This product was created from the original Ford Motor Company's publication. .....
pedal booster or master cylinder to be sure the correct parts are installed.
Click Here
www.FordManuals.com
1967 FORD
SHOP
MANUAL
Copyright © 2009, Forel Publishing Company, LLC, Woodbridge, Virginia All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoever without written permission of Forel Publishing Company, LLC. For information write to Forel Publishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192
1967 Ford Thunderbird Shop Manual EAN: 978-1-60371-017-6 ISBN: 1-60371-017-5 Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192 Email address:
[email protected] Website: http://www.ForelPublishing.com
This publication contains material that is reproduced and distributed under a license 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.
Note from the Editor This product was created from the original Ford Motor Company’s publication. Every effort has been made to use the original scanned images, however, due to the condition of the material; some pages have been modified to remove imperfections.
Disclaimer Although every effort was made to ensure the accuracy of this book, no representations or warranties of any kind are made concerning the accuracy, completeness or suitability of the information, either expressed or implied. As a result, the information contained within this book should be used as general information only. The author and Forel Publishing Company, LLC shall have neither liability nor responsibility to any person or entity with respect to any loss or damage caused, or alleged to be caused, directly or indirectly by the information contained in this book. Further, the publisher and author are not engaged in rendering legal or other professional services. If legal, mechanical, electrical, or other expert assistance is required, the services of a competent professional should be sought.
GROUP INDEX VEHICLE IDENTIFICATION
BRAKES
SUSPENSION, STEERING, WHEELS AND TIRES REAR AXLE
DRIVE SHAFT AND CLUTCH
MANUAL SHIFT TRANSMISSION (Not Applicable)
AUTOMATIC TRANSMISSION
ENGINE
IGNITION SYSTEM
FUEL SYSTEM
COOLING SYSi
AUST SYSTEM
CHARGING SYST
STARTING SYSTEM
LIGHTING SYSTEM, HORNS AND INSTRUMENTS
VENTILATING, HEATING AND ACCESSORIES BODY, DOORS AND WINDOWS !M, SEATS AND CONVERTIBLE TOP
ED
SCHEMATICS
(^Bo^d^)
SERVICE
PUBLICATIONS
FIRST PRINTING-FEBRUARY, 1967
1967 FORD MOTOR COMPANY,
DEARBORN,
MICHIGAN
Reprinted with Ford Motor Company's Permission
SPECIFICATIONS AND SPECIAL SERVICE TOOLS AT END OF EACH GROUP
FOREWORD
This shop manual provides the Service Technician with infor for the proper servicing of the 1967 Thunderbird.
mation
The
for maintenance oper in the 1967 Passenger Car Maintenance and Lubrication Manual. maintenance schedule and procedures
ations are published
The information in this
is
according to the type diagnosis and testing, fre quently performed adjustments and repairs, in-vehicle adjust ments, overhaul, etc. Specifications and recommended special tools are included. of
work
being
Refer to the data.
manual
such
performed,
opposite page
grouped
as
for important
vehicle
identification
The descriptions and specifications in this manual were in effect the time this manual was approved for printing. The Ford Motor Company reserves the right to discontinue models at any
at
time, out
or change specifications or
incurring
design,
without notice and with
obligation.
~&JJS
SERVICE
PUBLICATIONS
1-1
GROUP
Vehicle Identification
ASSEMBLY PLANT CODE
1
BODY SERIAL CODE
ENGINE CODE
MODEL YEAR CODE
CONSECUTIVE UNIT NUMBER
TRANSMISSION CODE BODY TYPE CODE
REAR AXLE CODE COLOR CODE
DISTRICT or DISTRICT AND SPECIAL EQUIPMENT CODE
TRIM CODE
N 1S88-A
p/G. 7
Typical
Warranty
Plate
Thunderbird
VEHICLE WARRANTY NUMBER The vehicle warranty number is the first line of numbers and letters appear ing on the Warranty Plate (Fig. 1). The first number indicates the model year. The letter
following
the
model year number
indicates the manufacturing as the Body Serial Code followed of six digits remaining on
sembly plant. The next two numbers designate by a letter expressing the Engine Code. The group
the first line indicate the Consecutive Unit Number.
VEHICLE DATA the second or lower line on the Warranty Plate. letter identify the Body Style. A letter or a num numberber appears next indicating the Exterior Paint Color followed by a letter combination designating the Interior Trim. To the right of this code A twoappears the Date Code indicating the date the car was manufactured.
The vehicle data appears The first two numbers and
on
a
which the car was ordered and Domestic Special Order or Foreign Special may Order number when applicable. The final two spaces indicate the Rear Axle Ratio (numbers for regular axles, letters for locking-types) and the Trans
digit
number
appear
mission
next
in
designates the district in
conjunction with a
type.
