 100-125
Shock Absorber Bracket Assembly to No. 2 Crossmember Bracket 40-55
Shock Absorber Assembly to No. 2 Crossmember Assembly (Top End) 20-30
Shock Absorber Assembly Lower Arm Spring Seat Reinforcement Assembly 20-30
Upper Ball Joint to Control Arm 21-29
Stabilizer Bar Assembly to Underbody 20-30
Stabilizer Bar to Lower Arm 5-10
Jounce Bumper Assembly to Strut (Lower Arm) 22-28
Front Splash Shield to Spindle 9-14
Caliper to Spindle 100-140
TORQUE LIMITS-REAR SUSPENSION

Description FtLbs
Shock Absorber to Frame (Upper Attachment) 20-28
Upper Arm to Axle Bracket (Nut) 90-100
Track Bar to Axle Track Bar Stud 80-105
Track Bar Stud to Axle 100-130
Track Bar to Frame (Bolt Torque) 80-105
Track Bar Stud to Axle Bracket (Nut) 80-105
Wheel Lug Nut 70-115
Brake Backing Plate and Bearing Retainer to Axle-All Cars except those with 240 or 302 CID Engines 50-70
Brake Backing Plate and Bearing Retainer to Axle-All Cars with 240 or 302 CID Engines 20-30
Shock Absorber to Axle (Lower Attachment) 50-35
Bumper Assembly to Frame 9-13
Lower Arm to Axle-Bolt 90-120
Lower Arm to Axle-Nut 70-90
Upper Arm to Frame-BoU 90-120
Upper Arm to Frame-Nut 70-90
Lower Arm to Frame-Bolt 90-120
Lower Arm to Frame-Nut 70-90
Bumper Assembly to No. 4 Crossmember 9-13
Universal Joint U-Bolt Nut 10-15
Air Leveling Compressor to Apron 10-13
Height Control Valve to Bracket 17-25
Height Control Valve Bracket to No. 4 Crossmember 9-13

MONTEGO, FALCON, FAIR LANE, MUSTANG AND COUGAR
Description Mont ego, Falcon, Fair lane Mustang and Cougar
Spring Shackle Bars to Body and Spring 15-22 15-22
Shock Absorber to Upper Mounting Bracket 20-28 20-28
Shock Absorber to Spring Clip Plate 20-28 20-28
Spring to Axle U-Bolt Nut 35-50 35-50
Wheel Lug Nut 5-Lug Wheel 70-115 70-115
Spring to Spring Front Hanger • Bolt 90-120 60-85
Spring to Spring Front Hanger • Nut 40-60 40-60
Universal Joint U-Bolt Nut - S t d . Trans. 6-11 6-11
Universal Joint U-Bolt Nut -Auto. Trans. 10-15 10-15

LINCOLN CONTINENTAL
Description Ft Lbs
Brake Backing Plate Bearing Retainer to Axle 30-55
Spring Center Bolt 15-20
Spring Front Bracket Assembly to Rear Floor Sidemember Assembly 70-90
Spring Front Eye Stud and Washer Assembly to Spring Front Hanger Bracket 76-106
Spring U-Bolt 45-65
Spring Assembly to Spring Shackle Assembly 34-59
Spring Shackle Assembly to Spring Rear Bracket Assembly 34-59
Spring Rear Bracket Assembly to Rear Floor Sidemember Assembly 40-67
Shock Absorber Upper Attaching Bracket to Body Crossmember 20-30
Shock Absorber Assembly to Shock Absorber Upper Attaching Bracket 20-28
Shock Absorber Assembly to Axle 30-45
Axle Bumper Bracket to Underbody 10-15
Pinion Bumper Assembly to Axle Carrier 18-25

THUNDERBIRD, CONTINENTAL.MARK I I I
Description Ft-Lbs
Shock Absorber to Frame (Upper Attachment) 20-28
Upper Arm to Axle (Front) 70-90
Track Bar to Axle Track Bar Stud 80-105
Track Bar Stud to Axle 100-130
Track Bar to Frame (Bolt Torqe) 70-90
Wheel Lug Nut 70-115
Brake Backing Plate and Bearing Retainer to Axle 50-75
Shock Absorber to Axle (Lower Attachment) 50-85
Bumper Assembly to Frame Self-Tapping
Lower Arm to Axle - Bolt 90-120
Lower Arm to Axle- Nut 70-80
Upper Arm to Frame -Bolt 90-120
Upper Arm to Frame • Nut 70-90
Lower Arm to Frame • Bolt 90-120
Lower Arm to Frame - Nut 70-90
Bumper Assembly to No. 4 Crossmember Self-Tapping
SPECIAL SERVICE TOOLS
Tool No. Description

T50T-100-A Slide Hammer-Long
T59L-100-B Slide Hammer-Short
T58L-101-A Puller Attachment
T53L-200-A Handle Adapter
T62L-201-A Input Shaft Seal Installer
OTC-462 Tie Rod Separator (Owatonna Tool Co.)
T57L-500-A Bench Mounted Holding Fixture
T69L-1102-A Front Wheel Bearing Remover
Tool 1175-AB Grease Seal Remover (Head Only)
Tool 1175-AH Grease Seal Replacer
T56P-1217-A Front Hub Bearing Cup and Grease Seal Replacer
T60K-1217-A Front Hub Bearing Cup and Grease Seal Replacer
Tool 1217-J Front Hub Outer Bearing Cup Replacer
Tool 1217-K Front Hub Inner Bearing Cup Replacer
Tool 1217- L Front Hub Outer Bearing Cup Remover
Tool 1217-M Front Hub Inner Bearing Cup Remover
T65P-3000-A, D Adjusting Bars-Caster and Camber
T65P-3000-B, C, E, F Alignment Spacers
T57P-3006-A Spindle Ball Joint Remover Press
T60K-3005-A Spindle Ball Joint Press Adapter Screw
T62F-3006-A Spindle Ball Joint Press Adapter Screw
Tool 3044-A Front Suspension Upper Arm Bushing Remover
T54P-3044-A Front Suspension Upper and Lower Arm Overhaul Kit
T60K-3044-A Front Suspension Lower Arm Bushing Remover and Replacer
T65P-3044-A Upper Arm Bushing Overhaul Kit
Tool 3068 Front Suspension Upper Arm Bushing Adapter
Tool 3069-AA Front Suspension Lower Arm Bushing Remover
Tool 3069- M Lower Arm Bushings-Remover and Replacer Kit
Tool 3290-C Tie Rod Ball Ends and Control Valve Ball Stud Remover
T65P-3524-A Input Shaft Bearing Remover and Installer
T66P-3553-A, B Spanner Wrench
T66P-3553-C Spacer
T65P-3548-A Oil Line Connector Seal Installer
T62F-3576-A Sector Shaft Bushing Remover and Replacer
T64K-3576-A Sector Shaft Needle Bearings and Seal Remover and Replacer
T64K-3576-B Sector Shaft Needle Bearings and Seal Remover and Replacer Adapter
T65P-3576-A, B Sector Shaft Bushing Remover and Installer
T65P-3576-C Remover and Installer Adapter
Tool 3583-J Control Valve Bearing and Seal Remover and Replacer
T65P-3590-F Steering Pitman Arm Remover
T67L-3600-A Steering Wheel Remover
T65P-3805-A Ring Compressor-Rack Piston
T63P-5310-A Front Coil Spring Remover and Replacer
T64K-5310-A, B Adapters
T66P-5310-A, B Adapters
T64N-5781-A Rear Spring Front Bushing Remover and Installer
T64K-5781-B Rear Spring Bushing Adapter
Tool 6306-AG Crankshaft Damper Remover and Power Steering Pump Sprocket Replacer
T63L-8620-A Bent Tension Gauge
T63L-10300-B Pulley Remover
T65P-10300-B Alternator Pulley Replacer
T56L-33610-D Pressure Testing Gauge Assembly
T68L-33610-A Bypass and Orifice Gauge
Tool 33623-D Pump Oil Seal Pilot
T65P-3A537-A Bearing Preload Spanner Wrench
T65P-3A537-B Adjuster Plug Seal Protector
T69P-3A674-A Fixture Adapter Plate
T65P-3A733-A Power Steering Pump Pulley Remover
T65T-3B177-A Front Suspension Bushings Remover and Replacer
T68P-3B586-A Pump Housing Hole Plugging Tool
T68P-3B592-A Pump Shaft Seal Replacer
T68P-3B592-B Pump Shaft Seal Protector
T64B-3C716-A Insulator Remover and Replacer Socket
T65P-3C732-A Lock Spring Installing Hook
T65P-3D517-A Rack Piston Arbor
T65P-3D525-A Adjuster Plug Bearing Remover and Installer
T65P-3D525-B Thrust Bearing Retainer Installer Adapter
T65P-3D526-A Adjuster Plug Seal Installer
T69P-3D608-A Pin Straightness Checking Block
T69P-3D608-B Pin Guide Support
T65P-3D642-A Sector Shaft Seal Installer
T67P-3D739-A Pivot Pin Remover
04-01-01 General Axle Service 04-01-01
GROUP
PART 4-1 PAGE

4
PART 4-4 PAGE
General Axle Service 04-01-01 Rear Axle — Ford
PART 4-2 Light-Duty (WER) 04-04-01
Rear Axle — Removable Carrier Type ... 04-02-01
PART 4-5
PART 4-3 Soecifications 04-05-01
Rear Axle — Integral CarrierType
(Except Ford Light Duty WER) 04-03-01
PART 4-1 General Axle Service

MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
COMPONENT INDEX
Mustang
Montego
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
ADJUSTING DIFFERENTIAL BEARING
PRELOAD AND BACKLASH 01-07
Locating Pinion-Integral Carrier 01-08 N / A 01-08 01-08 01-08 01-08 01-08 01-08 N / A N / A N / A
Locating Pinion-Removable Carrier 01-08
ADJUSTING PINION AND RING GEAR
TOOTH CONTACT 01-07
Integral Carrier 01-07 N / A 01-07 01-07 01-07 01-07 01-07 01-07 N / A N / A N / A
Removable Carrier 01-07
BEARING CONE AND ROLLER
ASSEMBLIES 01-10
BEARING CUPS 01-10
CARRIER HOUSING 01-09
CHECKING GEAR TOOTH PATTERNS 01-03
CHECKING LIMITED SLIP OR TRACTION
LOK DIFFERENTIAL OPERATION 01-02
CHECKING REAR AXLE COMPANIOM
FLANGE RUNOUT 01-05 01-05 01-05 01-05 01-05 01-05 01-05 01-05 01-05 01-06 01-06
DIFFERENTIAL BEARING ADJUSTING
NUTS 01-10
DIFFERENTIAL CASE 01-10
GEARS (ALL) 01-09
IDENTIFICATION 01-02
INSPECTION BEFORE DISASSEMBLY OF
CARRIER 01-09
LIMITED SLIP AND TRACTION-LOK
DIFFERENTIAL PARTS 01-10
MODEL APPLICATION
COMPONENT INDEX
I
Ji
o
3 i
LUBRICANT LEVEL CHECK 01-10
PINION RETAINER 01-10
SHIM AND BACKLASH CHANGES 01-03
Integral Carrier 01-04 N/A 01-04 01-04 01-04 01-04 01-04 01-04 N/A N/A N/A
Removable Carrier
U-JOINT FLANGE 01-10
1 COMMON ADJUSTMENTS AND REPAIRS

IDENTIFICATION It is important to use the model ferential can be checked for proper
The AXLE code on the vehicle designation when obtaining correct re- operation without removing the carrier
Warranty Plate (Fig. 1) identifies the placement parts. from the axle housing.
r e a r axle type (conventional or Jack up one rear wheel and remove
LIMITED-SUP OR the wheel cover. Install the tool on the
limited-slip differential) and gear TRACTION-LOK DIFFERENTIAL
ratio. axle shaft flange studs as shown in
OPERATION CHECK Fig. 3.
A metal tag (Fig. 2) stamped with
A limited-slip or Traction-Loc dif-
the model designation and gear ratio
is secured to one of the rear cover-
to-housing bolts (integral carrier-type)
AXLE MODEL
or to one of the carrier-to-housing
bolts (removable carrier-type).
The spaces on the top line provide
the axle model identification code.
T h i s c o d e , such as W D T - A N 4 ,
WDC-AS4, WEG-C2, etc. indicates a
specific combination of the following
factors: conventional or limited slip
differential; diameter of ring gear;
small or large wheel bearings; and the
gear ratio. Refer to the specifications PLANT CODING
group of this manual for the car-line DATE (YEAR, MONTH, WEEK)
rear axle ratios, gear and code identif-
RATIO (CONVENTIONAL)
ication. (LIMITED SLIP WOULD BE 3L00)
The second line on the tag is used
for gear ratio, the production date E 1918-A
code and the production plant identifi- FIG. 2—Rear Axle Model Identification Tag
cation code.
CONVENTIONAL LIMITED SLIP RATIO

2 K 2.75:1
NOT FOR TITLE OR REGISTRATION 3 L 2.79:1
4 . M
9G5IVI0000I WARRANTY NUMBER — 2.80:1
5 / 2.83:1
6 / - 3.00:1
7 p _ — 3.10:1
R — — — 3.25:1
A c 3.50:1
c — u 3.08:1
V 3.91:1
E1917-A — 4.30:1
FIG. 1 — Rear Axle Gear Ratio and Type Identification

Any combination of drive and coast

Tool-759L 4204-A, patterns shown in Fig. 4 will be acceep-
T65K 4204- A,
T66L-4204-A,
table.
OR
Tool-44211-A Non-Hunting Gear Set
In a non-hunting type gear set, any

one pinion gear tooth comes into con-
tact with only a few ring gear teeth.
In this type, only one revolution of the
ring gear is required to make all poss-
ible tooth contact combinations. Any
combination of drive and coast pat-
terns shown in Fig. 4 will be accept-
able.
Partial Non-Hunting
E1897-A Gear Set
FIG. 3—Limited-Slip Differential Check
In a partial non-hunting type gear
set, any one pinion tooth comes into
Using a torque wrench of at least ber of teeth in the gears. The non- contact with only part of the ring gear
200 ft-lbs capacity, rotate the axle hunting and partial non-hunting types teeth, but more than one revolution of
shaft. Be sure that the transmission is can be identified by the paint timing the ring gear is required to make all
in neutral, one rear wheel is on the marks on the pinion and ring gear possible gear tooth combinations. Any
floor, and the other rear wheel is teeth. (Part 4-2, Fig. 51). See Part 4-5 combination of drive and coast pat-
raised off the floor. The torque re- for complete identification specifica- terns shown in Fig. 4 will be accept-
quired to continuously rotate the shaft tions. able.
should be at least 75 ft-lbs or 40 ft-lbs
(Traction-Lok). The initial breakaway
torque may be higher than the contin-
uous turning torque, but this is nor- ACCEPTABLE TOOTH SHIM AND BACKLASH
mal. The axle shaft should turn with PATTERNS (ALL AXLES) CHANGES
^ven pressure throughout the check
without slipping or binding. Since each gear set rolls a charac-
If the torque reading is less than Figure 4 shows acceptable tooth teristic pattern, the patterns shown in
specified, check the differential for patterns for all axles. Any combina- Fig. 4 are considered acceptable and
improper assembly. tion of drive and coast patterns will be should be used as a guide. The drive
A vehicle equipped with a limited- acceptable. pattern is rolled on the convex side of
slip differential will always have both In general, desirable tooth patterns the tooth, and the coast pattern is
wheels driving. If, while the vehicle is should have the following character- rolled on the concave side.
being serviced, only one wheel is istics: The movement of tooth contact pat-
raised off the floor and the rear axle 1. The drive pattern should be fair- terns with changes in shimming can be
is driven by the engine, the wheel on ly well centered on the tooth. summarized as follows:
the floor will drive the vehicle off the 2. The coast pattern should be fair-
stand or jack. ly well centered on the tooth. Removable Carrier Type Axle
3. Some clearance between the pat-
tern and the top of the tooth is desir- 1. Thicker shim with the backlash
GEAR TOOTH CONTACT able. set to specifications moves the pinion
PATTERN CHECK 4. There should be no hard lines further from the ring gear:
where the pressure is high. 2. Thinner shim with the backlash
The individual gear set need not set to specifications moves the pinion
conform exactly to the ideal pattern closer to the ring gear:
When rolling a tooth pattern, use
to be acceptable. If the patterns are not correct,
the special compound (tube) packed
with each service ring gear and pinion Any combination of drive and coast make the changes as indicated. The
set. patterns shown in Fig. 4 are accep- pinion need not be disassembled to
table. change a shim. All that is required is
Paint all gear teeth and roll a pat-
tern as described in Section 3. After to remove the pinion, bearing, and re-
diagnosing the tooth pattern as ex- tainer assembly and install a different
plained here, make the appropriate Hunting Gear Set shim. When reinstalling the pinion
adjustments as outlined in Section 2. and retainer assembly of a non- hunt-
In making a final gear tooth con- In a hunting-type gear set, any one ing or partial non-hunting gear set, be
tact pattern check, it is necessary to pinion gear tooth comes into contact sure that the marked tooth on the pi-
recognize the fact that there are three with all ring gear teeth. In this type, nion indexes between the marked teeth
different types of gear sets, hunting, several revolutions of the ring gear are on the ring gear (Fig. 51, Part 4-2).
non-hunting and partial non-hunting. required to make all possible gear Refer to Pinion and Ring Gear Tooth
Each type is determined by the num- combinations. Contact Adjustment, Section 2.
ACCEPTABLE TOOTH PATTERN LIMITS
ANY COMBINATION OF DRIVE AND COAST PATTERNS SHOWN PERMISSIBLE
Toe Toe Toe Toe
Heel
Heel
LOW HEEL COAST

MM
DRIVE COAST
E 1680-A
FIG. 4—Acceptable Tooth Pattern Limits (All Axles)

Integral Carrier Type Axle and a cup-shaped dial indicator adapt- 7. Carefully retract the dial indica-
er tool (Fig. 6). To fabricate the tor stem and rotate the companion
1. Thinner shim with the backlash checking tool, modify a universal joint flange 180 degrees to position the ma-
set to specifications moves the pinion assembly by removing two bearing chined surface of the opposite univer-
farther from the ring gear. cups that are opposite each other, and sal bearing under the dial indicator
2. Thicker shim with the backlash cuttting or grinding off one of the uni- adapter tool. Again, slightly rotate the
set to specifications moves the pinion versal joint bearing flanges (Fig. 6). flange side-to-side to position the
closer to the ring gear. 5. Install the cup-shaped adapter on bearing perpendicular to the dial indi-
If the patterns are not correct, the dial indicator stem. Install the dial cator adapter. Again, this is the point
make the changes as indicated. The indicator on the pinion retainer or pi- at which the indicator hand will rev-
differential case and drive pinion will nion nose bumper bracket. Position erse direction as the flange is rotated.
have to be removed from the carrier the indicator to allow an indication at Record the flange bearing cup runout
casting to change a shim. When re- the ends of the universal joint bearing reading obtained from the indicator
installing the pinion and ring gear of a cups and the remaining exposed jour- (Fig. 7).
non-hunting or partial non-hunting nal of the cross-shaft. Rotate the companion flange 90
gear set, be sure that the marked 6. Turn the companion flange so degrees and position the dial indicator
tooth on the pinion indexes between that the dial indicator cup-type adapt- adapter on the machined end of the
the marked teeth on the ring gear er rests on the machined surface of exposed journal (Fig. 8). Be sure the
(Fig. 51, Part 4-2). Refer to Pinion the bearing cup (Fig. 6). Rotate the end surface of the exposed journal is
and Ring Gear Tooth Contact Adjust- companion flange side-to-side slightly perpendicular to the indicator cup-
ment, Section 2. to obtain a reading indicating that the type adapter. This requires that the
bearing cup surface is perpendicular to cross-shaft be moved fore and aft on
REAR AXLE COMPANION the flange bearing cups. Note the
the indicator cup-type adapter. This
FLANGE RUNOUT CHECK will be the point at which the dial in- point at which the indicator hand rev-
dicator cup is closest to the center of erses direction. Rotate the flange as-
ALL AXLES EXCEPT companion flange rotation. It is also sembly side-to-side until the cross-
THUNDERBIRD AND the point at which the dial indicator shaft is perpendicular to the pinion
CONTINENTAL MARK III hand will reverse direction as the com- shaft axis, and the indicator hand re-
1. Raise the vehicle on a hoist that panion flange is turning. Set the dial verses direction. Zero the dial indicator
supports the rear axle (twin-post indicator to zero. and check the zero point again by
hoist).
2. Remove the driveshaft assembly
(Group 5).
oo/-6565, Used
3. Check the companion flange 'With Bracket From
damage to the universal joint bearing Too!-4201-C
locating lugs. If the universal joint
bearing locating lugs on the compan-
ion flange are shaved (worn) or dam-
aged, replace the companion flange
(Fig. 5).
PROPERLY SEATED CUP SHAVES LUG
MOUNT HERE —
MOUNT HERE
Tool-6565, Used Too/-4207-C
Tool-4201-C With Bracket Fro
Tool-4201 -C E 1624-A
E 1622- A
FIG. 6—Flange Bearing Cup FIG. 8—Cross Shaft Runout

Run-out Check—Typical Check—Typical
FLANGE DRIVESHAFT UNIVERSAL

INDICATOR BEARING CUP CROSS-SHAFT
READING RUNOUT—INCH RUNOUT—INCH
E 1621-A 1 0.C04 0.005

2 0.002 0.004
FIG. 5—Checking Companion
Flange 3 0.003 0.003
Average 0.003 0.004
4. The rear axle companion flange
runout is checked with a modified uni-
versal joint (checking tool) a dial indi- FIG. 7—Flange Bearing Cup and Cross Shaft Runout Averaging
cator with 1.000 inch minimum travel, Chart—Typical Readings
DRIVE SHAFT UNIVERSAL CROSS-SHAFT RUNOUT-INCH

FLANGE BEARING
CUP RUNOUT 0.000 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
0.000 0.000 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
0.001 0.001 0.0013 0.0022 0.0032 0.0042 0.0051 0.0061 0.0071 0.0081
0.002 0.002 0.0022 0.0027 0.0037 0.0045 0.0053 0.0062 0.0072 0.0082
0.003 0.003 0.0032 0.0036 0.0042 0.005 0.0058 0.0067 0.0077 0.0085
0.004 0.004 0.0042 0.0045 0.005 0.0057 0.0064 0.0072 0.0081 0.009
0.005 0.005 0.0051 0.0053 0.0058 0.0063 0.0071 0.0078 0.0087 0.0094
0.006 0.006 0.0061 0.0062 0.0068 0.0072 0.0078 0.0085 0.0092 0.010
0.007 0.007 0.0071 0.0073 0.0075 0.0081 0.0087 0.0093 0.0099 0.0103
0.008 0.008 0.0081 0.0082 0.0087 0.009 0.0094 0.010 0.0104 0.011
The total (combined) companion flange runout is located in the square where the columns containing the flange bearing cup runout
and universal cross shaft runout readings intersect.
FIG. 9—Companion Flange Combined Runout Chart
slightly moving the cross-shaft fore pinion shaft and check the runout THUNDERBIRD AND
and aft, then rotate the companion (Steps 4 through 10). CONTINENTAL MARK III
flange from side-to-side. 13. If the runout is still excessive,
8. With the indicator at zero, care- replace the companion flange and 1. Raise the vehicle on a hoist that
fully retract the dial stem and rotate check the runout. If necessary, rotate supports the rear axle (twin-post
the flange 180 degrees. Rotate the the new flange on the pinion shaft hoist).
cross-shaft 180 degrees on the flange until an acceptable runout is obtained. 2. Remove the driveshaft assembly
bearing cups to position the exposed If excessive runout is still evident (Group 5).
journal under the dial indicator adapt- after replacement of the companion 3. Check the companion flange for
er. Rock the cross-shaft fore and aft flange, it will be necessary to replace damage.
and the companion flange side-to-side the ring and pinion gear, and repeat 4. To check radial runout, set up
to establish the point at which the in- the above checks until runout is within dial indicator as shown in Fig. 10.
dicator hand reverses direction. This 5. Rotate the companion flange
specifications.
will determine the driveshaft universal with the dial indicator in place. If the
cross-shaft run-out. Record this read- 14. Install the driveshaft assembly runout exceeds specifications, remove
ing (Fig. 8). (Group 5). Make sure the universal the flange and reinstall it 180 degrees
9. Repeat steps 5 through 8 at least joint bearing cups are properly posi- from original position. Follow the
three times and average the indicator tioned between the companion flange procedure in Part 4-2 for companion
readings obtained (Fig. 7). lugs. flange installation.
10. To determine the total (com- 15. Lower the vehicle. Road test 6. If the runout is still excessive, re-
bined) companion flange runout, it the vehicle. If drive shaft vibrations move and reinstall the flange an addi-
will be necessary to use the combined are evident during the road test, re- tional 90 degrees and recheck runout.
runout chart (Fig. 9). Position a move the driveshaft from the compan- 7. To check lateral (face) runout,
straight edge at the amount of flange ion flange and rotate it 180 degrees. set up the dial indicator as shown in
bearing cup runout indicated on the Road test the vehicle again. Fig. 11. Repeat steps 5 and 6.
left hand column of the chart. Posi-
tion another straight edge vertically at
the amount of driveshaft universal
cross-shaft runout indicated on the top
of the chart. The point at which the
straight edges cross the chart indicates
the combined rear axle flange runout.
For example:
With an indicated 0.003 inch flange
bearing cup runout and an indicated
0.004 inch universal cross-shaft runout
(Fig. 9), the combined companion
flange runout will be 0.005 inch as in-
dicated in the square on the chart
(Fig. 9). MOUNT HERE
11. If the reading obtained in Step
10 exceeds specifications, reposition
FLANGE Too/-4207-C
the companion flange 180 degrees on
the pinion shaft and repeat steps 1
through 10. Too/-6565 USED WITH BRACKET FROM Tool-4201 E1697-A
12. If the repeat readings still ex-
ceed specifications, re-position the FIG. 10—Checking Companion Flange Radial Runout—
flange an additional 90 degrees on the Thunderbird and Continental Mark III
Tool-4201- C procedure under Backlash and Differ-

ential Bearing Preload Adjustments.
If the tooth pattern indicates a change
in shim thickness, follow the proce-
dure under Pinion Location.
REMOVABLE CARRIER
TYPE AXLE
The shim location for the removable

carrier type axle is between the pinion
retainer and the carrier (Fig. 13).
When adjusting this type carrier re-
ducing shim thickness will move the
Tool-6565 USED WITH BRACKET pinion toward the ring gear; increas-
FROM Too/^*207-C ing shim thickness will move the pi-
nion away from the ring gear (Fig.
FLANGE
E1743-A 13).
FIG. 11—Checking Companion Flange Lateral Runout— INTEGRAL CARRIER

Thunderbird and Continental Mark III TYPE AXLE
The shim location for the integral

carrier type axle, is between the pi-
8. If the runout is still excessive, re- PINION AND RING GEAR nion gear and the pinion rear bearing
place the companion flange and check TOOTH CONTACT cone (Fig. 12). When adjusting this
the runout. If necessary, rotate the ADJUSTMENT type axle, increasing shim thickness
new flange on the pinion shaft until an moves the pinion toward the ring
acceptable runout is obtained. Two separate adjustments affect pin- gear; reducing shim thickness moves
If excessive runout is still evident ion and ring gear tooth contact. the pinion away from the ring gear
after replacement of the companion They are pinion location and backlash (Fig. 12).
flange, it will be necessary to replace (Figs. 12 and 13).
the ring and pinion gear, and repeat Individual differences in matching
the above checks until runout is within the differential housing and the gear
specifications. set require the use of shims to locate BACKLASH A N D DIFFERENTIAL
9. Install the driveshaft assembly the pinion for correct contact with the BEARING PRELOAD
(Group 5). ring gear. ADJUSTMENTS (ALL AXLES)
When adjusting either type axle,
shim thickness should be increased or On a Light-Duty (WER) Axle, it is
reduced only as indicated by the tooth necessary to remove the rear axle
pattern check described in the fore- shafts prior to performing the adjust-
going Section 1. ment procedures. Refer to Rear Axle
PINION LOCATION If the tooth pattern check indicates Shaft Wheel Bearing and Oil Seal Re-
ADJUSTMENT
a change in backlash only, follow the placement—Light-Duty (WER), Axle,
Part 4-4, Section 2.
To secure a more uniform control
BACKLASH of differential side bearing preload in
ADJUSTMENT,
PINION
service repairs, a dial indicator set-up
LOCATION such as shown in Fig. 12 is used.
ADJUSTMENT In both types of axle (Fig. 11 and
SHIMS 12), the ring gear is moved away from
or toward the pinion as described in
the following procedure.
1. Remove the adjusting nut locks,
loosen the differential bearing cap
bolts, then torque the bolts to 15 ft-lbs
on integral carrier type axle; 20 ft-lbs
on removable carrier type axles before
making adjustments.
2. The left adjusting nut is on the
RIGHT
ring gear side of the carrier. The right
LEFT LEFT ADJUSTING nut is on the pinion side. Loosen the
ADJUSTING ADJUSTING
NUT
BACKLASH NUT right nut until it is away from the cup.
NUT ADJUSTMENT E l 4 0 9 - A
E1476-A Tighten the left nut until the ring gear
is just forced into the pinion with
FIG. 12—Pinion and Ring Gear FIG. 13—Pinion and Ring Gear 0.000 backlash then rotate the pinion
Tooth Contact Adjustment — Tooth Contact Adjustment— several revolutions to be sure no bind-
Integral Carrier Type Axles Removable Carrier Axles ing is evident. (Recheck the right nut
04-01-08 General Axle Service 04 01-08
Too/-T57L-4067-A The non-hunting and pantial non-

hunting types can be identified by the
paint timing marks on the gear teeth
(Fig. 51, Part 4-2). Part 4-5 can also
be referred to for identification.
If the gear set is of the non-hunting
or partial non-hunting type clean the
teeth on both the pinion and drive
gear so that the timing marks are vis-
ible. Rotate the differential case and
ring gear assembly in the carrier until
the marked teeth on the ring gear are
opposite the pinion entry hole. Place
the assembly in the carrier so that the
marked tooth on the pinion indexes
between the marked teeth on the ring
gear (Fig. 51, Part 4-2).
In almost every case of improper
E 1595-A assembly (gear assembled out of time)
the noise level and probability of fai-
FIG. 14 —Adjusting Side Bearing Preload—Typical lure will be higher than they would be
with properly assembled gears.
at this time to be sure that it is still gears or their mountings, which must
When installing the hunting type
loose.) Tightening the left nut moves be corrected to obtain a satisfactory
gear set (no timing marks), assemble
the ring gear into the pinion to de- unit. If the backlash is out of specifi-
the pinion and retainer assembly into
crease backlash, and tightening the cation, loosen one adjusting nut and
the carrier without regard to the
right nut moves the ring gear away. tighten the oposite nut an equal a-
matching on any particular gear teeth.
3. Install a dial indicator as shown mount to move the ring gear away
5. Install the retainer-to-carrier
in Fig. 14. from or toward the pinion. When
mounting bolts and torque to specifi-
4. Tighten the right nut until it first moving the adjusting nuts, the final
cations.
contacts the bearing cup. Then pre- movement should always be made in a
tightening direction. For example, if 6. Adjust the backlash between the
load the bearings from 0.008-0.012
the left nut had to be loosened one ring gear and pinion as outlined in the
inch case spread. Rotate the pinion
notch, loosen the nut two notches, foregoing procedures.
gear several revolutions in each direc-
then tighten it one. This insures that 7. Make a tooth pattern check. If
tion while the bearings are loaded, to
the nut is contacting the bearing cup, the pattern is still unsatisfactory, re-
seat the bearings in their cups to be
and that the cup cannot shift after peat this procedure changing the shim
sure no bind is evident. This step is
being put in service. After all such ad- thickness each time until a satisfactory
important.
justments, check to be sure that the tooth pattern is obtained.
5. Again loosen the right nut to re-
lease the pre-load. If there is any case spread remains as specified for
Integral Carrier Type Axle
backlash between the gears as shown the new or original bearings used.
by the dial indicator,(Fig.l2 or Fig. 10 8. Again check the tooth contact 1. Remove the differential case and
Part 4-4) tighten the left nut just en- pattern. If the pattern is still incor- the drive pinion from the carrier cast-
ough to remove this backlash. At this rect, a change in pinion location (shim ing, and then remove the pinion bear-
time, make sure that one of the slots thickness) is indicated. ings as described under Removal of
in the left nut is so located that the Differential Case and Drive Pinion in
PINION LOCATION
lock can be installed without turning Section 4.
the nut. Carefully, tighten the right Removable Carrier Type Axle 2. Measure the original shim thick-
nut until it just contacts the cup. 1. Remove the attaching bolts and ness with a micrometer. Increase or
6. Torque the differential cap bolts the pinion and bearing retainer assem- decrease the shim thickness as indicat-
to specification. bly from the carrier. ed by the tooth pattern check des-
On integral carrier type axles, set a 2. Measure the original shim thick- cribed in the foregoing Section 1 and
preload of 0.008 to 0.012 inch case ness with a micrometer. Increase or shown in Fig. 4.
spread for new bearings and 0.003 to decrease the shim thickness as indicat- 3. Install the corrected shim pack
0.005 for the original bearings. ed by the tooth pattern check des- and the bearings on the pinion, and
On removable carrier type axles, cribed in Section 1. then install the pinion and the differ-
the preload is 0.008 to 0.012 inch case 3. Replace the pinion retainer O- ential case in the carrier casting as
spread for new bearings and 0.005 to ring (Fig. 39, Part 4-2). Coat the O- outlined under Installation of Drive
0.008 for the original bearings. As ring with axle lubricant before install- Pinion and Differential Case in Sec-
preload is applied from the right side, ing. Do not roll the O-ring into the tion 4 of Part 4-3.
the ring gear is forced away from the groove. Snap it into position. 4. Adjust the backlash between the
pinion and usually results in the cor- 4. Being careful not to pinch the ring gear and pinion as outlined in the
rect backlash. O-ring, install the pinion and bearing foregoing procedure.
7. Measure the backlash on several retainer assembly in the carrier with 5. Make a tooth pattern check. If
teeth around the ring gear. If the the corrected shim pack. the pattern is still unsatisfactory, re-
measurements vary more than 0.003 Before installing the pinion and peat this procedure changing the shim
inch (both integral and removable car- bearing retainer assembly, determine thickness each time until a satisfactory
rier) there is excessive runout in the which type of gear set is being used. tooth pattern is obtained.
INSPECTION BEFORE If no obvious defect is noted, check

DISASSEMBLY OF CARRIER the gear tooth contact.
DIFFERENTIAL BEARING
(ALL AXLES) To check the gear tooth contact, CAP BOLTS
paint the gear teeth with the special
The differential case or carrier compound furnished with each service
should be inspected before any parts ring gear and pinion. A mixture that
are removed from it. These inspec- is too wet will run and smear. Too dry
tions can help to find the cause of the a mixture cannot be pressed out from
trouble and to determine the correc- between the teeth.
tions needed. As shown in Fig. 17, rotate the ring
Mount the carrier in the holding gear (use a box wrench on the ring
fixture shown in Fig. 15. Wipe the lu- gear attaching bolts for a lever) five
bricant from the internal working complete revolutions in both directions
parts, and visually inspect the parts or until a clear tooth contact pattern
for wear or damage. is obtained.
1699-A
FIG. 18 -Checking Ring Gear

Runout—Typical
Loosen the differential bearing cap

bolts, and then torque them to 25 ft-
Tool-T57L-500-A
lbs. Remove the adjusting nut locks.
Carefully loosen one of the adjusting
nuts to determine if any differential
bearing preload remains. If any pre-
FIG. 15 — Bench Fixture for load remains, the differential bearings
Carrier Overhaul—Typical may be re-used, provided they are not
pitted or damaged.
Rotate the gears to see if there is
any roughness which would indicate
damaged bearings or chipped gears.
Check the gear teeth for scoring or INSPECTION AFTER
signs of abnormal wear. DISASSEMBLY OF CARRIER
Set up a dial indicator (Fig. 16) and (ALL AXLES)
check the backlash at several points
around the ring gear. Backlash should E 1001 - C
be within specifications. Thoroughly clean all parts. Syn-
FIG. 7 7—Checking Gear Tooth thetic seals must not he cleaned, soak-
ed or washed in cleaning solvents.
Contact—Typical
Always use clean solvent when clean-
ing hearings. Oil the bearings im-
Certain types of gear tooth contact mediately after cleaning to prevent rust-
patterns on the ring gear indicate in- ing. Inspect the parts for defects.
correct adjustment. Noise caused by Clean the inside of the carrier before
incorrect adjustment can often be cor- rebuilding it. When a scored gear set
rected by readjusting the gears. Ac- is replaced, the axle housing should he
ceptable patterns and the necessary washed thoroughly and steam cleaned.
corrections are explained under Tooth This can onl\ be done effectively if the
Contact Pattern Check in Section I. axle shafts and shaft seals are re-
Gear tooth runout can sometimes moved from the housing. Inspect indi-
be detected by an erratic pattern on vidual parts as outlined below.
the teeth. However, a dial indicator
should be used to measure the runout GEARS
of the back face of the ring gear as
shown in Fig. 18. If this runout ex- Examine the pinion and ring gear
E 1776-A ceeds specifications, disassemble the teeth for scoring or excessive wear.
carrier and replace necessary parts as Extreme care must he taken not to
FIG. 76-Backlash Check- indicated in Part 4-2, Section 4 and damage the pilot hearing surface of
Typical Part 4-3, Section 4. the pinion.
The pattern taken during disassem- if their fit is not proper. Be sure that the differential side gears in their
bly should be helpful in judging if the bearing caps and adjusting nuts counterbores. Be sure that the mating
gears can be re-used. Worn gears can- are on the side they were machined to surfaces of the two parts of the case
not be rebuilt to correct a noisy condi- fit. Observe the punch marks and are smooth and free from nicks or
tion. Gear scoring is the result of ex- scribe marks made during disassem- burrs.
cessive shock loading or the use of an bly.
incorrect lubricant. Scored gears can-
LIMITED SLIP AND
not be re-used. U-JOINT FLANGE TRACTION-LOK
Examine the teeth and thrust surfa- DIFFERENTIAL PARTS
ces of the differential gears. Wear on Be sure that the eai» of the flange
the hub of the differential gear can have not been damaged in removing
cause a chucking noise known as the drive shaft or in removing the Inspect the clutch plates for uneven
chuckle when the vehicle is driven at flange from the axle. The end of the or extreme wear. The dog-eared clutch
low speeds. Wear of splines, thrust flange that contacts the front pinion plates must be free from burrs, nicks
surfaces, or thrust washers, can con- bearing inner race as well as the flat or scratches which could cause excess-
tribute to excessive drive line back- surface of the pinion nut counterbore ive or erratic wear to the bonding ma-
lash. must be smooth. Polish these surfaces terial of the internally splined clutch
if necessary. Roughness aggravates plates. The internally splined clutch
BEARING CUPS AND backlash noises and causes wear of plates should be inspected for condi-
CONE AND ROLLER the flange and pinion nut with a resul- tion of the bond, bonding material,
ASSEMBLIES tant loss in pinion bearing preload. and wear. Replace the bonded plates
if their thickness is less than 0.085
C h e c k b e a r i n g cups for rings, PINION RETAINER inch or if the bonded material is
scores, galling, or excessively worn scored or badly worn. Inspect the
wear patterns. Pinion cups must be Be sure that the pinion bearing cups bonded plate internal teeth for wear.
solidly seated. Check by attempting to are seated. Remove any chips or burrs Replace them, if excessive wear is evi-
insert a 0.0015-inch feeler between from the mounting flange. Clean the dent. Bonded plates should be re-
these cups and the bottoms of their groove for the O-ring seal and all lu- placed as a set only
bores. bricant passages. If the cups were re- Examine all thrust surfaces and
When operated in the cups, cone moved, examine the bores carefully. hubs for wear. Abnormal wear on
and roller assemblies must turn with- Any nicks or burrs in these bores these surfaces can contribute to a
out roughness. Examine the roller must be removed to permit proper noisy axle.
ends for wear. Step-wear on the roller seating of the cups. Inspect the Belleville spring (limited
ends indicates the bearings were not slip) for proper free height of 1/4
preloaded properly, or the rollers were CARRIER HOUSING inch.
slightly misaligned.
If inspection reveals either a defec- Make sure that the differential
tive cup or a defective cone and roller bearing bores are smooth and the LUBRICANT LEVEL
assembly, both parts should be re- threads are not damaged. Remove any
placed to avoid early failure. nicks or burrs from the mounting sur- The l u b r i c a n t level should be
faces of the carrier housing. checked every 6000 miles with the ve-
DIFFERENTIAL BEARING hicle in normal curb attitude. The lu-
ADJUSTING NUTS DIFFERENTIAL CASE bricant level should be at the lower
edge of the filler plug hole located in
Temporarily install the bearing caps Make sure that the hubs where the either the carrier casting or housing
and test the fit of the adjusting nuts in bearings mount are smooth. Carefully cover. It is unnecessary to periodically
their threads. The nuts should turn examine the differential case bearing drain the axle lubricant. The factory
easily when the caps are tightened to shoulders, which may have been dam- fill should remain in the housing for
25 ft-lbs. The faces of the nuts that aged when the bearings were removed. the life of the vehicle, except when re-
contact the bearing cups must be The bearing assemblies will fail if they pairs are made. The specified lubri-
smooth and square. Replace the nuts do not seat firmly against the shoul- cant should be installed when the axle
or examine the threads in the carrier ders. Check the fit (free rotation) of is overhauled.
04-02-01 Rear Axle — Removable Carrier Type 04-02-01
PART 4-2 Rear Axle—Removable Carrier Type

MODEL APPLICATION
Continental-
Thunderbird
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
J
AXLE HOUSING (Coil Spring Suspension)
Cleaning and Inspection 01-09 01-09 01-09 N / A N/A N/A N/A N/A N/A 01-09 01-09
Removal and Installation 02-08 02-08 02-08 N / A N/A N/A N/A N/A N/A 02-08 02-08
AXLE HOUSING (Leaf Spring Suspension)
Cleaning and Inspection N/A N/A N / A 01-09 01-09 01-09 01-09 01-09 01-09 N / A N / A
Removal and Installation N/A N/A N/A 02-11 02-11 02-11 02-11 02-11 02-11 N / A N/A
AXLE SHAFT
CONVENTIONAL DIFFERENTIAL
DIFFERENTIAL BEARINGS AND RING
GEAR
Adjustment 02-19
DIFFERENTIAL CARRIER
LIMITED SLIP DIFFERENTIAL
Description 02-03
PILOT BEARING
PINION AND RING GEAR
PINION BEARING
PINION BEARING RETAINER
PINION SPACER (Collapsible)
Removal and Installation 02-17 N / A 02-17 02-17 02-17 02-17 02-17 02-17 N / A N/A N/A
PINION OIL SEAL
MODEL APPLICATION
Continental-
Thunderbird
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Mark III
Fairlane
Lincoln-
Cougar
Meteor
Falcon
Ford
PINION SPACER (Solid)
Determining Spacer Size 02-18
REAR WHEEL BEARINGS AND SEALS
TRACTION-LOK DIFFERENTIAL
Cleaning and Inspection N/A N/A N / A 01-10 01-10 01-10 01-10 01-10 N / A N / A N/A
Description N/A N/A N / A 02-03 02-03 02-03 02-03 02-03 02-03 N / A N/A
Disassembly and Overhaul N/A N/A N / A 02-22 02-22 02-22 02-22 02-22 N / A N / A N/A
Removal and Installation N/A N / A JN/A 02-13 02-13 02-13 02-13 02-13 N / A N / A N/A
U-JOINT FLANGE
1 DESCRIPTION
CONVENTIONAL AXLE 3/4, 9 or 9 3/8 inch ring gear, in The pinion gear and the pinion
which the centerline of the pinion is bearings are assembled in a pinion re-
T h e rear axle is of the banjo- mounted below the centerline of the tainer, which is bolted to the carrier.
housing, hypoid gear type using an 8 ring gear (Fig. 1). The pinion is straddle mounted; that
LEFT AXLE SHAFT

4235
DRIVE PINION
4209
TAPERED ROLLER
BEARINGS 4621
SEAL - 4676
FIG. 1 — Rear Axle Assembly—Integral Pinion Gear and Shaft—8-3/4, 9, or 9-3/8 Inch Ring Gear—Typical
is, it is supported by bearings both in CASE STEEL is splined to the left axle shaft. A
front of and to the rear of the pinion COVER PLATES Belleville spring washer maintains a
gear. Two opposed tapered roller constant pressure between the steel
BELLEVILLE BONDED
bearings support the pinion shaft in SPRING PLATES and bonded clutch plates so that the
front of the pinion gear with a col- clutch is always engaged.
lapsible spacer for 8-3/4 inch or 9 CLUTC
HUB
inch ring gear, and a solid spacer used TRACTION-LOK
with the 9 3/8 inch ring gear. A DIFFERENTIAL
straight roller (pilot) bearing supports
the pinion shaft at the rear of the pi- The Traction-Lok (torque sensitive)
nion gear. Pinion and ring gear tooth locking differential (Fig. 3) employs a
contact is adjusted by adding or re- multiple disc clutch to control differ-
moving shims from between the pinion E1741-A ential action. Shim(s), which control
retainer and the carrier housing. side gear mounting distance, four
The differential assembly is mount- FIG. 2—Limited-Slip Differential steel, four friction and one composite
ed on two opposed tapered roller plate (steel on one side and friction
bearings, which are retained in the material on the other) stacked on a
carrier by removable caps. The entire clutch hub, and four ear guides are
carrier assembly is bolted to the axle LIMITED-SUP DIFFERENTIAL housed in the differential cover. Lo-
housing. cated in the differential case between
Ball bearing assemblies (rear wheel The axle assembly, except for the the side gears is a one-piece pre-load
bearings) are pressed onto the outer differential case and its internal com- plate and block (four-pinion) and four
ends of the axle shafts and set in the ponents, is identical to the convention- calibrated pre-load springs, which
outer ends of the axle housing. These al axle. apply an initial force to the clutch
bearings support the semi-floating A constant-friction locking differen- pack. Additional clutch capacity is
axle shafts at the outer ends. The tial, which employs clutch plates to derived from the side gear thrust
inner ends of the shafts spline to the control differential action, is available loads. The four friction plates are
differential side gears. Bearing retain- as optional equipment (Fig. 2). splined to the clutch hub which in turn
er plates hold the shafts in the hous- Four steel clutch plates are locked is splined to the left axle shaft, and
ing. The left and right axle shafts are into the differential cover. Three the eared steel plates are dogged to
not interchangeable, the left shaft b r o n z e , bonded clutch plates are the case; thus, the clutch is always en-
being shorter than the right. splined to a clutch hub which, in turn, gaged.
PINION SHAFT
4211
DIFFERENTIAL PINION GEAR
CASE-4204 THRUST WASHER
7
PINION SHAFT
RETAINING PINS 4230
359475-S PINION GEARS
4215
PINION GEAR
THRUST WASHER
4230
PINION SHAFT SHIM(S)
44207 (AS REQ'D.)
4A324
DIFFERENTIAL
CASE-TO-COVER CASE COVER
RETAINING SCREWS 4204
50025-S2
SIDE GEAR
THRUST WASHER
4228
CENTER BLOCK
(SHORT PINION PINION
SHAFT SEAT) SHAFT
4420 44207
PRE-LOAD SPRING
PINION GEAR PLATE-4A326
THRUST WASHER
PINION GEAR
4230
THRUST WASHER
4230 CLUTCH PLATE
EAR GUIDES (4)
4A323
E 1896-A
FIG. 3—Traction-Lok Differential

REAR AXLE SHAFT, WHEEL ameter of the retainer should be wiped

BEARING AND OIL SEAL clean with a dry cloth. These parts
REPLACEMENT must not be degreased or lubricated.
5. Rear wheel oil seals with synthe-
The rear axle shafts, wheel bear- tic sealing elements have been incor-
ings, and oil seal can be replaced porated in production only. However,
without removing the differential as- leather seals only will be used as re-
sembly from the axle housing. placements for the synthetic sealing
elements. Install the new oil seal with
REMOVAL OF the tools shown in Figs. 10 and 12. Be
AXLE SHAFT sure the new seal has been soaked in
SAE 10 oil for 1/2 hour before in-
Synthetic wheel bearing seals are E 1731-A stalling it. Wipe a small amount of oil
used in production only. Removal and resistant sealer on the outer edge of
insertion of rear axle shafts must be FIG. 5—Removing Rear Wheel the seal before it is installed. Do not
performed with caution. The entire put sealer on the sealing lip.
Bearing Retainer Ring
length of the shaft (including spline)
up to the seal journal must pass
through the seal without cutting of the INSTALLATION OF
On Ford, Mercury and Meteor mo-
seal element during axle removal or AXLE SHAFT
dels, it is necessary to first drill a 1/4
installation will result in early seal fai- inch hole not more than 5/16 inch
lure. Leather seals only will be used as 1. Carefully slide the axle shaft into
deep in the retainer ring surface bef-
service r e p l a c e m e n t for synthetic the housing so that the rough forging
ore using the cold chisel.
wheel bearing seals. of the shaft will not damage the oil
2. Remove the bearing from the
1. Remove the wheel cover, wheel seal. Start the axle splines into the
axle shaft with the tool shown in Fig.
and tire from the brake drum. side gear, and push the shaft in until
6 or Fig. 7.
2. Remove the nuts that secure the the bearing bottoms in the housing.
3. Whenever a rear axle shaft is re-
brake drum to the axle shaft flange, 2. Install the bearing retainer plate
placed, the oil seal must be replaced.
then remove the drum from flange. and the nuts that secure it. Torque the
Remove the seal with Tool 1175-AB
3. Working through the hole pro- nuts to specifications.
and a slide hammer (Fig. 8). If new
vided in each axle shaft flange, re- 3. Install the brake drum and the
leather-type wheel bearing service
move the nuts that secure the wheel drum attaching (Tinnerman) nuts.
seals are to be installed, soak new oil
bearing retainer plate. Then pull the 4. Install the wheel and tire on the
seals in SAE 10 oil for 1/2 hour
axle shaft assembly out of the axle drum. Install the wheel cover.
before installing.
housing (Fig. 4). The brake backing
plate must not be dislodged. Install DRIVE PINION OIL SEAL
one nut to hold the plate in place after INSTALLATION OF REAR REPLACEMENT
the axle shaft is removed. WHEEL BEARING AND
SEAL COLLAPSIBLE SPACER
Too/-4235-C 1. Inspect the machined surface of Synthetic seals must not be cleaned,
the axle shaft and the axle housing for soaked or washed in cleaning solvent.
rough spots or other irregularities The drive pinion oil seal can be re-
which would affect the sealing action placed without removing the differen-
of the oil seal. Check the axle shaft tial carrier assembly from the axle
splines for burrs, wear or twist. Care- housing.
fully remove any burrs or rough spots. 1. Raise the vehicle and install
E1032-D
Replace worn or damaged parts. safety stands. Remove both rear wheels
FIG. 4—Removing Axle Shaft 2. Lightly coat wheel bearing bores and brake drums.
with axle lubricant. 2. Make scribe marks on the drive
3. Place the retainer plate on the shaft end yoke and the axle U-joint
REMOVAL OF REAR axle shaft, and press the new wheel flange to insure proper position of the
WHEEL BEARING AND bearing on the shaft with the tool drive shaft at assembly (Fig. 11). Dis-
SEAL shown in Fig. 6 or Fig. 9. Do not at- connect the drive shaft from the axle
Synthetic seals must not be cleaned, tempt to press on both the bearing U-joint flange. Be careful to avoid
soaked or washed in cleaning solvents. and the inner retainer ring at the same dropping the loose universal joint
Removal of the wheel bearings from time. bearing cups. Hold the cups on the
the axle shaft makes them unfit for 4. Using the bearing installation spider with tape. Mark the cups so
further use. tool (Tool 4621-A or 4234-4), press that they will be in their original posi-
1. On all models except Ford, Mer- the bearing inner retainer ring on the tion in relation to the flange when
cury or Meteor, if the rear wheel shaft until the retainer seats firmly they are assembled. Remove the drive
bearing is to be replaced, loosen the against the bearing. On Ford, Mercu- shaft from the transmission extension
inner retainer ring by nicking it deeply ry, or Meteor models, before assem- housing. Install an oil seal replacer
with a cold chisel in several places bling the retainer onto the axle shaft, tool in the transmission extension
(Fig. 5). It will then slide off easily. the shaft journal and the inside di- housing to prevent transmission fluid
FOR FIXED
Press Ram
BED PRESS
Bridge
Side Rail
_J f.
Press Ram
LSupport Flange^
BEARING REMOVAL
VIEW 3
BEARING
Detail 4
Adapter Ring
Tool-T60K-1225-A
Press Ram
1
— Support Plate —»
FOR BEARING INSTALLATION
ADJUSTABLE VIEW 4
BED PRESS
FOR
PUSH-PULLER
OPERATION
BEARING REMOVAL
Press Ram VIEW 5
' — Support Plat* —*

BEARING INSTALLATION
VIEW 2
BEARING
BEARING
BEARING
1 INSTALLATION
Support Plate VIEW 6
BEARING REMOVAL
VIEW 1 E1269-B
FIG. 6—Removing and Installing Wheel Bearing

SCRIBE MARKS
AXLE SHAFT 5/l<>-24

FLANGE 4 REQ'D.
12-15 LB. FT.
Tool
4621-A
U-BOLT-4529 2 REQ'D.
E1921A IE 1783-A
FIG. 9—Installing Wheel Bearing FIG. 11 — Drive Shaft-To-Axle

U-Joint Connection
13. Install a new integral nut and
washer on the pinion shaft. (Apply a drive shaft end yoke and the axle U-
small amount of lubricant on the joint flange (Fig. 11).
FIG. 7—Removing Wheel Bearing washer side of the nut). 19. Check the lubricant level Make
leakage. Refer to the transmission 14. Hold the flange with the tool sure the axle is in running position.
group for the appropriate tool. shown in Fig. 24 or Fig. 25 while Add whatever amount of specified lu-
3. Install an in-lb torque wrench on tightening nut. bricant is required to reach the lower
the pinion nut. Record the torque re- 15. Tighten the pinion shaft nut, edge of the filler plug hole.
quired to maintain rotation of the pi- rotating the pinion occasionally to in-
nion shaft through several revolutions. sure proper bearing seating, and take SOLID SPACER
4. Scribe the pinion shaft and the frequent preload readings until the
U-joint flange inner surface for as- preload is at the original recorded The drive pinion oil seal can be re-
sembly realignment. While holding the reading established in step 3. placed without removing the differen-
flange with the tool shown in Fig. 22 16. After original preload has been tial carrier assembly from the axle
or Fig. 23, remove the integral pinion reached, tighten the pinion nut slowly, housing.
nut and washer. until an additional preload of 8 to 14 1. Make scribe marks on the drive
5. Clean the pinion bearing retainer in-lb over the original reading is shaft end yoke and the axle U-joint
around the oil seal. PlaSe a drain pan reached. The preload should not ex- flange to insure proper position of the
under the seal, or raise the front of ceed 8 to 14 in-lb over the original drive shaft at assembly (Fig. 11). Dis-
the vehicle higher than the rear. reading, or bearing failure may result. connect the drive shaft from the axle
6. Using the tool shown in Fig. 24 Under no circumstances should the pi- U-joint flange. Be careful to avoid
or Fig. 25, remove the U-joint flange. nion nut be backed off to lessen pre- dropping the loose universal joint
7. Using the tool shown in Fig. 26 load. If this is done, a new pinion bearing cups. Hold the cups on the
remove the drive pinion oil seal. bearing spacer must be installed. In spider with tape. Mark the cups so
8. Clean the oil seal seat. addition, the U-joint flange must that they will be in their original posi-
9. Install the new seal in the retain- never be hammered on, or pneumatic tion in relation to the flange when
er, using the applicable tool shown in tools used. they are assembled. Remove the drive
Fig. 47. 17. Remove the oil seal replacer shaft from the transmission extension
10. Check splines on the pinion tool from the transmission extension housing to prevent transmission leak-
shaft to be sure they are free of burrs. housing. Install the front end of the age. Refer to the transmission group
If burrs are evident, remove them by drive shaft on the transmission output for the appropriate tool.
using a fine crocus cloth, working in a shaft. 2. Make punch marks on the end
rotational motion. Wipe the pinion 18. Connect the rear end of the of the pinion shaft and the U-joint
shaft clean. drive shaft to the axle U-joint flange, flange inner surface for realignment.
11. Apply a small amount of lubri- aligning the scribe marks made on the While holding the flange with the tool
cant to U-joint splines. shown in Fig. 22 or Fig. 23, remove
Align scribe marks on U-joint Tool-1177 the integral pinion nut and washer.
or 4245-B
flange and pinion shaft. 3. Clean the pinion bearing retainer
12. Install the U-joint flange using around the oil seal. Place a drain pan
the tool shown in Fig. 46. under the seal, or raise the front of
the vehicle higher than the rear.
4. Using the tool shown in Fig. 24
or Fig. 23, remove the U-joint flange.
5. Using the tool shown in Fig. 26
remove the drive pinion oil seal.
6. Clean the oil seal seat.
7. Install the new seal in the retain-
E1359-A er, using the applicable tool shown in
Fig. 47.
FIG. 8— Removing Rear Wheel FIG. 70—Installing Rear Wheel 8. Check splines on the pinion shaft
Bearing Oil Seal Bearing Oil Seal to be sure they are free of burrs. If
burrs are evident, remove them with a 3. Install an in-lb torque wrench on Add whatever amount of specified lu-
fine crocus cloth, working in a rota- the pinion nut. Record the torque re- bricant is required to reach the lower
tional motion, then wipe clean. Apply quired to maintain rotation of the pin- edge of the filler plug hole.
a small quantity of lubricant to U- ion shaft through several revolutions. SOLID SPACER
joint splines. 4. While holding the flange with the
9. Install the U-joint flange using tool shown in Fig. 23 or Fig. 24, re- 1. Disconnect the drive shaft from
the tool shown in Fig. 46. move the integral pinion nut and the axle U-joint flange. Be careful to
10. Install a new integral attaching washer. avoid dropping the loose universal
nut and washer on the pinion shaft. 5. Clean the pinion bearing retainer joint bearing cups. Hold the cups on
11. Tighten the pinion attaching around the oil seal. Place a drain pan the spider with tape. Mark the cups so
nut, rotating the pinion several times under the seal, or raise the front of that they will be in their original posi-
to seat the bearing, then torque the pin- the vehicle higher than the rear. Syn- tion in relation to the flange when
ion nut to 180-200 ft-lbs. Hold the thetic seals must not be cleaned, they are assembled. Remove the drive
flange with the tool shown in Fig. 22 soaked or washed in cleaning solvent. shaft from the transmission extension
or Fig. 23 while the nut is being tight- 6. Using the tool shown in Fig. 23 housing. Install an oil seal replacer
ened. or Fig. 24, remove the U-joint flange. tool in the transmission extension
12. Remove the oil seal replacer 7. Check splines on the pinion shaft housing to prevent transmission leak-
tool from the transmission extension to be sure they are free of burrs. If age. Refer to the transmission group
housing. Install the front end of the burrs are evident, remove them by for the appropriate tool.
drive shaft on the transmission output using a fine crocus cloth, working in a 2. While holding the flange with the
shaft. rotational motion, then wipe clean. tool shown in Fig. 23 or Fig. 24, re-
13. Connect the rear end of the Apply a small amount of lubricant move the integral pinion nut and
drive shaft to the axle U-joint flange, to U-joint splines. washer.
aligning the scribe marks made on the 8. Install the U-joint flange using 3. Clean the pinion bearing retainer
drive shaft end yoke and the axle U- the tool shown in Fig. 46. around the oil seal. Place a drain pan
joint flange. 9. Install a new integral nut and under the seal, or raise the front of
14. Check the lubricant level, and washer on the pinion shaft. (Apply a the vehicle higher than the rear.
add whatever amount of specified lu- small amount of lubricant on the 4. Using the tool shown in Fig. 23
bricant is necessary to reach the lower washer side of the nut.) or Fig. 24, remove the U-joint flange.
edge of the filler plug hole. Make sure 10. Hold the flange with the tool 5. Check splines on the pinion shaft
the axle is in running position when shown in Fig. 23 or Fig. 24 while the to be sure they are free of burrs. If
the level is checked nut is being tightened. burrs are evident, remove them by
11. Tighten the pinion shaft nut, using a fine crocus cloth, working in a
ORIGINAL U-JOINT FLANGE rotating the pinion occasionally to in- rotational motion, then wipe clean.
(IN VEHICLE REPLACEMENT) sure proper bearing seating, and take Apply a small amount of lubricant to
frequent preload readings until the U-joint splines.
Use procedure as outlined under preload is at the original recorded 6. Install the U-joint flange using
Drive Pinion Oil Seal Replacement. reading established in step 3. the tool shown in Fig. 46.
Synthetic seals must not be cleaned, 12. After original preload has been 7. Install integral attaching nut and
soaked or washed in cleaning solvent. reached, tighten the pinion nut slowly, washer on the pinion shaft.
until an additional preload of 8 to 14 8. Tighten the pinion attaching nut,
INSTALLATION OF A NEW in-lb over the original reading is rotating the pinion several times to
UNIVERSAL JOINT FLANGE reached. (The preload should not ex- seat the bearing, then torque the pin-
ceed 8 to 14 in-lb over the original ion attaching nut to 180-220 ft-lbs.
reading, or bearing failure may result. Hold the flange with the tool shown in
COLLAPSIBLE SPACER Under no circumstances should the Fig. 23 or Fig. 24 while the nut is
pinion nut be backed off to lessen pre- being tightened.
1. Raise the vehicle and install load. If this is done, a new pinion 9. Remove the oil seal replacer tool
safety stands. Remove both rear wheels bearing spacer must be installed. In from the transmission extension hous-
and brake drums. addition, the U-joint flange must ing. Install the front end of the drive
2. Disconnect the drive shaft from never be hammered on, or power tools shaft on the transmission output shaft.
the axle U-joint flange. Be careful to used. 10. Connect the rear end of the
avoid dropping the loose universal 13. Remove the oil seal replacer drive shaft to the axle U-joint flange.
joint bearing cups. Hold the cups on tool from the transmission extension 11. Check the lubricant level, and
the spider with tape. Mark the cups so housing. Install the front end of the add whatever amount of specified lu-
that they will be in their original posi- drive shaft on the transmission output bricant is necessary to reach the lower
tion in relation to the flange when shaft. edge of the filler plug hole. Make sure
they are assembled. Remove the drive 14. Connect the rear end of the the axle is in running position when
shaft from the transmission extension drive shaft to the axle U-joint flange, the level is checked.
housing. Install an oil seal replacer aligning the scribe marks made on the
tool in the transmission extension drive shaft end yoke and the axle U- DRIVE SHAFT PINION ANGLE
housing to prevent transmission fluid joint flange. ADJUSTMENT
leakage. Refer to the transmission 15. Check the lubricant level. Make Refer to Group 3, Part 3-2 for this
group for the appropriate tool. sure the axle is in running position. procedure.

CARRIER ASSEMBLY the sealed ball bearings, do not allow 7. Install the bearing retainers on
any quantity of solvent directly on the the attaching bolts on the axle housing
REMOVAL wheel bearings. Clean the mating sur- flanges. Install the nuts on the bolts
faces of the axle housing and carrier. and torque to specifications.
1. Raise the vehicle on a hoist and 2. Position the differential carrier 8. If the rear brake shoes were
remove the two rear wheels and tires. on the studs in the axle housing using backed off, adjust the brakes as out-
2. Remove the two brake drums (3 a new gasket between carrier and lined in Part 2-1 and install rubber
Tinnerman nuts at each drum) from housing. Install the carrier-to-housing plugs in the adjuster slots.
the axle shaft flange studs. If diffi- attaching nuts, and torque them to 9. Install the two rear brake drums
culty is experienced in removing the specifications. and the drum Tinnerman nuts.
drums, remove the brake adjuster 3. Remove the oil seal replacer tool 10. Install the rear wheels and tires.
knockout slug or rubber plug (if so from the transmission extension hous- 11. Fill the rear axle with specified
equipped) and back off the brake ing. Position the drive shaft so that lubricant.
shoes. the front U-joint slip yoke splines to
3. Working through the hole pro- the transmission output shaft. AXLE HOUSING (COIL
vided in each axle shaft flange, re- 4. Connect the drive shaft to the SPRING SUSPENSION)
move the nuts that secure the rear axle U-joint flange, aligning the scribe
wheel bearing retainer plate. Pull each marks made on the drive shaft end
axle shaft assembly out of the axle yoke and the axle U-joint flange dur- REMOVAL
housing using axle shaft remover, ing the removal procedure. Install the
Tool 4235-C. (Fig. 4). Care must be U-bolts and nuts and torque to speci- 1. Remove the carrier assembly
exercised to prevent damage to the fications. from the axle housing as outlined in
production-type synthetic oil seal, if so Differential Carrier Removal and In-
5. If the synthetic, production-type
equipped. Any roughing or cutting of stallation.
wheel bearing seals were replaced with
the seal element during removal or in- 2. Position safety stands under the
service-type leather seals, soak the
stallation can result in early seal fail- frame rear members, and support the
new rear wheel bearing oil seals in
ure. Install a nut on one of the brake SAE 10 oil for 1/2 hour before instal- axle housing with either a floor jack
backing plate attaching bolts to hold lation. Wipe a small amount of an oil or hoist.
the plate to the axle housing after the resistant sealer on the outer edge of 3. Disengage the brake line from
shaft has been removed. Whenever a each seal before it is installed. Do not the clips that retain the line to the
rear axle shaft is replaced, the wheel put any of the sealer on the sealing axle housing.
bearing oil seals must be replaced. lip. Install the oil seals in the ends of 4. Disconnect the vent tube from
Remove the seals with tool 1175AB. the rear axle housing with one of the the rear axle housing.
tools shown in Figs. 10 and 12. 5. Remove the brake backing plate
4. Make scribe marks on the drive
assemblies from the axle housing, and
shaft end yoke and the axle U-joint
support them with wire. Do not dis-
flange to insure proper position at as-
sembly. Disconnect the drive shaft at Tool connect the brake line.
T65F-1177.A 6. Disconnect the lower studs of the
the rear axle U-joint. Hold the cups
on the spider with tape. Mark the two rear shock absorbers from the
cups so that they will be in their orig- mounting brackets on the axle housing
inal position relative to the flange (Fig. 13 and 14).
when they are assembled. Remove the 7. Remove the attaching nut and
drive shaft from the transmission ex- washer, and disconnect the track bar
tension housing. Install an oil seal re- from the mounting stud on the axle
placer tool in the housing to prevent housing bracket.
transmission leakage. Refer to the 8. Lower the axle housing until the
transmission group for the appropriate coil springs are released. Lift out the
tool. E 1571-A coil springs and insulators.
5. Clean area around carrier to 9. Remove the nuts, washers and
housing surfaced with a wire brush and FIG. 12—Rear Axle Shaft Bearing pivot bolts that connect the suspension
wipe clean, to prevent dirt entry into Seal Installation lower arms to the axle housing. Dis-
the housing. Place a drain pan under connect both arms from the axle
the carrier and housing, remove the housing.
carrier attaching nuts, and drain the 6. Install the two axle shaft assem- 10. Disconnect the upper suspen-
axle. Remove the carrier assembly blies in the axle housing. Care must sion arm from the axle housing by re-
from the axle housing. be exercised to prevent damage to the moving the pivot bolt, nut, lock wash-
oil seals. The shorter shaft goes into er and the two eccentric washers (Fig.
INSTALLATION the left side of the housing. 13 and 14).
Carefully slide the axle shaft into 11. Lower the axle housing and re-
Synthetic production-type wheel the housing so that the rough forging move it from under the vehicle.
bearing seals must not be cleaned, of the shaft will not damage the oil
soaked or washed in cleaning solvent. seal. Start the axle splines into the INSTALLATION
1. Clean the axle housing and differential side gear, and push the
shafts using kerosene and swabs. To shaft in until the bearing bottoms in 1. Transfer the track bar mounting
avoid contamination of the grease in the housing. stud from the old to the new housing.
REAR SPRING
5560
VENT
TUBE
UPPER ARM
5500
INDENT TOWARD
FRONT OF VEHICLE
LEFT ARM INDENTED
BY 2 NOTCHES IN BUSHING FLANGE F 1353-A
f/Q. J3—R ear Axle Installation—Typical Coil Spring Suspension

NUT-33847-S8 9/16-12 100-130 LB FT. NO. 4 CROSSMEMBER-5029 VENT TUBE-4A001
• BOLT-304907-S2
9/16-12 80-105 LB. FT. • NUT-55754-S7 2
*-34785-S7
-CAM-5A637 (2 REQUIRED) NUT-34664-S
9/16-12 60-85 LB. FT. o
3/8-24 (2 REQUIRED) i
15-25 LB. FT. 4002 (2 REQUIRED)
O
BOLT-559bl-S2 WASHER-18041
TRACK BAR STUD-4269 VENT-4338 (2 REQUIRED) (2 REQUIRED)
•110-140 LB. FT. VENT MUST POINT
TO THE REAR CLIP-374998-S100 BUSHING-500939
BUMPER ASSEMBLY-4906 (4 REQUIRED)
WASHER-18171
(2 REQUIRED)
BOLT-40923-S2 BOLT-39883-S8
(2 REQUIRED) (4 REQUIRED)
NUT-33847- 9-13 LB. FT.
9/16-12*100-130 LB. FT BACKING PLATE
REAR AXLE ASSEMBLY
TRACK BAR AND L OC KWASHE R -34 785 -S 7 ASSEMBLY
4001 REFERENCE
BUSHING ASSEMBLY-5A639 *2290 R.H. #2210 L.H.
NUT-55754-S7 9/16-12 80-105 LB. FT.
TRACK BAR AND
oJSHfNG ASSEMBLY PARKING BRAKE
SHOCK ABSORBER-18080' CABLE »2A635 R.H
5A639 TO
REFERENCE (2 REQUIRED) •BOLT-2248 •2A809 L.H. <D
(8 REQUIRED) (2 REQUIRED) Q
• SEAL-2256
(2 REQUIRED) >
X
PRONGS MUST BE SECURELY
WHEEL-1007 LOCKED IN PLACE
INSULATOR-5536 (2 REQUIRED)
(4 REQUIRED) TIRE VALVE-1700
TIRE VALVE
(2 REQUIRED TO
XTENSION-1705© <D
(2 REQUIRED)
FRAME ASSEMBLY-5005 O
SPRING-5560
(2 REQUIRED) LOWER ARM-5A648 3
DRIVE SHAFT ASSEMBLY-4602 • NUT-34447-S8 7/16-20
(8 REQUIRED)
30-45 LB. FT. n
Q
•BRAKE DRUM-1126
(2 REQUIRED)
TIRE-1508
(2 REQUIRED)
BOLT-379334-S8 • NUT-372188-S32 (6 REQUIRED)
NUT-375022-S2 9/16-12 (2 REQUIRED) ASSEMBLE NUTS TO HOLD DRUM ASSEMBLY
70-90 LB. FT. NUT SECURELY AGAINST FLANGE
90-120 LB. FT. BOLT NUT-375022-S2
(2 REQUIRED)
-90 LB. FT. NUT
90-120 LB. FT. BOLT BOLT-3 79334-S8
(2 REQUIRED)
©USE 1705 VALVE EXTENSION
WITH FULL WHEEL COVERS
* TORQUE NUT OR BOLT
NUT-34988-S4
TORQUE NUT OR STUD
(4 REQUIRED)
NUT-375032-S36 1/2-23
ITEMS MARKED • 44-52 LB. FT. FRAME ASSEMBLY-5005
(2 REQUIRED) 50-85 LB. FT.
PURCHASED AS PART OF REFERENCE
4001 REAR AXLE ASSEMBLY NUT-375022-S2 (2 REQUIRED)
70-90 LB. FT. NUT
SPRING MUST BE POSITIONED
AS SHOWN FOR R.H. SIDE
SPRING MUST BE POSITIONED
AS SHOWN FOR L.H. SiDE
90-120 LB. FT. BOLTl
TIONAL
?6
El 746-A
FIG. 14—Redr Axle Installation—Thunderbird—Typical Ford, Mercury, Meteor and Continental Mark
If the axle housing is new, install a FRAME correct. Any shudder during heavy ac-
new vent. The hose attaching portion celeration, or deceleration may require
must face toward the front of the ve- a pinion and d r i v e s h a f t angle re-
hicle. adjustment as detailed in Driveshaft
2. If leather-type wheel bearing ser- and Pinion Angle Adjustment, Group
vice seals are to be installed, soak the 3, Part 3-2.
new rear wheel bearing oil seals in
SAE 10 oil for 1/2 hour before instal- AXLE HOUSING (LEAF
lation. Wipe a small amount of an oil SPRING SUSPENSION)
resistant sealer on the outer edge of TIGHTEN ARM 5-45/64 INCH
ATTACHING BOLTS HEIGHT FOR
each seal before it is installed. Do not AT 5-45/64 INCH INSTALLATION
put any of the sealer on the sealing HEIGHT POSITION OF ARMS REMOVAL
lip. Install the oil seals in the ends of E 1600-B
the axle housing with one of the tools 1. Raise the vehicle and support it
shown in Fig. 10 and 12. FIG. 75 -Axle Normal Curb with safety stands under the rear
3. Position the replacement axle Height and Controlled Height frame member.
housing under the vehicle, and raise for Arm Installation 2. Drain the lubricant from the
the axle with a hoist or floor jack. axle.
Connect the suspension lower arms to 13. With the axle at controlled curb 3. Make scribe marks on the drive
their mounting brackets on the axle height, torque the suspension upper shaft end yoke and the axle U-joint
housing with pivot bolts and nuts. Do and lower arm front pivot bolts and flange to insure proper position of the
not tighten the bolts and nuts at this nuts to specifications. Torque the drive shaft at assembly. Disconnect
point. lower arm-to-axle housing pivot bolts the drive shaft at the drive pinion
4. Position the suspension upper and nuts to specifications. flange.
arm in its mounting bracket on the 14. Remove the oil seal replacer 4. Disconnect the lower end of the
axle housing, and install the adjusting tool from the transmission extension shock absorbers.
bolt, eccentric washers, lock washer housing. Position the drive shaft so 5. Remove the wheels, brake drums
and nut. Leave the bolt and nut loose that the front U-joint slip yoke splines and both axle shafts as outlined in
at this point. to the transmission output shaft. Section 2.
5. Position the brake lines to the 15. Connect the drive shaft to the 6. Remove vent hose front vent
axle housing, and secure with the re- U-joint flange, aligning the scribe tube (Corbin clamp) and remove vent
taining clips. marks made on the drive shaft end tube from brake tube junction and
6. Install the brake backing plates yoke and the axle U-joint flange dur- axle housing.
on the axle housing flanges. ing the removal procedure. Install the 7. Remove the hydraulic brake T-
7. Connect the track bar to the U-bolts and nuts and torque to speci- fitting from the axle housing. Do not
mounting stud, install the washer and fications. open the hydraulic brake system lines.
attaching nut, and torque to specifica- 16. Carefully slide the two axle Remove the hydraulic brake line from
tions. shaft assemblies in the axle housing. its retaining clip on the axle housing.
8. Position the rear coil springs and The shorter shaft goes into the left 8. Remove both axle shaft oil seals
insulators in the pockets provided. side of the housing. Use care in slid- with the tool shown in Fig. 8.
9. Connect the lower studs of the ing the axle shafts into the housing so 9. Remove both brake backing
two rear shock absorbers to the that the rough forging of the shaft will plates from the axle housing and sus-
mounting brackets on the axle hous- not damage the oil seal. Start the axle pend them above the housing with
ing. Install the attaching nuts, and splines into the differential side gear, mechanic's wire. The hydraulic brake
torque to specifications. and push the shaft in until the rear lines and the parking brake cables are
10. Connect the vent tube to the wheel bearing bottoms in the housing. still attached to the brake backing
vent on the housing. If axle housing is 17. Install the rear wheel bearing plates.
new, install a new vent. retainers on the attaching bolts on the 10. Support the rear axle housing
11. Clean the mating surfaces of axle housing flanges. Install the nuts on a jack, and then remove the spring
the axle housing and differential car- on the bolts and torque to specifica- clip nuts. Remove the spring clip
rier. Position the carrier on the tions. plates (Fig. 16).
mounting studs on the housing using a 18. If the rear brake shoes were 11. Lower the axle housing and re-
new gasket between carrier and hous- backed off, adjust the brakes as out- move it from under the vehicle.
ing. Install the copper washers and the lined in Part 2-1, and install rubber 12. If the axle housing is being re-
carrier-to-housing attaching nuts, and plugs in the adjuster slots. placed, transfer all the differential and
torque to specifications. 19. I n s t a l l the two rear brake pinion parts to the new housing. See
12. Make sure that both the front drums and the drum attaching (Tin- Section 4, Major Repair Operation*.
and rear pivot bolts of the upper and nerman) nuts.
the two lower arms are loose, and 20. Install the rear wheels and tires. INSTALLATION
then raise the axle assembly to con- 21. Fill the rear axle to the bottom
trolled curb height (Fig. 15). Hold the of the filler plug hole located in either 1. Raise the axle housing into posi-
axle at controlled curb height by plac- the carrier casting or housing cover tion so that the spring clip plates can
ing blocks or pieces of steel pipe be- with specified lubricant. Be sure that be installed. On a Montego or Fair-
tween the axle housing and the bumper the axle is in operating position. lane, position the spring upper insula-
rear screw on the side rail. (See speci- 22. Road test the vehicle to be sure tors and retainers between the axle
fications for dimensions.) that pinion and driveshaft angles are housing and springs and install the
WASHER
18041
EXISTING HOLE
IN SIDE RAIL
#1 NUT 372188- S32
4137-WEDGES
SPRING-5556
INSULATOR-5732
SHACKLE 5A630
NUT34448-S8
E 1510-B
FIG. 16—Rear Axle Installation—Lincoln Continental—-Typical of Cougar, Fairlane, Montego and Mustang
lower insulators. Torque the spring edges of the new oil seal with a non- tube.
clip nuts to specification. hardening type of sealer such as Per- 7. Raise the axle housing and con-
2. Place the brake backing plates in matex No. 2 or its equivalent. nect the shock absorbers.
their normal position on the axle 4. Install the axle shafts, brake 8. Connect the rear end of the drive
housing. drums and wheels as outlined in Sec- shaft to the axle U-joint flange, align-
3. Install new axle shaft oil seals tion 2. ing the scribe marks made on the
with the tool shown in Fig. 10. Soak 5. Attach the hydraulic brake line drive shaft end yoke and the axle U-
the new seals in light weight engine oil T fitting to the axle housing, and se- joint flange.
(SAE 10) for 1/2 hour before install- cure the hydraulic brake line in its re- 9. Fill the axle with the proper
ing them. Installation without use of tainer on the axle housing. grade and amount of lubricant.
the proper tool will distort the seal 6. Install vent tube to brake tube 10. Road test the vehicle.
and cause leakage. Coat the outside junction and install vent hose to vent

DISASSEMBLY OF scribe marks for proper location dur- ential pinion shaft lock pin (Fig. 19),
DIFFERENTIAL CARRIER ing assembly. and separate the 2-piece differential
2. Remove the adjusting nut locks, case.
bearing caps, and adjusting nuts. Then 7. Drive out the pinion shaft with a
CONVENTIONAL lift the differential case assembly out brass drift (Fig. 20).
DIFFERENTIAL of the carrier. 8. Remove the gears and thrust
(Remove the bearing caps by tap- washers (Fig. 48).
A disassembled view of the rear ping the caps lightly with a soft mal-
axle assembly is shown in Fig. 17. let). LIMITED-SLIP DIFFERENTIAL
After mounting the carrier in a 3. Remove the differential bearings
holding fixture, disassemble the car- with the tools shown in Fig. 18. 1. Remove the differential case
rier as outlined in the following proce- 4. Mark the differential case, cover, from the carrier and remove the bear-
dures: and ring gear for assembly in the orig- ings from the differential case in the
1. Mark one differential bearing inal position. same manner as the conventional dif-
cap and the mating bearing support 5. Remove the bolts that attach the ferential case.
with punch marks to help position the ring gear to the differential case. Press 2. Place the differential case in a
parts properly during assembly of the the gear from the case or tap it off hydraulic press, and apply about one
carrier. Also, mark one of the bearing with a soft-faced hammer. ton pressure across the case bearing
adjusting nuts and the carrier with 6. With a drift, drive out the differ- hubs while removing the ring gear at-
AXLE HOUSING-4010
AXLE SHAFT-4725 RETAINER RING-1100
FLAT WASHER (LIMITED SLIP ONLY)
DRIVE GEAR ATTACHING BOLT
DIFFERENTIAL
PINION SHAFT-4211 DIFFERENTIAL CASE COVER -4206
DIFFERENTIAL PINION GEAR-4215
THRUST WASHER-4230
ADJUSTING NUT-4067
CARRIER HOUSING-4025 PINION BEARING

