Werkstatthandbuch Book 1 · Seiten 301–400

13-51-10 Power Steering Pump-Ford Model CII 13-51-10 N 800056-52 30-46 FT-LB - ASSY. 384094-S2 2.8 LITER ENGINE N500056-52 30-45 FT-LB 30673 ASSY. 30-45 FT-LB 30

3A674 ASSY. NB000S6-S2 REF - 39-45 FT-LB N800056-S2 2.BL ENGINE 55738-S2 30-45 3A732 3C510

13-51-12 Power Steering Pump-Ford Model CII 13-51-12 OUTLET FITTING 62561-lA 62569-IA FIG. 10 Removing Outlet Fitting, Flow Control FIG. 12 Loosening Reservoir Valve and Spring 02568-IA G257 0-lA FIG. 11 Removing Seals FIG. 13 Removing Reservoir "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further

13-51-13 Power Steering Pump-Ford Model CII 13-51-13 APPLY PETROLEUM JELLY TO THIS ENTRE SEALING AREA. 360 DEOREES 62572 1A FIG. 14 Removing 0-Ring FIG. 15 Applying Petroleum Jelly DISASSEMBLY AND ASSEMBLY: POWER STEERING PUMP 8. In the side o

13-51-14 Power Steering Pump-Ford Model CII 13-51-14 10. lubricate the inner and outer 0-ring seals with the LOWER SUPPORT PLATE specified power steering fluid and install these seals TOOL T7EP-3733-A2 on the lower pressure plate Fig. 27. 11. Insert the lower pressure plate with the 0-ring seals toward the front of the pump into the pump housing Fig. 28 and over the dowel pins. Place the entire

13-51-15 Power Steering Pump-Ford Model CII 13-51-15 "C" CLAMP UPPER COMPRESSOR PLATE TOOL TIEP-3733A1 LOWER SUPPORT PLATE T78P-3733-A2 G257 4-lA 02576-lA FIG. 17 Positioning Pump in C-Clamp FIG. 19 Disassembling Pump SLAM THE HOUSING PLATE ON A FLAT SURFACE TO RFMOVE LOWER PLATE & EELLflLLE SPR

13-51-16 Power Steering Pump-Ford Model CII 13-51-16 PRY OUT THE SHAFT SEAL G2578’lA FIG. 21 Removing Shaft Seal "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

13-51-17 Power Steering Pump-Ford Model CII 13-51-17 INSERT A SPRING INTO THE ROTOR SPRING POCKET USE ONE OF THE SLIPPERS/ TO COMPRESS THE SPRING AND INSTALL THE SLIPPER 02660 IA 02661-lA FIG. 22 Inserting Spring FIG. 23 Installing Slipper "This publication contains material that is rep

13-51-18 Power Steering Pump-Ford Model CII 13-51-18 INDEX THE ROTOR LITHER RIGHTOR LEFT TO THE BELLEVILLE WASHER NEXT CAVITY AND INSTALL ANOTHER SPRING AND SLIPPER UNTIL ALL 1101 CAVITIES ARE FILLED 02662-IA FIG. 24 Assembling Slippers and Springs

13-51-19 Power Steering Pump-Ford Model CII 13-51-19 TOOL T74P-3044-A-l PRESS ON LOWER PLATE INSTALL THE LOWER PLATE WITH LIGHTLY UNTIL IT IS THE SEALS FACING TOWARD THE FELT TO BOITOM PUMP HOUSING 02582-IA 02584-lA FIG. 28 Installing Lower Pressure Plate FIG. 30 Pressing Lower Plate Into Position

13-51-20 Power Steering Pump-Ford Model CII 13-51-20 UPPER PLATES RECESS MOUNTS DIRECTLY OVER PRESSURE CHANNEl IN THE VALVE COVER FITS TIlE RECESSED NUTCH IN IRE LAM AND DIRECTLY OVER TIlE RECESS IN THE UPPER APPROXIUATELV 100 DEGREES OPPOSITE PLATE THE SQUARE MOUNTING LUG 0258814 02588-IA FIG. 32 Installing Upper Pressure Plate FIG. 34 Installing Valve Cover - G258?-1A

13-51-21 Power Steering Pump-Ford Model CII13-51-21 C2ESO’lA FIG. 36 Installing Outlet Ftting "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

13-51-22 Power Steering Pump-Ford Model CII 13-51-22 SPECIFICATIONS MODEL C-Il PUMP TORnUE SPECIFICATIONS 3.31. 3 4.IL 5.OL 5,/LW 55L’H Engine Application 2.31 2.81 200 dO F 250 CID 302 LID 351W dO 35144OOdlD1 Pivot Boll Fl-LW 30-45 - 30-45 30-45 30-45 30-45 30-45 30-45 Front Bolts to SUpport Bracket Ft*Lb 30’45 I 30-45 30’45 30-45 30-45 30-45 30-45 30-45 SUpport Bracket to Engine Fl-LW 30-45 30-45 30-45 30-45

13-52-1 Power Steering Pump-Saginaw 13-52-1 PART Power Steering Pump-Saginaw 13-52 Applies to Furd, Mercury, Continental Mark V and Lincoln Continental SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS REMOVAL AND INSTALLATION Pump Belt Tension 52-2 Power Steering Pump 52-2 DESCRIPTION Power Steering Pump Pulley 52-2 Power Steering Pump 52-1 Rotor Shaft Seal 523 DISASSEMBLY AND ASSEMBLY SPECIFICATIONS