N 1526
FIG. 2
Thunderbird Identification
Number Location OFFICIAL VEHICLE IDENTIFICATION NUMBER The official Vehicle Identification Number for title and registration purposes hand side of center in the en is stamped on the cowl top panel tab right gine compartment
(Fig. 2).
-A
I
GROUP 1
1-2
MODEL YEAR CODE The
number
-Vehicle
Identification
CONSECUTIVE UNIT NUMBER
7 designates 1967 Each model year, each assembly plant begins 100001 and continues on for each unit built.
ASSEMBLY PLANT CODES
production with number
EXTERIOR PAINT COLOR CODES
A B
Atlanta
Oakville (Canada) Ontario Truck Dallas
C D E F G
Mahwah Dearborn
Chicago
H
Lorain
J K
Los Angeles Kansas City
L N P R S T U W
Michigan Truck Norfolk
Twin Cities San Jose Pilot Plant Metuchen Louisville Wayne Wixom St. Louis
Y
Z
A
1724-A
B C E F
1734-A 1900-A 2045-A
H
2067-A 1903-A
The two-digit
K M N P
the
The
1633-A
Yellow
1901-A 1631-A
Med. Gray Met. Lt. Beige
1619-A
921-A 2065-A 1624-A
R T U V X Z 2 4 6
1879-A
follows the assembly plant code identifies the is used in conjunction with the Body Style which consists of a two-digit number with a letter lists the Body Serial Codes, Body Style Codes and
numeral which
body series. This two-digit Code, in the Vehicle Date, suffix.
2008-A 1070-A 2066-A 1632-A 1915-A
Dk. Gray Met. Med. Beige Met. Lt. Blue Diamond Green Dk. Blue Met. White Platinum Pewter Met. Med. Blue Met. Dk. Green Met. Red Med. Turquoise Met. Bronze Met. Maroon Met. Med. Gold Met.
1226-A
Q
BODY SERIAL AND STYLE CODES
Black Lt. Aqua
following
chart
number
model.
INTERIOR TRIM CODES Trim Schemes
Code
THUNDERBIRD
Body
Body
Serial Code
Style Code
81 82 84
Body Type
65A 2-Door Hardtop 65B 2-Door Hardtop 57B 4-Door Sedan
Painted Roof Vinyl Roof-Landau Vinyl Roof
2A. 2B. 2D. 2F. 2G. 2K. 2U. 4A. 4B. 4D. 4G. 4K. 4L. 4U. 5A. 5U.
.Blue
Vinyl Vinyl Gold Vinyl Vinyl Vinyl W/Black Vinyl q Blue Vinyl
.Red
.Saddle
.Ivy
.Aqua
.Parchment
.Black
.Ivy
Type 8 Cyl. 390 Cu. In. (4V) 8 Cyl. 428 Cu. In. (4V) 8 Cyl. 428 Cu. In. (4V)
Z n
8 Low Compression
Gold Vinyl
Vinyl
.Aqua
.Lt.
Silver Cloth and Lt. Silver Vinyl Vinyl W/Black Cloth and Black Vinyl
.Parchment
.Black
.Parchment
.Black
86.
Code
Vinyt
.Red
8A.
ENGINE CODES
Vinyl Vinyl
.Black
.Blue
8D. 8G. 8K.
Cloth
and
Parchment Vinyl
Vinyl
Vinyt
Vinyl Gold Vinyl
.Red
.Ivy
.Aqua
Combined
Vinyl
Lt. Silver Cloth
81. 8U. HA. LA.
..Parchment
.Black
..Black
with cloth
and
Vinyl
Leather Leather
Lt. Silver Vinyl
GROUP 1
-Vehicle
DATE CODES A
number
year code
DISTRICT CODES (DSO)
signifying the date
letter
will
1-3
Identification
be
used
precedes
if the
the
model exceeds
month code
12
letter. A
second-
months.
Domestic Special Order, Foreign Special Order, or other have the complete order number in this space. Also to order appear in this space is the two-digit code number of the District which ed the unit. If the unit is a regular production unit, only the District code
Units built
special
on a
orders
will
number will appear.
Code Second Year
Code First Year
January
A
February... March April
B C D E F G H J
May June
July August September October....
N P
November December
11 13 15 16
Q R S T U
17
21 22 24 25 27 28 32 33 34 35 37 38 41
V W
K
X Y
L M
Code
Z
42
43
REAR AXLE RATIO CODES A
number
designates
a conventional
axle,
while a
letter designates a
locking
differential.