SPACER-4662
DRIVE PINION-4610
PINION FRONT
BEARING-4621
RING GEAR PILOT BEARING DEFLECTOR-4859

RETAINER-4627
PINION REAR
BEARING CUP-4616
PINION RETAINER-4668
PILOT BEARING-4A242
SEAL-4676 FLAN GE_4858 E1750-A
FIG. 17—Rear Axle Disassembled—Typical

gether and overcome pre-load spring

tension.) Then, while the case is still
DIFFERENTIAL
under pressure, loosen the two Allen
Tool— 7 571-4220-A
BEARING or Phillips head screws which hold the
T66P°4220-P case halves together until one or two
threads of the screws remain engaged.
Remove the case assembly from the
press. Tap on the cover to spring it
loose; then, remove both screws.
5. With the cover facing down, lift
off the case. Remove the pre-load
spring plate and four pre-load springs.
E 1724-A 6. From the cover remove the side
gear, four clutch plate ear guides,
FIG. 20—Driving Out Differential clutch hub, friction and steel clutch
Pinion Shaft plates and shim(s).
7. With a suitable drift, drive out
TRACTION-LOK the pinion shaft lock pins from the
E1015-B
DIFFERENTIAL case.
FIG. 18—Removing Differential 1. Remove the differential case 8. With a brass drift, drive out the
Bearing—Ford from the carrier and remove the bear- long pinion shaft from the case. Drive
ings from the differential case in the from the end opposite the lock pin
taching bolts. Applying pressure will same manner as the conventional dif- hole.
contain the spring pressure between ferential case. 9. Remove the two short pinion
the differential case and cover until 2. Remove ten bolts securing the shafts using a drift, driving each shaft
after the bolts are removed, and there- ring gear to the differential case as- from the center outward. Lift out the
by prevent stripping of the threads. sembly. The ring gear must be re- center block, then remove the pinion
moved in order to separate the case gears, thrust washers and side gear
3. Release the hydraulic press ram,
halves. and thrust washer.
and remove differential case cover.
4. Remove the Belleville spring 3. Remove the ring gear by tapping 10. If the differential bearings are
(Fig. 54). the gear with a soft hammer or press removed, the bearings can be installed
5. Remove the steel and the bonded the gear from the case. in one of the following ways:
clutch plates. 4. Place the differential case in a a. With the differential case and
6. Remove the differential clutch press to load the bearing journals so cover completely assembled.
hub, side gear, and thrust washer. that the pre-load of the springs is ov- b. On the case or cover when disas-
7. Remove the ring gear from the ercome (approx. 1,500 lbs.). (If a sembled. However, when pressing the
differential case. press is not available, two 7/16 inch bearings on the cover, a block of
8. Drive out the differential pinion bolts and nuts can be used in the ring wood or fiber must be used as shown
shaft lock pin. gear mounting holes (one on each in Fig. 21 in order to avoid damage to
side) to compress the case halves to- the cover.
9. With a brass drift, drive out the
differential pinion shaft. Then remove
the pinion gears, the other side gear,
and thrust washers.
DIFFERENTIAL BEARING
E 1709-A
E1892-A
FIG. 79—Removing Differential
Pinion Shaft Lock Pin FIG. 21—Installing Differential Bearing—Traction-Lok
REMOVAL AND ing manufacture by locating on these

DISASSEMBLY OF cups after they are installed in their
DRIVE PINION AND bores. If the cups are worn or dam-
BEARING RETAINER aged, they should be replaced.
Remove the bearing cups as shown
I. T u r n the c a r r i e r assembly in Figs. 30, 31 and 32. Install the cups
upright and remove the pinion shaft as shown in Figs. 33 and 34.
nut (Fig. 22 and Fig. 23).
2. Remove the U-joint flange from Press Ram
the pinion shaft (Figs. 24 and 25). Fiber Block
3. Remove the pinion seal (Fig. 26).
4. Remove the pinion, bearing, and Tool -
retainer assembly from the carrier 757L-4674-A
housing (Fig. 41). Measure the shim FIG. 24 — Removing U-Joint Flange
thickness with a micrometer. Record
this original shim thickness. If a new
gear set is installed during assembly, a
new shim will have to be installed.
The original shim thickness is one of HOSE
the factors necessary in determining
the new shim thickness. Extreme care
must be taken not to damage the
mounting surfaces of the retainer and \
carrier.
5. Place a protective sleeve (hose)
on the pinion pilot bearing surface. 1710-A
Press the pinion shaft out of the pin- FIG. 27 -Removing Pinion Front
ion front bearing cone with the tool
shown in Fig. 27. Bearing
O / - T 5 7 L - 4 8 5 7-A E1485-A
FIG. 22—Removing Pinion Shaft

Nut
E1902A
FIG. 25 —Flange Removal Tool
FIG. 28 —Removing Pinion Rear

Bearing Cone
E 1486-B
After the new cups are installed,
make sure they are seated in the re-
Tool- 7 7 75-AB
tainer by trying to insert a 0.0015-inch
FIG. 23— U-Joint Flange Holding Tool—T50T-100-A feeler gauge between the cup and the
Tool |E 1780. A
bottom of the bore.
Whenever the cups are replaced, the
6. Press the pinion shaft out of the FIG. 26—Removing Pinion Seal cone and roller assemblies should also
pinion rear bearing cone and roller be replaced.
(Fig. 28).
PINION BEARING CUPS DRIVE PINION AND
PILOT BEARING
RING GEAR SET
1. Remove the pilot bearing as Do not remove the pinion bearing
shown in Fig. 29. Drive out the pilot cups from the retainer unless the cups When replacing a ring gear and pin-
bearing and the bearing retainer to- are worn or damaged. The flange and ion, note that the original factory in-
gether. pilot of the retainer are machined dur- stalled shim is of the correct thickness
PINION BEARING Press Ram Tool -

RETAINER T57L - 4676-A2
Tool -
Tool~T53L-200-A T57L - 4614-A
E 1482-B
FIG. 31—Removing Pinion Front

Bearing Cup
indicated in Part 4-3, Specifications.
A new ring gear and pinion should 1736-/
always be installed in an axle as a

FIG. 33—Installing Pinion Front
matched set (never separately). Be
sure the same identifying (matching) Bearing Cup
number, appears on the bolt hole face
too;- IB .Press Ram
of the ring gear and on the head of
the drive pinion (Fig. 35). T55P-46U A2V • H " ^ ^
\
3. After determining the correct Tool-
shim thickness as explained in the T57L-46U-A
Tool-T57L-4625-A
or 4625-K
E 1725-A
FIG. 29—Removing Pilot Bearing ss Rom
to adjust for individual variations in Too/-T58L-70?-A

or4675-J
both the carrier housing dimension
and in the original gear set dimension.
Therefore, to select the correct shim
thickness for the new gear set to be
installed, follow these steps: FIG. 34—Installing Pinion Rear
1. Use a micrometer to measure Bearing Cup
the thickness of the original shim re- 2. Place the cups on the bearings
moved from the axle and use the same and set the differential case in the car-
thickness upon installation of the re- rier.
placement carrier assembly or drive 3. Install the bearing caps and ad-
pinion. If further shim change is ne- justing nuts as outlined in Steps 11
cessary, it will be indicated in the thru 14 under Assembly and Installa-
tooth pattern check. tion of Conventional Differential Case
2. If the original shim is lost, sub- which follows in this section.
stitute a nominal shim for the original FIG. 32—Removing Pinion Rear 4. Tighten the right nut two notches
and use the tooth pattern check to Bearing Cup beyond the position where it first con-
determine if further shim changes are tacts the bearing cup. Rotate the dif-
foregoing steps, install the new pinion
required. Nominal shim thicknesses is ferential case several revolutions in
and ring gear as outlined under As-
each direction while the bearings are
sembly.
DIFFERENTIAL CASE
BEARINGS AND RING
GEAR TEST
If the ring gear runout check (be-
fore disassembly) exceeded specifica-
tions, the condition may be caused by
a warped gear, a defective case, or ex-
cessively worn differential bearings.
To determine the cause of excessive MATCHED
E 1734-A GEAR SET
runout proceed as follows: IDENTIFICATION
E 1628-A
1. Assemble the two halves of the
differential case together without the
FIG. 30—Removing Pinion Front ring gear, and press the two differen- FIG. 35— Pinion and Ring Gear
Bearing Cup tial side bearings on the hubs. Markings
Press, Ram COLLAPSIBLE PINION

Too/-T53L-200-A Fiber B/oc. BEARING SPACER
INSTALLATION
1. Install the drive pinion rear bear-
REAR BEARING DRIVE
CONE AND
ing cone and roller on the pinion shaft
PINION
ROLLER (Figs. 37 m 38).
Place a new spacer on the pinion
Too/- Too/- shaft (Fig. 39).
T57L-4621-B
T57L-46U-A 2. Place the bearing retainer on the
pinion shaft, and install the front
bearing cone and roller. Press the
front bearing cone and roller into posi-
tion as shown in Fig. 40. Be careful
not to crush the bearing spacer.
3. Lubricate the O-ring with axle
L-462S-A lubricant and install it in its groove in
4625-K or 4625-KA
>: M E 1726-A 1701-A the pinion retainer. Be careful not to
twist it. Snap the O-ring into position.
FIG. 36—Installing Pilot Bearing FIG. 37—Installing Pinion Rear 4. Place the proper shim on the
Bearing Cone carrier housing and install the pinion
loaded to seat the bearings in their and retainer assembly, being careful
PRESS RAM not to pinch the O-ring (Fig. 41).
cups. This step is important.
5. Again loosen the- right nut to re- 5. Install the pinion attaching bolts.
lease the preload. Check to see that Torque the bolts to specification.
the left nut contacts the bearing cup. 6. Place the slinger over the pinion
Using the dial indicator set-up shown shaft and against the front bearing.
in Fig. 10, Part 4-1, adjust the preload Tool - 4621 L 7. Install a new seal in the bearing
to 0.008 to 0.012 case spread for new retainer (Fig. 47).
bearings or 0.005 to 0.008 for the ori- 8. Install the U-joint flange (Fig.
ginal bearings, if re-used. 49).
6. Check the runout of the differen- 9. Start a new integral nut and
tial case flange with a dial indicator. washer on the pinion shaft.
If the runout does not now exceed
Press Ram
specifications, install a new ring gear.
If the runout still exceeds specifica- L* Fiber Block
tions, the ring gear is true and the
trouble is due to either a defective
E1903A
case or worn bearings.
7. Remove the differential case FIG. 38—Installing Pinion Rear
from the carrier and remove the side Bearing Cone Tool-
bearings from the case. T57L-4621
8. Install new bearings on the case
ASSEMBLY OF DIFFERENTIAL
hubs, and again install the differential
CARRIER
assembly in the carrier without the
ring gear. PILOT BEARING
9. Check the case runout again with INSTALLATION
the new bearings. If the runout is now 1. Drive the new pilot bearing in-
within limits, the old bearings were ward until it bottoms, as shown in
excessively worn. Use the new bear- Fig. 36.
ings for assembly. If the runout is still 2. Using the same tool indicated in E 1712-A
excessive, the case is defective and Fig. 36, install the new pilot bearing
should be replaced. retainer with the concave side up.
FIG. 40—Installing Pinion Front
Bearing
O-RING PILOT
FLANGE REAR BEARING
BEARING
SPACER RETAINER
PILOT
PINION BEARING
FRONT BEARING
SEAL RETAINER SHIM
E 1782-A
FIG. 39—Pinion and Bearing Retainer

the proper preload is established. Do que wrench, torque the nut to 180-220
not overtighten the nut. If excessive ft-lbs. While tightening the nut, rotate
preload is obtained as a result of over- the bearing retainer to determine the
tightening, replace the collapsible existance of any bearing preload
bearing spacer. which will be indicated by a slight
Do not back off the pinion shaft nut drag in the rotation of the retainer.
to establish pinion bearing preload. If
the torque on the pinion shaft nut is DETERMINING SPACER
less than 175 ft-lbs after bearing pre- SIZE FROM
load is established, a new collapsible PRELOAD READING
spacer must be used.
1. If bearing drag indicates a pre-
SOLID PINION BEARING
load condition exists, apply an in-lb
SPACER INSTALLATION
torque wrench to the pinion nut as
The spacer is serviced in 20 sizes shown in Fig. 42 and read the torque
listed in Part 4-5. The manner of sel- required to turn the shaft. Effort
ecting the size spacer required for ob- should be 12-1/2 to 32-1/2 in-lbs.
taining correct preload is included in 2. If preload is the correct valve,
E 1195-C the following assembly procedure. p r o c e e d with assembly procedure
1. Install the drive pinion rear bear- given in Final Assembly of Pinion and
ing cone and roller assembly on the Retainer, which follows.
Pinion and Retainer Assembly pinion shaft as shown in Figs. 38 or 2. If preload exists, but is below
10. Hold the flange with the tool 39. specification, select the correct spacer
shown in Fig. 22 (Ford) or Fig. 23 2. Select a new solid spacer of a from Fig. 43 and install, completing
(Mercury), and torque the pinion shaft larger size (0.485 inch thick), and slide assembly as shown in Final Assembly
nut to 175 ft-lbs. Do not exceed 175 it over the pinion shaft against the of Pinion and Retainer.
ft-Ibs at this time. rear bearing.
The pinion bearing preload can be DETERMINING SPACER
11. Check the pinion bearing pre- SIZE FROM END
load as shown in Fig. 42. Correct accurately measured only when the
pinion shaft nut is torqued to 180- PLAY READING
pre-load will be obtained when the
torque required to rotate the pinion in 220 ft-lbs. If a spacer smaller than re- 1. If no perceptible preload is felt
the retainer is as specified in Part 4-3. quired was used, the specified 180- when rotating the pinion shaft, install
If the torque required to rotate the pin- 220 ft-lbs torque would damage the a dial indicator as shown in Fig. 44,
ion is less than specified, tighten the bearings. For this reason, the largest so that the indicator point is resting
pinion shaft nut a little at a time until spacer should be tried first. Then, if on the end of the pinion gear shaft
the bearings are too loose, the size of (companion flange end).
the spacer can be decreased until the 2. Use both hands to squeeze the
correct preload is obtained. pinion shaft and the bearing retainer
3. Position the bearing retainer and together (Fig. 45). Record the endplay
cup assembly on the pinion shaft and reading shown on the dial indicator.
install the front bearing cone and rol- 3. Disassemble the pinion shaft and
ler. Press the front bearing cone and retainer and install the correct spacer
r o l l e r a s s e m b l y i n t o position, as as shown in Fig. 43.
Inch-Pound
Torque Wrench shown in Fig. 38. 4. Proceed with assembly of the pin-
4. Mount the retainer in a holding ion shaft and retainer as directed in
fixture as shown in Fig. 23, and place Final Assembly of Pinion and Retain-
the slinger over the pinion shaft and er.
against the front bearing.
E1899A 5. Install the U-joint flange with FINAL ASSEMBLY OF
FIG. 42—Checking Pinion Bearing the tool shown in Fig. 46. PINION AND RETAINER
Preload 6. Hold the flange with the tool
shown in Fig. 23 or 24, and install the 1. Install the drive pinion rear bear-
old pinion shaft nut. Using a ft-lb tor- ing cone and roller assembly on the
AS END PLAY
READS
(10/1000 inch) 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
USE THIS
SPACER 0.481 0.480 0.479 0.478 0.476 0.476 0.474 0.474 0.472 0.472 0.470 0.470 0.468 0.468 0.466 0.465
If there is no end play and preload on the bearings exists:
IF PRELOAD READS 2-11 12-20 21-30 31-45

(in-lbs.)
USE THIS SPACER 0.482 0.483 0.484 0.485
FIG. 43— Solid Spacer Selection

(Fig. 48). Lubricate all differential

parts liberally with axle lubricant dur-
POINTER RESTING ON
PINION NUT
ing assembly.
2. With a soft-faced hammer, drive
the differential pinion shaft into the
case only far enough to retain a pin-
ion thrust washer and pinion gear.
3. Place the second pinion and
thrust washer in position, and drive
the pinion shaft into place. Carefully
line up the pinion shaft lock pin holes.
Tool - 4858- E 4. Place the second side gear and
thrust washer in position (Fig. 48),
and install the cover on the differen-
tial case. Install the pinion shaft lock
pin. A pinion or axle shaft spline can
be inserted in the side gear spline to
E 1197-D
check for free rotation of the differen-
E 1505-B
tial gears.
FIG. 44 — End Play Indicator FIG. 46—Installing U-Joint Flange 5. Insert two 7/16 (N.F.) bolts two
Installation inches long through the differential
case flange, and thread them three or
8. Install a seal in the bearing re- four turns into the ring gear as a
pinion shaft as shown in Figs. 37 and tainer, (Fig. 47). guide in aligning the ring gear bolt
38. 9. Start a new integral nut and holes. Press or tap the ring gear into
2. Slide the correct spacer over the washer on the pinion shaft. position.
pinion shaft against the rear bearing. 10. Hold the companion flange with 6. Install and tighten the ring gear
3. Position the bearing retainer and the tool shown in Fig. 20 or 22 and bolts and washers evenly, and torque
cup assembly on the pinion shaft and torque the pinion nut to specifications them alternately across the gear to
install the front bearing cone and rol- (200 ft-lbs). specification.
ler. Press the front cone and roller 11. With a new seal installed pin- 7. If the differential bearings have
into position, as shown in Fig. 46. ion bearing preload should now read been removed, press them on as
4. Lubricate a new O-ring with axle 17 to 32 in-lbs for new pinion bearings shown in Figs. 49 and 50.
lubricant and install it in the groove and new seal, or 8 to 14 in-lbs for ori- 8. Wipe a thin coating of lubricant
provided in the pinion retainer. Be ginal bearings and a new seal. on the bearing bores so that the dif-
careful not to twist the O-ring. Install ferential bearing cups will move easily.
it by snapping it into place. ASSEMBLY AND 9. Place the cups on the bearings.
5. Place the proper shim on the INSTALLATION OF If the gear set is of the non-hunting or
carrier housing and install the pinion DIFFERENTIAL CASE partial non-hunting type, assemble the
and retainer assembly, being careful differential case and ring gear assem-
not to pinch the O-ring (Fig. 41). Conventional bly in the carrier so that the marked
6. Install the pinion retainer bolts. Differential Case tooth on the pinion indexes between
Torque the bolts to specification. the marked teeth on the ring gear as
7. Place the slinger over the pinion 1. Place a side gear and thrust shown in Fig. 51.
shaft and against the front bearing. washer in the differential case bore In almost every case of improper
assembly (gears assembled out of
time), the noise level and probability
of failure will be higher than they
would be with properly assembled
gears.
When installing the hunting type
the differential case and ring gear as-
sembly in the carrier without regard
to the matching of any particular gear
teeth.
10. Slide the assembly along the
bores until a slight amount of back-
lash is felt between the gear teeth.
11. Set the adjusting nuts in the
bores so that they just contact the
bearing cups. The nuts should be en-
gaged about the same number of
E 1506-B threads on each side.
E 1629-A
12. Carefully position the bearing
FIG. 45— Checking Pinion End FIG. 47—Installing Oil Seal caps on the carrier. Match the marks
Play made when the caps were removed.
04-02-20 Rear Axle — Removable Carrier Type 0402-20
ring gear and pinion as outlined in

THRUST WASHER Part 4-1, Section 2.
16. Be sure to make a final tooth
pattern check before installing the
carrier assembly in the axle housing.
Limited-Slip
Differential Case
1. Place the inner side gear and

thrust washer in the differential case
(Fig. 52). Lubricate all parts liberally
with limited-slip axle lubricant during
assembly.
2. With a soft-faced hammer, drive
the pinion shaft into the case only far
enough to retain a pinion thrust wash-
er and pinion gear.
3. Place the second pinion and
thrust washer in position and drive
the pinion shaft into place. Carefully
line up the pinion shaft lock in holes.
4. Install the pinion shaft lock pin.
The lock pin must not extend beyond
the surface of the case.
5. Insert two 2-inch 7/16 (NF)
bolts through the differential case
flange, and thread them three or four
turns into the ring gear as a guide in
E1175-B aligning the ring gear bolt holes. Press
or tap the ring gear into position.
FIG. 48—Assembling Differential Case
6. Clamp the differential case in a
soft-jawed vise. Install the differential
13. Install the bearing cap bolts be sure that the cups and adjusting outer side gear on the differential pin-
and alternately torque them. The 9 nuts are seated. Loosen the cap bolts, ion gears. Place the clutch hub on
3/8 inch ring gear size axle requires and torque them to only 25 ft. lbs be- the side gear. Place the thrusi: washer
60-70 ft-lbs. The 8 3/4 inch and 9 fore making adjustments. on the huh
inch ring gear size axles require 70-85 15. Adjust the backlash between the
ft-lbs. Limited-Slip dutch
14. If the adjusting nuts do not turn Plate Installation
freely as the cap bolts are tightened,
remove the bearing caps and again in- Prior to clutch plate installation,
spect for damaged threads of incor- the friction bonded plates must be
rectly positioned caps. Tightening the s o a k e d in C 6 A Z - 1 9 5 7 0 - C (ESW-
bolts to the specified torque is done to M2C-104-A) differential lubricant for
approximately 1/2 hour. In addition,
the differential lubricant must be lib-
erally applied to all components to
DIFFERENTIAL be assembled.
BEARING 1. Place the clutch hub into posi-
CONE A N D tion in a soft-jawed vise.
ROLLER
2. First, install a steel clutch plate
in the cavity of the differential case
opposite the ring gear and then a
bonded friction plate (Fig. 53). Any
tab on the steel plates can be inserted
into any cavity in the differential case,
however when the first steel plate is
inserted the others must be placed in
the same manner (Fig. 54) so the tabs
with slots line up. Install the remain-
ing plates: a steel plate, bonded fric-
tion plate, a steel plate, bonded fric-
tion plate and lastly a steel plate.
E 1700-A 1376-A
Make sure the bonded friction plate
FIG. 49— Installing Differential FIG. 50—Installing Differential inner-spline teeth properly engage the
Bearing bearing hub spline.
STEEL PLATE THRUST WASHER E 1189-
FIG. 53—Installing Steel Clutch

Plates and Friction Plates
BELLEVILLE SPRING
SITION IN WHICH GEARS WERE LAPPED
FIG. 51—Gear Set Timing Marks
3. Center the Belleville spring on two 1/8 inch drill bits into the holes, E 1711-A
the clutch pack (spring concave-side and work the drill bits back-and forth
facing downward on the pack) to pre- until the plates are centered (Fig. 55). FIG. 54 — Belleville Spring
vent trapping the spring between the When the clutch plates are centered,
Installation
left and right handcase in an eccentric the weight of the cover will cause it to
position (Fig. 54). Improper location fall into position. Remove the drill
of the Belleville spring will cause ex- bits. breakaway torque required to start the
tremely high torque and differential 5. Install the ring gear to differen- side gear turning may exceed 300 ft-
chatter. Be sure the slots in the rabbit tial case bolts, and tighten them even- lbs. Observe only the torque required
ears of the steel plates are in proper ly and alternately across the diameter for continuous even rotation. There
alignment. of the ring gear. Tighten the bolts to should be no abnormal roughness or
4. Carefully set the differential case specification. binding. In some instances the rotat-
cover over the right hand case (Fig. 6. P r i o r to i n s t a l l a t i o n of the ing torque may reach 250 ft-lbs, this
55). At this point, no force or pressure limited-slip differential into the ve- condition is acceptable, if rotation is
should be applied to the cover. The hicle, a differential torque check must smooth. If the results of the bench
cover contains two 3/16 inch holes by be made. Check the torque required to check are not within specified limits,
which the clutch plates can be proper- rotate one side gear while the other internal trouble may be present and
ly aligned. Insert the shank ends of side gear is held (Fig. 56). The initial should be corrected before installing
the assembly in the vehicle. Some
possible torque problems as follows:
BELLEVILLE SPRING
STEEL PLATE.
PINION GEAR
BONDED PLATES
DIFFERENTIAL
1/8" DRILL DIFFERENTIAL
CASE _ LUBRICATOR
CASE COVER
HOLE / CLUTCH HUB CASE COVER
THRUST /
PINION \ \ W A S H E R S /
SHAFT
STEEL PLATES
SIDE GEARS
LOCK PIN
RING GEAR
E 1191-C
E 1738-A
FIG. 55— Differential Cover

FIG. 52—Limited-Slip Differential Assembly Installation
b. Improper amount of clutch 3. Install the pinion thrust washers

plates installed. and place the pinion gears on the side
Under no circumstances should the gear; aligning the holes in the washers
Belleville spring be ground down to and gears with the holes in the case.
reduce torque. The torque required to 4. Install the center block so that
keep the side gear turning with new the shaft holes are aligned with the
clutch plates is 155 to 195 ft-lbs. On holes in the pinion gears and case.
reused clutch plates, the torque re- The center block has two machined
Too/-T59L-4204-A quired is 75 ft-lbs minimun. sides and two rough sides.
or 44211 7. If the differential bearings have 5. With a brass drift, drive in the
and 44211-A
been removed, press them on as long pinion shaft from the outside of
shown in Figs. 49 and 50. the case aligning the lock pin holes in
8. Install the side bearings on the the shaft with the holes in the case.
differential case, and install the case The center block should be positioned
in the carrier as described in steps 7 so the long shaft is driven through the
through 16 under Assembly and In- rough side and short shafts driven
stallation of Conventional Differential through the machined side (Fig. 57).
EH92-C Case. Adjust and check backlash be- 6. With a suitable drift, install the
tween the ring gear and pinion as di- shaft lock pins. Make sure the pinion
FIG. 56—Checking Differential rected under Differential Bearing Pre- and side gears move freely.
Torque load Adjustments. 7. Place the four pre-load springs in
the holes provided in the center block.
ASSEMBLY OF 8. Position a pre-load plate over the
High Torque TRACTION-LOK four springs, making sure the springs
DIFFERENTIAL CASE are properly seated. The pre-load
a. Insufficient lubricant on the plate straddles the center block over
clutch plates. 1. Lubricate all parts with Ford its narrower or machined width.
b. A clutch plate wedged in be- Hypoid Lubricant (Ford Part No. 9. Mount the differential cover in a
tween the case halves. C6AZ-19580-C), during assembly of soft jawed vise or holding fixture.
c. An improperly centered Belleville differential. 10. Insert shim(s) of 0.050 total
spring. 2. Mount the differential case in a thickness in the cover cavity.
soft jawed vise and place a side gear 11. Install the composite plate (fric-
Low Torque
thrust washer and side gear in the tion material on one side and steel on
a. Weak Belleville spring. counterbore of the case. the opposite) on the back side of the
clutch hub with the friction material
against the hub; next, install a friction
plate, then steel, friction, stee, fric-
tion, steel, friction, and lastily a steel
plate (Figures 3 and 58). When new
clutch plates are used, soak the plates
in Ford Hypoid Lubricant (Ford Part
No. C6AZ-19580-C), or equivalent lu-
bricant, for approximately 30 minutes
before installation.
12. Place the clutch hub with the
clutch plates into the clutch ear cavi-
ties in the differential cover. Make
sure that the splines on the last fric-
ion plate are engaged on the hub.
13. Obtain locally a 5/8 inch x
CENTER BLOCK
2 1/2 inch or 9/16 inch x 2 1/2
PRELOAD SPRINGS inch bolt, nut and two I 1/2 inch
outside diameter flat washers approx.
PRELOAD PLATE 1/8 inch in thickness. These parts are
required to compress the clutch pack
in order to obtain the proper shim
PINION GEAR
selection.
Install a flat washer on the bolt,
DIFFERENTIAL CASE and place the bolt through the clutch
hub. Hold the bolt in position and
turn the cover over. Place a flat wash-
er on the bolt and then install the nut.
Be sure the washers are centered, and
torque the nut 10 to 15 ft-lbs (Fig.
E1893- A 59).
14. Place the shim template tool
(Ford Tool No. T68P-4946-A) in the
. 57—Center Block and Pre-Load Springs Installation clutch hub. Some clearance should be
observed between the shim tool and

the cover-to-case mating surface.
Using a feeler gauge, determine the DIFFERENTIAL COVER
exact amount of clearance. Refer to
the shim pack thickness chart specifi-
cations which will indicate the correct -COMPOSITE PLATE
amount of shim(s) to subtract from
the 0.050 shim originally installed. In CLUTCH HUB
order to correctly select the proper

shim(s), the shim template tool and
the chart must be used.
15. After the proper shim selection SIDE GEAR
is determined, remove the bolt, nut

and flat washers. If it is necessary to
revise the shim thickness, remove the
clutch hub and clutch plates.
16. Install the selected shim(s) in
the cover cavity, reinstall the compo-
nents as outlined in Steps 11 and 12.
17. Install the four steel clutch ear
guides and side gear.
18. Place both assemblies in a
press, and press the two halves togeth-
er; then, insert the two Allen or Phil- FRICTION PLATES
SHIM
lips head screws, and tighten evenly
until tight. If a press is not available,
any two stock bolts and nuts may be
used opposite each other in the ring
gear retaining holes to compress both
halves. E1894-A
19. Install the ring gear and ring
gear bolts and washers. Tighten evenly FIG. 58— Clutch Pack Installation
and alternately across the diameter of
the ring gear. Torque the bolts to
65-80 ft-lbs.
20. Prior to installation of the tor- CLEARANCE CHECK AREA
que sensitive locking differential into a SHIM TEMPLATE

vehicle, a bench torque check must be
made. Check the torque required to
rotate one side gear while the other is
held stationary (Fig. 56). The initial
break-away torque may exceed 250
ft-lbs. The rotating torque required to
keep the side gear turning with new
clutch plates is 100 to 250 ft-lbs. With
re-used clutch plates, the minimum
torque required is 40 ft-lbs. (The tor-
que may fluctuate 10-40 ft-lbs.).
E1895-A
59—Shim Template Tool Application

04-03-01 Rear Axles — Integral Carrier Type 04-03-01
PART 4-3 Rear Axles-Integral Carrier Type

(Except Ford Light Duty WER Axle)
MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
AXLE HOUSING
AXLE SHAFT
CONVENTIONAL DIFFERENTIAL CASE
Disassembly and Overhaul N/A N/A N/A 03-08 03-08 03-08 03-08 03-08 N/A N/A N/A
DIFFERENTIAL BEARINGS AND RING
GEAR
LIMITED SLIP DIFFERENTIAL CASE
Disassembly and Overhaul N/A N/A N/A 03-08 03-08 03-08 03-08 03-08 N/A N/A N/A
PINION BEARING CUPS
PINION OIL SEAL
REAR WHEEL BEARINGS AND SEALS
U-JOINT FLANGE
DESCRIPTION
The rear axle assembly is an integral- bearings. The bearings are retained in pinion shaft. Pinion and ring gear
type housing, hypoid design, with the the housing by removable caps. Dif- tooth contact is adjusted by shims be-
centerline of the pinion set below the ferential bearing preload and drive tween the rear bearing cone and
centerline of the ring gear (Fig. 1). gear backlash is adjusted by nuts lo- pinion gear.
The semi-floating axle shafts are re- cated behind each differential bearing A cover on the rear of the differen-
tained in the housing by ball bearings cup. tial housing provides access for inspec-
and a bearing retainer at the axle hous- The drive pinion assembly is mount- tion and removal and installation of
ing outer ends. ed on two opposed tapered roller the differential assembly and drive
The differential assembly is mount- bearings. Pinion bearing preload is pinion.
ed on two opposed tapered roller adjusted by a collapsible spacer on the
RING GEAR
4209
FLANGE-4676
DRIVE PINION
BEARINGS
4630
4621
E1905A
FIG. 7—Typical Rear Axle Assembly
IN-VEHICLE ADJUSTMENT AND REPAIR
REAR AXLE SHAFT, WHEEL Removal and insertion of rear axle as service replacements for synthetic
BEARING AND OIL SEAL shafts must be performed with cau- wheel bearing seals.
REPLACEMENT tion. The entire length of the shaft (in- The rear axle shafts, wheel bear-
cluding spline) up to the seal journal ings, and oil seal can be replaced
Synthetic wheel bearing seals are must pass through the seal without without removing the differential as-
used for production purposes only. contact. Any roughing or cutting of sembly from the axle housing. Re-
>Tool-T60K-4234-A the seal element during axle removal
or 4235-D moval of the wheel bearings from the
or installation will result in early seal axle shafts make them unfit for fur-
Tool-T50T-W0-A or 8-/66 failure. Leather seals only will be used ther use.
* El904A
FIG. 2—Removing Axle Shaft
E 1731-A E1421-B
FIG. 3—Removing Rear Wheel FIG. 4—Removing and Installing Rear Wheel Bearing—
Bearing Retainer Ring Montego—Cougar
FOR FIXED
Press Ram
BED PRESS
Bridge
1 Side Rail
I f
Press Ram
^-Support Flange-*
BEARING REMOVAL
VIEW 3
BEARING
Adapter Ring
MUSTANG, COUGAR,
FAIRLANE. MONT EGO
AND FALCON WITH- FALCON W I T H -
8 CYLINDER ENGINE 6 CYLINDER ENGINE
Tool-T60K-1225-A
Press Ram
t— Support Plate —>
FOR BEARING INSTALLATION
ADJUSTABLE VIEW 4
BED PRESS
FOR
PUSH-PULLER
OPERATION
BEARING REMOVAL
Press Ram VIEW 5
Support Plate —*
BEARING INSTALLATION
VIEW 2
BEARING
BEARING
BEARING
INSTALLATION
<• Support Plate »
VIEW 6
BEARING REMOVAL
VIEW 1 E1211-D
FIG. 5—Removing and Installing Rear Wheel Bearing—Falcon, Mustang and Fairlane
1. Remove the wheel cover, wheel thetic sealing elements have been in- preload, and this preload must be
and tire from the brake drum. corporated in production. However, carefully reset when assembling.
2. Remove the Tinnerman nuts that only leather seals will be used as re- 1. Raise the vehicle and install safe-
secure the brake drum to the axle placements for the synthetic sealing ty stands. Remove the rear wheels and
housing flange, and then remove the element seals. Install the new oil seal brake drums.
drum from the flange. with the tools shown in Fig. 8. Instal- 2. Make scribe marks on the drive
3. Working through the hole pro- lation without use of the proper tool shaft end yoke and the axle U-joint
vided in each axle shaft flange, re- will distort the seal and cause leakage. flange to insure proper position of the
move the nuts that secure the wheel Be sure the new seal has been soaked drive shaft at assembly (Fig. 14). Dis-
bearing retainer plate. Then pull the in SAE 10 oil for 1/2 hour. connect the drive shaft from the axle
axle shaft assembly out of the axle 14. Carefully slide the axle shaft U-joint flange. Be careful to avoid
housing (Fig. 2). The brake backing into the housing so that the rough dropping the loose universal joint
plate must, not be dislodged. Install forging of the shaft will not damage bearing cups. Hold the cups on the
one nut to hold the plate in place after the oil seal. Start the axle splines into spider with tape. Mark the cups so
the axle shaft is removed. the side gear, and push the shaft in that they will be in their original posi-
4. If the rear wheel bearing is to be until the bearing bottoms in the housing. tion in relation to the flange when
replaced, loosen the inner retainer 15. Install the bearing retainer plate they are assembled. Remove the drive
ring by nicking it deeply with a cold on the mounting bolts at the axle shaft from the transmission extension
chisel in several places (Fig. 3). It will housing, and install the attaching nuts. housing. Install an oil seal replacer
then slide off easily. Torque the nuts to specifications. tool in the transmission extension
5. Remove the bearing from the 16. Install the brake drum and the housing to prevent transmission leak-
axle shaft with the tool shown in Fig. drum retaining nuts. age. Refer to the transmission group
4 or 5. If the push-puller operation 17. Install the wheel and tire on the for the appropriate tool.
shown in Fig. 5 is used, be sure that drum, and install the wheel cover. 3. Install an in-lb torque wrench on
the puller arms contact the flat sur- the pinion nut Fig. 6. Record the tor-
face of the axle shaft flange rather REMOVAL AND REPLACEMENT que required to maintain rotation of
than the bolt heads. Also with this OF DRIVE PINION OIL SEAL the pinion shaft through several revo-
method, be careful not to damage or lutions. \
burr the oil seal journal as the bearing Synthetic seals must not be cleaned, 4. While holding the flange with the
breaks loose. soaked or washed in cleaning solvent. tool shown in Fig. 9, remove the inte-
6. Whenever a rear axle shaft is re- Replacement of the pinion oil seal gral pinion nut and washer.
placed the oil seal must be replaced. involves removal and installation of 5. Clean the pinion bearing retainer
Remove the seal with the tools shown only the pinion shaft nut and the uni- around the oil seal. Place a drain pan
in Fig. 8. Soak new oil seals in SAE versal joint flange. However, this op- under the seal, or raise the front of
10 oil for 1/2 hour before installing. eration disturbs the pinion bearing the vehicle higher than the rear.
7. Inspect the machined surfaces of
the axle shaft and the axle housing for
rough spots or other irregularities
which would affect the sealing action
of the oil seal. Check the axle shaft
splines for burrs, wear or damage.
Carefully remove any burrs or rough
spots. Replace worn or damaged
parts.
8. Lightly coat wheel bearing bores
with axle lubricant. Tool - 1175-AB
9. Place the retainer plate on the and T50T-100-A
^ _ _ _ or J 775- AE
axle shaft, and press the new wheel Torque Wrench
Ee I582
icot A
bearing on the shaft with the tool
shown in Fig. 4 or 5. The bearing
^ mm
KJ i A
- E 1681-A
should seat firmly against the shaft FIG. 6—Checking Pinion FiG 7_Removing pjnjon Sea,
shoulder. Do not attempt to press on Bearing Preload
both the bearing and the inner retain-
er ring at the same time. ,Tool-T58L-101-A or U75-AE
Tool-T50T-100-A
10. Using the bearing installation
tool, press the bearing inner retainer
ring on the shaft until the retainer
seats firmly against the bearing.
11. Wipe all lubricant from the in-
side of the axle housing in the area of
the oil seal before installing the new
seal.
12. Wipe a small amount of oil res- Tool-60K-1177-B
istant sealer on the outer edge of the or 1177-BorC
REMOVAL
seal before it is installed. Do not put INSTALLATION E1214-D
sealer on the sealing lip.
13. Rear wheel oil seals with syn- FIG. 8—Removing and Installing Axle Shaft Seal
6. Using the tool shown in Fig. 10, drive shaft on the transmission output INSTALLATION OF A NEW
remove the pinion U-joint flange. shaft. UNIVERSAL JOINT FLANGE
7. Using the tool shown in Fig. 7, 18. Connect the rear end of the
remove the drive pinion oil seal. drive shaft to the axle U-joint flange, 1. Raise the vehicle and install safe-
8. Clean the oil seal seat. aligning the punch marks made on the ty stands. Remove both rear wheels
9. Pinion oil seals have pre-applied drive shaft end yoke and the axle U- and brake drums.
oil resistant sealer. Install the seal in joint flange (Fig. 14). 2. Disconnect the drive shaft from
the retainer using the tool shown in 19. Check the lubricant level. Make the axle U-joint flange. Be careful to
Fig. 11. sure the axle is in running position. avoid dropping the loose universal
10. Check splines on the pinion Add whatever amount of specified lu- joint bearing cups. Hold the cups on
shaft to be sure they are free of burrs. bricant is required to reach the lower the spider with tape. Mark the cups so
If burrs are evident, remove them by edge of the filler plug hole, located in that they will be in their original posi-
using a fine crocus cloth, working in a the carrier casting or the housing tion in relation to the flange when
rotational motion. Wipe the pinion cover. they are assembled. Remove the drive
shaft clean. shaft from the transmission extension
11. Apply a small amount of lubri- housing. Install an oil seal replacer
cant to the U-joint splines. REMOVAL AND INSTALLATION tool in the transmission extension
12. Align the punch mark on the OF THE ORIGINAL U-JOINT housing to prevent transmission fluid
U-joint flange with the mark on the FLANGE leakage. Refer to the transmission
end of the pinion shaft, and install the group for the appropriate tool.
flange. Use procedure as outlined under 3. Install an in-lb torque wrench on
13. Install a new integral nut and drive pinion oil seal replacement. the pinion nut Fig. 6. Record the tor-
washer on the pinion shaft. (Apply a que required to maintain rotation of
small amount of lubricant on the the pinion shaft through several revo-
washer side of the nut.) lutions.
14. Hold the flange with the tool 4. While holding the flange with the
shown in Fig. 9 while tightening the tool shown in Fig. 9, remove the inte-
nut. gral pinion nut and washer.
15. Tighten the pinion shaft nut, 5. Clean the pinion bearing retainer
rotating the pinion occasionally to in- around the oil seal. Place a drain pan
sure proper bearing seating, and take under the seal, or raise the front of
frequent preload readings (Fig. 6) the vehicle higher than the rear. Syn-
until the preload is at the original rec- thetic seals must not be cleaned,
orded reading established in step 3. soaked or washed in cleaning solvents.
16. After original preload has been 6. Using the tool shown in Fig. 10,
reached, tighten the pinion nut slowly, remove the U-joint flange.
until an additional preload of 6 to 12 7. Check splines on the pinion shaft
in-lbs has been added. to be sure they are free of burrs. If
The preload should not exceed the burrs are evident, remove them by
amount indicated above, or bearing using a fine crocus cloth, working in
failure may result. Under no circum- Tool-T53T-4857-A rotational motion, then wipe clean.
stances should the pinion nut be or 4851 -A Apply a small amount of lubricant
backed-off to lessen preload. If this is to U-joint splines.
done, a new pinion bearing spacer 8. Install the U-joint flange using
must be installed. In addition, the U- the tool shown in Fig. 12.
joint flange must never be hammered
on, or power tools used.
17. Remove the oil seal replacer E1223-B
tool from the transmission extension FIG. 10—Typical Drive Pinion
housing. Install the front end of the Flange Removal
Tool-T55P-4676-A
or 4676-G
E l 906A E1907A
FIG. 9—Removing or Installing FIG. 11 — Typical Drive Pinion FIG. 12—U-Joint Flange
Drive Pinion Nut Flange Seal Installation Installation
9. Install a new integral nut and until an additional preload of 6 to 12 housing. Install the front end of the
ivasher on the pinion shaft. (Apply a in-lbs has been added. drive shaft on the transmission output
small amount of lubricant on the The preload should not exceed the shaft.
washer side of the nut.) amount shown above, or bearing fail- 14. Connect the rear end of the
10. Hold the flange with the tool ure may result. drive shaft to the axle U-joint flange,
shown in Fig. 9 while the nut is being Under no circumstances should the aligning the scribe marks made on the
tightened. pinion nut be backed off to lessen pre- drive shaft end yoke and the axle U-
11. Tighten the pinion shaft nut, load. If this is done, a new pinion joint flange (Fig. 14).
rotating the pinion occasionally to in- bearing spacer must be installed. (In 15. Check the lubricant level. Make
sure proper bearing seating, (Fig. 6) addition, the U-joint flange must sure the axle is in running position.
and take frequent preload readings never be hammered on, or pneumatic- Add whatever amount of specified lu-
until the preload is at the original rec- -tools used.) bricant is required to reach the lower
orded reading established in step 3. 13. Remove the oil seal replacer edge of the filler plug hole, located in
12. After original preload has been tool from the transmission extension the carrier casting or housing cover.
reached, tighten the pinion nut slowly,
REAR AXLE HOUSING fitting from the axle housing. Do not lines and the parking brake cables are
open the hydraulic brake system lines. still attached to the brake carrier
REMOVAL Remove the hydraulic brake line from plates.
its retaining clip on the axle housing. 10. Support the rear axle housing
1. Raise the vehicle and support it 8. Remove both axle shaft oil seals on a jack, and then remove the spring
with safety stands under the rear with the tools shown in Fig. 8. clip nuts. Remove the spring clip
frame member. 9. Remove both brake backing plates (Fig. 13)
2. Drain the lubricant from the plates from the axle housing and sus- 11. Lower the axle housing and re-
axle. pend them above the housing with me- move it from under the vehicle.
3. Make scribe marks on the drive chanic's wire. The hydraulic brake 12. If the axle housing is being re-
shaft end yoke and the axle U-joint placed, transfer all the differential and
flange to insure proper position of the pinion parts to the new housing. See
drive shaft at assembly (Fig. 14). Dis- Section 4, Major Repair Operations.
connect the drive shaft at the drive
pinion flange. SCRIBE MARKS
INSTALLATION
4. Disconnect the lower end of the
shock absorbers.
1. Raise the axle housing into posi-
5. Remove the wheels, brake drums
tion so that the spring clip plates can
and both axle shafts as outlined in the 5/16-24 be installed. On a Montego or Fair-
foregoing Section 2. 4 REQ'D.
12-15 LB. FT. lane, position the spring upper insula-
6. Remove vent hose front vent tors and retainers between the axle
tube (Corbin clamp) and remove vent U-BOLT - 4529 2 REQ'D.
housing and springs and install the
tube from brake tube junction and lower insulators. Torque the spring
axle housing. E 1783-A
clip nuts to specification.
7. Remove the hydraulic brake T- FIG. 14—Drive Shaft-to-Axle 2. Place the brake backing plates in
U-Joint Connection their normal position on the axle
housing. Use new gaskets on each side
of the brake backing plates.
3. Install new axle shaft oil seals
with the tool shown in Fig. 8. Soak
the new seals in light weight engine oil
(SAE 10) for 1/2 hour before install-
ing them. Installation without use of
the proper tool will distort the seal
and cause leakage. Coat the outside
edges of the new oil seal with a non-
hardening type of sealer such as Per-
matex No. 2 or its equivalent.
4. Install the axle shafts, brake
drums and wheels as outlined in Sec-
tion 2.
5. Attach the hydraulic brake line
T fitting to the axle housing, and se-
El231-A cure the hydraulic brake line in its re-
tainer on the axle housing.
FIG. 73—Rear Axle Installation—Typical 6. Install vent tube to brake tube
junction and install vent hose to vent 8. Connect the rear end of the drive joint flange (Fig. 14).
tube. shaft to the axle U-joint flange, align- 9. Fill the axle with the proper
7. Raise the axle housing and con- ing the scribe marks made on the grade and amount of lubricant.
nect the shock absorbers. drive shaft end yoke and the axle U- 10. Road test the vehicle.
DISASSEMBLY 6. Working through the hole pro- they are assembled. Remove the drive
vided in the axle shaft flange, remove shaft from the transmission extension
All service operations on the differ- the nuts that attach the wheel bearing housing. Install an oil seal replacer
ential case assembly and the drive pin- retainers to the axle housing. tool in the transmission extension
ion assembly can be performed with 7. Pull the axle shafts with the tool housing to prevent transmission leak-
the housing in the vehicle. shown in Fig. 2. Care must be exer- age. Refer to the transmission group
cised to prevent damage to the oil for the appropriate tool.
REMOVAL OF seals. Install a nut on one of the brake 9. Remove the differential bearing
DIFFERENTIAL backing plate attaching bolts to hold adjusting nut locks (Fig. 15).
CASE AND DRIVE PINION the plate to the axle housing after the 10. Mark one differential bearing
shaft has been removed. Remove both cap and the case (Fig. 16) to help po-
1. Raise the vehicle and support it seals with the tool shown in Fig. 8. sition the parts properly during as-
on the underbody, so that the rear 8. Make scribe marks on the drive sembly.
axle drops down as far as the springs shaft end yoke and the axle U-joint 11. Remove the differential bearing
and shock absorbers permit. flange to insure proper position of the cap bolts and bearing caps. Hold the
2. Remove the cover from the car- drive shaft at assembly (Fig. 14). Dis- differential case assembly in the hous-
rier casting rear face, and drain the connect the drive shaft from the axle ing after the caps are removed.
lubricant. U-joint flange. Be careful to avoid 12. Remove the differential case
3. Perform the Inspection Before dropping the loose universal joint and bearing cups (Fig. 17).
Disassembly of Carrier in Part 4-1, bearing cups. Hold the cups on the 13. Hold the drive pinion flange
Section 3. spider with tape. Mark the cups so and remove the pinion nut (Fig. 9).
4. Remove both rear wheels. that they will be in their original posi- 14. Remove the pinion flange (Fig.
5. Remove the brake drums. tion in relation to the flange when 10).
DIFFERENTIAL PINION GEAR

A N D THRUST WASHER
DIFFERENTIAL SIDE GEAR

A N D THRUST WASHER
COVER A N D GASKET SHAFT RETAINER DIFFERENTIAL
BEARING ADJUSTING NUT
PINION SHAFT DIFFERENT |AL
DIFFERENTIAL CASE CASE COVER
BEARING
ADJUSTING NUT LOCK
BEARING CAP
PINION LOCATING SHIMS

AXLE HOUSING
BEARING AND CUP

FILLER PLUG
WHEEL BEARING RETAINER
GASKET BEARING AND CUP
SEAL
AXLE SHAFT SEAL

BEARING PRELOAD SPACER/
AXLE SHAFT 'WHEEL BEARING
WHEEL BEARING RETAINER DEFLECTOR FLANGE
E1908A
FIG. 75—Disassembled Rear Axle

15. With a soft-faced hammer, micrometer. Record the thickness of 2. Remove the bolts that attach the
drive the pinion out of the front bear- the shim. ring gear to the differential case. Press
ing cone and remove it through the the ring gear from the case or tap it
rear of the carrier casting. DISASSEMBLY OF off with a soft-faced hammer.
16. Drive against the pinion front DIFFERENTIAL CASE 3. With a drift, drive out the differ-
bearing cone and drive the pinion ential pinion shaft lock pin (Fig. 21).
flange seal and the bearing cone out 1. If the differential bearings are to 4. Drive out the pinion shaft with a
of the front of the carrier casting. be removed, use the tools shown in brass drift. Remove the gears and
17. To remove and install the pin- Fig. 20. thrust washers.
ion rear bearing cone use the tools in
Fig. 18 and 19. PARTS REPAIR OR
18. Measure the shim which is REPLACEMENT
found under the bearing cone with a
Press Ram Clean and inspect all the parts as
Fiber
Block outlined in Part 4-1, Section 3. Before
assembling the carrier, repair or re-
place all parts as indicated by the in-
spection.
REAR BEARING
CONE AND The principal replacement opera-
ROLLER tions are covered in the following pro-
cedures. All other repair or replace-
ment operations are performed during
Cleaning and Inspection Part 4-1,
Section 3, or during the Assembly in
this section.
MARKINGS
E1909A PINION BEARING CUPS
FIG. 16—Typical Differential Do not remove the pinion bearing

Bearing Cap Marking cups from the carrier casting unless
the cups are worn or damaged.
If the pinion bearing cups are to be
replaced, drive them out of the carrier
E1911A
FIG. 79—Installing Pinion Rear

Bearing Cone
E1910A
FIG. 77—Differential Case

Removal or Installation
Tool-
4221-AL
DIFFERENTIAL
1368-A BEARING E1913A
E1912A
FIG. 18—Removing Pinion Rear FIG. 20—Differential Bearing FIG. 21—Differential Pinion
Bearing Cone Removal Shaft Lock Pin Removal
3. Install the bearing caps and ad-

justing nuts as outlined in steps 11
thru 14 under Installation of Drive
Pinion and Differential Case in this
section.
4. Tighten the right nut two notches
beyond the position where it first con-
tacts the bearing cup. Rotate the dif-
ferential case several revolutions in
each direction while the bearings are
loaded to seat the bearings in their
cups. This step is important.,
lease the preload. Check to see that
the left nut contacts the bearing cup.
Using the dial indicator set-up shown
in Fig. 10, Part 4-1, adjust the preload
E1914A to 0.008 to 0.012 case spread for new
bearings or 0.005 to 0.008 for the
FIG. 22—Pinion Bearing Cup Removal or Installation original bearings, if reused.
6. Check the runout of the differen-
set to be installed, follow these steps: tial case flange with a dial indicator.
1. With a micrometer, measure the If the runout does not now exceed
thickness of the original shim removed specifications, install a new ring gear.
from the axle and use the same thick- If the runout still exceeds specifica-
\ ness upon installation of the replace- tions, the ring gear is true and the
ment carrier assembly or drive pinion. trouble is due to either a defective
2. If further shim change is neces- case or worn bearings.
sary, it will be indicated in the tooth 7. Remove the differential case
pattern check. from the carrier and remove the side
3. If the original shim is lost, sub- bearings from the case.
stitute a nominal shim for the original 8. Install new bearings on the case
MATCHED
GEAR SET and use the tooth pattern check to de- hubs, and again install the differential
IDENTIFICATION assembly in the carrier without the
E 1628-A termine if further shim changes are re-
quired. Nominal shim thickness is in- ring gear.
FIG. 23—Pinion and Ring dicated in Part 4-5, Specifications. 9. Check the case runout again with
Gear Marking A new ring gear and pinion should the new bearings. If the runout is now
always be installed in an axle as a within limits, the old bearings were
casting with a drift. Install the new excessively worn. Use the new bear-
cups with the tool shown in Fig. 22. matched set (never separately). Be
sure the same identifying (matching) ings for assembly. If the runout is still
Make sure the cups are properly seat- excessive, the case is defective and
number, painted in white, appears on
ed in their bores. If a 0.0015-inch feel- should be replaced.
the bolt hole face of the ring gear and
er gauge can be inserted between a
on the head of the drive pinion
cup and the bottom of its bore at any ASSEMBLY
(Fig. 23).
point around the cup the cup is not
properly seated. 4. After determining the correct
shim thickness as explained in the Refer to Part 4-1 for Cleaning and
Whenever the cups are replaced, the Inspection before starting assembly
foregoing steps, install the new pinion
cone and roller assemblies should also operations.
and ring gear as outlined under As-
be replaced. ASSEMBLY OF
sembly.
DIFFERENTIAL CASE
DRIVE PINION AND GEAR DIFFERENTIAL CASE,
SET BEARINGS, AND RING 1. Lubricate all the differential
GEAR parts with axle lubricant, before they
Individual differences in machining If the ring gear runout checK (be- are installed in the case.
the carrier casting and the gear set re- fore disassembly) exceeded specifica- 2. Place the side gears and thrust
quire a shim between the pinion rear tions, the condition may be caused by washers in the case.
bearing cone and the pinion gear to a warped gear, a defective case, or ex- 3. Place the two pinion gears and
locate the pinion for correct tooth cessively worn differential bearings. thrust washers exactly opposite each
contact with the ring gear. To determine the cause of excessive other in the case openings and in
When replacing a ring gear and pin- runout proceed as follows: mesh with the side gears.
ion it should be noted that the original 1. Assemble the two halves of the 4. Turn the pinions and thrust
factory installed shim is of the correct differential case together without the washers until the holes in the pinion
thickness to adjust for individual vari- ring gear, and press the two differen- gears align with the pinion shaft holes
ations in both the carrier casting di- tial side bearings on the case hubs. in the case.
mension and in the original gear set 2. Place the cups on the bearings 5. Start the pinion shaft into the
dimension; therefore, to select the cor- and set the differential case in the car- differential case. Carefully align the
rect shim thickness for the new gear rier. shaft lock pin hole with the pin hole
in the case. Drive the shaft into place 2. Place a new pinion bearing pre- If the pinion shaft nut is tightened
and install the lock pin (Fig. 21). load spacer on the pinion shaft. to the point that pinion bearing pre-
6. Place the ring gear on the differ- 3. Lubricate the pinion rear bearing load exceeds the limits, the pinion
ential case and install the bolts. Tor- with axle lubricant. shaft must be removed and a new col-
que the bolts to specification. 4. Lubricate the pinion front bear- lapsible spacer installed. Do not de-
7. If the differential bearings have ing cone and place it in the housing. crease the preload by loosening the
been removed, press them on as 5. Install a new pinion oil seal in pinion shaft nut. This will remove the
shown (Fig. 24). the carrier casting (Fig. 11). compression between the pinion front
6. Insert the drive pinion shaft and rear bearing cones and the col-
INSTALLATION OF DRIVE flange into the seal and hold it firmly lapsible spacer and may permit the
PINION AND DIFFERENTIAL against the pinion front bearing cone. front bearing cone to turn on the pin-
CASE From the rear of the carrier casting, ion shaft.
insert the pinion shaft into the flange. & As soon as there is preload on
1. Place the shim and pinion rear 7. Start a new pinion shaft nut. the bearings, turn the pinion shaft in
bearing cone on the pinion shaft. Hold the flange with the tool shown in both directions several times to set the
Press the bearing and shim firmly Fig. 9 and tighten the pinion shaft bearing rollers.
against the pinion shaft shoulder (Fig. nut. As the pinion shaft nut is tight- 9. Adjust the bearing preload to
19). ened, the pinion shaft is pulled into specification. Measure the preload
the front bearing cone and into the with the tool shown in Fig. 6.
flange. 10. Apply a thin coating of lubri-
PRESS RAM
As the pinion shaft is pulled into cant on the bearing bores so that the
the front bearing cone, pinion shaft differential bearing cups will move
Tool T54P-3044-A end play is reduced. While there is easily.
Detail 7
still end play in the pinion shaft, the 11. Place the cups on the bearings
flange and cone will be felt to bottom. and set the differential case assembly
This indicates that the bearing cone in the carrier casting (Fig. 17).
and flange have bottomed on the col- If the gear set is of the non-hunting
lapsible spacer. or partial non-hunting type, assemble
From this point, a much greater the differential case and ring gear as-
torque must be applied to turn the sembly in the carrier so that the
pinion shaft nut, since the spacer must marked tooth on the pinion indexes
be collapsed. From this point, also, between the marked teeth on the ring
the nut should be tightened very slow- gear as shown in Fig. 25.
ly and the pinion shaft end play In almost every case of improper
checked often, so that the pinion bear- assembly (gears assembled out of
ing preload does not exceed the limits time), the noise level and probability
(Fig. 6). of failure will be higher than they
would be with properly assembled
FIG. 24—Differential Bearing gears.
Installation When installing the hunting type
the differential case and ring gear as-
sembly in the carrier without regard
to the matching of any particular gear
teeth.
12. Slide the case assembly along
the bores until a slight amount of
backlash is felt between the gear teeth.
Hold the differential case in place.
13. Set the adjusting nuts in the
7oo/—T60K-4067-A or 4067 E
PAINT MARKING INDICATES POSITION IN WHICH GEARS WERE LAPPED E1916A
E 1335-B
FIG. 26—Backlash and Bearing
FIG. 25—Typical Gear Set Timing Marks Pre-Load Adjustment
bores so that they just contact the freely as the cap bolts are tightened, LIMITED-SLIP DIFFERENTIAL
bearing cups. remove the bearing caps and again in-
14. Carefully position the bearing spect for damaged threads or incor- For integral carrier limited-slip dif-
caps on the carrier casting. Match the rectly positioned caps. Tightening the ferentials see the repair procedures for
marks made when the caps were re- bolts to the specified torcfue is done to removable carrier limited-slip differen-
moved. be sure that the cups and adjusting tials, Part 4-2. These procedures are
15. Install the bearing cap bolts nuts are seated. Loosen the cap bolts, good for the differential case only.
and lockwashers. As the bolts are and torque them to only 5 ft-lbs be- When the limited slip differential case
tightened, turn the adjusting nut with fore making adjustments. Refer to has been repaired replace the case
the tool shown in Fig. 26. Part 4-1 for backlash and bearing pre- using the procedure for the conven-
16. If the adjusting nuts do not turn load adjustment procedures. tional intergral carrier differendal case
in this part.
04-04-01 Rear Axle — Ford Light-Duty (WER) 04-04-01
PART 4-4 Rear Ax/e-Ford Light-Duty (WER)

MODEL APPLICATION
Continental-
Thunderbird
Continental
AN Models
COMPONENT INDEX
Mustang
Montego
Mercury
Mark III
Fairlane
Lincoln-
Cougar
Meteor
Falcon
Ford
AXLE HOUSING
Cleaning and Inspection 01-09 N / A 01-09 N / A N/A N/A N/A N/A N/A N/A N/A
Removal and Installation 04-04 N / A 04-04 N / A N/A N/A N/A N/A N/A N/A N/A
AXLE SHAFT
DESCRIPTION 04-01 N / A 04-01 N / A N/A N/A N/A N/A N/A N/A N/A
DIFFERENTIAL CASE
Disassembly and Overhaul 04-07 N / A 04-07 N / A N/A N/A N/A N/A N/A N/A N/A
DIFFERENTIAL BEARINGS AND DRIVE
GEAR
Cleaning and Inspection 01-10 N / A 01-10 N / A N / A N/A N/A N/A N/A N/A N/A
Removal and Installation 04-08 N / A 04-08 N / A N / A N/A N/A N/A N/A N/A N/A
PINION BEARING CUPS
A page number indicates that the item is for the vehicle listed at the head of tne column.
DESCRIPTION
A light-duty, integral-carrier, con- the front portion of the carrier casting backing plate retainer is welded in-
ventional-type rear axle assembly (Fig. and uses a 1/2-14 tapered pipe plug board of the outer edges of the tubes,
1) is used in Ford and Meteor passen- with a 3/8 inch square female drive. A and allows assembly of the backing
ger vehicles equipped with 240-IV and bumper pad is machined on the pinion plate, independent of the axle shafts.
302 2V engines and related transmis- nose portion of the carrier. The rub- The roller-type wheel bearings have
sions. The axle (model WER) incor- ber bumper is mounted on the vehicle no inner race, and contact the bearing
porates the following features: underbody. journals of the axle shafts.
The hypoid gear set consists of an The differential case is a one-piece The axle shafts do not use an inner
8.50 inch diameter ring gear and an design, with openings allowing assem- or outer bearing retainer. They are
overhung drive pinion which is sup- bly of the internal components and lu- held in the axle by means of C-locks,
ported by two opposed tapered roller bricant flow. The differential pinion positioned in a slot on the splined end.
bearings. A drive pinion pilot bearing shaft is retained with a threaded bolt These C-locks also fit into a machined
is not used in this axle. (lock) assembled to the case. recess in the differential side gears
The differential carrier is the non- The axle housing assembly consists within the differential case. There is
removable type, with a stamped bolt- of tube assemblies pressed and welded no retainer bolt access hole in the axle
on cover. The filler hole is tapped in into the differential casting. The brake shaft flange.
RING GEAR - LEFT AXLE

4209 SHAFT - 4235
DIFFERENTIAL
PINION-4215 1
DRIVE PINION -
4209
SEAL - 4676
FLANGE-4851
DEFLECTOR -4859
S E A L - 1177
E 1632-A
f\G. 7 —Rear Axle Assembly—Light Duty (WER) Axle

REAR AXLE SHAFT, WHEEL 2. Remove the wheel(s) and tire(s) lock bolt and the pinion shaft (Fig. 2).
BEARING A N D OIL SEAL from the brake drum(s). 8. Push the axle shaft(s) inward
REPLACEMENT 3. Position a drain pan and loosen toward the center of the axle housing.
the cover to differential housing re- Remove the C-lock(s) (Fig. 3) from
REMOVAL taining bolts. Drain the housing. the inner end of the axle(s). Remove
4. Remove the attaching (Tinner- the axle shaft(s) from the housing. Ex-
Synthetic wheel bearing seals are man) nuts that secure the brake treme care must be used to avoid con-
used for production and as service re- drum(s) to the axle shaft flange(s), tact of the axle shaft seal lip with any
placements. Removal and insertion of and then remove the drum(s). portion of the axle shaft except the
rear axle shafts must be performed 5. Remove the differential housing seal journal.
with caution. The entire length of the cover bolts, cover and gasket. Discard 9. Remove the bearing and oil seal
shaft (including spline) up to the seal the gasket. Remove the drain pan. from the housing as shown in Fig. 4.
journal must pass through the seal 6. Position safety stands under the 10. Inspect the machined surface of
without contact. Any roughing or cut- rear frame member. Lower the hoist the axle shaft and the axle housing for
ting of the seal element during axle and allow the axle to lower as far as rough spots or other irregularities
removal or installation will result in possible. which would affect the sealing action
early seal failure. 7. Working through the differential of the oil seal. Check the axle shaft
1. Raise the vehicle on a hoist. case opening, remove the pinion shaft splines for burrs, wear or damage.
LOCK BOLT
Tool - T66L-12132
Tool - 7507- 700-A
DIFFERENTIAL PINION SHAFT E 1596- A
FIG. 2—Differential pinion shaft

and Lock Bolt
AXLE SHAFT
1
T50T-100-A
Tool - 766L-72J32-8
(THREAD REDUCING
ADAPTER PART ONLY)
SEAL
BEARING
E 1598.A
FIG. 4—Removal of Axle Seal or Axle Bearing

in the axle housing. Exercise care that and torque it to specification.
splines or any portion of the axle 10. Install the brake drum and
LOCK E 1597-A
shaft(s) do not damage the oil seal(s) tighten the attaching (Tinnerman)
and that they engage with the splines nuts.
of the differential side gear(s). 11. Install the wheel and tire on the
FIG. 3—Removal and Installation 7. Install the axle shaft C-lock(s) brake drum.
of C-Locks and Axle Shaft on the inner end of the shaft(s) (Fig. 12. Clean the gasket mounting sur-
3) and push the shaft(s) outward so faces of the rear axle differential
Carefully remove any burrs or rough
that the shaft locks seat in the conter- housing and the cover. Install a new
spots. Replace worn or damaged
bore(s) of the differential side gear(s). cover gasket, cover and the attaching
parts. A brownish yellow color on the
8. Position the differential pinion bolts. Torque the bolts to specifica-
bearing journal of the shaft is normal
gears and thrust washers 180 degrees tion.
and the shaft need not be replaced.
Slight pitting and wear is also normal. apart to the differential side gears. 13. Raise the rear axle. Make sure
Revolve the gear assembly until the the rear axle is in running position.
INSTALLATION holes in the differential case are a- Add the amount of specified lubricant
1. Lightly coat the wheel bearing ligned with the pinion gears. required to reach to the bottom of the
rollers with axle lubricant. Install the 9. Position the differential pinion filler plug hole. Install the filler plug
bearings in the axle housing with the shaft through the case and pinions, a- and torque it to specification.
tool shown in Fig. 5. The bearing ligning the hole in the shaft with the 14. Remove the safety support
should seat firmly against the shoul- lock bolt hole. Install the lock bolt stands and lower the vehicle.
der.
Tool - 760K-7697.fi
2. Wipe all lubricant from the oil 7oo/
765F-7 777-A
seal bore before installing the seal.
3. Inspect the original seal for
nicks, scuffs or abnormal wear, and
replace it if necessary. The new seals
are pre-packed with lubricant and do
not require an oil soak before installa-
tion.
4. Install the oil seal with the tool
shown in Fig. 6. Installation without
the use of the proper tool will distort
the seal and cause leakage. E 1571-A
5. Replace the O-ring in the C-lock

groove on the axle shaft. FIG. 5—Installation of Axle FIG. 6—Rear Axle Shaft Bearing
6. Slide the axle shaft(s) into place Shaft Bearing Seal Installation
AXLE HOUSING 14. Support the rear axle housine 8. Place the brake backing plates
on a jack. on the axle housing flanges, install 4
Refer to Fig. 7. 15. Remove the right and left rear attaching bolts and nuts and torque
springs and insulators. them to specifications.
REMOVAL 16. Remove the nuts, washers and 9. Position the brake lines to the
pivot bolts that connect the suspension axle housing and secure them with the
1. Raise the vehicle on a hoist. lower arms to the axle housing. Dis- retaining clips. If the axle housing is
2. Remove the wheels and tires connect both arms from the axle new, install a new vent. When install-
from the brake drums. housing. ing the new axle vent apply a small
3. Position a drain pan and loosen 17. Disconnect the upper suspen- amount of Locktite (C5AZ-19554-B)
the rear axle cover to housing attach- sion arm from the axle housing by re- to prevent oil leakage between vent
ing bolts. Drain the housing. moving the pivot bolt, nut, lock wash- and axle housing. Connect the vent
4. Remove the attaching (Tinner- er and two eccentric washers. tube to the vent.
man) nuts that secure the brake drums 18. Lower the rear axle to the floor
10. Install the pinion side gears and
to the axle shaft flanges, and then re- with the jack and remove the axle
thrust washer.
move the drums (Fig. 7). from under the vehicle.
11. Slide the axle shafts into place
5. Remove the axle housing cover 19. Remove the wheel bearings and
in the axle housing. Exercise care that
bolts, cover and gasket. Discard the oil seals with the tool shown in Fig. 4.
splines or any portion of the axle
gasket. Remove the drain pan. 20. If the axle housing is being re-
shafts do not damage the oil seals and
6. Disconnect the drive shaft at the placed, transfer all the differential and that they engage with the splines of
drive pinion companion flange. Re- pinion parts to the new housing. Refer the differential side gears.
move the drive shaft from the trans- to Section 4, Major Repair Operation
for the procedure. 12. Install the axle shaft C-lock O-
mission extension housing. Install an
ring and C-lock on the inner end of
oil seal replacer tool in the transmis-
the shaft and push the shaft outward
sion housing to prevent leakage. Refer
so that the shaft lock seats in the
to the transmission group for the ap-
counterbore of the differential side
propriate tool. INSTALLATION
gear.
7. Disconnect the lower end of the
shock absorbers at the mounting 1. Lightly coat the wheel bearing 13. Position the pinion differential
brackets. rollers with axle lubricant. Install gears and thrust washers 180 degrees
8. Disconnect the track bar from wheel bearings in the axle housing apart to the differential side gears.
the axle housing stud. If the axle with the tool shown in Fig. 5. The Revolve the gear assembly until the
housing is to be replaced, transfer the bearings should seat firmly against the holes in the differential case are al-
stud to the new housing. shoulder. igned with the pinion gears.
9. Position safety stands under the 2. Wipe all lubricant from the oil 14. Position the differential pinion
rear frame members. Lower the vehi- seal bore before installing the seal. If shaft through the case and pinions, al-
cle with the hoist and allow the axle axle housing is being replaced, new igning the hole in the shaft with the
to lower far enough to relieve rear seals must be installed. lock bolt hole. Install the lock bolt
spring tension. 3. Inspect the original seal for and tighten it to specification.
10. Remove the pinion shaft lock nicks, scuffs or abnormal wear, and 15. Clean the gasket mounting sur-
bolt and pinion shaft (Fig. 2), differ- replace if necessary. New seals are face of the rear axle housing and the
ential pinion gears and thrust washers. pre-packed with lubricant and do not cover. Install a new cover gasket,
11. Push the axle shaft(s) inward require an oil soak. cover and the attaching bolts. Torque
toward the center of the axle housing. 4. Install the seal with the tool the bolts to specification.
Remove the C-locks from the inner shown in Fig. 6. Installation without
16. Raise the rear axle on a hoist
ends of the axles (Fig. 3). Remove the the use of the proper tool will distort
and remove the safety stands.
axle shafts from the housing. Extreme the seal and cause leakage.
care must be used to avoid contacting 5. Raise the rear axle into position 17. Connect the track bar to the
the axle shaft seal lip with any portion under the vehicle with a hoist or floor mounting stud. Install the washer and
of the axle shaft other than the seal jack. Connect the suspension lower nut. Torque the nut to specification.
journal. arms to their mounting brackets on 18. Connect the two rear shock ab-
12. Disconnect the vent hose from the axle housing with pivot bolts and sorbers to the mounting brackets on
the rear vent tube and remove all nuts. Do not tighten the mounting the axle housing and torque the at-
brake lines from the axle housing re- bolts at this point. taching nuts to specification.
taining clips. 6. Position the suspension upper 19. Make sure that both the front
13. Remove the brake backing arm in its mounting bracket on the and rear pivot bolts of the upper and
plate attaching nuts and the plates axle housing and install the adjusting the two lower arms are loose, then
from the axle housing. Suspend the bolt, eccentric washers, lock washer raise the axle assembly to the con-
plates above the axle housing with and nut. Do not tighten the mounting trolled height (Fig. 8). Hold the axle
mechanics wire. The hydraulic brake bolt at this point. at the controlled height by placing
lines and the parking brake cables will 7. Place the rear coil springs and blocks or pieces of steel pipe between
remain attached to the brake backing insulators into position in the pockets the axle housing and the bumper rear
plates. provided. screw on the side rail.
NUT-33847-S8-. .LOCK WASHER -
.CROSS MEMBER 9/16-12 34785-S7
CLIP -
353473-S8' 100-130 LB. FT.
NUT - 34664-S -
NUT - 375022-S2 3/8-24 2REQ'D UPPER ARM ADJUST
HOSE -4A001 70-90 LB. FT. NUT BOLT-
0PT 15-25 LB. FT. ING CAM - 5A637
90-120 LB. FT. BOLT 380826-S2
2 REQ'D.
NUT - 33847-S8
9/16-12
SPRING MUST BE POSITIONED 100-130 LB. FT.
AS SHOWN FOR R.H. SIDE
NUT - 55754-S7 - LOCK WASHER -
9/16-12 34785-S7
80-105 LB. FT.
WASHER - BUMPER
44741-S8 4002
VIEW FOR PASSENGER 2 REQ'D.
CARS SAME AS VIEW Z
SPRING MUST BE EXCEPT AS SHOWN
POSITIONED AS
SHOWN FOR L.H. SIDE
BOLT -
304685-S BOLT - 381877-S2
8 REQ'D 4 REQ'D.
9-13 LB. FT.
BRAKE DRUM -
1126 2 REQ'D
NUT - 34445-S7 TIRE - 1508
LOWER ARM - 20-30 LB. FT.
5A648 2 REQ'D.
NUT- DRIVE SHAFT -

375022-S2 4602 ASSY.
2 REQ'D.
70-90 LB. FT. NUT rtnT
90-120 LB. FT. BOLT " 0 P T USING SPECIAL TOOL,
ASSEMBLE NUTS TO NUT -
HOLD DRUM ASSEMBLY - 372188-S32
NUT - SECURELY AGAINST 6 REQ'D.
375032-S36
FLANGE
1/2-13
2 REQ'D.
50-85 LB. FT PRONGS MUST BE
SECURELY LOCKED /'
2209 ASSY. R.H. PLACE HUB CAP-
2210 ASSY. L.H. 1130
MUST BE USED 2 REQ'D.
FROM THE SAME
SUPPLIER IN NUT -
AXLE SETS 1012
10 REQ'D.
70-115 LB. FT.
NUT - 375022-S2 'NUT - 55754-S7

2 REQ'D VIEW T 9/16-12
VIEWN VIEW W 70-90 LB FT. NUT _ nPT
60-85 LB. FT.
90-120 LB. FT. BOLT BOLT - *
VIEW R 304907-S2
9/16-12 VIEW V
80-105 LB. FT. E 1633-A
FIG. 7—Rear Axle Installation—WER Axle

FRAME
20. With the axle at controlled 22. Install the brake drum and at-
height, torque the suspension upper taching (Tinnerman) nuts.
and lower arm front pivot bolts and 23. Install the wheel and tire on the
nuts to specifications. Torque the brake drum. Install the wheel covers.
lower arm to axle housing pivot bolts 24. Adjust the drive shaft and pin-
and nuts to specifications. ion angle to specification.
21. Remove the oil seal replacer 25. Add the amount of specified lu-
from the transmission extension hous- bricant required to reach to the bot-
ing. Install the drive shaft in the ex- tom of the filler plug hole. Make sure
TIGHTEN ARM 5-45/64 INCH
tension housing. Align the scribe ATTACHING BOLTS HEIGHT FOR
the rear axle is in running position.
marks on the cups, flange and drive AT 5-45/64 INCH INSTALLATION Install the filler plug and torque it to
HEIGHT POSITION OF ARMS
shaft and connect the drive shaft at specification.
E 1600-B
the drive pinion flange. Torque the at- 26. Lower the vehicle.
taching bolts to specification FIG.8— Axle Normal Curb Height
and Controlled Height for Arm
Installation
4 MAJOR REPAIR OPERATIONS

DISASSEMBLY OF AXLE The rear axle components are
shown in Fig. 9.
DIFFERENTIAL SIDE GEAR
THRUST WASHER
AXLE SHAFT C-WASHER \
^ ^ DIFFERENTIAL PINION GEAR
DIFFERENTIAL PINION SHAFT
BEARING ADJUSTING NUT
THRUST WASHER
BEARING ASSEMBLY
CUP
BOLT
LOCK WASHER
DIFFERENTIAL
PINION SHAFT ADJUSTING NUT LOCK
LOCK BOLT
LOCK WASHER
BEARING CAP
AXLE HOUSING ASSEMBLY
PINION LOCATING SHIM(S)
BEARING CUP
BOLT
NUT
BEARING CUP
COLLAPSIBLE SPACER
AXLE SHAFT
E 1572-C
FIG. 9—Disassembled Light-Duty (WER) Rear Axle

Tool - T6SL-485UA \
RUNOUT CHECK E 1573-A
FIG. 70—Checking Backlash and Runout—Light-Duty (WER) Axle
All service operations on the differ- portion of the axle shaft except the
ential case assembly can be performed seal journal. E 1574-A
with the axle housing in the vehicle. 10. Remove the bearings and oil
1. Raise the vehicle on a hoist. seals from the axle housing as shown FIG. 12—Drive Pinion Flange
2. Position the drain pan under the in Fig. 4. Removal
axle housing. Loosen the housing 11. Remove the pinion side gears
cover attaching bolts. Drain the lubri- and the side gear thrust washers.
cant from the housing. 12. Remove both side bearing ad-
3. Make scribe marks on the drive justing nut locks (bolts).
shaft end yoke and the rear axle shaft 13. Install a dial indicator (Fig. 10),
companion flange to insure proper po- and check and record the backlash
sition of the drive shaft at assembly. and ring gear runout.
Disconnect the driveshaft from the 14. Mark one differential bearing
rear axle companion flange. Be care- cap and the case to help in positioning
ful to avoid dropping the loose univer- the parts properly during assembly.
sal joint bearing cups. Hold the cups 15. Remove the bearing cap retain-
on the spider with tape. Mark the ing bolts. Remove the bearing caps,
cups so that they will be in their origi- cups, adjusting nuts and case assem-
nal position in relation to the flange bly. 1575-A
when they are reassembled. Remove 16. Hold the drive pinion flange
the drive shaft from the transmission and remove the pinion nut (Fig. 11). FIG. 13—Pinion Rear Bearing
extension housing. Install an oil seal Discard the nut. Removal
replacer tool in the transmission ex- 17. Remove the pinion flange (Fig.
tension housing to prevent transmis- 12).
sion leakage. Refer to the transmis- 18. Drive the pinion out of the 00/ - T57L-4220-A
sion group for the appropriate tool. front bearing cone and remove it from
4. Raise the vehicle and place the carrier housing. Remove and dis-
jack-type stands under the rear frame card the bearing spacer.
crossmember. Lower the vehicle on a 19. With a hammer and drift re-
hoist and allow the axle to lower as move the pinion shaft oil seal out
far as possible. through the front of the carrier hous-
ing.
5. Remove the axle housing cover
20. Remove the pinion rear bearing
and gasket. Discard the gasket.
from the drive pinion shaft (Fig. 13).
6. Perform the Inspection Before
21. Measure the shim which is
Disassembly of Carrier procedure. found under the bearing cone with a
Refer to Part 4-1, Section 3 of this
Shop Manual.
7. Remove the attaching (Tinner-
man) nuts that secure the rear brake
drums to the axle shaft flanges, and E 1576-A
then remove the drums.
8. Working through the differential FIG. 14—Differential Bearing
case opening, remove the pinion shaft Removal
lock bolt and pinion shaft (Fig. 2). micrometer. Record the thickness of
Tool-T57L-485T-A the shim.
9. Push the axle shafts inward or 4851-K
toward the center of the axle housing. DISASSEMBLY OF
Remove the C-locks (Fig. 3) from the DIFFERENTIAL CASE
inner ends of the rear axles. Remove 1. If the 2 differential side bearings
the axle shafts from the housing. Ex- El 906A are to be removed from the differen-
treme care must be used to avoid con- FIG. 11—Typical Drive Pinion tial case, use the tool shown in Fig.
tacting the axle shaft seal lip with any Shaft Nut Removal 14.
MATCHED
GEAR SET
IDENTIFICATION
E 1628-A
. ?6—Pinion and Ring Gear