13-52-2 Power Steering Pump-Saginaw 1 352-2 ADJUSTMENTS PUMP BELT TENSION ADJUSTMENT Pump drive belt tension cannot be checked 2. Loosen the three 3 bolts covering the slotted holes accurately using the thumb pressure or belt deflection in the engine mountinybracket Figs. 2 aRd 3. methods. The adjustment must be made with a belt 3. Increase belt tension by rotating the adjusting nuttension gauge. Figs. 2 and 3 in a clockwise direction. 1. Check the belt tension with belt tension gauge Tool 4. Decrease belt tension by rotating the adjusting nut T63L-8620-A. For a new belt, or a belt that has in a counter-clockwise direction. be

13-52-3 Power Steering Pump-Saginaw 13-52-3 4. Rotate the tool nut counterclockwise to remove the 3. Install the seal Fig. 4. pulley. Do not hammer the tool. This could 4. Install the pulley. damage the pulley and the snap ring at the inner end of the shaft. If the snap ring is damaged, disassemble the pump, as outlined in this Part, and replace the ring. Installation 1. Install the pulley on the shaft using the Pulley Installer Tool T75L-3733.A. ROTOR SHAFT SEAL To replace the rotor shoft seal, remove the pump as outlined in this Part. Removal 1. Drain as much fluid as possible through the filler tube. 2. Remove the pulley from the pump following the

13-52-4 Power Steering Pump-Saginaw 13-52-4 4. Do not use solvent on seals. with a pair of long nose pliers or a screwdriver. Do Disassembly not damage the shaft with the vise jaws. Discard the retaining ring. Remove the bracket and pulley from the pump. 1 4. Remove the rotor and thrust plate from the shaft. Clamp the front hub of the pump in a vise so the extending portion of the shaft points down. Do

13-52-5 Power Steering Pump-Saginaw 13-52-5 10. Install the cam ring on the dowel pins with the DOWEL PINS rotation arrow toward the rear of the housing Fig. 8. ARROWN FIG. 10 Installing the Pressure Plate 16. Lubricate the end plate with power steering fluid to prevent damage to the 0-ring, and press it into the housing with an arbor press Fig. 11. Depress FIG. 8 Installing the Cam Ring the end pl

13-52-6 Power Steering Pump-Saginaw 13-52-6 Replacement reservoirs do not have an next to the head hex. Insert the pressure union in identification number. If a new reservoir is installed, the flow control valve hole in the back of the imprint the model number of the defective reservoir reservoir and torque to specification. on the new part for future identification. 23. Attach the mounting bracket and pulley to the 21. Insert the mounting bolts and torque to pump. specification. 22. Lubricate a new 0-ring with power steering fluid, and install it on the pressure union in the groove SPECIFICATIONS SAGINAW POWER STEERING PUMP TORQUE LIMITS FT-La

14-01-1 Suspension 14-01-1 GROUP SUSPENSION 14 3000 S 5000 PART TITLE PART NO. PART TITLE PART NO. Front Suspension - Single Lower Arm 14-05 Manual Fill Load Leveler System - Air Front Suspension - Spring on Upper Arm 14-04 Sleeve Rear Shock Absorbers 14-45 Front Suspension - Spring on Lower Arm 14-03 Rear Suspension - Coil Springs 14-32 General Suspension Service 14-01 Rear Suspension - Leaf Springs

_______________ 14-01-2 General Suspension Service 14-01-2 work performed an 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. 1. Check the runout af each front wheel and tire using a dial indicator against the rim outer band. If the runout exceeds 1/8 inch, correction may be made by rotating the wheel on the drum. When the minimum runout has been obtained, mark the point of greatest runout so the wheels can be positioned as shown in Fig. 1 when checking the front end alignment. hold a piece of chalk against the wheel rim or the tire sidewall while spinning the wheels. The chalk will mark the rim or tire at the point of greatest runout.

14-01-3 General Suspension Service 14-01-3 The maximum camber difference side-to-side is Correct toe-in setting, or inward pointing of both specified at the end of this Part. front wheels, is given in the Specifications at the end of this Part. TOE FRONT WHEEL TURNING ANGLE Toe should only be checked and adjusted after the When the inside wheel is turned 20 degrees, the caster and camber have been adjusted to specifications. turning angle 0f the outside wheel should be as specified in the Specifications at end of this Pact. The Check the toe

14-01-4 General Suspension Service 14-01-4 Record and compare these caster/camber readings correcting alignment on current frame-body units. The with the nominal specifications on the chart to alignment equipment must be calibrated and in determine if adjustment is required. good working condition for accurate and See Fig. 7. acceptable results. hg. 7 shows the recorded readings and adustment 1. Check caster and camber and record the readings. required in a theoretical case that will be used as an 2. Compare camber and caster readings with nominal example in,the following instruction. Using the example specifications on appropriate chart depending on shown in Fig. 7, note the n

14-01-5 General Suspension Service 14-01-5 FRONT WHEEL ALIGNMENT CHART CASTER READING IN DEGREES CAMBER CAMBER -‘4 -¼’ 0 +1/4 +/z +¾ +1 +1r4 t11/2 +1% +2 +21/4 +2W +2W +3’ +31/40 +3W +3¾d1 -33 -34 -34 -35 -36 -37

_____________________________ 14-01-6 General Suspension Service 14-01-6 FRONT WHEEL ALIGNMENT CHART CASTER READING IN DEGREES LEFT .14° 0+ +1/4’ ÷ ½’, +4W +1’ +1W +1w +1W +2° +25W +214° +244° -4-3° +3W +3W +344 RIGHT -w CAMBER CAMBER 50 -51 -36 37