TRANSMISSION CODE Code
Type Automatic (C6)
44 45 51 52 53 54 55 61 62 63 64 65 71 72 73 74 75 81 83 84 85 89 90-99
District Boston New York Newark Philadelphia Washington Atlanta Charlotte Jacksonville Richmond Cincinnati Louisville
Cleveland Detroit Indianapolis
Lansing Buffalo Pittsburgh
Chicago Fargo Milwaukee Twin Cities Davenport Denver Des Moines Kansas City Omaha St. Louis Dallas Houston Memphis New Orleans Oklahoma City Los Angeles San Jose Salt Lake City
Seattle Phoenix Ford
of
Canada
Government Home Office Reserve American Red Cross Transportation Services Export
2-1 GROUP
2
akes PART 2-1 General Brake Service PART 2-2 Brake System
PAGE
PART 2-3
PAGE 2-1
2-26
Specifications
2-8
PART 2-1-Genera/ Brake Service Section 1 Diagnosis and Testing Brake Systems Tests Road Test Disc Brake Trouble Symptoms and Possible Causes Drum Brake Trouble Symptoms and
2-1 2-1 2-1 2-3
Possible Causes 2 Common Adjustments andRepairs Parking Brake Linkage Adjustment
PAGE
Section Power Brake Master Cylinder Push Rod Adjustment Hydraulic System Bleeding and Centralizing of the Differential Valve 3 Cleaning and Inspection Front Brakes Rear Brakes Booster Unit
Page
2-4
2-5 2-5
2-5 2-6 2-7 2-7 2-7 2-7
DIAGNOSIS AND TESTING BRAKE SYSTEM TESTS BRAKE FLUID LEVEL AND HYDRAULIC SYSTEM Always
check the fluid level in brake master cylinder reservoirs before performing the test procedures. If the fluid level is not within 1/4 to 1/2 inch of the top of the master
the
cylinder
Brake
Rotunda
add
reservoirs,
Fluid
Extra Heavy Duty C6AZ19542-A (ESA-M6C25-A).
The disc brake extra heavy duty is for brake fluid colored identification purposes. Do not mix low temperature brake fluids with the specified brake fluid. the ignition dual 1. Turn master cylinder brake system switch to the ACC or ON position. If the light on the brake warning lamp remains
on,
the
condition
caused
by
a
defective
switch wires or
grounded
tial
Centralize
the
be
switch, the differen
not
centered.
differential
pressure
outlined
as
valve
is
valve
pressure
may
under
Bleeding
the
Brake System in this section of the If the warning light re manual. mains on, the condition may be caus ed
by
switch valve
defective switch, grounded wires or the differential pressure
is
a
not centered.
ferential der
Bleeding
section
ing
of
light
the Brake System
the
and and
wire assembly. wire
manual.
remains
connector
condition
is good,
ing lamp
Centralize the dif
pressure valve as outlined un
on,
wire repair
If the
replace
switch.
If the
check
for or
a
in this warn
the switch grounded
replace
condition of
2. If brake the warning lamp does not light when a pressure dif ferential condition exists in the brake system, the warning lamp may be burned out, the warning lamp switch is inoperative or the switch to lamp wiring has an open circuit. Check the bulb and replace it, if required. Check the switch to lamp wires for an circuit
open
repair
replace
or
1. Install a Brake Pedal Effort on Gauge the pad brake pedal (Fig. 2). 2. Hook a steel measuring tape to the brake pedal as shown in Fig. 1. Measure and record the distance from the brake pedal free height po sition to the reference point, which is the
at
the
six
o'clock
position
3. With the
tape still hooked
steel
to the brake pedal depress the
MEASUREMENTS
brake a 50
With
the
engine
running
for
full
power brake operation, measure the brake pedal free height, and check the brake pedal travel with the use of the Brake Pedal Pressure Gauge, Tool WRE-500-50 as follows:
ed prod
specification,
point sound
check
the
brake pedal linkage for missing bushings or loose attaching bolts and replace them, if required. 3. If the pedal free height is still out
of
pedal
the
sure
specification,
booster the
the
or master cylinder
correct
parts
Replace the defective sary.
check
are
parts
by
and
gauge,
effort
load
the
measure pedal
erence point on the parallel
to
the
to the
steering
the
Apply
center
observing the
from the brake
ing
gauge.
brake on
of
pressure
distance fixed
ref
wheel rim
to the centerline of the steer
column.
difference between the brake and the depressed ped
free height
measurement under a 50 pound load should be within the specified max imum pedal travel service specification Bin Fig. 1. al
a
slender, sharp through the carpet and
within
pound
pedal
pedal
deadener to the dash panel metal and measure the distance to the brake pedal (Fig. 1). 2. If the position of the pedal is not
the
pressing downward
pedal
4. Tie
Brake Pedal Free Height Measurement 1. Insert
by
pedal
on
wheel rim.
steering
BRAKE PEDAL FREE HEIGHT AND TRAVEL
the
the brake warn
and
them, if required. If the warning lamp still does not light, replace the switch.