Markings
3
ress Ro-
E 1577-A Tool
T57L-4221-A-1
75—Pinion Bearing Cup Installation—Typical
DIFFERENTIAL
BEARING CONE
2. Remove the bolts that attach the DRIVE PINION AND ANC ROLLER
ring gear to the differential case. Press GEAR SET

the ring gear from the case or tap it
off with a soft-faced hammer. Individual differences in machining
the carrier casting and the gear set re-
quire a shim between the pinion rear
PARTS REPAIR OR bearing cone and the pinion gear to
REPLACEMENT locate the pinion for correct tooth
contact with the ring gear.
Clean and inspect all the parts as When replacing a ring gear and pin-
outlined in Cleaning and Inspection, ion it should be noted that the original
Part 4-1, Section 3 of this Shop Man- factory installed shim is of the correct
ual. Before assembling the carrier, re- thickness to adjust for individual vari- | E 1579-A
pair or replace all parts as indicated ations in both the carrier casting di-
by the inspection. The principle re- mension and in the original gear set PIG. 77—Differential Bearing
placement operations are covered in dimension; therefore, to select the cor- Installation
the following procedures. All other re- rect shim thickness for the new gear
pair or replacement operations are set to be installed, follow these steps: DIFFERENTIAL CASE,
performed during the Cleaning and BEARINGS, AND DRIVEN
Inspection, Part 4-1, Section 3 opera- 1. Use a micrometer to measure GEAR
tions noted above, or during the as- the thickness of the original shim re-
sembly in this section. moved from the axle and use the same If the ring gear runout check (be-
thickness upon installation of the re- fore disassembly) exceeded specifica-
placement carrier assembly or drive tions, the condition may be caused by
pinion. If further shim change is nec- a warped gear, a defective case, or ex-
essary, it will be indicated in the tooth cessively worn differential bearings.
PINION BEARING CUPS pattern check. To determine the cause of excessive
runout, proceed as follows:
2. If the original shim is lost, sub-
Do not remove the pinion bearing 1. Press the original bearings on
stitute a nominal shim for the original
cups from the carrier casting unless the one-piece differential case hubs
and use the tooth pattern check to de-
the cups are worn or damaged. without the ring gear installed.
termine if further shim changes are re-
If the pinion bearing cups are to be 2. Place the differential bearing
quired. Nominal shim thicknesses is
replaced, drive them out of the carrier cups on the bearing cone and roller
indicated in Part 4-3, Specifications.
casting with a drift. Tap on the side and set the differential case in the car-
A new ring gear and pinion should
opposite the cup. Use care to prevent rier.
always be installed in an axle as a
the cups from cocking in the carrier. matched set (never separately). Be 3. Install the matched (marked)
Install the new cups with the tool bearing caps and adjusting nuts as
sure the same identifying (matching)
shown in Fig. 15. Make sure the cups outlined in steps 11 thru 14 under In-
number, painted, appears on the bolt
are properly seated in their bores. If a stallation of Drive Pinion and Differ-
hole face of the ring gear and on the
0.0015-inch feeler gauge can be insert- ential Case which follows in this sec-
head of the drive pinion (Fig. 16).
ed between a cup and the bottom of tion.
its bore at any point around the cup, 3. After determining the correct 4. Tighten the left adjuster nut until
the cup is not properly seated. shim thickness as explained in the it just touches the bearing cup then
Whenever the cups are replaced, the foregoing steps, install the new pinion tighten the nut two notches beyond
cone and roller assemblies should also and ring gear as outlined under As- the point where it first contacts the
be replaced. sembly which follows in this section. bearing cup. Rotate the differential
case several revolutions in each direc- REAR BEARING Press Ram

CONE AND
tion while the bearings are loaded to ROLLER
seat the bearings in their cups. This
step is important.
lease the preload. Check to see that
the left nut contacts the bearing cup.
Using the dial indicator set-up shown
in Fig. 13, Part 4-1, adjust the preload
to 0.008 to 0.012 case spread for new
bearings or 0.005 to 0.008 for the / Tool - T58L-4676-A
original bearings, if re-used. / E 1581-A
6. Check the runout of the differen-
tial case flange with a dial indicator.
If the runout does not now exceed FIG. 19—Installing Pinion Seal
specifications, install a new ring gear,
if the runout still exceeds specifica-
tions, the ring gear is true and the
trouble is due to either a defective
FIG. 18—Drive Pinion Bearing
casting or worn bearings.
7. Remove the differential case Installation
from the carrier and remove the side 3. Lubricate the pinion rear bearing
bearings from the case. with axle lubricant.
8. Install new bearings on the case 4. Lubricate the pinion front bear-
hubs, and again install the differential ing with axle lubricant. Lubricate the
assembly in the carrier without the pinion front bearing cone and place it
ring gear. in the carrier housing. E 1582-A
9. Check the case runout again with 5. Install a new oil seal in the car-
the new bearings. If the runout is now rier casting (Fig. 19).
within limits, the old bearings were 6. Insert the drive pinion shaft (U- FIG. 20—Checking Pinion Bearing
excessively worn. Use the new bear- joint) flange into the pinion seal and Preload
ings for assembly. If the runout is still hold it firmly against the pinion front
excessive, the case is defective and bearing cone. From the rear of the pinion shaft nut. This will remove the
should be replaced. carrier casting, insert the pinion shaft compression between the pinion front
into the flange. and rear bearing cones and the col-
ASSEMBLY OF AXLE 7. Apply a small amount of lubri- lapsible spacer and may permit the
cant to the washer side of the flange front bearing cone to turn on the pin-
Refer to Part 4-1 of this Shop nut and start the nut. Use a new nut. ion shaft.
Manual for Cleaning and Inspection Hold the flange with the tool shown in 8. As soon as there is preload on
procedures before starting assembly Fig. 12 and tighten the pinion shaft the bearings, turn the pinion shaft in
operations. nut. As the pinion shaft nut is tight- both directions several times to seat
ened, the pinion shaft is pulled into the bearing rollers.
ASSEMBLY OF the front bearing cone and into the 9. Adjust the bearing preload to
DIFFERENTIAL CASE flange. specification. Measure the preload
As the pinion shaft is pulled into with the tool shown in Fig. 20.
1. Place the ring gear on the differ- the front bearing cone, pinion shaft 10. Apply a thin coating of lubri-
ential case. Install the retaining bolts end play is reduced. While there is cant on the bearing bores so that the
and torque them to specification. still end play in the pinion shaft, the differential bearing cups will move
2. If the differential bearings were flange and cone will be felt to bottom. easily.
removed, press them on as shown in This indicates that the bearing cone 11. Place the cups on the bearings
Fig. 17. and flange have bottomed on the col- and set the differential case assembly
3. Insert the pinion gear shaft lock lapsible spacer. in the carrier casting.
bolt into the case (loosely). From this point, a much greater If the gear set is of the non-hunting
torque must be applied to turn the or partial non-hunting type, assemble
pinion shaft nut, since the spacer must the differential case and ring gear as-
INSTALLATION OF DRIVE be collapsed. From this point, also, sembly in the carrier so that the
PINION AND the nut should be tightened very slow- marked tooth on the pinion indexes
DIFFERENTIAL CASE ly and the pinion bearing preload play between the marked teeth on the ring
checked often, so that the pinion bear- gear as shown in Fig. 49, Part 4-2.
1. Place the shim(s) and pinion rear ing preload does not exceed the speci- In almost every case of improper
bearing cone on the pinion shaft. fied limits. assembly (gears assembled out of
Press the bearing and shim(s) firmly If the pinion shaft nut is tightened time), the noise level and probability
against the pinion shaft shoulder (Fig. to the point that pinion bearing pre- of failure will be higher than they
18). load exceeds the limits, the pinion would be with properly assembled
2. Place a new pinion bearing pre- shaft must be removed and a new col- gears.
load (collapsible) spacer on the pinion lapsible spacer installed. Do not de- When installing the hunting type
shaft. crease the preload by loosening the gear set (no timing marks), assemble
the differential case and ring gear as- .BEARING CAP IDENTIFICATION-j 19. Install the differential pinion
sembly in the carrier without regard MARKS A
side gears and thrust washers.
to the matching of any particular gear 20. Install the rear wheel bearings
teeth. seals, rear axle shafts, wheels and tires
12. Slide the case assembly along and the axle carrier cover as outlined
the bores until a slight amount of under Part 4-3, Section 2, Rear Axle
backlash is felt between the gear teeth. Shaft, Wheel Bearing and Oil Seal
Hold the differential case in place. Replacement, Steps 10 through 19.
13. Set the adjusting nuts in the 21. Raise the axle all the way up.
bores so that they just contact the Rdnove the safety support stands.
bearing cups. 22. Connect the track bar to the
14. Carefully position the bearing T57L-4067-A mounting stud. Install the washer and
caps on the carrier casting. Match the E 1583-A
retaining nut, and torque the nut to
marks made when the caps were re- specification.
27—Bearing Cap Installation
moved (Fig. 21). 23. Remove the oil seal replacer
15. Install the bearing cap bolts nuts are seated. Loosen the cap bolts, tool from the transmission extension
and lockwashers. As the bolts are and torque them to only 5 ft-)bs be- housing. Install the front end of the
tightened, turn the adjusting nut with fore making adjustments. Refer to drive shaft on the transmission.output
the tool shown in Fig. 21. part 4-1, Section 2 of this shop manu- shaft. Align the scribe marks on the
16. If the adjusting nuts do not turn al for backlash and bearing preload cups, flange and drive shaft and con-
freely as the cap bolts are tightened, adjustment procedures. nect the rear end of the drive shaft to
remove the bearing caps and again in- 17. Clean the marking compound the axle U-joint flange. Torque the re-
spect for damaged threads or incor- from the gear teeth. taining bolts to specification.
rectly positioned caps. Tightening the 18. Install both side bearing adjust- 24. Lower the vehicle.
bolts to the specified torque is done to ing nut locks (bolts) and torque them
be sure that the cups and adjusting to specification.
REAR AXLE RATIOS. GEAR AND CuDE IDENTIFICATION - COUGAR FALCON. FAIRLANE. MUSTANG AND MONTEGO
Identifi- Ring Gear No. of Teeth Identifi- Ring Gear No. of Teeth
cation Diameter Type of Axle cation Diameter Type of Axle
Tag (Inches) Differential® Ratio Ring Gear Pinion Tag (Inches) Differential® Ratio Ring Gear Pinion
WCY-R1 7 1/4 Conventional 2.83:1 34 12 WEC-K 9 Conventional 3.00:1 39 13
WCY-AJ2 7 1/4 Conventional 3.08:1 37 12 WEC-L 9 Conventional® 3.25:1 39 12
WCZ-F1 8 Conventional 3.00:1 39 13 WEC-M 8 3/4 Conventional 3.25:1 39 12
WCZ-V 8 Conventional 2.79:1 39 14 WEC-N 9 Conventional 3.25:1 39 12
WDJ-C1 8 Limited Slip 3.00:1 39 13 WEC-R 9 Conventional® 3.50:1 35 10
WDV-B 7 1/4 Conventional 2.83:1 34 12 WES-F 9 Conventional® 3.00:1 39 13
WDV-G 7 1/4 Conventional 3.20:1 32 10 WES-G1 9 Limited Slip® 3.25:1 39 12
WDW-H 7 1/4 Limited Slip 3.20:1 32 10 WES-M 9 Conventional® 3.25:1 39 12
WDW-B1 8 Conventional 3.00:1 39 13 WES-N 8 3/4 Conventional 3.00:1 39 13
WDW-C1 8 Conventional 3.25:1 39 12 WES-P 8 3/4 Conventional 3.25:1 39 12
WDW-F 8 Conventional 3.00:1 39 13 WES-SI 9 Conventional® 2.75:1 44 16
WDW-J 8 Conventional 2.79:1 39 14 WES-T1 9 Conventional 2.75:1 44 16
WDW-K 8 Conventional 2.79:1 39 14 WES-U 9 Conventional® 3.50:1 35 10
WDY-A1 8 Conventional 3.00:1 39 13 WES-AA 9 Conventional 3.00:1 39 14
WDY-B1 8 Conventional 3.25:1 39 12 WES-AB 9 Conventional 3.25:1 39 12
WDZ-B1 8 Limited Slip 3.00:1 39 13 WES-AC 9 Conventional® 3.00:1 39 13
WDZ-E 8 Limited Slip 3.00:1 39 13 WES-AD 9 Conventional® 3.25:1 39 12
WEA-A1 8 Limited Slip 3.00:1 39 13 WFA-A 9 Traction Lok® 3.25:1 39 12
WEA-F1 8 Limited Slip 3.25:1 39 12 WFA-C 9 Traction Lok® 3.25:1 39 12
WEB-F6 9 Conventional® 3.00:1 39 13 WFA-D 9 Traction Lok® 3.25:1 39 12
WEB-F6 9 Conventional® 3.25:1 39 12 WFA-E 9 Traction Lok® 3.00:1 39 13
WEB-H2 9 Conventional 2.75:1 44 16 WFB-A 9 Traction Lok® 3.25:1 39 12
WEB-L 9 Conventional® 3.50:1 35 10 WFB-C 9 Traction Lok® 3.25:1 39 12
WEB-M 9 Conventional® 3.00:1 39 13 WFC-A 9 Traction Lok® 3.50:1 35 10
WEB-N 8 3/4 Conventional 3.00:1 39 13 WFC-B 9 Traction Lok© 3.91:1 43 11
WEB-P 9 Conventional® 2.75:1 44 16 WFC-C 9 Traction Lok© 4.30:1 43 10
WEB-R 9 Conventional 3.00:1 39 13 WFC-D 9 Traction Lok® 3.91:1 43 11
WEB-S 9 Conventional 3.25:1 39 12 WFC-E 9 Traction Lok® 4.30:1 43 10
WEB-T 9 Conventional® 3.25:1 39 12 WFC-F 9 Traction Lok® 3.91:1 43 11
WEB-U 8 3/4 Conventional 3.25:1 39 12 WFOS 9 Traction Lok® 3.50:1 35 10
WEC-D5 9 Conventional® 3.00:1 39 13 WFC-K 9 Traction LokCD 4.30:1 43 10
WEC-E5 9 Conventional® 3.25:1 39 12 WFC-G 9 Traction Lok® 3.00:1 39 13
WEC-H 9 Conventional® 3.00:1 39 13 WFD-A 9 Traction Lok® 3.50:1 35 10
WEC-J 8 3/4 Conventional 3.00:1 39 13 WFD-B 9 Traction Lok® 3.91:1 43 11
© 2 - Pini on Unless Otherwise Noted ©Conventional 4 • Pinion WFD-C 9 Traction Lok® 4.30:1 43 10
©Torque Sensitive Locker (4 • Pinion) ©Limited Slip 4 - Pinion WFD-H 9 Traction Lok® 3.25:1 39 12
REAR AXLE RATIOS, GEAR AND CODE IDENTIFICATION -FORD, MERCURY AND METEOR
Tag (Inches) Differential Ratio Ring Gear Pinion Tag (Inches) Differential Ratio Ring Gear Pinion
WDC-AS4 8 3/4 Conventional 3.25:1 39 12 WDL-AC4 8 3/4 Limited Slip 3.25:1 39 12
WDC-AV4 8 3/4 Conventional 3.00:1 39 13 WDL-AE 9 Limited Slip 3.25:1 39 12
WDC-CA4 9 Conventional 2.75:1 44 16 WDL-AF 9 Limited Slip® 2.75:1 44 16
WDC-CC4 9 Conventional® 3.00:1 39 13 WDL-AG 9 Limited Slip® 3.25:1 39 12
WDC-CK4 9 Conventional 3.25:1 39 12 WDT-F4 9 3/8 Conventional 2.80:1 42 15
WDC-CL4 9 Conventional® 3.25:1 39 12 WDT-R4 9 3/8 Conventional® 3.25:1 39 12
WDC-CM4 9 Conventional® 3.50:1 35 10 WDT-AL4 9 3/8 Conventional 3.25:1 39 12
WDC-CN 9 Conventional® 2.75:1 44 16 WDT-AM4 9 3/8 Conventional® 3.50:1 35 10
WDC-CR 9 Conventional® 3.25:1 39 12 WDT-AN4 9 3/8 Limited Slip© 3.25:1 39 12
WDL-W4 8 3/4 Limited Slip 3.00:1 39 13 WDT-AS4 9 3/8 Limited Slip 2.80:1 42 15
WDL-AA4 9 Limited Slip 2.75:1 44 16 WER - A4 81/2 Conventional 3.10:1 31 10
WER-C4 8 1/2 Conventional 2.80:1 42 15
© 4 - Pinion ©Equipped With Torsional Damper
REAR AXLE RATIOS, GEAR AND CODE IDENTIFICATION - LINCOLN CONTINENTAL

WEG-C2 9 3/8 Conventional 2.80:1 42 15 WEG-E2 9 3/8 Conventional 3.00:1 39 13
WEG-D2 9 3/8 Limited Slip 2.80:1 42 15 WEG-F2 9 3/8 Limited Slip 3.00:1 39 13
REAR AXLE RATIOS, GEAR AND CODE IDENTIFICATION -THUNDERBIRD AND CONTINENTAL MARK III
WGA-A 9 3/8 Conventional 2.80:1 42 15 WGA-C 9 3/8 Limited Slip 2.80:1 42 15
WGA-B 9 3/8 Conventional 3.00:1 39 13 WGA-D 9 3/8 Limited Slip 3.00:1 39 13
CLEARANCE, TOLERANCE AND ADJUSTMENT SPECIFICATIONS (BY AXLE RING GEAR DIAMETER)
Description Inches Description Inches
Maximum Runout of Backface of 0.003 Nominal Pinion Locating Shim •
Ring Gear 8 3/4", 9 " & 9 3/8" Ring Gear 0.015
8 1/2" Ring Gear 0.030
Differential Side Gear Thrust 8" Ring Gear 0.022
Washer Thickness 0.030-0.032 7 1/4" Ring Gear 0.017
Differential Pinion Gear Thrust Available pinion Gear Shims
Washer Thickness 0.030-0.032 in steps of .001":
8 3/4", 9" & 9 3/8" 0.010 0.029
Drive Pinion Bearing Solid Spacers- 8 1/2" 0.022 0.038
(9-3/8" only) 7 1/4" 0.008 0.024
6 spacers in increments of
0.002 inches 0.466-0.476 Backlash between ring gear and
14 spacers in increments of pinion teeth 0.0080.012
0.001 inches 0.477-0.490
Differential Bearing Preload Maximum backlash variation
(Case spread across Differential) between teeth 0.003
New Bearings (All) 0.008-0.012
Original Bearings- Maximum radial runout of U-joint
7 1/4" Ring Gear 0.003-0.005 flange in assembly:
8 3/4" & 9 3/8" Ring Gear 0.005-0.008 All except 9 3/8" 0.010-T.I.R.
8 1/2" Ring Gear 0.006-0.010 9 3/8" 0.005-T.I.R.
SHIM PACK THICKNESS CHART TRACTION-LOK DIFFERENTIAL

Feeler Remove Shim(s) Total Req'd Feeler Remove Shim(s) Total Req'd
Gauge From Shim Pack Gauge From Shim Pack
Reading Nominal Thickness® Reading Nominal Thickness ®
0.001
None 0.050 0.028
0.002
0.029
0.030 0.030 0.020
0.003 0.031
0.004 0.032
0.005 0.005 0.045
0.006
0.007
0.033
0.034
0.008 0.035 0.035 0.015
0.009 0.036
0.010 0.010 0.040 0.037
0.011
0.012
0.013 0.038
0.014 0.039
0.040 0.040 0.010
0.015 0.015 0.035
0.041
0.016
0.042
0.017
0.018 0.043
0.019 0.044
0.020 0.020 0.030 0.045 0.045 0.005
0.021 0.046
0.022 0.047
0.023
0.024 0.048
0.025 0.025 0.049 0.050 0.000
0.025
0.026 0.050
0.027
©Service Shims are available in 0.010" and 0.005" Thicknesses.
ADJUSTMENT TORQUE SPECIFICATION - ( B Y AXLE RING GEAR DIAMETERS

Torque Torque
Description Lbs. In. . Lbs. Ft. Description Lbs. In. Lbs. Ft.
Minimum torque required to tighten Lockers Only • Minimum rotating
pinion flange nut to obtain Torque required to turn axle
correct pinion bearing preload shaft and side gear with one
7 1/4" & 8 1/2" 140® wheel on ground:
8", 8 3/4" & 9" 175® Limited Slip 7 1/4" 50
9 3/8" 180-220 All other R. G. Sizes 75
Traction-Lok-All 40
Pinion Bearing Preload- Lockers only-Rotating Torques
collapsible spacer)® required during bench check
Original Bearings 7 1/4" 6-12 after assembly:
8 " , 8 1/2", 8 3/4", 9" 8-14 Original Clutch Plates-
New Bearings 7 1/4" 17-32 Limited Slip 7 1 / 4 " , 50 Min.
8 " , 8 1/2", 8 3/4", 9" 22-32 All other R. G. Sizes 75 Min.
Traction-Lok-(All) 40 Min.
Pinion Bearing Preload- New Clutch Plates-
(Solid Spacer) 9 3/8" Only 15-35 Limited Slip 7 1/4" 100-125
All other R. G. Sizes 155-195
Traction-Lok-All 100-250G
© I f pinion bearing preload exceeds specification before this torque is obtained, install a new spacer.
©With Oil Seal.
©Rotating torque may fluctuate up to 40 Lbs. Ft.
ATTACHING TORQUE SPECIFICATIONS - ( B y Axle Ring Gear Diameter)

Description Torque Lbs. Ft. Description Torque Lbs. Ft.
Differential Bearing Cap Bolt- 7 1/4" 40-55 Rear Cover Screw and Washer
8" 55-70 Assemblies - 8 1/4" & 8 1/2
All Others 70-85 Only 25-35
Differential Bearing Adjusting Oil Filler Plug 25-50
Nut Lock Bolts 12-25
Rear Axle Shaft Bearing Retainer
Carrier to Housing Stud Nuts- Bolt Nuts:
8", 8 3/4", 9" 8 3/8" 25-40 Falcon, Fairlane, Montego,
Mustang and Cougar (All) 20-40
Pinion Retainer to Carrier Bolts-
8", 8 3/4", 9" 9 3/8" 30-45 Ford & Meteor (Exc. 8 1/2" R.G.)
Mercury, T Bird 50-75
Ring Gear Attaching Bolts-
7 1/4" 40-55 Lincoln Continental (All) 30-55
All Others 65-80
Brake Backing Plate Bolt Nuts-
Differential Pinion Shaft Ford & Meteor 8 1/2" Only 20-40
Lock Pin • 8 1/2" Only 15-22
LUBRICANT CAPACITIES AND CHECKING PROCEDURES®

Engine Axle U.S. Measure Imperial
Vehicle (C.I.D.) Ratio Capacity® (Pints) Capacity CD (Pints)
Falcon, Mustang 170, 200 All 2.5 2
Cougar, Fairlane, Falcon
Montego, Mustang 250, 302 All 4.0 31/5
Ford, Meteor 240, 302 2.80:1, 3.10:1 4.0 3 1/5
Ford, Meteor 240, 302 All Except 5.0 4.0
2.80:1, 3.10:1
Cougar, Fairlane, Falcon, Ford, 351, 390,
Mercury, Meteor, Montego, Mustang 428, 429 All 5.0 4.0
Lincoln, Thunderbird 429, 460 All 5.0© 4.0©
©All limited slip and Traction-Lok axles use ESW-M2C-104-A lubricant (C6AZ-19580-C).
All conventional axles use ESW-M2C-105-A lubricant (C6AZ-19580-B).
©Approximate refill capacity-Actual lubricant capacities are determined by filling to bottom of filler hole.
©To check these axles, the plug should be backed out slowly. If seepage occurs around the threads, the plug should be turned back in
immediately to avoid any drainage. This indicates that the specified amount of lubricant is present in the axle.
SPECIAL TOOLS
Ford Tool No. Former No. Description Ford Tool No. Former No. Description
42211 or Limited-Slip Differential Check T53T4851-A 4851-A, D U-Joint Flange Remover
T66L-4204-L 42211-A
T00L4858-D — U-Joint Flange Remover
T57L-500-A 6005-M Bench Fixture
6005-MS T57L4614-A 4614 Drive Pinion Retainer Support
T50T-100-A B-160 Impact Hammer T00L4621-K 4621-K Pinion Rear Bearing Cone Remover
TOOL-4235-C 4235C Axle Shaft Remover T53L-200-A — Handle Adapter
T00L-4621-A — Drive Pinion Bearing and T57L-4625-A or 4625-K Pinion Pilot Bearing Remover and
Rear Wheel Bear Replacer T00L4625-K Installer
TOOL-1225-D — Rear Wheel Bearing Remover T57L4616-A or — Pinion Front Bearing Cup Remover
T00L4615-D and Replacer
T00L42344 4234-A Rear Wheel Bearing Installer
T58L-101-A — Puller Attachment—For Bearing
TOOL-1177 4245-B Rear Wheel Bearing Oil Seal Installer Cup Removal
TOOL-U75-AB 1175-AB Rear Wheel Bearing Oil Seal Remover T55P4616-A2 — Pinion Rear Bearing Cup Remover
and Replacer
T57L4220-A — Differential Bearing Remover
T57L4621-B or — Pinion Rear Bearing Cone Installer
T00L4221-AE T00L4621-L
T00L-4221-AF 4221-AF Differential Bearing Remover
T66P-4220-P T58L4676-A 4676-F Drive Pinion Oil Seal Replacer
TOOL-4851-K T57L-4851-A U-Joint Flange Holder T00L4858-E 4858-E U-Joint Flange and Pinion Bearing
4851-K Replacer
SPECIAL TOOLS
FORD MERCURY, METEOR (Continued)
Ford Tool No. Foniisr NO. Description Ford Tool No. Fomor No. Description
T57L-4221-A1 or 4222-H Differential Bearing Installer TOOL-T60K- Transmission Extension Housing

Tool-4222-K 7697-B Bushing Repiacer
TOOL 6565-AB 6565-AB Adapter T00L-T65F- — Rear Wheel Bearing Oil Seal Repiacer
1177-A
TOOL 6565 6565 Dial Indicator
T00L-T65L- — Flange (Universal Joint) Axle End
TOOLS 4201-C 4201-C Differential Backlash and Runout 4851-A Remover
andD Gauge with Universal Bracket, Dial
Indicator and Bracket TOOL-OTC-951 — Universal Puller
TOOL-T57L- 4067-B Differential Bearing Adjuster Wrench

4067-A T00L-T67P- — Pinion Bearing Cups Repiacer
4616-A
TOOL-T50T-100-A — Impact Hammer-Long
TOOL-T53T- — Pinion Bearing Cone Repiacer
T00L-T66L- — 4621-C
Adapter
12132-B
CJ-6625 (Snap- —
On) Puller
COUGAR, FAIRLANE, FALCON, MONTEGO, MUSTANG

T50T-100-A B-160 Impact Hammer
T58L-101-A Puller Attachment T57L-4614-A 4614 Drive Pinion and Drive Pinion Retainer
T62L-201-A - Handle Adapter Assembly Support
T56L-400-A 4851-A Puller T00L-4615-J 4615-J Drive Pinion Front Bearing Cup Remover
T57L-500-A - Bench Mounted Holding Fixture T60K-4616-A 4615-HF Pinion Bearing Cup Repiacer
4625-HR
T00L-1175-AB 1175-AB Grease Seal Remover (Head Only)
T57L-4616-A 4615- E Pinion Front Bearing Cup Remover
T50T-100-Aand 1175-AE Seal Remover andP
TOOL-1175-AB
T57L-4616-A2 4615- E Pinion Front Bearing Cup Repiacer
T60K-1177-B 1177-B Rear Wheel Bearing Oil Seal andF
T60K-1225-Aor Axle Shaft Bearing Remover and Repiacer
T00L-1225-C Axle Shaft Searing Remover
T55P-4616-A2 - Pinion Rear Bearing Cup Repiacer
TOOL-1225-B T00L-4621-K 4621-K Drive Pinion Rear Bearing Cone Remover

Axle Shaft Bearing Repiacer
T00L-T54-P- Front Suspension Upper and Lower Arm T62F-4621A Pinion Bearing Cone Repiacer
3044-A Overhaul Tool Kit T62F-4625-A 4625-AC Drive Pinion Pilot Bearing Remover
land 2 and Repiacer
T00L-T57L- 4067-B Differential Bearing Adjuster Nut
4067-A Wrench T55P-4676-A 4676-G Drive Pinion Oil Seal Repiacer
T57L-4067-Aor 4221 or Limited-Slip Differential Check T62F4676A 4676- H Drive Pinion Oil Seal Repiacer
T60K-4067-A 4211-A T53T-4851A 4851-A Flange (Universal Joint) Axle End
4858-D Remover
TOOL-4201-C 4201-C Differential Backlash and Runout Gauge
andD With Universal Bracket, Dial Indicator T57L-4851-A 4851-K Universal Joint Flange Holder
and Bracket T00L-4858-E 4858- E Companion Flange and Pinion Bearing
T65K-4204A or 4067-E Differential Bearing Adjuster Nut Repiacer
T59L-4204-A Wrench T65K-4204-A — Limited-Slip Differential Torque Check
T00L-4221-AL 4221-AL Differential Bearing Cone Remover Adapter
Pilot (Use with T00L-4221C or T59L-4204-A 44211 and Locking Differential Torque Check
T00L-4851-A) 44211-A
T57L-4221-A 4222-K Differential Bearing Cone Repiacer T00L-6565-AB 6565-AB Adapter
T00L-4222-H 4222 Differential Bearing Cone Repiacer TOOL-6565 6565 Dial Indicator
T66L-4235-A Rear Axle Shaft Assembly Remover
Adapter T68P-4946-A - Traction-Lok Shim Template Tool
THUNDERBIRD, CONTINENTAL MARK III
T50T-100-A T50T-100-C Slide Hammer TOOL-4616 4616 Drive Pinion Bearing Cup Replacer
T50T-100-A& (Front)
TOOL-1175-AB 1175-AE Seal Remover T00L-4621-A 4621-A Drive Pinion Bearing and Rear Wheel
T00L-1225-DA 1225-DA Rear Wheel Bearing Remover Bearing Replacer
T00L-4621-BA 4621-BA Rear Pinion Bearing Remover
TOOL-4005 4005 Engine Repair Stand Axle Adapter- TOOL-4628 4628 Pinion Rear Bearing Cup Replacer
Keyed Shaft T00L-4628-B 4628-B Pinion Bearing Front Cup Remover
TOOL-4020-B 4020-B Pinion Depth Gauge-Complete With T00L-4628-D 4628-D Pinion Rear Bearing Cup Remover
Depth Micrometer and Gauge Block T64N-4676-A 4676 Pinion Shaft Oil Seal Replacer
T57L-4067-A _ Differential Bearing Adjuster Wrench T68P-4851-A - Universal Joint Flange Holder
TOOL-4201 4201 Pinion Shaft Drive Nut T64N-4858-A 4858-B Companion Flange & Pinion Bearing
TOOL-4201-C 4201-C Differential Backlash & Runout Replacer
Gauge With Univ. Bracket, Dial
Indicator and Bracket T00L-4858-G 4858-G Pinion Flange Nut Adjusting Wrench
TOOL-4205-B 4205-B Differential Assembly Bench Holder (Use With T64N-4858-A)
TOOL-4205-C 4205-C Axle Housing Dummy Bearings (1 pr.) TOOL-4859 4859 Companion Flange Dust Shield Replacer
T00L-4221-C 4221-C Differential Side Bearing Remover T00L-6565-AB - Dial Indicator Adapter
T00L-4222-H 4222-H Differential Bearing Cone Replacer TOOL-6565 - Dial Indicator
T00L-4235-C 4235-C Axle Shaft & Bearing Remover T00L-7657-J 7657-J Extension Housing Bushing &
T00L-4245-B 4245-B Wheel Bearing Seal Replacer Seal Replacer
LINCOLN CONTINENTAL
T00L-4245-B 4245-B Wheel Bearing Seal Replacer T50T-100-A T50T-100-C Slide Hammer
TOOL-4616 4616 Drive Pinion bearing Cup T50T-100-A&
Replacer (Front) TOOL-1175-AB 1175-AE Seal Remover
T00L-4621-A 4621-A Drive Pinion Bearing and Rear TOOL-1225-DA 1225-DA Rear Wheel Bearing Remover
Wheel Bearing Replacer TOOL-4000-C 4000-C Differential Housing Spreader
T00L-4621-BA 4621-BA Rear Pinion Bearing Remover TOOL-4005 4005 Engine Repair Stand Axle Adapter-
TOOL-4628 4628 Pinion Rear Bearing Cup Replacer Keyed Shaft
T00L-4628-B 4628-B Pinion Bearing Front Cup Remover TOOL-4020-B 4020-B Pinion Depth Gauge-Complete With
T64N-4628-B Depth Micrometer and Gauge
T00L-4628-D 4628-D Pinion Rear Bearing Cup Remover Block
T64N-4676-A 4676 Pinion Shaft Oil Seal Replacer TOOL-4201 4201 Pinion Shaft Drive Nut
T00L-4851-K T57L-4851-A Universal Joint Flange Holder TOOL-4201-C 4201-C Differential Backlash & Runout
T64N-4858-A 4858-B Companion Flange & Pinion Bearing Gauge With Univ. Bracket, Dial
Replacer Indicator and Bracket
TOOL-4204-A Limited Slip Differential Check
T00L-4858-G 4858-G Pinion Flange Nut Adjusting Wrench TOOL-4205-B 4205-B Differential Assembly Bench Holder
(Use With T64N-4858-A) TOOL-4205-C 4205-C Axle Housing Dummy Bearings
TOOL-4859 4859 Companion Flange Dust Shield
(1 pi")
Replacer T00L-4209-C 4209-C Pinion Tension Scale With
T00L-6565-AB Dial Indicator Adapter 4209-C12 Socket
TOOL 6565 Dial Indicator T00L-4221-C 4221-C Differential Side Bearing Remover
T00L-7657-J 7657-J Extension Housing Bushing & T00L-4222-H 4222-H Differential Bearing Cone Replacer
Seal Replacer T00L-4235-C 4235-C Axle Shaft & Bearing Remover
05-01-01 05-01-01
GROUP
Clutch 5
Drive Shaft 05-01-01 Clutch 05-03-01
PART 5-2 PART 5-4
General Clutch Service 05-02-01 Specifications 05-04-01
PART 5-1 Drive Shaft

MODEL APPLICATION
Continental-
Thunderbird
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
DESCRIPTION 01-01
DRIVE SHAFT ANGLE CHECK 01-01
DRIVE SHAFT BALANCE CHECK 01-01
DRIVE SHAFT BALANCING
(Single Universal Joint) 01-04 01-04 01-04 01-04 01-04 01-04 01-04 01-04 N / A N/A N/A
DRIVE SHAFT DISASSEMBLY AND
OVERHAUL
Single Universal Joint — Ford Design 01-04 01-04 01-04 01-04 01-04 01-04 01-04 01-04 N / A N / A N / A
Double Cardan Joint — Dana Design N / A N / A N / A N / A N / A N / A N / A N / A 01-04 N / A N / A
Double Cardan Joint — Saginaw Design N / A N / A N / A N / A N / A N / A N / A N / A N / A 01-05 01-05
DRIVE SHAFT REMOVAL AND
INSTALLATION 01-02
DRIVE SHAFT RUNOUT CHECK 01-01
DRIVE SHAFT TESTS
DRIVE LINE BALANCE CHECK DRIVE LINE ANGLE CHECK only) are loose, torque the nuts to
specification.
If detailed parts of the drive shaft Vibration or "shudder" which is no-
are replaced and shaft vibration is en- ticeable either on fast acceleration or DRIVE SHAFT RUNOUT CHECK
countered after installation, disconnect when coasting, using the engine for a
the shaft at the slip yoke. Rotate the brake, may be caused by the rear axle Using a dial indicator, check the
slip yoke 180 degrees; then, reconnect housing being loose on the rear runout at each end and in the middle
the shaft to the slip yoke. If the vibra- springs or by improper pinion angle. of the driveshaft. The rear check
tion persists, disconnect the shaft at Refer to Group 3, Part 2 for pinion should be made on the small tube sec-
the rear axle companion flange. Ro- angle checking procedures. If the rear tion of the shaft between the balance
tate the companion flange 180 degrees axle U - b o l t s (Fairlane, Montego, weights and the yoke welds. Drive-
and reconnect the shaft to the flange. Mustang, Cougar, Falcon models shaft runout should not exceed 0.035
inch at any one point.
DESCRIPTION
The drive shaft is the means of ferential in the rear axle, and then to yoke (Fig. 1) or two double cardan
transferring power from the engine, the rear wheels. The drive shaft incor- universal joints, one at each end of the
through the transmission, to the dif- porates two universal joints and a slip shaft (Figs. 2 and 3). Each double
05-01-02 Drive Shaft 05-01-02
cardan has a center yoke (or cage), a

centering socket yoke, and a stud
yoke which is welded to each end of
the tube assembly. The splines in the
yoke and on the transmission output
shaft permit the drive shaft to move
forward and rearward as the axle
NUT-33796-S moves up and down.
r SNAP RING-
DUST SEAL 1 All drive shafts are balanced. If the
4859 • .BEARING'
vehicle is to be undercoated, cover the
drive shaft and universal joints to pre-
vent application of the undercoating
material.
SLIP YOKE - 4841
C 2059-A
FIG. 1—Drive Shaft and Universal Joints Disassembled
CENTERING
SOCKET YOKE-
4782
UNIVERSAL
SPIDE
JOINT KIT-4635
li
. P A I .70n CENTERING
SEAL-4790 S0CKETYOKE-4782
DRIVE SHAFT- CENTER YOKE-

4602 4778 C1594-B
FIG. 2—Drive Shaft and Universal Joints Disassembled—Lincoln Continental

05-01-03 Drive Shaft 05-01-03
DUST SEAL-4859
BALL SOCKET-4A031
UNIVERSAL
JOINT KIT-4635 WASHER
BALL SEAT i \ SPRING
BEARING \ \ RETAINER
SEAL
0 \ X \ CENTER
\ \ RETAINER \ YOKE-47R4
SPRING \
BALL SOCKET-4A031
SLIP YOKE-4841
C1770-A
FIG. 3—Drive Shaft and Universal Joints Disassembled —Thunderbird, Continental Mark
REMOVAL damaged in any manner, replace the the extension housing. Install the yoke
seal or seals as required. Also, if the on the transmission output shaft. Do
1. To maintain drive line balance, lugs on the axle pinion flange are not allow the yoke assembly to bot-
mark the relationship of the rear drive shaved or distorted so that the bear- tom on the output shaft with excessive
shaft yoke and the drive pinion flange ings slide, replace the flange. force.
of the axle (if the yellow alignment 2. On Lincoln Continental models, Install the drive shaft so that the
marks are not visible) with the shaft install the bearing assemblies over the index marks or the yellow mark (if
so that they may be installed in their spline teeth in the slip yoke. Lubricate visible) on the yoke (light side) is in
original positions. the yoke spline with B8A-19589-A lu- line with the yellow mark on the com-
2. Disconnect the rear U-joint or bricant. This spline is sealed so that panion flange. This prevents vibration
rear double cardan joint from the t h e t r a n s m i s s i o n fluid d o e s not which occurs when the balance of the
companion flange. Wrap tape around "wash" away the spline lubricant shaft and balance of the axle pinion
the loose bearing caps to prevent (Figs. 4 and 5). Remove the tool from flange become additive instead of neu-
them from falling off the spider. Pull
the drive shaft toward the rear of the 01L SEAL (AUTOMATIC TRANSMISSION ONLY)
vehicle until the slip yoke clears the
transmission extension housing and
the seal. On Lincoln Continental
models, remove the three roller bear-
ing assemblies off the spline teeth in-
side the slip yoke (Fig. 3). Install the
appropriate tool in the extension
housing to prevent lubricant leakage.
INSTALLATION
YOKE
1. If either the rubber seal on the SNAP RING (WRAP TYPE) E U73-C
output shaft or the seal in the end of . 4—Output Shaft Spline Seal — All except Continental
the transmission extension housing is Mark III and Thunderbird
05-01-04 Drive Shaft 05-01-04
tralizing. If a vibration exists, the

drive shaft should be disconnected
from the axle, rotated 180 degrees and
reinstalled.
3. Install the U-blots and nuts that
attach the U-joint to the drive pinion
flange. Torque the U-bolt nuts to
specification. On vehicles equipped
with a double cardan joint, install the
rear joint-to-drive pinion flange at-
taching bolts. Torque the bolts to spe-
cification. YOKE
C1773-A
FIG. 5—Output Shaft Spline Seal —

Continental Mark III and Thunderbird
IN-VEHICLE REPAIR
CHALK MARK
USE SUPPORT STAND

>
AS A STEADY REST CLAMPS 18d*FR0M CHALK MARK *«
E 1685-A E 1686-A E 1687- A
FIG. 6—Marking Driveshaft FIG. 7—Installing Whittek Clamps . 8—Rotating Whittek Clamps
DRIVESHAFT BALANCING carefully bring a crayon or colored 4. Run the vehicle up to 65-70 mph
(SINGLE UNIVERSAL JOINT) pencil up until it just barely contacts speedometer speed. If no vibration is
the rearward end of driveshaft (Fig. felt, lower the vehicle and road test. If
If rotating the driveshaft 180 de- 6). The mark made by the crayon or unbalance still exists rotate the clamp
grees does not eliminate vibration, the pencil will indicate the heavy side of heads approximately 45 degrees away
driveshaft may be balanced using the the shaft. Care should be exercised from each other and test for vibration
following procedure: w h e n w o r k i n g near the b a l a n c e (Fig. 8).
1. Place the vehicle on a twin post weights to prevent injury to the hands. 5. Continue to rotate the clamp
hoist so that the rear of the vehicle is 3. Install two Whittek type hose heads apart in smaller amounts until
supported on the rear axle housing clamps on the driveshaft so that the vibration is eliminated. To prevent
with the wheels free to rotate. heads are located 180 degrees from overheating, do not run the vehicle
2. With the driveshaft rotating at a the crayon marking (Fig. 7). Tighten on the hoist for an extended period.
speedometer speed of 40-50 mph, the clamps. 6. Road test the vehicle.
05-01-05 Drive Shaft 05-01-05

DISASSEMBLY (SINGLE 7. Clean all foreign matter from the
UNIVERSAL JOINT — permit easier entry.
yoke area at each end of the drive 7. Reposition the drive shaft and
FORD DESIGN) shaft. install the new spider and two new
1. Place the drive shaft in a vise ASSEMBLY (SINGLE bearings in the same manner as the
being careful not to damage it. UNIVERSAL J O I N T - rear yoke.
2. Remove the snap rings that re- FORD DESIGN) 8. Position the slip yoke on the spi-
tain the bearings in the slip yoke and der and install two new bearings,
in the drive shaft. 1. Start a new bearing into the nylon thrust bearings and snap rings.
3. Position the tool shown in Fig. 9 yoke at the rear of the drive shaft. 9. Check the joint for freedom of
on the shaft and press the bearing out 2. Position the spider in the rear movement. If a bind has resulted from
of the slip yoke. If the bearing cannot yoke and press the bearing 1/4 inch misalignment during the foregoing
be pressed all the way out of the yoke, below the surface (Fig. 10).
remove it with vise grip or channel 3. Remove the tool and install a
lock pliers. new snap ring. SPIDER
4. Reposition the tool to press on 4. Start a new bearing into the op-
the spider to remove the bearing from posite side of the yoke.
the opposite side of the yoke. 5. Install the tool and press on the
5. Remove the yoke from the spi- bearing until the opposite bearing con-
der. tacts the snap ring.
6. Remove the bearings and spider 6. Remove the tool and install a
from the drive shaft in the same man- new snap ring. It may be necessary to
ner. grind the surface of the snap ring to
CENTER YOKE Adapter C206J-A
FIG. 12—Removing Bearing from

Center Yoke
BEARING CUP
C 1781-A C 2062-A
FIG. 9—Removing Universal Joint FIG. 11— Partially Pressing Bearing

Bearing from Center Yoke SPIDER
C 2064-A
FIG. 13—Removing Bearing Cup

from Centering Yoke Socket
Tool-CJ91B
C 1782-A C 2065-A
FIG. 10—Installing Universal Joint FIG. 14 — Removing Center

Bearing Socket Yoke
05-01-06 Drive Shaft 05-01-06
procedures, a sharp rap on the yokes 6. Lift the two bearings (Fig. 13) 15. Remove the center yoke from
with a brass hammer will seat the from the spider at this time. the spider.
bearings needles and usually provide 7. Reposition the tool on the yoke 16. Remove the spider from the
freedom of movement. Care must be and move the remaining bearing in the drive shaft yoke in the same manner.
taken to support the shaft end during opposite direction so that it protrudes 17. Clean all serviceable parts in
this operation, as well as preventing approximately 3/8 inch out of the cleaning solvent. If using a repair kit,
blows to the bearings themselves. Do yoke. install all of the parts supplied in the
not install the drive shaft unless the 8. Grip the bearing in a vise. Drive kit. If the drive shaft is damaged, re-
universal joints are free of bind. on the center yoke to free it from the place the complete shaft to be assured
bearing (Fig. 12). of a balanced assembly.
9. Remove the spider from the cen-
DISASSEMBLY (DOUBLE ter yoke. ASSEMBLY (DOUBLE
CARDAN JOINT — LINCOLN 10. Pull the centering socket yoke CARDON JOINT —
CONTINENTAL — DANA DESIGN) off the center stud (Fig. 14). Remove LINCOLN CONTINENTAL —
the rubber seal from the centering ball DANA DESIGN)
1. Mark the position of the spiders, stud.
the center yoke, and the centering 11. Remove the snap rings from the 1. To assemble the double cardan
socket yoke as related to the stud center yoke and from the drive shaft joints, position the spider in the drive
yoke which is welded to the front of yoke. shaft yoke. Make sure the spider boss-
the drive shaft tube. The spiders must 12. Position the tool on the drive es (or lubrication plugs on kits) will be
be assembled with the bosses in their shaft yoke (Fig. 15) and press the in the same position as originally in-
original position to provide proper bearing outward until the inside of the stalled. Press in the bearing cups. In-
clearance. center yoke almost contacts the sling- stall the snap rings.
2. Remove the snap rings that se- er ring at the front of the drive shaft 2. Position the center yoke over the
cure the bearings in the front of the yoke. Pressing beyond this point can spider ends and press in the bearing
center yoke. distort the slinger ring. The arrow in cups. Install the snap rings.
3. Position the tool as shown in Fig. 16 illustrates the interference 3. Install a new seal on the cen-
Fig. 11. Thread the tool clockwise point. tering ball stud. Position the centering
until the bearing protrudes approxi- 13. Clamp the exposed end of the socket yoke on the stud.
mately 3/8 inch out of the yoke. bearing in a vise and drive on the cen- 4. Place the front spider in the cen-
4. Remove the drive shaft from the ter yoke with a soft-faced hammer to ter yoke. Make sure the spider bosses
vise. free it from the bearing. (or lubrication plugs on kits) are prop-
5. Tighten the bearing in the vise 14. Reposition the tool and press erly positioned. Press in the bearing
and drive on the center yoke as shown on the spider to remove the opposite cups and install the snap rings.
in Fig. 12 to free it from the bearing. bearing. 5. Apply pressure on the centering
socket yoke and install the remaining
bearing cup.
CENTER
YOKE 6. On kits, remove the plug from
each spider and lubricate the universal
joints. Reinstall the plug in each spi-
der.
DISASSEMBLY (DOUBLE
CARDAN JOINT — CONTINENTAL
MARK III, THUNDERBORD —
Tool-CJ91B SAGINAW DESIGN)
C 2066-A C1772-A
1. Working at the rear axle end of
FIG. 15—Removing Bearing from FIG. 17—Partially Pressing Bearing the shaft, mark the position of the spi-
Rear of Center Yoke From Center Yoke ders, the center yoke, and the cen-
tering socket yoke as related to the
companion flange. The spiders must
SLINGER RING be assembled with the bosses in their
original position to provide proper
CENTER YOKE clearance.
2. Position tool CJ91B as shown in
Fig. 17. Thread the tool clockwise
until the injected nylon moulding
snaps and the bearing protrudes ap-
proximately 3/8 inch out of the yoke.
3. Remove the driveshaft from the
vise.
4. Tighten the bearing in the vise
C 2067-A C1771-A and tap on the weld yoke to free the
FIG. 16—Center Yoke Interference FIG. 18—Removing Bearing From bearing from the center yoke (Fig.
Point Center Yoke 18). Do not tap on the driveshaft tube.
05-01-07 Drive Shaft 05-01-07
5. Reposition tool CJ91B on the piece ball seat, washer and spring 3. Position the spider in the drive-
yoke and force the opposite bearing from the ball socket. shaft yoke. Make sure the spider
outward and remove it. 12. Inspect the centering ball socket bosses are in the same position as
6. Position the tool on one of the assembly for worn or damaged parts. originally installed. Press in the bear-
remaining bearings and force it out- If any damage is evident replace the ing cups with tool CJ91B. Install the
ward approximately 3/8 inch. entire assembly. internal snap rings provided in the re-
7. Grip the bearing in the vise and 13. Repeat Steps 1 through 12 to pair kit.
tap on the weld yoke to free the bear- disassemble the transmission end of 4. Position the center yoke over the
ing from the center yoke. Do not tap the driveshaft. spider ends and press in the bearing
on the driveshaft tube. cups. Install the snap rings.
8. Reposition the tool on the yoke 5. Install the spider in the compan-
ASSEMBLY (DOUBLE
to press out the remaining bearing. ion flange yoke. Make sure the spider
CARDAN JOINT — CONTINENTAL
9. Remove the spider from the cen- bosses are. in the same position as
MARK III, THUNDERBIRD — originally installed. Press on the bear-
ter yoke.
SAGINAW DESIGN) ing cups and install the snap rings.
10. Remove the bearings from the
driveshaft yoke as outlined above and 1. Working at the rear axle end of 6. Position the center yoke over the
remove the spider from the yoke. the driveshaft, insert the spring, wash- spider ends and press on the bearing
11. Insert a screwdriver into the er, three piece ball seat and retainer cups. Install the snap rings.
centering ball socket located in the into the ball socket. 7. Repeat steps 1 through 6 to as-
companion flange and pry out the 2. Using a suitable tool, install the semble the transmission end of the
rubber seal. Remove the retainer, three centering ball socket seal. driveshaft.
05-02-01 General Clutch Service 05-02-01
PART 5-2 General Clutch Service

MODEL APPLICATION
COMPONENT INDEX o> !-

il i
CLUTCH DISC
3
a>
1
•U II
Cleaning and Inspection 02-04 02-04 02-04 02-04 02-04 02-04 02-04 02-04 N / A N/A N / A
CHECKING FLYWHEEL HOUSING
ALIGNMENT 02-01 02-01 02-01 02-01 02-01 02-01 02-01 02-01 N / A N / A N / A
CORRECTING FLYWHEEL HOUSING
ALIGNMENT 02-03 02-03 02-03 02-03 02-03 02-03 02-03 02-03 N / A N / A N / A
PILOT BUSHING
Cleaning and Inspection 02-04 02-04 02-04 02-04 02-04 02-04 02-04 02-04 N / A N / A N / A
PRESSURE PLATE AND COVER
Cleaning and Inspection 02-04 02-04 02-04 02-04 02-04 02-04 02-04 02-04 N / A N/A N / A
RELEASE BEARING
Cleaning and Inspection 02-04 02-04 02-04 02-04 02-04 02-04 02-04 02-04 N / A N / A N / A
l FLYWHEEL HOUSING ALIGNMENT

Alignment of the flywheel housing 8. Position the dial indicator to 13. Position the Dia-L-lgner on the
bore and rear face with the engine check bore alignment (Fig. 1). The face of the housing (Fig. 3) with the
should be checked as a possible cause bore must be clean and free of burrs, pilot in the bore.
of any of the following troubles- ex- nicks and paint. 14. Rotate the face runout arrow to
cessive transmission gear wear, ..ans- 9. Pull the crankshaft through one the positive face runout mark on the
mission jumping out of gear, especial- revolution. Note the indicator reading housing.
ly third gear, drive line vibration, ex- and mark the maximum point of run- 15. Without moving the face runout
cessive pilot bushing wear, noisy re- out on the face of the housing as arrow, rotate arrow A until it is at the
lease bearing, or excessive clutch spin shown in Fig. 1. negative bore reading.
time. 10. Remove the dial indicator from 16. Slide arrow A to register the
the crankshaft and the housing. amount of bore runout on the . 0 1 0 -
INSPECTION 11. Select the Dia-L-lgner pilot line of the white scale. Use the
(Fig. 2) which will fit snugly in the scale No. to coincide with the pilot
1. With the clutch release bearing bore of the flywheel housing. being used.
removed, install the indicator pilot 12. Press the pilot into place on the 17. Rotate arrow B until it points
tool shown in Fig. 1. locator on the back of the dial.
2. Clean the faces of the flywheel
housing bolt bosses, and remove all
burrs, nicks, and paint from the
mounting face of the housing.
3. Install the dial indicator on the
pilot and adjust the holder so the but-
ton will contact a circumference just
inside of the transmission mounting
holes.
4. Push the flywheel forward to re-
move crankshaft end play. Set the dial
indicator face to read zero.
5. Remove the spark plugs to alle-
viate compression.
6. Pull the engine crankshaft
through one revolution. The crank-
shaft must be held in the forward po-
sition while rotating it. CHECKING FACE RUN OUT CHECKING BORE RUN OUT
7. Note the indicator reading and C 1783- A
mark the maximum point of runout
on the face of the housing (Fig. 1). FIG. 1—Flywheel Housing Alignment Check
in the direction of the face runout

arrow and its center line is parallel to
the center line of the face runout
arrow.
18. Determine the amount of the
face runout on the B arrow scale.
19. The value of the circular line
beneath the amount of face runout
will be the desired reading. If the
reading is in excess of 0.014 inch the
housing alignment is unacceptable.
20. Remove the Dia-L-lgner gauge
from the flywheel housing.
21. Install the spark plugs and con-
nect the wires.
ENGINE IN VEHICLE
Since any change in face alignment
will change bore alignment, it may be
possible to correct bore alignment by
changing face alignment. Face align-
ment can be changed by shimming be-
tween the flywheel housing and en-
gine. Fig. 4 shows the type of shim
which can be fabricated.
Not more than 0.010 inch thickness
shims may be used between the fly-
wheel housing and engine. If a 0.010-
inch shim will not bring face and bore C2068-A
alignment within limits, replace the
flywheel housing. . 3—Dia-L-lgner Gauge Installed
The shim required is one half the
maximum (—) indicator reading, and
should be located at the point of max- required to bring face alignment with-
imum minus (—) indicator reading. in limits.
If both the bore and face alignment 3. Position the indicator to check
are out of limits, shim between the the bore alignment. If the bore align-
flywheel housing and engine to bring ment is not within limits, reduce the
face alignment within limits. Check tension on the flywheel housing at-
the bore alignment. taching bolts so that the housing can
If the bore alignment is out of lim- be moved by striking it with a lead
its and the face alignment is within hammer or a block of wood and a
limits, shim the flywheel housing to steel hammer.
the limit of face misalignment and 4. The lateral alignment should be
check the bore alignment. If it is not brought within limits so that an indi- C 178 4-A
within limits, replace the housing. cator reading is within limits between
the 9 o'clock and the 3 o'clock posi- FIG. 4— Fabricated Flywheel
tions on the bore circle. When the lat- Housing Shim
ENGINE OUT OF VEHICLE
eral alignment is within limits the
The same procedure to correct housing usually can be moved straight
alignment may be used with the en- up or down without disturbing the lat- hand ream the dowel pin holes 1/32
gine out of the vehicle or in the vehi- eral alignment. When alignment is inch larger. Use a straight reamer and
cle, up to the point of replacing the within limits, torque the housing bolts ream from the flywheel housing side.
flywheel housing. If the bore align- and recheck bore alignment. Oversize dowel pins can be made from
ment cannot be brought within limits 5. If the flywheel housing cannot be drill rod stock.
by shimming, follow this procedure: moved enough to bring the alignment 7. Remove the flywheel housing
dure: within limits, mark the holes restrict- and then install the oversize dowel
1. Remove the flywheel housing ing movement, and then remove the pins in the cylinder block. Complete
from the engine and remove the dowel housing and drill the marked bolt the assembly in the usual way.
pins. Install the flywheel housing and holes 1/32 inch larger. 8. Recheck the flywheel housing
tighten the attaching bolts. 6. When the flywheel housing bore with the Dia-L-lgner gauge to make
2. Install the dial indicator (Fig. 1). alignment is within limits and the at- sure that the housing is within the spe-
Check the face alignment, and shim as taching bolts are at normal torque, cified limits.
RELEASE BEARING lever is bent out of plane, or is not Inspect the clutch disc for worn or
centering on the bracket on the fly- loose facings. Check the disc for worn
Wipe all oil and dirt off the release wheel housing. or loose facings. Check the disc for
bearing. The bearing is prelubricated Misalignment between the engine distortion and for loose rivets at the
and should not be cleaned with sol- and transmission can cause release h u b . Check for b r o k e n s p r i n g s .
vent. bearing failure. Other symptoms of Springs loose enough to rattle will not
Inspect the bearing retainer for misalignment are transmission jump- cause noise when the car is operating.
loose spring clips and rivets. ing out of gear, especially third gear, Replace the disc assembly if any of
Inspect the release bearing assembly drive line vibration; excessive wear in these defects are present. Be especially
for burrs which may cause the assem- the pilot bushing, excessive clutch disc careful when installing a new disc to
bly to drag on the transmission bear- spin time resulting in gear clash, and avoid dropping it or contaminating it
ing retainer. Any such burrs should be excessive transmission gear wear. with oil or grease.
cleaned up with fine crocus cloth. If
PRESSURE PLATE A N D COVER
burrs are found, inspect the transmis-
PILOT BUSHING
sion input shaft bearing retainer for
evidence of scoring. Any scoring Inspect the surface of the pressure
plate for burn marks, scores, or rid- Check the fit of the clutch pilot
should be polished out with crocus bushing in the bore of the crankshaft.
ges. Generally, pressure plate resur-
cloth. Coat the bearing retainer with a The bushing is pressed into the
facing is not recommended. However
thin film of l i t h i u m - b a s e grease crankshaft and should not be loose.
minor burn marks, scores, or ridges
(C3VY-19586-A). Prior to release Inspect the inner surface of the bush-
may be removed. During the resurfac-
bearing installation, apply a light film ing for wear or a bell-mouthed condi-
ing process, the flatness of the pres-
of l i t h i u m b a s e g r e a s e ( C 3 V Y - tion. If the bushing is worn or dam-
sure plate must be maintained. If the
19586-A) on both sides of the release aged, replace the bushing with a new
pressure plate is badly heat-checked or
lever fork where it contacts the release deeply scored, replace the pressure service bearing. Refer to the applica-
bearing hub and retaining springs. plate and cover assembly. Clean pres- ble engine for the replacement proce-
Apply a light film of lithium base sure plate and flywheel surfaces with a dure.
grease (C3VY-19586-A) plate to the suitable solvent, such as alcohol to be
release bearing surface that contacts sure the surfaces are free from any oil
the pressure plate fingers. Carefully film. Do not use cleaners with petrole-
fill the grease groove inside the bear- um base, and do not immerse the
ing hub with lithium base grease (no pressure plate in the solvent.
polyethylene). Clean all excess grease
from the bore of the bearing hub. Ex- Place the plate on the floor, being
careful not to score or scratch the sur-
cess grease will be forced onto the
face. Force each individual finger
spline by the transmission input shaft
down, then release quickly. If the fin-
bearing retainer and will contaminate
ger does not return quickly, a binding
the clutch disc. Also, care must be
condition is indicated, and the pres-
exercised when applying lubricants to
sure plate should be replaced.
the release bearing, release bearing
The pressure plate should be lubri-
hub and the release lever fork to avoid
cated with a lithium-base grease be- C 1785-A
excessive grease from contaminating
tween the driving lugs and the edges FIG. 5—Installing Clutch Release
the clutch disc.
of the pressure plate openings, as Bearing on Hub
Hold the bearing inner race and ro-
shown in Fig. 6. Depress the pressure
tate the outer race while applying PRESSURE PLATE
plate fingers fully, apply the lubricant,
pressure to it. If the bearing rotation AND COVER
and then move the fingers up and
is rough or noisy, replace the bearing. down until the lubricant is worked in.
Most release bearing failures are Do not apply excessive lubricant.
caused by improper clutch pedal ad-
justments. If the clutch linkage does
CLUTCH DISC
not have enough free travel, the re-
lease bearing will constantly touch the Inspect the clutch disc facings for
release fingers and will spin whenever oil or grease. Eliminate the source of
the engine is running. any oil or grease before replacing the
When installing a release bearing on disc. An excessive amount of grease in
vehicles equipped with separate hub the pilot bushing or release bearing
and bearing, use the tool shown in hub will find its way to the disc fac-
Fig. 5. ings. Too much lubricant in the trans-
Release bearing failure can be mission or a plugged transmission
caused by the release lever contact vent will force the transmission lubri-
points being out of plane. Check the cant out the input shaft and onto the
wear on the release bearing assembly disc facings. Also, rear main bearing DRIVING FLYWHEEL
LUG C2048-A
where the release lever contacts it. oil seal leaks or oil leaks from the fly-
If one side of the assembly shows wheel mounting bolts can contaminate FIG. 6—Pressure Plate Lubrication
more wear than the other, the release the clutch disc. Points
05-03-01 Clutch 05-03-01
PART 5-3 Clutch

MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
CLUTCH EQUALIZER BAR AND/OR
BUSHING
Removal and Installation 03-05 03-05 03-05 03-05 03-05 03-05 03-05 03-05 N / A N / A N/A
CLUTCH PEDAL ASSIST SPRING
Removal and Installation N / A N / A N / A N / A 03-03 03-03 03-03 N / A N/A N/A N/A
CLUTCH PEDAL AND/OR BUSHING
Removal and Installation N / A N / A N / A N / A 03-04 03-04 03-04 N / A N / A N / A N/A
CLUTCH PEDAL, PEDAL ASSIST SPRING
AND/OR BUSHING
Removal and Installation 03-03 03-03 03-03 03-04 N / A N/A N / A 03-04 N / A N/A N/A
CLUTCH PEDAL FREE PLAY ADJUSTMENT 03-03 03-03 03-03 03-03 03-03 03-03 03-03 03-03 N / A N/A N/A
CLUTCH REMOVAL AND INSTALLATION 03-05 03-05 03-05 03-05 03-05 03-05 03-05 03-05 N / A N/A N/A
DESCRIPTION 03-01 03-01 03-01 03-01 03-01 03-01 03-01 03-01 N / A N/A N/A
DESCRIPTION
DESCRIPTION
The clutch is of the centrifugal sin- clutch disc, pressure plate and the
gle dry disc type and consists of the clutch release bearing.
CLUTCH PEDAL
7519
351538-S
VIEW A
BUSHING-2 REQ'D.
7517 C2055-A
FIG. 1—Clutch Pedal and Linkage Adjustments — Ford, Mercury, Meteor

05-03-02 Clutch 05-03-02
SPRING-7A600
EQJALIZER ROD-7A516 EQUALIZER BAR-7528

FELTWASHER-375475 SPRING-7523
EQUALIZER EQUALIZER ROD-7A516
RELEASE ROD/ LOCKNUT-34809-S7

7B543
SNAP RING-7A629
OUTER BRACKET-7507
PIVOT-7A531
RELEASE ROD-7B543
RELEASE ROD-7B543
BUSHING-7526
OUTER EQUALIZER BAR-7528
SPRING-7A632
BUSHING-7543 SPRING-7523 SNAP RING-7A629
SPRING-7545 FELT WASHER-358979-S FELT WASHER-375475-S
FAIRLANE AND MONTEGO FAIRLANE AND MONTEGO

390 AND 428 ENGINES 302 AND 351
FIG. 2—Clutch Pedal and Linkage Adjustment — Fairlane, Montego and Falcon
ASSIST SPRING 7B572

ASSIST SPRING BRACKET 7535-
SPRING
7A632
RELEASE ROD 7B543 351 ENGINE
390 ENGINE SAME AS MAIN VIEW
SAME AS MAIN VIEW EXCEPT AS SHOWN
EXCEPT AS SHOWN C2056-A
FIG. 3—Clutch Pedal and Linkage Adjustment — Mustang, Cougar

05-03-03 Clutch 05-03-03
CLUTCH PEDAL adjust if necessary. 5. Position the assist spring in the

ADJUSTMENTS 9. As a final check, measure the clutch pedal spring bracket and the
pedal free travel with the transmission a s s i s t s p r i n g bracket. Rotate the
Adjust the clutch pedal free travel
in neutral and the engine running at spring bracket downward until the
whenever the clutch does not disen-
about 3000 rpm. If the pedal free forward bolt holes in the assist spring
gage properly, or when new clutch
travel at this speed is not a minimum bracket line up with the holes in the
parts are installed. Improper adjust-
of 1/2 inch, readjust the clutch pedal brake pedal bracket (Fig. 4).
ment of the clutch pedal is one of the
free travel. Otherwise, the release fin- 6. Install the forward bolt retaining
most frequent causes of clutch failure
gers may contact the release bearing the assist spring bracket to the brake
and can be a contributing factor in
continuously, resulting in premature pedal bracket and torque the forward
some transmission failures.
bearing and clutch failure. Free travel and rear bolts to specification.
FREE TRAVEL must be exactly to specification. 7. Install the clutch rod to the
clutch pedal lever and insert the cotter
1. Disconnect the clutch return CLUTCH ASSIST pin.
spring from the release lever. SPRING REPLACEMENT
2. Loosen the release lever rod (FAIRLANE, FALCON, CLUTCH PEDAL, PEDAL
locknut and adjusting nut (Figs. 1, 2 MONTEGO) ASSIST SPRING AND/OR
and 3). BUSHING REMOVAL
3. Move the clutch release lever 1. Remove the cotter pin from the AND INSTALLATION
rearward until the release bearing clutch rod at the clutch pedal lever as-
lightly contacts the clutch pressure sembly inside the passenger compart- FORD, MERCURY,
plate release fingers. ment. METEOR
4. Adjust the rod length until the 2. Grasp the clutch pedal lever 1. Remove the pin that secures the
rod seats in the release lever pocket. firmly to prevent slipping and remove clutch pedal-to-equalizer rod to the
5. Insert the specified feeler gauge the clutch rod from the lever. Allow clutch pedal.
between the adjusting nut and the the clutch pedal lever to rest on the 2. Grasp the clutch pecal lever
swivel sleeve. Then tighten the adjust- floor panel. firmly to prevent slipping and remove
ing nut against the gauge finger tight. 3. Remove the forward bolt secur- the clutch rod from the lever. Allow
6. Tighten the locknut against the ing the assist spring bracket to the the clutch pedal lever to rest on the
adjusting nut, being careful not to di- brake pedal bracket and loosen the floor.
sturb the adjustment. Torque the lock- rear bolt two or three turns. Do not 3. Loosen the lower bolt securing
nut to specification and remove the remove the rear bolt. the assist spring bracket to the pedal
feeler gauge. 4. Grasp the assist spring bracket support bracket two or three turns.
7. Install the clutch return spring. with pliers and rotate upward until the Then, remove the upper bolt from the
8. Check the free travel at the pedal spring can be separated from the bracket. Do not remove the lower
for conformance to specification. Re- bracket. bolt.
BRAKE PEDAL
4. Grasp the assist spring bracket
BRACKET with pliers and rotate it counterclock-
wise until the spring is free (Fig 5).
5. Remove the retaining ring from
the end of the clutch pedal shaft. Then
remove the shaft, bushings and clutch
pedal from the support.
6. Remove the bushings from the
pedal shaft and pedal support and
transfer the rubber pedal pad.
7. After lubricating the pedal shaft
CLUTCH ASSIST SPRING

BRACKET - 7535
CLUTCH PEDAL
7519
ASSIST SPRING
LOWER BOLT
ASSIST SPRING BRACKET-

UPPER BOL"
C2058-A
C 1769-B ;. 5—Removing Clutch Assist

FIG. 4—Clutch Pedal Assembly — Fairlane, Montego, Falcon Spring — Ford, Mercury and Meteor
05-03-04 Clutch 05-03-04
bushings, position the clutch pedal and rod, bushing and nylon washer from shown in Fig. 6.
bushings in the pedal support. the brake pedal pin. 18. Position the pedal support
8. Install the retaining ring on the 8. Remove the screw retaining the bracket assembly to the dash panel
clutch pedal shaft. pedal support bracket to the top inner and to the steering column retainer
9. Position the assist spring in the cowl bracket (Fig. 6). studs.
pedal support bracket and the assist 9. Remove the two sheet metal 19. Align the pedal support bracket
s p r i n g b r a c k e t . Rotate the assist screws retaining the pedal support holes with the holes in the dash panel
spring bracket clockwise until the bracket to the dash panel. and install the two sheet metal screws.
upper bolt holes line up and install the 10. Remove the two screws retain- 20. Install the two capscrews at-
bolt. Torque both the upper and lower ing the pedal support bracket to the taching the pedal support bracket to
bolts to specification. upper cowl brace and lower the pedal the upper cowl bracket.
10. Check the clutch pedal free support bracket away from the steer- 21. Install the screw attaching the
travel and adjust as required. ing column studs. support bracket to the top inner cowl
11. Remove the pedal support bracket (Fig. 6).
MUSTANG, COUGAR 22. Install the inner nylon washer,
bracket assembly from the vehicle.
1. Disconnect the battery ground 12. Mount the bracket in a vise. bushing master cylinder push rod on
cable. 13. Remove the small C-clamp se- the brake pedal pin. Position the stop
2. Remove the steering column. curing the clutch pedal to the bumper. light switch so that it straddles the
Refer to Group 3 of this manual for Slowly pivot the pedal away from the push rod with the switch slot on the
the procedure. bumper until the assist spring can be pedal pin and the switch outer hole
3. Remove the two capscrews re- lifted from its seat. just clearing the pin. Slide the switch
taining the master cylinder or booster 14. Remove the retainer clip from completely onto the pin, and install
to the dash panel. Then remove the the clutch and brake pedal shaft. the outer nylon washer. Secure with
two capscrews retaining the pedal sup- Then, remove the clutch pedal and the self-locking pin.
port bracket to the dash panel. shaft assembly, brake pedal assembly, 23. Connect the stop light switch
4. Working inside the vehicle, dis- and bushings from the pedal support wires to the connector and install the
connect the clutch pedal-to-equalizer bracket. wires to the retaining clip.
rod at the clutch pedal by removing 15. Apply a coating of SAE 10 en- 2 4 . C o n n e c t the clutch pedal-
the retainer and bushing. gine oil to the bushings and locate all to-equalizer rod to the clutch pedal
5. Secure the clutch pedal against bushings in their proper places on the assembly with the bushing and retain-
the bumper stop with a small C-clamp brake and clutch pedal assemblies. er and remove the C-clamp from the
as shown in Fig. 6. 16. Position the brake pedal to the bracket.
6. Disconnect the stop light switch pedal support bracket. Install the 25. Working from the engine side
wires at the connector. clutch and brake pedal shaft through of the dash panel, install the two cap-
7. Remove the switch retainer and the pedal support and brake pedal as- screws attaching the pedal support
slide the stop light switch off the sembly. Install the retainer. bracket to the dash panel. Then install
brake pedal pin just far enough for 17. Install the clutch pedal assist the two screws attaching the master
the switch outer hole to clear the pin. spring and pivot the pedal against its cylinder to the dash panel.
Then lower the switch away from the bumper stop. Secure the pedal against 26. Install the steering column.
pin. Remove the master cylinder push the bumper with a small C-clamp as Refer to Group 3 of this manual for
the procedure.
27. Adjust the clutch pedal free
TOP INNER COWL-TO-BRACKET travel.
CLUTCH PEDAL ASSIST SPRING RETAINING SCREW
28. Check the brake pedal free
height and travel m e a s u r e m e n t s
(Group 2).
29. Connect the battery ground
cable.
CLUTCH PEDAL AND/OR
BUSHING REMOVAL
AND INSTALLATION
M O M EGO, FALCON
FAIRLANF
1. Remove the retaining clip (Fig.

2) that secures the equalizer rod to the
clutch pedal. Disconnect the rod from
the pedal.
2. Remove the lower bolt retaining
the assist spring bracket to the pedal
s u p p o r t . T h e n , loosen the upper
bracket retaining bolt (approximately
4 turns) and disconnect the spring
from the clutch pedal and bracket.
C2057-A 3. Disconnect the brake pedal push
FIG. 6—Clutch Pedal —Mustang and Couga? rod from the brake pedal.
05-03-05 Clutch 05-03-05
4. Remove the bolt that secures the from the inner pivot stud to replace equalizer rod at the equalizer bar (Fig.
left air vent control cable bracket to the inner bushing. 2).
the instrument panel. Position the 6. Position the flat washer, felt 2. Raise the vehicle and disconnect
control cable to one side. washer and bushing on the inner and the return spring at the release lever.
5. Remove the retaining clip and outer pivots. Secure these parts with Disconnect the release lever rod from
flat washer from the clutch pedal the snap ring. the equalizer lever.
shaft. Then, remove the shaft, bush- 7. Position the equalizer bar on the
ing, clutch pedal and brake pedal inner pivot and bolt the equalizer bar 3. Remove the equalizer bar center
from the support. bolt.
frame bracket to the frame. Torque
6. Remove the bushings from the the attaching bolts to specification. 4. Separate the equalizer bar and
pedal shaft, and transfer the pedal 8. Install the clutch release rod, re- remove both sections from the vehicle.
pad. turn spring and retaining spring. 5. Remove the bolts retaining the
7. Lubricate the clutch pedal shaft 9. Connect the clutch pedal rod to equalizer bar inner bracket to the fly-
bushings and position them on the the equalizer bar. wheel housing and remove the bracket
shaft. Then, position the brake pedal 10. Adjust the clutch pedal free and bushing assembly.
and clutch pedal in the pedal support. travel. 6. Remove the equalizer bar outer
8. Install the flat washer and re- bracket and bushing assembly.
taining clip on the pedal shaft. MUSTANG, COUGAR,
MONTEGO, FALCON, 7. Remove the snap ring, bushing,
9. Position the assist spring to the and felt washer from each bracket as-
pedal and bracket. Pry the bracket FAIRLANE (EXCEPT
MONTEGO AND FAIRLANE sembly.
forward and install the lower bolt.
WITH 390 V-8) 8. Position a felt washer, and bush-
Torque the bolts to specifications.
ing on each bracket assembly and se-
10. Position the master cylinder 1. D i s c o n n e c t the clutch pedal cure with the snap ring.
push rod, bushing, and washers on the equalizer rod at the equalizer bar 9. Install the outer bracket and
brake pedal and secure with a retain- (Figs. 2 and 3). bushing assembly to the frame (Fig.
ing clip. 2. Raise the vehicle and disconnect 2). Torque the bracket attaching bolts
11. Connect the equalizer rod to the release lever, return spring at the to specifications.
the clutch pedal and secure it in place lever.
with a retaining clip. 3. Remove the equalizer bar outer 10. Position the outer section of the
12. Position the air vent control bracket and bushing assembly. equalizer bar on the outer bracket
cable bracket to the instrument panel pivot.
4. Remove the release rod from the
and secure with the attaching bolt. equalizer bar, and then remove the 11. Connect the two sections of the
13. Adjust the clutch pedal free equalizer bar. Remove the bushing equalizer bar. Insert the inner bracket
travel. pivot into the equalizer bar and install
and washers from the inner mounting
the assembly to the flywheel housing.
EQUALIZER BAR AND/OR stud.
Torque the attaching bolts to specifi-
BUSHING REMOVAL AND 5. Position the equalizer bar, wash-
cations.
INSTALLATION ers, inner bushing, and retainer on the
inner stud. 12. Install the equalizer bar center
FORD, MERCURY 6. After positioning the outer bush- bolt and torque to specifications.
AND METEOR ing, install the outer bracket (with the Make sure that both ends of the
1. Raise the vehicle and disconnect equalizer bar in place). equalizer bar are against the felt
the clutch pedal-to-equalizer rod at 7. Connect the release rod and the washers.
the equalizer bar (Fig. 1). release lever return spring. 13. Connect the release rod and the
2. Disconnect the return spring and 8. Lower the vehicle. Connect the release lever return spring.
retaining spring at the release lever. clutch pedal equalizer rod to the 14. Adjust the clutch pedal free
Separate the release lever rod from equalizer baY and secure with the re- travel.
the release lever. taining pin. 15. Lower the vehicle. Connect the
3. Remove the equalizer bar frame 9. Adjust the clutch pedal free trav- clutch pedal equalizer rod to the
bracket from the frame. el as required. equalizer bar and secure with the re-
4. Remove the equalizer bar from taining clip.
MONTEGO AND
the pivot on the flywheel housing. 16. Check the free travel at the
FAIRLANE—390 V-8 pedal for conformance to specifica-
5. Remove the wire clip to replace
the outer bushing and the snap ring 1. D i s c o n n e c t the clutch pedal tions. Readjust if necessary.

member from the vehicle.
CLUTCH REMOVAL 3 . D i s c o n n e c t the speedometer 5. Remove the bolts that attach the
cable from the extension housing. transmission to the flywheel housing.
1. Raise the vehicle on a hoist. 4. Disconnect the gear shift rods 6. Move the transmission rearward
2. Disconnect the drive shaft from from the transmission. If the vehicle is until the input shaft clears the fly-
the rear U-joint flange. Then, slide the equipped with a four-speed transmis- wheel housing, then remove it from
drive shaft off the transmission output sion, remove the bolts that secure the the vehicle.
shaft. Insert the appropriate tool over four-speed transmission, disconnect 7. Disconnect the clutch release
the output shaft and into the extension the front brake cable from the cross- lever retaining spring from the release
housing oil seal. member and remove the crossmem- lever.
05-03-06 Clutch 05-03-06
8. Remove the starter cable then 4. Apply a light film of grease install the crossmember. Install and
remove the starter motor from the fly- (C3VY-19586-A) to the outside diam- torque the crossmember attaching
wheel housing. eter of the transmission front bearing bolts to specifications, then lower the
9. Remove the bolts that secure the retainer. Apply a light film of grease engine.
engine rear plate to the front lower (C3VY-19586-A) to both sides of the 10. Install the extension housing-
part of the flywheel housing. release lever fork where it contacts the to-engine rear support attaching bolts.
10. Remove the flywheel housing release bearing bore spring clips. Torque the bolts to specification.
lower cover (390 CID housing only). Apply a light film of grease to the re- 11. Remove the transmission jack
11. Remove the bolts that attach lease bearing surface that contacts the and connect the parking brake cable.
the housing to the cylinder block. pressure plate release fingers. Fill the 12. If the vehicle is equipped with a
12. Move the housing back just far grease groove of the release bearing four-speed transmission, connect the
enough to clear the pressure plate, hub with lithium base grease (C3VY- gear shift linkage control bracket to
then move it to the right to free the 19586-A). Clean all excess grease the extension housing.
pivot from the clutch equalizer bar. Be from inside the bore of bearing hub. 13. Connect the gear shift rods to
careful not to disturb the linkage and Excess grease will be forced onto the the transmission. Adjust the shift link-
assist spring. spline by the transmission input shaft age as required.
13. Loosen the six pressure plate bearing retainer and will contaminate 14. Connect the release lever retain-
cover attaching bolts evenly to release the clutch disc. Also, place the release ing spring. Install the flywheel housing
the spring tension. If the same pres- bearing and hub on the release lever. cover (390 CID housing only).
sure plate and cover is to be installed 5. Make certain that the flywheel 15. Remove the tool from the
after the clutch is overhauled, mark housing and the cylinder block mount- transmission output shaft and install
the cover and flywheel so that the ing surfaces are clean. Position the the drive shaft.
pressure plate can be installed in the felt washer on the pivot in the fly- 16. Check the clutch pedal free
same position. wheel housing. Slip the pivot into the travel.
14. Remove the pressure plate and clutch equalizer shaft being careful
the clutch disc from the flywheel. not to disturb the linkage and at the
same time position the housing on the CLUTCH ARBOR CLUTCH DISC
CLUTCH INSTALLATION dowels in the cylinder block. Install

and torque the attaching bolts to spec-
1. Install the clutch release lever if ification.
it was removed. 6. Install the starting motor and
2. Place the clutch disc, and pres- connect the cable.
sure plate assembly in position on the 7. The mounting surfaces of the
flywheel. Start the cover attaching transmission and the flywheel housing
bolts to hold the pieces in place, but must be free of dirt, paint, and burrs.
do not tighten them. Avoid touching Install two guide pins in the flywheel
the clutch disc facing, dropping the housing lower mounting bolt holes.
parts or contaminating them with oil Move the transmission forward on the
or grease as clutch chatter may result. guide pins until it is tightly positioned
3. Align the clutch disc with the against the flywheel housing.
tool shown in Fig. 7, and alternately 8. Install the two upper mounting
tighten the bolts a few turns at a time bolts. Then, remove the guide pins
until they are all tight. Then torque and install the two lower mounting PRESSURE PLATE
C 1788-A
the six pressure plate cover attaching bolts. Torque all the bolts to specifica-
bolts to specification before removing tion. FIG. 7—Installing Clutch Disc —
the tool. 9. Raise the rear of the engine and Typical
CLUTCH IDENTIFICATION
Pressure Plate Disc
Car Line Engine Transmission Diameter No. of Color Identification Diameter No. of Color Identification
(Inches) Springs (Paint Daub) (Inches) Springs (Paint Daub)
Pressure Plate-No Color Clutch-Yellow

Ford
240-IV 3-Speed 9.5 6 Cover—Green 9.5 6 Springs—2 Purple (Small)
Meteor Springs—Aluminum 4 Aluminum (Large)
Pressure Plate-White Clutch-No Color

3-Speed
Ford 240-IV 11 9 Cover-Pink and Blue 11 8 Springs—4 Aluminum
Heavy Duty 4 Pink
Springs 8-Green
Pressure Plate-Green Clutch-Blue

Ford
302-2V 3-Speed 10 9 Cover-White 10 12 Springs-6 Orange (Small)
Meteor Springs-White on Bronze 6 Pink (Large)
Ford Pressure Plate—Orange Clutch-Pink

390-2V, 3-Speed 12
Meteor 11 9 Cover-Black 11 Springs-6 Green (Small)
4V 4-Speed Springs-Aluminum
Mercury 6 Orange (Large)
Pressure Plate-Yellow Clutch-Gray

Ford 429-4V 4-Speed 11.5 12 Cover-Black 11.5 10 Springs—5 Red Stripe (Small)
Springs-Green 5 No Color (Large)
Pressure Plate-Orange
Clutch-Pink
Falcon 170-1V 3-Speed 9 6 Cover—Purple 9 6
Springs—Blue
Springs-Aluminum Stripe
Fairlane Pressure Plate-Orange

200-IV 3-Speed Clutch-Pink
Falcon 9 6 Cover-Purple 9 6
250-1V Springs-Blue
Montego Springs-Aluminum Stripe
Fairlane Pressure Plate—Green Clutch-Blue

3-Speed
Montego 302-2V 10 9 Cover-White 10 12 Springs-6 Pink
4-Speed Springs-Bronze
Falcon 6 Orange
Pressure Plate—Orange
200-IV 3-Speed Clutch-Blue
Mustang 9 6 Cover—Purple 9 6
250-1V Springs—Blue
Springs—Aluminum Stripe
Pressure Plate-Blue
Mustang 3-Speed Clutch-Green
302-2V 10 9 Cover—Purple 10 6
Cougar 4-Speed Springs-Orange
Springs—Bronze
Pressure Plate-Green
Fairlane 390-2V, 3-Speed Clutch-Pink and Orange
Montego 4-Speed
11 9 Cover-Purple 11 8
4V Springs—Aluminum
Springs-Purple
Fairlane
Pressure Plate-Green
Montego 3-Speed Clutch-Pink and Orange
Mustang
390-4V GT 11.5 12 Cover-Purple 11.5 8
4-Speed Springs—Aluminum
Cougar Springs-Purple
Fairlane
Pressure Plate-Blue
Montego 351-2V, 3-Speed 11 9 Clutch—Pink and Orange
Cover-Yellow 11 8
Mustang 4V 4-Speed Springs—Aluminum
Springs-Silver
Cougar
Fairlane
Pressure Plate-Yellow
Montego 12 Clutch-Gray
428-4V 4-Speed 11.5 Cover-Black 11.5 10
Mustang Springs-Red Stripe
Springs—Green
Cougar
CLUTCH-DRIVELINE ADJUSTMENTS (INCHES) *

Release Lever Rod Adjusting Nut to Swivel Sleeve Clutch Pedal Free Travel (Engine Running) 7/8"-l 1/8"
Ford, Mercury Meteor 0.194
Clutch Housing Alignment If Dia-L-lgner reading 0.014
Fairlane, Montego, Falcon, Mustang, Cougar ex. with
is greater than that indicated, the clutch
390, 428 engine 0.136
housing alignment is unacceptable.
390, 428 Engines 0.178
Maximum Shim to Correct Alignment 0.010
TORQUE LIMITS (FT-LBS)

Meteor Mustang, Cougar
Description Ford, Mercury Fairlane, Montego, Falcon
Lower Access Clutch Cover Pan to Flywheel Housing Bolts (Cast Iron Housing) 17-20 -
Transmission Assembly to Flywheel Housing Bolts 37-42 -
Pressure Plate and Cover Assembly to Flywheel Attaching Bolts 12-20 12-20
Clutch Release Equalizer Frame Bracket Bolts 15-24 15-24
Clutch Pedal Free Travel Adjustment Nut 15-20 15-20
Flywheel Housing to Cylinder Block Bolts 6-Cylinder 23-33
8-Cylinder _ 40-50
Clutch Pedal Assist Spring Bracket to Brake Pedal Support Bracket 12-17 12-17
SPECIAL TOOLS
Tool No. Description Tool No. Description
A-37H Clutch Disc Aligner-Universal CJ91B Universal Joint Bearing Replacer
T61L-7657-Aor B Transmission Extension Housing Oil Seal T64L-6392-A Dia-L-lgner Gauge
T57L-7657-A Replacer
T64P-7657-A T49P-7580-A Clutch Release Bearing Replacer
06-01-01 06-01-01
GROUP
ual Shift
6
General Transmission Service 06-01-01 Ford Design Four-Speed
PART 6-2 Transmission .06-03-01
Ford Design Three-Speed PART 6-4
Transmission 06-02-01 Specifications .06-04-01
Part 6-1 General Transmission Service

MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
REAR SEAL
Removal and Installation 01-02 01-02 01-02 01-02 01-02 01-02 01-02 01-02 N / A N/A N/A
REAR BUSHING AND SEAL
Removal and Installation 01-02 01-02 01-02 01-02 01-02 01-02 01-02 01-02 N / A N/A N / A
TRANSMISSION
Cleaning 01-02 01-02 01-02 01-02 01-02 01-02 01-02 01-02 N / A N/A N/A
Inspection 01-02 01-02 01-02 01-02 01-02 01-02 01-02 01-02 N / A N/A N/A
Lubrication 01-02 01-02 01-02 01-02 01-02 01-02 01-02 01-02 N / A N/A N/A
CODE TRANSMISSION
1 THREE-SPEED
5 FOUR-SPEED (WIDE RATIO)
54E M IB I2H 33 6 FOUR-SPEED (CLOSE RATIO)
C2086-A
FIG. 1—Typical Warranty Plate—Transmission Identification

06-01-02 General Transmission Service 06-01-02
REAR SEAL REPLACEMENT
1. Remove the drive shaft.