14-01-7 General Suspension Service 14-01-7 FRONT WHEEL ALIGNMENT CHART CASTER READING IN DEGREES LEFT RIGHT .1/3 + 3’ 0- t!1JS*1 +114 +11/2 +1Jt3L1/4 +2’/, +2% CAMBER CAMBER + 2¾ + 21/2 F,onI -31 -32 -33 -34 -3S -36 -37 -38 -39 -40 -42 -43 -44 -45 -47 -48 Rear -52 -51 -50 - -48 - -6 -45 -44 -43

14-01-8 General Suspension Service 14-01-8 - LOOSEN RETAINI NO AJt,jttrtrg on- NUTS .PPER 59 INNER SHAFT HETI’1 N0 BOLT REVOLVE WRENCH 1/ PPEP AV INNER SHAFT REAR ALIGNMENT FRONT TOOL ALIGNMENT TOOL HEX USED TO DETERMINE

14-01-9 General Suspension Service 14-01-9 TURN UOWNWARD TO TURN UPWARD TO TURN INCREASE ROD LENGTH INCREASE ROD

14-01-10 General Suspension Service 14-01-10 CLEANING AND INSPECTION FRONT-END GENERAL INSPECTION Do not check and adjust front wheel alignment without first making the following inspection for front-end damage, or wear. L Check for specified air pressures in all four tires. 2. Raise the front of the vehicle off the floor. Grasping the Upper and lower surfaces of the tire, shake each front wheel to check for worn bearings. Check the front suspension ball joints and mounts for looseness, wear, and damage. Check the brake backing plate mountings. Torque all loose nuts and bolts to specification. Replace all worn parts as outlined in Parts 14-03 and 14-04. 3. Check the steering gear mountings and all steering linkage connections for

14-01-11 General Suspension Service 14-01-11 2. Wipe the grease fitting and checking surface so they are free of dirt and grease. The checking surface is the round boss into which the grease fitting is threaded Fig. 19. 3. The checking surface should project outside the cover Fig. 19. If the checking surface is inside the

14-01-12 General Suspension Service 14-01-12 extension than on compression is a normal shock absorber. The replacement shock absorber condition. Faint swish noises are also normal. resistance will appear to be higher than either Remove the shack absorber for a bench test if original due to initial friction of the rod seal. action is erratic. If the action is smooth, but the shock absorbers are suspected of being weak, Bench Test follow Step 4: With the shock absorber right side up as installed 4. Repeat StepS on the mating shock absorber on the in vehicle, extend it fully. Then turn the shock absorber opposite side of the vehicle, and compare results

14-01-13 General Suspension Service 14-01-13 SPECIFICATIONS WHEELOASE AND TREAD WIDTH - INCHES Tread Width Vehicle Wheelbase Front Rear Pinto/Bobcat 94.2 55.0 55.8 SPECIAL SERVICE TOOLS Fairmont/Zephyr 105.5 56.4 57.1] Tool No. Description Monarch/Granada L09.9 58.5 57.1 Mustang II 96.2 ‘Tj’ 55.8 33 T69P3000-A Except Cougar X117

14-03-1 Front Suspension-Spring On Lower Arm 14-03-1 Front Suspension- 14-03 Spring On Lower Arm Applies To All Cars Except Granada/Monarch/Versailles/Fairmont/Zephyr SUBJECT PAGE SUBJECT PAGE DESCRIPTION REMOVAL AND INSTALLATION Cont’d. Front Suspension 03-1 Front Wheel Spindle 03-8 Lower Arm 03-4 REMOVAL AND INSTALLATION Lower Arm Strut and/or Bushing 03-4 Adjustable Shock Absorbers 03-7

14-03-2 Front Suspension-Spring On Lower Arm 14-03-2 INNER SHAFT VIEW S STRUT STABILIZER RAP VIEW U NVIEW v BALL JOINTS MUST NOT BE REPLACED. UPPER OR LOWER SUSPENSION ARMS SHOULD BE REPLACED AS A UNIT. UPPER HOWEVER UPPER ARM BUSHINGS AND SHAFTS AND BOTH UPPER

14-03-3 Front Suspension-Spring On Lower Arm 14-03-3 ASSEMBLED VIEW ASSEMBLED VIEW MuSTANG P1 NTO/BCBCAT - - -I x VIEW W FRONT VIEWW S -c VIEW Z & V

14-03-4 Front Suspension-Spring On Lower Arm 14-03-4 4. Using a new nut and bolt, secure each end of the stabilizer bar to the lower suspension arm making sure that the bolt head is at the top to eliminate interference with the brake hose using new fasteners, secure stabilizer attaching brackets to frame. Remove the supports and lower the vehicle. Pinto/Bobcat/Mustang II Using a new nut, secure each end of the stabilizer bar to the link assembly using new fasteners, secure stabilizer attaching brackets to body side rajI. Remove the support and lower the vehicle. LOWER ARM STRUT AND/OR BUSHING Removal and Installation 1. Remove the nut from the lower arm strut at the frame and remove the washer and bushing from the st