Brake Pedal Travel Measurement
brake to be
installed. as
neces
5. If the
pedal
travel is more than
the specified maximum shown, in
Fig.
1, dimension B, make several sharp re verse stops (equivalent to 50 pounds pedal pressure) with a forward stop be fore each. Move the vehicle in reverse and forward for a distance of approx imately ten feet; then apply the brakes sharply and hold the brake pedal down
until
the vehicle is
completely the brake self-adjusters. If these stops do not bring the brake pedal travel within
stopped.
This
will
actuate
GROUP 2-Brakes
2-2 specification, make several additional
STEERING COLUMN 2-11/32"
forward
and
reverse stops as outlined
above.
CENTERLINE
THE VERTICAL CENTERLINE
6. If the
bring
not
DIMENSION TO BE
MEASURED PARALLEL TO
second
the
series
brake
do
of stops
OF THE STEERING COLUMN WITH A 50 LB. LOAD APPLIED
pedal travel with
TO THE CENTERLINE OF THE BRAKE PEDAL PAD.
in specification, remove the brake drums and check the brake adjusters to make sure they are functioning. Check the brake linings for wear or
damaged parts and non-functioning ad justers. Adjust the brake lining out side diameter to the approximate in side diameter of the brake drum with Rotunda Tool HRE-8650 (Fig. 11, Part 2-2). 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 bushings or loose attachments. Bleed the brakes and centralize the dif ferential valve. POWER BRAKE FUNCTIONAL TEST STEEL
1. With the transmission in neutral,
MEASURING TAPE
stop the engine and apply the parking brake. Depress the brake pedal sev eral
to
times
all
exhaust
in
vacuum
the system.
2. With the engine shut off, exhaust in the system. Depress the brake pedal and hold it in the applied If the pedal gradually falls position. this pressure, the hydrau under away lic system is leaking. Check all tubing,
METAL DASH PANEL
all vacuum
hoses calipers,
H1536-A
Brake Pedal Height
FIG. 7
and
Travel Measurements
Too/-WRE-500-50
wheel cylinders and con
for leaks. 3. With the engine shut off and all vacuum in the system exhausted, de press the pedal and hold it in the ap plied position. Start the engine. If the vacuum system is operating, the pedal will tend to fall away under foot pres sure and less pressure will be required nections
to hold the pedal in the applied position.
is felt, the vacuum booster system is not functioning. If the brake pedal movement feels If
no action
spongy,
to
bleed
remove air
hydraulic
the
from the
system.
system
'
W&F
M^m
^^^^H
'
^p
'
^m
Vtfl
^
^B
*
^1
*
^'
^MC^^
*/f]
'
jj^
jLjHJ
SkR m iL
WL*
jH
Ik.*
>afl
HnC^I
Refer to
Hydraulic System Bleeding, Section 2.
Also,
check
for leaks
insufficent
or
MPP
fluid.
Should
locked open
let
of the
one
and
vehicle must
the
the bleeder
out a
screw
few drops
bleeding
of
operation
brakes but
wheel
will
not
long
age
be
repair
moved,
enough
to
brake fluid. This release
will
correct
the
the
cause
of trouble.
VACUUM RELEASE
Visually
TESTS VACUUM
PARKING BRAKES
check
brake linkage
as
the
operation
the
park
of the
brake
ped
is depressed. Then, check the opera the tion of the brake linkage when lever is activated. release manual
al
These
checks
should
indicate
the manual parking brake
is operating properly
brakes be
whether
control
link-
or
HI 525
-A
requires
due to inability parking brake to hold against
or
the
of
0'H
Brake Pedal Pressure Gauge Ins tailed
FIG. 2
BRAKE LOCKED WHEEL
adjustment
inoperative. This
come
would
the location of the
pendent on
be de vacuum
age and manual controls operate pro
leak. If the leak is in the vacuum sup ply, all systems will become inopera tive. If the leak is in the component side of the vacuum control for the specific
perly.
system,
moderate
vehicle
tests of the
controls after
Diagnosis tems is
movement.
parking brake making
ot
basically
Perform
system and
certain the
vacuum similar
link
rctease
sys
to electrical
diagnosis. That is, the vacuum system must be complete from the source to the
like
vacuum
a
system
in
one of
all of
components.