2. Remove the seal from the exten- Too/-7J75-AB
sion housing with the tool shown in
Fig. 2.
3. Install the new seal in the exten-
sion housing with the tool shown in
Fig. 3.
4. Install the drive shaft.
Tool-TSOT-lOO-A
D 1927. A
FIG. 2—Removing Extension Housing Seal
.REAR OIL SEAL EXTENSION HOUSING

EXTENSION HOUSING
Tool-T61L-7657-A
Tool-T52L-7000-GAE Tool—T57P-7697-B
or 7000-G 57-G
BUSHING
EXTENSION HOUSING C 1832.A
C 1830.A C1O28-D
FIG. 3—Installing Extension FIG. 4—Removing Extension FIG. 5—Installing Extension

Housing Seal Housing Bushing and Seal Housing Bushing
REAR BUSHING AND SEAL 3. Turn the screw clockwise until

LUBRICATION
the seal and the bushing are free of
the housing.
4. Drive a new bushing into the ex- Lubricant level should be even with
1. Remove the drive shaft from the tension housing with the tool shown in the bottom of the filler hole at the
vehicle. Fig. 5. right side of the transmission case.
2. Insert the tool shown in Fig. 4 5. Install a new seal in the housing
into the extension housing until it as shown in Fig. 3.
grips on ihe front side of the bushing. 6. Install the drive shaft.
CLEANING INSPECTION or other damage. Check the bearings

for looseness in the bores. If any of
1. Wash all parts, except the ball 1. Inspect the transmission case for these conditions exist, replace the
bearings and seals in a suitable clean- cracks, worn or damaged bearings bearings.
ing solvent. Brush or scrape all foreign bores, damaged threads or any other 6. Replace roller bearings that are
matter from the parts. Be careful not damage that could affect the opera- broken, worn or rough.
to damage any parts with the scraper. tion of the transmission. 7. Replace the countershaft (clust-
Do not clean, wash or soak transmis- 2. Inspect the front face of the case er) gear if the teeth are chipped, brok-
sion seals in cleaning solvents. Dry all for small nicks or burrs that could en or worn. Replace the countershaft
parts with compressed air. cause misalignment of the transmis- if it is bent, scored or worn.
2. Rotate the ball bearings in a sion with the flywheel housing. Re- 8. Replace the reverse idler gear or
cleaning solvent until all lubricant is move all small nicks or burrs with a sliding gear if the teeth are chipped,
removed. Hold the bearing assembly fine stone. worn or broken. Replace the idler
to prevent it from rotating and dry it 3. Replace a cover that is bent or gear shaft if bent, worn or scored.
with compressed air. distorted. Make sure that the vent 9. Replace the input shaft and gear
3. Lubricate the bearings with ap- hole in the cover is open. if the splines are damaged or if the
proved transmission lubricant and 4. Check the condition of the shift teeth are chipped, worn or broken. If
wrap them in a clean, lint-free cloth levers, forks, shift rails and the lever the roller bearing surface in the bore
or paper until ready for use. and shafts. of the gear is worn or rough, or if the
4. Clean the magnet welded to the 5. Examine the ball bearing races cone surface is damaged, replace the
bottom of the case with kerosene or for cracks, wear or roughness. Inspect gear and the gear rollers.
mineral spirits. the balls for looseness, wear, end play 10. Replace all other gears that are
chipped, broken or worn. cone, the distance between the face of of the splines are damaged.
11. Check the synchronizer sleeves the blocker ring and the clutch teeth 15. Inspect the bushing and the seal
for free movement on their hubs. on the gear must not be less than in the extension housing. Replace
Make sure that the alignment marks 0.010 inches. them if they are worn or damaged.
(etched marks) are properly indexed. 13. Replace the speedometer drive The bushing and/or seal should be re-
12. Inspect the synchronizer block- gear if the teeth are stripped or dam- placed after the extension housing has
ing rings for widened index slots, aged. Make certain to install the cor- been installed on the transmission.
rounded clutch teeth and smooth in- rect size replacement gear. 16. Replace the seal in the input
ternal surfaces (must have machined 14. Replace the output shaft if shaft bearing retainer.
grooves). With the blocker ring on the there is any evidence of wear or if any 17. Replace the seals on the cam
and shafts.
06-02-01 Ford Design Three Speed Transmission 06-02-01
PART 6-2 Ford Design Three Speed Transmission

MODEL APPLICATION
Thunderbird
Continental-
Trans- Shift
Continental
All Models
mission Engine Lever
Mustang
Montego
Mercury
Fairiane
Mark III
Lincoln-
Cougar
Meteor
Model Model Location
Falcon
Ford
RAN-AL 200-IV, 250-IV Column X X X
RAN-AM 200-IV, 250-IV Floor X
RAN-AN 170-1V Column X
RAN-AZ 240-IV Column X X
RAT-AJ 351-2V-4V Column X X
RAT-AM 351-2V-4V Floor X X
RAT-A2 390-2V-4V Column X X X
RAT-B2 390-4V-GT Floor X X
RAT-C2 390-4V-GT Column X X
RAT-N2 390-4V Floor X
RAT-SI 302-2V Column X
RAT-T 302-2V-4V Column X X X
RAT-U1 302-2V Floor X
COMPONENT INDEX AH Models
COUNTERSHAFT GEAR BEARINGS

DESCRIPTION 02-02
GEAR SHIFT CONTROL ASSEMBLY—
Floor Mounted
GEAR SHIFT LEVERS AND SEALS
GEAR SHIFT LINKAGE ADJUSTMENT
Column Mounted 02-02
Floor Mounted 02-03
INPUT SHAFT BEARING
SYNCHRONIZERS
Disassembly and Assembly 02-06
TRANSMISSION (Complete)
Cleaning and Inspection See Part 06-01
DESCRIPTION
DESCRIPTION tag is located on the right side of the This transmission is of the fully
case at the front (Fig. 2). The first synchronized type, with all gears ex-
The RAN and RAT Model three- line on the tag will show the transmis- cept the reverse gear and sleeve being
speed transmission (Fig. 1) are used sion model and service identification in constant mesh. All forward-speed
on models having 170, 200, 240, 250, code when required. The second line changes are accomplished with syn-
302, 351 and 390 C.I.D. engines. The will show the transmission serial num- chronizer sleeves.
specifications of this section, Part 6-4, ber. Additionally, a driveline compo- T h e f o r w a r d - s p e e d gears are
lists the transmission model numbers nent identification tag is attached to helical-cut and are in constant mesh.
and vehicles in which they are used. the upper right side of the transmis- Gears used in the reverse gear train
A transmission service identification sion case. are spur-cut and are not synchronized.
TRANS. MODEL
SERIAL NO.
C2O87-A
C 2089-A
FIG. 1—Three-Speed Transmission—Typical FIG. 2—Transmission Identification

Tag
GEAR SHIFT LINKAGE

ADJUSTMENT—COLUMN
MOUNTED
1. Place the gear shift lever in the

neutral position.
2. Loosen the two gear shift rod
adjustment nuts.
3. Check shift levers on transmis-
sion to be in neutral position.
4. I n s e r t a 3/16-inch diameter
alignment tool through the first and
reverse gear shift lever, the second and
third gear shift lever and both holes
in the lower casting (Fig. 3). An align-
ment tool can be made from 3/16
inch drill rod bent to an L shape.
The extensions should be 1 inch and 2
inches from the elbow. The short end
of the tool should be inserted into the
alignment holes.
5. Tighten the two gear shift rod
adjustment nuts.
6. Remove the alignment tool from
the levers.
7. Start the engine and shift the se-
lector lever to each position to make
sure it operates freely. FIG. 3—Gearshift Linkage Adjustment—Typical
STOP PIN
GROMMET
Tool - T67P.7347.A
GROMMET
LEVER
^S. GROMMET INSTALLATION
CONTROL ROD REMOVAL
SET STOP PIN SO THAT THE GROMMET

OMMET—^
ANDSHIFT
Tool - T67P.734LA SEATED
ROD ARE PROPERLY SEATED \
CONTROL ROD INSTALLATION

CONTROL ROD
STOP PIN
C 2090-A
FIG. 4—Removing or Installing Shift Linkage Grommet
GEAR SHIFT LINKAGE sembly incorporates an oil impregnat- adjust the stop pin as necessary to
ADJUSTMENT—FLOOR MOUNTED ed plastic grommet in the end of each properly install the grommet and coat
lever arm. A special tool T 6 7 P - the outside of the grommet with lubri-
1. Loosen the three shift linkage 7341-A is required to install the grom- cant. Then, place the grommet on the
adjustment nuts. Install a 1/4 inch di- met in the shift lever, and to install stop pin and force it into the shift
ameter alignment pin through the con- the shift linkage rod into the grom- lever hole. Turn the grommeit several
trol bracket and lever alignment holes met. Remove and install the grommet times to be sure it is properly seated.
shown in Fig. 18. as follows: 3. Readjust the stop pin to a length
2. Tighten the three linkage adjust- 1. Place the lower jaw of the tool which is sufficient to install the shift
ment nuts and then remove the align- between the shift lever and the shift rod into the grommet (Fig. 4). If the
ment pin. rod. Position the stop pin against the pin height is not adjusted, the shift
3. Check the gear shift lever for a end of the shift rod (Fig. 4) and force rod may be pushed too far through
smooth crossover. the rod out of the grommet. Remove the grommet causing damage to the
the grommet from the shift lever by grommet retaining lip.
COLUMN-MOUNTED cutting off the large shoulder with a 4. With the pin height properly ad-
SHIFT LINKAGE sharp knife. The groin met must be re- justed, position the shift rod on the
GROMMET REMOVAL AND moved from the shift lever and a new tool and force the rod into the grom-
INSTALLATION one installed each rime 'he rod is dis- met until the groove in the rod seats
connected. on the inner retaining lip of the grom-
The column-mounted shift lever as- 2. Before installing a new grommet, met.
REMOVAL out of the transmission extension cable retainer to the extension hous-
housing and off the output shaft In- ing. Pull the speedometer cable out of
1. Raise the vehicle on a hoist. sert the tool shown in (Fig. 2), Part the extension housing.
2. Mark the drive shaft so that it 6-1 into the extension housing to pre- 5. On vehicles equipped with a
may be installed in the same relative vent the lubricant from leaking out of column-mounted gear shift selector,
position. Disconnect the drive shaft the transmission. remove the shift rods from the shift
from the rear U-joint flange. 4. Remove the cap screw and lock levers at the transmission. On vehicles
3. Slide the front of the drive shaft washer that secures the speedometer equipped with a floor-mounted gear
shift selector, remove the shift selector 2. Install a guide pin in each lower bolts and lock washers.
assembly from the extension housing. mounting bolt hole. 6. On Ford, Mercury and Meteor
6. On Ford, Mercury and Meteor 3. Start the input shaft through the models, insert the parking brake front
vehicles disconnect the parking brake release bearing. Align the splines on cable in the equalizer and install the
cable from the equalizer lever and sep- the input shaft with the splines in the e q u a l i z e r in the b r a c k e t on the
arate the lever from the crossmember. clutch disc. Move the transmission c r o s s m e m b e r . Secure the parking
7. On Ford, Mercury and Meteor forward on the guide pins until the brake rear cable to the equalizer.
models, remove the bolts that secure input shaft pilot enters the bearing or 7. On vehicles equipped with a
the extension housing to the engine bushing in the crankshaft. If the column-mounted gear shift selector,
rear support. transmission front bearing retainer secure the shift rods to the shift levers
8. Raise the rear of the engine high binds up on the clutch release bearing at the t r a n s m i s s i o n . On vehicles
enough to remove the weight from the hub, work the release bearing lever equipped with a floor-mounted gear
crossmember. until the hub slides onto the transmis- shift selector, attach the shift selector
9. Support the transmission with a sion front bearing retainer. Install the assembly to the extension housing.
transmission jack and remove the two transmission-to-flywheel housing 8. Insert the speedometer cable and
transmission from the flvwheel hous- upper mounting bolts and lockwash- driven gear in the extension housing
ing. ers. Remove the two guide pins and and secure it with a cap screw and
10. Move the transmission and jack install the lower mounting bolts and lock washer.
rearward until the input shaft is clear lock washers. 9. Remove the tool shown in Fig. 2,
of the flywheel housing. 4. Raise the rear of the engine high Part 6-1, from the extension housing.
11. Remove the transmission from enough to provide clearance for in- Align the reference marks and slide
the jack and mount it in a holding stalling the crossmember. Bolt the the front universal joint yoke onto the
fixture. crossmember assembly to the frame output shaft and into the extension
Do not depress the clutch pedal side supports. housing. Connect the rear universal
while the transmission is removed. 5. On Ford, Mercury and Meteor joint to the axle pinion flange and tor-
models, lower the engine until the ex- que the nuts to specifications.
INSTALLATION tension housing just contacts the rear 10. Fill the transmission to the
support. Align the bolt holes in the proper level with the approved lubri-
1. Make certain that the machined extension housing with those in the cant.
surfaces of the transmission case and support. Then lower the engine and 11. Adjust the clutch pedal free
the flywheel housing are free of dirt, remove the jack. Install the two exten- travel and the shift linkage as re-
paint, and burrs. sion housing-to-support attaching quired.
DISASSEMBLY cover and the gasket (Fig. 5) from the and gasket from the case.
case. 5. Remove the cap screws and lock
1. Mount the transmission in a 3. Remove a long spring that re- washers that attach the front bearing
holding fixture and drain the lubricant tains the detent plug in the case (Fig. retainer to the case. Remove the front
by removing the drain plug, if so 9). Remove the detent plug with a bearing retainer and gasket from the
equipped, or the lower extension hous- small magnet. case.
ing bolt. 4. Remove the cap screws and lock 6. Remove the lubricant filler plug
2. Remove the cap screws that at- washers that attach the extension from the right side of the case. Work-
tach the cover to the case. Remove the housing to the case. Remove extension ing through the plug opening, drive
COVER
the roll pin out of the case and coun-
tershaft with a 1/4-inch punch (Fig.
6).
TERSHAFT'
FRONT #
BEARING RETAINER PIN
C 1841-A
C2069-A
FIG. 6—Removing Countershaft

FIG. 5—Transmission Case and Related Parts—Typical Roll Pin
18. Pull the input gear and shaft

forward until the gear contacts the
case, and then remove the large snap
ring. It is necessary to move the gear
forward to provide clearance when re-
moving the output shaft assembly
from RAT model transmissions. On
all other models, the input shaft and
Dummy
gear is removed from the front of the
Shaft
case at this time.
19. Rotate the second and third-
speed shift fork upward, and lift it
C2070 A from the case.
20. Carefully lift the output shaft
FIG. 7—Removing Countershaft assembly out through the top of the
case.
7. On 6-cylinder vehicles with a shaft. Remove the bearing from the 21. On an RAT model, work the
m o d e l R A N t r a n s m i s s i o n except case and shaft as shown in Fig. 8. input shaft bearing and gear back
Ford, tap the countershaft from the 11. Place both shift levers in the through the bore in the case and out
rear of the case with a dummy shaft neutral (center) position. through the top. Remove idler gear
to remove the expansion plug from 12. Remove the set screw that se- shaft, driving from the front of the
the countershaft bore at the front of cures the first and reverse shift fork to case.
the case. the shift rail. Slide the first and rev- 22. Lift the reverse idler gear and
8. Hold the countershaft gear with erse shift rail out through the rear of two thrust washer (Fig. 12) from the
a hook and with the tool shown in the case. case. Lift the countershaft gear, thrust
Fig. 7, push the countershaft out the 13. Slide the first and reverse syn- washer, and dummy shaft from the
rear of the case. chronizer forward as far as possible, case.
The countershaft (cluster) gear and and rotate the first and reverse shift 23. Remove the snap ring from the
thrust washers (Fig. 21) can be low- fork upward. Then lift it from the front of the output shaft, and slide the
ered to the bottom of the case. Re- case. synchronizer and the second-speed
move the countershaft from the rear 14. Move the second and third- gear (Fig. 13) off the shaft.
of the case. speed shift fork to the second-speed 24. Remove the next snap ring and
9. On some models, remove the position to gain access to the set tabbed thrust washer from the output
snap ring that secures the speedometer screw. Remove the set screw from the shaft. Then slide the first gear and
drive gear on the output shaft. Slide fork. Rotate the shift rail 90 degrees blocking ring off the shaft.
the speedometer drive gear off the as shown in Fig. 11. 25. Remove the next snap ring
shaft. Remove the speedometer drive 15. Lift the interlock plug (Fig. 9) from the output shaft. The first and
gear lock ball from the shaft. If the from the case with a magnet. reverse synchronizer hub is a press fit
vehicle is equipped with the new de- 16. Tap on the inner end of the sec- on the output shaft. To eliminate the
sign retainer, depress the tang on the ond and third-speed shift rail to re- possibility of damaging the synchro-
speedometer drive gear retaining clip move the expansion plug (Fig. 9) from nizer assembly, remove the synchro-
and slide the gear off the output shaft the front of the case. Remove the shift nizer hub using an arbor press as
(Fig. 10). rail. shown in Fig. 21. Do not attempt to
10. Remove the snap ring that re- 17. Remove the second and third- remove or install the hub by hammer-
tains the output shaft bearing on the speed shift rail detent plug and spring ing or prying.
from the detent bore.
SCREW
MACHINED SURFACE
SET SCREW
2ND AND 3RD SHIFT FORK
EXPANSION PLUG
C2071-A 1ST AND REVERSE

SHIFT RAIL C1798-A
FIG. 8—Removing Output Shaft
Bearing FIG. 9—Shift Rails and Forks Disassembled
SPEEDOMETER DRIVE
GEAR case.
SPRING CLIP 4. Position a shift lever on each
shaft and secure them with a flat
washer, lock washer, and nut.
INPUT SHAFT BEARING
1. Remove the snap ring securing

the input shaft bearing (Fig. 15), and
press the input shaft out of the bear-
ing.
2. Press the input shaft bearing
onto the input shaft with the tool
shown in Fig. 16, and install the snap
ring on the shaft.
FRONT C2052-A
SYNCHRONIZERS
FIG. 10—Speedometer Drive Gear Installation—New Design
1. Push the sychronizer hub from
each synchronizer sleeve.
2. Separate the inserts and insert
TOOL-T52T springs from the hubs. Do not mix the
6500-DJD parts from the second and third-speed
synchronizer with the first and reverse
synchronizer (Figs. 17 and 18).
3. Install the rear insert spring in
the groove of the first and reverse syn-
SHAFT AND LEVER
0-RING
C1564-A
FIG. 11—Rotating Second and Third-Speed Shift Rail
PARTS REPAIR OR the transmission case. Lift the levers

REPLACEMENT off the shaft. Slide each lever and
shaft out of the case. Discard the CD- SHIFT
LEVER
SHIFT LEVERS AND SEALS ring from each shaft.
2. Lubricate the new seals with C 1845-A
1. Remove the nut, lock washer, t r a n s m i s s i o n lubricant and install
and flat washer that secure each shift them on the shafts. FIG. 74—Shift Lever and Shafi
lever (Fig. 14) to the lever and shaft in 3. Install the lever and shafts in the Disassembled
BLOCKING RING SPEEDOMETER DRIVE GEAR

OUTPUT SHAFT
BLOCKING RINGS
REVERSE
IDLER GEAR THRUST SNAP RING
WASHER ROLL PIN
REVERSE IDLER
GEAR SHAFT
REAR BEARING
THRUST WASHER REVERSE GEAR
C1799-A SYNCHRONIZER AND SLEEVE C2072-A
FIG. 72—Reverse Idter Shaft

Disassembled FIG. 13—Output Shaft Disassembled
4. Install one insert spring (Fig. 18)

into a groove of the second and third
speed synchronizer hub, making sure
that all three insert slots are fully cov-
ered. With the alignment marks on
the hub and sleeve aligned, start the
hub into the sleeve. Place the three in-
serts on top of the retaining spring
and push the assembly together. In-
stall the remaining insert spring so
that the spring ends cover the same
slots as does the other spring. Do not
SNAP RINGS C1802- A stagger the springs. Place a synchro-
nizer blocking ring on each end of the
FIG. 15—Input Shaft Gear Disassembled
synchronizer sleeve.
chronizer hub. Make sure that the
spring covers all insert grooves. Start COUNTERSHAFT GEAR
the hub in the sleeve making sure that BEARINGS
the alignment marks are properly in-
dexed. Position the three inserts in the 1. Remove the dummy shaft, fifty
hub making sure that the small end is roller bearings, and the two bearing
over the spring and that the shoulder retainer washers from the countershaft
is on the inside of the hub. Slide the gear (Fig. 21).
sleeve and reverse gear onto the hub 2. Coat the bore in each end of the
until the detent is engaged. Install the countershaft gear with grease.
front insert spring in the hub to hold 3. Hold the dummy shaft in the
the inserts against the hub. Be sure gear and install the twenty-live roller
REMOVAL INSTALLATION
C1O25-B the spring humps of the rear spring bearings and a retainer washer in each
cover different inserts than the front end of the gear.
FIG. 76—Replacing Input Shaft spring humps (Fig. 20). 4. Position the countershaft gear,
Bearing dummy shaft, and roller bearings in
the case.
5. Place the case in a vertical posi-
tion. Align the gear bore and the
thrust washers with the bores in the
case and install the countershaft.
6. Place the case in a horizontal
position and check the countershaft
gear end play with a feeler gauge. The
end play should be within specifica-
tion. If not within specification, re-
place the thrust washers.
7. After establishing the correct end
BLOCKING RING play, install the dummy shaft in the
countershaft gear and allow the gear
SLEEVE AND to remain at the bottom of the case
REVERSE GEAR until the output and input shafts have
been installed.
C1803- A GEAR SHIFT LEVER AND

CONTROL ASSEMBLY
FIG. 17—First and Reverse Synchronizer Disassembled REMOVAL AND
INSTALLATION—
FLOOR-MOUNTED
INSERT HUB A N D SLEEVE ALIGNMENT MARKS
SPRING 1. Remove the four screws attach-
ing the lower boot to the floor pan.
2. Remove the two bolts attaching
the gear shift lever to the control as-
sembly.
3. Remove the two piece lock nuts
that connect the shift rods to the con-
trol assembly.
INSERT SPRING
4. Remove the three bolts retaining
BLOCKING m$ERTS
C1804- A
the shift control assembly to the ex-
RING
tension housing. Allow the back-up
FIG. 18—Second and Third Synchronizer Disassembled light switch to hang free.
5. Lower the control assembly from

the vehicle and remove the boot.
FIRST-REVERSE 6. Remove* the nut from the selec-
SELECTOR LEVER tor lever shaft and remove the shaft
from the assembly. Then, llift the se-
lector arm and selector levers out of
the support bracket. Do not lose the
SELECTOR LEVER detent spring located between the
SHAFT
first-reverse selector lever and the se-
lector arm (Fig. 19).
7. Lubricate all mating surfaces
with lithium grease before assembly.
8. Position the detent spring be-
SUPPORT BRACKET
tween the first-reverse selector lever
and the selector arm. Be sure the wide
base of the spring rests against the se-
lector lever. Position the second-third
selector lever against the selector arm
SECOND-THIRD and insert the entire assembly into the
SELECTOR LEVER
support bracket.
9. Install the selector lever shaft
through the support bracket and selec-
tor lever assembly and install the re-
taining nut.
C 2053-A 10. Slide the control assembly into
the boot and attach the entire assem-
79—Gear Shift Control Assembly Disassembled—3-Speed bly to the extension housing. Do not
lose the spacer located inside the as-
sembly. Be sure the back-up light
switch is properly installed.
11. Install the two bolts securing
the gear shift lever to the shift control
assembly.
12. Insert a 1/4 inch diameter
alignment pin in the alignment holes
of the control assembly.
13. Position the shift rods on the
selector levers and install the lock
nuts.
14. Remove the alignment pin.
15. Check the operation of the shift
mechanism for smooth cross-over and
adjust as required.
FRONT REAR
C 1742-A ASSEMBLY
FIG. 20—First and Reverse Speed Synchronizer Insert Spring 1. Coat the reverse idler gear thrust
surfaces in the case with a thin film of
Installation
lubricant and position the two thrust
washers in place.
2. Position the reverse idler gear
and dummy shaft in place. Align the
iNEEDLE BEARINGS (25 EACH END
gear bore and thrust washers with the
case bores and install the reverse idler
shaft.
3. Measure the reverse idler gear
end play with a feeler gauge. End play
should be within specification. If the
end play is not within specification,
replace the thrust washers. If the end
BEARING play is within limits, leave the reverse
RETAINER
\ idler gear installed.
BEARING
RETAINER ROLL PIN
C1805- A 4. L u b r i c a t e the output shaft
splines and machined surfaces with
. 27—Countershaft Gear Disassembled transmission lubricant.
PRESS RAM Tool-T63P7025-A

PRESS RAM
OUTPUT SHAFT
OUTPUT SHAFT
SYNCHRONIZER
SYNCHRONIZER
HUB
REMOVAL INSTALLATION c 1718-A C1806-A
FIG. 22—Removing and Installing First and Reverse Synchronizer FIG. 23—Installing Output Shaft
Rear Bearing
5. The first and reverse synchroniz- 11. Position the output shaft as-
er hub is a press fit on the output sembly in the case. Position the sec- bearing retainer and new gasket mak-
shaft. To eliminate the possibility of ond and third-speed shift fork on the ing sure that the oil return slot is at
damaging the sychronizer assembly, second and third-speed synchronizer. the bottom of the case. Install and
install the synchronizer hub with the 12. Place a detent plug spring and torque the attaching screws to specifi-
teeth end of the gear facing toward a plug in the case (Fig. 9). Place the cation.
the rear of the shaft, using an arbor second and third-speed synchronizer in 19. Install the large snap ring on
press as shown in Fig. 22. Do not at- the second speed position (toward rear the rear bearing. Place the bearing on
tempt to remove or install the hub by of transmission). Align the fork and the output shaft with the snap ring
hammering or prying. install the second and third-speed shift end toward the rear of the shaft. Press
6. Place the blocking ring on the rail. It will be necessary to depress the the bearing into place with the tool
tapered machined surface of the first detent plug to enter the rail in the shown in Fig. 23. Secure the bearing
gear. bore. Move the rail inward until the to the shaft with a snap ring.
7. Slide the first gear onto the out- detent plug engages the forward notch 20. On some models, hold the
put shaft with the blocking ring (second-speed position). speedometer drive gear lock ball in
toward the rear of the shaft. Rotate 13. Secure the fork to the shaft the detent and slide the speedometer
the gear as necessary to engage the with the set screw. Move the synchro- drive gear into place. Secure the gear
three notches in the blocking ring with nizer to the neutral position. with a snap ring. On models equipped
the synchronizer inserts. Secure the 14. Install the interlock plug in the with the new design retainer, install
first gear with the thrust washer and case. If the second and third-speed the speedometer drive gear retaining
snap ring. shift rail is in the neutral position, the clip on the shaft with the lower tang
8. Slide the blocking ring onto the top of the interlock will be slightly in the retaining hole. Align the groove
tapered machined surface of the sec- lower than the surface of the first and in the gear with the clip and slide the
ond gear. Slide the second gear with reverse shift rail bore. gear forward until the upper tang on
blocking ring and the second and third 15. Move the first and reverse syn- the clip locks the gear (Fig. 9).
gear synchronizer onto the mainshaft. chronizer forward to the first-speed 21. Place the transmission in the
The tapered machined surface of the position. Place the first and reverse vertical position. Working through the
second gear must be toward the front shift fork in the groove of the first drain hole in the bottom of the case,
of the shaft. Make sure that the and reverse synchronizer. Rotate the align the bore of the countershaft gear
notches in the blocking ring engage fork into position and install the first and the thrust washers with the bore
the synchronizer inserts. Secure the and reverse shift rail. Move the rail of the case with a screwdriver.
synchronizer with a snap ring. inward until the center notch (neutral) 22. Working from the rear of the
9. Coat the bore of the input shaft is aligned with the detent bore. Secure case, push the dummy shaft out of the
and gear with a thin film of grease. A the fork to the shaft with the set countershaft gear with the counter-
thick film of grease will plug the lu- screw. shaft. Before the countershaft is com-
bricant holes and prevent lubrication 16. Install a new shift rail expan- pletely inserted in the bore, make sure
to the bearings. Install the 15 bearings sion plug in the front of the case. that the hole that accommodates the
(Fig. 15) in the bore. 17. Hold the input shaft and block- roll pin is aligned with the hole in the
10. If working on a RAT model ing ring in position. Then move the case. Drive the shaft into place and in-
transmission, install the input gear output shaft forward to seat the pilot stall the roll pin. On all 8 cylinder ve-
and bearing through the top of the in the roller bearings of the input hicles and Ford 6 cylinder models, the
case and through the bore in front of gear. countershaft is a press fit in the case.
the case. On RAN models, me input 18. Tap the input gear bearing into On 6 cylinder models with model
shaft is installed through the front of place in the case while holding the RAN transmissions there is a counter-
the transmission. Install the snap ring output shaft to prevent the roller bear- shaft-to-case clearance of 0.020 inch
in the bearing groove. ings from dropping. Install the front at the front bore and 0.010 at the rear
bore. On these 6 cylinder models, in- cap screws to specification. plug in the case. Install the long
stall a new expansion plug in the 25. Install the filler and drain plugs spring (which is retained by the case)
countershaft bore at the front of the (if equipped) in the case. Make sure to secure the detent plug.
case. that the magnetic plug is installed in 28. Coat a new cover gasket (Fig.
23. Coat a new extension housing the bottom of the case. 5) with sealer. Secure the cover with
gasket with sealer and position it on 7.6. Place the transmission in gear. cap screws. Torque the screws to spec-
the case. Pour lubricant over the entire gear ification.
24. Install lock washers on the five train while rotating the input or out- 29. Check the operation of the
attaching screws. Dip the threads of put shaft. transmission in all of the gear posi-
the cap screws in sealer. Secure the 27. Install the remaining detent tions.
housing to the case and torque the
06-03-01 Ford Design Four-Speed Transmission 06-03-01
PART 6-3 Ford Design Four Speed Transmission
MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
Mustang
Montego
Mercury
Trans- Engine Shift
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
mission Model Lever
Ford
Model Location
RUG-ADI 390-4V-GT Floor X X

RUG-AE1 428-4V-CJ Floor X X
RUG-AG 351-2V-4V Floor X X
RUG-AH 351-2V-4V Floor X X
RUG-AJ 428-4V Floor X X
RUG-AL 390-4V-GT Floor X X
RUG-C2 390-2V-4V Floor X X
RUG-D2 351-2V-4V Floor X X
RUG-E3 302-2V-4V.351-2V-4V Floor X X
RUG-JZ 390-4V-GT Floor X X
RUG-M3 390-4V Floor X X
RUG-AK 351-2V-4V Floor X X
RUG-VI 429-4V Floor X
® Used with 3.75:1 and lower axle ratios
© Used with 3.50:1 and higher axle ratios
All Models
COMPONENT INDEX
COUNTERSHAFT GEAR BEARINGS

DESCRIPTION 03-02
GEAR SHIFT CAMS AND SEALS
GEAR SHIFT LINKAGE ADJUSTMENT 03-02
GEAR SHIFT CONTROL ASSEMBLY
INPUT SHAFT BEARING
INPUT SHAFTSEAL
REVERSE IDLER GEAR BEARING
SYNCHRONIZERS
Disassembly and Assembly 03-06
TRANSMISSION (Complete)
Cleaning and Inspection See Part 06-01
1 DESCRIPTION
DESCRIPTION All forward-speed gears in the A transmission service identification

transmission are helical-type, however, tag is located on the right side of the
The Ford designed 4-speed trans- the reverse sliding gear and the exter- case at the front (Fig. 2). The first
mission (Fig. 1) is of the fully syn- ior of the first-and second-speed syn- line on the tag will show the transmis-
chronized type with all gears except chronizer sleeve are spur-type gears. sion model and service identification
the reverse sliding gear being in con- The specifications of this section Part code when required. The second line
stant mesh. All forward-speed changes 6-4 lists the transmission model num- will show the transmission serial num-
are accomplished with synchronizer bers and vehicles in which they are ber. Additionally, a driveline compo-
sleeves. used. nent identification tag is attached to
the upper right side of the transmis-
sion case.
TRANS. MODEL
RUG-C-2
O 10001
O
SERIAL NO.
C 2088-A
FIG. 2—Transmission
Identification Tag
C 1765-B
FIG. 7—Four-Speed Transmission—Typical
SHIFT LINKAGE ADJUSTMENT should be 2 1/2 inch and 3 3/4 inch 4. Tighten the 1-2 and 3-4 shift rod
from the elbow. Short end of align- adjustment nuts.
1. Loosen the three shift linkage ment pin should be inserted into con- 5. Connect the reverse gear shift
adjustment nuts. Install a 1/4 inch di- trol bracket and linkage holes until it rod to the shift lever. Shift the reverse
ameter alignment tool through the bottoms. lever to the neutral position and tight-
control bracket and lever holes as 2. Disconnect the reverse gear shift en the adjustment nut.
shown in Fig. 13. rod from the shift lever. 6. Remove the alignment pin.
An alignment tool can be made 3. Shift the transmission into re- 7. Check the gear shift lever for a
from 1/4 inch diameter drill rod bent verse gear. smooth crossover.
to an " L " shape. The extensions

REMOVAL position. Disconnect the drive shaft housing to prevent lubricant leakage.
from the rear U-joint flange. Slide the See Fig. 2, Part 6-1.
1. Raise the vehicle on a hoist. drive shaft off the transmission output 3 . D i s c o n n e c t the speedometer
2. Mark the driveshaft so that it shaft and install the extension housing cable from the extension housing.
may be installed in the same relative seal installation tool into the extension 4. Disconnect the parking brake
cable from the equalizer lever and sep- INSTALLATION transmission rear support crossmemb-
arate the lever from the crossmember. er. Secure the cable assembly to the
5. Remove the hairpin retainer se- 1. Make sure that the mounting crossmember with the hair pin retain-
curing the cable to the transmission surface of the transmission and the er.
rear support crossmember, and then flywheel housing are free of dirt, 8. Insert the parking brake front
pull the cable assembly forward and paint, and burrs. Install two guide cable in the equalizer and install the
out of the crossmember. pins in the flywheel housing lower e q u a l i z e r in the b r a c k e t on the
6. Remove the retaining clip, flat mounting bolt holes. Move the trans- c r o s s m e m b e r . Secure the parking
washer, and spring washer that se- mission forward on the guide pins brake rear cable to the equalizer.
cures the shift rods to the shift levers. until the input shaft splines enter the 9. Connect the speedometer cable
7. Remove the bolts that attach the clutch hub splines and the case is posi- to the extension housing.
shift linkage control bracket to the ex- tioned against the flywheel housing. 10. Remove the extension housing
tension housing and position the as- 2. Install the two upper transmis- installation tool and slide the forward
sembly out of the way. sion to flywheel housing, mounting end of the drive shaft over the trans-
8. Support the engine with a trans- bolts snug, and then remove the two mission output shaft. Connect the
mission jack and remove the extension guide pins. Install the two lower drive shaft to the rear U-joint flange.
housing-to-engine rear support attach- mounting bolts. Torque all mounting 11. Place both forward gear shift
ing bolts. bolts to specifications. levers and the reverse shift lever in the
9. Raise the rear of the engine high 3. Raise the rear of the engine and neutral position and insert a 1/4 inch
enough to remove the weight from the install the crossmember. Install and diameter alignment tool in the shift
crossmember. Remove the bolts retorque the crossmember attaching linkage alignment hole (Fig. 17). It
taining the crossmember to the frame bolts to specifications, then lower the may be necessary to loosen the adjust-
side supports and remove the engine. ment nuts to install the alignment
crossmember. 4. With the transmission extension tool. Adjust the linkage as necessary
10. Support the transmission on a housing resting on the engine rear and tighten the adjustment nuts to
jack and remove the bolts that attach support, install the transmission ex- specifications. Remove the alignment
the transmission to the flywheel hous- tension housing attaching bolts. Tor- tool.
ing. que the bolts to specifications. 12. Fill the transmission to the
11. Move the transmission and jack 5. Position the shift linkage control proper level with the specified lubri-
rearward until the transmission input bracket to the extension housing and cant.
shaft clears the flywheel housing. If install the attaching bolts. 13. Lower the car. Check tne shift
necessary, lower the engine enough to 6. Secure each shift rod to its re- and crossover motion for full shift en-
obtain clearance for transmission respective lever with the spring washer, gagement and smooth crossover oper-
moval. flat washer, and retaining pin. ation.
Do not depress the clutch pedal 7. Guide the parking brake cable
while the transmission is removed. assembly through the hole in the
DISASSEMBLY the front of the case. Then withdraw

the third and fourth-speed shift rail
1. Mount the transmission in a from the front of the case. Do not
holding fixture and drain the lubri- lose the interlock pin from the shift
cant. rail.
2. Remove the cover attaching 9. Remove the set screw from the
screws from the case. Lift the cover first and second-speed shift fork.
and gasket from the case. Slide the first and second-speed shift
3. Remove the long spring that re- Tool-T64P-711hA rail out the rear of the case.
tains the detent plug in the case (Fig. COUNTERSHAFT
10. Remove the interlock plug and
4). Remove the detent plug with a the detent plug from the top of the
small magnet. case (Fig. 4) with a magnet.
4. Remove the extension housing C2073-A 11. On some models, remove the
attaching screws and lock washers. FIG. 3—Removing Countershaft snap ring that secures the speedometer
Remove the housing and the gasket. From Case drive gear to the output shaft. Slide
5. Remove the input shaft bearing the gear off the shaft, then remove the
retainer attaching screws. Slide the re- 7. Place the first and second-speed speedometer gear drive ball. On mod-
tainer off the input shaft. gear shift lever and the reverse shift els equipped with the new design re-
6. Support the countershaft gear lever in the neutral position. Place the tainers, depress the tang on the speed-
with a wire hook. Working from the third and fourth-speed gear shift lever ometer drive gear retaining clip and
front of the case, push the counter- in the third-speed position. slide the speedometer gear off the
shaft out the rear of the case as shown 8. R e m o v e the attaching screw shaft. (Fig. 5).
in Fig. 3. Lower the countershaft to from the third and fourth-speed shift 12. Remove the snap ring that se-
the bottom of the case with the wire fork. Tap on the inner end of the shift cures the output shaft bearing to the
hook. Remove the hook. rail to unseal the expansion plug from shaft.
13. Remove the output shaft bear-

ing as shown in Fig. 6.
14. Remove the input shaft and jjL -SPRING • 7234
bearing and the blocking ring from
the front of the case.
if
15. Move the output shaft to the Q-* 'DETENT PtUG 7C316
right side of the case to provide clear- FIRST AND SECOND SPEED SHIFT RAIL
7240
ance for the shift forks. Rotate the
forks as shown in Fig. 7, then lift THIRD AND FOURTH f l - « - — SCREW - 377386 • S
them from the case. SPEED SHIFT FORK- 7230
16. Support the thrust washer and SCREW. 377886 - S

FIRST AND SECOND
first-speed gear to prevent them from SPEED SHIFT FORK • 7230
DETENT PLUG-fr-fl
sliding off the shaft, then lift the out- 7C316 **
put shaft assembly from the case as INTERLOCK PIN
7235
shown in Fig. 8.
17. Remove the reverse gear shift
fork set screw. Rotate the reverse shift
rail 90 degrees as shown in Fig. 9.
THIRD AND FOU
Slide the shift rail out of the rear of SPEED SHIFT RAIL
the case. Lift the reverse shift fork 7241
from the case.
18. Remove the reverse detent plug
and spring from the case with a mag-
net.
19. Remove the reverse idler gear
shaft from the case as shown in Fig.
10.
20. Lift the reverse idler gear and
the thrust washers from the case. Be
careful not to drop the bearings and
the dummy shaft from the gear.
EXPANSION
21. Lift the countershaft gear and PLUG-74112-S
the thrust washers from the case. Be
careful not to drop the bearings or the
dummy shaft from the counter-shaft
gear.
22. Remove the snap ring from the
front of the output shaft. Slide the
third and fourth-speed synchronizer
(Fig. 11) blocking ring and the third-
speed gear off the shaft.
MAGNETIC DRAIN PLUG -373719-S
23. Remove the next snap ring and
the second-speed gear thrust washer
C2074-A
from the shaft. Slide the second-speed
gear and the blocking ring off the FIG. 4—Shift Rails and Forks Disassembled
shaft.
24. Remove the next snap ring.
SPEEDOMETER DRIVE
25. Remove the thrust washer, first GEAR
speed gear and blocking ring from the SPRING CLIP
rear of the shaft. The first and second
synchronizer hub is a press fit on the
output shaft. To eliminate the possi-
bility of damaging the synchronizer
assembly, remove the synchronizer
hub using an arbor press as shown in
Part 6-2, Fig. 20. Do not attempt to
remove or install the hub by hammer-
ing or prying.
PARTS REPAIR OR
REPLACEMENT
CAM AND
SHAFT SEALS
1. Remove the attaching nut, lock FRONT C2052-A
washer and the flat washer from each
shift lever and remove the three levers.
2. Remove the three cam and shafts # 5—Speedometer Drive Gear Installation
from inside the case.
REVERSE SHIFT
RAIL
Tool-T52T-
C2076-A
DETAIL 4
FORD AND MERCURY
DETAIL 5 FIG. 9—Rotating Reverse
COUGAR. FAIRLANE,
FALCON, MONTEGO,
Shift Rail
AND MUSTANG
plate. Lift the inner support bracket,
selector arm, and reverse selector lever
from the back plate.
9. Lubricate all mating surfaces
with lithium grease before assembly.
10. Position the reverse gear selec-
tor lever, selector arm and the inner
C1533-B support bracket on the back plate.
The reverse gear selector lever will
FIG. 6—Removing Output Shaft Bearing
have a flat spot on the top of the lever
to distinguish it from the third-fourth
3. Remove and discard the O-ring 3. Remove the two piece lock nuts selector lever. Install the two retaining
from each cam and shaft (Fig. 12). that secure the shift rods to the shift bolts finger tight.
4. Dip the new Orings in gear lu- levers. 11. Insert a 1/4 inch gauge pin
bricant and install them on the cam 4. Remove the three bolts attaching through the alignment holes of the se-
and shafts. the control assembly to the extension lector levers and support brackets.
5. Slide each cam and shaft into its housing. Lower the control assembly Line up the gauge pin perpendicular
respective bore in the transmission and boot and remove the control as- to the back plate. Torque the two sup-
case. sembly from the boot. port bracket-to-back plate retaining
6. Secure each shaft lever with a 5. Remove the back-up light switch. nuts to specification and remove the
flat washer, lock washer and nut. 6. Remove the outer nut from the gauge pin.
selector lever shaft and slide the shaft 12. Position the rubber washer,
GEAR SHIFT CONTROL from the control assembly. first-second and third-fourth selector
ASSEMBLY 7. Lift the outer support bracket, levers in the outer support bracket.
1. Remove the four screws attach- rubber washer, first-second, and Position this assembly against the
ing the lower boot to the floor pan. third-fourth selector levers off the as- inner support so that the selector lever
2. Remove the two bolts that secure sembly (Fig. 13). shaft holes in the selector levers and
the gear shift lever to the shift control 8. Remove the two bolts retaining support brackets are aligned.
assembly. the inner support bracket to the back 13. Install the selector lever shaft
THIRD AND, "~ REVERSE IDLER
THIRD AND FOURTH
FOURTH GEAR SHAFT
SPEED SYNCHRONIZER
SPEED
SHIFT
FORK
FIRST AND
REVERSE
SPEED
SHIFT
FORK
Tool-T64P-7140
OUTPUT SHAFT MOVED

TO RIGHT SIDE OF CASE C2075-A C2077-A C2078-A
FIG. 7—Removing Shift Fork FIG. 8—Removing Output FIG. TO—Removing Reverse Idler
From Case Shaft Assembly Gear Shaft
SPEEDOMETER
DRIVE GEAR
172
BEARING
7C
OUTPUT
SHAFT
SEAL
SNAP RING 7 A o n
SPEEDOMETER GEAR
DRIVE BALL
353351•S
BLOCKING RING
7107
FIRST AND SECOND

SPEED SYNCHRONIZER
7124
SECOND SPEED GEAR

7102
THIRD AND FOURTH

SPEED SYNCHRONIZER •7124
C1529-C
SNAP RING - 7109
FIG. 7 7—Output Shaft Disassembled
and torque the retaining nuts to speci- mechanism for smooth cross-over. synchronizer with the third and
fication. Adjust as required. fourth-speed synchronizer.
14. Install the back-up light switch 3. Position the hub in the sleeve,
INPUT SHAFT BEARING making sure that the alignment marks
on the control assembly.
1. Remove the snap ring that se- are properly indexed.
15. Slide the lower boot over the 4. Place the three inserts into place
cures the bearing to the shaft (Fig.
shift control assembly and attach the on the hub. Install the insert springs
14).
entire assembly to the extension hous- making sure that the irregular surface
ing with the three bolts. 2. Press the input shaft gear out of
the bearing as shown in Fig. 15. (hump) is seated in one of the inserts.
16. Install the two bolts securing Do not stagger the springs.
the gear shift lever to the control as- 3. Press a new bearing onto the
sembly. input shaft with the tool shown in Fig.
15. COUNTERSHAFT GEAR
17. Pull the top lip of the lower BEARINGS
boot over the edges of the floor pan 4. Secure the bearing with a snap
and secure the upper boot to the lower ring. 1. Remove the dummy sKo.ft, two
boot and floor pan with the four re- bearing retainer washers, and the 21
SYNCHRONIZERS
taining screws. roller bearings (Fig. 17) from each
18. Position the shift rods in the se- 1. Push the synchronizer hub from end of the countershaft gear.
lector levers and install the retainers. each synchronizer sleeve (Fig. 16). 2. Coat the bore in each end of the
19. Adjust the shift linkage as out- 2. Separate the inserts and insert countershaft gear with grease.
lined previously in this section. springs from the hubs. Do not mix the 3. Hold the dummy shaft in the
20. Check the operation of the shift parts of the first and second-speed gear and install the 21 roller bearings
06-03-07 Ford Design Four-Speed Transmission 06 03-07
and a retainer washer in each end of REVERSE GEAR CAM AND SHAFT-7C124
the gear.
REVERSE IDLER GEAR • FIRST AND SECOND SPEED CAM AND SHAFT-7C124
BEARINGS
O-RING-7288
1. Slip the reverse idler sliding gear

off the reverse idler gear (Fig. 18).
2. Remove the dummy shaft, two
bearing retainer washers and the 44
roller bearings from the reverse idler
gear.
THIRD AND FOURTH SPEED
3. Coat the bore in each end of the FIRST AND SECOND SPEED SHIFT LEiVER-7290
CAMANDSHAFT-7C124
reverse idler gear with grease. 44727-S
4. Hold the dummy shaft in the 34807-S
gear and install the 22 roller bearings 33800-S
and the retainer washer in each end of

the gear.
5. Install the reverse idler sliding
gear on the reverse idler gear making
sure that the shift fork groove is
toward the front (Fig. 18).
INPUT SHAFT SEAL

1. Remove the seal from the input
shaft bearing retainer as shown in Fig.
19.
2. Coat the sealing surface with lu- THIRD AND FOURTH SPEED SHIFT LEVER-7285
bricant. 44727-S'
3. Install the seal as shown in Fig. 34807-S 33800-S C1767-A
20
ASSEMBLY FIG. 12—Cam and Shafts and Shift Levers Disassembled
1. Coat the countershaft gear thrust
lubricant and position a thrust washer SELECTOR LEVER
(Fig. 17) at each end of the case. SHAFT
INNER SUPPORT
2. Position the countershaft gear, BRACKET
dummy shaft, and roller bearings in
the case. OUTER SUPPORT
BRACKET
3. Place the case in a vertical posi-
tion. Align the gear bore and the
thrust washers with the bores in the
case and install the countershaft.
4. Place the case in a horizontal
position and check the countershaft
gear end play with a feeler gauge. The
end play should be 0.004-0.0018 with-
in specification. If not within these
limits, replace the thrust washers.
5. After establishing the correct end
play, install the dummy shaft in the
countershaft gear and allow the gear
to remain at the bottom of the case.
6. Coat the reverse idler gear thrust
lubricant and position the two thrust
washers (Fig. 18) in place.
7. Position the reverse idler gear,
REVERSE SELECTOR LEVER
sliding gear, dummy shaft and the
roller bearings in place making sure FIRST-SECOND
that the shift fork groove in the slid- SELECTOR LEVER
ing gear is toward the front of the

case.
8. Align the gear bore and thrust C 2054.A
washers with the case bores and install
the reverse idler shaft.
FIG. 13—Gear Shift Control Assembly
9. Measure the reverse idler gear
end play with a feeler gauge. End play

should be within specification. If the
end play is not within limits, replace
ROLLER BEARINGS the thrust washers. If the end play is
within limits, leave the reverse idler
gear installed.
10. Position the reverse gear shift
rail detent spring and detent plug in
the case. Hold the reverse shift fork in
place on the reverse idler sliding gear
and install the shift rail from the rear
SNAP RINGS C1802- A
of the case. Secure the fork to the rail
with the Allen head set screw.
FIG. 14—Input Shaft Gear Disassembled 11. Install the first and second-
speed synchronizer onto the front of
Hardwood
the output shaft (Fig. 11) making sure
Block that the shift fork groove is toward
the rear of the shaft. The first and
reverse synchronizer hub is a press fit
on the output shaft. To eliminate the
possibility of damaging the synchro-
nizer assembly, install the synchroniz-
er hub with the teeth end of the gear
Tool-7025-G
OR 7025-B facing toward the rear of the shaft,
Detail 5 using an arbor press as shown in Part
6-2, Fig. 20. Do not attempt to re-
move or install the hub by hammering
or prying.
12. Position the blocking ring on
the second-speed gear.
13. Slide the second-speed gear
onto the front of the shaft, making
REMOVAL INSTALLATION C2079-A
sure that the inserts in the synchroniz-
er engage the notches in the blocker
FIG. 15—Replacing Input Shaft Bearing ring.
14. Install the second-speed gear
ETCH MARKS thrust washer and snap ring.
INSERT SPRING INSERT SPRING 15. Slide the third-speed gear onto
the shaft with the synchronizer coned
surface toward the front.
16. Place a blocking ring on the
third-speed gear.
17. Slide the third and fourth-
speed gear synchronizer onto the shaft
making sure that the inserts in the
synchronizer engage the notches in the
blocking ring.
18. Install the snap ring on the
SLEEVE HUB front of the output shaft.
19. Position the blocking ring on
FIRST AND SECOND SPEED SYNCHRONIZER the first-speed gear.
SLEEVE 20. Slide the first-speed gear onto
INSERT INSERT SPRING
the rear of the output shaft making
sure that the notches in the blocking
INSERT SPRING
ring engage the synchronizer inserts.
21. Install the heavy thrust washer
HUMP on the rear of the output shaft.
INSERT 22. Support the thrust washer and
first-speed gear to prevent them from
sliding off the shaft and carefully
lower the output shaft assembly into
the. case as shown in Fig. 8.
GROOVE TO FACE 23. Position the first and second-
TOWARD FRONT
OF TRANSMISSION
speed shift fork and the third and
THIRD AND FOURTH SPEED SYNCHRONIZER C2080.A fourfh-speed shift fork in place on
their respective gears and rotate them
FIG. 16—Synchronizers Disassembled into place.
COUNTIERSHAFT
24. Place a detent plug (Fig. 5) in 7111
the detent bore. Place the reverse shift
rail into neutral position.
25. Coat the third and fourth-
speed shift rail interlock pin with
grease and position it in the shift rail. RETAINER WASHER
378559 • S
26. Align the third and fourth-
speed shift fork with the shift rail
bores and slide the shift rail into place THRUST WASHER -7119
making sure that the three detents are
facing toward the outside of the case.
Place the front synchronizer into
third-speed position and install the set
screw in the third and fourth-speed THRUST ROLLER BEARINGS- 7121(21)
WASHER
shift fork. Move the synchronizer to 7119
the neutral position. Install the third
and fourth-speed shift rail detent plug,
spring and bolt in the left side of the
transmission case (Fig. 5). Place the COUNTERSHAFT GEAR - 7113
interlock plug (tapered ends) in the
detent case. ROLLER BEARINGS'7121(21)
27. Align the first and second-
speed shift fork with the case bores RETAINER
and slide the shift rail into place. Se- WASHER
cure the fork with the set screw. 378559 • S C2081-A
28. Coat the input gear bore with a

thin film of grease, then install the 15 FIG. 17—Countershaft Gear Disassembled
roller bearings in the bore. A thick
film of grease could plug the lubricant
holes and restrict lubrication of the REVERSE IDLER
GEAR SHAFT
bearings. 7140
29. Position the front blocking ring
in the third and fourth-speed synchro-
nizer. ROLLER BEARINGS
Place the input shaft gear in the 7D271 22)
transmission case making sure that
the output shaft pilot enters the roller
THRUST WASHER
bearings in the input gear. 7149
30. Place a new gasket on the input
shaft bearing retainer. Dip the attach-
RETAINER
ing bolts in sealer and install and WASHER
tighten them to specifications. 351529 - S
31. Install the output shaft bearing
REVERSE IDLER GEAR -7142
as shown in Fig. 21. Install the snap
ring to retain the bearing.
32. On some transmissions, position
the speedometer gear iometer drive
gear retaining clip on the output shaft 'REVERSE SLIDING GEAR • 7D223
with the lower tang in the retaining
hole. Align the groove in the gear with •THRUST WASHER • 7149
the clip and slide the gear forward
until the upper tang on the clip locks
the gear (Fig. 4). C2082-A
33. Place the transmission in a ver-
tical position as shown in Fig. 22. FIG. 78—Reverse Idler Gear Disassembled
Align the countershaft gear bore and
thrust washers with the bore in the the magnetic plug (if so equipped) is to secure the detent plug.
case. Install the countershaft. installed in the bottom of the case. 39. Use a new cover gasket and in-
34. Use a new gasket and secure 36. Pour the specified lubricant stall the cover. Coat the cover attach-
the extension housing to the case with over the entire gear train while rotating screws with sealer and install and
the attaching screws. Use a sealer on ing the input shaft. tighten them to specifications.
the extension housing attaching 37. Place each shift fork in all posi- 40. Coat the third- and fourth-
screws. Torque the screws to specifications to make sure that they operate speed shift rail plug bore with a sealer
tions. properly. and install a new expansion plug.
35. Install the filler plug and drain 38. Install the remaining detent 41. If the extension housing bush-
plug (if so equipped) in the case if plug in the case. Install the long ing and seal are to be replaced, refer
they were removed. Make sure that spring (which is retained by the case) to Section 1.
INPUT SHAFT
BEARING RETAINER
C2083-A
FIG. 79—Removing Input Shaft Seal
Tool-T64P-7025-B
DETAIL 1
DETAIL 4
FORD AND MERCURY
DETAIL 5
COUGAR, FAIRLANE,
FALCON, MONTEGO,
AND MUSTANG
Tool-T57P-77047-A DETAIL 3
OR 70256-6B
DETAIL 2
C1144-B C1518-B
FIG. 20—Installing Input Shaft FIG. 21—Installing Output Shaft Bearing

Seal
OUNTERSHAFT
Tool-T64P-7111-A-
FIG. 22—Installing Countershaft

TRANSMISSION IDENTIFICATION 3-SPEED TRANSMISSION
Trans. Gear Ratios

Car Model Engine Model 1st 2nd Rev.
Ford, Mercury, Meteor 390-2V-4V RAT-A2 2.42 1.61 2.33
Ford, Meteor 240-1V RAN-A2 2.99 1.75 3.17
Ford, Meteor 302-2V RAT-SI 2.99 1.75 3.17
Trans. Gear Ratios Trans. Gear Ratios

Car Model Engine Car Model Engine
Model 1st 2nd Rev. Model 1st 2nd Rev.
Fairlane, Montego 390-4V RAT-B2, RAT-C2 2.42 1.61 2.33 Mustang 200-lV, 250-IV RAN-AM 2.99 1.75 3.17
Cougar 390-4V RAT-N2 Fairlane, Montego
302-4V RAT-T
Falcon
Falcon 170-1V RAN-AN 3.41 1.86 3.51
Mustang, Cougar 351-2V-4V RAT-AM 2.42 1.61 2.33
Mustang 302-2V RAT-U1
Fairlane, Montego 250-IV RAN-AL 2.99 1.75 3.17
Falcon 200-lV,
Fairlane, Montego 351-2V-4V RAT-AJ 2.42 1.61 2.33
4-SPEED TRANSMISSIONS
Trans. Gear Ratios Trans. Gear Ratios

Car Model Engine Car Model Engine Model
Model 1st 2nd 3rd Rev. 1st 2nd 3rd Rev.
Montego, 390-2V-4V RUG-C2® Mustang, Cougar 351-2V-4V RUG-E3® 2.78 1.93 136 2.78
Fairlane, Ranchero 302-2V-4V
Montego, Fairlane, 351-2V-4V RUG-D2® Mustang, Cougar 390-4VGT RUG-M3®
Ranchero
Mustang, Cougar 351-2V-4V RUG-AG
Fairlane, Ranchero 390-4V RUG-J2® 302-4V
2.32 1.69 1.29 2.32
Montego GT
Fairlane, Montego, 351-2V-4V RUG-AH ® 2.32 1.69 1.29 2.32
Mustang, Cougar 390-4V, GT RUG-ADI Ranchero
Mustang, Cougar 428-4V-CJ RUG-AE1® Fairlane, Montego, 351-2V-4V RUG-AK ®
Ranchero
Fairlane, Montego, 428-4V-CJ RUG-AJ ®
Ranchero Ford, Meteor 429-4V RUG-V1
Fairlane, Montego, 390-4V-GT RUG-AL ® Fairlane, 428-4V- RUG-AF
Ranchero Montego 6V
® With 3.25:1 and lower axle ratios. © With 3.50:1 and higher axle ratios.
CLEARANCES(INCHES) MANUAL TRANSMISSION REFILL CAPACITIES

Countershaft Gear End PI ay-3-and 4-Speed Ford 0.004-0.018 Approximate Capacity
Reverse Idler Gear End PI ay-3- and 4-Speed Manual Transmission U.S. Imperial
Ford...: .0.004-0.018 Measure Measure
3-Speed 3-1/2 pts. 3 pts.
4-Speed 4pts. 3 pts.
TORQUE LIMITS(FT-LBS)
3-Speed 4-Speed
Transmissions Transmissions
Extension Housing Bolts 42-50 42-50
Input Shaft Bearing Retainer-to-Transmission Case Bolts 30-36 19-25
Speedometer Cable Retainer-to-Transmission Extension 3.0-4.5 3.0-4.5
Transmission-to-Flywheel Housing Bolts 37-42 37-42
Gearshift Control Levers to Cam and Shaft Assembly Lock Nuts 18-23 18-23
Transmission Cover Bolts 14-19 14-19
Filler Plug-to-Case 10-20 10-20
Drain Plug-to-Case 20-30 20-30
Shift Fork-to-Shift Rail 10-18 10-18
Third and Fourth Shift Rail Detent Bolt - 10-18
Gear Shift Control Assembly to Transmission Extension 8-12 8-12
Shift Selector Levers to Shift Rods 10-20 10-20
Gear Shift Control Support Bracket to Back Plate - 8-13 <D
® Inch-pounds
SPECIAL TOOLS SPECIAL TOOLS (Continued)

Tool Numbers Description Tool Numbers Description
T50T-100A Impact Hammer-Long Tool-7025-B Rear Main Shaft Bearing Removei
T59L-100B Impact Hammer-Short Tool-7025-G Main Shaft Bearing Remover
Tool-1175AB Grease Seal Remover & Replacer
T53T-4621-Bor(4621-F) Drive Pinion Bearing Cone T64P-7111-A Cluster Gear Roller Retainer Shaf
Replacer Front & Rear T63P-7111-A Cluster Gear Roller Retainer Shaft
T57L-4220-A4 Differential Side Bearing Cone T64P-7140-A Reverse Idler Shaft Remover
Replacer or Input Shaft Bearing T61L-7657-A Transmission Extension Housing
Remover Oil Seal Replacer
T52L-7000-GAE Extension Housing Bushing and T57P-7697-B Extension Housing
Seal Remover Bushing Replacer
T63P-7025-A Output Shaft Bearing Remover T57P-7657-G Extension Housing
& Replacer Bushing Replacer
T64P-7025-B Output Shaft Bearing Remover T67P-7341-A Shift Linkage Grommet
& Replacer Replacer
T53T-4621-C Drive Pinion Bearing
Cone Replacer
07-01-01 07-01-01
*.v:;V*> -"^g&ly- GROUP
'y.y... -4^*:
7
General Transmission Service 07-01-01 C6 Automatic Transmission .... 07-04-01
PART 7-2 PART 7-5
C4 Automatic Transmission 07-02-01 Specifications 07-05-01
PART 7-3
FMX Transmission 07-03-01
TRANSMISSION TRANSMISSION
CODE TYPE
AUTOMATIC (C4)
U AUTOMATIC (C6)
X AUTOMATIC (FMX)
Z AUTOMATIC (C6 SPECIAL)
D2040-A
FIG. 1—Typical Warranty Plate—Transmission Identification
PART 7-1 General Transmission Service

MODEL APPLICATION
Continental-
Thunderbird
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Fairiane
Mark III
Lincoln-
Meteor
Cougar
Falcon
Ford
AIR PRESSURE CHECKS 01-06

ANTI-STALL DASHPOT CLEARANCE
CHECK
(Engine Compartment) 01-04
CASE (Transmission)
Inspection 01-17
CONTROL PRESSURE CHECK 01-05
CONTROL VALVE BODY
Inspection 01-17
CONVERTER
Checking 01-04
Cleaning 01-11
DRAIN AND REFILL (Transmission) 01-08
ENGINE IDLE SPEED CHECK 01-04
EXTENSION HOUSING INSPECTION 01-15
FLUID AERATION CHECK 01-03
MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
COMPONENT INDEX
Mustang
Montego
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
FLUID LEAKAGE CHECK 01-03
FLUID LEVEL CHECK 01-03
FRONT CLUTCH (Forward) INSPECTION
C4 Transmission 01-16 N / A 01-16 N / A 01-16 01-16 01-16 01-16 N / A N / A N / A
C6 Transmission 01-16 01-16 01-16 01-16 01-16 N / A 01-16 01-16 01-16 01-16 01-16
FMX Transmission 01-16 N / A 01-16 01-16 01-16 N / A 01-16 01-16 N / A N / A N / A
FRONT PUMP AND STATOR SUPPORT
Inspection 01-16
FRONT SERVO (Intermediate) INSPECTION
FMX Transmission 01-17 N / A 01-17 01-17 01-17 N / A 01-17 01-17 N / A N / A N / A
GOVERNOR INSPECTION 01-17
HYDRAULIC SYSTEM BENCH TESTS
(FMX)
Pressure Tests 01-08 N / A 01-08 01-08 01-08 N / A 01-08 01-08 N / A N/A N/A
Testing Tool Installation 01-07 N / A 01-07 01-07 01-07 N / A 01-07 01-07 N / A N/A N/A
MANUAL LINKAGE CHECKS 01-04
MANUAL SHIFT LINKAGE GROMMET
COLUMN SHIFT
Removal and Installation 01-11 01-11 01-11 N / A 01-11 01-11 01-11 N / A 01-11 01-11 01-11
NEUTRAL START SWITCH-COLUMN
SHIFT
Adjustment 01-09 01-09 01-09 N / A 01-09 01-09 01-09 N / A 01-09 01-09 01-09
Removal and Installation 01-10 01-10 01-10 N / A 01-10 01-10 01-10 N / A 01-10 01-10 01-10
OIL COOLER CLEANING 01-11
OIL COOLER TUBES
ONE-WAY CLUTCH INSPECTION 01-17
OUTPUT SHAFT AND PRIMARY SUN
GEAR
Shaft (FMX)
Inspection 01-12 N / A 01-12 01-12 01-12 N / A 01-12 01-12 N / A N/A N/A
PINION CARRIER, ONE-WAY CLUTCH
AND CENTER SUPPORT (FMX)
PINION CARRIERS INSPECTION
PRESSURE REGULATOR (FMX)
REAR CLUTCH (Reverse-High) INSPECTION
C4 Transmission 01-16 N / A 01-16 N / A 01-16 01-16 01-16 01-16 N/A N/A N/A
FMX Transmission 01-16 N / A 01-16 01-16 01-16 N / A 01-16 01-16 N/A N/A N/A
REAR SERVO (Low-Reverse) INSPECTION 01-17 N / A 01-17 N / A 01-17 01-17 01-17 01-17 N/A N/A N/A
C4 Transmission 01-17 N / A 01-17 01-17 01-17 N / A 01-17 01-17 N/A N/A N/A
MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
COMPONENT INDEX
Montego
Mustang
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
FMX Transmission 01-17 N/A 01-17 01-17 01-17 N/A 01-17 01-17 N/A N/A N/A
REAR SUPPORT (FMX)
SHIFT POINT CHECKS 01-06
STATOR ONE-WAY CLUTCH CHECK 01-12
STATOR TO IMPELLOR INTERFERENCE
CHECK 01-12
STATOR TO TURBINE INTERFERENCE
CHECK 01-12
TRANSMISSION CLEANING 01-11
TURBINE AND STATOR END PLAY
CHECK 01-12
VACUUM DIAPHRAGM ADJUSTMENT
Altitude Compensating Type N / A N / A N / A N / A N / A N / A N / A N / A 01-09 01-09 01-09
Non-Altitude Compensating Type 01-08 01-08 01-08 01-08 01-08 01-08 01-08 01-08 N / A N / A N / A
VACUUM UNIT CHECK
Altitude Compensating Type N / A N / A N / A N / A N / A N / A N / A N / A 01-06 01-06 01-06
Non-Altitude Compensating Type 01-05 01-05 01-05 01-05 01-05 01-05 01-05 01-05 N / A N / A N / A
Three different three-speed trans- mon adjustments and repairs, and are differences in procedures or speci-
missions are used. The C4 Automatic, cleaning and inspection for the three fications, the type of transmission af-
C6 Automatic and the FMX Auto- types of transmissions. Where there fected will be designated.
matic. Part 7-1 covers testing, com-
l AUTOMATIC TRANSMISSION TESTS

When d i a g n o s i n g transmission line; otherwise the parking brake will 8. Connect the vacuum brake re-
problems, refer to the Ford Car and not hold the transmission in any drive lease line if so equipped, and test it
Truck Diagnosis Manual for the de- position. for proper operation.
tailed information on the items that 4. Shift the selector lever through
could be causing the problem. all positions, and place the lever at P. FLUID AERATION CHECK
The following preliminary checks Do not turn off the engine during the
should be made before proceeding fluid level checks. A fluid level that is too high will
with other diagnosis checks. 5. Clean all dirt from the transmis- cause the fluid to become aerated:
sion fluid dipstick cap before remov- Aerated fluid will cause low control
TRANSMISSION FLUID LEVEL ing the dipstick from the filler tube. pressure, and the aerated fluid may be
CHECK forced out the vent.
6. Pull the dipstick out of the tube, Check the transmission fluid level.
1. Make sure that the vehicle is wipe it clean, and push it all the way Low fluid level can affect the opera-
standing level. Then firmly apply the back into the tube. Be sure it is prop- tion of the transmission, and may in-
parking brake. erly seated. dicate fluid leaks that could cause
2. Run the engine at normal idle 7. Pull the dipstick out of the tube transmission damage.
speed. If the transmission fluid is cold again, and check the fluid level. The
run the engine at fast idle speed fluid level should be above the ADD TRANSMISSION FLUID
(about 1200 rpm) until the fluid reach- mark. If necessary, add enough fluid LEAKAGE CHECKS
es its normal operating temperature. to the transmission through the filler
When the fluid is warm, slow the en- tube to bring the level between the Check the speedometer cable con-
gine down to normal idle speed. ADD and FULL marks on the dip- nection at the transmission. Replace
3. On a vehicle equipped with a stick. Do not overfill the transmission. the rubber seal if necessary.
vacuum brake release, disconnect the Install the dipstick, making sure it is Leakage at the oil pan gasket often
release line and plug the end of the fully seated in the tube. can be stopped by tightening the at-
taching bolts to the proper torque. If a" STEEL PLATE HEX. HEAD SCREW
necessary, replace the gasket. 5
/8"X \W, 3
/ 8 " - 2 4 X Vl
Check the fluid filler tube connec- DRILL TO SUIT
DISHED OR
tion at the transmission case or pan. FLAT WASHER
If leakage is found here, install a new " O.D., HEX. NUT W— 24
O-ring or tighten the fitting to the WELD
specified torque. TOGETHER
Check the fluid lines and fittings
between the transmission and the
cooler in the radiator tank for loose-
ness, wear, or damage. If leakage can-
not be stopped by tightening a fitting,
replace the damaged parts. RUBBER PLUG FLAT WASHER
Check the engine coolant in the ra- 1 Vi" DIA. X 2" Vs" O.D.
diator. If transmission fluid is present WING NUT
LONG Vl"
in the coolant, the cooler in the radia- HOLE THRU
>/ 2 "_13 THREAD
APPROXIMATELY
tor is probably leaking. 4 0 DUROMETER
STANDARD BOLT
The cooler can be further checked PLUG W - 1 3 X 4Vl"
LONG SQUARE
for leaks by disconnecting the lines THREAD END
CHAIN, 10" LONG
from the cooler fittings and applying WELD TOGETHER REMOVE HEAD
SECURELY—MUST
50-75 psi air pressure to the fittings. NOT LEAK
AND WELD TO
Remove the radiator cap to relieve the WASHER
STANDARD 1/8" FITTING-87971-S FOR
pressure build at the exterior of the oil RETAPPED DRAIN PLUG THREADS-USE
cooler tank. If the cooler is leaking 1/4" OVERSIZE FITTING-87973-S
and will not hold this pressure the VALVE D 1067-B
cooler must be replaced. Cooler re-
placement is described in the Cooling FIG. 2—Converter Leak Checking Tool
System Section of Group 11.
If leakage is found at either the
downshift control lever shaft or the CONVERTER LEAKAGE ANTI-STALL DASHPOT
manual lever shaft, replace either or CHECK CLEARANCE CHECK
both seals.
Inspect the pipe plug on the left If there are indications that the After the engine idle speed has been
side of the transmission case at the welds on the torque converter are properly adjusted, check the anti-stall
front. If the plug shows leakage, tor- leaking, the converter will have to be dashpot clearance. Follow the proce-
que the plug to specifications. If tight- removed and the following check dure given in Group 10 for checking
ening does not stop the leaks, replace made before the unit is replaced. and adjusting this clearance.
the plug. On a C6 transmission, a TV A leak checking tool (Fig. 2) can be
pressure plug is also provided on the made from standard parts. The tool MANUAL LINKAGE CHECKS
right rear side of the case. can be used to check all converters.
When converter drain plugs leak, 1. Install the plug in the converter Correct manual linkage adjustment
remove drain plugs with a six-point (Fig. 3) and expand it by tightening is necessary to position the manual
wrench. Coat the threads with FoMo- the wing nut. Attach the safety chains. valve for proper fluid pressure direc-
Co Perfect Seal Sealing Compound or 2. Install the air valve in one of the tion to the different transmission com-
its equivalent, and install the plugs. drain plug holes. ponents. Improperly adjusted manual
Torque the drain plugs to specifica- 3. Introduce air pressure into the
tion. Fluid leakage from the converter converter. Check the pressure with a
housing may be caused by engine oil tire gauge and adjust it to 20 psi.
leaking past the rear main bearing or 4. Place the converter in a tank of
from oil gallery plugs, or power steer- water. Observe the weld areas for
ing oil leakage from steering system. bubbles. If no bubbles are observed, it
Be sure to determine the exact cause may be assumed that the welds are
of the leak before repair procedures not leaking.
are started.
Oil-soluble aniline or fluorescent dyes
premixed at the rate of 1/2 teaspoon
of dye powder to 1/2 pint of transmis- ENGINE IDLE SPEED CHECK
sion fluid have proved helpful in locat-
ing the source of the fluid leakage. Check and, if necessary, adjust the
Such dyes may be used to determine engine idle speed, using the procedure
whether an engine oil or transmission given in Group 10.
fluid leak is present or if the fluid in If the idle speed is too low, the en-
Tire Pressure Gauge
the oil cooler leaks into the engine gine will run roughly. An idle speed
coolant system. A black light, how- that is too high will cause the vehicle D1921-A
ever, must be used with the fluorescent to creep, have harsh engagements and
dye solution. harsh closed-throttle downshifts. FIG. 3—Converter Leak Checking
Tool Installation
linkage may cause crossleakage and 2. Attach the pressure gauge to the releases when the transmission selec-
subsequent transmission failure. Refer control pressure outlet at the trans- tor lever is moved to a drive position.
to Linkage Adjustments in Part 7-2, mission (Figs. '., and 7). 4. Adjust the engine idle speed lo
7-3 or 7-4 for detailed manual linkage 3. Firmly apply the parking brake the specified rpm. If the engine idle
adjustment procedures. and start the engine. speed cannot be brought within limits
On a vehicle equipped with a vacu- by adjustment at the carburetor idle
CONTROL PRESSURE um brake release, apply the service adjustment screw, check the throttle
CHECK brakes. The parking brake can not be and downshift linkage for a binding
used because the brake automatically condition. If the linkage is satisfacto-
When the vacuum diaphragm unit is ry, check for vacuum leaks in the
operating properly and the downshift transmission diaphragm unit (Fig. 8
VACUUM DIAPHRAGM UNIT CLIP or 9) and its connecting tubes and
linkage is adjusted properly, all the
transmission shifts (automatic and hoses. Check all other vacuum oper-
kickdown) should occur within the ated units (such as the power brake)
road speed limits specified in Part 7-5. for vacuum leaks.
If the shifts do not occur within
limits or the transmission slips during
shift point, the following procedure is VACUUM UNIT CHECK
suggested to determine engine, trans-
mission, linkage, vacuum diaphragm
unit or valve body problems. NON-ALTITIDE
1. Using the automatic transmis- COMPENSATING TYPE
sion tester (Fig. 4), attach the tachom-
eter to the engine and the vacuum To check the vacuum unit for dia-
gauge to the transmission vacuum line phragm leakage, remove the unit from
at the vacuum unit (Fig. 5). the transmission. Use a distributor
I
| CONTROL PRESSURE TAKE-OFF HOLE
D 1823-A D1840-A
D2041-A
. 4—Rotunda ARE-2905 FIG. 6—Typical Vacuum FIG. 8—Testing Transmission