14-03-5 Front Suspension-Spring On Lower Arm 1443-5 2. Disconnect the lower end of the shock absorber, and push it up to the retracted position. On Pinto, Bobcat and Mustang, remove the nut that attaches the shock absorber to the crossmember and remove the shack absorber downward. 3. If so equipped, disconnect the stabilizer bar link from the lower arm. 4. Remove the cotter pin from the lower ball joint stud nut. 5. Remove nuts attaching the strut to the lower arm Fig. 1 or Fig. 2, and remove the strut and bolts from the arm as a unit. 6. Loosen the lower ball joint stud nut one or two turns. Do not remove the nut from the stud at this time. 7. Install Tool TS7P-3006-B for all except Pinto, Bobcat and Mustang Ilor 17

14-03-6 Front Suspension-Spring On Lower Arm 14-03-6 at curb height, torque the lower arm inner pivot nut FRONT WHEEL SPINDLE to specification. Removal 10. If the lower arm is being replaced due to accidental 1. Raise the vehicle and position safety stands. damage, check the caster, camber, and toe-in and adjust as required Part 14.01. 2. Remove the two bolts attaching the caliper anchor plate assembly to the spindle. Remove the caliper UPPER ARM anchor plate assembly from the rotor Group

14-03-7 Front Suspension-Spring On Lower Arm 14-03-7 2. Rake the lower arm, and guide the upper baIl joint hole in the crossmember. Install the bolt attaching stud into the spindle. Install the stud nut. the shock absorber to the lower arm. Torque to 3. Torque the nut to specifications and install a new specification. cotter pin. Remove the floor jack. 5. Remove the safety stands and lower the vehicle. 4. Connect the spindle connecting rod end to the a. Place a bushing and washer on the shock absorber spindle arm and install the attaching nut. Torque top stud and install a new attaching nut. Torque the nut to specification and install a new cotter pin. to specifi

14-03-8 Front Suspension-Spring On tower Arm 14-03-8 5. Install Tool T57P-3006-B for all except Mustang! TOOL-TBSP 3044-A3 Pinto/Bobcat or T74P-3006.A for Mustang! 3044-A2 joint studs. The tool should be seated firmly N TOOL-T65P Pinto/Bobcat between the upper and lower ball against the ends of both studs and not against the stud nuts.

14-03-9 Front Suspension-Spring On Lower Arm 14-03-9 3. If so equipped, disconnect the stabilizer bar link 3. Tighten the nut until the ball joint seal is firmly from the lower arm. seated. Remove the nut and tool. 4. Remove the cotter pin from the lower bali joint stud 4. Using a floor jack, position the lower arm and nut. spring to the spindle. 5. Remove the bolts and nuts that attach the strut to 5. Install the ball joint stud attaching nut and torque the lower arm. to specification. Continue to tighten the nut until 6. Loosen the lower ball joint stud nut one or two turns. the

14-04-1 Front Suspension-Spring On Upper Arm 14-04-1 Front Suspension- 14-04 Spring On Upper Arm Applies to Granada/Monarch/Versailles SUBJECT PAGE SUBJECT PAGE DESCRIPTION REMOVAL AND INSTALLATION Cont’d. Front Suspension 04-1 Lower Arm 04-3 Lower ,Arm Strut and/or Insulators 04-2 REMOVAL AND INSTALLATION Stabilizer Bar End Bushing 04-2 Front Shock Absorber 04-6 Stabilizer Bar I

14-04-2 Front Suspension-Spring On Upper Arm 14-04-2 -SPRING UPPER BUMPER ARM SPINDLE LOWER ARM STABI LIZER BAR LOWER BALL STRUT

14-04-3 Front Suspension-Spring On Upper Arm 14-04-3 7. Position the strut into the crossmember and to the lower suspension arm. Install the strut-to-arm attaching bolts and nuts, and torque them to specification. 8. Install the forward insulator washer small ID, inner sleeve, and adjustment nut on the forward end of the strut. NOTE: Remove 1/4 inch from the inner sleeve prior to assembly. 9. Remove the safety stands, and lower the vehicle. Remove the wood blocks from under the upper arm. 10. Adjust the caster and camber to specification. FRONT SPRING Removal 1. Remove the shock absorber and upper mounting bracket as an assembly. Position wood blocks Fig. 2. 2. Raise the vehicle on a hoist, install safety stands, and remove the

BOLT MUST BE INSTALLED PART IDENTIFIED BY WORDa HEAD UP FRONT 38238 3 80952-Si 00 WITH

14-04-5 Front Suspension-Spring On Upper Arm 14-04-5 7. Install Tools T71P-3006-A and 160K-3006-A 8. Position the appropriate ball joint remover tool between upper and lower ball joint studs, against between the upper and lower ball joint studs. The ends of studs, not nuts. tool should seat firmly against the ends of 8. With a wrench, turn the adapter screw until the tool both studs and not against the stud nuts. places the stud under compression. Tap the spindle 9. Turn the fool with a wrench until the tool places the near the lower stud with a hammer to loosen the studs Under considerable compression; then, hit the stud in the spindle. Do not loosen the stud from spindle sha

14-04-6 Front Suspension-Spring On Upper Arm 14-04-6 9. Turn the tool with a wrench until the tool places the 8. Remove the safety stands, and lower the vehicle. studs under considerable tension, and, with a 9 Remove the wood blocks from between the upper hammer, sharply hit the spindle near the studs to arm and frame. break them loose in the spindle. Do not loosen the 10. If the spindle is being replaced due to accidental studs in the spindle with tool pressure alone. damage, check and adjust caster, camber and toe- 10. Position a floor jack under the lower arm. in as required.