Any leaks,
bad connection, will make the inoperative. If a leak develops
the
the
vacuum
systems, one
vacuum components
may
or
be-
all
when the
other systems
leaking system
When testing uum
a
is
will
operate
off.
parking brake
vac
release system, a minimum of
inches
of
available
vacuum at
Rotunda (ARE
all
This
is applied.
Fuel
345)
and
(Hg.)
points
can
be
Pump
should
where
10
be
vacuum
checked with a
Tester
Gauge
two Distributor Tester
hose adapters( Marked Q)connected
to-
PART 2-1
-Gen
era I
2-3
Brake Service TROUBLE SYMPTOMS
8
c
ed
ed
Oa
~Z -c
tc
C/>
D.
o CU
"E.
(A
o
*s
E
la
u-
3 0-
"3 o
o.
o c
c o
rt
aaal
O
oo c
< (30 c
*a>
1>
Q 5
3 H
{=
Q
"c3
o
o
3
/>
u
O
JC
CU
c 00
3 o
"8 Cu
S
Shoe or
Shoe or
Leak
Lining Knock-back
and
Violent
after
or
Lining Assembly
not
or
X
3
m
03
UJ
Dm
or
X
Caliper
Worn Caliper Piston Seal
and
or
or
on
Linings
X
Below Specifications
with
X
X
X
Build-
X
and
Missing
or
Improperly
X
OQ
J*
"ed
O
ed la
CQ
-J
0
Z
"8
OS
Oa
E
ed
ed
al
?J
oo
oo
c
C
'c
'c la
ed
X X
X
X X
X X
X
X
X or on
the
X
X
Rotor
X
X X
Switch is Grounded
an
X
X
Warning Lamp Switch is Grounded
X
X X
Open Circuit
X
Switch is Inoperative
Warning Lamp
X
X
with
Warning Lamp Warning Lamp Switch Has
FIG. 3
o
a
X
is Burned Out
to
la
la
X
Positioned
Differential Pressure Valve is Not Centered
Wiring
l/>
ed
E
or
One Section Dual Brake System is Inoperative
Warning Lamp
o
3 "O
X
in the Cylinder Bore
Caliper Out-of-Parallel
Warning Lamp
la.
"ed
X
Caliper
Piston Surface
to
Q
ed
X
Bleeder Screw Still Open
Wiring
IS
CM
>
a
X
Brake Pedal
Up
la
cn
X
Scores in the Cylinder Bore Corrosion
c
Z
ed
JX e
X
Splash Shield
Shoe Hold Down Clips
Riding
*-
X
X
Rotor
Excessive Clearance Between Shoe
Operator
o
u
Leaks
and
>
aJ
X
Loose Caliper Attachment
Between Shoe
V J=
o
X
Alignment
Metering Valve Seal
V
06.
aa
a-
X
Booster Inoperative of
t>
ed
Hi
H >
la
ed
X
Incorrect Tire Pressure or
u"O
rt
X
Improper Master Cylinder Push Rod Adjustment
Frozen
la
O
9*
la
X
X
Adjustment
Excessive Rotor Runout
o o o
taa
X
X
Bearing
UL
>
la
Properly Seated
Insufficient Fluid in System
Damaged
CU U
u.
>>
Q
X
Positioned
Loose Wheel
1
(/>
ed
Cornering
Rough Road Travel and
ed
X
V
UJ
i/>
J o
"O
V
CJ
g
C/l
to
"ed
C V
">>
JC
Q
on
ed
OQ C It
U
Q
12
o c
X
>
> If)
POSSIBLE CAUSES OF TROUBLE
la
4>
o
aa
z o
Oa
aa
la
u
"3 5
00
c
a-*
> ed la
MS
ii
c cd
Cu JC (/
cd
> cd
ii
oo
cd
cd
la
a-
0
u
_
U
cu rt
u c
u
O
la
JX &
8 X
la
UJ
CQ
3 "O cd
"rt "O o>
CU
X
Faulty Dirty
X X
X
X X
Drum-Lining
X
Self Adjusters Not
X
X
X
X
X
X
X
Q
u-
Si o o mi
oo c aa
ii
00 c
"5 aa
ii
3
3 co i.
o 0>
OC
CN
6
3-12
GROUP 3-Suspension, Steering, Wheels And Tires
IN-VEHICLE ADJUSTMENTS AND REPAIRS HOISTING INSTRUCTIONS
2
a
hoist
post
is
to
lift
under
the
used
the adapters
place
the
contact
member,
a
inches) will
placed piece
the
the
prevent
the
pad
the
pilot
from
pin
remove
the
over
the
nut.