Automatic Transmission Tester Diaphragm and Control Pressure Vacuum Unit for Leakage
Connecting Point
T - FITTING
VACUUM DIAPHRAGM D 1643 -C
FIG. 5—Typical Vacuum Test FIG. 7—Vacuum Diaphragm and Control and TV Pressure Connecting
Line Connections Points—C6 Transmission
MAKE MARK HERE
BELLOWS INTACT BELLOWS FAILED
D 1791.A
FIG. 9—Checking Vacuum Unit Bellows
tester equipped with a vacuum pump visible with 12 pounds of force regis- a C6 transmission or 35 mph with an
(Fig. 8). Set the regulator knob so tered on the scale, the bellows are in- FMX transmission. This check will
that the vacuum gauge reads 18 inches tact. If the mark disappears before 4 determine if the governor pressure and
with the end of the vacuum hose pounds of force is exerted, the bellows shift control valves are functioning
blocked off. have failed and the diaphragm must properly.
Then connect the vacuum hose to be replaced. If the bellows are intact, During the shift point check opera-
the transmission vacuum unit. If the then perform various pressure checks. tion, if the transmission does not shift
gauge still reads 18 inches, the vacuT within specifications or certain gear
urn unit diaphragm is not leaking. As SHIFT POINT CHECKS ratios cannot be obtained, refer to the
the hose is removed from the trans- Ford Car and Truck Diagnosis Manu-
mission vacuum unit, hold a finger Check the minimum throttle up- al to resolve the problem.
over the end of the control rod. When shifts in D. The transmission should
the hose is removed, the internal start in first gear, shift to second, and AIR PRESSURE CHECKS
spring of the vacuum unit should push then shift to third, within the shift
the control rod outward. points specified in the specification A NO DRIVE condition can exist,
section. even with correct transmission fluid
ALTITUDE While the transmission is in third p r e s s u r e , b e c a u s e of inoperative
COMPENSATING-TYPE gear, depress the accelerator pedal clutches or bands. Erratic shifts could
through the detent (to the floor). The be caused by a stuck governor valve.
The vacuum diaphragm should be transmission should shift from third to The inoperative units can be located
checked for ruptured or damaged bel- second or third to first, depending on through a series of checks by subst-
lows. Check the diaphragm assembly the vehicle speed. ituting air pressure for the fluid pres-
as follows: Check the closed throttle downshift sure to determine the location of the
1. R e m o v e the diaphragm and from third to first by coasting down malfunction.
throttle valve rod from the transmis- from about 30 mph in third gear. The To make the air pressure checks,
sion. shift should occur within the limits drain the transmission fluid and re-
2. Insert a rod into the diaphragm, specified in the specification section. move the oil pan and the control valve
making sure that the rod is buttonec When the selector lever is at 2, the body assembly. The inoperative units
in the hole. Make a reference mark on transmission can operate only in sec- can be located by introducing air pres-
the rod where it enters the diaphragm ond gear. sure into the transmission case passa-
hole. With the transmission in third gear ges leading to the clutches, servos, and
3. Hold the assembly in such a way and road speed over 30 mph, the governor (Figs. 10, 11 or 12).
that the end of the rod is resting on transmission should shift to second
the weighing surface of a scale (Fig. gear when the selector lever is moved
9). from D to 2 to 1. The transmission HYDRAULIC SYSTEM BENCH
4. Gradually press down on the dia- will downshift from second or third to TESTS (FMX TRANSMISSION)
phragm assembly until the rod is first gear when this same manual shift
pressed into the diaphragm body. If is made below approximately 25 mph After the transmission has been as-
the reference mark on the rod is still with a C4 transmission, 30 mph with sembled and is ready for installation
FRONT PUMP FRONT GOVERNOR

DISCHARGE CLUTCH OUTPUT
PUMP IN
REVERSE AND
HIGH CLUTCH
INTERMEDIATE
SERVO RELEASE FORWARD
CLUTCH
PUMP OUT
CONVERTER IN
INTERMEDIATE
SERVO APPLY
FRONT FROM REAR

PUMP CONVERTER REAR CLUTCH
INTAKE SERVO
D1932-A
CONTROL
PRESSURE
TO PRIMARY
FIG. 12—Case Fluid Hole
THROTTLE VALVE
Identification—FMX Transmission
in the vehicle, check the hydraulic sys-

PRIMARY THROTTLE tem to make sure it is operating prop-
PRESSURE-TO-VALVE
LOW AND erly. These hydraulic tests can be
BODY
GOVERNOR PRESSURE REVERSE SERVO made on the bench so that most mal-
TO VALVE BODY functions of the system can be cor-
PRIMARY THROTTLE CONTROL PRESSURE
VALVE EXHAUST TO GOVERNOR rected before the transmission is in-
D1841-A
stalled in the vehicle.
FIG. 70—Case Fluid Passage Hole Identification—C4 Automatic TESTING TOOL

INSTALLATION
PUMP SUCTION REVERSE-HIGH FORWARD CLUTCH 1. Install a plug in the filler tube
SERVO RELEASE APPLY APPLY CONVERTER CHARGE hole in the case or pan, and pour
PUMP PRESSURE about four quarts of clean transmis-
SERVO APPLY
sion fluid into the t r a n s m i s s i o n
through the speedometer gear open-
ing.
2. Remove the vacuum diaphragm
unit and the diaphragm unit control
rod, and reinstall the vacuum unit if
these parts had been previously in-
stalled.
TV PRESSURE
LINE PRESSURE
TV PRESSURE
EXHAUST
-S>*REVERSE CLUTCH
GOVERNOR PRESSURE CONTROL PRESSURE APPLY
Tool-7003
OUT PUT GOVERNOR D1933-A
D1587-B
FIG. 7 7—Case Fluid Passage Hole Identification—C6 Automatic FIG. 73—Bench Testing Tool
Installation—Typical
3. Install the bench testing tool on bleeds the air from the pump. and note the gauge readings. The
the transmission. 5. Install the pressure gauge (77820 pressure readings on the bench test
4. Remove the 1/8-inch pipe plug or T57L-77820-A) as shown in Fig. must be within the limits as outlined
at the transmission case. Turn the 13. in Figure 13, for the engine idle check.
front pump in a clockwise direction at If pressure gauge readings are with-
75-100 rpm until a regular flow of PRESSURE TESTS in limits in all selector lever positions,
transmission fluid leaves the hole in install the vacuum diaphragm control
the transmission case. This operation Turn the front pump at 75-100 rpm rod unit.
TRANSMISSION FLUID DRAIN necessary, add enough fluid io the When one or more of the fluid
AND REFILL transmission to bring the level be- cooler steel tubes must be replaced,
tween the ADD and FULL marks on each replacement tube must be fabri-
Normal maintenance and lubrica- che dipstick. Do not overfill the trans- cated from the same size steel tubing
tion requirements do not necessitate mission. as the original line.
periodic automatic transmission fluid Using the old tube as a guide, bend
changes. FMX OK C6 the new tube as required. Add the
If a major repair, such as a clutch TRANSMISSION necessary fittings, and install the tube.
band, bearing, etc., is required in the After the fittings have been tight-
transmission, it will have to be re- 1. Raise the vehicle on a hoist or
ened, add fluid as needed, and check
moved for service. At this time the jack stands.
for fluid leaks.
converter, transmission cooler and 2. Place a drain pan under the
c o o l e r lines m u s t be thoroughly transmission.
VACUUM DIAPHRAGM
flushed to remove any dirt. 3. Loosen the pan attaching bolts
When filling a dry transmission and to drain the fluid from the transmis-
converter, install five quarts of fluid. sion. ADJUSTMENT NON-ALTITUDE
Start the engine, shift the selector 4. After the fluid has drained to the COMPENSATING TYPE
lever as outlined below, and check and level of the pan flange, remove the
add fluid as necessary. rest of the pan bolts working from the The C4 and C6 transmissions are
Following are the procedures for rear and both sides of the pan to equipped with an adjustable vacuum
partial drain and refill due to in- allow it to drop and drain slowly. diaphragm assembly. A similar ad-
vehicle repair operation. 5. When the fluid has stopped justable diaphragm has been released
draining from the transmission, re- for service with the FMX transmis-
move and thoroughly clean the pan sion. However, the FMX service dia-
C4 TRANSMISSION
and the screen. Discard the pan gas- phragm is not interchangeable with
ket. that used on C4 and C6 models.
1. On PEA models, disconnect the
6. Place a new gasket on the pan,
fluid filler tube from the transmission The vacuum diaphragm assembly
oil pan to drain the fluid. and install the pan on the transmis-
has an adjusting screw in the vacuum
sion.
On PEB and PEE models, loosen hose connecting tube (Fig. 14).
7. Add three quarts of fluid to the
the pan attaching bolts to drain the
fluid from the transmission. transmission through the filler tube.
2. When the fluid has stopped 8. Run the engine at idle speed for SPRING
SEAT
draining from the transmission, re- about two minutes, and then run it at
move and thoroughly clean the pan fast idle speed (about 1200 rpm) until
and the screen. Discard the pan gas- it reaches normal operating tempera-
ket. ture. Do not race the engine.
3. Place a new gasket on the pan, 9. Shift the selector lever through
and install the pan on the transmis- all the positions, place it at P, and
sion. check the fluid level. The fluid level
4. On PEA models, connect the should be above the ADD mark. If
filler tube to the pan and tighten the necessary, add enough fluid to the
THIS CLEARANCE CHANGED
fitting securely. transmission to bring the level be- BY ADJUSTING SCREW
5. Add three quarts of fluid to the tween the ADD and FULL marks on D1830-A
transmission through the filler tube. the dipstick. Do not overfill the trans-
6. Run the engine at idle speed for mission. FIG. 14—Adjustable Vacuum Unit
about two minutes, and then run it at
OIL COOLER TUBE
fast idle speed (about 1200 rpm) until The inner end of the screw bears
it reaches it's normal operating temp- against a plate which in turn bears
erature. Do not race the engine. When fluid leakage is found at the against the vacuum diaphragm spring.
7. Shift the selector lever through oil cooler, the cooler must be re- All readings slightly high or all
all the positions, place it at P, and p l a c e d . Cooler replacement is de- readings slightly low may indicate the
check the fluid level. The fluid level scribed in the Cooling System Section vacuum unit needs adjustment to cor-
should be above the ADD mark. If of Group 11. rect a particular shift condition.
For example, on a C4 transmission, cation Section have been performed lined in the Specification Section. All
if the pressure at 10 inches of vacuum and pressures are within specification tests must be within specifications.
was 120 psi and the pressure at 1.0 but shift feel is unsatisfactory, or if The adjustable vacuum unit must not
inch of vacuum was 170 psi, and up- the pressure is too high or too low at be used to allow for adjusting control
shifts and downshifts were harsh, a di- 10 inches of vacuum, the vacuum di- or TV pressures that are out of speci-
aphragm adjustment to reduce the diaphragm may be adjusted to improve fications. If these pressures are found
aphragm assembly spring force would the shift feel. to be out of specifications the cause
be required. If shifts are excessively harsh, the must be determined and corrected bef-
If the pressure readings are low, an diaphragm should be adjusted to re- ore making any adjustment.
adjustment to increase diaphragm duce control pressure by backing off
spring force is required. the adjusting screw (counterclock- NEUTRAL START SWITCH
To increase control pressure, turn wise). If shift quality is extremely soft, ADJUSTMENT AND
the adjusting screw in clockwise to re- control pressure should be increased REPLACEMENT—COLUMN SHIFT
duce control pressure, back the adjust- by turning the adjusting screw inward
ing screw out by turning it counte- (clockwise). There are two types of column-
rclockwise. One complete turn of the To adjust the vacuum diaphragm to mounted neutral start switches: A and
adjusting screw (360 degrees) will compensate for harsh shift quality, B. Type A switch has a parking brake
change idle line control pressure ap- first check control pressure in D, 2 brake-release vacuum valve. Type B
proximately 2-3 psi. After the adjust- and 1 at 10 inches manifold vacuum switches do not have a vacuum valve.
ment is made, install the vacuum line and note the pressure reading ob- The switches differ in appearance but
and make all the pressure checks as tained. Remove the T-fitting from the not in operation. Both switches are
outlined in the Specification Section. vacuum hose and back off the adjust- actuated by a removable steel lever,
The diaphragm should not be ad- ing screw (counterclockwise) by one which is installed in the shifter tube
justed to provide pressure below the full turn. Each full turn will reduce within the steering column assembly.
ranges shown in the Specification Sec- control pressure by approximately 2 The following procedures outline the
tion in order to change shift feel. To 1/2 psi at 10 inches of vacuum. Test steps necessary to correctly adjust and
do so could result in soft or slipping the vehicle for shift feel. If shift quali- replace the neutral start switch.
shift points and damage to the trans- ty is still harsh, a further adjustment
mission. should be made to reduce control SWITCH ADJUSTMENT
pressure. However, control pressure
ALTITUDE should not be reduced below the speci-
COMPENSATING TYPE fication shown for 10 inches of vacu- Neutral Position
um. If control pressure has been re-
The altitude—compensating di- duced to the low limit and shift feel is 1. With the selector lever held light-
aphragm is provided with an adjust- still excessively harsh, the clutches and ly against the neutral stop, attempt to
ment screw located in the vacuum band should be checked for correct start the engine. If the engine starts
connecting tube (Fig. 15). The adjus- operation. while holding the lever but does not
table feature allows control and TV To adjust the vacuum diaphragm to start when the lever is released, the
pressures to be adjusted (within limits) compensate for extremely soft shifts, shift linkage should be adjusted. If the
to correct soft or harsh shift feel. record the control pressure reading at engine does not start in either condi-
C o n t r o l and TV pressures are in- 10 inches of vacuum in D, 2 and 1, tion, adjust the switch.
creased or decreased by turning the then make an initial adjustment of 2. To adjust the switch in neutral,
adjusting screw. one full turn inward (clockwise). Test place the transmission selector lever
Before replacing or adjusting the di- the vehicle for shift feel and again ad- against the stop of the neutral detent
aphragm, it must first be determined just the diaphragm, if necessary. Con- position.
that the pressure or vacuum is actual- trol pressure at 10 inches of vacuum 3. Loosen the two retaining screws
ly out of specification and that the must not exceed the high limit shown that locate the switch on the steering
cause of the problem is not due to in the Specification Section. column (Fig. 16).
other items within the transmission or When the necessary adjustments 4. With the selector lever against
vacuum connecting lines. have been completed and shift feel is the neutral stop, rotate the switch
If the tests outlined in the Specifi- satisfactory, repeat all the tests out- until a start in the neutral position is
obtained. Then, tighten the switch at-
taching screws to 20 in-lbs torque.
ADJUSTING 5. With the switch properly adjust-
SCREW ed in neutral, place the selector lever
in the 1 position and push the park
reset button (Fig. 16) to the left
(counterclockwise) until it stops. The
park reset must be performed when-
ever the switch has been adjusted.
DIAPHRAGM
Park Position
PRIMARY SPRING
THROTTLE VALVE 1. Place the selector lever in the
D 1639-A park position, release the lever and at-
tempt to start. If the engine does not
FIG. 15—Altitude Compensating Type Vacuum Diaphragm start, reset the park adjustment.
2. To adjust the switch for the park

position, place the transmission selec-
tor lever in 1 and push the park reset
button (Fig. 16) to the left (counter-
clockwise) until it stops.
3. Check the operation of the
switch in each selector lever position.
The starter should engage in only the
neutral and park positions. Be sure to
perform the park reset if for any rea-
son the neutral switch is adjusted.
If, after performing the switch ad-
justments, the starter still will not en-
gage in the neutral or park positions,
replace the switch. Never replace the
neutral switch until the switch adjust-
ments have been made.
SWITCH REPLACEMENT
ACTUATOR LEVER INSTALLED
1. Disconnect the neutral start
switch wires at the plug connector. WHEN INSTALLING THE ACTUATOR
LEVER BE SURE THAT IT 1$ SEATED
2. Disconnect the vacuum hoses, if AS FAR FORWARD AGAINST THE SHIFT FORWARD
so equipped. TUBE BEARING AS IS POSSIBLE.
3. Remove the two screws securing D2019-A
the neutral start switch to the steering
column and lift the switch from the FIG. 17—Removing or Installing Neutral Start Switch Actuator Lever
column.
Check the column to be sure the
metal switch actuator is secure to the
shift tube and that it is seated as far position, place the switch on the col- ed in neutral, push the park reset but-
forward against the shift tube bearing umn and install the two attaching ton (Fig. 16) to the left (counterclock-
as is possible. Also check for a broken screws. Tighten the screws to 20 in-lbs wise) until it stops. The park reset
or damaged actuator. If it is broken torque. must be performed whenever the
or damaged, replace it as shown in 6. Remove the gauge pin (or No. switch has been adjusted or replaced.
Figure 17. 43 drill if used). 9. To adjust the switch for the park
4. Before installing a new switch to 7. Connect the switch wires to the position, place the transmission selec-
the column, check to see that the red plug connector and check for a start tor lever in 1 and push the park reset
neutral position gauge inserted in the in the neutral position. The starter button (Fig. 16) to the left (counter-
neutral pinning hole. If the pin is should engage with the selector lever clockwise) until it stops.
missing, align the two holes at the against the neutral stop. If not, loosen 10. Connect the vacuum hoses to
neutral pinning hole on top of the the attaching screws and move the the switch, if so equipped.
switch and install a No. 43 drill or switch just enough to engage the start- 11. Check the operation of the
0.092-0.093 inch gauge pin. er. Tighten the screws to 20 in-lbs tor- switch in each selector lever position.
5. While holding the selector lever que. The starter should engage in only the
against the stop in the neutral detent 8. With the switch properly adjust- neutral and park detent positions.
NEUTRAL SWITCH-TYPE A NEUTRAL SWITCH-TYPIE B

(USED ON VEHICLES WITH VACUUM (USED ON VEHICLES WITHOUT VACUUM
OPFRATED PARKING BRAKE) OPERATED PARKING BRAKE)
ATTACHING
D2018-A
FIG. 16—Ad justing Neutral Switch—Column Shift

STOP PIN
GROMMET
Tool - T67P-734LA
GROMMET
LEVER
CONTROL ROD REMOVAL GROMMET INSTALLATION
Tool - T67P-734LA
r 3/16"-1/4'
CONTROL ROD INSTALLATION

CONTROL ROD
STOP PIN
D 1742-A
FIG. 18—Removing or Installing Shift Linkage Grommet
MANUAL SHIFT LINKAGE the end of the control rod (Fig. 18) height shown in Fig. 18. The pin
GROMMET REPLACEMENT- and force the rod out of the grommet. height is determined by the length of
COLUMN SHIFT Remove the grommet from the manu- the rod end which is to be installed
al lever by cutting off the large shoul- into the grommet. If the pin height is
The manual lever assembly on ve- der with a sharp knife. The grommet not adjusted, the control rod may be
hicles equipped with a column shift in- must be removed from the manual pushed too far through the grommet
corporates an oil impregnated plastic lever and a new one installed each causing damage to the grommet re-
grommet in the end of the lever arm. time the rod is disconnected. taining lip.
A special tool T67P-7341-A is re- 2. Before installing a new grommet, 4. With the pin height properly ad-
quired to install the grommet in the adjust the stop pin to 1/2 inch and justed, position the control rod on the
manual lever, and to install the manu- coat the outside of the grommet with tool and force the rod into the grom-
al linkage rod into the grommet. Re- lubricant. Then, place the grommet on met until the groove in the rod seats
move and install the grommet as fol- the stop pin and force it into the man- on the inner retaining lip of the grom-
lows: ual lever hole. Turn the grommet sev- m e t . Be sure the rod p r o t r u d e s
1. Place the lower jaw of the tool eral times to be sure it is properly through the grommet approximately
between the manual lever and the con- seated. 1/4 inch after installation.
trol rod. Position the stop pin against 3. Readjust the stop pin to the
CLEANING with any type of detergent solution. son to believe that the converter con-
To clean these parts, wipe them off tains an excessive amount of foreign
with a lint-free cloth. New clutch material, it should be thoroughly
TRANSMISSION plates or bands should be soaked in cleaned. See the instructions provided
transmission fluid for fifteen minutes with the Rotunda Automatic Trans-
Clean the parts with suitable solvent before the plates or bands are as- mission Torque Converter and Cooler
and use moisture-free air to dry off all sembled. Cleaner LRE-60081.
the parts and clean out oil passages. CONVERTER OIL COOLER
The composition clutch plates,
bands and synthetic seals should not The c o n v e r t e r cannot be disas- When a clutch or band failure or
be cleaned in a vapor degreaser or sembled for cleaning. If there is rea- other internal trouble has occurred in
the transmission, any metal particles 3. Expand the split fiber bushing in 4. If there is an indication of scrap-
or clutch plate or band material that the turbine spline by tightening the ing, the trailing edges of the stator
may have been carried into the cooler adjusting nut. Tighten the adjusting blades may be interfering with the
should be removed from the system by nut until the tool is securely locked leading edges of the impeller blades.
flushing the cooler and lines before into the spline. In such cases, replace the converter.
the transmission is put back into serv- 4. Attach a dial indicator to the
ice. In no case should an automatic tool (Fig. 20 or 21). Position the indi- STATOR TO TURBINE
transmission having a clutch or band cator button on a converter pump INTERFERENCE CHECK
failure or other internal trouble result- drive hub, and set the dial face at 0
ing in fluid contamination, be put (zero). 1. Position the converter on the
back into service without first flushing 5. Lift the tool upward as far as it bench front side down.
the transmission oil cooler. will go and note the indicator reading. 2. Install a front pump assembly to
To flush the oil cooler, follow the The indicator reading is the total end engage the mating splines of the stator
instruct! on > provided with the Rotun- play which the turbine and stator support and stator, and pump drive
da Automatic Transmission Torque share. If the total end play exceeds gear lugs.
Converter and Cooler Cleaner LRE- the limits specified in Part 7-5, replace 3. Install the input shaft, engaging
60081. the converter unit. the splines with the turbine hub (Fig.
6. Loosen the adjusting nut to free 23).
the split bushing, and then remove the 4. While holding the pump station-
INSPECTION tool from the converter. ary, attempt to rotate the turbine with
the input shaft. The turbine should ro-
TURBINE AND STATOR END tate freely in both directions without
PLAY CHECK STATOR ONE-WAY CLUTCH any signs of interference or scraping
CHECK noise.
A special tool (Fig. 19) must be 5. If interference exists, the stator
used to check the condition of the 1. Install the stator outer race hold- front thrust washer may be worn, al-
converter. This special tool is used to ing tool in one of the four holes pro- lowing the stator to hit the turbine. In
check the turbine and stator end play vided in the stator (Fig. 20 or 21). such cases, the converter must be re-
and the operation of the one-way sta- 2. Insert the tool in the converter placed.
tor clutch. pump drive hub. As the tool enters the The c o n v e r t e r crankshaft pilot
converter, the pins will engage the sta- should be checked for nicks or dam-
tor clutch inner race spline. aged surfaces that could cause inter-
CRUISE-O-MATIC
3. Place a torque wrench on the ference when installing the converter
Too/-T58L-7902-A
C-4 AND C-6 TRANSMISSION tool (Fig. 20 or 21). The tool (and sta- into the crankshaft. Check the con-
Tool-T59P.7902.Bor 7937-B tor inner race) should turn freely verter front pump drive hub for nicks
clockwise (from the pump drive hub or sharp edges that would damage the
inside the converter). It should lock up pump seal.
and hold a 10 ft-lb pull when the
wrench is turned counterclockwise. OUTPUT SHAFT AND
Try the clutch for lockup and hold in PRIMARY SUN GEAR SHAFT
at least five different locations around (FMX TRANSMISSION)
the converter. On the C4 or C6 Auto-
matics, the metal ring holding the 1. Inspect the thrust surfaces and
locking tool will have to be held by journals for scores. Inspect the inter-
hand during this check. nal gear for broken or worn teeth.
4. If the clutch fails to lock up and 2. Inspect the aluminum sleeve for
hold a 10 ft-lb torque, replace the scores or leakage. Inspect the ring
converter unit. grooves for burrs.
3. Inspect the keyway and drive
STATOR TO IMPELLER ball pocket for wear, and inspect the
INTERFERENCE CHECK splines for burrs, twist or wear.
4. Inspect the output shaft sleeve
1. Position the front pump assem- for alignment with the governor drive
bly on a bench with the spline end of ball (Fig. 24).
the stator shaft pointing up (Fig. 22). 5. Inspect the external parking gear
ON C-4 AND C-6 TRANSMISSION 2. Mount a converter on the pump teeth for damage and the speedometer
Tool-T64L-7902-A D 1499-E so that the splines on the one-way drive gear teeth for burrs.
clutch inner race engage the mating 6. If either the output shaft or ring
FIG. 19—Converter Checking Tool splines of the stator support, and the gear has been replaced, place the as-
converter hub engages the pump drive sembled unit with the gear face down
gear. on the bench, push the shaft down-
3. While holding the pump station- ward, and check the clearance be-
1. Insert the tool (Fig. 19) into the ary, try to rotate the converter counter- tween the top of the snap ring and its
converter pump drive hub until it bot- clockwise. The converter should ro- groove (Fig. 25). If this clearance ex-
toms. tate freely without any signs of inter- ceeds 0.002 inch, replace the snap ring
2. Install the guide over the con- ference or scraping within the convert- with a thicker ring to reduce the clear-
verter pump drive hub. er assembly. ance to less than 0.002 inch. Selective
07-01-13 General Transmission Service
Tool -T59P-7902-C
or 7937-
(C4 and C6)
STATOR CLUTCH INNER RACE
Split Fiber Bushing
END PLAY CHECK
Torque Wrench
Torque Wrench
Tool-T64L.790~2-A
C4 TRANSMISSION
STATOR CLUTCH CHECK
D1842-A
FIG. 20—Typical Converter Checking Tool—C4 and C6 Transmissions
STATOR CLUTCH INNER RACE
Splh Fiber Bushing
END PLAY CHECK
Torque Wrench
Torque Wrench
Tool - T 5 8 L - 7 9 0 2 - B or 7 9 4 6 - A
TURBINE HUB
STATOR CLUTCH CHECK
D1934-A
FIG. 21—Typical Converter Checking Tool—FMX Transmission

GOVERNOR 12. Install the seal rings on the

DRIVE BALL shaft, and check for free movement in
POCKET
the grooves.
PINION CARRIER, ONE-WAY

CLUTCH AND CENTER
SUPPORT (FMX
TRANSMISSION)
1. Inspect the clutch outer race,

inner race, band surface, pinion gears,
bearings, and thrust washer (Fig. 27)
for roughness.
2. Inspect the center support bush-
ing for roughness.
FRONT PUMP AND STATOR 3. Inspect the one-way clutch cage
SUPPORT SHAFT rollers and springs for excessive wear
D1922-A or damage.
FIG. 22—Stator to Impeller PINION CARRIERS (C4 or

Interference Check C6 TRANSMISSIONS)
Individual parts of the planet car-

snap rings are available in several riers are not serviceable.
thicknesses for this purpose. 1. The pins and shafts in the planet
7. Inspect the rubber seal and stop assemblies should be checked for loose
ring at the front of the output shaft fit and/or complete disengagement.
spline. If wear or damage is evident, Use a new planet assembly if either
replace the parts. condition exists. Before installing a
TEAR DROP D1935-A
8. Inspect the primary sun gear for planet assembly, the shaft retaining
broken or worn teeth. Inspect all pins should be checked for adequate
thrust surfaces and journals for scores.
FIG. 24—Correct Position of staking. If staking does not appear
Check all fluid passages (Fig. 26) for Output Shaft Aluminum Sleeve adequate, the pins should be restaked
obstructions and leakage. Inspect the before installation. When restaking,
seal ring grooves for burrs. the retaining pins must not be driven
9. Inspect the sun gear shaft splines into the carrier any further than 0.040
for burrs and wear. inch below the surface of the carrier.
10. Check the fit of the seal rings 2. Inspect the pinion gears for dam-
in the grooves of the shaft. The rings aged or excessively worn teeth.
should enter the grooves freely with- 3. Check for free rotation of the
out bind. pinion gears.
11. Check the fit of the seal rings
in their respective bores. If equipped EXTENSION HOUSING
with cast iron seal rings, a clearance
of 0.002-0.009 inch should exist be- 1. Inspect the housing for cracks.
tween the ends of the rings. Inspect the gasket surface for burrs or
D1936-A warpage.
INPUT SHAFT
2. Inspect the bushing for scores or
FIG. 25—Checking Output wear.
FRONT PUMP AND Shaft Snap Ring Clearance 3. Inspect the rear seal for hard-
STATOR SUPPORT ness, cracks, or wear. If the seal
SHAFT
CONVERTER FRONT LUBRICATION REAR

LUBRICATION LUBRICATION
ASSEMBLY CLUTCH \ CLUTCH
FRONT CLUTCH
D1923-A D1937-A
FIG. 23—Stator to Turbine FIG. 26—Primary Sun Gear Shaft—Cross Sectional View
Interference Check
07-01-16 General Transmission bervice 07-01-16
4. Inspect the composition and the

steel clutch plates and the clutch pres-
sure plate for worn or scored bearing
CENTER SUPPORT " C A M TYPE" CLUTCH RACE surfaces. Replace all parts that are
PLANETARY CLUTCH deeply scored.
5. On FMX and C4 transmissions,
check the clutch plates for flatness
and fit on the clutch hub serrations.
Discard any plate that does not slide
freely on the serrations or that is not
flat.
6. Check the clutch hub thrust sur-
faces for scores and the clutch hub
splines for wear.
7. On an FMX transmission, in-
CHAMFER O N PRODUCTION spect the turbine shaft bearing sur-
PART, ONLY-SERVICE PART NOT CHAMFERED PLANET CARRIER
faces for scores. If excessive clearance
D1938-A
or scores are found, discard the unit.
Check the splines on the turbine
shaft for wear and replace the shaft if
FIG. 27—Roller Type Planetary Clutch, Carrier and Center Support the splines are excessively worn. In-
spect the bushing in the turbine shaft
shows wear or deterioration, replace serrations for scores or burrs. Minor for scores. On a C4 or C6 Automatic
the seal. scores or burrs may be removed with transmission, check the input shaft for
4. Inspect the seal counterbore and crocus cloth. Replace the clutch cylin- damaged or worn splines.
remove all burrs and scores with cro- der if it is badly scored or damaged.
cus cloth. 2. Check the fluid passage in the
clutch cylinder for obstructions. Clean FRONT PUMP AND
out all fluid passages. Inspect the STATOR SUPPORT
REAR CLUTCH (FMX)
AND REVERSE-HIGH CLUTCH clutch piston for scores and replace if
(C4 AND C6 AUTOMATIC) necessary. Inspect the piston check 1. Inspect the mating surfaces of
ball for freedom of movement and the pump body and cover for burrs.
1. Inspect the drum band surface, proper seating (Fig. 28). 2. Inspect the drive and driven gear
the bushing, and thrust surfaces for bearing surface for scores, and check
scores. Minor scores may be removed the gear teeth for burrs. Inspect the
with crocus cloth. Badly scored parts CLUTCH stator support splines for burrs and
must be replaced. CYLINDER CLIP
wear.
Inspect the clutch piston bore and 3. Check the fluid passages for ob-
the piston inner and outer bearing sur- structions.
faces for scores. Check the air bleed PISTON 4. If any parts other than the stator
ball valve in the clutch piston for free SEAL support are found defective, replace
movement. Check the orifice to make the pump as a unit. Minor burrs and
sure it is not plugged. scores may be removed with crocus
2. Check the fluid passages for ob- cloth. The stator support is serviced
structions. All fluid passages must be separately.
clean and free of obstructions. 5. On a C4 or C6 Automatic trans-
3. Inspect the clutch plates for wear mission, check the oil ring grooves in
and scoring and check the plates for the stator support for nicks, burrs or
fit on the clutch hub serrations. Re- damaged edges. On a C6 transmis-
place all plates that are badly scored, sion, check the large seal ring groove
worn or do not fit freely in the hub of the pump body for damage. Check
serrations. the gasket mating surface of the pump
4. Inspect the clutch pressure plate body for damage.
for scores on the clutch plate bearing
surface. Check the clutch release
spring(s) for distortion. REAR SUPPORT
5. On an FMX transmission, in- (FMX TRANSMISSION)
spect the needle bearing for worn rol-
lers. D1939-A
1. Inspect the gasket mating sur-
FRONT CLUTCH (FMX) faces for damage.
. 28—Clutch Piston Check
AND FORWARD CLUTCH 2. Inspect the support bushing for
(C4 OR C6 Valve scores.
TRANSMISSIONS) 3. Inspect the rear support fluid
3. Check the clutch release spring passages for obstructions.
1. Inspect the clutch cylinder thrust for distortion and cracks. Replace the 4. Check the fit of the fluid tubes in
surfaces, piston bore, and clutch plate spring if it is distorted or cracked. the support.
PRESSURE REGULATOR removed from the valves with crocus REAR SERVO (FMX)
(FMX TRANSMISSION) cloth. Replace the governor if the AND LOW-REVERSE SERVO
valves or body is deeply scored. (C4 TRANSMISSION)
1. Inspect the regulator body and 2. Check for free movement of the
cover mating surface for burrs. valves in the bores. The valves should 1. Inspect the servo body for cracks
2. Check all fluid passages for ob- slide freely of their own weight in the and the piston bore for scores.
structions. bores when dry. Inspect fluid passages 2. Check the fluid passages for ob-
3. Inspect the control pressure and in the valve body and counterweight structions.
converter pressure valves and bores for for obstructions. All fluid passages 3. Inspect the band and the struts
burrs and scores. Remove all burrs must be clean. for distortion. Inspect the band ends
carefully with crocus cloth. 3. Inspect the mating surfaces of for cracks.
4. Check free movement of the the governor body and governor dis- 4. Inspect the servo spring for dis-
valves in their bores. The valves tributor (C4 or C6 Automatic) for tortion.
should fall freely into the bores when burrs and distortion. Mating surfaces 5. Inspect the band lining for exces-
both the valve and bore are dry. must be smooth and flat. sive wear and bonding to the metal
5. Inspect the valve springs and 4. Check the mating surface of the band.
spacers for distortion. governor valve and the counterweight 6. On an FMX transmission, check
on a FMX transmission for burrs or the servo body to case mating surface
scratches. for burrs. Check the accumulator pis-
CONTROL VALVE BODY 5. When cleaning the governor as- ton and the check valve for freedom
sembly (C4 Automatic), the oil screen of movement. Check the actuating
1. Clean all parts thoroughly in should be removed from the collector lever socket for scores.
clean solvent, and then blow them dry body and thoroughly blown out with 7. Replace seals that are damaged.
with moisture-free compressed air. compressed air.
2. Inspect all valve and plug bores CASE
for scores. Check all fluid passages for
obstructions. Inspect the check valve FRONT SERVO (FMX) Inspect the case for cracks and
for free movement. Inspect all mating AND INTERMEDIATE stripped threads. Inspect the gasket
surfaces for burrs or distortion. In- SERVO (C4 AND C6 surfaces and mating surfaces for
spect all plugs and valves for burrs AUTOMATIC) burrs. Check the vent for obstructions,
and scores. Crocus cloth can be used and check all fluid passages for ob-
to polish valves and plugs if care is 1. Inspect the servo bore for cracks structions and leakage (Figs. 10, 11
taken to avoid rounding the sharp and the piston bore and the servo pis- and 12).
edges of the valves and plugs. ton stem for scores. Check fluid pas- Inspect the case bushing for scores.
3. Inspect all springs for distortion. sages for obstructions. Replace seals Check all parking linkage parts for
Check all valves and plugs for free that are damaged. wear or damage.
movement in their respective bores. 2. On an FMX transmission, check
Valves and plugs, when dry, must fall the actuating lever for free movement, ONE-WAY CLUTCH
from their own weight in their respec- and inspect it for wear. If necessary to
tive bores. replace the actuating lever or shaft, 1. Inspect the outer and inner races
4. Roll the manual valve on a flat remove the retaining pin and push the for scores or damaged surface area
surface to check it for a bent condi- shaft out of the bracket. where the rollers contact the races. If
tion. Inspect the adjusting screw threads the outer race on the C6 transmission
and the threads in the lever for dam- is damaged, the low-reverse clutch hub
age. must be replaced.
GOVERNOR 3. Check the servo spring and servo 2. Inspect the rollers and springs
band strut(s) for distortion. for excessive wear or damage.
1. Inspect the governor valves and 4. Inspect the cover seal and gasket 3. Inspect the spring and roller case
bores for scores. Minor scores may be cover sealing surface for defects. for bent or damaged spring retainers.
07-02^01 C4 Automatic Transmission 0702-01
PART 7-2 C4 Automatic Transmission

MODEL APPLICATION
Thunderbird
Continental-
Continental
All Models
Montego
Mustang
Mercury
Fairiane
Mark III
Lincoln-
Cougar
Meteor
Falcon
Ford
PEA-A2 240-1V Column X X
PEA-MI 302-2V Column X X
PEA-N1 3O2-2V Console X X
PEB-B2 200-1V Console X
PEB-C2 17O-1V,2OO-1V Column X
PEE-M 302-2V Console X X
PEE-V 302-2V Column X X X
PEE-AC 302-2V Console X
PEE-AD 250-1V Console X
PEE-AE 250-1V Column X X
PEE-AF 250-1V Console X X
All Models
All Models
COMPONENT INDEX COMPONENT INDEX
ASSEMBLY OF TRANSMISSION 02-27 GOVERNOR AND OIL DISTRIBUTOR

BAND ADJUSTMENTS Cleaning and Inspection 01-16
Intermediate Band 02-09 Disassembly and Overhaul 02-26
Low-Reverse Band 02-09 Removal and Installation 02-10
CONTROL VALVE BODY INTERMEDIATE SERVO
Cleaning and Inspection 01-16 Cleaning and Inspection 01-16
Disassembly and Overhaul 02-19 Parts Repair or Replacement 02-16
Removal and Installation 02-11 Removal and Installation 02-09
DESCRIPTION 02-02 INPUT SHELL AND SUN GEAR
DISASSEMBLY AND OVERHAUL OF Disassembly and Overhaul 02-25
TRANSMISSION 02-12 LOW-REVERSE BRAKE DRUM BUSHING
End Play Check 02-12 Disassembly and Overhaul 02-26
DOWNSHIFT LINKAGE LOW-REVERSE SERVO
Adjustments 02-04 Cleaning and Inspection 01-16
Parts Repair or Replacement 02-17 Parts Repair or Replacement 02-16
EXTENSION HOUSING LOW-REVERSE SERVO PISTON
Cleaning and Inspection 01-14 Removal and Installation 02-09
Removal and Installation 02-10 MANUAL LINKAGE
EXTENSION HOUSING BUSHING Adjustments 02-04
Removal and Installation 02-10 Parts Repair or Replacement 02-17
EXTENSION HOUSING REAR SEAL NEUTRAL START SWITCH-CONSOLE
Removal and Installation 02-10 SHIFT
FORWARD CLUTCH Adjustment 02-04
Cleaning and Inspection 01-15 Removal and Installation 02-07
Disassembly and Overhaul 02-24 (Refer to Part 7-1 for Column Shift Adjus
FORWARD CLUTCH HUB AND RING ment and Removal and Installation Pro-
GEAR cedures)
Disassembly and Overhaul 02-25 OIL PAN
FRONT PUMP Removal and Installation 02-09
Cleaning and Inspection 01-15 REVERSE-HIGH CLUTCH
Disassembly and Overhaul 02-21 Cleaning and Inspection 01-15
J7-02-02 C4 Automatic Transmission 07-02-02
All Models
All Models
Disassembly and Overhaul 02-22 Adjustments 02-04

REVERSE RING GEAR AND HUB TRANSMISSION (Complete)
Disassembly and Overhaul 02-26 Removal and Installation 02-11
SELECTOR LEVER-CONSOLE SHIFT TRANSMISSION CASE BUSHING
THROTTLE LINKAGE TRANSMISSION CASE THREAD REPAIR 02-18
DESCRIPTION
CONVERTER HOUSING, STATOR SUPPORT
CONVERTER FRONT PUMP CASE INTERMEDIATE REVERSE RING GEAR GOVERNOR
BAND LOW REVERSE BAND DISTRIBUTOR
LOW-REVERSE DRUM - , ONE-WAY SLEEVE
FORWARD CLUTCH CLUTCH GOVERNOR
HUB AND RING GEAR DISTRIBUTOR
INPUT
SHELL
SPLINE SEAL
EXTENSION
HOUSING
SPEEDOMETER
DRIVE GEAR
GOVERNOR
REVERSE PLANET CARRIER
FRONT PLANET CARRIER
PARK TOGGLE LEVER
LOW-REVERSE SERVO PISTON
FORWARD CLUTCH
CONTROL LEVERS
REVERSE-HIGH CLUTCH
IMPELLER CONTROL VALVE BODY

D 1474-A
FIG. 1—C4 Automatic Transmission

TRANSMISSION MODEL
DESCRIPTION
Figure 1 shows the location of the
converter, front pump, clutches, gear
train and most of the internal parts
used in the C4 transmission. The iden-
tification tag (Fig. 2) is located under
the lower front intermediate servo
cover bolt. The tag shows the model
prefix and suffix, assembly part num-
bers, and the built date code. The
service identification number indicates ASSEMBLY PART NO. BUILD DATE SHIFT D1846-A
changes to service details which affect
interchangeability when the transmis- FIG. 2—Identification Tag
sion model is not changed. For inter- The C4 transmission is a three the three forward gear ratios, and also
pretation of this number, see the Mas- speed unit capable of providing auto- capable of providing manual selection
ter Parts Catalog. matic upshifts and downshifts through of first and second gears.
07-02-03 C4 Automatic Transmission 07-02-03
CONVERTER PRIMARY GOVERNOR

FORWARD CLUTCH ONE-WAY
CLUTCH
DRAIN-BACK
CONVERTER VALVE
CHECK VALVE
FRONT LUBE LOW AND
AND DIRECT REVERSE
CONVERTER CLUTCH SERVO
PRESSURE
RELIEF VALVE L
SECONDARY
INTERMEDIATE GOVERNOR
BAND
ACCUMULATOR CUT-BACK VALVE
VALVE
2-3 BACK-OUT
VALVE
MAIN MANUAL LOW

REGU- VALVE
LATOR 1-2 SHIFT
VALVE VALVE THROTTLE
D 2 VALVE MODULATOR
VALVE
THROTTLE
BOOST VALVE
PRESSURE
BOOSTER
VALVE
DOWNSHIFT VALVE
LINE
COASTING
BOOST ENGINE MANIFOLD VACUUM
VALVE LESS THAN 2 0 INCHES
PRIMARY
THROTTLE VACUUM
VALVE DIAPHRAGM
(CASE)
OIL SCREEN
I) 1724-E
FIG. 3—Hydraulic Control System

The transmission consists essentially one-way clutch and a hydraulic con- mission proper are the intermediate
of a torque converter, planetary gear trol system (Fig. 3). and low-reverse bands.
train, two multiple disc clutches, a The only adjustments on the trans-
2 IN-VEHICLE ADJUSTMENTS AND REPAIRS

CONTROL LINKAGE ADJUSTMENTS
The transmission control linkage
adjustments should be performed in COLUMN SHIFT LEVER
the order in which they appear in this
section of the manual.
THROTTLE AND DOWNSHIFT
LINKAGE ADJUSTMENTS
Adjusting the throttle linkage is im-
portant to be certain the throttle and
kickdown systems are properly adjust-
ed. The kickdown system should come
in when the accelerator is pressed
through detent, and not before detent.
R e f e r to Group 10 for detailed
throttle and downshift linkage adjust-
TRANSMISSION
ment procedures. MANUAL LEVER
D2020-A
MANUAL LINKAGE
ADJUSTMENTS FIG. 4—Manual Linkage—Column Shift—Ford and Meteor
Column Shift
1. Place the selector lever in the D
position tight against the D stop.
2. Loosen the shift rod adjusting
nut at point A (Fig. 4 or 5). "COLUMN
3. Shift the manual lever at the SHIFT LEVER
transmission into the D detent posi-
tion, third from the rear.
4. Make sure that the selector lever
has not moved from the D stop; then,
tighten the nut at point A to 10-20 ft- POINT A
lbs.
5. Check the transmission operation
for all selector lever detent positions.
Console Shift
1. Position the transmission selec-
tor lever in D position. SHIFT ROD D2021-A
2. Raise the vehicle and loosen the
manual lever shift rod retaining nut FIG. 5—Typical Manual Linkage—Column Shift—Fairlane,
(Fig. 6, 7 or 8). Move the transmis- Falcon and Montego
sion manual lever to the D position,
fourth detent position from the back ly adjusted, check the starter en- forth until the gauge pin (No. 43 drill)
of the transmission. gagement circuit in all positions. The can be fully inserted into the gauge
3. With the transmission selector circuit must be open in all drive posi- pin holes (Fig. 9).
lever and manual lever in the D positions and closed only in park and neu- 6. Place the transmission selector
tions, torque the attaching nut 10 to tral. lever firmly against the stop of the
20 ft-lbs. 2. Remove the four screws and neutral detent position.
4. Check the operation of the trans- plates securing the selector lever 7. Slide the combination starter
mission in each selector lever position. handle to the lever. Remove the neutral and back-up light switch for-
handle and detent control. ward or rearward as required, until
NEUTRAL START SWITCH 3. Remove two screws from the the switch lever contacts the selector
ADJUSTMENT—CONSOLE SHIFT rear of the console top panel. Pull the lever actuator. If an adjustment can
On v e h i c l e s equipped with a panel back to unhook it from the not be made by rotating the switch,
column-mounted neutral start switch, front of the console and remove the loosen the actuator lever attaching
refer to Part 7-1, Section 2, for the panel. bolt and adjust the lever (Fig. 9).
adjustment procedures. 4. Loosen the two combination 8. Tighten the neutral start switch
starter neutral and back-up light attaching screws. If the actuator lever
FORD-METEOR switch attaching screws (Fig. 9). was adjusted, tighten the actuator
1. With the manual linkage proper- 5. Move the selector lever back and lever bolt to 6-10 ft-lbs.
07-02-05 C4 Automatic Transmission 07 02-05
7E263
NUT
382384-S4
XP3 TRANSMISSION
D 1813-A
FIG. 6—Manual Linkage—Console Shift—Ford and Meteor
TRANSMISSION
MANUAL
LEVER
FLAT WASHER
372285-S8
S D
MANUAL ™
LINKAGE ROD
7340
D1825-A
FIG. 7—Manual Linkage—Console Shift—Fairlane and Montego

PLUG-7256 •HANDLE-7217
BUTTON-7C439
DIAL HOUSING
ASSEMBLY-7E034
POINTER BACK-UP
SHIELD
ENGAGE FLATS OF STUD IN SLOT OF

ROD BEFORE APPLYING TORQUE
D2022-A
FIG. 8—Manual Linkage—Console Shift—Mustang
ACTUATOR LEVER ATTACHING BOLT lever and secure with the four plates
and attaching screws.
FAIRLANE-MONTEGO
1. With the manual linkage proper-

ly adjusted, check the starter en-
gagement circuit in all positions. The
circuit must be open in all drive posi-
tions and closed only in park and neu-
tral.
Gauge Pin
(No.43 D r i l l )
NEUTRAL START
SWITCH
D1812-A
FIG. 9—Neutral Start Switch Adjustments—Console Shift—Ford-Meteor
9. Turn the ignition key to the 10. Place the console top panel on
Dl759-A
ACC position and place the selector the console and install the retaining
lever in the reverse position and check screws. 70—Neutral Start Switch
the operation of the back-up lights. 11. Position the selector lever de- Adjustments—Console Shift—
Turn the key off. tent control and handle on the selector Fairlane-Montego
2. Remove the selector lever handle adjusted, loosen the two switch attach- 2. Remove the trim panel from the
from the lever. ing bolts (Fig. 11). top of the console.
3. Remove the trim panel from the 2. With the transmission manual 3. Remove the cover and dial indi-
top of the console. lever in neutral, rotate the switch and cator as an assembly.
4. Remove the cover and dial indi- insert the gauge pin (No. 43 drill 4. Remove the four screws that se-
cator as an assembly. shank end) into the gauge pin holes of cure the selector lever retainer to the
5. Remove the four screws that se- the switch. The gauge pin has to be selector lever housing. Lift the retainer
cure the selector lever retainer to the inserted to a full 31/64 inch into the from the housing.
selector lever housing. Lift the retainer three holes of the switch (Fig. 11). 5. Remove the two screws securing
from the housing. 3. Torque the two switch attaching the neutral start switch to the selector
6. Loosen the two combination bolts to specification. Remove the lever housing. Disconnect the neutral
starter neutral and back-up light gauge pin from the switch. start switch wires at the plug connec-
switch attaching screws (Fig. 10). 4. C h e c k the o p e r a t i o n of the tor and remove the switch.
7. Move the selector lever back and switch. The engine should start only 6. Position the neutral start switch
forth until the gauge pin (No. 43 drill) with the transmission selector lever in to the selector lever housing and in-
can be fully inserted into the gauge Neutral and Park. stall the two attaching screws.
pin holes (Fig. 10). 7. With the selector lever in neu-
NEUTRAL START SWITCH
8. Place the transmission selector tral, move the selector lever back and
REPLACEMENT—CONSOLE SHIFT
lever firmly against the stop of the forth until the gauge pin (No. 43 drill)
neutral detent position. On vehicles equipped with a column can be fully inserted into the gauge
9. Slide the combination starter mounted neutral start switch, refer to pin holes (Fig. 10).
neutral and back-up light switch for- Part 7-1, Section 2, for the replace- 8. Place the transmission selector
ward or rearward as required, until ment procedures. lever firmly against the stop of the
the switch actuating lever contacts the neutral detent position.
FORD-METEOR 9. Slide the combination starter
selector lever.
10. Tighten the switch attaching 1. Remove the four screws and neutral and back-up light switch for-
screws and remove the gauge pin. p l a t e s s e c u r i n g the selector lever ward or rearward as required, until
Check for starting in the park posi- handle to the lever. Remove the the switch actuating lever contacts the
tion. handle and detent control. selector lever.
11. Turn the ignition key to the 2. Remove the two screws from the 10. Tighten the switch attaching
ACC position and place the selector rear of the console top panel. Pull the screws and remove the gauge pin.
lever in the reverse position and check panel back to unhook it from the 11. Connect the neutral start switch
the operation of the back-up lights. front of the console and remove the wires to the plug connector and check
Turn the key off. panel. for starting in the park position.
12. Position the selector lever re- 3. Remove the two screws securing 12. Position the selector lever re-
tainer to the selector lever housing. the dial indicator assembly to the se- tainer to the selector lever housing.
Install the four attaching screws. lector lever housing and remove the Install the attaching screws.
13. Install the cover and dial indi- indicator assembly. 13. Install the cover and dial indi-
cator. 4. Disconnect the neutral start cator.
14. Install the trim panel on the top switch wires at the plug connector. 14. Install the trim panel on the top
of the console. Install the selector Remove the wires from under the re- of the console. Install the selector
lever handle. taining clip. lever handle
5. Remove the two screws securing
MUSTANG the neutral start switch to the selector
lever housing and remove the switch MUSTANG
1. With the manual lever properly
(Fig. 9).
1. Remove the downshift linkage
NEUTRAL START 6. Position the neutral start switch
SWITCH
rod from the transmission downshift
to the selector lever housing and in-
lever.
stall the two attaching screws.
2. Apply penetrating oil to the
7. Adjust the neutral start switch as
downshift lever shaft and nut. Remove
outlined under the Neutral Start
the transmission downshift outer lever
Switch Adjustment procedures in this
retaining nut and lever (Fig. 11).
section.
3. Remove the two neutral start
8. Connect the neutral start switch
switch attaching bolts.
wires to the plug connector. Position
4. Disconnect the multiple wire
the wires in the retaining clip and
connector. Remove the neutral switch
close the clip.
from the transmission.
9. Place the console top panel on
the console and install the retaining 5. Install the neutral start switch on
screws. the transmission. Install the two at-
10. Position the selector lever de- taching bolts.
tent control and handle on the selector 6. With the transmission manual
lever and secure with the four plates lever in neutral, rotate the switch and
and attaching screws. install gauge pin (No. 43 drill) into
(D1439-A
the gauge pin hole (Fig. 11).
FIG. 11—Neutral Start Switch FAIRLANE-MONTEGO 7. Tighten the switch attaching
Adjustments—Console Shift— 1. Remove the selector lever handle bolts to specification and remove the
Mustang from the lever. gauge pin.
8. Install the outer downshift lever

and attaching nut, and torque the nut
to specification. Install the downshift
linkage rod to the downshift lever. DETENT PAWL
9. Install the switch wires. Connect
the wire multiple connector. Check
the operation of the switch in each de-
tent position. The engine should start
only with the transmission selector
lever in N (neutral) and P (park).
SELECTOR LEVER
LOCK NUT
REPLACEMENT—CONSOLE SHIFT DETENT PAWL
FORD-METEOR ADJUSTMENT SCREW
DETENT PLATE
1. Raise the vehicle and disconnect
the link assembly from the selector
lever arm (Fig. 6). D 1644-A
2. Lower the vehicle. Remove the
four screws and plates securing the se- FIG. 72—Typical Selector Lever Detent Pawl Adjustment
lector lever handle to the lever. Re-
move the handle and detent control. 5. Remove the console trim panel 19. Place the console in position
3. Remove the two screws from the from the top of the console. Remove and install the retaining bolts. Tighten
rear of the console top panel. Pull the the console retaining screws and re- the selector lever housing attaching
panel back to unhook it from the move the console. bolts.
front of the console and remove the 6. Remove the cover and dial indi- 20. Position the console trim panel
panel. cator as an assembly. and secure it with the attaching
4. Disconnect the neutral start 7. Remove the four screws that se- screws.
switch wires at the plug connector. cure the selector lever retainer to the 21. Install the handle and the but-
Disconnect the bulb socket from the selector lever housing. Lift the retainer ton on the selector lever. Secure the
quadrant. from the housing. handle with the set screw.
5. Remove the four bolts that at- 8. Disconnect the neutral start 22. Secure the manual linkage rod
tach the selector lever housing to the switch wires at the plug connector. to the arm with two insulating wash-
floor pan and remove the selector Disconnect the bulb socket from the ers, a flat washer and a retainer (Fig.
lever and housing. selector lever housing. 7).
6. Position the new selector lever 9. Remove the three bolts that se- 23. Adjust the linkage as required.
r
and housing assembly on the floor pan cure the selector lever control housing J the vehicle.
and install the attaching bolts. to the console. Lift the selector lever MUSTANG
7. Connect the bulb socket to the housing from the console.
10. Remove the selector lever to 1. Raise the vehicle and remove the
quadrant and the neutral start switch manual lever control rod attaching nut
wires to the plug connector. housing attaching nut. Remove the
lever from the housing. (Fig. 8).
8. Raise the vehicle and secure the 2. Lower the vehicle, remove the se-
link assembly to the selector lever arm 11. Install the selector lever in the
housing and install the attaching nut. lector lever handle attaching screw.
with the bushing, insulator, flat wash- 3. Remove the dial housing attach-
er and cotter pin (Fig. 6). Lower the Torque the nut to 20 to 25 ft-31bs.
12. Install the selector lever handle. ing screws and the housing.
vehicle.
13. Position the selector lever as 4. Remove the two pointer back-up
9. Place the console top panel on shield attaching screws and remove
the console and install the retaining shown in Figure 12. With a feeler
gauge, check the clearance between the shield.
screws. 5. Disconnect the dial indicator
10. Position the selector lever de- the detent pawl and plate. The clear-
ance should be 0.005 to 0.010 inch. If light.
tr*rtt control and handle on the selector 6. Remove the selector housing and
lever and secure with the four plates necessary adjust the height of the de-
tent pawl as shown in Figure 12. lever assembly attaching bolts. Re-
and attaching screws. move the selector lever and housing.
14. Remove the handle from the se-
lector lever. 7. Remove the selector lever to
FAIRLANE-MONTEGO housing attaching nut. Remove the
15. Position the selector lever hous-
1. Raise the vehicle on a hoist or ing in the console and install the three lever from the housing.
jack stands. attaching bolts. Do not tighten the at- 8. Install the selector lever in the
2. Remove the retainer that secures taching bolts at this time. housing and install the attaching nut.
the manual linkage rod to the lower 16. Connect the bulb socket to the Torque the nut to 20 to 25 ft-lbs.
end of the manual lever (Fig. 7). selector lever housing and the neutral 9. Install the selector lever handle.
3. Remove the flat washer and two start switch wires to the plug connec- 10. Position the selector lever as
insulator washers and disconnect the tor. shown in Figure 12. With a feeler
rod from the arm. 17. Position the selector lever re- gauge check the clearance between the
4. Working from inside of the vehi- tainer to the selector lever housing. detent pawl and plate. The clearance
cle, remove the selector lever handle Install the four attaching screws. should be 0.005 to 0.010 inch. If nec-
attaching screw. Lift the handle off 18. Install the cover and dial indi- essary adjust the height of the detent
the selector lever. cator. pawl as shown in Figure 12.
11. Remove the handle from the se- 3. Back off the adjusting screw ex- INTERMEDIATE SERVO
lector lever. actly 1 3/4 turns. REPLACEMENT
12. Install the selector housing and 4. Hold the adjusting screw from
1. Raise the vehicle and remove the
lever assembly as shown in Figure 8. turning and torque the lock nut to
four servo cover-to-case attaching
Torque the attaching bolts 4-6 ft-lbs. specification.
bolts.
13. Connect the dial indicator light.
LOW-REVERSE BAND 2. Remove the servo cover, gasket,
14. I n s t a l l the pointer back-up
piston, and piston return spring. Re-
shield on the housing and lever assem-
1. Clean all the dirt from the band move the piston from the cover (Fig.
bly.
adjusting screw area. Remove and dis- 45).
15. Install the dial housing and
card the locknut. 3. Remove the piston seals and
tighten the attaching screws.
2. Install a new locknut on the ad- cover gasket.
16. Install the selector lever handle
justing screw with the tools shown in 4. Install new piston seals on the
and tighten the attaching screw.
Fig. 14, tighten the adjusting screw piston. Lubricate the piston seals with
17. Position the selector lever in the
until the tool handle clicks. The tool is clean transmission fluid. Install the
D position.
a pre-set torque wrench which clicks servo piston in the cover.
18. Raise the vehicle. Install the
and overruns when the torque on the 5. Install the piston retvrn spring in
transmission manual lever rod to the
adjusting screw reaches 10 ft-lbs. the case. Place a new gasicet on the
selector lever. Adjust the manual link-
3. Back off the adjusting screw ex- cover. Install the piston and cover into
age.
actly 3 full turns. the transmissic se. Use two 5/16
19. Lower the vehicle and check the
4. Hold the adjusting screw from 18 x 1 1/4 bolts, 180 degrees apart to
transmission operation in each selo:c-
turning and torque the lock nut to position the cover against the case.
tor lever detent position.
specification. 6. Install the two servo cover at-
taching bolts. Remove the two 1 1/4
BAND ADJUSTMENT
inch bolts and install two attaching
INTERMEDIATE BAND bolts. Torque the bolts to specifica-
OIL PAN AND CONTROL tion.
1. Clean all the dirt from the band VALVE BODY REPLACEMENT
adjusting screw area. Remove and dis- 7. Adjust the intermediate band.
card the locknut. Lower the vehicle and check the trans-
1. Raise the vehicle so the transmission fluid level.
2. Install a new locknut on the ad- mission oil pan is accessible.
justing screw. With the tool shown in 8. If the band can not be adjusted
2. Drain the transmission fluid. properly, the struts are not in posi-
Fig. 13, tighten the adjusting screw If the same fluid is to be used
until the tool handle clicks. The tool is tion. Remove the pan and valve body.
again, filter the fluid through a 100 Install the struts, valve body, pan, and
a pre-set torque wrench which clicks mesh screen. Re-use the fluid only if it
and overruns when the torque on the adjust the band. Refill the transmis-
is in good condition. sion with fluid.
adjusting screw reaches 10 ft-lbs. 3. Remove the transmission fluid
pan attaching bolts, pan and gasket. LOW-REVERSE SERVO
4. Remove the valve body-to-case PISTON REPLACEMENT
attaching bolts (Fig. 25). Remove the 1. Raise the vehicle on a hoist.
valve body from the case and the 2. Loosen the reverse band adjust-
transmission inner control levers. ing screw lock nut. Tighten the reverse
5. Refer to the Major Repair Oper- band adjusting screw to 10 ft-lbs tor-
ation for control valve body repair op- que. (Tightening the screw will insure
eration. that the band strut will be held against
6. Thoroughly clean and remove all the case by the band, preventing it
the gasket material from the pan and from falling down when the reverse
the pan mounting face of the case. In- servo piston assembly is removed).
stall the valve body to the case, engag- 3. Remove the four servo cover to
I D1854-A ing the transmission inner control le- case attaching bolts. Remove the iden-
FIG. 13—Adjusting Intermediate vers with the valve body manual and tification tag and vent tube retaining
Band downshift valves. clip. Remove the servo cover and s»»^
7. Install the eight valve body to from the case.
Tool-T59P-77370-B case attaching bolts. Torque the bolts 4. Remove the servo piston from
to specification. Operate the external the case. The piston seal cannot be re-
manual and downshift levers to check placed, without replacing the piston.
for proper travel of the valve body The seal is bonded to the piston.
manual and downshift valves. 5. To remove the piston from the
8. Place a new gasket on the pan. stem, insert a small screw driver in the
Install the pan and attaching bolts. hole of the piston (Fig. 44). Remove
Torque the bolts to specification. In- the piston attaching nut.
stall the fluid filler tube if it was re- 6. Position the accumulator spring
moved. Torque the attaching nut to and spacer (Fig. 43) on the piston
specifications. stem. Make sure the crowned side of
9. Lower the vehicle and fill the the spring is facing toward the rod.
D1855-A
transmission with fluid. Check the Install.a new piston on the piston re-
FIG. 14—Adjusting Low-Reverse transmission pan area for fluid leak- taining shaft. Install the attaching nut.
Band age. Torque the nut to specification.
7. Install the piston into the case.

Install a new seal on the cover. Install
the cover by using two 5/16—18 bolts,
1 1/4 inch long, at 180 degrees apart
to position the servo cover on the
case. Install the vent tube retaining Tool— I775-AB
clip and identification tag. Install two

cover attaching bolts. Remove the two
installing bolts and install the last two
a t t a c h i n g bolts. Torque the cover-
to-case attaching bolts to specifica-
tion. Tool— T50T-100-A
D 1927-A
8. Adjust the low-reverse band.
Lower the vehicle and check the trans- FIG. 15—Removing Extension Housing
mission fluid level.
EXTENSION HOUSING 5. Loosen the extension housing at-
9. If the band can not be adjusted
taching bolts to drain the transmission
properly, the struts are not in posi-
fluid. Disconnect the exhaust inlet
tion. Remove the fluid pan and valve
pipes at the manifold and lower the
body. Install the struts, valve body,
inlet pipes.
pan and adjust the band. Refill the
6. R e m o v e the six e x t e n s i o n
transmission with fluid.
housing-to-case attaching bolts and re-
EXTENSION HOUSING move the extension housing.
rIG. 16—Removing Extension 7. Remove the governor housing to
BUSHING AND REAR
Housing Bushing governor distributor attaching bolts
SEAL REPLACEMENT
BUSHING (Fig. 19). Remove the governor hous-
I Tool—T57P-76 7-B ing from the distributor.
1. Disconnect the drive shaft from ^mmmfm^ 0^7000-Ht
the transmission. 8. Refer to Major Repair Opera-
2. When only the rear seal needs tions for governor repair operations.
replacing, carefully remove it with a 9. Install the governor housing on
tapered chisel or the tools shown in the governor distributor (Fig. 19). In-
Fig. 15. Remove the bushing as shown EXTENSION HOUSING D1O26-B stall the attaching bolts and torque the
in Fig. 16. Use the bushing remover FIG. 17—Installing Extension bolts to specification.
carefully so that the spline- seal is not Housing Bushing
damaged.
3. When installing a new bushing Tool— T6 U-7657-A or B,
use the special tool shown in Fig. 17. 7657AA, or 7657-AB
4. Before installing a new seal, in-
spect the sealing surface of the univer-
sal joint yoke for scores. If scores are
found, replace the yoke.
5. Inspect the counterbore of the
housing for burrs and remove with
crocus cloth.
6. Install the seal into the housing
with the tool shown in Fig. 18. The EXTENSION HOUSING
seal should be firmly seated in the REAR SEAL

D 2042-A
bore. Coat the inside diameter of the FIG. 18—Installing Extension Housing Seal
fiber portion of the seal with B8A- GOVERNOR GOVERNOR GOVERNOR
19589-A lubricant. BOLTS (4) DISTRIBUTOR DISTRIBUTOR
10. Install a new extension housing
7. Coat the front universal joint SLEEVE gasket on the case. Install the exten-
spline with B8A-19589-A lubricant sion housing and six attaching bolts.
and install the drive shaft. Torque the bolts to specification.
11. Install the transmission mount-
EXTENSION HOUSING AND ing pad on the crossmember. Lower
GOVERNOR REPLACEMENT the transmission and install the exten-
sion housing to crossmember attach-
1. Raise the vehicle on the hoist. ing bolts. Torque the bolts to specifi-
2. Remove the drive shaft. Position cation. Remove the transmission jack.
the transmission jack to support the 12. Install the speedometer cable in
transmission. the extension housing. Install the drive
3. Remove the speedometer cable shaft.
from the extension housing. 13. Install the inlet pipes on the
4. Remove the extension housing to manifold.
crossmember mount attaching bolts.
Raise the transmission and remove the
I 14. Lower the vehicle and fill the
transmission with fluid.
D1859-A 15. Check the extension housing
mounting pad between the extension
housing and the crossmember. FIG. 79—Governor Installed area for fluid leakage.
An oil impregnated plastic grommet pan bolts and drain the fluid at one stalled, place the transmission on the
is incorporated in the end of the man- corner of the pan. Tighten the attach- jack (Fig. 21). Secure the transmission
ual shift linkage lever arm on all col- ing bolts after the fluid has drained. to the jack with the safety chain.
umn shift vehicles. A special tool 10. Disconnect the fluid cooler lines 2. Raise the transmission into posi-
T67P-7341-A is required to install the from the transmission case. tion and install the five converter
grommet in the manual lever, and to 11. Remove the manual and kick- housing-to-engine attaching bolts.
install the manual linkage rod into the down linkage rods from the transmis- Torque the bolts to specification. Re-
grommet. Refer to Part 7-1, Section sion control levers. move the safety chain from the trans-
2, for the grommet replacement pro- On vehicles equipped with a column mission.
cedures. shift, use tool T67P-7341-A to remove 3. Position the crossmember and
the selector rod from the manual install the four attaching bolts. Torque
lever. the bolts to specifications.
TRANSMISSION REMOVAL 12. On a Mustang, disconnect the 4. Lower the transmission and in-
neutral start switch wires from the re- stall the extension housing and
1. Raise the vehicle and remove the taining clamps and connectors. crossmember attaching bolts. Torque
converter cover attaching bolts, at the 13. Disconnect the starter cable. the bolts to specification.
lower front side of the converter hous- Remove the starter attaching bolts 5. Install the four flywheel to con-
ing. Remove the cover. and remove the starter from the converter attaching nuts. Torque the nuts
2. Remove the two conveter drain verter housing. to specification.
plugs (Fig. 20). Drain the fluid from 14. On PEB and PEE models, lift 6. Remove the transmission jack.
the converter. Install the two convert- the fluid filler tube from the case. Install the fluid filler tube in the
er drain plugs. 15. Remove the four converter- transmission case or pan. Install the
3. Remove the drive shaft and in- to-flywheel attaching nuts. vacuum hose on the transmission vac-
stall the extension housing seal repla- 16. Position the transmission jack uum unit. Install the vacuum line re-
cer tool in the extension housing. to support the transmission and secure taining clip.
4. Remove the vacuum line hose the transmission to the jack with a 7. Connect the fluid cooling lines to
from the transmission vacuum unit. safety chain. the transmission case.
Disconnect the vacuum line from the 17. Remove the four crossmember 8. On a Mustang, connect the neu-
retaining clip. attaching bolts and lower the tral start switch wires to their respec-
5. Remove the two extension crossmember. tive connectors and secure the harness
housing-to-crossmember attaching 18. Remove the five converter in the retaining clamps.
bolts. housing-to-engine attaching bolts. 9. Install the linkage rods on the
6. Remove the speedometer cable Lower the transmission (Fig. 21) and transmission downshift and manual
from the extension housing. remove it from under the vehicle. control levers.
7. Disconnect the exhaust pipe On vehicles equipped with a column
flange from the manifolds. TRANSMISSION shift, use tool T67P-7341-A to install
8. Remove the parking brake cable INSTALLATION a new grommet in the manual lever,
from the equalizer lever. and to install the manual linkage rod
9. Remove the fluid filler tube from 1. With the converter properly in- into the grommet.
the pan and drain the transmission 10. Connect the speedometer cable
fluid on PEA models. On PEB and to the extension housing.
PEE models, loosen the transmission 11. Connect the exhaust inlet pipes
to the manifolds.
12. Install and adjust the parking
CONVERTER ATT, brake cable at the equalizer lever.
13. Install the converter housing
cover and torque the attaching bolts
to specification.
14. Install the starter and torque
the attaching bolts to specification.
Connect the starter cable.
15. Install the drive shaft. Torque
the companion flange U-bolts attach-
ing nuts to specification.
16. Lower the vehicle. Fill the
transmission to the proper level with
D 2043-A
the specified fluid. Adjust the manual
and downshift linkage.
FIG. 20—Converter Drain Plug FIG. 21—Transmission Mounted
Location on Jack
Before removing any of the sub- 3. Remove the primary throttle joint yoke in the extension housing.
assemblies, thoroughly clean the out- valve (Fig. 23) from the opening at the
side of the transmission to prevent dirt rear of the case. 2. Remove one of the converter
from entering the mechanical parts. 4. Remove the two e x t e n s i o n housing-to-case attaching bolts and
During the repair operations, refer to housing-to-case bolts shown in Fig. 24 mount the dial indicator as shown in
Part 7-1 for common adjustments and and mount the transmission in the Fig. 27.
repairs or cleaning and inspection pro- holding fixture.
cedures. 5. Remove the transmission pan at- 3. The input shaft is a loose part
During the transmission disassem- taching bolts, pan and gasket. and has to be properly engaged with
bly or assembly operations, ten thrust 6. Remove the control valve body the spline of the forward clutch hub
w a s h e r s l o c a t e d between the sub- attaching bolts (Fig. 25). Remove the during the end play checking proce-
assemblies must be removed and in- control valve body from the case. dure. Move the input shaft and gear
stalled. It is important that each 7. Loosen the intermediate band train toward the rear of the transmis-
thrust washer be in the correct posi- adjusting screw (Fig. 26) and remove sion case.
tion during the assembly operation. the intermediate band struts from the
To properly locate and identify the case. Loosen the low-reverse band ad- V* - 20 x V/7 INCH V* - 20 x 1 INCH
thrust washers, the various positions justing screw and remove the low-
of the thrust washers are shown in the reverse band struts.
illustrations and are numbered 1
through 10. No. 1 is at the first thrust
washer located at the front pump. The TRANSMISSION END
last thrust washer, No. 10, is located PLAY CHECK
at the parking pawl ring gear.
1. To keep the output shaft in
DISASSEMBLY OF alignment during the end play check,
TRANSMISSION install the extension housing oil seal
replacer tool or a front universal
1. Remove the converter from the
transmission front pump and convert-
er housing.
2. Remove the transmission vacuum
unit with the tool shown in Fig. 22.
Remove the vacuum unit gasket and
the control rod.
GRIND OFF
SHADED AREA
TO DIMENSION SHOWN L . V* - 20 x 1 INCH
D1863-A
D1861-A
FIG. 23—Removing or Installing FIG. 25—Control Valve Body

Primary Throttle Valve Attaching Bolts
INTERMEDIATE INTERMEDIATE BAND
BAND STRUTS ADJUSTING SCREW
SNAP-ON
Tool-FCO-24
(Reworked)
I
Tool-T57L-500-A LOW-REVERSE BAND LOW-REVERSE
or 6005-M or 6005-MS D1862-A ADJUSTING SCREW BAND STRUTS D 1384-B
D1380-A
FIG. 24—Transmission Mounted FIG. 26—Band Adjusting Screws
FIG. 22—Removing Vacuum Unit in Holding Fixture and Struts—Typical
4. With the dial indicator contact- 2. Remove the five c o n v e r t e r

ing the end of the input shaft, set the TER HOUSING housing-to-case attaching bolts (Fig.
indicator at zero (Fig. 27). 29). Remove the converter housing
5. Insert a screwdriver behind the from the transmission case.
input shell (Fig. 27). Move the input 3. Remove the seven front pump at-
shell and the front part of the gear INNER DOWNSHIFT
train forward. LEVER
6. Record the dial indicator read-

ing. The end play should be 0.008 to
0.042 inch. If the end play is not with- D 1590-A
in specification, the selective thrust
washers (Fig. 28) must be replaced as
required. The selective thrust washers
can be replaced individually to obtain FIG. 29—Removing or Installing
the specified end play. Input Shaft
7. Remove the dial indicator and
remove the input shaft from the front
pump stator support (Fig. 29).
REMOVAL OF CASE
AND EXTENSION
HOUSING PARTS
INPUT SHELL
1. Rotate the holding fixture to put D1869-A
the transmission in a vertical position
with the converter housing up. FIG. 32— Lifting Input Shell
and Gear Train
FORWARD
•?*
PART OF
GEAR TRAIN
THRUST
WASHER
NO. 6
D1867-A
FIG. 30—Removing Front Pump
GEAR TRAIN
END PLAY
LIMITS
0.008-0.042
Tool-4201-C INTERMEDIATE BAND CLEARANCE

D1864-A
HOLE IN CASE D1868-A D1870-A
FIG. 27—Checking End Play
FIG. 31—Position of Intermediate FIG. 33—Removing or Installing
Band for Removal or Installation Forward Part of Gear Train
FORWARD GEAR TRAIN ASSEMBLY
SELECTIVE THRUST WASHERS
(FOR END-PLAY CORRECTION)
THRUST WASHER NO. 1 THRUST WASHER NO. 2
FRONT PUMP
0.053-0.0575 Red No. Stamped Metal
STATOR SUPPORT Washer Thrust Washer
0.070-0.074 Green
0.087-0.091 Natural
0.104-0.108 Block
0.121-0.125 Yellow 5 0.109-0.107
4 0.092-0.090
3 0.075-0.073
2 0.058-0.056
NYLON SELECTIVE
1 0.043-0.041
"'THRUST WASHER
Metal Thrust
NO. 1 Washers are Same
EI\ Jtth.
SELECTIVE THRUST WASHER NO. 2
Holding Fixture Tool—77530-A D1871-A

D 1865-C
FIG. 34— Forward Part of Gear
FIG. 28—Selective Thrust Washer Locations Train Positioned in Holding Fixture
SUN GEAR
INPU SHELL
FORWARD CLUTCH FRONT PLANET CARRIER ^
FORWARD CLUTCH HUB AND
RING GEAR
REVERSE-HIGH CLUTCH THRUST WASHER

NO. 5
D1872-A
FIG. 35—Forward Part of Gear Train Disassembled
taching bolts. Remove the front pump 7. From the gear train in the hold- No. 6 from the top of the reverse
by inserting a screwdriver behind the ing fixture, remove the reverse-high planet carrier.
input shell (Fig. 30). Move the input clutch and drum from the forward 14. Remove the reverse planet car-
shell forward until the front pump seal clutch (Fig. 35). rier and thrust washer No. 7 from the
is above the edge of the case. 8. If thrust washer No. 2 (Fig. 28) reverse ring gear and hub (Fig. 36).
Remove the front pump and gasket did not come out with the front pump, 15. Move the output shaft forward
from the case. If the selective thrust remove the thrust washer from the and with the tool shown in Fig. 37 re-
washer No. 1 did not come out with forward clutch cylinder. Remove the m o v e the reverse ring gear h u b -
the front pump, remove it from the forward clutch from the forward to-output shaft retaining ring.
top of the reverse-high clutch. clutch hub and ring gear (Fig. 35). 16. Remove the reverse ring gear
4. Remove the intermediate and 9. If thrust washer No. 3 (Fig. 35) and hub from the output shaft. Re-
low-reverse band adjusting screws did not come out with the forward move thrust washer No. 8 from the
from the case. Rotate the intermediate clutch, remove the thrust washer from low and reverse drum.
band to align the band ends with the the forward clutch hub. 17. Remove the low-reverse band
clearance hole in the case (Fig. 31). 10. Remove the forward clutch hub from the case (Fig. 38).
Remove the intermediate band from and ring gear from the front planet 18. Remove the low-reverse drum
the case. carrier (Fig. 35). from the one-way clutch inner race
5. Using a screwdriver between the 11. Remove thrust washer No. 4 (Fig. 36).
input shell and rear planet carrier and the front planet carrier from the 19. Remove the one-way clutch
(Fig. 32), lift the input shell upward input shell. inner race by rotating the race clock-
and remove the forward part of the 12. Remove the input shell, sun wise as it is removed.
gear train as an assembly (Fig. 33). gear and thrust washer No. 5 from the 20. Remove the 12 one-way clutch
6. Place the forward part of the holding fixture. rollers, springs and the spring retainer
gear train in the holding fixture shown 13. From inside the transmission from the outer race (Fig. 36). Do not
in Fig. 34. case (Fig. 33) remove thrust washer lose or damage any of the 12 springs
THRUST WASHER N O . 9
REVERSE PLANET CARRIER
SPRING RETAINER
INNER RACE
ONE-WAY
CLUTCH
LOW AND REVERSE DRUM OUTER RACE
THRUST WASHER N O . 6 SPRINGS (12)
AND ROLLERS (12)
D1394-A
FIG. 36—Lower Part of Gear Train Disassembled

GOVERNOR DISTRIBUTOR 24. Remove the four distributor

sleeve-to-case attaching bolts. Remove
the distributor sleeve from the case.
Do not bend or distort the fluid tubes
as the tubes are removed from the
case with the distributor sleeve.
25. Remove the parking pawl re-
turn spring, pawl, and pawl retaining
pin from the case (Fig. 41).
26. Remove the parking gear and
LOCK RING thrust washer No. 10 from the case.
27. Remove the six one-way clutch
D1876-A
outer race-to-case attaching bolts with
the tool sh^'vn in Fig. 42. As the bolts
FIG. 40—Removing or Installing are removed, hold the outer race lo-
Governor Distributor Snap Ring cated inside the case in position. Re-
REVERSE RING GEAR
HUB RETAINING RING move the outer race and thrust washer
D 2044-A or rollers. The outer race of the one- No. 9 from the case (Fig. 36).
way clutch cannot be removed worn
FIG. 37—Removing or Installing the case until the extension housing,
Reverse Ring Gear Hub Retaining output shaft and governor distributor
Ring sleeve are removed.
21. Remove the transmission from
the holding fixture. Position the trans-
mission on the bench in a vertical po-
sition with the extension housing up.
Remove the four extension housing-
to-case attaching bolts. Remove the
extension housing and gasket from the
I® case.
Too/-
LOW-RE'VERSE BAND 22. Pull outward on the output T65P.7B456-8
D1873-A
shaft and remove the output shaft and
FIG. 38—Removing or Installing governor distributor assembly from D1879-A
the governor distributor sleeve (Fig.
Low-Reverse Band
39). FIG. 42—Removing One-Way
23. Remove the governor distribu- Clutch Outer Race
tor lock ring from the output shaft
Attaching Bolts
(Fig. 40). Remove the governor dis-
OUTPUT SHAFT
tributor from the output shaft.
GOVERNOR
DISTRIBUTOR
SLEEVE
PARKING GEAR
D1875-A i^ffif THRUST WASHER NO. 10 ^ * t ^

$ D1399-A
Output Shaft and Governor
Distributor FIG. 41—Parking Pawl, Return Spring Retaining Pin and Gear
COVER SEAL fluid and install the servo pistion into

STEM NUT
the bore of the case.
SERVO PISTON STEM
5. Place a new cover seal on the
cover and install the servo cover. In-
stall the vent tube and retaining clip.
Install the four cover attaching bolts.
Torque the cover-to-case retaining
bolts to specifications.
Intermediate Servo
PISTON RETURN SPRING PISTON AND SEAL COVER
(SEAL BONDED TO PISTON) 1. Remove the transmission identif-
D1880-A
ication tag and the four servo cover to
case attaching bolts.
FIG. 43—Low-Reverse Servo Disassembled 2. Remove the servo cover, gasket,
servo piston, and piston return spring
PARTS REPAIR OR LOW-REVERSE
from the case (Fig. 45).
REPLACEMENT PISTON 3. Remove the intermediate servo
piston from the cover.
D u r i n g the r e p a i r of the s u b - 4. Remove the seal rings from the
assemblies, certain general instructions servo piston and cover.
which apply to all units of the trans- 5. Install a new seal on the cover
missions must be followed. These in- and servo piston. Figure 46 shows the
structions are given here to avoid un- correct servo piston and cover for
necessary repetition. each transmission model. Lubricate
Handle all transmission parts care- the seals with clean transmission fluid.
fully to avoid nicking or burring the Install the piston into the cover. Be
bearing or mating surfaces. careful not to damage the piston seal.
Lubricate all internal parts of the D1881-A 6. Install the piston return spring in
transmission before assembly with the servo bore of the case.
clean automatic transmission fluid. Do FIG. 44—Removing or Installing 7. Place a new gasket on the servo
not use any other lubricants except on Low-Reverse Servo Piston cover. Position the servo piston and
gaskets and thrust washers which may cover assembly into the case with the
be coated with vaseline to facilitate piston stem slot in a horizontal posi-
assembly. Always install new gaskets on the stem, torque the nut to specifi- tion to engage the strut. Use two
when assembling the transmission. cation. 5/16-18 bolts, 1 1/4 inch long, 180
Tighten all bolts and screws to the 4. Place the piston return spring in degrees apart, to position the cover
recommended torque as outlined in the servo bore of the case. Lubricate against the case. Install two cover at-
the Specification Section. the piston seal with clean transmission taching bolts. Remove the two 1 1/4
TRANSMISSION CASE AND