14-05-1 Front Suspension-Single Arm 14-05-1 PART - Front Suspension Single Arm 14-05 Applies To Fairmont/Zephyr SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS REMOVAL AND INSTALLATION Corit’d. Non-Adjustable Suspension. Front Spring 05-2 Refer to Parts 13-32 or 13-45 Lower Suspension Arm 05-4 For Toe Adjustment.

14-05-2 Front Suspension-Single Arm 14-05-2 SHOCK 5Th UT INSULATOR .4.- SHOOK STRUT NO- 2CROSM5MBER / 1 ST- FRONT STABILIZER BAR LOWER A"

14-05-3 Front Suspension-Single Arm 14-05-3 bushings. Remove the steering gear bolts and move 5. Install the wheel and tire assembly. the steering gear out of the way. 6. Remove the safety stands and lower the vehicle. 5. Remove the two lower arm to crossmember bolts SPINDLE ASSEMBLY and nuts. Removal6. Lower the floor jack slowly to relieve spring tension and remove the spring. 1. Raise the front of the vehicle and position safety Installation stands under both sides at the

14-05-4 Front Suspension-Single Arm 14-05-4 5. Remove the cotter pin from the ball jdnt stud nut, Installation and loosen the ball joint nut one or two turns. 1. Place the new arm assemlby into spindle and torque CAUTION: DO NOT REMOVE THE NUT ball joint nut to 80-120 ft-lb. Install cotter pin. FROM THE BALL JOINT STUD AT THIS TIME. 2. Position the coil spring in the upper spring pocket. 6. Tap the spindle boss smartly to relieve the stud Be sure the insulator is on top of the spring, and pressure. the lower end pigtail is properly positioned 7. Place a floor jack under the lower suspens

14-05-5 Front Suspension-Single Arm 14-05-5 8. Lower the floor jack and remove from the work 10. Install the wheel and tire assembly. area. 11 - Remove the safety stands and lower the vehicle. 9. Install the disc brake dust shield, rotor, and caliper assembly as outlined in Part 12-20. "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

380335-9 C N80023 7-5 100 4 V. REDO, 38391

1440-1 Rear Suspension-Leaf Springs 14-30-1 PART - Rear Suspension Leaf Springs 14-30 Applies To Granada/Monarch/Versailles, Mustang I I/Pinto/Bobcat SUBJECT PAGE SUBJECT PAGE DESCRIPTION SPECIFICATIONSAND Rear Suspension 30-1 SPECIAL TOOLS 30-9 REMOVAL AND INSTALLATION Rear Shock Absorber 30-1 Rear Spring 30-2

14302 Rear Suspension-Leaf Springs 14-30-2 2. Remove the bolts retaining the mounting bracket 3. Remove the U-bolt plate nuts from the "U" bolts; at the upper end of the shock absorber Figs. 3 and then, remove the plate Figs. 1 tru 5. Raise the rear 4. axle lust enough to remove the weight from the 3. Compress the shock absorber and remove it from spring. the vehicle. Remove the attaching bracket, nut, 4. Remove the two attaching nuts, and rear shackle bushings and washers from the shock absorber bar, and the two shackle inner bushings. studs. 5. Remove the rear s

5627 3769 18-52 14-22 Ft-LB 5791 ISACOI REF. 5776

3769’ B-S2 14-22 FT-LB 18A001 REF. 5716 353473-58 4730 381 LOCATEON TUBE PAINTAT CLIPSTRIPE 4730

OG5IEO-S100 50-68 FT-LB REAR FLOOR 38448 5-52 FRONT C/M Ii 353473-S8 .16041 LOCATE ON PAINT

8A005 LH. ‘ 5-4004 H.P. REF. 4130 COLOR YELLOW FOR

53473S8 4A001 REAR FLOOR FRONT C/M 38 187/- 31fl4 4022r 2A448 4001 384676-52

14-30-8 Rear Suspension-Leaf Springs 14-30-8 5652 1-52 14-26 FT-LD 5B486 5C494 ASSY L.H. 371 SB4SB ASSY. PH.

14-30-9 Rear Suspension-Leaf Springs 1440-9 -STAKE 44 PLAOESI F2O1G-18 FIG. S Rear Spring Front Bushing Installation- Typical SPECIFICATIONS TOROUE LIMITS - REAR SUSPENSION Ft-tB SPECIAL SERVICE TOOli MIlstang/PInto/ Granada/Monarch Description Bobcat VerjJIes Tool No. Ducription Spring Shackle Bars to Body and Spring 14-22

14-32-1 Rear Suspension-Coil Springs 14-32-1 PART - Rear Suspension Coil Springs 14-32 Applies To All Cars Except Mustang Il/Pinto/Bobcat SUBJECT PAGE SUBJECT PAGE ADJUSTMENT REMOVAL AND INSTALLATION Cont’d.} Adjustment - Double Upper Arm 32-S Rear Shock Absorber 32-7 - Single Upper Arm 32-5 Rear Spring 32-8 Adjustment Checking Procedure

1432-2 Rear Suspension-Coil Springs 14-32-2 FRONTVOF VEHICLE VIEW A VIEWS LOWER ARM VIEW A * ECCENTRIC BUSHING INNER CONTINENTAL MARK V SLEEVE * SERVICE ARMSI VIEW B ONLY F1729.2C FIG. 1 Rear Suspension-LTD Il/Cougar/thunderbird/Continental Mark V On LTD II, Cougar, Thunderbird, and