5. Place lower end
3,
This
seat
both
of
aging the front suspension struts.
box
a
wrench
tool
the
of
the
position
and
should
from dam
adapters
head through
rivet
spring tension. 4. Remove the cotter the ball joint stud, and
the hoist
on
contact
a
as
the bumper.
coil
cross-
adapters.
long damaging
hole with a 3/8-inch drill, and drive out both rivets. 3. Position a jack or safety stand under the lower arm, and lower the vehicle about 6 inches to offset the
(2x4x16
wood
placed
between
If
the
under
of
be
should
channel
linkage.
steering
are
the
off
lower arms or the No. 1 crossmem ber. Do not allow the adapters to adapters
prevent
2. If the ball joint is riveted to the drill a 1/8-inch pilot hole com pletely through each rivet. Then drill
vehicle.
If
or
to
arm,
Damage to steering linkage com ponents and front suspension struts may occur if care is not exercised when positioning the hoist adapters of 2 post hoists prior to lifting the
the car,
4 inches
3
firmly
tool. against
The
tool
the
end
the
against
not
and
studs,
in Fig.
shown
upper stud nut.
6. Turn studs
UPPER BALL JOINT
with
REPLACEMENT ARM
IN
the
VEHICLE
the
provide
high
vehicle
working
place
contact
or
to
pad
3. Drill
a
damaging
prevent
tire.
wheel and
hole
through
ball joint retaining rivet. large chisel, cut off the
a
rivets.
arm.
and
nuts
the
to specification.
upper
arm
suspen
the
spindle
taching
nut
bore,
torque
and
to specification.
the
at
Install
a
12. Install the wheel and tire. 13. Remove the safety stands,
7. Turn
the
are
over
tension,
under
the
14. Check and, if necessary, ad and toe-in. just camber, caster, front part of the Whenever any
upper
the
loosen
stud
spindle.
the
stud
to
then,
and
loosen
Do
not
with
the
stud
attempt
tool
suspension
installed, front be
been
has
wheel
removed
and
alignment
must
VEHICLE
1. Raise
holes,
and
at
if it
is
cracked.
9. Attach the new ball joint to the Use only the specified arm. upper
8. Position the stud of the ball joint to the spindle bore, and install the retaining nut finger-tight. 9. Attach the ball joint
lower
arm.
Use
the
only
to
the
specified
bolts,
and washers. Do not nuts, rivet the new ball joint to the arm. Torque nuts to specifications. 10. Torque the ball joint stud nut to specification, and install a new
11. Remove the jack. 12. Check and, if necessary,
just caster, camber, Whenever any part suspension
has
installed, front be
been wheel
of
ad
toe-in.
and
the
front
removed
and
alignment
must
checked.
replace
stabilizer
the
link,
end use
bushings the
on
following
procedure.
pressure
metal arm
stud
7. Clean the end of the arm, and all burrs from the hole edges. Check for cracks in the metal at the holes, and replace the arm it it is
each
the
vehicle
high
enough
tension is eased. If a chain hoist or a jack that has a narrow contact pad is to be used on the bumper to raise the vehicle, distribute the load along
the
pressure
the
loosen the alone. Re
remove
To
IN
the
in the
replace
with
the ball joint.
not
LOWER BALL JOINT REPLACEMENT ARM
to provide working space, leaving the lower arm free to drop as coil spring
cracks
Do
spindle.
STABILIZER REPAIR
8. Clean the end of the arm, and remove all burrs from the hole edges. Check for
the spindle near
checked.
to
Remove the ball joint.
then,
loosen
to
stud
move
vehicle.
both
the spindle near
both
and
cotter pin.
lower the
remover
until
wrench
hammer, tap
a
hammer, tap
tool
until
tension,
stud
and
the lower stud nut.
against
alone.
the
to
nut
tool, and position the tool as in Fig. 3. The tool should seat firmly against both studs, and not ends of the
from
Torque the
not
bumper. Torque the nut to speci fication. 11. Position the ball joint stud in
suspen
arm
upper
5. Remove the cotter pin from the upper ball joint stud. 6. Place a box wrench lower end of the ball joint
the
joints
Do
new cotter pin.
4. Remove the bumper.
studs
washers.
ball
new
10. Install
sion
with
the
rivet
and
nuts,
sion
1/8-inch
wrench
cracked.
bolts,
the
upper
Using
Disconnecting
the Ball Joints
Typical
a
bumper. 2. Remove the each
FIG. 3
under
hoist
chain
272- A
enough
and
space,
the lower arm. If a jack that has a nar row contact pad is to be used on the bumper to raise the vehicle, distribute the load along the bumper by using a steel plate 3 or 4 inches long as a support
a
a
lower
from the
Raise
1. to
the under
are
the
bumper
by
using
a
steel
plate
1. Raise the vehicle on a hoist. 2. Remove the link-to-stabilizer bar retaining nut, washers, and insu lators, and disconnect the link from the bar (Fig. 1). 3. Remove the link-to-lower arm retaining nut, washers, and insula tors, and remove the link from the arm.