LINKAGE REPAIR V-8 ENGINE COVER
Low-Reverse Servo
1. Remove the four servo cover-

to-case attaching bolts. Remove the
vent tube and retaining clip from the
case.
2. Remove the servo cover, cover
seal, servo piston and piston return
spring from the case (Fig. 43).
3. The servo piston seal is bonded
to the piston. If the seal has to be re-
placed, replace the piston assembly COVER SEAL COVER^ GASKET
which includes the seal. Disassemble RETURN SPRING
PISTON SEALS
the servo piston from the piston stem PISTON
by inserting a small screwdriver in the
hole of the piston stem and removing
the piston attaching nut (Fig. 44).
Position the accumulator spring and

COVER
spacer (Fig. 43) on the piston stems. 6 CYLINDER ENGINE
Make sure the crowned side of the
D1882-A
spring is facing toward the rod. Install
the new servo piston and attaching nut
FIG. 45—Intermediate Servo Disassembled
ring and flat washer from the parking

pawl link (Fig. 48). Remove the pawl
link from the case retaining pin.
3. From the back of the transmis-
sion case, remove the parking pawl
link, toggle rod, and manual lever link
as an assembly (Fig. 49).
UPPER
r RETAINING
RING
Servo Piston Servo Cover Spring

Vehicle Engine Transmi ssion
Dia. A Dia. B Dia. C Dia. D Free Length Color
(Inches) Cniif
Ford, Meteor 302-2V PEA-MI, Nl 3.7875 2.8265 None 2.840 2.480 White
Fairlane,
Montegc, Falcon, 302-2V PEE-M, V, AC
Mustang
Ford, Meteor 240-IV PEA-A2 3.7875 2.7065 None 2.975 2.480 White
Fairlane, PEE-AD,
Montego, Mustang 250-1V
AE, AF
D1885-A
Mustang 200-1V PEB-B2 3.3265 2.4865 3.340 2.500 2.480 White
Falcon 170-1V PEB-C2
FIG. 48—Parking Pawl Link
200-1V
D 1800-D
/7^-MANUAL LEVER LINK

FIG. 46—Intermediate Servo Piston, Cover and Spring Identification
inch bolts and install the transmission breaking the inner lever shaft. Remove
identification tag and the other two the downshift outer lever nut. Remove
cover attaching bolts. Torque the bolts the downshift outer and inner lever.
to specifications. From inside the transmission case, re-
move the upper retaining ring from
Downshift and Manual the manual lever link (Fig. 47). Re-
Linkage move the upper end of the lever link
from the case retaining pin. Parking Pawl Link
1. Apply penetrating oil to the 2. From the back of the transmis-
outer lever attaching nut to prevent sion case, remove the upper retaining 4. Remove the rear parking pawl
link lower retaining ring, flat washer
UPPER RETAINING RING
INNER MANUAL
mmM and link from the toggle rod (Fig. 50).
m
'ER ATTACHING NUT
5. Remove the manual lever link,
lower retaining ring, flat washer, and
link from the toggle rod.
6. Install the manual and marking
pawl links, flat washers and retaining
rings to the toggle rods.
7. Remove the inner manual lever
attaching nut and lever. Remove the
outer manual lever from the case.
8. To remove the manual lever seal,
use the tools shown in Fig. 51. To in-
stall the new seal, use a driver that fits
the ID of the seal.
9. Install the outer manual lever in
the case. Install the inner manual
lever and attaching nut with the cham-
fer facing toward the lever (Fig. 47).
Torque the nut to specification.
10. From the back of the transmis-
sion case, install the parking toggle
rod and link assembly into the case
(Fig. 49).
INNER MANUAL LEVER MANUAL LEVER LINK 11. Install the parking pawl link on
D1405-B the case retaining pin. Install the flat
washer and link retaining ring (Fig.
FIG. 47—Case Internal Linkage 48).
2. Install the transmission case

bushing with the tool shown in Fig.
53.
OUTER MANUAL LEVER Thread Repair-Case
MANUAL LEVER LINK
Thread service kits may be pur-
chased from local jobbers or the
Heli-Coil Corporation. To repair a
INNER MANUAL LEVER damaged thread, the following proce-
dures should be carefully followed.
1. Drill out the damaged threads,
PARKING PAWL LINK
using the same drill size as the thread
TOGGLE ROD 01). For example, use a 5/16-inch
drill for a 5/16-18 thread.
2. Select the proper special tap and
tap the drilled hole. The tap is marked
for the size of the thread being re-
paired. Thus, the special tap marked
5/16-18 will not cut the same thread
as a standard 5/16-18 tap. It does cut
a thread large enough to accommo-
PARKING PAWL LINK
date the insert, and after the insert is
i n s t a l l e d the original thread size
(5/16-18) is restored.
D1887-A
3. Select the proper coil inserting
tool. These tools are marked with the
FIG. 50—Case Linkage thread size being repaired. Place the
insert on the tool and adjust the sleeve
12. Position the inner manual lever to the length of the insert being used.
behind the manual lever link, with the Press the insert against the face of
cam on the lever contacting the lower the tapped hole. Turn the tool clock-
link pin (Fig. 52). wise and wind the insert into the hole
13. Install the upper end of the until the insert is 1/2 turn below the
manual lever link on the case retain- face.
ing pin. Install the retaining ring. 4. Working through the insert, bend
14. Operate the manual lever and the insert tang straight up and down
check for correct linkage operation. until it breaks off at the notch.
D1888-A 15. Install the inner and outer 5. If the inserts are not properly in-
downshift levers. Torque the attaching stalled, they can be removed with the
FIG. 51—Removing Manual nut to specification. extractor tool. Place the extractor tool
in the insert so that the blade rests
Lever Seal Bushing Replacement—Case against the top coil 1/4 to 1/2 turn
away from the end of the coil. Tap
1. Remove the transmission case the tool sharply with a hammer so
bushing as shown in Fig. 53. that the blade cuts into the insert.
Press Ram Press Rom
Handle
Handle
Too/ - T66L-7003-B7
Tool - T666-7003-B3
TOGGLE ROD
MANUAL INNER LEVER
D1890-A
FIG. 52— Inner Manual Lever REMOVAL INSTALLATION D 1730-A

Location—As Viewed from the
Control Lever Side of Case FIG. 53—Replacing Transmission Case Bushing
Tool-T64P-7A128-A
LOWER
VALVE BODY
GASKET
OIL f
SCREEN -, -^L*«^M*i UPPER
VALVE BODY
MANUAL VALVE
D1891-A D1892-A
FIG. 54—Upper and Lower Valve Bodies Disassembled FIG. 56—Removing Manual Valve
Exert downward pressure on the tool pin) from the upper valve body. Re- 12. Remove the intermediate accu-
and turn it counterclockwise until the move the spring and detent plunger. mulator sleeve, 3-2 control valve,
insert is removed. 4. Slide the manual valve out of the spring and the intermediate servo ac-
body. cumulator valve.
CONTROL VALVE BODY 5. Remove the cut-back and the 13. Remove the pressure booster
back-out valve cover plate from the valve, cover plate (Fig. 57).
Disassembly valve body (Fig. 57). 14. Remove the pressure booster
6. Remove the cut-back valve from valve, sleeve, springs and the main re-
1. Remove the eight screws that at- the body. gulator valve.
tach the oil screen to the body and re- 7. Remove the 2-3 back-out valve, 15. Remove the spring and the line
move the screen (Fig. 54). spring and the manual low valve from pressure coasting boost valve (Fig.
2. R e m o v e the seven attaching the body. 57).
screws from the underside of the lower 8. Remove the 1-2 shift valve and 16. Carefully pry the downshift
valve body. Separate the lower valve 2-3 shift valve cover plate from the valve retainer from the body, then re-
body, gasket, separator plate and valve body. move the spring and valve.
hold-down plates (Fig. 55) from the 9. Remove the 2-3 shift valve and 17. Hold the upper valve body as
upper valve body. Be careful not to the throttle modulator valve from the shown in Fig. 58 and depress the
lose the upper valve body steel ball body. throttle booster valve plug to release
shuttle valve and spring when separat- 10. Remove the 1-2 shift valve, D2 the retaining pin. Remove the plug,
ing the upper and lower valve bodies. valve and the spring from the body. valve and the spring.
3. Depress the manual valve detent 11. Remove the intermediate band 18. Remove the two hold-down
spring with the tool shown in Fig. 56. accumulator valve cover plate from plates and the separator plate from
Remove the spring retaining pin (roll the valve body. the lower body. Be careful not to lose
the rubber ball shuttle valve when re-
moving the separator plate and gasket
SEPARATOR RUBBER BALL SERVO from the lower valve body.
PLATE SHUTTLE VALVE CHECK VALVE
Assembly
1. Place the rubber ball shuttle

valve in the lower body as shown in
Fig. 55. Position the separator plate
and the two hold-down plates on the
lower valve body and install the four
attaching screws and torque them to
specification.
2. Place the throttle booster valve
spring, valve (long end into spring)
and the plug (Fig. 57). Depress the
UPPER VALVE
BODY plug and install the retaining pin.
RUBBER BALL 3. Insert the downshift valve into
SHUTTLE VALVE D 1726-A the body with the large diameter fac-
ing inward. Install the downshift valve
FIG. 55—Separating Upper and Lower Valve Bodies spring and the retainer (Fig. 57).
1-2 SHIFT VALVE
2-3 BACK-OUT VALVE
CUT-BACK VALVE
SLEEVE
2-3 SHIFT VALVE

D2 VALVE
MANUAL LOW VALVE
3-2 CONTROL VALVE THROTTLE MODULATOR VALVE
ACCUMULATOR
VALVE
THROTTLE BOOSTER VALVE
UPPER BODY
stmina—E \
RETAINER
MAIN REGULATOR
VALVE MANUAL VALVE DETENT MANUAL VALVE
PLUG, SPRING AND
RETAINING PIN
CONTROL PRESSURE
BOOSTER VALVE
AND SLEEVE
D 1727-A
FIG. 57—Upper Valve Body Disassembled

11. Place the manual low valve,

spring, and the 2-3 back-out valve in
the body.
12. Place the cut-back valve in the
body.
13. Secure the cut-back and the
back-out cover plate to the body with
two screws. Torque the screws to
specifications.
14. Slide the manual valve into the
body making sure that the notch for
D1893-A the manual lever is toward the inside
and that the detent notches are facing
upward.
FIG. 58—Removing or Installing 15. Place the detent plunger and
Throttle Booster Valve spring in the body. Depress the spring
and install a new roll pin.
D 1731-A
16. Position a new rubber check
4. Insert the line pressure coasting valve in the upper valve body (Fig.
boost valve and spring in the body 55). FIG. 60—Removing Stator
(Fig. 57). 17. Position the check valve and
5. Place the main regulator valve in Support Bushing
spring in the upper valve body (Fig.
the body (Fig. 57) with the large di- 55). Place a new gasket, the separator
ameter facing inward. Install the two plate and the lower valve body in breaks through the bushing wall. Pry
springs and the pressure booster valve place on the upper valve body and se- the loose ends of the bushing up with
and sleeve. cure it with the seven a t t a c h i n g an awl and remove the bushing.
6. Hold the pressure booster valve screws. Torque the screws to specifica- 4. Remove the drive and driven
cover plate in place and install the tions. gears from the front pump housing.
three attaching screws and torque 18. Secure the oil screen to the 5. Press the bushing from the front
them to specification. body with the eight attaching screws. pump housing as shown in Fig. 61.
7. Place the intermediate servo ac- Torque the screws to specifications.
cummulator valve and spring in the
body. Install the interim iiate accum- FRONT PUMP Assembly
mulator sleeve and 3-2 control valve.
Secure the cover to the body with the Disassembly 1. Press a new bushing into the
attaching screw. Torque the screw to pump housing with the handle and
specifications. 1. Remove the four seal rings from tool shown in Fig. 61. Make sure the
8. Position the spring, D2 valve and stator support. bushing is installed with the slot and
the I-2 shift valve in the body. 2. Remove the five bolts that attach groove positioned to the rear of the
9. Place the throttle modulator the stator support to the front pump pump body and 60 degrees below the
valve, spring, and 2-3 shift valve in the housing. Remove the stator support horizontal center line.
body. from the pump housing (Fig. 59). 2. Install the drive and driven gears
10. Secure the 1-2 shift valve and 3. Remove the front and rear stator in the pump housing. Each gear has
the 2-3 valve cover plate to the body an identification mark on the side of
bushings if they are worn or damaged.
and torque the screws to specifica- the gear teeth that are chamfered. The
Use the cape chisel (Fig. 60) and cut
tions. chamfered side with the identification
along the bushing seam until the chisel
PUMP HOUSING
STATOR SUPPORT
SEAL RINGS
FRONT PUMP SEAL
SELECTIVE
THRUST WASHERS
GASKET
D 1894-B
59—Front Pump and Stator Support Disassembled

Fress Ram ress Ram
Handle Hand!
Tool - T66L-7003-S9
J
INSTALL BUSHING WITH GROOVE
Too/ - T66L-7003-B5 AND SLOT IN THIS POSITION
REMOVAL INSTALLATION
D 1732-C
FIG. 61—Replacing Front Pump Housing Bushing
mark has to be positioned downward 3. To remove the piston spring re-

Toot-T63L-77837-A
against the face of the pump housing. or 77837-A tainer snap ring, place the clutch hub
3. Press new bushings into the sta- in the arbor press. With the tools
tor support with the tool shown in shown in Fig. 67, compress the piston
Fig. 62. Use the end with the 1/8 inch return springs and remove the snap
step for the front bushing and the end ring. When the arbor press ram is re-
with the 1/4 inch step for the rear leased, guide the spring retainer to
D1896-A
bushing. When installing the rear clear the snap ring groove of the
bushing, be sure the hole in the bush- FIG. 64—Installing Front drum.
ing is lined up with the lube hole in
the stator support. Pump Seal
SNAP RING
T00I-T66L
4. Place the stator support in the
pump housing and install the five at-
taching bolts. Torque the bolts to spe-
cifications.
5. Install the four seal rings on the
stator support. The two large oil rings
are assembled first in the oil ring
grooves toward the front of the stator
support (Fig. 59).
6. Check the pump for free rotation
by placing the pump on the converter D1420-A
drive hub in its normal running posi-

tion and turning the pump housing. FIG. 65—Removing or Installing
7. If the front pump seal must be Reverse-High Pressure Plate
replaced, mount the pump in the Snap Ring
transmission case and remove the seal
with the tool shown in Fig. 63. To in-
D 1733 - A stall the new seal, use the tool shown
in Fig. 64. 4. Remove the spring retainer and
10 piston return springs.
FIG. 62—Installing Stator 5. Remove the piston by inserting
Support Bushings REVERSE-HIGH CLUTCH air pressure in the piston apply hole of
the clutch hub (Fig. 68).
Disassembly 6. Remove the piston outer seal
from the piston and the piston inner
1. Remove the pressure plate re- seal from the clutch drum (Fig. 66).
taining snap ring (Fig. 65). 7. Remove the drum bushing if it is
2. Remove the pressure plate, and worn or damaged. Use thw âpe chisel
the drive and driven clutch plates (Fig. (Fig. 69) and cut a shallow groove 3/4
66). If the composition clutch plates inch in length along the bushing seam
Tool-T50T-100-A D1895-A are to be reused, do not clean them in until the chisel breaks through the
a vapor degreaser or with a detergent bushing wall. Pry the loose ends of
FIG. 63—Removing Front solution. Wipe the plates with a lint- the bushing up with an awl and re-
Pump Seal free cloth. move the bushing. To prevent leakage
SNAP RING
DRIVE PLATES
REVERSE A N D HIGH SPRING RETAINER
CLUTCH CYLINDER
PISTON
PISTON
RETURN SPRING
(10) SNAP RING PRESSURE PLATE
PISTON SEALS
DRIVEN PLATES D1897-A
. oo —Reverse-High Clutch Disassembled
REVERSE-HIGH
CLUTCH DRUM
Cape Chisel
Tool T65L-77575-A
Tool T 65 L- 77575 -A D 1591-A D 1734-A
FIG. 67—Removing or Installing Reverse-High Clutch Piston Spring FIG. 69—Removing Reverse-High
Snap Ring Clutch Bushing
at the stator support O-rings, be care- press a new bushing into the drum Tool - T66L-7003-B4 Handle
ful not to nick or damage the hub sur- with the handle and tool shown in Fig.
face with the chisel. 70.
2. Install a new inner seal in the
Assembly
clutch drum and a new outer seal on
the clutch piston. Lubricate the seals
1. Position the drum in a press and with clean transmission fluid and in-
stall the piston into the clutch drum.
Tool—7000-DD 3. P l a c e the 10 clutch p i s t o n
springs into position on the clutch pis-
ton. Place the spring retainer on top
of the springs. To install the snap ring
use the tools shown in Fig. 67.
As the press ram is moved down-
ward, make sure the spring retainer is
centered to clear the drum. Install the
snap ring. Before the press ram is re-
leased make sure the snap ring is posi- D 1735-A
tioned inside of the four snap ring
guides on the spring retainer. FIG. 70—Installing Reverse-High
D1422-A 4. When new composition clutch
plates are used, soak the plates in Clutch Bushing
FIG. 68—Removing Reverse-High
Clutch Piston transmission fluid for fifteen minutes
D1898-A
FIG. 71—Checking Reverse-High Tool - T65L - 77575 - A

DISC ii—mi -
Clutch Snap Ring Clearance SPRING
before installing them. Install the

clutch plates alternately starting with
a steel plate, then a non-metallic plate
(Fig. 66). The last plate installed is
the pressure plate. For the correct
number of clutch plates required for
each transmission model, refer to Part
7-5.
5. Install the pressure plate retain-
ing snap ring (Fig. 66). Make sure the
snap ring is fully seated in the snap
ring groove of the clutch hub.
SNAP RING
D 1635-A
FIG. 74—Removing Disc Spring
6. With a feeler gauge, check the FORWARD CLUTCH

clearance between the snap ring and
the pressure plate (Fig. 71). Disassembly
7. The pressure plate should be held
downward as the clearance is checked. 1. Remove the clutch pressure plate
The clearance should be 0.050 to retaining snap ring (Fig. 72).
0.066 inch. If the clearance is not 2. Remove the pressure plate, and
within specifications, selective thick- the drive and driven clutch plates from
D1899-A
ness snap rings are available in these the clutch hub (Fig. 73).
thicknesses, 0.060-0.064, 0.074-0.078, 3. Remove the disc spring retaining
FIG. 72—Removing or Installing 0.088-0.092, and 0.102-0.106 inch. In- snap ring (Fig. 74).
Forward Clutch Pressure Plate stall the correct size snap ring and re- 4. Apply air pressure at the clutch
Snap Ring check the clearance. piston pressure hole (Fig. 75) to re-
SNAP RING
PISTON SEALS RING (STEEL)
FORWARD CLUTCH CYLINDER DRIVEN PLATES

D1900-A
FIG. 73—Forward Clutch Disassembled

7oo/- ward pressure on the plate should be Assembly

7000-
used when making this check. The
clearance should be 0.026 to 0.042 1. Install a new bushing into the
inch for PEA and PEE models, or clutch hub as shown in Fig. 78.
0.020 to 0.036 inch for PEB models. 2. Install the forward clutch hub in
6. If the clearance is not within the ring gear. Make sure the hub is
specifications, selective snap rings are bottomed in the groove of the ring
available in these thicknesses: 0.060- gear.
0.064, 0.074-0.078, 0.088-0.092, and 3. Install the front clutch hub re-
0.102-0.106 inch. Insert the correct taining snap ring. Make sure the snap
size snap ring and recheck the clear- ring is fully seated in the snap ring
ance. groove of the ring gear.
INPUT SHELL AND SUN

FIG. 75—Removing Forward GEAR
Clutch Piston FORWARD CLUTCH HUB
AND RING GEAR Disassembly
move the piston from the clutch hub. Disassembly 1. Remove the external snap ring
5. Remove the clutch piston outer from the sun gear (Fig. 79).
seal and the inner seal from the clutch 1. Remove the forward clutch hub
hub (Fig. 73). retaining snap ring (Fig. 77).
EXTERNAL SNAP RING
Assembly SUN GEAR
1. Install new clutch piston seals on RING GEAR

SNAP RING
the clutch piston and drum. Lubricate
the seals with clean transmission fluid.
2. Install the clutch piston into the
clutch hub. Install the disc spring and
retaining snap ring (Fig. 73).
3. Install the lower pressure plate
with the flat side up and the radius
side downward. I n s t a l l one non- D1904-A
metallic clutch plate and alternately
FORWARD
install the drive and driven plates. Be- CLUTCH HUB D1903-A FIG. 79—Removing or Installing
fore installing new composition clutch
plates, soak them in transmission fluid Sun Gear External Snap Ring
FIG. 77—Forward Clutch Hub
for fifteen minutes. The last plate in- and Ring Gear Disassembled
stalled will be the upper pressure 2. Remove thrust washer No. 5
plate. Refer to Part 7-5 for the correct from the input shell and sun gear (Fig.
number of clutch plates for the appli- 2. Remove the forward clutch hub 80).
cable model transmission. from the ring gear. 3. From inside the input shell, re-
4. Install the pressure plate retain- 3 . P r e s s the b u s h i n g from the move the sun gear. Remove the inter-
ing snap ring (Fig. 73). Make sure the clutch hub as shown in Fig. 78. nal snap ring from the sun gear.
snap ring is fully seated in the ring
groove of the clutch hub.
Tool - T66L-7003-B10 Handle Handle Tool - T66L-V003-B5
5. With a feeler gauge, check the
clearance between the snap ring and
the pressure plate (Fig. 76). Down-
CHECK BETWEEN SNAP RING

AND PRESSURE PLATE
REMOVAL INSTALLATION D 1736-A
FIG. 76—Checking Forward

Clutch Snap Ring Clearance FIG. 78 — Replacing Forward Clutch Hub Bushing
EXTERNAL SNAP RING of the bushing up with an awl and re-

move the bushing.
2. Install a new bushing with the
tool shown in Fig. 83.
Tool - Handle
T66L-7003-B6
SUN GEAR
D1905-A
FIG. 80—Input Shell and Sun Gear Disassembled
4. If the sun gear bushings are to Assembly

be replaced, use the tool shown in Fig. D 1738-A
81 and press both bushings through 1. Press a new bushing into each
the gear. end of the sun gear with the tool FIG. 83—Installing Low and
shown in Fig. 81. Reverse Brake Drum Bushing
2. Install the internal snap ring on
Tool - T66L-7003-B8 Tool - T66L-7003-B2 the sun gear. Install the sun gear in
Handle Handle
the input shell.
3. Install thrust washer No. 5 on GOVERNOR AND OIL
the sun gear and input shell (Fig. 80). DISTRIBUTOR
4. Install the external snap ring on
the sun gear (Fig. 79). Disassembly
1. Remove the oil rings from the

governor oil distributor (Fig. 84).
REVERSE RING GEAR 2. Remove the governor housing-
AND HUB to-distributor attaching bolts. Remove
the governor from the oil distributor.
Disassembly Remove the governor oil screen.
3. Remove the primary governor
1. Remove the hub retaining snap valve retaining ring (Fig. 85). Remove
ring from the reverse ring gear. the washer, spring, and primary gov-
REMOVAL INSTALLATION 2. Remove the hub from the reverse ernor valve from the housing.
D 1737-A 4. Remove the secondary governor
ring gear (Fig. 82).
valve spring retaining clip, spring, and
FIG. 81—Replacing Sun Gear governor valve from the housing.
Bushing Assembly 5. Install the secondary governor
valve in the housing. Install the spring
1. Install the hub in the reverse ring and retaining clip. Make sure the dip
gear. Make sure the hub is fully seat- is installed with the small concaved
ed in the groove of the ring gear. area facing downward, to hold the
GEAR
2. Install the snap ring in the rev- spring in the correct position.
erse ring gear. Make sure the snap
ring is fully seated in the snap ring Assembly
groove of the ring gear.
1. Install the primary governor
LOW-REVERSE valve in the housing. Install the spring,
BRAKE DRUM BUSHING washer and retaining ring. Make sure
REPLACEMENT the washer is centered in the housing
on top of the spring and the retaining
1. Replace the low reverse brake ring is fully seated in the ring groove
drum bushing if it is worn or dam- of the housing.
HUB AND FLANGE D1906-A aged. To remove the bushing, use the 2. Install the governor oil screen.
cape chisel and cut along the bushing 3. Install the governor assembly on
FIG. 82—Reverse Ring Gear and seam until the chisel breaks through the oil distributor and torque the at-
Hub Disassembled the bushing wall. Pry the loose ends taching bolts to specification.
8. Install the governor distributor

assembly on the output shaft. Install
the distributor retaining snap ring
'OIL RINGS (Fig. 40). Figure 91 shows the correct
snap ring to be used.
9. Check the rings in the governor
distributor, making sure the rings are
SNAP RING
fully inserted in the ring grooves and
will rotate freely. Install the output
shaft and governor distributor assem-
bly in the distributor sleeve (Fig. 39).
10. Place a new extension housing
gasket on the case. Install the exten-
sion housing, vacuum tube clip, and
the extension housing-to-case attach-
ing bolts. Torque the bolts to specifi-
cation.
11. Place the transmission in the
holding fixture with the front pump
SECONDARY
GOVERNOR VALVE mounting face of the case up. Make
sure thrust washer No. 9 is still lo-
1
cated at the bottom of the transmis-
s
v
sion (Fig. 86).
GOVERNOR HOUSING
12. I n s t a l l the one-wa> clutch
D1907-A spring retainer into the oui:er race
(Fig. 92).
FIG. 84—Governor and Oil Distributor 13. Install the inner race inside of
the spring retainer.
14. Install the individual springs be-
4. Install the oil rings on the distri- specifications after the transmission is tween the inner and outer race as
butor. Check the oil rings for free assembled, either the wrong selective shown in Fig. 92.
rotation in the ring grooves on the oil thrust washers were used, or a thrust 15. Starting at the back of the
distributor. washer came out of position during transmission case, install the one-way
the transmission assembly operation. clutch rollers by slightly compressing
ASSEMBLY OF 1. Install thrust washer No. 9 inside each spring and positioning the roller
TRANSMISSION the transmission case (Fig. 87). between the spring and the spring re-
2. Place the one-way clutch outer tainer.
When assembling the transmission race inside the case. From the back of 16. After the one-way clutch has
sub-assemblies (Fig. 86), make sure the case install the six outer race- been assembled, rotate the inner race
that the correct thrust washer is used to-case attaching bolts. Torque the clockwise to center the rollers and
between certain sub-assemblies. Lubri- bolts to specification with the tools springs. Install the low and reverse
cate remaining surfaces with transmis- shown in Fig. 88. drum (Fig. 86). The splines of the
sion fluid. Vaseline should be used to 3. Place the transmission case in a drum have to engage with the splines
hold the thrust washers in their proper vertical position with the back face of of the one-way clutch inner race.
location. If the end play is not within the case upward. Install the parking Check the one-way clutch operation
pawl retaining pin in the case (Fig. by rotating the low and reverse drum.
89). The drum should rotate clockwise but
4. Install the parking pawl on the should not rotate counterclockwise.
case retaining pin. Install the parking 17. Install thrust washer No. 8 on
pawl return spring as shown in Fig. top of the low and reverse drum (Fig.
89. 93). Install the low-reverse band in the
5. Install thrust washer No. 10 on case, with the end of the band for the
the parking gear (Fig. 90). Place the small strut toward the low-reverse
gear and thrust washer on the back servo (Fig. 38).
PRIMARY GOVERNOR
VALVE AND face of the case (Fig. 89). 18. Install the reverse ring gear and
LOCK RING 6. Place the two distributor tubes in hub on the output shaft.
the governor distributor sleeve. Install 19. Move the output shaft forward
the distributor sleeve on the case. As and install the reverse ring gear hub-
the distributor sleeve is installed, the to-output shaft retaining ring (Fig. 37).
tubes have to be inserted in the two 37).
holes in the case and the parking pawl 20. Place thrust washers Nos. 6 and
retaining pin has to be inserted in the 7 on the reverse planet carrier (Fig.
alignment hole in the distributor 94).
D1908-A
sleeve. 21. Install the planet carrier in the
7. Install the four governor distrib- reverse ring gear and engage the tabs
FIG. 85—Removing or Installing utor sleeve-to-case attaching bolts and of the carrier with the slots in the
torque the bolts to specification.
Retaining Ring low-reverse drum.
y
Q !
17
3*1 - " -N
1. CONVERTER 12. THRUST WASHER NO. 3 2 1 . REVERSEH*ING GEAR 30. THRUST WASHER NO. 9
2. INPUT SHAFT 13. FORWARD CLUTCH HUB AND HUB 31. CASE
3. CONVERTER HOUSING 2 2 . LOW AND REVERSE BAND 32. THRUST WASHER NO. 10
AND RING GEAR
4. FRONT PUMP 2 3 . BAND STRUTS 33. PARKING GEAR
14. THRUST WASHER NO. 4 34. GOVERNOR DISTRIBUTOR
5. THRUST WASHER N O . 1 2 4 . THRUST WASHER N O . 8
6. THRUST WASHER N O . 2 15. FRONT PLANET CARRIER SLEEVE
2 5 . LOW AND REVERSE DRUM
7. FRONT PUMP GASKET 16. INPUT SHELL, SUN GEAR 35. SNAP RING
2 6 . ONE-WAY CLUTCH 36. GOVERNOR VALVES &
8. INTERMEDIATE BAND AND THRUST WASHER N O . INNER RACE
9. BAND STRUTS DISTRIBUTOR
17. THRUST WASHER NO. 6
2 7 . ROLLER (12) AND SPRING (12) 37. OUTPUT SHAFT
10. REVERSE AND HIGH
18. REVERSE PLANET CARRIER 2 8 . SPRING AND ROLLER CAGE 38. EXTENSION HOUSING AND GASKET
CLUTCH DRUM
1 1 . FORWARD CLUTCH AND 19. THRUST WASHER N O . 7 2 9 . ONE-WAY CLUTCH OUTER 39. CONTROL VALVE BODY
CYLINDER 20. SNAP RING RACE 40. OIL PAN AND GASKET
D 1378-D
FIG. 86—Transmission Sub-Assemblies

THRUST WASHER N O . 9 PARKING GEAR b. Install the reverse-high clutch

and the forward clutch on the stator
support.
c. Invert the complete unit making
sure that the intermediate brake drum
bushing is seated on the forward
clutch mating surface.
d. Select the thickest fiber washer
(No. 1) that can be inserted between
the stator support and the intermedi-
ate brake drum thrust surfaces and
still maintain a slight clearance. Do
not select a washer that must be
forced between the stator support and
intermediate brake drum.
THRUST
e. Remove the intermediate brake
BOTTOM WASHER drum and forward clutch unit from
OF CASE NO. 10 D1911-A the stator support.
f. Install the selected Nos. 1 and 2
FIG. 87—Number 9 Thrust FIG. 90—Number 10 Thrust thrustwashers on the front pump sta-
Washer Location Washer Location tor support (Fig. 28) using enough
vaseline to hold the thrust washers in
position during the front pump instal-
22. On the bench, install the for- lation.
ward clutch in the reverse-high clutch 24. Install thrust washer No. 3 on
by rotating the units to mesh the the forward clutch (Fig. 96).
reverse-high clutch plates with the 25. Install the forward clutch hub
splines of the forward clutch (Fig. 95). and ring in the forward clutch by ro-
23. Using the end play check read- tating the units to mesh the forward
ing that was obtained during the clutch plates with the splines on the
transmission disassembly to determine forward clutch hub (Fig. 97).
which No. 2 steel backed thrustwasher 26. Install thrust washer No. 4 on
is required, proceed as follows: the front planet carrier (Fig. 98). In-
a. Position the stator support verti- stall the front planet carrier into the
cally on the work bench and install forward clutch hub and ring gear.
Tool-T65P-7B456-B the correct No. 2 thrustwasher to Check the forward thrust bearing race
bring the end play within specifica- inside the planet carrier for proper
tions. location against the thrust bearing.
Make sure the race is centered for
alignment with the sun gear on the
D1910-A input shell (Fig. 99).
27. Install the input shell and sun
FIG. 88—Installing One-Way gear on the gear train (Fig. 100). Ro-
Clutch Outer Race Attaching Bolts tate the input shell to engage the drive
lugs of the reverse-high clutch. If the
drive lugs will not engage, the outer
REJURN S PAWL
race inside the forward planet carrier
is not centered to engage the end of
RETAINS REVERSE RING GEAR AND
the sun gear inside the input shell.
HUB TO OUTPUT SHAFT Center the thrust bearing race and in-
stall the input shell.
28. Hold the gear train together
and install the forward part of the
gear train assembly in the case (Fig.
33).
The input shell sun gear must mesh
with the reverse pinion gears. The
front planet carrier internal splines
must mesh with the splines on the out-
put shaft.
RETAINS GOVERNOR DISTRIBUTOR 29. A new band should be soaked
TOOUTPUTSHAFT in transmission fluid for fifteen min-
D1549-A utes before it is installed. Install the
PARKING
GEAR RETAINING PIN D1440-A intermediate band through the front of
FIG. 91—Governor and Reverse the case (Fig. 31).
Ring Hub-Retaining Snap Ring 30. Install a new front pump gasket
FIG. 89— Parking Pawl and Gear
Identification on the case. Line up the bolt holes in
SPRING RETAINER OUTER RACE INNER RACE
STEP-1 STEP-2
INSTALL SPRING RETAINER INTO OUTER RACE INSTALL INNER RACE
STEP-3 ROLLERS (12) STEP-4

INSTALL 12 SPRINGS INSTALL 12 ROLLERS D1913-A
FIG. 92—One-Way Clutch
THRUST WASHER the gasket with the holes in the case. 34. Place the converter housing on
NO. 8
31. Install the front pump stator the transmission case. Install the five
support into the reverse-high clutch. converter housing-to-case attaching
Align the pump-to-case attaching bolt bolts. Torque the bolts to specifica-
holes. Install the front pump-to-case tion.
attaching bolts and torque them to 35. Install the intermediate and
specification. low-reverse band adjusting screws in
32. Install the input shaft (Fig. 29). the case. Install the struts for each
Rotate the holding fixture to place the band (Fig. 26).
transmission in a horizontal position. 36. Adjust the intermediate and
Check the transmission end play as low-reverse band. Refer to In-Vehicle
shown in Fig. 27. If the end play is Adjustments and Repair for band ad-
not within specification, either the justing procedures.
wrong selective thrust washers (Fig. 37. Install a universal joint yoke on
28) were used, or one of the 10 thrust the output shaft. Rotate the input and
washers (Fig. 86) is not properly posi- output shafts in both directions to
LOW AND tioned. check for free rotation of the gear
REVERSE
DRUM D1443-A 33. Remove the dial indicator used train.
for checking the end play and install 38. Install the control valve body
FIG. 93—Number 8 Thrust the one front pump-to-case attaching (Fig. 25). As the valve body is in-
Washer Location bolt. Torque the bolt to specification. stalled engage the manual and down-
REVERSE PLANET CARRIER THRUST WASHER N O . 7
THRUS
WASHER
NO. 4
D1916-A
FIG. 98—Number 4 Thrust

Washer Location
the holding fixture. Install the two ex-

THRUST WASHER N O . 6 tension housing-to-case attaching
D1444-A
bolts. Torque the bolts to specifica-
tion.
FIG. 94 —Number 6 and 7 Thrust Washer Location 41 Install the primary throttle
valve in the transmission case (Fig.
23).
shift valves with the inner control le- 42. Install the vacuum unit, gasket,
vers. Torque the control valve body- and control rod in the case. Using the
to-case attaching bolts to specifica- tools shown in Fig. 101, torque the
tion. vacuum unit to 15-23 ft-lbs.
39. Place a new pan gasket on the
case and install the pan and pan- FRONT PLANET FORWARD CLUTCH
to-case attaching bolts. Torque the at- CARRIER HUB AND
GEAR
taching bolts to specification.
40. Remove the transmission from FORWARD
CLUTCH
FORWARD CLUTCH HUB FORWARD

AND RING GEAR CLUTCH
FORWARD
CLUTCH
REVERSE-HIGH
CLUTCH
D1914-A
FIG. 95—Installing Clutch Units
THRUST WASHER N O . 3 FORWARD

CLUTCH CYLINDER
REVERSE-HIGH CLUTCH
REVERSE-HIGH CLUTCH
D1446-A D1915-A D1917-A
FIG. 96—Number 3 Thrust FIG. 97—Installing Forward FIG. 99—Installing Front

Washer Location Clutch Hub and Ring Gear Planet Carrier
43. Make sure the input shaft is Tool-FCO-24
INPUT SHELL
properly installed in the front pump Reworked
SUN GEAR stator support and gear train. Install

the converter in the front pump and
the the converter housing.
D1919-A
FIG. 707—Installing Vacuum Unit
REVERSE-HIGH
DRIVE LUG CLUTCH
ENGAGEMENT
D1918-A
FIG. TOO—Installing Input Shell

07-03-01 FMX Transmission 07-03-01
PART 7-3 FMX Transmission

MODEL APPLICATION
Thunderbird
Continental-
Continental
SELECTOR
All Models
Montego
TRANSMISSION ENGINE
Mustang
LEVER
Mercury
Fairlane
Mark III
Lincoln-
Cougar
Meteor
Falcon
MODEL MODEL LOCATION
Ford
PHB-A 390-2V Column X X
PHB-C 351-2V Column X X
PHB-D 351-2V Console X X
PHB-E 351-2V Console X X
PHB-F 351-4V Column X X
PHB-G 351-4V Console X X
PHB-H 351-4V Console X X
PHD-A 240-1V Column X X
PHD-B 302-2V Column X X
1
Page
Page
ASSEMBLY OF TRANSMISSION 03-26 Removal and Installation 03-13

End Play Check 03-08 EXTENSION HOUSING REAR SEAL
BAND ADJUSTMENTS Removal and Installation 03-13
Front Band 03-09 FLUID FILTER ASSEMBLY 03-29
Rear Band (Ford and Meteor) 03-09 FRONT CLUTCH
Rear Band (Fairlane, Montego, Mustang and Assembly 03-26
Cougar) 03-10 Disassembly and Overhaul 03-19
External Adjustment 03-10 Inspection 03-15
Internal Adjustment 03-10 FRONT PUMP
CENTER SUPPORT, ONE-WAY CLUTCH Assembly 03-28
AND PINION CARRIER Disassembly and Overhaul 03-20
Assembly 03-26 Inspection 01-15
Center Support With Chamfered Edge 03-26 FRONT SERVO
Center Support not Chamfered 03-27 Assembly 03-28
Inspection 03-14 Disassembly and Overhaul 03-24
CONTROL VALVE BODY Inspection 01-16
Assembly 03-28 Removal and Installation 03-12
Disassembly and Overhaul 03-21 GOVERNOR
Inspection 03-16 Assembly 03-28
Removal and Installation 03-11 Disassembly and Overhaul 03-24
DESCRIPTION 03-03 Inspection 01-16
DISASSEMBLY AND OVERHAUL OF Removal and Installation 03-10
TRANSMISSION 03-16 MANUAL LINKAGE
End Play Check 03-16 Adjustments 03-05
DOWNSHIFT LINKAGE Parts Repair or Replacement 03-25
Adjustment 03-05 NEUTRAL START SWITCH-CONSOLE SHIFT
Parts Repair or Replacement 03-25 Adjustment 03-05
EXTENSION HOUSING Removal and Installation 03-07
Assembly 03-28 (Refer to Part 7-1 for Column Shift
Inspection 03-14 Adjustment and Removal and Installation
EXTENSION HOUSING BUSHING procedures)
COMPONENT INDEX
Page
Page
OIL PAN REAR SERVO
Assembly 03-29 Assembly 03-28
OUTPUT SHAFT Inspection 01-16
Inspection 01-11 REAR SUPPORT
OUTPUT SHAFT BUSHING Assembly 03-28
Disassembly and Overhaul 03-17 Inspection 03-15
PARKING PAWL REAR SUPPORT BUSHING
PRESSURE REGULATOR SELECTOR LEVER-CONSOLE SHIFT
Disassembly and Overhaul 03-21 THROTTLE LINKAGE
Inspection 01-16 Adjustment 03-05
PRIMARY SUN GEAR SHAFT TRANSMISSION (Complete)
Inspection 01-11 TRANSMISSION CASE BUSHING
REAR BRAKE DRUM SUPPORT BUSHING Parts Repair or Replacement 03-26
Disassembly and Overhaul 03-17 TRANSMISSION CASE LINKAGE
REAR CLUTCH Parts Repair or Replacement 03-25
Assembly 03-26 VACUUM DIAPHRAGM UNIT
Disassembly and Overhaul 03-18 Assembly 03-29
Inspection 01-15 Adjustment 01-07
Checking 01-04
DESCRIPTION
DESCRIPTION fix, assembly part number and the installed on. If the tag was removed
build date code. during disassembly, reinstall it on the
same unit.
The service identification number The FMX transmission is a three
Figure 1 shows the location of the
indicates changes to service details speed unit capable of providing auto-
c o n v e r t e r , front p u m p , clutches,
which affect interchangeability when matic upshifts and downshifts through
bands, gear train and most of the in-
the t r a n s m i s s i o n m o d e l is not the three forward gear ratios, and also
ternal parts used in the FMX Trans-
changed. For interpretation of this capable of providing manual selection
mission
number, see the Master Parts Catal- of first and second gears.
The identification tag (Fig. 2) on an og- The transmission consists essentially
FMX transmission is attached under of a torque converter, planetary gear
the oil pan by a pan to case bolt. The The tag must be kept with the indi- train, two multiple disc clutches and a
tag includes the model prefix and suf- vidual transmission it was originally hydraulic control system (Fig. 3).
07-03-03 FMX Transmission 0703-03
PRIMARY DISTRIBUTOR SLEEVE EXTENSION HOUSING SEAL

SUN GEAR ! SPEEDOMETER DRIVE GEAR /
OIL SEAL ONE-WAY CLUTCH
FRONT FRONT
PUMP BAND
FRONT
CLUTCH
OUTPUT SHAFT
EXTENSION HOUSING
SPLINE SEAL
GOVERNOR
PRIMARY PINION
SECONDARY SUN GEAR
SECONDARY PINION
DIAPHRAGM
CONTROL VALVE BODY
OIL PAN
TURBINE SHAFT 'REAR CLUTCH PISTON

REAR CLUTCH
REAR CLUTCH SPRING
FRONT CLUTCH PISTON
FRONT SERVO
PRESSURE REGULATOR BODY
FLYWHEEL STATOR SUPPORT
D 2045-A
FIG. 7—Typical FMX Transmission
TRANSMISSION MODEL
ENGINE DISPLACEMENT BUILD DATE SHIFT

FMX TRANSMISSION D 2046-A
FIG. 2—Identification Tags

REVERSE-HIGH ' INTERMEDIATE SERVO LOW REVERSE

CLUTCH SERVO
FORWARD
CLUTCH RELEASE
APPLY
CHECK BALL
ORIFICE
USED IN PHD
MODEL
3-2 KICKDOWN TRANSMISSIONS
CONTROL VALVE ONLY
2-3 SHIFT VALVE

AND THROTTLE
REDUCING VALVE
1-2 SHIFT
ACCUMULATOR
VALVE
LOW SERVO
MODULATOR
VALVE
LOW SERVO
LOCKOUT GOVERNOR
VALVE
CONVERTER
CONTROL PRESSURE
REGULATOR VALVE
FRONT PUMP CONVERTER
PRESSURE
REGULATOR
VALVE
THROTTLE
BOOST VALVE
COOLER RETURN
OIL SCREEN OIL CHECK
THROTTLE
BOOST VALVE VALVE OIL
POLICE AND TAXI, COOLER
REAR
ONLY LUBE
X EXHAUST D 2047-A
FIG. 3—Hydraulic Control System—FMX Transmission

CONTROL LINKAGE
COLUMN SHIFT LEVER
ADJUSTMENTS

adjustments should be performed in
the order in which they appear in this
THROTTLE AND €>

DOWNSHIFT LINKAGE
ADJUSTMENTS

kickdown systems are properly adjust-
TRANSMISSION
ed. The kickdown system should come MANUAL LEVER
through detent, and not before detent.
R e f e r to G r o u p 10 for d e t a i l e d FIG. 4—Manual Linkage—Column Shift—Ford-Mteor
throttle and downshift linkage adjust-
ment procedures.
MANUAL LINKAGE
ADJUSTMENT
COLUMN SHIFT

position tight against the stop.
nut at point A (Fig. 4 or 5).
3. Shift the manual lever at the
4. Make sure that the selector lever D2024-A
has not moved from the D stop, then
tighten the nut at point A to 10-20 ft- FIG. 5—Manual Linkage—Column Shift—Fairlane-Montego
lbs.
5. Check the pointer alignment and
the transmission operation for all se-
lector lever detent positions. NEUTRAL START SWITCH 3. Remove the trim panel from the
ADJUSTMENT top of the console.
CONSOLE SHIFT 4. Remove the cover and dial indi-
CONSOLE SHIFT cator as an assembly.
On v e h i c l e s e q u i p p e d with a 5. Remove the four screws that se-
1. Position the transmission selec- column-mounted neutral start switch, cure the selector lever retainer to the
tor lever in D position. refer to Part 7-1, Section 2, for the selector lever housing. Lift the retainer
2. Raise the vehicle and loosen the adjustment procedures. from the housing.
manual lever shift rod retaining nut 6. Loosen the two combination
(Fig. 6 or 7). Move the transmission FAIRLANE-MONTEGO
starter neutral and back-up light
manual lever to the D position, fourth switch attaching screws (Fig. 8).
detent position from the back of the 1. With the manual linkage proper-
transmission. ly adjusted, check the starter en- 7. Move the selector lever back and
3. With the transmission selector gagement circuit in all positions. The forth until the gauge pin (No. 43 drill)
lever and manual lever in the D posi- circuit must be open in all drive posi- can be fully inserted into the gauge
tions, torque the attaching nut 10 to tions and closed only in park and neu- pin holes (Fig. 8).
20 ft-lbs. tral. 8. Place the transmission selector
4. Check the operation of the trans- 2. Remove the selector lever handle lever firmly against the stop of the
mission in each selector lever position. from the lever. neutral detent position.
BUTTON-7C489
HANDLE-7217
MANUAL LINKAGE
ROD-7340
TRANSMISSION
MANUAL LEVER
MANUAL LINKAGE
ROD-7340
BUSHING-7343
D2025-A
FIG. 6—Manual Linkage—Console Shift—Fairlane-Montego
PLUG-7256 HANDLE-7217
BUTTON-7C489
DIAL HOUSING
ASSEMBLY-7E034
SELECTOR LEVER
POINTER 3ACK-UP
SHIELD
HOUSING AND LEVER
ASSEM3LY-7C453 ,'
SEAL-7C370

NUT — ^
MANUAL LINKAGE ROD-7326

D2026-A
FIG. 7—Manual Linkage—Console Shift—Mustang-Cougar

NEUTRAL START SWITCH

AND HARNESS ASSEMBLY
Gauge Pin
(No. 43 Drill)
NEUTRAL START
SWITCH
ADJUSTMENT
SCREWS
D 1759-A
FIG. 8— Neutral Start Switch-

Console Shift—Fairlane-Montego
9. Slide the combination starter

neutral and back-up light switch for-
ward or rearward as required, until 32027-A
the switch actuating lever contacts the
selector lever. FIG. 9—Neutral Start Switch—Console Shift—Mustang-Cougar
10. Tighten the switch attaching
screws and remove the gauge pin. 5. Remove the two screws securing 2. Remove the trim panel from the
Check for starting in the park posi- the neutral start switch to the selector top of the console.
tion. lever housing. 3. Remove the cover and dial indi-
11. Turn the ignition key to the 6. Lift the switch from the housing cator as an assembly.
ACC position and place the selector and move the actuator lever all the 4. Remove the four screws that se-
lever in the reverse position and check way to the left. Then, return the actu- cure the selector lever retainer to the
the operation of the back-up lights. ator lever to the neutral position as selector lever housing. Lift the retainer
Turn the key off. shown in Figure 9. from the housing.
12. Position the selector lever re- 7. Position the neutral switch as- 5. Remove the two screws securing
tainer to the selector lever housing. sembly to the selector lever housing, the neutral start switch to the selector
Install the four attaching screws. and secure with the two attaching lever housing. Disconnect the neutral
13. Install the cover and dial indi- screws. start switch wires at the plug connec-
cator. 8. Place the selector lever in the P tor and remove the switch.
14. Install the trim panel on the top (Park) position and check the opera- 6. Position the neutral start switch
of the console. Install the selector tion of the switch. The engine should to the selector lever housing and in-
lever handle. start with the selector lever in the stall the two attaching screws.
park position. If the engine does not 7. With the selector lever in neu-
start, replace the switch. Refer to the tral, move the selector lever back and
MUSTANG-COUGAR Neutral Start Switch Replacement forth until the gauge pin (No. 43 drill)
procedures in this section. can be fully inserted into the gauge
1. With the manual linkage proper- 9. Install the pointer back-up shield pin holes (Fig. 8).
ly adjusted and the engine turned off, on the housing and lever assembly. 8. Place the transmission selector
place the selector lever in the N (Neu- 10. Install the dial housing on the lever firmly against the stop of the
tral) position. Then, shift the selector selector lever housing assembly. neutral detent position.
lever from neutral to 1, to P (park) 11. Install the selector lever.'handle. 9. Slide the combination starter
and back to neutral. Shifting the se- neutral and back-up light switch for-
lector lever through this shift pattern NEUTRAL START SWITCH ward or rearward as required, until
should adjust the switch automatical- REPLACEMENT- the switch actuating lever contacts the
ly. If not, adjust it manually as fol- CONSOLE SHIFT selector lever.
lows: 10. Tighten the switch attaching
2. With the selector lever in neu- On vehicles equipped with a screws and remove the gauge pin.
tral, remove the selector lever handle column-mounted neutral start switch, 11. Connect the neutral start switch
attaching screw and remove the refer to Part 7-1, Section 2, for the wires to the plug connector and check
handle (Fig. 7). replacement procedures. for starting in the park position.
3. Remove the dial housing attach- 12. Position the selector lever re-
ing screws and remove the housing. FAIRLANE-MONTEGO tainer to the selector lever housing.
4. Remove the two pointer back-up Install the attaching screws.
shield attaching screws and remove 1. Remove the selector lever handle 13. Install the cover and dial indi-
the shield. from the lever. cator.
07-03-08 FAAX Transmission 07-03-08
14. Install the trim panel on the top

of the console. Install the selector
lever handle. DETENT PAWL
MUSTANG-COUGAR
1. Place the transmission selector

lever in the N (Neutral) position.
2. Raise the vehicle and remove the
manual lever control rod attaching nut
(Fig. 7). LOCK NUT
DETENT PAWL
3. Lower the vehicle and remove ADJUSTMENT SCREW
the selector lever handle attaching DETENT PLATE
screw and the handle.
4. Remove the dial housing attach-
ing screws and the housing. D 1644-A
5. Disconnect the dial indicator
light.
6. Disconnect the neutral start FIG. 10—Typical Selector Lever Detent Pawl Adjustment
switch and dial indicator light wires
from their connectors at the dash SELECTOR LEVER the detent pawl and plate. The clear-
panel.
REPLACEMENT—CONSOLE ance should be 0.005 to 0.010 inch. If
7. Remove the four selector housing
SHIFT—FAIRLANE necessary adjust the height of the de-
and lever assembly attaching bolts.
AND MONTEGO tent pawl as shown in Figure 10.
Remove the selector lever and housing
14. Remove the handle from the se-
assembly.
lector lever.
8. Remove the two pointer back-up 1. Raise the vehicle on a hoist or 15. Position the selector lever hous-
shield attaching screws and remove jack stands. ing in the console and install the three
the shield. 2. Remove the retainer that secures attaching bolts. Do not tighten the at-
9. Remove the two screws securing the manual linkage rod to the lower taching bolts at this time.
the neutral start switch to the selector end of the manual lever (Fig. 6). 16. Connect the bulb socket to the
lever housing. Push the neutral start 3. Remove the flat washer and two selector lever housing and the neutral
switch harness plug inward and re- insulator washers and disconnect the start switch wires to the plug connec-
move the switch and harness assembly rod from the arm. tor.
(Fig. 9). 4. Working from inside of the vehi- 17. Position the selector lever re-
10. Before i n s t a l l i n g the new cle, remove the selector lever handle tainer to the selector lever housing.
switch, hold it with the wires facing attaching screw. Lift the handle off Install the four attaching screws.
downward and move the actuator the selector lever. 18. Install the cover and dial indi-
lever all the way to the left. Then, re- 5. Remove the console trim panel cator.
turn the actuator lever to the neutral from the top of the console. Remove 19. Place the console in position
position as shown in Figure 9. the console retaining screws and re- and install the retaining bolts. Tighten
11. Position the harness and neutral move the console. the selector lever housing attaching
switch assembly in the selector lever 6. Remove the cover and dial indi- bolts.
housing. Secure with the two attach- cator as an assembly. 20. Position the console trim panel
ing screws. 7. Remove the four screws that se- and secure it with the attaching
12. Install the pointer back-up cure the selector lever retainer to the screws.
shield on the housing and lever assem- selector lever housing. Lift the retainer 21. Install the handle and the but-
bly. from the housing. ton on the selector lever. Secure the
13. Position the selector lever and 8. Disconnect the neutral start handle with the set screw.
housing assembly on the console and switch wires at the plug connector. 22. Secure the manual linkage rod
install the attaching bolts. Disconnect the bulb socket from the to the arm with two insulating wash-
14. Connect the dial indicator light. selector lever housing. ers, a flat washer and a retainer (Fig.
15. Connect the neutral start switch 9. Remove the three bolts that se^ 6).
and dial indicator light wires to their cure the selector lever control housing 23. Adjust the linkage as required.
respective connectors at the dash to the console. Lift the selector lever Lower the vehicle.
panel. housing from the console.
16. Install the dial housing on the 10. Remove the selector lever to
selector lever housing assembly. housing attaching nut. Remove the MUSTANG-COUGAR
17. Install the selector lever handle. lever from the housing.
18. Raise the vehicle and secure the 11. Install the selector lever in the 1. Raise the vehicle and remove the
manual lever control rod to the selec- housing and install the attaching nut. manual lever control rod attaching nut
tor lever arm. Torque the nut to 20 to 25 ft-lbs. (Fig. 7).
19. Lower the vehicle. 12. Install the selector lever handle. 2. Lower the vehicle, remove the se-
20. Place the selector lever in the 13. Position the selector lever as lector lever handle attaching screw.
park position and check the operation shown in Figure 10. With a feeler 3. Remove the dial housing attach-
of the switch. gauge, check the clearance between ing screws and the housing.
4. Remove the pointer back-up

shield attaching screws and the shield. Too/— 7225-C-13B FRONT SERVO
inch Driv f/2 inch Driv
5. Disconnect the dial indicator /A -inch Spacer
Detail #2
light.
6. Disconnect the neutral start D.tai\ # 3
switch and dial indicator light wires T-Hond/e Extension
from their connectors at the dash Tool-758L-7195-A
panel.
7. Remove the selector housing and
lever assembly attaching bolts. Re- Detail #7
move the selector lever and housing.
8. Remove the selector lever to
housing attaching nut. Remove the
lever from the housing.
9. Install the selector lever in the
housing and install the attaching nut.
ACTUATING LEVER
Qj-«— TM-470 TM-82
Torque the nut to 20 to 25 ft-lbs.
10. Install the selector lever handle. D 2048-A D1950-A
11. Position the selector lever as FIG. 7 7—Adjusting Front Band— FIG. 12—Front and Rear Band
shown in Figure 10. With a feeler
gauge check the clearance between the Typical Adjusting Tools
detent pawl and plate. The clea r ince 9/16-inch wrench. Check the. adjusting
2. Remove the pan, then remove
should be 0.005 to 0.010 inch. If nec- screw for free rotation in the actuating
the fluid filter and clip from the trans-
essary, adjust the height of the detent lever after the lock nut is loosened,
mission. Clean the inside of the pan.
pawl as shown in Figure 10. and free the screw if necessary.
Remove all gasket material from the
12. Remo"~ the handle from tte se- 4. Pull the adjusting screw end of
pan and pan mounting face of the
lector lever. the actuating lever away from the
case.
13. Install the selector housing and servo body, and insert the 1/4 inch
3. Loosen the front servo adjusting
lever assembly as shown in Figure 4. spacer (Fig. 12) between the servo pis-
screw lock nut.
Torque the attaching bolts 4-6 ft-lbs. ton stem and the adjusting screw.
4. Pull back on the actuating rod,
14. Connect the dial indicator light.
and insert the 1/4 inch spacer between 5. Install the socket handle on the
15. Connect the neutral start switch 9/16-inch socket.
the adjusting screw and servo piston
and dial indicator light wires to their 6. Insert the T-handle extension
stem (Fig. 11). Tighten the adjusting
respective connectors at the dash through the socket handle and socket,
screw to 10 in-lbs. torque. Remove the
panel. and install the screwdriver socket on
spacer and tighten the adjusting screw
16. I n s t a l l the pointer back-up the T-handle extension.
an additional 3/4 turn. Hold the ad-
shield and tighten the attaching
justing screw stationary and tighten 7. Place the tool on the adjusting
screws.
the lock nut securely. screw so that the screwdriver socket
17. Install the selector lever handle engages the screw and the 9/16-inch
and tighten the attaching screw. 5. Install the transmission fluid
screen and clip. Install the pan using a socket engages the lock nut.
18. Position the selector lever in the 8. With a torque wrench on the T-
D position. new gasket.
6. Refill the transmission to the handle extension, tighten the adjusting
19. Raise the vehicle. Install the screw to 10 in-lbs torque.
FULL mark on the dipstick.
transmission manual lever rod to the 9. Remove the spacer and tighten
7. Start the engine and engage the
selector lever. Adjust the manual link- the adjusting screw an additional 3/4
transmission in each drive range to fill
age. turn. Hold the adjusting screw station-
all fluid passages, then place the selec-
20. Lower the vehicle and check the ary, and torque the lock nut to speci-
tor lever in the P position. Check the
transmission operation in each selec- fication.
fluid level and add enough fluid to
tor lever detent position. 10. Place a new gasket on the pan,
bring the level above the ADD mark
on the dipstick. and install the screen and pan on the
transmission.
11. Fill the transmission with fluid.
ALTERNATE FRONT
BAND ADJUSTMENTS BAND ADJUSTMENT
REAR BAND ADJUSTMENT—
FRONT BAND FORD-METEOR
1. Drain the fluid from the trans-
ADJUSTMENT
mission. If the same fluid is to be 1. Fold back the floor mat to ex-
used again in the transmission after pose the right side of the floor pan.
1. Drain the fluid from the trans- Che band adjustment, filter the fluid 2. Remove the access hole cover
mission by loosening the pan attach- through a 100-mesh screen as it drains from the floor pan. Remove all dirt
ing bolts starting at the rear of the from the transmission. Re-use the from the adjusting screw threads, then
pan and working toward the front. fluid only if it is in good condition. oil the threads.
When most of the fluid has drained 2. Remove and thoroughly clean 3. Loosen the rear band adjusting
from the pan, remove the remainder the pan and screen. Discard the pan screw lock nut with the tool shown in
of the attaching bolts. Use a clean gasket. Fig. 13. Using the T-handle portion of
drain can equipped with a 100-mesh 3. Loosen the front servo adjusting the tool, tighten the adjusting screw
screen if the fluid is to be reused. screw locknut two full turns with a until the wrench overruns.
Too/-T69P-7B793-A ADJUSTING
I IN SCREW
ADJUSTING SCREW
REAR SERVO \ LOCK NUT
LOCK NUT
Tool—7795-C D1329-A D2029-A
FIG. 13—Adjusting Rear Band— FIG. 15—Rear Servo Lever

Ford-Meteor Adjusting Screw Dimension—
Fairlane, Montego, Mustang and
If the screw is found to be tighter TorqueWrench REAR SERVO APPLY LEVER Cougar
D2028-A
than wrench capacity (10 ft-lbs tor-
que), loosen the screw and tighten FIG. 14—Adjusting Rear Band—
until the wrench overruns. Fairlane, Montego, Mustang and External Band Adjustment
4. Back off the adjusting screw 1 Cougar
1/2 turns. Hold the adjusting screw 1. With the transmission mounted
stationary, and tighten the adjusting the external adjustment procedure in a holding fixture, loosen the inter-
screw lock nut to specifications. only when the transmission has been nal rear servo adjusting screw lock nut
Severe damage may result if the ad- removed from the vehicle, or when all (Fig. 15).
justing screw is not backed off exactly available internal adjustment has been 2. Set the internal adjusting screw
1 1/2 turns. taken up and a further band adjust- to the dimension shown in Figure 15.
ment is required. Tighten the lock nut.
ALTERNATE REAR BAND Internal Band Adjustment 3. With the internal adjusting screw
ADJUSTMENT— properly adjusted, loosen the external
1. Drain the fluid from the trans- adjusting screw lock nut.
FORD-METEOR mission. If the same fluid is to be 4. Using a torque wrench with an
used again in the transmission after Allen head socket, tighten the adjust-
The tool shown in Fig. 12 may be the band adjustment, filter the fluid
used to adjust the rear band. ing screw to 10 ft-lbs torque.
through a 100-mesh screen as it drains 5. Back off the adjusting screw
1. Place the socket holder on the from the transmission. Re-use the
3/4-inch socket (Fig. 12). Insert the 1-1/2 turns.
fluid only if it is in good condition. 6. Hold the adjusting screw from
T-handle extension through the handle 2. Remove and thoroughly clean
and socket. turning and torque the lock nut to
the pan and filter. Discard the pan specification.
2. Place the 5/ 16-inch 8-point sock- gasket.
et on the extension. Place a torque 3. Loosen the rear servo adjusting
wrench on the T-handle extension. screw lock nut.
3. Insert the assembled tool in the 4. Pull the adjusting screw end of
access hole so that it engages the ad- GOVERNOR REPLACEMENT
the actuating lever away from the
justing screw and the lock nut. servo body, and insert the spacer tool 1. Raise the vehicle so that the
4. Loosen the adjusting screw lock shown in Fig. 14 between the servo transmission extension housing is ac-
nut. accumulator piston and the adjusting cessible.
5. Torque the adjusting screw to 10 screw. Be sure the flat surfaces of the 2. Drain the fluid from the trans-
ft-lbs. tool are positioned squarely between mission.
6. Remove the torque wrench from the adjusting screw and the accumula- 3. Disconnect the drive shaft from
the T-handle extension and back off tor piston. The tool must not touch the rear axle and slide the front yoke
the adjusting screw exactly 1 1/2 the servo piston and the tool handle out of the extension housing.
turns. Severe damage may result to must not touch the servo piston spring
the transmission if the adjusting screw 4. D i s c o n n e c t the speedometer
retainer. cable from the extension housing.
is not backed off exactly 1 1 / 2 turns. 5. Using a torque wrench with an
7. Hold the adjusting screw station- 5. Remove the two bolts that secure
Allen head socket (Fig. 14), tighten the extension housing to the engine
ary and tighten the lock nut securely. the adjusting screw to 24 in-lbs tor- rear support.
que. 6. Remove the nut and bolt that se-
REAR BAND ADJUSTMENT— 6. Back off the adjusting screw cures the engine rear support to the
FAIRLANE, MONTEGO 1-1/2 turns. Hold the adjusting screw crossmember.
MUSTANG AND COUGAR stationary and tighten the adjusting 7. R a i s e the transmission high
screw lock nut sequrely. Remove the enough to provide clearance for the
Adjustment of the rear band may spacer tool. rear mount.
be performed either internally or ex- 7. Install the transmission fluid fil- 8. Lift the engine rear support from
ternally. Use the internal band adjust- ter and clip. Install the pan using a the crossmember.
ment procedures when making a nor- new gasket. 9. Lower the jack until the exten-
mal (in-vehicle) band adjustment. Use 8. Fill the transmission with fluid. sion housing just clears the crossmem-
07-03-11 FMX Transmission 07 03-11
COMPENSATOR MAIN CONTROL

PRESSURE TUBE VALVE TUBE
GOVERNOR
FRONT SERVO
FLUID TUBES
COUNTERWEIGHT
D 1815-A
FIG. 16—Governor Installed PRESSURE

REGULATOR
ber to remove all weight from the

housing.
10. Loosen the parking brake cable
adjustment nut enough to disconnect
the cables from the equalizer.
11. Remove the extension housing
D 1817-A
attaching bolts. Slide the housing off
the output shaft and remove the gas-
ket. When removing the extension
housing and/or governor, hold the FIG. 17—Typical Hydraulic Control System
output shaft and rear support from
moving rearward to prevent the needle gine rear support on the crossmember. 3. Disconnect the hose from the
bearing and race from dropping out of Secure the support to the crossmem- vacuum diaphragm unit. Remove the
location. ber with attaching bolt. diaphragm unit using tool FCO-24.
12. Remove the governor to coun- 19. Lower the transmission and re- Do not use any tools on the dia-
terweight attaching screws. Lift the move the jack. Secure the extension phragm housing, such as pliers, pipe
governor from the counterweight (Fig. housing to the rear support with the wrenches, etc. Do not allow solvents
16). two attaching bolts. to enter the diaphragm unit. Remove
13. Lubricate the governor valve 20. Connect the parking brake the push rod. Remove the fluid screen
parts with clean transmission fluid. cables to the equalizer and adjust the retaining clip and the screen.
Make certain that the valve moves cables as required. 4. Remove the fluid filter retaining
freely in the valve body bore. 21. Install the driveshaft. clip and the filter.
14. Position the governor valve 22. Fill the transmission to the cor- 5. Remove the two tubes which
body on the counterweight with the rect level with the specified fluid. connect to the pressure regulator and
cover facing toward the front of the the control valve body (Fig. 17).
vehicle. Install and tighten the two at- 6. Loosen the front servo attaching
taching screws to the specified torque. bolts three turns.
15. Position a new extension hous- OIL PAN AND CONTROL 7. Remove the three control valve
ing gasket on the rear of the transmis- VALVE BODY REPLACEMENT body attaching bolts, and lower the
sion case. valve body while pulling it off the
16. Slide the extension housing into 1. Raise the vehicle so that the front servo tubes. Be carefull not to
place and secure it to the transmission transmission fluid pan is accessible. damage the valve body or the tubes.
case with the attaching bolts. Torque 2. Drain the fluid from the trans- 8. Before installing the control
the bolts to specification. With the ex- mission by loosening the pan attach- valve body, check for a bent manual
tension housing installed, rotate the ing bolts starting at the rear of the valve by rolling it on a flat surface.
output shaft. The shaft must rotate pan and working toward the front. 9. Install the control valve body by
freely by hand. If the shaft is tight or When most of the fluid has drained aligning the front servo tubes with the
bound up, it is likely that the needle from the pan, remove the remainder holes in the valve body. Shift the man-
bearing and race have dropped out of of the attaching bolts. Remove the ual lever to the 1 detent, and place the
location, in which case, the transmis- pan and gasket. Discard the gasket. If inner downshift lever between the
sion must be partially disassembled the same fluid is to be used again in downshift lever stop and the downshift
and the bearing and race repositioned. the transmission, filter the fluid valve. The manual valve must engage
17. Connect the speedometer cable through a 100-mesh screen before in- the actuating pin in the manual detent
to the extension housing. stalling it in the transmission. Re-use lever.
18. Raise the transmission high the fluid only if it is in good condi- 10. Install but do not tighten, the
enough with a jack to position the en- tion. control valve body attaching bolts.
11. Move the control valve body 4. Remove the pressure regulator Check the clearance between the
toward the center of the case until the attaching bolts and washers, and re- manual valve and manual lever actuat-
clearance is less than 0.050 inch, be- move the regulator. ing pin as given in Oil Pan and Con-
tween the manual valve and the act- 5. Position the replacement regula- trol Valve Body Replacement.
uating pin on the manual detent lever. tor body on the transmission case and 9. Adjust the front band.
12. Torque the attaching bolts to install the two attaching bolts. Torque 10. Install the vacuum diaphragm
specification. Be sure that the rear the bolts to specification. unit and rod.
fluid filter retaining clip is installed 6. Check the converter pressure and 11. Install the fluid filter and pan,
under the valve body bolt as shown in control pressure valves to be sure the and fill the transmission with fluid.
Figure 17. valves operate freely in the bores. 12. Adjust the downshift and manu-
13. Install the tubes to the pressure 7. Install the valve springs, spacer, al linkage.
regulator and the control valve body. and retainer.
14. Turn the manual valve one full 8. Install the large control pressure
turn in each manual lever detent posi- tube, and the small compensator pres-
tion. If the manual valve binds against sure tube. REAR SERVO REPLACEMENT
the actuating pin in any detent posi- 9. Install the fluid filter and the
tion, loosen the valve body attaching pan, and fill the transmission to the 1. Drain the fluid from the trans-
bolts and move the body away from correct level with the specified fluid. mission, and remove the pan and fluid
the center of the case. Move the valve filter.
body only enough to relieve the bind- 2. Remove the vacuum diaphragm
ing. Torque the attaching bolts and FRONT SERVO REPLACEMENT unit.
recheck the manual valve for binding. 3. Remove the control valve body
15. Position the push rod in the 1. Drain the fluid from the trans- and the two front servo tubes.
bore of the vacuum diaphragm unit. mission, and remove the pan and fluid 4. Remove the attaching bolts from
Using the diaphragm unit as a guide, filter. the rear servo, hold the actuating and
insert the push rod into the threaded 2. Remove the vacuum diaphragm anchor struts with the fingers, and re-
opening of the case. Torque the dia- unit. move the servo. Remove the servo
phragm unit to specification. Connect 3. Loosen the three control valve dowel on PHB models.
the vacuum hose. body attaching bolts. 5. To install the rear servo, position
16. Torque the front servo attach- 4. Remove the attaching bolts from the servo anchor strut on the servo
ing bolts to specification. the front servo (Fig. 17), hold the band, and rotate the band to engage
17. Adjust the front band. If the strut with the fingers, and remove the the strut.
unit is a model PHB-C, D, E, F, G or servo. 6. Hold the servo anchor strut in
H, adjust the rear band at this time. 5. To install the front servo, posi- position with the fingers, position the
18. Install the fluid filter and the tion the front band forward in the actuating lever strut, and install the
filter retaining clip. case with the end of the band facing servo. Insert the servo dowel on PHB
19. Position a new fluid pan gasket downward. Make sure the front servo models.
on the bottom of the transmission anchor pin is in position in the case 7. Install the servo attaching bolts,
case, and install the pan. Torque the web. Align the large end of the servo and torque them to specification. The
pan screws to specification. strut with the servo actuating lever, longer bolt must be installed in the
2 0 . A d j u s t the rear band on and align the small end with the band inner bolt hole.
PHB-A and PHD models. end. 8. Install the two front servo tubes
21. Fill the transmission with fluid. 6. Rotate the band, strut, and servo and the control valve body.
If the fluid that was drained from the to align the anchor end of the band Check the clearance between the
transmission is to be used again, filter with the anchor in the case. manual valve and the manual lever
the fluid through a 100-mesh screen as Push the servo body onto the con- actuating pin as given above in Oil
it is poured back into the transmis- trol valve body tubes. Pan and Control Valve Body Replace-
sion. Re-use the fluid only if it is in 7. Install the attaching bolts and ment.
good condition. torque to specification. 9. Adjust the rear band.
22. If the control valve body was 8. Torque the control valve body 10. Install the fluid filter and pan,
replaced, adjust the transmission con- attaching bolts to specification. and fill the transmission with fluid.
trol linkage.
PRESSURE REGULATOR
REPLACEMENT
1. Drain the fluid from the trans-

mission, and remove the pan and fluid Too/~7?75-AB
filter.
2. Remove the small compensator
pressure tube and the large control
pressure tube from the control valve
body and the pressure regulator.
3. Remove the pressure regulator 7oo/-T50T-JOO-A
spring retainer, springs, and spacer. D 1927-A
Maintain pressure on the retainer to
prevent the springs from flying out. 78—Removing Extension Housing Seal
EXTENSION HOUSING
EXTENSION HOUSING move the toggle to the rear of the case
BUSHING AND REAR SEAL to move the pin outward. Repeat this
Tool-T57P-7697-A
REPLACEMENT or 7000-G or AD procedure until the pin can be re-
1. Disconnect the drive shaft from moved from the case. Lift the pawl
the transmission. and toggle from the case as an assem-
2. Carefully remove the seal with bly.
the tools shown in Fig. 18. 19. Remove the pawl and toggle
D1O25-B
3. Remove the bushing as shown in lever as an assembly.
Fig. 19. Use the bushing remover
FIG. 79—Removing Extension 20. Position the new parking pawl
carefully so that the spline seal is not Housing Bushing and link assembly, then install the
damaged. toggle lever pin and the plug.
4. When installing a new bushing 21. Secure the pawl to the case
BUSHING
use the special tool shown in Fig. 20. Tool—T57P-7697-B
with the pawl pin.
5. Before installing a new seal, in- 7000-HF 22. Position a new gasket on the
spect the sealing surface of the univer- front of the support and at the rear.
sal joint yoke for scores. If scores are Hold them in place with transmission
found, replace the yoke. fluid or vaseline.
6. Inspect the counterbore of the 23. Make sure that the thrust wash-
housing for burrs. Polish off all burrs EXTENSION HOUSING D1O26-B er is in place, then position the sup-
with crocus cloth. port and output shaft in place making
FIG. 20—Installing Extension sure that the pressure tubes are en-
7. Install the seal into the housing
with tool shown in Fig. 21. The seal
Housing Bushing tered in the case.
should be firmly seated in the bore. 24. Secure the extension housing to
band adjusting screw lock nut and the case with the attaching bolts.
PARKING PAWL tighten the adjusting screw to 24 in-lbs 25. Install the main control valve
REPLACEMENT torque. This will tighten the rear band assembly.
1. On Ford and Meteor vehicles, around the planet carrier and will hold 26. Adjust the front band.
loosen the right front scuff plate and the planet carrier and clutch assem- 27. Adjust the rear band on a Fair-
lift the carpet back until the rear band blies in position during the parking lane, Montego, Mustang or Cougar.
adjusting stud access hole is accessi- pawl repair operation. 28. Position the vacuum control rod
ble. 12. Remove the vacuum control di- in the case. Install the vacuum dia-
Remove the access hole plug and, phragm unit.
aphragm unit and control rod.
with T o o l 7195-C or T o o l T58L- 29. Install the filter, transmission
13. Remove the main control valve pan and a new gasket.
7195-A, loosen the adjusting stud lock rear support assembly from the case.
nut. Turn the adjusting stud in until 30. Connect the speedometer cable
14. Remove the extension housing to the extension housing.
the tool handle overruns. This will attaching bolts and housing.
tighten the rear band around the plan- 31. Raise the transmission high
15. Remove the output shaft and enough to position the engine rear
et carrier and will hold the planet car-
assembly retaining bolts and valve as- support on the crossmember. Secure
rier and clutch assemblies in position
sembly. the support with the attaching bolt.
during the parking pawl repair opera-
tion. 16. Remove the parking pawl pin 32. Lower the transmission and re-
from the case with a magnet. move the jack. Install the two exten-
2. Raise the vehicle and drain the
fluid from the transmission. 17. Working from inside of the sion housing-to-engine rear support
3. Place the adjustable support case, drive on the shoulder of the tog- attaching bolts.
stand under the rear of the engine. gle lever (Fig. 52) pin with a small 3 3 . C o n n e c t the parking brake
4. Remove the driveshaft. punch to move the retaining plug part cables to the equalizer.
5. Disconnect the parking brake way out of the case. Remove the plug 3 4 . I n s t a l l the driveshaft, then
cables from the crossmember and with a pair of pliers. lower the vehicle.
equalizer bracket. 18. To remove the toggle lever pin, 35. On Ford and Meteor vehicles,
6. Remove the engine r e a r slide the toggle lever toward tlfe front adjust the rear band.
support-to-extension housing bolts. of the case. Cock the lever to one side 36. Fill the transmission to the cor-
7. Remove the bolt that secures the to apply pressure on the pin, then rect level with the specified fluid.
engine rear support to the crossmemb-
er. Raise the engine with the adjusta- Too/— T6U-7657-A or 8,
ble support stand just high enough to 7657-AA, or 7657 AB
provide clearance for removing the
support.
8. Lower the jack until the exten-
sion housing just clears the crossmem-
ber to remove all weight from the
housing.
9. D i s c o n n e c t the speedometer
cable from the transmission. EXTENSION HOUSING
10. Remove the transmission pan
and fluid filter. REAR SEAL
1 1 . On a F a i r l a n e , M o n t e g o ,
Mustang or Cougar, loosen the rear FIG. 21—Installing Extension Housing Seal
An oil impregnated plastic grommet 12. Support the transmission on a 14. Install the starter motor.
is incorporated in the end of the man- stand. Remove the engine rear support 15. Connect the fluid filter tube to
ual shift linkage lever arm on all col- to transmission bolts, and raise the the transmission case. Connect the
umn shift vehicles. A special tool t r a n s m i s s i o n slightly to take the v a c u u m hose to the vacuum dia-
T67P-7341-A is required to install the weight off the cross member. Remove phragm unit and the tube to its clip.
grommet in the manual lever, and to the cross member. Support the rear 16. Lower the transmission support
install the manual linkage rod into the part of the engine. stand. Then install the upper two con-
grommet. Refer to Part 7-1, Section 13. Remove the remaining convert- verter housing-to-engine bolts and
2, for the grommet replacement pro- er housing to engine attaching bolts. tighten them to specification.
cedures. Move the assembly to the rear and 17. Lower the vehicle and fill the
down to remove it. transmission with transmission fluid,
TRANSMISSION AND following the recommended procedure.
CONVERTER REPLACEMENT— 18. Check the transmission, con-
FORD-METEOR INSTALLATION verter assembly, and fluid cooler lines
for fluid leaks, and then adjust the
1. If the converter has been re- manual and downshift linkages.
moved from the converter housing,
REMOVAL carefully position the converter in the TRANSMISSION REPLACEMENT
housing, and then install the housing WITHOUT CONVERTER—
1. Drive the vehicle on a hoist, but lower front cover plate to prevent the FORD-METEOR
do not raise at this time. converter from slipping out of the
2. Remove the two upper bolts and housing. The frame construction of the con-
lock washers which attach the con- 2. Install the transmission vent vertible will not permit the transmis-
verter housing to the engine. tube. Rotate the converter until the sion to be moved rearward enough to
3. Raise the vehicle and remove the studs adjacent to the drain plugs are clear the turbine shaft from the con-
cover from the lower front side of the in a vertical position. verter. For this reason, the converter
converter housing. Drain the fluid 3. Rotate the flywheel as required and transmission must be removed as
from the transmission. to align the drain plug holes with the a unit from this model.
4. Remove one of the converter drain plugs in the converter. With the REMOVAL
drain plugs. Then rotate the converter transmission mounted on a support
180 degrees and remove the other stand, move the converter and trans- 1. Raise the vehicle on a hoist.
plug. Do not attempt to turn the con- mission assembly forward into posi- 2. Drain the fluid from the trans-
verter with a wrench on the converter tion, using care not to damage the fly- mission.
stud nuts. If desired, the converter wheel and the converter pilot. 3. Disconnect the hose from the
may be drained after the unit has been 4. I n s t a l l the c o n v e r t e r lower vacuum diaphragm unit and the tube
removed from the vehicle. housing-to-engine bolts, then torque from its clip. Disconnect the fluid fill-
5. Disconnect the fluid filler tube the bolts to specification. er tube from the case.
from the transmission case. Discon- 5. Install the cross member. 4. Remove the cover from the lower
nect the vacuum hose from the vacu- 6. Lower the transmission until the front side of the converter housing.
um diaphragm unit and the tube from extension housing rests on the cross 5. Remove one of the converter
the extension housing clip. member, and then install the extension drain plugs. Then rotate the converter
6. When the fluid has stopped housing-to-cross member bolts. 180 degrees and remove the other
draining from the transmission and 7. The converter must rest squarely plug. Do not attempt to turn the con-
converter, remove the flywheel to con- against the flywheel. This indicates verter with a wrench on the converter
verter nuts and flat washers. Install that the converter pilot is not binding stud nuts.
the drain plugs in the converter and in the engine crankshaft. 6. Disconnect the drive shaft from
torque to specifications. Install the 8. Install the converter attaching the rear axle, and remove the drive
converter housing front plate to hold nuts and flat washers. Install the ac- shaft.
the converter in place when the trans- cess plates. 7. Disconnect the fluid cooler lines
mission is removed. 9. Connect the oil cooler inlet and from the transmission. Remove the
7. Disconnect the starter cables outlet lines to the transmission case. vent tube.
from the starter and remove the start- 10. Coat the front universal joint 8. Disconnect the downshift linkage
er. y o k e s e a l and spline with B8A- at the transmission.
8. Disconnect the oil cooler lines 19589-A lubricant, and install the 9. Disconnect the selector rod from
from the transmission. Remove the drive shaft. the transmission manual lever with
transmission vent tube. 11. Connect the speedometer cable tool T67P-7341-A.
9. Disconnect the downshift linkage at the transmission. 10. Disconnect the speedometer
from the transmission. 12. Using tool T67P-7341-A install cable at the extension housing.
10. Disconnect the selector rod from a new grommet in the manual lever. 11. Remove the two engine rear
the transmission manual lever with Then secure the manual selector rod support to transmission bolts.
T67P-7341-A. to the lever. 12. Position a transmission jack
11. Disconnect the speedometer 13. Connect the downshift linkage under the transmission and raise it
cable from the extension housing, and and b u s h i n g at the transmission slightly to take the weight off the
remove the driveshaft. throttle lever. cross member.
end of the input shaft to hold the 14. Remove the thrust washer from
clutch units together. Then remove the the front of the input shaft.
center support and the front and rear 15. To remove the front band, posi-
clutch assemblies as a unit (Fig. 25). tion the band ends between the case
13. Install the clutch assemblies in webbing and tilt the bottom of the
the bench fixture (Fig. 26). band rearward. Then, squeeze the
ends of the band together and remove
from the rear of the case.
FRONT CLUTCH 16. Lift the front clutch assembly
CYLINDER
from the primary sun gear shaft.
TUBES
REAR CLUTCH
17. Remove the bronze and the
DRUM steel thrust washers from the rear
REAR SUPPORT clutch assembly. Wire the thrust
washers together to assure correct in-
stallation.
18. Remove the front clutch seal
OUTPUT SHAFT
rings from the primary sun gear shaft.
D 1819-A 19. Lift the rear clutch assembly
INPUT SHAFT
from the primary sun gear shaft.
FRONT BAND
FIG. 23 — Rear Support and D1957-A 20. Remove the rear clutch seal
rings from the primary sun gear shaft.
Output Shaft Installed FIG. 25—Removing or Installing Do not break the seal rings.
Input Shaft and Clutch 21. Remove the primary sun gear
6. Remove the rear support and front thrust washer.
gasket from the output shaft. Remove
the needle bearings and race from the FRONT CLUTCH INPUT SHAFT PARTS REPAIR AND
CYLINDER
rear support (Fig. 24). SECONDARY REAR
REPLACEMENT
7. Remove the selective thrust SUN GEAR a u T C H
washer from the rear of the pinion DRUM During the repair of the sub-
carrier. assemblies, certain general instructions
8. Remove the pinion carrier. which apply to all units of the trans-
9. Remove the primary sun gear mission must be followed. These in-
rear thrust bearing and races from the structions are given here to avoid un-
pinion carrier. necessary repetition.
10. Note the rear band position for Handle all transmission parts care-
reference in assembly. The end of the fully to avoid nicking or burring the
band next to the adjusting screw has a bearing or mating surfaces.
depression (dimple) in the center of Lubricate all internal parts of the
the boss. Squeeze the ends of the rear transmission with transmission fluid
-77530-A
band together, tilt the band to the before assembly. Do not use any other
rear, and remove the rear band from lubricants except on gaskets and
the case. thrust washers which may be coated
11. Remove the two center support D1958-A with vaseline to facilitate assembly.
outer bolts (one each side) from the Always install new gaskets when as-
transmission case. FIG. 26—Input Shaft and Clutch sembling parts of the transmission.
12. Exert enough pressure on the in Holding Fixture Tighten all bolts and screws to the
recommended torque. For detail
cleaning and inspection operations
refer to Part 7-1.
REAR BRAKE DRUM