SHOCK ABSORBER REAR SPRING 55W SPRING RUBBER- 5A705 COVER INSULATORS UPPER AA ADJUSTMENT BOLT a TRACKING BAR 5A639 I,C

14.324 Rear Suspensuon__c01 Springs 1432-4 385253 SEDANS 384485-S2 14-26 FT LB

14-32-5 Rear Suspension-Coil Springs 14-32-5 ADJUSTMENTS DRIVE SHAFT-PINION ANGLE The pinion drive shaft working angle must be checked and adlusted to specification whenever the rear axle has been removed. CHECKING PROCEDURE On LTD II, Cougar, Thunderbird and Continental Mark V vehicles, a load must be applied to attain a height of 4 82 inches measured from the top of the - axie housing to a point on the frame side rail, adjacent to the jounce bumper rear mounting bolt head. On Ford, Mercury, and Lincoln Continental units, loading is required to attain a controlled height oF 5.70 inches, measured as described above. See the illustration in the Specifications section at the end of this Part. 1, Position the vee-magnet part of Tool T68P-4602- A on

14-32-6 Rear Suspension-Coil Springs 14-32-6 3. If the angle is less than specifications, rotate the If further adjustment is required to get the angle adjusting cam, so as to move bolt forward, and within specification, the eccentric bushing at the recheck the angle. If the angle is more than rear of each arm may also be adjusted by follow specification adlust accordingly and recheck the ing the front eccentric procedure. angle. 9. Install new nuts and bolts. Flanged nuts and bolts 4. When the axle housing is adjusted in such a way are required at frame attachment. that the driveshaft angle reading is within speci 10. Wh

14-32-7 Rear Suspension-Coil Springs 14-32-7 If the pinion angle is not within specifications, peors to be rusty, tap the cam with a drift to adjust the pinion angle as follows: remove the rust so the cam will rotate. 3. Now rotate the eccentric bushing clockwise or 1. Remove the upper arms as outlined in Upper Arm counter-clockwise to raise or lower the pinion Removal, nose angle to Specification given at the end of 2. Using a fabricated tool as shown in Fig. 8, insert

14.32-8 Rear Suspension-Coil Springs 14-32-8 REAR SPRING - 5. Remove the springs and the insulators from the EXCEPT FAIRMONT/ZEPHYR vehicle. Installation Removal 1. Position the spring in the upper and lower seats 1. Position o hoist under the rear axle housing and with an insulator between upper end of spring raise the vehicle. Place jock stands under the and frame seat. frame side rails, 2. Raise the hoist and axle housing with th

14-32-9 Rear Suspension-Coil Springs 14-32-9 FAIRMONT/ZEPHYR Installation Removal Refer to FIg. 3 The rear suspension lower arms are interchange If one spring requires replacement, replace the able side-to-side and end-for-end. They can be iden other spring also. Note: If vehicle is equipped with a tified by color codes Fig. 10. rear stabilizer bar, remove the bar per procedure 1. Postion the lower arm in the bracket on the frame given under Rear Stabilizer Bar - Removal. side rail. Install a new pivot bolt and new nut 1. Raise the vehicle and support the body at the Fig. 9. Do not tighten the nut at this time. rear body cros

14-32-10 Rear Suspension-Coil Springs 14-32-10 Approximate Lg. Approximate Body Diameter of Bushinv Suspension Side Arm Inches Miesured Outer Sleeve Canine Arm Used On Color Code at 8ushin I Frame Body Ford/Mercury! Lincoln Upper - Unpainted 12-5/8" 27!16" Ford/Mercury Police, Taxi, Trailer Tow. Ford/Mercury! Left & Lincoln Lower

14-32-11 Rear Suspension-Coil Springs 14-32-11 FRONT P’VOT BOLT REAR PIVOT BOLT NUT FIG. 11 Rear Suspension Lower Arm Installed-Typical 4. Torque all upper arm front bolts to specification. bushing. Install a new pivot bolt and nut with nut On LTD II, Cougar, Thunderbird, and Continental facing inboard. Do not torque at this time. Mark V vehicles, torque the bolt head of the 3. Connect lower shock absorber to the lower shock upper arm at the axle attachment to specifica bracket and torque a new nut to 40-55 ft-lb. flon. Remove the jack stands. 4. Raise the suspension to curb height and torque 5. On Ford, Mercury, and

14-32-12 Rear Suspension-Coil Springs 1432-12 2. Remove the bolts and nuts that fasten the REPLACER RECEIVING BUSHING REPLACER CUP - T78P-E38-A2 stabilizer bar assembly to the rear link as - T78P-5638-A3 semblies at both sides Fig. 14. 3. Remove the nuts that fasten mounting bracket to the U-bolts two nuts each side. 4. Remove the stabilizer bar

1432-13 Rear Suspension-Coil Springs 1432-13 SAul .ASSV. REF. FIG. 14 Stabilizer Bar Installation - LTD II, Thunderbird Max. Handling, Cougar, Continental Mark V Similar "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

1432-14 Rear Suspension_Coil Springs1432-14 547721 5EE VIEW A I STABILIZER BAR ISMi2 .a605920-S1 00 A EGO. 4VIEW A 4

_______ 14-32-15 Rear Suspension-Coil Springs 1432-15 SPECIFICATIONS TORQUE LIMITS- REAR SUSPENSION FTL6 Thunderbird! Ford/ Mark V LTD Il/ Faimmont/ Description Mercury Lincoln___._JIIII7Continental Zephyr Shock Absorber no Frame Upper Attachment 20-26 14-2 6 Upper Arm to Frame 720-730

14-45-1 Manual Fill Load Leveler System-Air Sleeve Rear Shock Absorbers 14-45-1 Manual Fill Load Leveler System- 1Z5 Air Sleeve Rear Shock Absorbers Applies to Ford/Mercury SUBJECT PAGE SUBJECT PAGE DESCRIPTION TESTING Manual Fill Load Leveler System 45-1 Leak Test 45.3 System Functional Check 45-3 REMOVAL AND INSTALLATION Air Line Assembly 45-3 Air Sleeve Shock Absorber 45-3

SCREW - 54667 ASSY. F P AM E SACS? ASSY. MUST LIE ON NO.4 CROSSMEM8ER AND MUST BE EXISTING CLIP ON TOP OF FUEL LINE BRAKE LINE SAG67 FENOER APRON REF.