3-13
PART 3-2-Suspension
4. Assemble the link and new and insulators to the lower arm, then install the link-to-lower
washers
arm
attaching 5. Connect
with
new
2. Remove nuts, washers,
nut.
link
the
secure with the
attaching
6. Lower the
to
bar
the
insulators
washers and
and
nut.
3. Pull the
from
strut
strut.
the
bump frame
lower
6. Position the
1. Remove the
lower
arm
strut
bushing
and
crossmember
rear
from
washer
the
strut.
from the the frame front
cotter pin at
the
side
rubber
nuts
ers,
and
the
lower
bolts to
arm.
the
nut
and
bumper
bolts,
attaching ihe Torque the
on
wash
strut nuts
to
and
specification.
7. Install the bushing,
4. Remove
frame
the
to
strut
arm.
the strut and install
crossmember.
FRONT SUSPENSION LOWER ARM STRUT AND/OR BUSHING
the
position
bolts
and
attaching the strut and rubber er to the lower arm (Fig. 1 ).
vehicle.
nut,
from the
bushing
and
the
remove
and
crossmember
washer,
the
on
member.
strut
the
at
Tighten the
nut
washer, and
front
cross-
install
and
the cotter pin.
5. Place the
crossmember rear side
bushing
washer and
on
the sturt and
8. Check caster, camber, in and adjust if necessary.
toe-
and
REMOVAL AND INSTALLATION
HOISTING INSTRUCTIONS
7. Remove
Damage to steering linkage com ponents and front suspension struts may occur if care is not exercised
positioning the hoist
when
2
of
hoists
post
prior
to
adapters
lifting
the
vehicle.
If
a
2
to lite the
both
the adapters under the
nuts.
hoist is
post
place
used
studs
to
strut
firmly
seated
vehicle,
bolts
2
nuts
and
the
against
and
not
the
ends
under
tension.
adapters
are
lower
stud
member,
a
inches)
the
wood
cross-
(2x4x16
be placed on the hoist between the adapters. This
should
channel will
under
of
the adapters
prevent
aging the front
from dam
suspension struts.
FRONT SUSPENSION LOWER ARM REMOVAL
1. Raise
front
the
of
the
vehicle
safety stands under both the frame just back of the
position
and sides
of
lower arms. 2. Remove the wheel cover. 3. Remove the wheel and tire from the hub. Remove 2 bolts and washers the caliper and brake attach that hose bracket to the spindle. Remove the caliper from the rotor and wire it to the underbody to prevent dam to the brake hose.
age
Then,
remove
from the spindle. 4. Disconnect the lower end of the shock absorber, and push it up to the the hub
and rotor
10. With
stabilizer the 5. Disconnect link from the lower arm.
6. Remove the
upper
nuts.
and
the
cotter
pins
the
lower ball joint
stud
with
a
the spindle near the
hammer to loosen not loosen
stud
from the
spindle
tool
with
pressure only.
11. Position lower arm and
a
floor jack
remove
under
the
the lower ball
joint stud nut. 12. Lower the floor jack and re move the spring and insulator (Fig. 4). 13. Remove one nut and bolt at taching the lower control arm to the No. 2 crossmember and remove the lower arm.
down
absorber
ing
bolts
and
nuts
and
torque
to
specification.
6. Torque
2
lower
the
crossmember
to
No.
bolt
and
arm
attaching
nut to specifications.
7. Position the
lower
attaching
the
bar link install the
stabilizer
arm
and
nuts.
8. If
equipped
4
Removing
with disc brakesInstall the hub and rotor on the spin dle. Position the caliper over the rotor and install the attaching bolts. Be sure to insert the upper bolt through the brake hose bracket. Torque the bolts to specification. Install the wheel and tire on the hub and adjust the wheel bearings as outlined in Part 3-4.
INSTALLATION 1. Position the lower arm to the No. 2 crossmember and loosely in stall the attaching bolt and nut (Fig. 4).
2. Position the spring and insula to the upper spring pad and lower arm. Using a floor jack, com press the spring and guide the lower ball joint stud into the spindle hole.
tor
3. Install
taching tion.
from
Tap
the stud in the spindle. Do
retracted position.
bar
wrench, turn the adapt the stud
a
shock
the lower arm.