SUPPORT BUSHING
REPLACEMENT
1. If the rear brake drum support

bushing is to be replaced, press the
bushing from the support as shown in
Fig. 27.
2. Press a new bushing into the
brake drum support with the tool
, GOVERNOR
shown in Fig. 27.
GOVERNOR NEEDLE ROLLER OUTPUT SHAFT BUSHING

DRIVE BALL BEARING REPLACEMENT
D 1820-A
1. Remove the output shaft bushing

FIG. 24—Output Shaft Disassembled if it is worn or damaged. Use the cape
Press Rom ton out of the clutch drum with air

pressure. Hold one hand over the pis-
ton to prevent damage.
5. Remove the inner and outer seal
Handle rings from the clutch piston.
6. Remove the rear clutch sun gear
Tool - T64L-7003-A4
bushing if it is worn or damaged. Use
the cape chisel (Fig. 31) and cut along
the bushing seam until the chisel
breaks through the bushing wall. Pry
the loose ends of the bushing up with
an awl and remove the bushing.
7. Press a new bushing into the rear
Tool - T64L.7003.B4
clutch sun gear with the tool shown in
Fig. 32.
8. Install new inner and outer seal
rings on the piston.
REMOVAL INSTALLATION D 1751-A 9. To install the piston in the clutch
drum, lubricate the piston seals and
FIG. 27—Replacing Rear Brake Drum Support Bushing tools (Fig. 30) with clean transmission
fluid.
10. Push the small fixture down
chisel and cut along the bushing seam from the shaft with a sharp knife. Be over the cylinder hub.
until the chisel breaks through the careful not to score the ring grooves. 11. Insert the piston into the large
bushing wall. Pry the loose ends of 3. Replace the teflon seals with cast fixture with the seal toward the thin-
the bushing up with an awl and re- iron seal rings, and check for free walled end.
move the bushing. movement in the groove. 12. Hold the p i s t o n and large
2. Insert a new bushing into the in- fixture and insert as a unit into the
stallation tool and position the tool REAR CLUTCH cylinder. Push down over the small
and bushing over the output shaft hub. fixture until the large tool stops
Then, press the bushing on the output 1. Remove the clutch pressure plate
shaft hub as shown in Fig. 28. snap ring, and remove the pressure Too/-
plate from the drum. Remove the T68P-7D758-A
Press Ram Tool - T64L-7003.A7 waved cushion spring. Remove the

composition and steel plates.
2. Compress the spring with the
tools shown in Fig. 29 and remove the
snap ring.
3. Guide the spring retainer while
releasing the pressure to prevent the
retainer from locking in the snap ring
REAR CLUTCH
grooves. DRUM
4. Position the primary sun gear
shaft in the rear clutch. Place an air D2038-A
hose nozzle in one of the holes in the

shaft, and place one finger over the FIG. 30— Installing Rear Clutch
other hole. Then force the clutch pis- Piston
Too/-T65L-77575-A
FIG. 28—Installing Output Shaft

Bushing
PRIMARY SUN GEAR SHAFT
1. Position the primary sun gear

shaft in the clutch bench fixture.
2. Check the fit of the seal rings in
their respective bores. If equipped
with cast iron seal rings, a clearance
of 0.002-0.009 inch should exist be-
tween the ends of the rings. REAR CLUTCH D 1592-A
DRUM
If equipped with teflon seals that
are worn or damaged, cut the seals FIG. 29—Removing Rear Clutch Spring Snap Ring
16. Install the clutch pressure plate

with the bearing surface down. Then
install the clutch pressure plate snap
Cape Chisel ring. Make sure the snap ring is fullv
seated in the groove,
17. Check the free pack clearance
between the pressure plate and the
snap ring with a feeler gauge. The
clearance should be O.O3O-O.O55 inch.
If the clearance is not within specifi-
cations, select? 5 snap rings are avail-
able in the following thicknesses:
0.060-0.064, 0.074-0.078, 0.088-0.092
and 0.102-0.106 inch. Insert the cor-
FRONT
rect size snap ring and recheck the CLUTCH
clearance. CYLINDER
18. Install the thrust washer on the
primary sun gear shaft. Lubricate all D 2049-A
parts with automatic transmission
FIG. 31—Removing Rear Clutch fluid or petroleum jelly. Install the FIG. 33—Removing or Installing
Sun Gear Bushing two center seal rings. Front Clutch Snap Ring
19. Install the rear clutch on the
primary sun gear shaft. Be sure all of chisel and cut along the bushing seam
against the shoulder in the cylinder; the needles are in the hub if the unit is until the chisel breaks through the
then push the piston down, out of the equipped with loose needle bearings. bushing wall. Pry the loose ends of
tool, until it bottoms in the cylinder. Assemble two seal rings in the front the bushing up with an awl and re-
Remove the tools. grooves. move the bushing.
13. Install the clutch release spring, 20. Install the steel and the bronze 9. Slip a new bushing over the end
and position the retainer on the thrust washers on the front of the sec- of the installation tool and position
spring. ondary sun gear assembly. If the steel the tool and bushing to the bushing
14. Install the tool on the spring re- washer is chamfered, place the cham- hole. Then, press the bushing into the
tainer as shown in Fig. 29. Compress fered side down. input shaft as shown in Fig. 35.
the clutch spring, and install the snap 10. Lubricate all parts with trans-
ring. While compressing the spring, FRONT CLUTCH mission fluid. Install a new piston
guide the retainer to avoid interference inner seal ring in the clutch cylinder.
of the retainer with the snap ring 1. Remove the clutch cover snap Install a new piston outer seal in the
groove. Make sure the snap ring is ring with a screwdriver, and remove groove in the piston.
fully seated in the groove. When new the input shaft from the clutch drum. 11. Install the piston in the clutch
composition clutch plates are used, 2. Remove the thrust washer from housing. Make sure the steel bearing
soak the plates in automatic transmis- the thrust surface of the clutch hub. ring is in place on the piston.
sion fluid for 15 minutes before they Insert one finger in the clutch hub, 12. Position the release spring in
are assembled. and lift the hub straight up to remove the clutch cylinder with the concave
15. Install a steel clutch plate and the hub from the clutch drum. side up. Place the release spring com-
the waved cushion spring. Then, in- 3. Remove the composition and the pressor on the spring, and compress
stall steel and friction plates alternate- steel clutch plates, and then remove the spring with an arbor press. Then
ly starting with a steel plate. the pressure plate from the clutch
Tool - T64L-7003-A3 OR Tool - T64L-7003-A4 drum.
4. Place the front clutch spring
compressor on the release spring, po- PISTON APPLY
• *'£- ' •
jRflg. >...•...!• Hondle sition the clutch drum on the bed of HOLE
an arbor press, and compress the re-
lease spring with the arbor press until
the release spring snap ring can be re-
moved (Fig. 33).
5. Remove the clutch release spring
from the clutch drum.
6. Install the special nozzle shown
in Fig. 34 on an air hose. Place the
nozzle against the clutch apply hole in
the front clutch housing, and force the PISTON
piston out of the housing.
7. Remove the piston inner seal Air
Nozzle ool-7000-DD
from the clutch housing. Remove the
D 1747-A
piston outer seal from the groove in D1959-A
the piston.
FIG. 32—Installing Rear Clutch 8. Remove the input shaft bushing FIG. 34—Removing Front Clutch
Sun Gear Bushing if it is worn or damaged. Use the cape Piston
PRESSURE PLATE The final friction plate to be in-

Handle stalled is selective. Install the thickest
plate that will be a minimum of 0.010
inch below input shaft shoulder in cyl-
inder. For all other plates, use the
thinnest available. Refer to the Speci-
fications Section for available plate
thickness.
16. Install the turbine shaft in the
clutch cylinder, and then install the
snap ring. Make sure the snap ring is
fully seated in the groove.
Tool - T64L-7003-A6 17. Install the thrust washer on the
turbine shaft.
FRONT PUMP
D 1752-A D1O45-A
1. Remove the stator support at-
taching screws and remove the stator
FIG. 35—Installing Input Shaft FIG. 37—Installing Pressure Plate support. Mark the top surface of the
Bushing pump driven gear with Prussian blue
to assure correct assembly. Do not
scratch the pump gears.
2. Remove the drive and driven
install the snap ring as shown in Fig. gears from the pump body.
33. Make sure the snap ring is fully 3. Refer to Fig. 39 for a disas-
seated in the groove. . sembled view of the front pump. In-
13. Install the front clutch housing spect the pump body housing, gear
on the primary sun gear shaft by ro- pockets and crescent for scores.
tating the clutch units to mesh the 4. If the pump housing bushing is
rear clutch plates with the serrations to be replaced, press the bushing from
on the clutch hub. Do not break the the front housing with the tools shown
seal rings. in Fig. 40.
14. Install the clutch hub in the 5. Press a new bushing into the
D1961-A
clutch cylinder with the deep counter- pump housing with the handle and
bor down (Fig. 36). Install the thrust FIG. 38—Installing Clutch Plates tool shown in Fig. 40.
washer on the clutch hub. 6. If any parts other than the stator
15. Install the pressure plate in the BUSHING ^ . ^ ^ DRIVE GEAR support or bushings are found defec-
clutch cylinder with the bearing sur- tive, replace the pump as a unit.
face up (Fig. 37). Install the composi- Minor burrs and scores may be re-
tion and the steel clutch plates alter- moved with crocus cloth. The stator
nately, starting with a composition support is serviced separately.
plate (Fig. 38). Lubricate the plates as 7. Bolt the front pump to the trans-
they are installed. D 1047-B mission case with capscrews.
39—Front Pump Disassembled
HUB
REMOVAL INSTALLATION D 1748-A

D1960-A
/:/G. 36—Installing Clutch Hub 4Q—Replacing Front Pump Housing Bushing

Tool—1175-AB Tool— T50T-100-A

12. Place the pump driven gear in 4. Install the pressure tubes.
the pump body with the mark on the
gear facing down. Install the drive PRESSURE REGULATOR
gear in the pump body with the cham-
fered side of the flats facing down. 1. Remove the valves from the re-
13. Install the stator support and gulator body.
D1962-A attaching screws. Check the pump 2. Remove the regulator body cover
gears for free rotation. attaching screws, and remove the
FIG. 41—Removing Front Pump cover (Fig. 45).
Seal REAR SUPPORT BUSHING 3. Remove the separator plate.
REPLACEMENT 4. Wash all parts thoroughly in
clean solvent and blow dry with
8. I n s t a l l the oil seal remover 1. Remove the three pressure tubes moisture-free compressed air.
shown in Fig. 41. Then pull the front from the support housing.
seal from the pump body. 5. Inspect the regulator body and
2. Remove the rear support bushing cover mating surfaces for burrs.
9. Clean the pump body counter- if it is worn or damaged. Use a cape 6. Check all fluid passages for ob-
bore. Then inspect the bore for rough chisel and cut along the bushing seam structions.
spots. Smooth up the counterbore until the chisel breaks through the 7. Inspect the control pressure and
with crocus cloth. bushing wall. Pry the loose ends of converter pressure valves and bores for
10. Remove the pump body from the bushing up with an awl and re- burrs and scores. Remove all burrs
the transmission case. move the bushing. carefully with crocus cloth.
11. Coat the outer diameter of a 3. Press a new bushing into the 8. Check the free movement of the
new seal with FoMoCo Sealing Com- support housing with the tool shown valve in their bores. Each valve should
pound, or its equivalent. Then position in Fig. 44. fall freely into its bore when both the
the seal in the pump body. Drive the
valve and bore are dry.
seal into the pump body with the tool Too/ - T64L-7003-A2 Handle
9. Inspect the valve springs for dis-
shown in Fig. 42 until the seal is firm-
tortion.
ly seated in the body. Tool 77837 may
be reworked (Fig. 43) to install the 10. Position the separator plate on
the regulator cover.
latest type seal.
11. Position the regulator cover and
separator plate on the regulator body,
and install the attaching screws. Tor-
que the screws to specification.
12. Insert the valves in the pressure
regulator body (Fig. 45).
CONTROL VALVE BODY
During the disassembly of the con-

FRONT PUMP D 2050-A trol valve assembly, avoid damage to
BODY
valve parts and keep the valve parts
clean. Place the valve assembly on a
FIG. 44—Installing Rear Support clean shop towel while performing the
Housing Bushing disassembly operation. Do not sepa-
D1963-A
FIG. 42—Installing Front Pump REGULATOR CONTROL PRESSURE

Seal BODY VALVE
CHAMFER TO REMOVE BURRS
CONVERTER RETAINER
SEPARATOR PRESSURE CONVERTER PRESSURE
VALVE SPRINGS RETAINER
FRONT PUMP OIL SEAL

1111
INSTALLATION
MACHINE OFF
COVER
1111
D1964-A
D1965-A
FIG. 43— Front Pump Seal
Installing Tool Modification FIG. 45— Pressure Regulator Disassembled
TRANSMISSION CASE
DETENT S P R I N G — « ^ DETENT PLUNGER
BUSHING REPLACEMENT
MANUAL SHAFT DETENT
MANUAL SHAFT NUT
AND LEVER / LEVER
INNER DOWNSHIFT LEVER 1. If the transmission case bushing
/ DOWNSHIFT is to be replaced, press the bushing
/ SHAFT NUT TOGGLE LIFT
out of the case with the tools shown in
ijG LEVER SPRING
Fig. 53.
2. Install a new transmission case
bushing with the tool shown in Fig.
53.
ASSEMBLY OF TRANSMISSION
TOGGLE LEVER- Do not use force to assemble mat-

PAWL RETURN SPRING- ing parts. If the parts do not assemble
TOGGLE LEVER PIN- freely, examine them for the cause_pf
PLUG' the difficulty. Always use new gaskets
D1967-A
and seals during the assembly opera-
tions.
FIG. 52—Transmission Case Control Linkage
CLUTCH ASSEMBLIES
pawl return spring. Assemble the tog- Hold the detent plug on the spring
1. Install the front band in the
gle lever to the link with the toggle with a 3/16-inch socket wrench, then
transmission case so that the anchor
link pin. Position the pawl return depress the spring until the plug is
end is aligned with the anchor in the
spring over the toggle link pin, and se- flush with the case. Carefully rotate
case.
cure it in place with the washer and the manual lever to the front of the
case to secure the plug. A piece of 2. Make sure the thrust washer is
the small retainer clip (Fig. 52). In- in place on the input shaft. Lift the
stall the assembly in the transmission thin walled tubing may be used to
depress the plug if a small socket clutch assemblies out of the holding
case by installing the pawl pin and the block. Do not allow the clutches to
toggle lever pin. Install the torsion wrench is not available.
separate.
lever assembly. Position the spring on 5. Position the ends of the parking
3. Install the clutch sub-assemblies
the torsion lever with a screwdriver. pawl operating rod in the detent lever
in the transmission case while posi-
Make certain that the short side of and toggle lift lever, and secure with
tioning the servo band on the drum.
toggle does not extend beyond the the two small retaining pins.
Hold the units together while install-
largest diameter of the ball or the tog- 6. Install a new seal on the down- ing them (Fig. 25).
gle lever pin (Fig. 52). Tap the toggle shift lever shaft, then install the lever
lever in or out as necessary to center and shaft in the case. Position the
the toggle lever on the ball. inner downshift lever on the inner end CENTER SUPPORT,
4. Install the manual lever and of the shaft with the mark O facing ONE-WAY CLUTCH,
shaft in the transmission case. Posi- toward the center of the case. Install PINION CARRIER, AND
tion the detent lever on the shaft, and the lock washer and nut, then tighten OUTPUT SHAFT
secure it with a nut. Tighten the nut the nut to 17-20 ft-lbs torque.
to 20-30 ft-lbs torque. Rotate the 7. Check the operation of the link- The production center supports are
manual lever to the rear of the case. age. The linkage should operate freely chamfered at the edge of the race
Position the detent spring in the case. without binding. (Fig. 54). The service center supports
are not chamfered. The following as-
sembly procedures cover both types of
Handle
center supports.
Press Ram
Installation—Center Support
With Chamfered Edge
1. Install the center support and the

rear band in the case.
2. Install the primary sun gear rear
thrust bearing race, needle bearing,
and front thrust bearing race if used
in the planet carrier using petroleum
jelly to retain them in place.
3. Lubricate the bearing surface on
the center support, the rollers of the
planetary clutch, and the cam race in
Tool - T64L.7003-BS Tool - T64L-7003-A5 the carrier with petroleum jelly (Fig.
REMOVAL INSTALLATION D 1745-B 54).
4. Install the planetary clutch in the
FIG. 53—Replacing Transmission Case Bushing carrier (Fig. 55).
07-03-27 FMX Transmission 0703-27
Installation—Center Support
not Chamfered
CENTER SUPPORT
" C A M TYPE" CLUTCH RACE 1. Install the center support and the
PLANETARY CLUTCH rear band in the case.
2. Install the primary sun gear, rear
thrust bearing race, needle bearing
and front thrust bearing race if used
in the planet carrier using petroleum
jelly to retain them in place.
3. Lubricate the bearing surface of
the center support, the rollers of the
planetary clutch, and the cam race in
the carrier with vaseline.
CHAMFER O N PRODUCTION
i. Install the^ planetary clutch on
PART, ONLY-SERVICE PART NOT CHAMFERED PLANET CARRIER
the center support with the saw teeth
of the clutch cage pointing in the
D1938-A
clockwise direction as viewed from the
rear (Fig. 56). Make sure that all roll-
FIG. 54—Planetary Clutch, Planet Carrier and Center Support ers are in the cage.
5. Position the planet carrier on the
support so that the cams in the carrier
5. Carefully position the planet car- 8. Check the operation of the plan- engage the saw teeth on the clutch
rier on the center support. Move the etary clutch by rotating the carrier co- cage.
carrier forward until the clutch rollers unterclockwise. It should rotate count- 6. Push the planet carrier forward
are felt to contact the bearing surface erclockwise (viewed from the rear) until the rollers are felt to contact the
of the center support. with a slight drag, and it should lock surface of the cam race.
6. While applying forward pressure up when attempting to rotate it in a 7. While applying forward pressure
on the planet carrier, rotate it counte- clockwise direction. on the carrier, rotate it counterclock-
rclockwise, as viewed from the rear 9. Install the selective thrust washer wise as viewed from the rear. This will
(Fig. 55). This will cause the clutch on the pinion carrier rear pilot. II the cause the rollers to roll toward the
rollers to roll toward the large open- end play was not within specifications large opening end of the cams in the
ing end of the cams in the race, com- when checked prior to disassembly, race, compressing the springs slightly,
pressing the spring slightly, so that the replace the washer with one of proper so that the rollers will enter the cams.
rollers will ride up the chamfer on the thickness. Refer to the Specification 8. Some rollers may become
planetary support and onto the inner Section of Group 7 for selective thrust cocked preventing their entry into the
race. washer thickness. outer race. These rollers must be posi-
7. Push the planet carrier all the 10. Install the output shaft, careful- tioned individually with a small screw-
way forward. ly meshing the internal gear with the driver by pushing the rear of the roll-
pinions. ers toward the transmission and into
the cam race (Fig. 56). Keep pressure
applied to the carrier at all times.
PLANET 9. After all of the rollers have been
CARRIER started into the cam race, rotate the
carrier counterclockwise while pushing
it forward. Again, straighten any roll-
ers which still may be in a cocked po-
sition and prevent the carrier from
sliding onto the support.
10. Make sure that all springs are
entered in the cam race before at-
tempting to push the carrier on the
support. Push the carrier all the way
forward and check the operation of
the clutch by rotating it in a counte-
rclockwise direction. The carrier
should rotate counterclockwise with a
slight drag and should lock up when
attempting to rotate it in a clockwise
direction.
ROTATE CARRIER
11. Install the selective thrust wash-
COUNTER CLOCKWISE er on the pinion carrier rear pilot. If
the end play was not within specifica-
tions when checked prior to disassem-
bly, replace the washer with one of
D 1292-C
proper thickness. Refer to the Specifi-
. 55—Planetery Clutch Installation in Carrier—Chamfered Center cation Section of Group 7 for selective
Support thrust washer thickness.
er between the large internal gear and

ROTATE
the transmission case. Note the indi-
CENTER CARRIER cator reading. End play should be
COUNTER
SUPPORT
CLOCKWISE
0.010-0.029 inch (minimum end play
is preferred).
4. Remove the indicator and the
tool from the extension housing.
5. Install the one remaining front
pump attaching bolt and torque it to
specification.
FRONT SERVO
1. Position the front band forward

in the case with the band ends up.
SAWTEETH IN 2. Position the servo strut with the
CLOCKWISE slotted end aligned with the servo act-
DIRECTION
uating lever, and with the small end
aligned with the band end. Rotate the
band, strut, and servo into position
MOVE ROLLER engaging the anchor end of the band
TOWARD CENTER with the anchor pin in the case.
3. Locate the servo on the case, and
install the attaching bolts. Tighten the
D 1291-D
attaching bolts only two or three
threads.
FIG. 56—Planetary Clutch Installation in Carrier—Center Support 4. Install the servo release tube.
Not Chamfered
REAR SERVO
12. Install the output shaft, careful- 19554-A sealer and install the exten- 1. Position the servo anchor strut,
ly meshing the internal gear with the sion housing attaching bolts, breather and rotate the rear band to engage the
pinions. tube clip, vacuum tube clip, and exter- strut.
nal tooth lock washer. The lock wash- 2. Position the servo actuating lever
REAR SUPPORT ers must be installed with the rolled strut with a finger, and then install the
edge toward the transmission case to servo and attaching bolts. Torque the
1. Position the needle bearing and insure a tight seal. bolts to specification.
retainer on the rear support (Fig. 24). 2. Torque the extension housing at- 3. Install the front servo apply
2. Position a new rear support to taching bolts to specification. tube.
case gasket on the rear support. Re- 3. Install the lubrication tube.
tain the gasket with transmission PRESSURE REGULATOR
fluid. FRONT PUMP BODY
3. Install the rear support. As the
support is installed, insert the tubes 1. Position a new front pump gask- 1. Install the pressure regulator
into the case. et in the counterbore of the transmis- body and attaching bolts, and torque
sion case. the bolts to specifications.
GOVERNOR 2. Install the front pump, aligning 2. Install the control and converter
the pump bolt holes with the holes in valve guides and springs. Install the
1. Position the governor drive ball the case. Install three of the front spring retainer.
in the pocket in the output shaft. Re- pump attaching bolts and torque them
tain the ball with transmission fluid. to specification. CONTROL VALVE BODY
2. Install the governor assembly, al-
igning the groove with the ball in the TRANSMISSION END 1. Install the control valve assem-
output shaft. PLAY CHECK bly, carefully aligning the servo tubes
3. Install the governor with the gov- with the control valve. Align the inner
ernor body plate toward the front of 1. Mount the dial indicator support downshift lever between the stop and
the vehicle (Fig. 23). Install the gover- in a front pump bolt hole. Mount a the downshift valve. Shift the manual
nor snap ring dial indicator on the support so that lever to the 1 position. Align the man-
the contact rests on the end of the tur- ual valve with the actuating pin in the
EXTENSION HOUSING bine shaft. manual detent lever. Do not tighten
2. Use a large screwdriver to pry the attaching bolts.
1. Insert the extension housing oil the front of the clutch drum toward 2. Move the control valve body
seal re placer and pilot in the housing. the rear of the transmission. Set the toward the center of the case until the
Position a new gasket to the extension dial indicator at zero. clearance is less than 0.050 inch be-
housing and install the extension 3. Remove the screwdriver and pry tween the manual valve and the act-
housing on the transmission case. the units toward the front of the uating pin on the manual detent lever.
C o a t t h e b o l t t h r e a d s with B5A- transmission by inserting a screwdriv- 3. Torque the attaching bolts to
specification. Be sure that the rear FRONT AND REAR rear clip so that the tang enters the
fluid screen retaining clip is installed BAND ADJUSTMENTS hole in the filter flange. Then, rotate
under the valve body bolt as shown in the filter (clockwise) until the grom-
Fig. 17. Adjust the front and rear bands as met is over the pump inlet port of the
4. Install the large control pressure detailed in Section 2. valve body regulator and press the fil-
tube in the valve body and regulator. ter down firmly. Install the filter re-
5. Install the small control pressure taining clip.
compensator tube in the valve body VACUUM DIAPHRAGM UNIT 2. Place a new gasket on the trans-
and regulator. mission case and install the pan. In-
6. Turn the manual valve one full 1. Position the control rod in the stall the attaching bolts and lock
turn in each manual lever detent posi- bore of the vacuum diaphragm unit washers and torque the bolts to speci-
tion. If the manual valve binds against and install the diaphragm unit. Make fication.
the actuating pin in any detent posi- sure the control rod enters the throttle If the converter and converter hous-
tion, loosen the valve body attaching valve as the vacuum unit is installed. ing were removed from the transmis-
bolts and move the body away from 2. Torque the diaphragm unit to sion, install these components. Posi-
the center of the case. Move the body specification. tion the transmission assembly on the
only enough to relieve the binding. transmission jack, and refer to Trans-
Torque the attaching bolts and check FLUID FILTER mission Installation Procedures for in-
the manual valve for binding. AND OIL PAN stalling the transmission.
7. Torque the front servo attaching
bolts to specification. 1. Position the fluid filter on the
07-04-01 C-6 Automatic Transmission 07-04-01
PART 7-4 C-6 Automatic Transmission

MODEL APPLICATION
Trans- Selector
Thunderbird
Continental-
Continental
mission Engine Lever
All Models
Montego
Mustang
Mercury
Fairlane
Mark III
Model Model Location
Lincoln-
Cougar
Meteor
Falcon
Ford
1
PGA-A3 390-2V Column X X
PGA-J3 390-2V Console X x X
PGA-AC 390-4VI.P. Column X X
PGA-AD 390-2VI.P. Console X X
PGA-AE 390-2V I.P. Console X X
PGA-Z 429-2V Column X X X
PGA-AA 429-2V Console X X X
PGB-F2 428-4 V®@ Column X X
PGB-G2 390-2V,4V© Column X X X
PGB-H2 428-4V® Column X X X
PGB-J1 429-4V Column X
PGB-AD 429-4V Column X X X
PGB-AE 429-4V Console X X X
PGB-AF-1 428-4VC.J. Console X X
PGB-AG 428-4V C. J. Column X X
PGB-AH 428-4V C.J. Console X X
PGC-B 460-4V Column X
PGC-C1 460-4V Column X
©Police Interceptor
©All Except 3.25: 1 Axle
©Police, Fleet and Heavy Duty Units
All Models
All Models
ASSEMBLY OF TRANSMISSION 04-29 EXTENSION HOUSING REAR SEAL

BAND ADJUSTMENT Removal and Installation 04-13
Intermediate Band 04-11 FORWARD CLUTCH
CONTROL VALVE BODY Cleaning and Inspection 04-15
Cleaning and Inspection 04-16 Disassembly and Overhaul 04-25
Disassembly and Overhaul 04-22 FRONT PUMP
Removal and Installation 04-12 Cleaning and Inspection 04-15
DESCRIPTION 04-02 Disassembly and Overhaul 04-24
DISASSEMBLY AND OVERHAUL OF GOVERNOR
TRANSMISSION 04-18 Cleaning and Inspection 04-16
DOWNSHIFT LINKAGE Removal and Installation 04-11
Adjustment 04-05 INPUT SHELL AND SUN GEAR
Parts Repair or Replacement 04-20 Disassembly and Overhaul 04-27
EXTENSION HOUSING LOW-REVERSE CLUTCH PISTON
Cleaning and Inspection 04-14 Disassembly and Overhaul 04-28
Removal and Installation 04-11 MANUAL LINKAGE
EXTENSION HOUSING BUSHING Adjustment 04-05
All Models
All Models
NEUTRAL START SWITCH-CONSOLE SELECTOR LEVER-CONSOLE SHIFT

SHIFT Removal and Installation 04-09
Adjustment 04-05 SERVO
Removal and Installation 04-09 Cleaning and Inspection 04-16
(Refer to Part 7-1 for column shift adjust- Disassembly and Overhaul 04-28
ment and removal and installation procedures) Removal and Installation 04-11
ONE-WAY CLUTCH SERVO APPLY LEVER
Cleaning and Inspection 04-16 Parts Repair or Replacement 04-21
Disassembly and Overhaul 04-28 SERVO SEAL
OUTPUTSHAFT Removal and Installation 04-12
Disassembly and Overhaul 04-28 THROTTLE LINKAGE ADJUSTMENT 04-05
OUTPUT SHAFT HUB AND RING GEAR TRANSMISSION (Complete)
PARKING PAWL LINKAGE TRANSMISSION CASE THREAD REPAIR 04-21
Parts Repair Replacement 04-21
REVERSE-HIGH CLUTCH
1 DESCRIPTION
DESCRIPTION converter, front pump, clutches, gear tification tag (Fig. 2), attached to the
train and most of the internal parts intermediate servo lower front cover
Figure 1 shows the location of the used in the C6 transmission. The iden- bolt, includes the model prefix and
FORWARD CLUTCH HUB LOW-REVERSE GOVERNOR EXTENSION

SUPPORT AND RING GEAR CLUTCH DISTRIBUTOR SLEEVE HOUSING
INTERMEDIATE
CONVERTER GOVERNOR SEAL
BAND
REVERSE
RING GEAR
OUTPUT
SHAFT
EXTENSION
HOUSING
REVERSE PLANET
CARRIER
'FRONT PLANET CARRIER

INPUT
SHAFT
PARKING PAWL ACTUATING ROD
FORWARD CLUTCH
CONVERTER
ONE-WAY
CONTROL LEVERS
v > L U I v*ri «wi>i-»>p^fc_ iivir" n LTR i
REVERSE-HIGH CLUTCH
D1924- A
CONTROL VALVE BODY
FIG. 1—C6 Automatic Transmission—Sectional
suffix, a service identification number, TRANSMISSION

MODEL
and serial number. The service identif-
ication number indicates changes to
service details which affect interchan-
geability when the transmission model
is not changed. For interpretation of
this number, see the Master Parts Ca-
talog.
The C6 transmission is a three
speed unit capable of providing auto-
matic upshifts and downshifts through
the three forward gear ratios, and also D1925-A
capable of providing manual selection
of first and second gears. The hydrau- FIG. 2—Identification Tag
lic control system schematic is shown
in Figure 3. The converter housing along with the forward clutch is used and allowing it to drain. Finally, to
and the fixed splines which engage the to obtain intermediate gear. allow the pan to drain more thorough-
splined OD of the low-reverse clutch The only adjustment on the trans- ly, remove all bolts except the two
steel plates, are both cast integrally mission proper is the intermediate from the front.
into the case. band.
Only one (intermediate) band is The fluid is drained from the trans-
used in the C6 transmission. This mission by loosening the pan bolts
.CONVERTER FORWARD CLUTCH LOW AND REVERSE CLUTCH.

INTERMEDIATE SERVO PRIMARY
CHECK VALVE GOVERNOR
(STATOR SUPPORT)
SECONDARY
GOVERNOR
REVERSE AND HIGH CLUTCH
INTERMEDIATE
CHECK VALVE INTERMEDIATE SERVO
(STATOR SUPPORT) SERVO CAPACITY
ACCUMULATOR MODULATOR
CONTROL
PRESSURE
COASTING
REGULATOR
MAIN OIL THROTTLE

PRESSURE PRESSURE
REGULATOR MODULATOR
3-2 SHIFT
X TIMING
VALVE
MANUAL LOW
2-1
SCHEDULING
3-2ORFICE
AND CHECK
VALVE
MAIN OIL
PRESSURE
BOOSTER THROTTLE
PRESSURE
THROTTLE DOWNSHIFT BOOSTER
THROTTLE
PRESSURE
RELIEF
MANUAL VALVE
n
CONVERTER I I 1! I I
PRESSURE P RND2 1
RELIEF
X EXHAUST
D1816-A
FIG. 3—Hydraulic Control System

CONTROL LINKAGE
ADJUSTMENTS
COLUMN SHIFT LEVER
adjustments should be performed in
the order in which they appear in this SHIFT ROD
THROTTLE AND
DOWNSHIFT LINKAGE
ADJUSTMENTS

kickdown systems are properly adjust- TRANSMISSION
ed. The kickdown system should come MANUAL LEVER

through detent, and not before detent. D2031-A
R e f e r to G r o u p 10 for d e t a i l e d
throttle and downshift linkage adjust- FIG. 4—Manual Linkage—Column Shift—Ford-Mercury-Meteor
ment procedures.
TRANSMISSION
MANUAL LEVER
MANUAL LINKAGE
ADJUSTMENT
Column Shift

position tight against the stop.
nut at point A (Fig. 4, 5, 6 or 7).
3. Shift the manual lever at the
4. Make sure that the selector lever
has not moved from the D stop; then, D2032-M
tighten the nut at point A to 10-20 ft-
lbs. FIG. 5—Manual Linkage—Column Shift—Fairlane-Montego
5. Check the transmission operation
for all selector lever detent positions.
NEUTRAL START SWITCH handle to the lever. Remove the
ADJUSTMENT- handle and detent control.
CONSOLE SHIFT 3. Remove the two screws from the
Console Shift rear of the console top panel. Pull the
On v e h i c l e s e q u i p p e d with a panel back to unhook it from the
column-mounted neutral start switch, front of the console and remove the
1. Position the transmission selec- refer to Part 7-1, Section 2, for the panel.
tor lever in the D position. adjustment procedures. 4. Loosen the two combination
2. Raise the vehicle and loosen the starter neutral and back-up light
manual lever shift rod retaining nut FORD, MERCURY switch attaching screws (Fig. 11).
(Fig. 8, 9 or 10). Move the transmis- AND METEOR 5. Move the selector lever back and
sion manual lever to the D position, forth until the gauge pin (No. 43 drill)
fourth detent position from the back 1 . With the manual linkage proper- can be fully inserted into the gauge
of the transmission. ly a d j u s t e d , check the starter en- pin holes (Fig. 11).
3. With the transmission selector gagement circuit in all positions. The 6. Place the transmission selector
lever and manual lever in the D posi- circuit must be open in all drive posi- lever firmly against the stop of the
tions, torque the retaining nut 10 to tions and closed only in park and neu- neutral detent position.
20 ft-lbs. tral. 7. Slide the combination starter
4. Check the operation of the trans- 2. Remove the four screws and neutral and back-up light switch for-
mission in each selector lever position. p l a t e s s e c u r i n g the selector lever ward or rearward as required, until
07-04-06 C-6 Automatic Transmission 0704-06
TRANSMISSION
MANUAL LEVER
STUD-7B415

D2033-A
FIG. 6—Manual Linkage—Column Shift—Lincoln Continental

the console and install the retaining
screws.
11. Position the selector lever de-
tent control and handle on the selector
lever and secure with the four plates
and attaching screws.
FAIRLANE-MONTEGO
INNER BRACKET-7C431
1. With the manual linkage proper-
TRANSMISSION
ly a d j u s t e d , check the starter en-
MANUAL LEVER gagement circuit in all positions. The
circuit must be open in all drive posi-
tions and closed only in park and neu-
tral.
ROD-7326
2. Remove the selector lever handle
from the lever.
3. Remove the trim panel from the
top of the console.
SHIFT ROD-7A024
4. Remove the cover and dial indi-
cator as an assembly.
5. Remove the six screws that se-
cure the selector lever retainer to the
POINT A
ENGAGE FLAT OF STUD IN SLOT OF selector lever housing. Lift the retainer
BRACKET ASSEMBLY-7C324 D1831-A
from the housing.
6. Loosen the two combination
FIG. 7—Manual Linkage—Column Shift—Thunderbird-Continental Mark III starter neutral and back-up light
switch attaching screws (Fig. 12).
the switch lever contacts the selector was adjusted, tighten the actuator 7. Move the selector lever back and
lever actuator. If an adjustment can lever bolt. forth until the gauge pin (No. 43 drill)
not be made by rotating the switch, 9. Turn the ignition key to the can be fully inserted into the gauge
loosen the actuator lever attaching ACC position and place the selector pin holes (Fig. 12).
bolt and adjust the lever (Fig. 11). lever in the reverse position and check 8. Place the transmission selector
8. Tighten the neutral start switch the operation of the back-up lights. lever firmly against the stop of the
attaching screws. If the actuator lever Turn the key off. neutral detent position.
7E263 ASSEMBLY • • - { p i —
NUT
332334-S-l
D 1822-A
FIG. 8—Manual Linkage—Console Shift—Ford-Mercury-Meteor
TRANSMISSION
MANUAL
LEVER
SELECTOR LEVER
SELECTOR
LEVER
RETAINER
NUT
MANUAL 382384-S4
LINKAGE ROD
7340
FLAT WASHER
372285-S8
ENGAGE FLATS OF
STUD IN SLOT OF BUSHING
7343
ROD BEFORE APPLYING
TORQUE
D1829-A
FIG. 9—Manual Linkage—Console Shift—Fairlane-Montego

PLUG-7256 • •HANDLE-7217
I DIAL HOUS NG
ASSEMBLY-7E034
HOUSING AND LEVER

ASSEMBLY-7C453
POINTER BACK-JP
SHIELD

D2034-A
FIG. 10—Manual Linkage—Console Shift—Mustang-Cougar
ACTUATOR LEVER ATTACHING BOLT
Gauge Pin
(No. 43 Drill)
NEUTRAL START
SWITCH
FIG. 72—Neutral Start Switch

Adjustment—Console Shift—
Fairlane-Montego
D1812-A
FIG. 11—Neutral Start Switch Adjustments—Console Shift 12. Position the selector lever re-
tainer to the selector lever housing.
9. Slide the combination starter Check for starting in the park posi- Install the six attaching screws.
neutral and back-up light switch for- tion. 13. Install the cover and dial indi-
ward or rearward as required, until 11. Turn the ignition key to the cator.
the switch actuating lever contacts the ACC position and place the selector
selector lever. lever in the reverse position and check 14. Install the trim panel on the top
10. Tighten the switch attaching the operation of the back-up lights. of the console. Install the selector
screws and remove the gauge pin. Turn the key off. lever handle.
MUSTANG AND COUGAR NEUTRAL START 12. Position the selector lever re-
SWITCH
tainer to the selector lever housing.
Install the attaching screws.
1. With the manual lever properly 13. Install the cover and dial indi-
adjusted, loosen the two switch attach- cator.
ing bolts (Fig. 13). 14. Install the trim panel on the top
2. With the transmission manual of the console. Install the selector
lever in neutral, rotate the switch and lever handle.
insert the gauge pin (No. 43 drill
shank end) into the gauge pin holes of MUSTANG AND COUGAR
the switch. The gauge pin has to be
inserted to a full 31/64 inch into the 1. Remove the downshift linkage
three holes of the switch (Fig. 13). rod from the transmission downshift
3. Torque the two switch attaching lever.
bolts to specification. Remove the 2. Apply penetrating oil to the
gauge pin from the switch. downshift lever shaft and nut. Remove
4. Check the operation of the the transmission downshift outer lever
switch. The engine should start only D1459-A retaining nut and lever (Fig. 13).
with the transmission selector lever in 3. Remove the two neutral start
Neutral and Park. FIG. 73—Neutral Start Switch switch attaching bolts.
Adjustment—Console Shift— 4. Disconnect the multiple wire
NEUTRAL START SWITCH Mustang and Cougar connector. Remove the neutral switch
REPLACEMENT—CONSOLE from the transmission.
SHIFT 10. Position the selector lever de- 5. Install the neutral start switch on
tent control and handle on the selector the transmission. Install the two at-
On v e h i c l e s e q u i p p e d with a lever and secure with the four plates taching bolts.
column-mounted neutral start switch, and attaching screws. 6. With the transmission manual
refer to Part 7-1, Section 2, for the lever in neutral, rotate the switch and
replacement procedures. install gauge pin (No. 43 drill) into
FAIRLANE AND MONTEGO
the gauge pin hole (Fig. 13).
FORD, MERCURY 7. Tighten the switch attaching
AND METEOR 1. Remove the selector lever handle bolts to specification and remove the
1. Remove the four screws and from the lever. gauge pin.
p l a t e s securing the selector lever 2. Remove the trim panel from the 8. Install the outer downshift lever
handle to the lever. Remove the top of the console. and attaching nut, and torque the nut
handle and detent control. 3. Remove the cover and dial indi- to specification. Install the downshift
2. Remove the two screws from the cator as an assembly. linkage rod to the downshift lever.
rear of the console top panel. Pull the 4. Remove the four screws that se- 9. Install the switch wires. Connect
panel back to unhook it from the cure the selector lever retainer to the the wire multiple connector. Check
front of the console and remove the selector lever housing. Lift the retainer the operation of the switch in each de-
panel. from the housing. tent position. The engine should start
3. Remove the two screws securing 5. Remove the two screws securing only with the transmission selector
the dial indicator assembly to the se- the neutral start switch to the selector lever in N (neutral) and P (park).
lector lever housing and remove the lever housing. Disconnect the neutral
indicator assembly. start switch wires at the plug connec- SELECTOR LEVER
4. Disconnect the neutral start tor and remove the switch. REPLACEMENT-
switch wires at the plug connector. 6. Position the neutral start switch CONSOLE SHIFT
Remove the wires from under the re- to the selector lever housing and in-
taining clip. stall the two attaching screws. FORD, MERCURY
5. Remove the two screws securing 7. With the selector lever in neu- AND METEOR
the neutral start switch to the selector tral, move the selector lever back and
lever housing and remove the switch forth until the gauge pin (No. 43 drill) 1. Raise the vehicle and disconnect
(Fig. 11). can be fully inserted into the gauge the link assembly from the selector
6. Position the neutral start switch pin holes (Fig. 12). lever arm (Fig. 8).
to the selector lever housing and in- 8. Place the transmission selector 2. Lower the vehicle. Remove the
stall the two attaching screws. lever firmly against the stop of the four screws and plates securing the se-
7. Adjust the neutral start switch as neutral detent position. lector lever handle to the lever. Re-
outlined under the Neutral Start 9. Slide the combination starter move the handle and detent control.
Switch Adjustment procedures in this neutral and back-up light switch for- 3. Remove the two screws from the
section. ward or rearward as required, until rear of the console top panel. Pull the
8. Connect the neutral start switch the switch actuating lever contacts the panel back to unhook it from the
Wires to the plug connector. Position selector lever. front of the console and remove the
the wires in the retaining clip and 10. Tighten the switch attaching panel.
close the clip. screws and remove the gauge pin. 4. Disconnect the neutral start
9. Place the console top panel on 11. Connect the neutral start switch switch wires at the plug connector.
the console and install the retaining wires to the plug connector and check Disconnect the bulb socket from the
screws. for starting in the park position. quadrant.
5. Remove the four bolts that at-

tach the selector lever housing to the
floor pan and remove the selector DETENT PAWL
lever and housing.
6. Position the new selector lever
and housing assembly on the floor pan
and install the attaching bolts.
7. Connect the bulb socket to the
quadrant and the neutral start switch
wires to the plug connector.
8. Raise the vehicle and secure the
link assembly to the selector lever arm LOCK NUT
with the bushing, insulator, flat wash- DETENT PAWL
ADJUSTMENT SCREW
er and cotter pin (Fig. 8). Lower the DETENT PLATE
vehicle.
the console and install the retaining
D 1644-A
screws.
10. Position the selector lever de-
tent control and handle on the selector FIG. 14—Typical Selector Lever Detent Pawl Adjustment
lever and secure with the four plates
and attaching screws. the detent pawl and plate. The clear- 3. Remove the dial housing attach-
ance should be 0.005 to 0.010 inch. If ing screws and the housing.
necessary adjust the height of the de- 4. Remove the pointer back-up
FAIRLANE AND MONTEGO tent pawl as shown in Figure 14. shield attaching screws and remove
14. Remove the handle from the se- the shield.
lector lever. 5. Disconnect the dial indicator
1. Raise the vehicle on a hoist or 15. Position the selector lever hous- light.
jack stands. ing in the console and install the three 6. Remove the selector housing and
2. Remove the retainer that secures attaching bolts. Do not tighten the at- lever assembly attaching bolts. Re-
the manual linkage rod to the lower taching bolts at this time. move the selector lever and housing.
end of the manual lever (Fig. 9). 16. Connect the bulb socket to the 7. Remove the selector lever to
3. Remove the flat washer and two selector lever housing and the neutral housing attaching nut. Remove the
insulator washers and disconnect the start switch wires to the plug connec- lever from the housing.
rod from the arm. tor. 8. Install the selector lever in the
4. Working from inside of the vehi- 17. Position the selector lever re- housing and install the attaching nut.
cle, remove the selector lever handle tainer to the selector lever housing. Torque the nut to 20 to 25 ft-lbs.
attaching screw. Lift the handle off Install the four attaching screws. 9. Install the selector lever handle.
the selector lever. 18. Install the cover and dial indi- 10. Position the selector lever as
5. Remove the console trim panel cator. shown in Figure 14. With a feeler
from the top of the console. Remove 19. Place the console in position gauge check the clearance between the
the console retaining screws and re- and install the retaining bolts. Tighten detent pawl and plate. The clearance
move the console. the selector lever housing attaching should be 0.005 to 0.010 inch. If nec-
6. Remove the cover and dial indi- bolts. essary adjust the height of the detent
cator as an assembly. 20. Position the console trim panel pawl as shown in Figure 14.
7. Remove the four screws that se- and secure it with the attaching 11. Remove the handle from the se-
cure the selector lever retainer to the screws. lector lever.
selector lever housing. Lift the retainer 21. Install the handle and the but- 12. Install the selector housing and
from the housing. ton on the selector lever. Secure the lever assembly as shown in Figure 10.
8. Disconnect the neutral start handle with the set screw. Torque the attaching bolts 4-6 ft-lbs.
switch wires at the plug connector. 22. Secure the manual linkage rod 13. Connect the dial indicator light.
Disconnect the bulb socket from the to the arm with two insulating wash- 14. I n s t a l l the pointer back-up
selector lever housing. ers, a flat washer and a retainer (Fig. shield on the housing and lever assem-
9. Remove the three bolts that se- 9). bly.
cure the selector lever control housing 23. Adjust the linkage as required. 15. Install the dial housing and
to the console. Lift the selector lever Lower the vehicle. tighten the attaching screws.
housing from the console. 16. Install the selector lever handle
10. Remove the selector lever to and tighten the attaching screw.
housing attaching nut. Remove the 17. Position the selector lever in the
lever from the housing. MUSTANG AND COUGAR D position.
11. Install the selector lever in the 18. Raise the vehicle. Install the
housing and install the attaching nut. transmission manual lever rod to the
Torque the nut to 20 to 25 ft-lbs. 1. Raise the vehicle and remove the selector lever. Adjust the manual link-
12. Install the selector lever handle. manual lever control rod attaching nut age.
13. Position the selector lever as (Fig. 10). 19. Lower the vehicle and check the
shown in Figure 14. With a feeler 2. Lower the vehicle, remove the se- transmission operation in each selec-
gauge, check the clearance between lector lever handle attaching screw. tor lever detent position.
BAND ADJUSTMENT nental, connect the parking brake

equalizer. Adjust the parking brake as
required.
INTERMEDIATE BAND 9. Install the drive shaft.
10. Fill the transmission to the cor-
1. Raise the vehicle on a hoist or rect level with the specified fluid.
jack stands.
2. Clean all the dirt from the band
adjusting screw area. Remove and dis-
card the lock nut. SERVO REPLACEMENT
3. Install a new lock nut and tight-
en the adjusting screw to 10 ft-lbs tor- ALL VEHICLES EXCEPT
que (Fig. 15). LINCOLN CONTINENTAL
4. Back off the adjusting screw ex-
actly 1 full turn.
5. Hold the adjusting screw from
Removal
turning and torque the lock nut to TOOL-T59 P-77370-B
specification. D 1597-A
1. Raise the vehicle on a hoist or
6. Lower the vehicle. stands.
FIG. 75—Adjusting Band
2. Remove the engine rear
EXTENSION HOUSING OR support-to-extension housing attaching
GOVERNOR REPLACEMENT bolts.
3 . R a i s e the transmission high
enough to remove the weight from the
REMOVAL engine rear support.
TUBES 4. Remove the bolt that secures the
1. Raise the vehicle on a hoist or engine rear support to the crossmemb-
stands. DISTRIBUTOR
er. Remove the support.
2. Disconnect the parking brake 5. Lower the transmission and re-
cable from the equalizer. On a Lin- move the jack.
coln Continental, remove the equaliz- GOVERNOR
6. Place a drain pan beneath the
er. servo. Remove the bolts that attach
3. Disconnect the driveshaft from the servo cover to the transmission
the rear axle flange and remove it case.
from the transmission. 7. Remove the cover, piston, spring
4. D i s c o n n e c t the speedometer and gasket from the case, screwing the
cable from the extension housing. band adjusting screw inwards as the
5. Remove the engine rear piston is removed. This insures that
SPACER
support-to-extension housing attaching D1598-A there will be enough tension on the
bolts. band to keep the struts properly en-
On a Lincoln Continental, remove FIG. 76—Governor Installed gaged in the band end notches while
the reinforcement plate from under the piston is removed.
the transmission oil pan. 2. Clean the mounting surface on
6. Place a jack under the transmis- the transmission and on the extension
sion and raise it just enough to re- housing. Position a new gasket on the
move the weight from the engine rear transmission.
support. 3. Hold the extension housing in SEAL REPLACEMENT
7. Remove the bolt that secures the place and secure it with the attaching
engine rear support to the crossmemb- bolts. 1. Apply air pressure to the port in
er and remove the support. 4. R a i s e the transmission high the servo cover to remove the piston
8. Place a drain pan under the rear enough to position the engine rear and rod.
of the transmission case. support on the crossmember. 2. Remove the seals from the piston
9. Lower the transmission and re- 5. Secure the support to the cross (Fig. 17).
move the extension housing attaching member with the attaching bolt and On a Continental Mark III, replace
bolts. Slide the extension housing off nut. Torque the bolt to specification. the complete piston and rod assembly
the output shaft and allow the fluid to 6. Lower the transmission and re- if the piston or piston sealing lips are
drain. move the jack. Install and torque the unserviceable or damaged.
10. Remove the governor attaching engine rear support-to-extension hous- 3. Remove the seal from the cover.
bolts (Fig. 16) and remove the gover- ing attaching bolts to specification. 4. Dip the new seals in transmission
nor from the flange. On a Lincoln Continental, install fluid.
the reinforcement plate and secure it 5. Install the new seals on the pis-
INSTALLATION with the attaching bolts. ton and cover.
7. Secure the speedometer cable to 6. Coat two new gaskets with pe-
1. Secure the governor (Fig. 16) to the extension housing with the attach- troleum jelly and install the gaskets
the distributor flange with the attaching bolt. on the cover.
ing bolts. Torque the bolts to specifi- 8. Connect the parking brake cable 7. Dip the piston in transmission
cation. to the equalizer. On a Lincoln Conti- fluid and install it in the cover.
2. Position the servo spring on the

•TRANSMISSION piston rod.
CASE SEAL-7D024
3. Insert the servo piston rod in the
SEAL-7D025 case. Secure the cover with the attach-
COVER .7D027 ing bolts taking care to back off the
band adjusting screw as the cover
bolts are tightened. Make sure that
the transmission identification tag is
installed utfider the lower front cover
bolt.
4. Adjust the band as detailed in
Section 2.
5. "Raise the transmission high
enough to install the engine rear sup-
ports. Secure the supports to the ex-
tension housing with the attaching
bolts. Lower the transmission as re-
D1599-B q u i r e d to i n s t a l l and t o r q u e the
support-to-crossmember nuts.
FIG. 17—Servo Disassembled—Typical 6. Position the manual and down-
shift control rod splash shield to the
frame side rail and secure it with the
INSTALLATION 4. Loosen the band adjusting screw attaching bolts.
lock nut. 7. Remove the jack.
1. Position a new gasket on the 5. Remove the two nuts that attach 8. Install the reinforcement plate
servo cover. the engine rear mounts to the and secure it with the attaching bolts.
2. Position the servo spring on the crossmember. 9. Lower the vehicle and replenish
piston rod. 6. Place a transmission jack under the fluid as required.
3. Insert the servo piston rod in the the transmission and raise it just high
case. Secure the cover with the attach- enough to remove the weight from the
ing bolts, taking care to back off the crossmember.
band adjusting screw as the cover 7. Remove the engine rear CONTROL VALVE
bolts are tightened. Make sure that support-to-extension housing attaching BODY REPLACEMENT
the vent tube retaining clip and service bolts and remove the supports.
identification tag are in place. 8. Remove the servo cover, piston,
4. R a i s e the transmission high spring and gasket from the case, turn- REMOVAL
enough to install the engine rear sup- ing the band adjusting screw inward
port. Secure the support to the exten- as the piston is removed. This insures 1. Raise the vehicle on a hoist or
sion housing with the attaching bolts. that there will be enough tension on jack stands.
Lower the transmission as required to the band to keep the struts properly 2. On a Lincoln Continental, re-
install the support to crossmember at- engaged in the band end notches while move the reinforcement plate from
taching bolt. Torque the attaching the piston is removed. under the oil pan.
bolts to specification. 3. Place a drain pan under the
5. Remove the jack. transmission and loosen the bolts to
6. Adjust the band as detailed in Seal Replacement drain the fluid from the transmission.
Section 2. 4. Remove the transmission pan at
7. Lower the vehicle and replenish 1. Apply air pressure to the port in taching bolts from both sides and the
the fluid as required. the servo cover to remove the piston rear to allow the fluid to drain fur-
and rod assembly. If the piston or pis- ther. Finally, remove the remainder of
ton sealing lips are unserviceable or the attaching bolts.
damaged, the complete piston and rod 5. Remove the valve body attaching
assembly must be replaced. bolts and remove the valve body from
LINCOLN
2. Remove the seal from the cover the case.
(Fig. 17).
Removal 3. Dip the new seals in transmission INSTALLATION
fluid.
1. Raise the vehicle on a hoist. 4. Install a new seal on the cover. 1. Position the valve body to the
2. Place a drain pan under the 5. Dip the piston and rod assembly case making sure that the selector and
servo. Remove the bolts that attach in transmission fluid and install it in downshift levers are engaged, then in-
the servo cover to the transmission the cover. stall and torque the attaching bolts to
case. specification.
3. Remove the three bolts that at- 2. Clean the fluid pan and gasket
tach the manual and downshift control Installation surfaces thoroughly.
rod splash shield to the frame side rail 3. Using a new pan gasket, secure
and remove the shield. Remove the 1. Coat two new gaskets with pe- the pan to the transmission case and
reinforcement plate from under the troleum jelly and position them on the torque the attaching bolts to specifica-
transmission oil pan. servo cover. tion.
On a Lincoln Continental, install

the reinforcement plate and secure it
with the attaching bolts.
4. Lower the vehicle and fill the
transmission to the correct level with
Too/— 1175-AB
the specified fluid.
EXTENSION HOUSING
Tool—750T-70O-A
BUSHING AND REAR D 1927-A
SEAL REPLACEMENT
FIG. 18—Removing Extension Housing Seal
1. Disconnect the drive shaft from

BUSHING
the transmission.
2. On a Lincoln Continental, re-
Tool-T 57 P - 7 6 9 7 - B
move the parking brake equalizer. Po-
sition the equalizer and cables out of
the way to obtain free access to the
transmission extension housing.
3. When only the rear seal needs
BUSHING
replacing, carefully remove it with a
tapered chisel or the tools shown in
T o o / - 7 5 7 P-7697-A
Fig. 18. Remove the bushing as shown
in Fig. 19. Use the bushing remover D1600-A D 1601 -A
carefully so that the spline seal is not
damaged. FIG. 19—Removing Extension FIG. 20—Installing Extension
4. When installing a new bushing Housing Bushing Housing Bushing
use the special tool shown in Fig. 20.
5. Before installing a new seal, in-
spect the sealing surface of the univer-
sal joint yoke for scores. If scores are bore. Coat the inside diameter of the
Tool- T61 L - 7657- B
found, replace the yoke. fiber portion of the seal with B8A-
6. Inspect the counterbore of the 19589-A lubricant.
housing for burrs and if present, re- 8. Coat the front universal joint
move with crocus cloth. spline with B8A-19589-A lubricant
7. Install the seal into the housing and install the drive shaft.
with the tool shown in Fig. 21. The 9. On a Lincoln Continental, con-
seal should be firmly seated in the nect the parking brake equalizer.
D1602-A
FIG. 21—Installing Extension

Housing Seal
An oil impregnated plastic grommet REMOVAL—FORD ward from the transmission. Install a
is incorporated in the end of the man- MERCURY AND METEOR seal installation tool in the extension
ual shift linkage lever arm on all col- housing to prevent fluid leakage.
umn shift vehicles. A special tool 3. Disconnect the cable from the
T67P-7341-A is required to install the terminal on the starter motor. Re-
grommet in the manual lever, and to 1. Raise the vehicle on a hoist or move the three attaching bolts and re-
install the manual linkage rod into the stands. Drain the fluid from the trans- move the starter motor.
grommet. Refer to Part 7-1, Section mission and from the converter. 4. Remove the four converter-
2, for the grommet replacement pro- 2. Disconnect the drive shaft from to-flywheel attaching nuts. Place a
cedures. the rear axle and slide the shaft rear- wrench on the crankshaft pulley at-
taching bolt to turn the converter to 6. Move the transmission toward REMOVAL—FAIRLANE,
gain access to the nuts. the cylinder block until they are in MONTEGO, MUSTANG
5. Remove the rear mount to contact. Install and torque the attach- AND COUGAR
crossmember attaching bolt. ing bolts to specification making sure 1. On Mustang and Cougar, dis-
6. Remove the two crossmember- that the vacuum tube retaining clips connect the neutral switch wires from
to-frame attaching bolts. are properly positioned. the harness connector and the retain-
7. Remove the two engine rear 7. Remove the transmission jack ing clip on the dash.
support-to-extension housing attaching chain from around the transmission. 2. Remove the bolt that secures the
bolts. 8. Install a new Oring on the lower filler tube to the rear of the right
8. Disconnect the downshift rod end of the transmission filler tube. In- cylinder head.
from the transmission downshift lever. sert the tube in the transmission case 3. Raise the vehicle on a hoist or
9. Disconnect the manual linkage and secure the tube to the engine with jack stands.
rod from the lever at the transmission. the attaching bolt. 4. Remove the converter drain plug
On a column shift, use tool T67P- 9. Connect the speedometer cable access cover from the lower end of the
7341-A to remove the rod. to the extension housing. converter housing.
10. Remove the two bolts securing 10. Connect the oil cooler lines to 5. Place a drain pan under nhe con-
the bellcrank bracket to the converter the right side of transmission case. verter housing and remove the two
housing. 11. Connect the vacuum line to the converter drain plugs. Install the plugs
11. Raise the transmission with a vacuum diaphragm making sure that after the fluid has drained.
transmission jack to provide clearance the metal tube is secured in the retain- 6. Place the drain pan under the
to remove the crossmember. ing clip. transmission fluid pan. Starting at the
12. Remove the rear mount from 12. Position the cross member on rear of the pan and working toward
the crossmember and remove the the side supports. Position the rear the front, loosen the attaching bolts
crossmember from the side supports. mount on the crossmember and install and allow the fluid to drain. Finally
13. Lower the transmission to gain the attaching bolt and nut. remove all of the pan attaching bolts
access to the oil cooler lines. 13. Secure the engine rear support except two at the front, to allow the
14. Disconnect each oil line from to the extension housing and torque fluid to further drain. After the fluid
the fittings on the transmission. the bolts to specification. has drained, install two bolts on the
15. Disconnect the vacuum line 14. Lower the transmission and re- rear side of the pan to temporarily
from the diaphragm located at the move the jack. hold it in place.
right rear of the transmission. Remove 15. Secure the crossmember to the 7. Disconnect the drive shaft from
the metal line from the retaining clip side supports with the attaching bolts the rear axle flange and remove it
on the transmission. and torque them to specification. from the transmission. Install tool
16. Disconnect the speedometer 16. Position the bellcrank bracket T61L-7657-A in the rear of the exten-
cable from the extension housing. to the converter housing and install sion housing to prevent the fluid from
17. Remove the bolt that secures the two attaching bolts. leaking.
the transmission fluid filler tube to the 17. Connect the downshift rod to 8. Disconnect the downshift rod
cylinder block. Lift the filler tube and the transmission downshift lever. from the transmission downshift lever.
the dipstick from the transmission. 18. Connect the selector rod to the 9. Disconnect the shift rod from the
18. Secure the transmission to the manual lever at the transmission. On manual lever. On a column shift, use
jack with the chain. a column shift, use tool T67P-7341-A tool T67P-7341-A to remove the rod.
19. Remove the converter housing- and install a new grommet in the 10. Disconnect the speedometer
to-cylinder block attaching bolts. manual lever. Then, secure the manual cable from the extension housing.
20. Carefully move the transmission selector rod to the lever. 11. Disconnect the rubber hose
away from the engine and, at the 19. Secure the converter-to-flywheel from the vacuum diaphragm at the
same time, lower it to clear the und- attaching nuts and torque them to rear of the transmission. Remove the
erside of the vehicle. specification. Use a wrench on the vacuum tube from the retaining clip at
21. Remove the converter and crankshaft pulley attaching nut to ro- the transmission.
mount the transmission in a holding tate the flywheel. Do not use a wrench 12. Disconnect the starter cable
fixture. on the converter attaching nuts to ro- from the terminal on the starter. Re-
tate it. move the starter attaching bolts and
INSTALLATION—FORD 20. Install the converter housing remove it from the housing.
MERCURY AND METEOR dust shield and secure it with the at- 13. Lift the fluid filler tube from
taching bolts. the transmission case.
1. Torque the two converter drain 21. Secure the starter motor in 14. Remove the four converter-
plugs to specification. place with the attaching bolts. Con- to-flywheel attaching nuts.
2. Install the converter on the sta- nect the cable to the terminal on the 15. On a Mustang or Cougar, dis-
tor support. starter. connect the complete exhaust system
3. Secure the transmission to the 22. Install the driveshaft. and allow it to hang on the rear axle.
jack with the chain. 23. Adjust the shift linkage as de- 16. Remove the two nuts that at-
4. Rotate the flywheel to place two tailed in Section 2. tach the engine rear support to the
converter mounting stud holes that are 24. Lower the vehicle. crossmember.
adjacent to the drain plug holes in a 25. Fill the transmission to the cor- 17. Raise the transmission with a
vertical position. rect level with the specified lubricant. jack just enough to remove the weight
5. Rotate the converter so that the Start the engine and shift the trans- from the crossmember.
studs and drain plugs are in alignment mission to all ranges, then recheck the 18. Remove the cotter pins from
with those in the flywheel. fluid level. the crossmember-to-frame side sup-
port attaching nuts and remove the 11. Install the converter-to-flywheel 8. Remove the drive shaft.
nuts. Lift the crossmember from the attaching nuts and torque them to 9. Remove the frame side rail sup-
frame side supports. specifications. Tighten the drain plugs port brace attaching bolts and remove
19. Remove the bolts that attach to specification. the brace.
the engine rear support to the exten- 12. Secure the converter drain plug 10. After the fluid has been drained
sion housing and remove the support. access cover to the lower end of the from the converter, install the plug.
20. Lower the transmission, then converter housing with the attaching 11. Place the drain pan under the
disconnect the fluid cooler lines from bolts. transmission pan and loosen the at-
the transmission case. 13. Install a new O-ring on the taching bolts and allow the fluid to
21. Secure the transmission to the lower end of the fluid filler tube. Dip drain. Finally remove all of the pan
jack with a chain. the O-ring in clean automatic trans- attaching bolts except two, to allow
22. Remove the six bolts that at- mission fluid and insert the filler tube the oil to further drain. After the fluid
tach the converter housing to the cylin the transmission case. has drained, install two bolts on the
inder block. 14. Secure the starter to the con- opposite side of the pan to temporari-
23. Move the jack rearward until verter housing. Connect the cable to ly hold it in place.
the transmission clears the engine, the terminal on the starter. 12. R e m o v e the c o n v e r t e r -
then tip it forward to provide clear- 15. Connect the speedometer cable to-flywheel attaching nuts.
ance. Lower the transmission and re- to the extension housing.
move it from under the vehicle. 13. Disconnect the downshift link-
16. Connect the shift rod to the
24. Remove the converter from the age from the transmission downshift
manual lever at the transmission. On
transmission. Mount the transmission lever.
a column shift, use tool T67P-7341-A
in a holding fixture if repairs are nec- 14. Using tool T67P-7341-A, re-
and install a new grommet in the
essary. move the selector rod from the manu-
manual lever. Then, secure the manual
al lever.
selector rod to the lever.
15. Remove the two screws that at-
17. Connect the downshift rod to
tach the shift rod bellcrank bracket to
INSTALLATION—FAIRLANE, the lever on the transmission. Adjust
the converter housing and remove the
MONTEGO, MUSTANG the rod.
bracket.
AND COUGAR 18. Remove the tool from the ex-
16. Disconnect the vacuum dia-
tension housing and install the drive
phragm hose from the upper end of
1. Mount the transmission in a shaft.
the vacuum tube.
transmission jack and secure it with a 19. Lower the vehicle.
17. Disconnect the speedometer
safety chain. 20. Working from the engine com-
cable from the extension housing and
2. Install the converter on the front partment, secure the fluid filler tube
place it to one side.
pump. to the rear of the right cylinder head
with the attaching bolt. 18. Remove the starting motor two
3. Rotate the flywheel so that the
21. On Mustang and Cougar, con- lower attaching bolts and place the
drain plug holes are in a vertical posi-
nect the neutral switch wires to the motor to one side.
tion. Rotate the converter so that the
harness. Secure the wires to the dash 19. Disconnect the two oil cooler
drain plugs are in the same relative
with the retaining clip. lines from the right side of the trans-
position as the drain plug holes in the
22. Fill the transmission with the mission.
flywheel.
specified lubricant as detailed in Part 20. Disconnect the muffler inlet
4. Roll the transmission into posi-
7-1. pipes at the exhaust manifolds and
tion under the vehicle and raise it to
allow the pipes to hang.
alignment with the engine. Move it
REMOVAL—THUNDERBIRD 21. Remove the vibration absorber
forward until the converter housing
from the extension housing.
contacts the cylinder block. Install
1. Working from the engine com- 22. Remove the two engine rear
and torque the converter-to-cylinder
partment, remove the fluid filler tube support-to-extension housing attaching
block attaching bolts.
bracket attaching screw that secures it bolts.
5. Remove the jack safety chain
to the rear of the right cylinder head. 23. Place a transmission jack under
from the transmission.
Lift the tube and dipstick from the the transmission and raise it just
6. Connect the two fluid cooler
transmission. enough to remove the weight from the
lines to the fittings in the transmission
2. Remove the starting motor upper support.
case.
attaching bolt using a long extension. 24. Remove the two support attach-
7. Secure the engine rear support to
3. Remove the two converter housing bolts and remove the support.
the extension housing with the attach-
ing upper attaching bolts. 25. Lower the jack just enough to
ing bolts. Torque the bolts to specifi-
4. Raise the vehicle on a hoist or remove the weight.
cation.
8. Position the crossmember on the stands. 26. Remove the four remaining
frame side supports and install and 5. Remove the dust shield from the converter housing-to-cylinder block at-
tighten the attaching nuts to specifica- front lower end of the converter hous- taching bolts and the accelerator link-
tion. Install cotter Dins to retain the ing. age stop from the left side of the
nuts. 6. Crank the engine until one of the housing.
9. Remove the transmission jack converter drain plugs is accessible. 27. Carefully lower the transmis-
from under the vehicle. Install and Then, remove the plug. sion and remove it from under the ve-
t o r q u e the engine rear support- 7. Crank the engine until the other hicle.
to-crossmember attaching nuts. plug is at the bottom. Place a drain 28. Remove the converter and
10. Install the exhaust system on pan to catch the fluid, then remove mount the transmission in a holding
Mustang and Cougar. the pan and allow the fluid to drain. fixture.
INSTALLATION— 22. Install the starting motor upper 17. Disconnect the starter cable
THUNDERBIRD bolt. from the terminal on the starter. Re-
23. Place a new O-ring on the end move the starter attaching bolts and
of the fluid filler tube and insert it in remove it from the housing.
1. Torque the two converter drain the transmission case. Secure the tube 18. Remove the clip securing the oil
plugs to specification. to the rear of the right cylinder head cooler lines to the support bracket.
2. Install the converter on the sta- with the attaching screw and lock 19. Disconnect the two oil cooler
tor support. washer. lines from the right side of the trans-
3. Secure the transmission on a 24. Fill the transmission to the mission.
transmission jack. proper level with the specified fluids. 20. Disconnect the muffler inlet
4. Rotate the converter so that the 25. Adjust the manual and throttle pipes at the exhaust manifolds and
studs and drain plugs are in alignment linkage as required. allow the pipes to hang.
with their holes in the flywheel. 21. Remove the vibration absorber
5. Move the transmission toward REMOVAL- from the extension housing.
the cylinder block until they contact CONTINENTAL MARK III 22. Remove the engine rear support
each other. Install and torque the at- to extension housing attaching bolts.
taching bolts to specification. Before 1. Working from the engine com- 23. Place a transmission jack under
tightening the center bolt on the left partment, lift the fluid filler tube dio- the transmission and raise it just
side, make sure that the accelerator stick from the transmission. enough to remove the weight from the
linkage stop bracket is properly posi- 2. Raise the vehicle on a hoist or support.
tioned so that the left upper bolt may stands. 24. Remove the two support attach-
be installed later. 3. Remove the dust shield from the ing bolts and remove the support.
6. Connect the fluid cooler lines to front lower end of the converter hous- 25. Lower the jack and secure the
their fittings on the right side of the ing. transmission to the jack with a safety
transmission. 4. Crank the engine until one of the chain.
7. Raise the transmission and in- converter drain plugs is accessible. 26. Remove the bolt that secures
stall the engine rear support and tor- Then, remove the plug. the filler tube to the rear of the right
que the bolts to specification. Make 5. Crank the engine until the other cylinder head and lift the tube from
sure that the hand brake equalizer is plug is at the bottom. Place a drain the transmission case.
positioned properly. pan to catch the fluid, then remove 27. Remove the six converter
8. Lower the transmission and re- the pan and allow the fluid to drain. housing-to-cylinder block attaching
move the jack. 6. Remove the driveshaft. bolts.
9. Install the engine rear support- 7. Remove the frame side rail sup- 28. Carefully lower the transmis-
to-extension housing attaching bolts. port brace attaching bolts and remove sion and remove it from under the ve-
10. Install the drive shaft. the brace. hicle.
11. Connect the speedometer cable 8. After the fluid has been drained 29. Remove the converter and
to the extension housing. from the converter, install the plug. mount the transmission in a holding
12. Position the starting motor on 9. Place the drain pan under the fixture.
the converter housing and secure it transmission pan and loosen the at-
with the two lower bolts. taching bolts and allow the fluid to
13. Install the torque converter- drain. Finally remove all of the pan INSTALLATION—
to-flywheel attaching nuts and torque attaching bolts except two, to allow CONTINENTAL MARK III
them to specification. the oil to further drain. After the fluid
14. Install the converter housing has drained, install two bolts on the 1. Torque the two converter drain
dust shield. opposite side of the pan to temporari- plugs to specification.
15. Secure the frame side rail sup- ly hold it in place. 2. Install the converter on the sta-
port brace with the attaching bolts 10. R e m o v e the. c o n v e r t e r - tor support.
and lock washers. Torque the bolts to to-flywheel attaching nuts. 3. Secure the transmission on a
specification. 11. Disconnect the downshift link- transmission jack.
16. Connect the downshift rod to age from the transmission downshift 4. Rotate the converter so that the
the transmission downshift lever. lever. studs and drain plugs are in alignment
17. Connect the vacuum diaphragm 12. Using tool T67P-7341-A, re- with their holes in the flywheel.
hose to the upper end of the vacuum move the selector rod from the manu- 5. Move the transmission toward
tube. al lever. the cylinder block until they contact
18. Using Tool T67P-7341-A, in- 13. Remove the two screws that at- each other. Install and torque the at-
stall a new grommet in the manual tach the shift rod bellcrank bracket to taching bolts to specification
lever. Then, secure the manual selec- the converter housing and remove the 6. Remove the jack safety chain
tor rod to the lever. bracket. from the transmission.
19. Position the vibration absorber 14. Disconnect the vacuum dia- 7. Connect the fluid cooler lines to
to the transmission extension housing phragm hose at the transmission. their fittings on the right side of the
and secure it with the three attaching 15. Disconnect the speedometer transmission.
bolts. cable from the extension housing and 8. Install a new O-ring on the lower
20. Connect the muffler inlet pipes place it to one side. end of the fluid filler tube. Dip the
to the exhaust manifolds. 16. Remove the two idler arm O-ring in clean automatic transmis-
21. Lower the vehicle and install bracket retaining bolts at the frame sion fluid and insert the tube in the
the two converter housing upper bolts side rail and allow the linkage to transmission case. Install the attach-
and torque them to specification. hang. ing bolt.
9. Raise the transmission and in- 5. Place a drain pan under the 27. Remove the c r o s s m e m b e r -
stall the engine rear support and tor- transmission. Loosen all transmission to-frame attaching nuts and remove
que the bolts to specification. pan attaching bolts and allow the fluid the crossmember.
10. Lower the transmission and re- to drain. Remove the bolts from the 28. Secure the transmission to the
move the jack. rear and both sides of the pan to jack with the safety chain. Lower the
11. Install the engine rear support- allow further drainage; then, finally transmission and remove the upper
to-extension housing attaching bolts. remove the pan. After all fluid has converter housing-to-cylinder block at-
12. Install the drive shaft. been drained, install the pan using taching bolts.
13. Connect the speedometer cable four attaching bolts. 29. Move the transmission away
to the extension housing. 6. Remove the two bolts that attach from the cylinder block.
14. Connect the muffler inlet pipes the cover to the lower end of the con- 30. Carefully lower the transmis-
to the exhaust manifolds. verter housing. sion and remove it from under the ve-
15. Position the starting motor on 7. Remove the two front support hicle.
the converter housing and secure it bracket bolts at the converter housing. 31. Remove the converter and mount
with the attaching bolts. Connect the 8. Remove the two drain plugs the transmission in a holding fixture.
cable to the terminal on the starter. from the converter and allow it to
16. Position the idler arm bracket drain. INSTALLATION-
to the frame side rail and install the 9. Remove the four nuts that attach LINCOLN CONTINENTAL
attaching bolts. the converter to the flywheel.
17. Install the torque converter- 10. Lift the fluid filler tube from 1. Torque the two converter drain
to-flywheel attaching nuts and torque the transmission case. plugs to specification.
them to specification. 11. Remove the two idler arm 2. Install the converter on the sta-
18. Install the converter housing bracket bolts from the frame side rail tor support.
dust shield. and allow the idler arm to hang free. 3. Secure the transmission on a
19. Secure the frame side rail sup- 12. Disconnect the starter cable transmission jack.
port brace with the attaching bolts from the starter. Remove the starter 4. Rotate the converter so that the
and lock washers. Torque the bolts to attaching bolts and remove the starter. studs and drain plugs are in alignment
specification. 13. Disconnect the oil cooler lines with those in the flywheel.
20. Connect the downshift rod to from the transmission. 5. Move the transmission toward the
the transmission downshift lever. 14. Disconnect the vacuum hose cylinder block until they contact each
21. Using Tool T67P-7341-A, in- from the diaphragm. other. Install and torque the attaching
stall a new grommet in the manual 15. Loosen the parking brake ad- bolts to specification.
lever. Then, secure the manual selec- justing nut at the equalizer and re- 6. Secure the converter to the fly-
tor rod to the lever. move the retracting spring. Disconnect wheel with the four attaching nuts.
22. Connect the vacuum hose to the the rear brake cables and remove the Torque the nuts to specification.
vacuum diaphragm. equalizer from the bracket. 7. Secure the converter access cover
23. Install the oil cooler line retain- 16. Disconnect the speedometer to the converter housing with the at-
ing clip at the transmission support. cable from the extension housing. taching bolts.
24. Position the vibration absorber 17. Disconnect the drive shaft from 8. Secure the two front support
to the transmission extension housing the transmission flange and position brackets to the converter housing with
and secure it with the three attaching the shaft out of the way. the attaching bolts.
bolts. 18. Disconnect the downshift rod 9. Raise the transmission high en-
25. Lower the vehicle. from the transmission downshift lever. ough to position the crossmember. In-
26. Fill the transmission to the 19. Using tool T67P-7341-A, re- stall the bolts, but do not tighten at
proper level with the specified fluids. move the manual selector rod from this time.
27. Adjust the manual and throttle the manual lever. 10. Secure the engine rear support
linkage as required. 20. Remove the lower bellcrank at- to the extension housing and torque
taching bolts and remove the bell- the bolts to specification. At this time,
crank. install and torque the crossmember-
21. Pry the upper bellcrank out of to-frame attaching nuts to specifica-
REMOVAL- the converter housing and allow it to tion.
LINCOLN CONTINENTAL hang free. 11. Lower the transmission and in-
22. Remove the cooler lines from s t a l l the engine rear support-
1. Raise the hood and remove the the clip at the cylinder head. to-crossmember attaching nuts and
transmission dipstick. 23. Remove the converter housing- plates. Torque the •"its to specifica-
2. Raise the vehicle on a hoist. Re- to-cylinder block lower attaching tion. Remove the transmission jack.
move the bolt that secures the trans- bolts. 12. Install the upper bellcrank in
mission filler tube to the cylinder 24. Remove the two nuts that at- the left side of the converter housing.
head. tach the engine rear mounts to the 13. Position the lower bellcrank to
3. Remove the bolts that attach the crossmember. the transmission and floor pan and se-
reinforcement plate at the rear of the 25. Place a transmission jack under cure it with the two attaching bolts.
transmission oil pan and remove the the transmission and raise it just high 14. Connect the downshift rod to
plate. enough to remove the weight from the transmission downshift lever.
4. Remove the three bolts that at- crossmember. 15. Using tool T67P-7341-A, install
tach the manual and downshift control 2 6 . R e m o v e t h e engine rear a new grommet in the manual lever.
rod splash shield to the side rail and support-to-extension housing attaching Then, secure the manual selector rod
remove the shield. bolts and remove the supports. to the lever.
16. Position the manual and down- 20. Install the cooler lines under 25. Install the starting motor and
shift control rod splash shield to the the clip at the cylinder head. connect the cable.
frame side rail and secure it with the 21. Position the reinforcement plate 26. Install the idler arm bracket-
attaching bolts. and torque the attaching bolts. to-frame side rail.
17. Connect the speedometer cable 22. Install the equalizer and park- 27. Lower the vehicle.
to the extension housing. ing brake cables. Install the equalizer 28. Fill the transmission to the cor-
18. Connect the vacuum hose to the lever retracting spring. rect level with the specified fluid.
vacuum diaphragm and secure with a 23. Install the drive shaft. 29. Adjust the manual and throttle
clamp. 24. Install a new seal on the filler linkage as required.
19. Connect the two oil cooler lines tube and install it in the transmission
to the fittings on the right side of the case. Secure the filler tube to the cyl-
case. inder head.
DISASSEMBLY OF
TRANSMISSION
1. Mount the transmission in hold-

ing fixture T64L-6001-A (Fig. 22).
2. Remove the 17 fluid pan attach-
ing bolts. Remove pan and gasket.
3. Remove the 8 valve body attach-
ing bolts (Fig. 23). Lift the valve body
from the transmission case.
4. Attach a dial indicator to the
front pump as shown in Fig. 24. In-
stall tool T61L-7657-B in the exten-
sion housing to center the shaft.
5. Pry the gear train to the rear of
the case and at the same time, press
the input shaft inward until it bottoms
(Fig. 24). Set the dial indicator to
read zero.
6. Pry the gear train forward (Fig.
24) and note the amount of gear train
end play on the dial indicator. Record
the end play to facilitate assembling
the transmission. Remove the dial in-
dicator from the pump and the tool
from the extension housing.
7. Remove the vacuum diaphragm,
rod and the primary throttle valve
from the case. Slip the input shaft out D16Q3-B
of the front pump.
8. Remove the front pump attach-
ing bolts. Pry the gear train forward FIG. 22—Transmission Mounted in Holding Fixture
as shown in Fig. 25 to remove the
pump. hub on the output shaft. Slide the ring 18. Remove the distributor sleeve
9. Loosen the band adjustment gear and hub off the shaft. attaching bolts and remove the sleeve,
screw and remove the two struts. 14. Rotate the low-reverse clutch parking pawl gear and the thrust
10. Rotate the band 90 degrees co- hub in a clockwise direction and at washer.
unterclockwise to align the ends with the same time, withdraw it from the
case. If the thrust washer is staked in
the slot in the case (Fig. 26). Slide the
place, use a sharp chisel and cut off
band off the reverse-high clutch drum. 15. Remove the reverse clutch snap
the metal from behind the thrust
11. Remove the forward part of the ring from the case, then remove the
washer. Be sure to clean the rear of
gear train as an assembly as shown in clutch discs, plates and pressure plate
the case with air pressure or a suitable
Fig. 27. from the case.
solvent to remove any metal particles.
12. Remove the large snap ring that 16. Remove the extension housing
secures the reverse planet carrier in attaching bolts and vent tube from the 19. Compress the reverse clutch pis-
the low-reverse clutch hub. Lift the case. Remove the extension housing, ton release spring with tool T65P-
planet carrier from the drum. and gasket. 77515-A (Fig. 29). Remove the snap
13. Remove the snap ring (Fig. 28) 17. Slide the output shaft assembly ring. Remove the tool and the spring
that secures the reverse ring gear and from the transmission case. retainer.
PARKING
FLUID
PAWL ROD SCREEN
INTERMEDIATE
SERVO
LEVER
D 1606-A
FIG. 25—Removing Front Pump
SLOT BAND ENDS D 1607-A
FIG. 26—Rembving or Installing