14-45-3 Manual Fill Load Leveler System-Air Sleeve Rear Shock Absorbers 14-45-3 TESTING SYSTEM FUNCTIONAL CHECK Conventional tire valve. If leakage is detected at the elbow fittings, at the shock absorbers, check the 1. Place the Unloaded vehicle on o level surface. Make fittings for the presence of, or damaged rubber sure that all tires are at the recommended pressure. ‘0" rings Fig. 3. Replace the "0" rings 87004- 2. Measure and record the distance from the rear 594 if required. Leaks anywhere else in the air line fender opening to the ground with 18-20 psi as

_______ 15-00-1 Driving Axles and Drive Shafts 15-00-1 GROUP Driving Axles and Drive Shafts 15 PART TITLE PART NO. PART TITLE PART NO. Drive Shaft - Double Cardan Type U-Joint 15-66 Integral Carrier Axle - Ford WGX 15-06 Drive Shaft - Single Cardan Type U-Joint 15-60 Removable Carrier Ax le - Ford .15-10 General Driving Axle and Drive Shaft Service . . . 15-01 Traction-Lok Limited Slip Differential Integral Carrier Axle - Conventional 15-02 - Ford 15-40 Integral Carrier Axle - Ford WER 15-03

75-01-2 General Driving Axle and Drive Shaft Service T5-OT-2 AJ1 General Driving Axle and_Drive_Shaft_Service Applies To AU Cars SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS DIAGNOSIS 01-2 Backlash and Differential Bearing Preload Adjustments 01-9 SPECIAL TOOLS 01-12 Pinion and Ring Gear Tooth TESTING Contact Adjustment 01-8 Acceptable Tooth Contact Patterns CLEANING AND INSPECTION All Axles

15-014 General Driving Axle and Drive Shaft Service 15-01-3 GENERAL DIAGNOSTIC PROCEDURE CONDITION POSSIBLE CAUSE , Noise is the same on drive or coast p Road noise. p Tire noise. * Front wheel bearing noise p Noise changes with type of road p Road noise. p Tire noise. p Noise tone lowers as car speed is lowered p T

15-01-4 General Driving Axle and Drve Shaft Service 15-01-4 Partial Nonhunting Gear Set In a partial nonhunting-type gear set, any one pinion tooth comes into contact with only part of the ring gear teeth, but more than one revolution of the ring gear is required to make all possible gear tooth combinations. Any combination of drive and coast patterns shown in

15-01-5 General Driving Axle and Drive Shaft Service 15-01-5 ACCEPTABLE TOOTH PATTERN LIMITS ANY COMBINATION OF DRIVE AND COAST PATTERNS SHOWN PERMISSIBLE HEEL POLL LENctk tO.T 6 HIGH HEELCDAST W*. 10

15-01-6 General Driving Axle and Drive Shaft Service 15-01-6 2. Remove the driveshaft assembly Part 15-60. 3. Check for companion flange damage to the universal loint bearing locating lugs. If the lugs on the companion flange are shoved worn or damaged, replace the companion flange Fig. 4. PROPLHLY SEATED CUP SHAVPS LUG FIG. 5 Flange Bearing Cup Runout Check- Typical 7. Carefully retract the dial indicator stem and rotate the companion flange 180 degrees, to position the

15-01-7 General Driving Axle and Drive Shaft Service 15-01-7 moved fore and aft an the flange bearing cups. combined runout chart Fig. 8. Position a straight Note the point at which the indicator hand edge at the amount of flange bearing cup runout reverses direction. Rotate the flange assembly indicated on the left-hand column of the chart. side-to-side until the cross-shaft is perpendicular to Position another straight edge vertically, at the the pinion shaft axis, and the indicator hand amount of the universal crass-shaft runout indicated reverses direction. Zero the dial indicator and check on the top of the chart. The point at which the the zero point again by slightly moving the cross- straight

15-01-8 General Driving Axle and Drive Shaft Service 1541-8 TOOL-6565 USED WITH BRACKET FROM TOOL-4201-C E1691-1A FIG. 9 Checking Companion Flange Radial Runout-Lincoln Continental and Continental Mark V- Typical Versailles, Fairmont and Zephyr 2. Remove the driveshaft assembly Part 15-66. 3. Check the companion flange for damage. 4- To check radial runout, set up dial indicator as shown in Fig. 9. 5. Rotate the companion flange with the dial indicator in place. If the runout exceeds specifications, remove the flange and reinstall it 180 degrees from original position. Follow the procedure in Part 15- 66 for companion fla

15-01-9 General Driving Axle and Drive Shaft Service 1541-9 on removable carrier-type axles before making adjustments. 2. The left adjusting nut Is on the ring gear side of the carrier. The right nut Is on the pinion side. loosen the right nut until it is away from the cup. Tighten the left nut until the ring gear is just

15-01-10 General Driving Axle and Drive Shaft Service 15-01-10 E2173-2A FIG. 13 Adjusting Side Bearing Preload-Typical 7 Again check the tooth contact pattern. If the Malor Repair, under the removable carrier or pattern is still incorrect, a change in pinion location integral carrier axle involved for the necessary shim thickness is indicated. If this is so, refer to steps. CLEANING AND INSPECTION INSPECTION BEFORE DISASSEMBLY OF CARRIER ALL AXLES The differential case or carrier should be inspected before any parts are removed from it. These inspections can help to find the cause of the trouble and to d

15-01-11 General Driving Axle and Drive Shaft Service 15-01-il DIFFERENTIAL BEARING 7SLTS N ‘a FIG. 15 Backlash Check-Typical FIG. 17 Checking Ring Gear Runout-Typical Loosen the differential bearing cap bolts, and then

15-01-12 General Driving Axle and Drive Shaft Service 15-01-12 When operated in the bearing cups, cone and roller carefully. Any nicks or burrs in these bores must be assemblies must turn without roughness. Examine the removed to permit proper seating of bearing cups. roller ends for wear. Step-wear on the roller ends indicates that bearings were not preloaded properly, or CARRIER HOUSING that the rollers were slightly misaligned. Make sure that the differential bearing bores are If inspection reveals either a worn bearing cup or a smooth and the threads are not damaged. Remove any worn cone and roller assembly, both parts should be nicks or burrs from the mounting surfaces of the carrier replaced to avoid damag

15-02-1 Integral Cornier Axle-Conventional 15-02-1 PART Integral Carrier Axle-Conventional 15-02 Applies To Mustang/Pinto/Bobcat SUBJECT PAGE SUBJECT PAGE DESCRIPTION 02-1 REMOVAL AND INSTALLATION Cont’d. Drive Pinion Oil Seal 02-3 DISASSEMBLY AND ASSEMBLY Installation of New Universal Assembly of Axle 02-13 Joint Flange 02-5 Differential Case

15-02-2 Integral Carrier Axle-Conventional 15-02-2 PINION GEAn RING GEAR 4215 4200 LEFIHAND AXLE SHAFT / 4234 I - DIF F ER EN1IAL CASE RIGHT AXLE SHAFT 4234

15-02-3 Integral Carrier Axle-Conventional 15-02-3 irregularities which would affect the sealing action 2. Place the retainer plate and a new bearing on the of the oil seal. Check the axle shaft splines for burrs, axle shaft, and press the new wheel bearing on the wear or damage. Carefully remove any burrs or shaft with the to:l shown in Fig. 4. The bearing rough spots. Replace worn or damaged parts. should seat firmly against the shaft shoulder. Do not attempt to press on both the bearing and the Inner retainer ring at the same time. 3. Using the bearing install

15-02-4 Integral Carrier Axle-Conventional 15-02-4 FIG. 6 Checking Pinion Bearing Preload FIG. 1 Removing or Installing Drive Pinion Nut Removal 1. Raise the vehicle and install safety stands. Remove the rear wheels and brake drums. 2. Make scribe marks on the drive shaft end yoke and the axle U-joint flange to insure proper position of the drive shaft at assembly. Disconnect the drive shaft from the axle U-joint flange. Be careful to avoid dropping the loose universal joint bearing cups. Hold the cups on the spider with tape. Mark the cups so that they will be in their original position in relation to the flange when they are assembled. Remove the drive shaft from the transmission extension housing. Install an

15-02-5 Integral Carrier Axle-Conventional 15-02-S the drive shaft end yoke and the axle U-joint flange. - 11. Check the lubricant level. Make sure the axle is in running position. Add whatever amount of specified lubricant is required to reach the lower edge of the filler plug hole, located in the carrier

1542-6 Integral Carrier Axle-Conventional 15-02-6 pinion nut be backed off to lessen preload, If this 17. Install the rear wheels and brake drums. Lower the is done, a new pinion bearing spacer must be vehicle and torque the wheel-attaching nuts to installed. In addition, the U-joint flange must never specification. Install hub caps or wheel covers. be hammered on, or power tools used. 14. Remove the oil seal replacer tool from the transmission extension housing. Install the front end AXLE HOUSING of the -drive shaft on the transmission output shaft. Removal 15. Connect the-rear end of the drive shaft to the axle 1. Raise the vehicle and support it with safety stands U-Ioint flange, aligning the scribe ma

15-02-7 !ntegral Carrier Axle-Conventional 15-02-7 12. If the axle housing is being replaced, transfer all 4. Install the axle shafts, brake drums and wheels as the differential and pinion parts to the new housing. outlined n Port fl. 5. Attach the hydraulic brake line of T-fitting to the Installation axle housing, and secure the hydraulic brake line 1. Raise the axle housing into position so that the in its retainer on the axle housing. spring clip U.bolt plates can be installed. Torque 6. Install vent tube to brake tube junction and install the spring clip U-bolt nuts to

15-02-8 Integral Carrier Axle-Conventional 15-02-8 THRUST WASHE R-4228 DIFFERENTIAL SIDE GEAR COVER GASKET SHAFT RETAINER DIFFERENTIAL 423k PINION SHAFT DFERENTIAL BEARING ADJUSTING NUT 711 5E COVER C7 DIFFERENTIAL CASE 4204 BEARING CLJP-4222