Band
FIG. 23—Transmission with Pan Removed
REVERSE-HIGH OUTPUT
CLUTCH DRUM SHAFT
D 1608 - A

Forward Part of Gear Train
LOW-REVERSE OUTPUT SNAP
CLUTCH DRUM SHAFT RING
Tool-4201-C
D1609-A
D1605-A
Reverse Ring Gear Hub Retaining
FIG. 24— Checking Gear Train End Play Ring
SNAP RING LOW-REVERSE

CLUTCH PISTON Tighten all bolts and screws to the
recommended torque as outlined in
the Specification Section.
TRANSMISSION CASE
AND LINKAGE
Downshift and Manual

Linkage
1. Remove the nut and lock washer

Tool -
that secures the outer downshift lever
T6SL-77515-A RETAINER Toof - T65L- 77575- A to the transmission and remove the
D1610-A
lever.
FIG. 29—Compressing Reverse Clutch Spring 2. On a Mustang or Cougar, re-
move the two bolts that secure the
20. Remove the one-way clutch neutral safety switch to the case. In-
AIR NOZZLE inner race attaching bolts from the sert a screwdriver between the switch
rear of the case. Remove the inner and case as close as possible to the
Tool- 7000- DD race from inside of the case. shaft. Gently pry the switch from the
21. Remove the reverse clutch pis- case.
ton from the case as shown in Fig. 30. 3. Slide the downshift lever out
from the inside-of the case (Fig. 31).
PARTS REPAIR OR
Remove the seal from the recess in
REPLACEMENT
the manual lever shaft.
D u r i n g the r e p a i r of the sub- 4. Remove the C-ring that secures
assemblies, certain general instructions the parking pawl actuating rod to the
LOW- REVERSE CLUTCH
APPLY PASSAGE D1611-A which apply to all units of the trans- manual lever. Remove the rod from
mission must be followed. Following the case.
FIG. 30—Removing Low-Reverse these instructions will avoid unneces- 5. Remove the nut that secures the
Clutch Piston sary repetition. inner manual lever to the shaft. Re-
OUTER
move the inner lever from the shaft.
MANUAL LEVER Slide the outer lever and shaft from
AND SHAFT the case.
6. Remove the seal from the case
with Tools T59L-1OO-B and T58L-
101-A or 7600-E.
7. Dip the new seal in transmission
fluid and install it in the case as
shown in Fig. 32.
PARKING
PAWL ACTUATING
8. Slide the outer manual lever and
ROD shaft in the transmission case.
9. Position the inner lever on the
D1612-A shaft and install the attaching nut.
Tighten the nut to specification. In-
FIG. 31—Downshift and Manual Linkage stall the parking pawl actuating rod
and secure it to the inner manual lever
All transmission parts must be with a C-washer.
handled carefully to avoid nicking or
burring the bearing or mating surfa- 10. Install a new downshift lever
ces. seal in the recess of the outer lever
shaft. Slide the downshift lever and
Lubricate all internal parts of the shaft into position.
transmission with clean automatic 11. On a Mustang or Cougar, posi-
transmission fluid before assembling tion the neutral switch on the manual
them. lever and secure it with the two at-
7"oo/ - 77288 Do not use any other lubricants ex- taching bolts. Leave the attaching
cept on gaskets and thrust washers. bolts loose to adjust the switch after
These may be coated with vaseline to installing the control valve.
D1613-A
facilitate assembly. Always use new 12. Place the outer downshift lever
FIG. 32—Installing Manual Lever gaskets and seals when assembling a on the shaft and secure it with a lock
Seal transmission. washer and nut.
Parking Pawl Linkage GUIDE PLATE PIN SPRING CUPPED PLUG
1. Remove the bolts that secure the

parking pawl guide plate to the case
(Fig. 33). Remove the plate.
2. Remove the spring, parking pawl
and shaft from the case.
3. Working from the pan mounting
surface, drill a 1/8 inch diameter hole
through the center of the cupped plug. PARKING
Pull the plug from the case with a GEAR
wire hook.
4. Lift the end of the spring off the
park plate pin to relieve the tension.
5. Thread a 1/4-20 inch or # 8-32
x 1 1/4 inch screw (Fig. 34) into the
par1: plate shaft. Pull the shaft from
the case with the screw.
6. Position the spring and park
plate in the case and install the shaft.
Hook the end of the spring over the
pin on the park plate.
7. Install a new cupped washer
(Fig. 33) to retain the shaft.
8. Install the parking pawl shaft in
the case. Slip the parking pawl and
SHAFT
spring into place on the shaft.
9. Position the guide plate on the SPRING PARK PLATE
PARKING PAWL
case making sure that the actuating
D1614-A
rod is seated in the slot of the plate.
Secure the plate with two bolts and FIG. 33—Parking Pawl Mechanism
lock washers.
INSTALL CUP PLUG FLUSH WITH
Servo Apply Lever 1/4 - 20 x 1 1/4 INCH BOLT SHOULDER OF COUNTERBORE
OR #8 • 32 x 1 1/4 INCH BOLT
1. Working from inside of the
transmission case, carefully drive on
the servo apply lever shaft to remove
the cup plug. The shaft (Fig. 35) can
be withdrawn from the case by hand.
2. Hold the servo apply lever in
position and install the new shaft.
3. Using the fabricated tool shown
in Fig. 35, drive the cup plug into
position in the case. Be sure the plug
is flush with the shoulder of the count-
erbore. The cup plug may be coated
with L o c t i t e , P a r t N o . C3AZ- INSTALLING TOOL
19554-A, before installation. PARK PLATE MAKE FROM 1/2" DIA. DRILL ROD
SHAFT
D 1629-B D 1783-A
FIG. 34—Removing Park Plate FIG. 35—Servo Apply Lever

Thread Repair-Case Shaft Installation
Thread service kits may be pur- paired. Thus, the special tap supplied Press the insert against the face of
chased from local jobbers or the with the repair kit marked 5/16-18 the tapped hole. Turn the tool clock-
Heli-Coil Corporation. To repair a will not cut the same thread as a wise and wind the insert into the hole
damaged thread, the following proce- standard 5/16-inch tap. It will cut a until the insert is one half turn below
dures should be carefully followed: thread large enough to accommodate the face.
1. Drill out the damaged threads the insert, and after the insert is in- 4. Working through the insert, bend
using the same size threads as the stalled, the original thread size (5/16- the insert tang straight up and down
thread OD. For example, use a 5/16- 18 inch) is restored. until it breaks off at the notch.
inch drill when repairing a 5/16-18 3. Select the proper coil inserting 5. If the inserts are not properly in-
inch thread. tool. These tools are marked with the stalled, they can be removed with the
2. Select the proper special tap and thread size being repaired. Place the extractor tool. Place the extractor tool
tap the drilled hole. The tap is marked insert on the tool and adjust the sleeve in the insert so that the blade rests
for the size of the thread being re- to the length of the insert being used. against the top coil 1/4-1/2 turn away
LOWER VALVE UPPER VALVE

BODY BODY
7A101 7A092
PLATE
7C056
PLATE
7D259
D1616-A
FIG. 36—Upper and Lower Valve Bodies Disassembled
Remove the retaining pin from the 15. Remove the 1-2 shift valve, D2
upper valve body. Remove the spring shift valve and the spring from the
and detent plunger. valve body.
5. Slide the manual valve (Fig. 38) 16. Remove the coasting regulator
Tool - T64P.7A128-A out of the valve body. valve from the body.
17. Remove the cutback control
6. Cover the downshift valve port valve.
with a finger, then working from the 18. Remove the 3-2 shift timing
underside of the body remove the valve retainer and remove the plug.
downshift valve retainer. Remove the Remove the 3-2 shift timing valve and
spring and downshift valve. spring to complete the disassembly of
7. Apply pressure on the pressure the control valve. Do not remove the
booster valve retaining plate and re- 3-2 shift timing valve plug if it is
move the two attaching screws. Slowly found to be peened, preventing the re-
release the pressure and remove the moval of the plug and the 3-2 shift
ROLL PIN plate, sleeve and the pressure booster timing valve. This condition will not
valve. Remove the two springs and the affect transmission operation and is
D 1617-A
main regulator valve from the same not cause for replacement of the main
bore. control. The 3-2 shift timing valve is
FIG. 37—Removing Manual Valve 8. Apply pressure on the throttle non-functional and removal of the
booster valve retaining plate and re- plug, 3-2 shift timing valve and spring
from the end of the coil. Tap the tool move the two attaching screws. Slowly is not required.
sharply with a hammer so that the release the pressure and remove plate,
blade cuts into the insert. Exert down- throttle booster valve and spring, and
ward pressure on the tool and turn it the manual low 2-1 scheduling valve
counterclockwise until the insert is re- Assembly
and spring from the body.
moved.
9. Apply pressure on the remaining 1. Place the spring 3-2 shift timing
valve retaining plate and remove the valve and plug in the valve body if
CONTROL VALVE BODY
eight attaching screws. they were previously removed. Install
10. Hold the valve body so that the the plug retainer.
plate is facing upward. Slowly release 2. Place the downshift valve and
Disassembly the pressure and remove the plate. spring in the valve body. Compress
11. When removing the various the spring and install the retainer
1. Remove the nine screws that at- valves from the control valve body, from the underside of the body.
tach the screen to the lower valve keep all ports covered with your fin- 3. Place the valve body on a clean
body and remove the screen and gas- gers except the bore the valve is being surface and the passage side facing up.
ket (Fig. 36). removed from. Remove the spring and Place the converter relief valve spring
2. Remove the twelve screws and the intermediate servo modulator valve in its bore (Fig. 39). Coat the convert-
the 2 plates that attach the two valve (Fig. 38) from the valve body. er relief valve check valve with vase-
bodies. 12. Remove the intermediate servo line and place it on top of the spring.
3. Separate the bodies and remove accumulator valve and springs. Place the 2-3 shift check valve ball in
the separator plate and gasket. Be 13. Remove the 2-3 back-out valve, its cavity. Place the throttle pressure
careful not to lose the check valves and spring. relief valve spring in its bore (Fig. 39).
and springs. 14. Remove the 2-3 shift valve, Coat the throttle pressure relief valve
4. Depress the manual valve detent spring and the throttle modulator check ball with vaseline and place it
spring with the tool shown in Fig. 37. valve. on top of the spring.
2-3 SHIFT PLATE

1-2 SHIFT VALVE 2-3 BACK-OUT VALVE
CUT-BACK VALVE INTERMEDIATE SERVO

MODULATOR VALVE
LINE PRESSURE RETAINER
COASTING REGULATOR VALVE
DR-2 SHIFT 3-2 SHIFT TIMING VALVE
THROTTLE MODULATOR VALVE INTERMEDIATE SERVO

ACCUMULATOR VALVE
MANUAL LOW
2-1 SCHEDULING VALVE
THROTTLE PRESSURE
BOOST VALVE
PLATE
UPPER VALVE
BODY ,v.i4 7***W,
*i*Swito!**i
.4 .-^.» »! A V
"^^RETAINER
DETENT PLUG, SPRING AND PIN MANUAL VALVE
THROTTLE PRESSURE
RELIEF SPRING
THROTTLE PRESSURE
RELIEF BALL 1/4 INCH DIA.
PRESSURE BOOST VALVE
SLEEVF
PLATE
D 1764-C
FIG. 38 —Upper Valve Body Disassembled

stall the retaining plate. Torque the

CONVERTER PRESSURE RELIEF VALVE
attaching screws to specification.
THROTTLE PRESSURE 15. Place the main regulator, two
RELIEF BALL1/4 INCH springs, pressure booster valve and the
DIA. AND SPRING
sleeve in the valve body.
16. Install the pressure booster
CONVERTER plate and torque the two attaching
PRESSURE
RELIEF screws to specification.
SPRING 17. Place the manual valve in the
valve body and install the detent plug,
spring and the retaining pin in the
body.
FRONT PUMP
The front seal can be replaced after

the pump has been installed on the
transmission (Figs. 40 and 41).
Disassembly
1. Remove the two seal-rings and

the selective thrust washer (Fig. 42).
2 - 3 SHIFT
2. Remove the large square-cut seal
CHECK VALVE D 1765-C from the O.D. of the pump housing.
3. Remove the 5 bolts that secure
FIG. 39—Converter Pressure Relief Valve, Throttle Pressure Relief Valve, the pump support to the pump hous-
and 2-3 Shift Check Valve Locations ing. Lift the support from the housing.
4. Remove the drive and the driven
gear from the housing.
FRONT PUMP Assembly
Tool - 7775-AS 1. Install the drive and driven gears

Tool - T50T- 100-A
in the pump housing. Each gear has
or 73-760 an identification mark on one face.
The identification mark on each gear
must be toward the front of the pump
housing.
2. Position the pump support in the
pump housing and install and torque
the five attaching bolts to specifica-
tion.
Tool -T63L- 77837 -A
3. Carefully install two new seal
D 1636 -A rings on the pump support. Make sure
D 1637-A that the ends of the rings are engaged
to lock them in place. Install a new
FIG. 40—Removing Front Pump FIG. 41—Installing Front Pump square-cut seal on the O.D. of the
Seal Seal pump housing.
4. Install the selective thrust wash-
4. Carefully position the separator 10. Place the spring and the 2-3 er. Make sure that the correct thick-
plate, new gasket and the lower valve backout valve in the valve body. ness selective washer is being used to
body on the upper valve body and in- obtain the specified end play.
stall and torque the attaching bolts to 11. Place the two springs and the
intermediate servo accumulator valve 5. Place the pump on converter
specification. making sure that the drive gear enga-
in the valve body.
5. Secure the screen to the lower ges the converter hub. Rotate the
valve body with the attaching bolts 12. Place the intermediate servo pump to make sure that the gears ro-
and torque them to specification. modulator valve and spring in the tate freely.
6. Place the cutback control valve body.
(Fig. 38) in the valve body. 13. Carefully place the valve retain- REVERSE-HIGH CLUTCH
7. P l a c e the coasting regulator ing plate on the body and secure it
valve in the body. with the eight attaching screws. Tigh- Disassembly
8. Place the spring D2 shift valve ten the screws to specification.
and the 1-2 shift valve in the body. 14. Place the throttle booster valve 1. Separate the drive train as shown
9. Place the throttle modulator and spring in the valve body. Place in Fig. 43. Remove the pressure plate
valve and spring and the 2-3 shift the manual low 2-1 scheduling valve retaining snap ring as shown in Fig.
valve in the valve body. and spring in the valve body and in- 44.
FRONT DRIVEN
PUMPSEAL-7A24& GEAR-7C011
STATOR SUPPORT-7A109
SELECTIVE THRUST
WASHER
7D014
SEAL
RINGS
GASKET 7D429
7A136
D 1619-B
FIG. 42—Front Pump Disassembled
2. Remove the pressure plate and 5. Install Tool T65L-77515-A (Fig. 3. Remove the snap ring (Fig. 53)
the drive and driven clutch plates (Fig. 46) and compress the springs. Make that secures the disc spring in the
45). certain that the spring retainer is cen- clutch cylinder. Remove the disc
3. Install Tool T65L-77515-A (Fig. tered while compressing the springs. spring.
46) on the reverse-high clutch drum. Install the snap ring. Before releasing 4. Apply air pressure to the clutch
Make sure that the legs clear the the pressure on the tool, make certain apply passage in the cylinder (Fig. 54)
snap ring enough to permit expanding that the snap ring is positioned inside to remove the piston.
it enough for removing it. Remove the of the four snap ring guides on the 5. Remove the seal from the piston
snap rings and remove the tool. spring retainer. and the seal from the clutch hub (Fig.
4. Remove the spring retainer and 6. Clutch plate usage varies with 52).
the piston return springs. each model, refer to the Specifications
5. Apply air pressure to the piston Section for the number of plates re-
apply hole in the clutch hub (Fig. 47) quired. Dip the clutch plates in clean
and remove the piston. transmission fluid. Install the clutch
Assembly
6. Remove the piston outer seal plates alternately starting with a steel
from the piston and the inner seal drive plate (Fig. 45).
1. Dip two new seals in transmis-
from the clutch drum (Fig. 45). 7. After all clutch plates have been sion fluid. Install the smaller seal on
7. Remove the front and rear bush- installed, position the pressure plate in the clutch hub and the other seal on
ings from the clutch drum if they are the clutch drum. Install the pressure the clutch piston.
worn or damaged. To remove the plate snap ring. 2. Install the clutch piston in the
front bushing, use a cape chisel and 8. With a feeler gauge, check the cylinder.
cut along the bushing seam until the clearance between the pressure plate 3. Make sure that the steel pressure
chisel breaks through the bushing and snap ring (Fig. 50). ring is in the groove on the piston.
wall. Pry the loose ends of the bushing 9. The pressure plate should be held Position the disc spring in the cylinder
up with an awl and remove the bush- downward as the clearance is checked. with the dished face downward. Install
ing. Refer to the Specification Section for the spring as shown in Fig. 56. Secure
To remove the rear bushing, use the the proper clearance. If the clearance the disc with the retaining snap ring.
tool shown in Fig. 48, and press the is not within specifications, selective 4. Install the forward pressure plate
bushing from the drum. thickness snap rings are available in with the flat side up and the beveled
the following thicknesses: 0.065-0.069, side downward. Install first a compos-
0.074-0.078, and 0.083-0.087 inch. In- ition driven plate and a steel drive
stall the correct size snap ring and re- plate (Fig. 52). Install the remaining
Assembly
check the clearance. plates in this sequence. Refer to the
1. If the clutch drum bushings were Specification Section for the number
removed, position the drum in a press of plates required. The last plate in-
and press new bushings into the drum FORWARD CLUTCH stalled will be the rear pressure plate.
with the tools shown in Figs. 48 or 49. Install the snap ring and make certain
2. Dip the new seals in transmission Disassembly that it seats fully in the groove.
fluid and install one on the drum and 5. With a feeler gauge, check the
one on the piston. 1. Remove the clutch pressure plate clearance between the snap ring and
3. Install the piston in the clutch retaining snap ring (Fig. 51). the pressure plate (Fig. 55). Down-
drum. 2. Remove the rear pressure plate, ward pressure on the plate should be
4. Position the piston return springs the drive and driven plates and the maintained when making this check.
in the piston sockets. Place the spring forward pressure plate from the clutch Refer to the Specifications Section for
retainer on the springs. hub (Fig. 52). the proper clearance.
1 2
1. FRONT PUMP SEAL RING 11. FORWARD CLUTCH HUB 20. REVERSE RING GEAR AND SPRING RETAINER
2. FRONT PUMP ASSEMBLY HUB RETAINING RING 30. RETURN SPRING
3. GASKET 12. NUMBER 5 THRUST WASHER 21. REVERSE RING GEAR AND HUB 31. LOW-REVERSE PISTON
4. SEAL 13. FORWARD PLANET ASSEMBLY 22. NUMBER 9 THRUST WASHER 32. CASE
5. NUMBER 1 THRUST WASHER 14. INPUT SHELL AND SUN 23. LOW-REVERSE CLUTCH HUB 33. NUMBER 10 THRUST WASHER
(SELECTIVE) GEAR ASSEMBLY 24. ONE-WAY CLUTCH 34. PARKING GEAR
6. REVERSE-HIGH CLUTCH 15. NUMBER 6 THRUST WASHER 25. ONE-WAY CLUTCH INNER RACE 35. GOVERNOR DISTRIBUTOR SLEEVE
ASSEMBLY 16. SNAP RING 26. SNAP RING 36. SNAP RING
7. NUMBER 2 THRUST WASHER 17. NUMBER 7 THRUST WASHER 27. LOW-REVERSE CLUTCH 37. GOVERNOR DISTRIBUTOR
8. FORWARD CLUTCH ASSEMBLY 18. REVERSE PLANET ASSEMBLY 28. SNAP RING 38. GOVERNOR
9. NUMBER 3 THRUST WASHER 19. NUMBER 8 THRUST WASHER 29. LOW-REVERSE PISTON RETURN 39. OUTPUT SHAFT
10. NUMBER 4 THRUST WASHER
D 1620-A
FIG. 43—Drive Train Disassembled

SNAP RING REVERSE-HIGH

CLUTCH DRUM
D1420-A

Reverse-High Clutch Pressure Plate
Tool 765 L-77515-A
Snap Ring
Tool 7 65 L-77575-A D 1591-A
FIG. 46—Removing or Installing Reverse-High Clutch Piston Snap Ring
REVERSE-HIGH INTERNAL SPLINE SELECTIVE

CLUTCH DRUM PLATE-7E>164 SNAP
7D044 RING
£T 377126-S
\
7D427
D1631 - A
FIG. 45— Reverse-High Clutch Disassembled

Tool— 7000- DD
6. If the clearance is not within 2. Place the No. 6 thrust washer on
specifications, selective snap rings are the sun gear and install the rear snap
available in the following thicknesses: ring.
0.056-0.060, 0.065-0.069, 0.074-0.078,
0.083-0.087 and 0.092-0.096 inch. In-
sert the correct size snap ring and re-
check the clearance. OUTPUT SHAFT HUB
AND RING GEAR
Disassembly
INPUT SHELL AND
SUN GEAR D1422-A
1. Remove the hub retaining snap
FIG. 47—Removing Reverse-High ring (Fig. 58) from the ring gear.
Clutch Piston 2. Lift the hub from the ring gear.
Disassembly
1. Remove the external snap ring Assembly

on from the sun gear as shown in Assembly
Fig. 56. 1. Install the forward snap ring on
2. Remove the thrust washer from the forward end (short end) of the sun
the input shell and sun gear (Fig. 57). gear (Fig. 57). Working from inside 1. Position the hub in the ring gear.
3. Working from inside the input the input shell, slide the sun gear and 2. Secure the hub with the retaining
shell remove the sun gear. Remove the snap ring into place making sure that snap ring. Make certain that the snap
internal snap ring from the gear. the longer end is at the rear (Fig. 57). ring is fully engaged with the groove.
SNAP RING
REMOVAL INSTALLATION D2035-A D1899-A
FIG. 48 — Replacing Reverse-High Clutch Rear Bushing FIG. 51—Removing Forward

Clutch Pressure Plate Snap Ring
Assembly
Press Ram
1. Install a snap ring in the forward Assembly

snap ring groove of the low-reverse
clutch hub. 1. Dip the new seals in transmission
Tool-T69L-7D044-A
2. Place the low-reverse clutch hub fluid.
on the bench with the forward end 2. Install new seals on the cover
down (Fig. 60). and servo piston. Fig. 61 shows the
3. Place the forward clutch bushing correct servo piston and cover for the
against the snap ring with the flat side transmission.
up. Install the one-way clutch spring 3. Dip the piston in transmission
retainer on top of the bushing. Be sure fluid and install it in the cover.
to install the retainer in the hub so
that the springs load the rollers in a LOW-REVERSE CLUTCH
counterclockwise direction when look- PISTON
ing down at the unit (Fig. 60).
4. Install a spring and roller into Disassembly
D2036-A each of the spring retainer compart-
ments by slightly compressing each 1. Remove the inner and the outer
FIG. 49—Installing Reverse-High spring and positioning the roller be- seal from the reverse clutch piston.
Clutch Front Bushing tween the spring and the spring retain-
er (Fig. 60). Assembly
5. Install the rear bushing on top of
the retainer with the flat side down. 1. Dip the two new seals in clean
6. Install the remaining snap ring transmission fluid.
at the rear of the low-reverse clutch 2. Install the seals on the piston.
hub to secure the assembly.
OUTPUT SHAFT
D1898-A
Disassembly
FIG. 50—Checking Reverse-High
Clutch Snap Ring Clearance SERVO
1. Remove the governor attaching
bolts and remove the governor.
ONE-WAY CLUTCH 2. Remove the snap ring that se-
Disassembly
cures the governor distributor on the
output shaft (Fig. 62) and slide it off
1. Apply air pressure to the port in
the front of the shaft.
Disassembly the servo cover to remove the piston
3. Remove the seal rings from the
and rod.
distributor.
1. Remove the snap ring and rear 2. Remove the seals from the pis-
bushing from the rear of the low- ton.
reverse clutch hub (Fig. 59). On Lincoln Continental and Conti- Assembly
2. Remove the springs and rollers nental Mark III models, replace the
from the spring retainer and lift the complete piston and rod assembly if 1. Carefully install new seal rings
spring retainer from the hub. the piston or piston sealing lips are on the distributor.
3. Remove the remaining bushing unserviceable or damaged. 2. Working from the front end of
and snap ring from the hub. 3. Remove the seal from the cover. the output shaft, slide the governor
FORWARD CLUTCH OUTER SEAL DISC SPRING FORWARD PRESSURE INTERNAL SPLINE REAR PRESSURE
CYLINDER-7D424 7A548 7B070 PLATE-7B066 PLATE-7B164 PLATE-7B066
PISTON
7A262 STEEL
INNER SEAL SNAP
RING SELECTIVE
377130894 RING EXTERNAL SPLINE
7D256 PLATE-7B442 SNAP RING
377127-S
377126-S
D1632-A
FIG. 52—Forward Clutch Disassembled
7oo/-
7000-DD
DISC
SPRING
D1901-A
FIG. 54—Removing Forward

Clutch Piston
CHECK BETWEEN SNAP RING

AND PRESSURE PLATE
1902-A
D 1635-A FIG. 55—Checking Forward

FIG. 53—Removing or Installing Disc Spring Clutch Clearance
PICK
distributor into place on the shaft. In- and tap the piston into place in the
stall the snap ring to secure it. Make case with a clean rubber hammer.
sure that the snap ring is seated in the 3. Hold the one-way clutch inner
groove. race in position and install and torque
3. Position the governor on the dis- the attaching bolts to specification.
tributor (Fig. 62) and secure them 4. Install a low-reverse clutch re-
with the attaching screws. turn spring in each pocket in the
clutch piston. Press the springs firmly
ASSEMBLY OF TRANSMISSION
into the piston to prevent them from
1. Place the transmission case in a falling out.
holding fixture. 5. Position the spring retainer over SCREWDRIVER
D 1633-A
2. Position the low-reverse clutch the springs and position the retainer
piston so that check ball is in the 6 o' snap ring in place on the one-way FIG. 56—Removing Sun Gear
clock position (toward bottom of case) clutch inner race. Snap Ring
6. I n s t a l l the compressing tool

shown in Fig. 29 and compress the FORWARD INPUT
springs just enough to install the low- SNAP SHELL THRUST
RING SUN GEAR 7D064 WASHER
reverse clutch piston retainer snap 377300-S 7A348 \ 7D066
•
ring.
7. Install the snap ring, then re-
move the compressing tool.
8. Place the transmission case on
the bench with the front end facing
downward.
9. Position the parking gear thrust
washer and the gear on the case (Fig.
33). Do not restake the thrust washer.
-IT
10. Position the oil distributor and REAR
tubes in place on the rear of the case. SNAP
RING
Install and torque the attaching bolts
377300-S
to specification.
11. Install the output shaft, and I) 1634-A
governor as an assembly.
57—Input Shell and Sun Gear Disassembled
12. Place a new gasket on the rear
of the transmission case. Position the
of the forward planet ring gear and
extension housing on the case and in- GEAR
hub. Insert the ring gear into the for- SNAP RING
stall the attaching bolts. Torque the
ward clutch.
attaching bolts to specification.
20. Install the thrust washer on the
13. Place the case in the holding
front end of the forward planet assem-
fixture.
bly. Retain the washer with vaseline
14. Align the low-reverse clutch hub
and insert the assembly into the ring
and one-way clutch with the inner
gear. Install the input shell and sun
race at the rear of the case. Rotate
gear assembly.
the low-reverse clutch hub clockwise
21. Install the reverse-high clutch,
while applying pressure to seat it on
forward clutch, forward planet assem-
the inner race.
bly and drive input shell and sun gear
15. Install the low-reverse clutch HUB AND FLANGE D1906-A
as an assembly into the transmission
plates, starting with a steel plate and
case.
following with friction and steel plates FIG. 58—Output Shaft Hub and
22. Insert the intermediate band
alternately. Retain them with vaseline. Ring Gear
into the case around the direct clutch
Refer to the Specifications Section for
the number of plates required. If new
composition plates are being used, LOW-REVERSE
CLUTCH DRUM-
soak them in clean transmission fluid 7D390
for fifteen minutes before installation. SPRING
RETAINER-
Install the pressure plate and the snap 7D191
BUSHING -
ring. Test the operation of the low- 7E194
reverse clutch by applying air pressure
at the clutch pressure apply hole in
the case.
16. Install the reverse planet ring
gear thrust washer and the ring gear
and hub assembly. Insert the snap
ring in the groove in the output shaft.
17. Assemble the front and rear
thrust washers onto the reverse planet
assembly; retain with vasoline. Insert
the assembly into the ring gear and SPRING - 7D170
install the snap ring. ROLLER-7190
D 1928-A
18. Set the reverse-high clutch on
the bench, with the front end facing FIG. 59—One-Way Clutch Disassembled
down. Install the thrust washer on the
rear end of the reverse-high clutch as-
sembly. Retain the thrust washer with cylinder.Install the struts and then to disassembly, replace the washer with
vaseline and insert the splined end of tighten the band adjusting screw suffi- one of proper thickness. Refer to
forward clutch into the open end of ciently to retain the band. Specifications Section for selective
the reverse-high clutch so that the 23. Place a selective thickness bronze thrust washer thicknesses. Lay a new
splines engage the direct clutch fric- thrust washer on the rear shoulder of gasket on the rear mounting face of
tion plates (Fig. 43). the stator support and retain it with the pump and position on the case
19. Install the thrust washer and re- vaseline. If the end play was not being careful not to damage the large
tain it with vaseline, on the front end within specification when checked prior seal on the O.D. of the pump hous-
ing. Install six of the seven mounting 25. Install tool 4201-C at the sev- primary throttle valve, rod, and the
bolts and torque them to specifica- enth pump mounting bolt (Fig. 24) vacuum diaphragm in the case.
tion. and check the transmission end play. 27. Install a new pan gasket and
24. Adjust the intermediate band as Remove the tool. the pan.
detailed in Section 2 and install the 26. Install the control valve in the 28. Install the converter assembly.
input shaft with the long splined end case, making sure that the levers en- 29. Install the transmission in the
inserted into the forward clutch as- gage the valves properly. Install the vehicle.
sembly.
PISTON
AND ROD PISTON COVER
Piston Diameter - Inches
Models Assembly Cover
LOW-REVERSE A ' B c D
SPRING LOAD ON ROLLERS CLUTCH HUB PGA-A3, C6AP-7D021-C C6AP-7D027-A 2.075 2.980 2.971 2.066
MUST BE IN A COUNTERCLOCKWISE J3, Z, AA
DIRECTION FOR INSTALLATION PGB-AD, AE, Jl
Q 192O A
PGB-F2/G2, H2 C6AP-7D021-D C6AP-7D027-D 2.342 3.025 3.016 2.333
PGB-AF1, AG, AH 2.477 NONE 3.492 2.468
FIG. 60—Installing One-Way
Clutch Diameter — Inches
Piston and
Models Rod Assembly Cover
A B C D
PGC-B, Cl 2.183 2.739 2.705 2.220
D 2037-B
FIG. 61 — Intermediate Servo Cover and Piston Dimensions
OUTPUT GOVERNOR
SHAFT
D 1623 -A
FIG. 62—Output Shaft Disassembled

APPROXIMATE REFILL CAPACITIES

U.S. Imperial
Measure Measure
FMX Transmission—All Car Lines 11 qt. 9M qt.
C4 Transmission—Ford All Engines WA qt. 8Va qt.
Falcon and Mustang—170 and 200 Engines 8 qt. V/i qt.
All Other Engines 9 qt. 7% qt.
C6Transmission—Lincoln, Mark III 13 qt. 103/4 qt.
All Other Models 123/4 qt. 10VS qt.
CONVERTER IDENTIFICATION AND STALL SPEEDS

FMX TRANSMISSION
Nominal Stall Identification Transmission Engine Stall
Converter Part Number CID Speed
Size Ratio No. 0 Model
PHD-A 240-IV 1300-1500
PHD-B 302-2V 1450-1650
C90P-7902-A 12 2.05:1 54
PHB-C, D, E, 351-2V 1580-1780
PHB-F, G, H, 351-4V 1650-1850
C8AP-7902-D 12 2.05:1 48 PHB-A 390-2V 1680-1880
® Converter identification is stamped on the converter cover adjacent to the converter drive stud.
C4 TRANSMISSION
Converter Part Number Nominal Stall Identification Transmission Engine Stall

Size Ratio No.® Model CID Speed
PEB-C2 170-1V 1400-1600
C5DP-7902-D ioy4 2.10:1 AL
PEB-B2, C2 200-IV 1500-1700
PEA-A2, 240-IV 1300-1500
C8AP-7902-E 12 2.05:1 BB
PEA-MI, Nl 302-2 V 1450-1650
PEE-AD, AE, AF 250-IV 1630-1830
C8ZP-7902-A 11V4 2.02:1 BC
PEE-M, V, AC 302-2V 1800-2000
® Converter identification is stamped on the converter cover adjacent to the converter drive stud.
C6 TRANSMISSION
Nominal Stall Identification Transmission Engine Stall
Converter Part Number Speed
Size Ratio No.® Model CID
C8AP-7902-A PGA-A3
C8OP-7902-A® 12 2.05:1 44 390-2V©® 1680-:,900
PGA-J3 PGB-G2
C8SP-7902-A
C8OP-7902-A® 12 2.05:1 46 PGB-JI, AD, AE 429-4V 1880-2100
C8VP-7902-B
C8OP-79O2-A0 12 2.05:1 52 PGC-B, Cl 460-4V 1950-2150
PGA-A3, J3, G2 390-2V®® 1680-1880

PGB-G2 390-4V 1740-1940
C8OP-7902-B 12 2.05:1 55 PGA-AC,AD,AE 390-4V © 1760-1980
PGB-F2, ® H2 428-4V 1850-2050
PGA-Z, AA, AB 429-2V 1820-2020
427-4V 1850-2050
C8OP-7902-A 12 2.05:1 53 PGB-AF-1, AG, AH
428-4V CJ 1830-2030
D Converter identification is stamped on the converter cover adjacent to the converter drive stud.
v Regular © Premium Fuel 0 Service Replacement ® Improved Performance ® Police
Poli Interceptor
CONTROL PRESSURE AT ZERO GOVERNOR RPM -

FMX TRANSMISSION
Control Line Pressure (PSI)
LJanifnlrl
Engine Speed Throttle ManiioiQ Range PHB-F, G, H-
Vac. Ins. Hg. PHB-A, C, D, E,
PHD-A,B
P, N, D, 2 , 1 57-73 5777
Idle Closed Above 18 ®
R 66-101 64105
As Required As Required 10 D,2, 1 83-110 82111
D, 2, 1 147-173 146-175
As Required As Required Below 10
R 191-213 201-213
D At altitudes above sea level, it may not be possible to obtain 18 inches of engine vacuum at idle. For idle vacuum of less than 1 8 inches,
refer to the following table to determine idle speed pressure specification in D driving range.
Engine Vacuum Line Pressure
17 inches 57-67
16 inches 57-67
15 inches 57-72
14 inches 57-79
13 inches 57-86
12 inches 57-92
11 inches 57-99
C4 TRANSMISSION
Engine Manifold
Speed Throttle Vac. Ins. Hg Range P.S.I.
Idle Closed 0) Above 18 P, N, D. 55-61
2, 1 55-102
R 55-182
As R e q u i r e d As Required 10 D, 2, 1 93-101
As R e q u i r e d As Required Below 1.0 D, 2, 1 142-150
R 254-268
0) At a l t i t u d e s above sea l e v e l , i t may not be possible t o o b t a i n 18 inches of engine vacuum at i d l e . For i d l e vacuums of less t h a n
18 inches, r e f e r t o t h e f o l l o w i n g t a b l e t o d e t e r m i n e idle speed pressure s p e c i f i c a t i o n i n D d r i v i n g range.
Engine Vacuum Line Pressure
17 inches 55-66
16 inches 55-71
15 inches 55-76
14 inches 55-81
13 inches 55-86
12 inches 55-91
11 inches 55-96
C6 TRANSMISSION
Engine Speed Idle As Required As Required
Throttle Closed As Required As Required
Manifold Vacuum (Inches Hg) Above 18 (o 10 Below 1.0
Range Control TV Control TV Control TV
Pressure (psi) Pressure Pressure (psi) Pressure Pressure (DSI) Pressure
P, N, D, 2, 1 R (psi) 0,2,1 (psi) D, 2, 1 R (psi)
Barometric Nominal
Pressure in Altitude
Inches HG (Feet)
psi @
Barometric 29.5 Sea Level 56-62 71-86 7-10 100-115 40-44 160-190 240-300 77-84
Pressure ®
28.5 1000 49-59 65-30 4-7 99-114 37-41 158-176 233-290 74-80
27.5 2000 49-56 60-75 2-5 96-111 35-69 156-174 228-284 72-78
psi@ 26.5 3000 49-56 56-71 0-3 91-106 32-36 151-169 222-277 69-75
Barometric 25.5 4000 49-56 56-65 0 88-103 30-34 146-164 215-269 66-72
Pressure ® 24.5 5000 49-56 56-65 0 84-98 27-31 143-161 211-264 64-70
23.5 6000 49-56 56-65 0 80-55 25-29 138-156 204-256 61-67
C6 TRANSMISSION (Continued)
Barometric Pressure at 29.5 Inches <2) Barometric Pressure at 24.5 Inches ®

Manifold Vacuum T.V. Cont. T.V. Cont.
17 11-14 56-69 0-1 49-56
16 15-18 56-75 2-5 49-56
15 20-22 56-S4 7-9 49-61
14 23-26 56-92 10-13 56-67
13 28-31 56-98 15-18 56-75
12 32-35 56-105 19-22 56-84
11 36-40 56-111 23-27 56-92
© It may not be possible to obtain 18 inches of engine vacuum at idle. For idle vacuums of less than 18 inches the following table
provides idle speed pressure specifications in D range:
£> These specifications (with altitude compensating diaphragm) apply at observed barometric pressure of 29.5 inches (nominal sea level)
© Specifications for barometric pressures of less than 29.5 inches.
<S> At barometric pressures between 29.5 inches and 24.5 inches idle, pressures should fall between the values shown.
CHECK SAND ADJUSTMENTS

FMX TRANSMISSION
Operation Specification
Transmission End Play Check 0.010-0.029 (Selective Thrust Washers Available)
Turbine and Stator End Play Check PHB, PHD-New or rebuilt 0.023 max., Used 0.030 max.®
Front Band Adjustment (Use 1/4 inch spacer Adjust screw to 10 in-lbs torque. Remove spacer, then tighten screw an additional 3/4 turn
between adjustment screw and servo piston and lock.
stem)
Rear Band Adjustment, Model PHB-A.PHD Adjust screw to 10 in-lbs torque. Remove spacer, then tighten screw an a d d i t i o n 3/4 turn
Rear Band Adjustment, Adjusting Internally: Loosen internal locknut. Install spacer tool number T69P-7B193-A between
Model PHB-C, D, E, F, G, H internal adjusting screw and servo piston, tighten internal adjusting screw to 24 in-lbs torque.
Back off 1 1/2 turns. Hold screw and tighten locknut. Remove spacer.
Adjusting Externally: Loosen internal locknut and reset internal adjusting screw to 0.27-0.28 inch.
Tighten internal locknut. Loosen external locknut and adjust external adjusting screw to 10 ft-lbs
torque. Back off 1 1/2 turns. Hold screw and tighten locknut.
Primary Sun Gear Shaft Ring End Gap Check 0.002-0.009
Rear Clutch Selective Snap Ring Thicknesses 0.060-0.064, 0.074-0.078, 0.080-0.092, 0.102-0.106
® To check end play, exert force on checking tool to compress turbine to cover thrust washer wear plate. Set indicator at zero.
C4 TRANSMISSION
Transmission End Play 0.008-0.042 inch (Selective Thrust Washers Available)
Turbine and Stator End Play Model PEB - N e w or rebuilt 0.044 max., Used 0.060 max.
Model PEE, PEA New or rebuilt 0.023 max., Used 0.040 max.
Intermediate Band Adjustment Remove and discard lock nut. Adjust screw to 10 ft-lbs torque, then back off
1-3/4 turns. Install new lock nut and torque to specification.
Low-Reverse Band Adjustment Remove and discard lock nut. Adjust screw to 10 ft-lbs torque, then back off 3 turns.
Install new locknut and torque to specification.
Selective Snap Ring Thickness 0.102-0.106, 0.088-0.092, 0.074-0.078, 0.060-O.064
C6 TRANSMISSIONS
Transmission End Play 0.008-0.044 (Selective Thrust Washers Available)
Turbine and Stator End Play New or rebuilt 0.021 max., Used 0.030 max. G)
Intermediate Band Adjustment Remove and discard lock nut. Adjust screw to 10 f t - lbs torque, then back off 1 turn,
install new lock nut and tighten lock nut to specification.
Forward Clutch Pressure
Plat eto-Snap Ring Clearance 0.031-0.044
Selective Snap Ring Thicknesses 0.056-0.060, 0.065-0.069, 0.074-0.078, 0.083-0.087, 0.092-0.096
Reverse-High Clutch Pressure Transmission Models
Plate-to-Snap Ring Clearance
PGA PGB, PGC
0.022-0.036 0.027-0.043
Selective Snap Ring Thicknesses 0.065-0.069, 0.074-0.078, 0.083-0.087
(D To check end play, exert force on checking tool to compress turbine to cover thrust washer wear plate. Set indicator at zero.
SELECTIVE THRUST WASHERS

FMX TRANSMISSION
Identification No. Thrust Washer Thickness -Inch Identification No. Thrust Washer Thickness - Inch
By Thickness 0.061-0.063 By Thickness. 0.074-0.076
0.067-0.069 0.081-0.083
C4 TRANSMISSION
THRUST WASHER NO. 1 THRUST WASHER NO. 2
Nylon Thrust Washer Color Of No. Stamped Metal Thrust
W/Tangs Washer On Washer Washer
0.053-4.0575 Red 1 0.041-0.043
0.070-0.074 Green 2 0.056-O.058
0.087-0.091 Natural (White) 3 0.073-0.075
0.104-0.108 Black 4 0.090-0.092
0.121-0.125 Yellow 5 0.107-0.109
C6 TRANSMISSION
Identification No. Thrust Washer Thickness -Inch Identification No. Thrust Washer Thickness - Inch
1 0.056-0.058
4 0.103-0.105
2 a.073-0.07F
3 0.088-0.090 5 0.118-0.120
CLUTCH PLATES
FMX TRANSMISSION
FORWARD CLUTCH REAR CLUTCH
Transmission Steel Friction Selective Plate Selective Plate Steel Friction Free Pack
Model Plates Plates Thicknesses Identification Plates Plates Clearance
0.0605-0.063 No Stripe
PHB, PHD 4 5© 0.0785-0.081 One Stripe 5® 4 0.030-0.055
0.0965-0.099 Two Stripes
© Last plate (Friction) in FMX forward clutch is selective. Install thickest plate in pack that will be a minimum of 0.010 inch below input shaft shoulder
in cylinder. All other friction plates in* pack are thinnest available.
© Plus one waved plate installed between two steel plates at piston end of pack.
C4 TRANSMISSION
Forward Clutch Reverse Clutch
External Internal Free Pack External Internal Free Pack
Model Spline Spline Clear. Spline Spline Clear.
(Steel-Grit Blasted) (Comp.) (Inches) (Steel) (Comp.) (Inches)
PEB 3(4) '., 4 ( 5 ) >.r< 0.020-0.036 <* 3(5) j) 3 ( 3 ) J> 0.050-0.066
PEA-PEE 4 5 0.026-0.042 4 4 0.050-0.066
i Use the quantities shown in parenthesis when a service replacement cylinder is installed.
$• 0.026-0.042 inches on PEB models with service replacement cylinder.
C6 TRANSMISSION
Steel Friction Steel Friction

Transmission Model Transmission Model
Plates Plates Plates Plates
Forward Clutch Plates- PGA 3 4 Low-Reverse Clutch Plates-PGA 4(6)® 4

PGB, PGC 4 5 PGB-F2, G2, H2,
6(6)© 6
AF-1, AG, AH
Reverse-High Clutch Plates-PGA 3 3
PGB-J1, AD,
PGB-F2, G2, AE, PGC
5(5)® 5
H2J1, AD, 4 4
AE, PGC ©Use the quantities shown in parenthesis when a service replacement
case is installed.
PGB-AF-1,
5 5
AG, AH
CONTROL VALVE SPRING IDENTIFICATION

FMX TRANSMISSION
Free Spring Wire
Spring Total Length Dia. O.D. Dia. Length at Lbs. Load Spring Color
Coils (Inches) (Inches) (Inches) Load Length Code
8.5 1.170 0.470 0.035 2.900 0.445 Yel.ow
1 2 Shift Accumulator Valve '° C
Model PHD 9 1.260 0.470 0.038 4.250 0.445 None
W °nri Shift Pnntrnl Vilur

7 1.650 0.725 0.047 4.900 0.560 Pin<
Model PHD 7 1.880 0.725 0.044 4.600 0.560 White
Throttle Press. Booster Model PHB-A, PHD 15.5 1.980 0.470 0.047 6.650 0.890 Blue
Valve: Model PHB-C,D,E,F,G,H 15.5 1.660 0.470 0.047 5.250 0.890 Green
M
11 0.880 0.265 0.026 2.400 0.415 Orange
.M 1 Scheduling
Scheduling Valve.
Valve- °delPHB
Mode, PHD 12 0.910 0.265 0.023 1.400 0.415 (2) Pink
Stripes
Low Inhibitor Valve: Model PHB, PHD 42 2.140 0.205 0.028 1.900 1.660 Yellow
Control Oil Press. Comp. Model PHB-A,C,D,E 8 1.640 0.509 I.D. 0.038 3.200 0.500 Whte
Valve-Outer: Model PHB-F,G,H, PHD 9 1.650 0.509 I.D. 0.035 2.400 0.500 None
Control Oil Press. Comp. Model PHB-A,C,D,E 13.5 1.620 0.310 I.D. 0.023 1.000 0.460 Pink
Valve-Inner: Model PHB-F,G,H, PHD 13.5 1.230 0.310 I.D. 0.030 2.000 0.460 None
Downshift Valve 13.5 1.107 0.250 0.023 1.400 0.640 None
Control Check Valve 12 0.480 0.214 0.014 0.100 0.280 None
3rd-2ndDownshift Control Valve 14.5 0.820 0.200 0.018 0.605 0.520 Purple
Transition Valve: Model PHB-A, PHD 8 1.600 0.470 I.D. 0.031 2.000 0.460 None
Model PHB-C,D,E,F,G,H 7 1.320 0.470 I.D. 0.035 2.750 0.460 None
2nd-3rd Shift Valve-Inner 21 1.340 0.295 0.028 1.500 0.670 Green
2nd-3rd Shift Valve-Outer 4 1.008 0.692 I.D. 0.041 2.950 0.430 White
Low Servo Modulator Valve 29.5 1.800 0.235 0.028 2.975 1.050 None
C4 TRANSMISSION
Free Spring Wire
Total Length at Lbs. Load Spring Color
Spring Length Dia. 0. D. Dia.
Coils Load Length Code
(inches) (inches) (inches)
Manual Valve Detent: All except PEC-EI 10 0.764 0.295 0.44 6.5 0.601 White
Model PEC-EI 9 0.74 0.295 0.045 7.5 0.601 None
2-3 Backout Control Valve 10 1.515 0.450 0.026 1.353 0.580 White
Main Oil Press. Reg. Valve 12 2.53 0.615 0.047 7.24 0.716 Pink
Throttle Press. Modulator 15 1.513 0.292 0.028 3.675 0.620 Yellow
Drive 2 Valve 10 0.735 0.230 0.019 0.80 0.450 Gray
Throttle Downshift Valve 9 0.962 0.380 0.034 3.44 0.440 Dk. Green
Throttle Press. Booster Valve 15 1.39 0.249 1. D. 0.036 5.250 0.730 Purple
Control Press. Booster Valve 12.8 1.66 0.350 1. D. 0.028 1.63 0.696 None
Inter. Band Accumulator Valve .T, 11 1.38 0.375 1. D. 0.024 1.0 0.400 Purple
Inter. Band Accumulator Valve i 10 1.293 0.375 1. D. 0.0258 1.25 0.400 None
Line Press Coasting Boost Valve 10 1.03 0.346 0.034 4.42 0.464 White
® Used on Models PEA-A2, Ml, Nl,
'i. Used on Models PEB-B2, C2, PEE
C6 TRANSMISSION
Free Spring Wire

Total Length at Lbs. Load Spring Color
Spring Length Dia. O. D. Dia.
Coils Length Load Code
(inches) (inches) (inches)
Manual Valve Detent: Model PGA-AA, A3,
J3, Z, PGB-AD, AE, 9 0.740 0.295 0.045 0.601 9.50 None
F2, G2, H2, Jl
Model PGC 11.5 0.800 0.295 0.041 0.601 5.25 Yellow
Model PGA-AC,
AD, AE, PGB-AFI, 10 0.764 0.295 0.044 0.601 6.50 White
AG, AH
2-1 Scheduling Valve: All except, PGB-JI 12 0.730 0.250 0.023 0.385 1.20 Green
Green
Model PGB-JI 12 0.700 0.250 0.023 0.385 1.050
Daub
1-2 Shift Valve: Model PGA, PGB 20 1.160 0.235 0.025 0.650 1.725 White
Model PGC 20 1.120 0.235 0.0244 0.650 1.370 Purple
Throttle Modulator Valve: Model PGA, PGB 17.6 1.257 0.280 0.0286 0.660 2.30 Pink
Model PGC 17.5 1.120 0.280 0.0317 0.660 2.81 Lt. Blue
Throttle Pressure Booster Valve 18 1.570 0.310 0.0379 0.917 5.90 Yellow
3-2 Shift Timing Valve 18.5 1.900 0.340 0.032 0.784 4.25 None
Inter. Oil Pressure Booster Valve 17 2.097 0.480 0.032 0.734 1.50 None
Intermediate Servo Capacity Modulator Valve 9.5 0.580 0.250 0.020 0.330 0.63 Brown
Throttle Downshift Valve 12 0.790 0.240 0.023 0.480 1.15 White Daul
Front Pump Relief Valve 14 1.020 0.250 0.032 0.750 3.30 Brown
Intermediate Servo Accumulator Valve—Inner ® 9.1 1.630 0.500 0.035 1.297 1.0 None
Intermediate Servo Accumulator Valve—Outer © 7.2 1.500 0.615 0.044 1.297 1.14 None
Main Oil Pressure Regulator 7 1.190 0.690 0.054 0.549 6.45 None
2-3 Backout Shift Valve 11.6 0.812 0.270 0.026 0.485 1.57 Blue
Converter Pressure Relief Valve 18.5 1.120 0.180 1. D. 0.041 0.900 5.0 Blue
cxy None used on Models PGB-F2, G2, H2
SHIFT SPEED ACTUAL MPH

FMXTRANSMISSION - F O R D , METEOR POLICE AND TAXI WITH 2401V ENGINE
Throttle Range Shift 1 2 3
Closed D 1-2 910 10-11 10-12
(Above D 2-3 10-20 10-21 11-23
17" D 3-1 7-9 7-10 8-11
Vacuum) 1 2-f 19-26 21-29 22-31
To Detent D 1-2 21-38 22-42 24-45
(Torque D 2-3 32-54 35-58 38-63
Demand) D 3-2 23-36 25-39 27-42
Through D 1-2 35-44 38-48 40-51
Detent D 2-3 55-67 60-75 64-78
(W.O.T.) D 3-2 53-63 57-68 61-73
D 3 1 or 2-1 25-33 27-36 29-38
Axle Ratio Tire Size Use Column No.
3.25:1 ALL 1
3.00:1 ALL 2
2.80:1 ALL 3
FMXTRANSMISSION - F O R D , METEOR POLICE AND TAXI WITH 3022V ENGINE
Throttle Range Shift 1 2 3

Closed D 1-2 9-12 10-13 11-14
(Above D 2-3 10-22 11-23 11-25
17" D 3-1 6-10 7-10 7-11
Vacuum) 1 2-1 21-29 22-32 24-34
To Detent D 1-2 22-40 24-43 26-46
(Torque D 2-3 39-61 42-67 45-71
Demand) D 3-2 25-40 27-43 29-46
Through D 1-2 38-48 42-52 45-56
Detent D 2-3 60-74 65-80 69-85
(W.O.T.) D 3-2 57-68 62-74 65-79
D 3-1 or 2 1 27-37 30-40 31-42
AXLE RATIO TIRE SIZE USE COLUMN NO.
3.25:1 ALL 1
3.00:1 ALL 2
2.80:1 ALL 3
FMXTRANSMISSION -FAIRLANE, MONTEGO, MUSTANG, COUGAR WITH 351-2V ENGINE

Throttle Range Shift 1 2 3 4 5 6
Closed D 1-2 9-11 9-12 9-12 10-13 10-13 10-14
(Above D 2-3 9-19 10-21 10-22 10-22 11-23 11-24
17" D 3-1 6-9 6-9 6-10 7-10 7-10 7-11
Vacuum) 1 21 27-35 28-36 29-38 31-40 32-41 33-43
To Detent D 1-2 25-40 26-42 27-44 28-45 30-47 30-48
(Torque D 2-3 41-64 42-64 44-67 46-70 48-73 50-74
Demand) D 3-2 22-36 22-37 23-39 25-40 26-42 26-44
Through D 1-2 33-41 34-42 35-44 37-46 39-48 40-49
Detent D 2-3 53-62 54-65 57-68 59-71 62-74 63-76
(W.O.T.) D 3-2 50-58 50-61 53-63 55-66 58-69 59-71
D 3-1 or 2-1 23-31 24-32 25-34 26-35 28-36 28-37
3.25:1 6.95 x 14, C78 x 14 1
All Except 2
6.95 x 14, C78 x 14
3.00:1 6.95 x 14, 7.35 x 14, 3
C78 x 14
7.75 x 14, E70 x 14, 4
E78 x 14, F70 x 14
FR70 x 14
2.75:1 6.95 x 14, C78 x 14 5
All Except 6
6.95 x 14, C78 x 14
FMX TRANSMISSION -FAIRLANE, 1MONTEGO, MUSTANG, COUGAR WITH 351-4V ENGINE
Closed D 1-2 9-11 9-12 9-12 1013 10-13 10-14

(Above D 2-3 9-19 10-21 10-22 10-22 11-23 11-24
17" D 3-1 6-9 6-9 6-10 7 7-10 7-11
Vacuum) 1 2-1 27-35 28-36 29-38 31-. 32-41 33-43
To Detent D 1-2 30-43 30-45 32-47 33-49 35-50 36-53

(Torque D 2-3 47-65 49-68 51-71 53-74 56-76 57-79
Demand) D 3-2 30-43 30-45 32-47 33-49 35-50 36-53
Through D 1-2 36-43 38-46 40-48 41-50 43-51 44-53

Detent D 2-3 57-67 59-70 62-74 65-76 68-79 69-82
(W.O.T.) D 3-2 52-61 54-65 57-68 59-70 62-72 63-75
D 3-1 or 2-1 ?5-33 26-35 27-36 28-37 30-39 30-40
3.25:1 6.95 x 14, C78 x 14 1
All Except 2
6.95 x 14, C78 x 14
3.00:1 6.95 x 14. 7.35 x 14 3
C78 x 14
7.75 x 14, E70 x 14 4
E78 x 14, F70 x 14
FR70 x 14
2.75:1 6.95 x 14, C78 x 14 5
All Except 6
6.95 x 14, C78 x 14
FMX TRANSMISSION - F O R D , METEOR WITH 390-2V ENGINE

Throttle Range Shift 1 2 3 4
Closed D 1-2 9-12 10-13 10-13 11-14

(Above D 2-3 10-22 11-23 11-23 11-25
18" D 3-1 6-10 7-10 7-10 7-11
Vacuum) 1 2-1 29-38 32-40 32-42 34-45
To Detent D 1-2 22-40 24-42 24-43 26-46

(Torque D 2-3 39-61 42-65 42-67 45-71
Demand) D 3-2 25-40 27-41 27-43 29-46
Through D 1-2 35-45 38-47 39-49 41-53

Detent D 2-3 56-69 61-73 62-75 65-80
(W.O.T.) D 3-2 53-65 57-68 58-70 61-75
D 2-1 or 3-1 25-34 27-36 27-37 29-40
3.25:1 All 1
3.00:1 7.75x15 2
215R x15
3.00:1 8.25 x 15 3
8.55 x 15
H70 x 15
2.80:1 All 4
C4 TRANSMISSION-FORD, METEOR, FAIRLANE, MONTEGO, FALCON, MUSTANG WITH 6 CYLINDER ENGINE
Closed D 1-2 8-10 9-10 9-10 9-11 10-11 10-12

(Above D 2-3 11-20 12-21 12-21 13-22 13-23 14 25
18" D 3-1 10 10 10 11 11 12:
Vacuum) 1 2-1 16-25 17-26 18-27 19-29 19-29 20-32
To Detent D 1-2 17-29 18-30 18-31 20-33 20-34 21-36

(Torque D 2-3 31-49 33-51 34-53 36-56 37-57 39-61
Demand) D 3-2 32 34 35 36 38 41
D 2-1 or 3-1 18 19 20 20 21 23
Through D 1-2 26-35 28-37 29-38 30-40 31-41 33-44

Detent D 2-3 50-65 53-68 55-70 57-74 59-76 66-82
(W.O.T.) D 3-2 69 72 74 77 81 87
2-1 or 3-1 27 28 29 30 32 34
Vehicle Axle Ratio Tire Size Use Col. No. Vehicle Axle Ratio Tire Size Use Col. No.
Ford 3.25:1 7.75x15, 215Rx 15 2 Fairlane, 3.25:1 7.35x14, FR70x 14 1
or 8.25x15,8.55x15 3 Montego, 7.75x14, F70x 14 2
Meteor H70 x 15 Falcon E 7 0 x l 4 , FR70xl4
3.10:1 7.75x15,8.25x15 4 or 3.08:1 6.95x14,7.35x14, 2
215Rx 15 Mustang C78 x 14
8.55x15, H70x 15 5 E78 x 14, 7.75 x 14 3
3.00:1 All 5 3.00:1 C78 x 14 2
7.35x14,6.95x14 3
2.80:1 All 6 7.75x14, F70 x 14 4
E70 x14, FR70 x14
E78 x 14
2.83:1 C78 : 14 4
6.95x1-:, 7.35x14 5
E78 x 14
2.79:1 All 5
C4 TRANSMISSION - F O R D , METEOR, FAIRLANE, MONTEGO, FALCON, MUSTANG WITH 302 2V ENGINE

Throttle Range Shift 1 2 3 4 5 6 7
Closed D 1-2 9-10 9-10 9-10 10-11 10-11 10-11 10-12
(Above D 2-3 12-20 13-21 13-22 13-22 13-23 14-24 14-25
18" D 3-1 10 10 10 11 11 11 12
Vacuum) 1 2-1 18-26 18-27 18-28 19-28 19-29 20-30 21-32
To Detent D 1-2 20-32 22-33 22-34 23-35 23-36 24-37 25-39

(Torque D 2-3 38-55 39-57 41-58 41-60 43-61 45-64 46-66
Demand) D 3-2 33 34 35 36 37 39 41
D 2-1 or 3-1 19 19 20 20 21 22 23
Through D 1-2 29-38 31-40 32-41 32-42 34-43 35-45 36-46

Detent D 2-3 57-71 58-73 60-75 60-77 63-79 66-83 63-86
(W.O.T.) D 3-2 71 73 74 78 79 84 87
D 2-1 or 3-1 28 29 29 30 31 33 34
Vehicle Axle Ratio Tire Size Use Col. No. Vehicle Axle Ratio Tire Size Use Col. No.
Ford 3.25:1 7.75 x 15 2 Fairlane, 3.25:1 7.35x14,7.75x14 1
or 215R x15 Montego, FR70 x14, F70 x14 2
Meteor 8.25x15 3 Falcon, E70 x 14
8.55x15, H70x 15 4 Mustang 3.00:1 C78 x 14 2
3.10:1 7.75x15, 8.25 x 15 4 6.95x14,7.35x14 3
215R x15 7.75 x 14, F70xl4, 4
8.55x15, H70x 15 5 FR70xl4, E70xl4,
3:00:1 All 5 E78 x 14
2.80:1 7.75 x 15 6 2.79:1 All Except-7.75 x 14 5
215Rxl5,8.25x 15 7.75 x 14 6
8.55x15, H70x 15 7
C6 TRANSMISSION -FORD, 1MERCURY, METEOR WITH 390-2V, 429-2V ENGINES
Closed D 1-2 8-10 8-10 7-10 7-9 7-9 7-9 6-8

(Above D 2-3 8-19 8-19 7-19 7-18 7-17 7-16 6-16
17" D 3-1 8-10 8-10 7-10 7-9 7-9 7-9 6-8
Vacuum) 1 2-1 23-32 22-32 21-31 21-30 20-29 19-27 18-27
To Detent D 1-2 29-44 28-43 28-42 27-40 26-39 25-37 24-36

(Torque D 2-3 51-71 50-69 48-68 47-65 45-63 43-60 41-58
Demand) D 3-2 26-40 25-39 24-39 23-37 23-36 22-34 21-33
Through D 1-2 45-54 44-53 43-52 42-50 40-48 38-46 37-45

Detent D 2-3 78-89 7687 74-86 72-82 69-80 66-75 63-73
(W.O.T.) D 3-2 72-82 70 81 69-79 66-75 64-73 61-69 59 68
D 3-1 or 2 1 35-43 34 43 34-42 33-40 31-39 30-37 29-36
Use Axle Ratio Use

Axle Ratio Tire Sizes Tire Sizes
Column No. Column No.
2.75:1 8.55x15, H70x 15 1 3.00:1 8.55 x 15 4
8.25x15 2 8 . 2 5 x 1 5 , 215Rx 15 5
215RX 15 3 3.25:1 8.55 x 15r H70x 15 6
2.80:1 8.55x15, H70x 15 2 7.75x15,8.25x15 7
8.25x15, 215Rx 15 3 215R x 15 7
C6 TRANSMISSION -FIARLANE, MONTEGO, MUSTANG, COUGAR WITH 390-4V

(IMPROVED PERFORMANCE) ENGINES AND FORD, MERCURY, METEOR WITH 429-4V ENGINE
Throttle Range Shift 1 2 3 4 5 6 7 8
Closed D 1-2 8-10 7-10 7-9 6-9 6-8 6-8 5-7 46

(Above D 2-3 819 7-18 7-18 6-16 615 6-14 5-13 4 12
17" D 3-1 8-10 710 7-9 6-9 6-8 6-8 5-7 4-6
Vacuum) 1 21 22-32 21-31 19-30 18-28 17-26 16-24 14-21 13-20
To Detent D 1-2 34-48 32-47 29-45 28-41 26-39 25-36 22-32 20-29
Torque D 2-3 58-75 55-73 51-69 48-64 46-61 43-55 41-50 35-45
Demand) D 3-2 25-40 24-39 22-37 21-34 20-33 18-30 16-27 15-24
Through D 1-2 46-55 44-54 41-51 39-47 37-49 34-41 30-37 28-34
Detent D 2-3 80-91 76-89 70-85 66-78 63-74 59-68 52-61 48-55
(W.O.T.) D 3-2 71-82 67-80 62-76 59-70 56-67 52-61 46-54 42-50
D 3-1 or 2-1 35-44 33-42 30-40 29-37 27-35 25-32 23-29 21-26
Use Use
Axle Ratio Tire Sizes Axle Ratio Tire Sizes
Column No. Column No.
2.75:1 8.55x15, H 7 0 x l 5 1 3.25:1 8.25 x 15, 8.55 x 15, H 7 0 x l 5 4

7.75 x 14, F70 x 14 2 215Rx 15
FR70 x 14 2 7.35x14,7.75x14 5
8 . 2 5 x 1 5 , 215Rx 15 2 F70x 14, FR70x 14 5
7.35 x 14, E78 x 14 3 E78x 14, 7.75x15 5
2.80:1 8.55 x 15, H70x 15 1 3.50:1 All 6

8 . 2 5 x 1 5 , 215Rx 15 2 3.91:1 All 7
3.00:1 8.25 x 15, 8.55 x 15, 215R x 15 3
4.30:1 All 8
7 . 7 5 x 1 4 , F70x 14 3
7 . 3 5 x 1 4 , FR70x 14, E78 x 14 4
C6TRANSMISSION - F O R D , MERCURY, METEOR WITH 3902V, 4V and 428-4V ENGINES

(POLICE AND FLEET UNITS)

Closed D 1-2 8-10 8-10 7-10 7-9 7-9 7-9 6-8
(Above D 2-3 8-22 8-21 7-21 7-20 7-19 7-18 6-18
17" D 3-1 8-10 8-10 7-10 7-9 7-9 7-9 6-8
Vacuum) 1 2-1 26-35 25-34 24-34 23-32 23-31 22-30 21-29
To Detent D 1-2 36-51 35-50 34-50 33-47 32-46 31-43 29-42
(Torque D 2-3 64-83 62-81 61-80 58-76 56-74 54-70 52-68
Demand) D 3-2 29-43 28-42 27-42 26-40 25-39 24-37 23-36
Through D 1-2 49-57 48-56 46-55 45-53 43-51 41-49 40-47

Detent D 2-3 84-95 82-93 80-91 77-87 75-85 71-80 68-78
(W.O.T.) D 3-2 75-84 73-83 71-82 68-78 66-76 63-72 60-70
D 3-1 or 2-1 36-43 35-43 34-42 33-40 32-39 31-37 29-36
Use Axle Ratio Tire Sizes Use

Axle Ratio Tire Sizes Column No.
Column No.
2.75:1 8.55 x 15, H70 x 15 1 3.00:1 8.55 x 15 4
8.25 x 15 2 3.00:1 8.25 x 15, 215R x 15 5
215R x 15 3
3.25:1 8.55x15, H 7 0 x l 5 6
2.80:1 8.55x15, H 7 0 x l 5 2 7.75 x 15, 8.25 x 15 7
8.25 x 15, 215R x 15 3 215R x 1 5 7
C6 TRANSMISSION - F O R D AND MERCURY WITH 428-4V (POLICE INTERCEPTOR) ENGINES
Throttle Range Shift 1 2 3 4 5
Closed D 1-2 8-10 8-10 7-10 7-9 7-9

(Above D 2-3 8-22 8-22 111 7-20 7-20
17" D 3-1 8-10 8-10 7-10 7-9 7-9
Vacuum) 1 2-1 27-37 26-36 25-36 25-34 24-33
To Detent D 1-2 38-54 37-53 36-52 35-50 34-48

(Torque D 2-3 67-87 65-86 63-84 61-80 60-78
Demand) D 3-2 30-46 29-45 28-44 27-42 26-41
Through D 1-2 51-60 50-59 49-58 47-56 45-54

Detent D 2-3 88-100 86-98 84-96 81-92 78-39
(W.O.T.) D 3-2 78-89 76-88 74-86 72-82 70-30
D 3-1 or 2 1 38-46 37-45 36-44 35-42 34-41
2.75:1 8:55x15, H70x 15 1

8.25 x 15 2
215RX15 3
2.80:1 8.55x15, H70x 15 2
8.25xl5,215Rxl5 3
3.00:1 8.55 x 15 4
8.25xl5,215Rxl5 5
C6 TRANSMISSION -FAIRLANE, 1MONTEGO, MUSTANG AND COUGAR WITH 428-4V C. J. ENGINE

Closed D 1-2 7-9 7-9 6-9 6-8 6-8 5-7 4-6

(Above D 2-3 7-23 111 6-21 6-20 6-18 5-16 415
17" D 3-1 7-9 7-9 6-9 6-8 6-8 5-7 4-6
Vacuum) 1 2-1 27-38 25-37 24-35 23-33 21-30 19-27 17-25
To Detent D 1-2 40-56 37-55 35-51 33-49 31-44 28-40 25-36

(Torque D 2-3 69-91 63-89 60-83 57-79 53-72 47-64 43-58
Demand) D 3-2 30-47 28-46 26-43 25-41 23-37 21-33 19-30
Through D 1-2 55-65 51-64 4859 46-56 42-51 38-46 34-42

Detent D 2-3 94-107 86105 82-98 78-93 73-85 65-76 59-69
(W.O.T.) D 3-2 84-96 77-94 73-87 70-83 65-76 58-68 52-62
D 3-1 or 2-1 41-51 38-50 36-46 34-44 32-40 28-36 26-33
Use Tire Sizes

Use
Axle Ratio Tire Sizes Axle Ratio
Column No.
Column No.
2.75:1 7.75 x 14, F70 x 14, 1 3.25:1 All 4
FR70 x 14, 1 3.50:1 All 5
7.35 x 14, E78 x 14 2
3.90:1 All 6
3.00:1 7.75 x 14, F70 x 14 2
7.35 x 14, FR70 x 14, 3 4.30:1 All 7
E78 x 14 3
C6 TRANSMISSION -THUNDERBIRD WITH 429-4V ENGINES
Closed D 1-2 7-9 7-9 7-10 810

(Above D 2-3 7-17 7-17 7-18 8-19
17" D 3-1 7-9 7-9 7-10 8-10
Vacuum) 1 2-1 17-26 18-27 18-28 19-29
To Detent D 1-2 30-43 31-44 33-46 34-47

(Torque D 2-3 53-67 55-69 56-71 58-73
Demand) D 3-2 22-36 23-37 24-38 25-39
Through D 1-2 42-50 43-51 45-53 46-54

Detent D 2-3 72-82 75-84 77-88 80-90
(W.O.T.) D 3-2 64-73 66-75 69-79 71-81
D 3-1 or 2 1 31-39 32-40 34-42 35-43
Axle Ratio Tire Sizes Use Column No.

2.80:1 8.25x15, 215R x 15 1
8.55 x 15 2
3.00:1 8.25 x 15, 215R x 15 3
8.55 x 15 4
C6 TRANSMISSION -LINCOLN CONTINENTAL AND CONTINENTAL MARK III VEHICLES WITH 460-4V ENGINES
Closed D 1-2 8-10 7-10 8-10 7-9
(Above D 2-3 8-22 7-21 8-22 7-21
17" D 3-1 8-10 7-10 8-10 7-9
Vacuum) 1 2-1 21-30 20-28 20-29 19-28
To Detent D 1-2 29-42 27-39 29-41 27-38
(Torque D 2-3 59-76 55-71 58-75 54-70
Demand) D 3-2 27-42 25-39 27-41 25-38
Through D 1-2 43-50 40-47 42-49 40-46
Detent D 2-3 83-92 77-86 81-90 76-85
(W.O.T.) D 3-2 2-81 67-76 70-79 66-74
D 3-1 or 2-1 26-34 25-32 26-33 24-31
Vehicle Axle Ratio Tire Size Use Column No.
Lincoln Continental 2.80:1 9.15 x 15 1
3.00:1 9.15x15 2
Continental Mark III 2.80:1 8.55 x 15 3
9.15 x 15 1
3.00:1 8.55 x 15 4
9.15 x 15 2
TORQUE LIMITS
Ft-Lbs Ft-Lbs
Item Item
FMX C4 C6 FMX C4 C6
Converter to Flywheel 23-28 23-28 20-30 Extension Assy, to Trans. Case 30-40 28-40 25-30
Converter Hsg. to Trans. Case 40-50 28-40 - Pressure Gauge Tap 7-15 9-15 9-15
Front Pump to Trans. Case 17-22 28-40 12-20 Band Adj. Screw Locknut to Case - 35-45 35-45
Front Servo to Trans. Case 30-35 - - Yoke to Output Shaft - 60-80 -
Rear Servo to Trans. Case 40-45 - - Reverse Servo Piston to Rod - ® -
Upper Valve Body to Lower Valve Body 4-6 - - Cooler Tube Connector Lock - - 25-35
Overrunning Clutch Race to Case — 13-20 18-25 Converter Drain Plug 15-28 20-30 14-28
Oil Pan to Case 10-13 12-16 12-16 Rear Band Adjusting Screw to Case 35-40 - -
Rear Servo Cover to Case - 12-20 - Front Band Adjusting Screw Locknut 20-25 - -
Stator Support to Pump - 12-20 12-16 Manual Valve Inner Lever to Shaft 8-12 8-12 8-12
Converter Cover to Converter Hsg. 12-16 12-16 12-16 Downshift Lever to Shaft 17-20 12-16 12-16
Guide Plate to Case - - 12-16 Filler Tube to Engine 20-25 20-25 20-25
Intermediate Servo Cover to Case - 16-22 10-14 Filler Tube to Pan - 32-42 -
Regulator to Case 17-22 - - Transmission to Engine 40-50 40-50 40-50
Planetary Support to Trans. Case 20-25 - - Transmission to Engine: Falcon

- 23-33 -
Mustang-6-Cyl.
Control Valve Body to Trans. Case 8-10 - -
Lower to Upper Valve Body - 40-55 40-50
Dia; 'iragm Assy, to Case 20-30 15-23 15-23
Reinforcement Plate to Body - ; 40-55 20-30
Cooler Return Check Valve 9-12 - -
Screen and Lower to Upper Valve Body - 40-55 40-50
Distributor Sleeve to Case - 12-20 12-16
Neutral Switch to Case 2^ - 55-75 55-75
Governor to Counterweight 50-60 - -
Neutral Switch to Column 20 20 20
Governor Valve Body Cover Screws 20-30 - -
r Accumulator Plate to Body - 50-90 -
Pressure Regulator Cove Screws 20-30 - -
Lower Valve Body Cover and Plate to
Control Valve Body Screws (10-24) 20-30 - - 48-72 - -
Valve Body
Front Servo Release Piston 20-30 - - Control Assy, to Case 96-120 80-120 90-125
End Plates to Body 20-30 20-35 20-30 Gov. Body to Collector Body - 80-120 80-120
Stator Support to Pump 23-35 - - Cooler Line Fittings - 80-120 -
Inner Downshift Lever Stop - 40-55 20-30
r^ Tighten to 10 ft-lbs and back off 5/8 turn.
-• Mustang and Cougar only.

Ford 1969 Car Shop Manual Volume One Chassis PDF

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What information is provided on the warranty plates?

What information is provided on the warranty plates?

What does the vehicle identification number provide?

What does the vehicle identification number provide?

FOREWORD

The information is grouped according to the type of work being per-

The descriptions and specifications in this manual were in effect at the

To locate the beginning page of any particular Group, first select

On the beginning page of each Part, there is a Part index which

All pages carry a six-digit number which indicates the Group,

For Example: Page 03-02-01 indicates

Each Part will start with Page 01.

I 9Y82A848000 | Y89A848000 rMMUNTrNUMBW

^J MODEL YEAR CODE (7) COLOR CODE

2) ASSEMBLY PLANT CODE 0 TRIM CODE

5) BODY SERIAL CODE ® DATE CODE

T) ENGINE CODE (JO) DISTRICT-SPEC. EQUIP. CODE

T) BODY TYPE CODE (12) TRANSMISSION CODE

Fig. 1—Warranty Plates—Passenger Cars

Fig. 2—Typical Vehicle Identification Number (VIN) Tab

VEHICLE WARRANTY NUMBER COUGAR

VEHICLE DATA 91 65C 2-Door Hardtop® Standard

BODY SERIAL AND STYLE CODES-(continued)

©Bench Seat ©Split Bench ©Bucket Seats Body Body

52 62B 2-Door Sedan® Custom 500

10 62A 2-Door Sedan® Standard

20 62B 2-Door Sedan® Futura

©Bench Seat ©Split Bench ©Bucket Seat

BODY SERIAL AND STYLE CODES-(continued) ENGINE CODES

INTERIOR TRIM CODES INTERIOR TRIM CODES-(continued)

INTERIOR TRIM CODES-(continued) INTERIOR TRIM CODES-(contlnuad)

Code District Code District

11... Boston 51 . . . Denver

Part 2-1 General Brake Service

1 BRAKE SYSTEM TESTS

o'clock position on the steering wheel

COMMON ADJUSTMENTS AND REPAIRS

FORD, MERCURY, METEOR,

brake, the first notch will be approxi- H 1537-C

ft-lb breakaway torque. The breaka- THUNDERBIRD, POWER BRAKE MASTER

CABLE ASSEMBLY H1632-A

#16 U.J>.S. GAUGE SHEET STEEL

TIGHTEN RETAINING NUTS

3. Submerge the free end of the

CLEANING AND INSPECTION

Part 2-2 Brake System

Disc brakes are available as option- DISC BRAKE FLOATING CALIPER—

PRIMARY SYSTEM BRAKE

FIG. I — Dual Master Cylinder—Typical

VALVE PISTON HAS MOVED

LOW PRESSURE SIDE HIGH PRESSURE SIDE U

FIG. 2—Pressure Differential Valve and Brake Warning Light Switch

CALIPER ASSEMBLY EXTERNAL

The caliper assembly is bolted di-

piston seals are positioned in grooves

The cast iron disc is of the ventilat-

DRUM BRAKE FIG. 6—Fixed Caliper Assembly—Sectional View

The drum brake system employs

FIG. 8—Self-Adjusting Brake Assemblies—Typical