5. Position the strut and bumper to the lower arm. Install the attach
to
er screw until the tool places
placed
of
the
and connect to
the stud
against
lower arms or the No. 1 crossmem ber. Do not allow the adapters to contact the steering linkage. If the piece
4. Pull
at
lower arm. 8. Loosen the lower ball joint stud nut one or two turns. Do not remove the nut from the stud at this time. 9. Install Tool T57P-3006-A be tween the upper and lower ball joint studs (Fig. 3). The tool should be the
taching
til
the
nut
the
ball joint
and
torque
Continue
to
to tighten the
the cotter pin hole is in nut
slots.
the upper and
stud
at
specifica nut
line
un
with
Install a cotter pin in lower ball joint studs.
F1275-A
FIG.
Lower Arm
Typical
3-14
GROUP 3-Suspension, Steering, Wheels And Tires
9. Install
hub
the
or
cap
wheel
cover.
10. Remove the safety stands lower the vehicle. 11. Check the caster, camber, toe-in tion
and
adjust
as
of
lower
arm.
2. Remove
and
and
2, Part 3-1).
3. Remove the wheel hub. 4. Remove the cotter upper ball joint stud nut.
nut
one
front
end
vehicle
frame
the
of
support
and
jack under the lower arm to support it. 3. Disconnect the lower end of the shock absorber from the lower 4. Remove strut
bolts
the
and
the
that
studs
with
(Fig.
3).
lower arm. 5. Disconnect the lower end of sway bar stud from the lower arm. 6. Remove the nut and bolt that secures the inner end of the lower crossmember.
Carefully
lower
ly
to
relieve
on
the
lower arm,
the
the
jack
slow
pressure
spring then
firmly
the
this
at
stud
lower
remove
screw
ends
seated
both
of
the
or
nuts
stud
upper
the
hammer
a
with
near
spindle
to
the underbody to prevent damage to the brake hose. Then, remove the to
hub and rotor from the spindle (Part 3-4). Remove 3 bolts attaching the
4. Remove the steering connecting from the spindle arm with Tool
OTC462.
or
remove
jack
under
6.
from
pressure
to
jack
the
relieve
ball
upper
ball
stud nut and remove the nut.
end
properly
2. Raise the lower carefully a jack while guiding the inner end to align with the bolt hole in the crossmember. Insert the attach
the
shaft
attaching
upper
arm
upper
bolts. inner
and
inner
arm
Remove
shaft
as
as
11. Remove
bumper from the
the
in
bolt
member
Install
the
through
and
the
INSTALLATION Position
1.
lower
the
nut
to
fication. 3. Secure the lower end of the shock absorber to the lower arm with the
Torque the
Position
2. stall
specification.
stud
the attaching
insulators
as
3-11
the
of
Shop
shown
Manual.
washers and
in Fig. 1
on
page
1966 FordMercury Torque the nut to
fications if
nut
and
specifica
upper
side
3. Connect
the
the
to
the
nut
and
cotter
is in line
Then, install 4. Install
hub
and
as outlined
with
joint the to
nut
tighten
to
pin
hole in
the nut slots.
the cotter pin. the
wheel
adjust
the
and wheel
tire
on
bearings
in Part 3-4.
5. Install
position
the
hub
or
cap
wheel
7. Check caster, camber,
front
safety
of
stands
the
under
both
in
and
near
adjust
Part 3-1).
the
as
required
under
studs
hammer, tap
a
the
the studs to loosen them attempt
to
with
spindle
pressure only.
the ball 9. Remove and lower the lower remove
under
joint
the
stud
arm enough
the spindle.
INSTALLATION
the
to
ball
the
joint
attaching
the
nut
Torque
the
cotter
nut
tighten
to
pin
in line with the slots in Then, install the cotter pin. is
the
install
and
Continue the
until
to
spindle stud
nut.
specification.
the
hole nut.
2. Raise the lower arm and guide upper ball joint stud into the spindle hole and install the attaching nut. Torque the nut to sepcification and install the cotter pin as outlined in the preceding step. under
and
the
floor
jack
from
the lower arm.
and
4. Attach rod
vehicle
the
nut with a wrench
places with
3. Remove
6. Remove the safety stands lower the front of the vehicle.
REMOVAL
I. Raise
the
ends
the
cover.
UPPER ARM
tool
1. Position
the
continue
the
until
the stud
the
Torque
nut.
retaining
specification
tool
the
against
not
and
lower
The
wash
and
install
and
remover
and
against
nuts
in
and
ball
upper
spindle
at
inner
arm rail
required.
FRONT SUSPENSION
and
the
not
studs
joint
8. Position a floor jack lower control arm.
lower
specification.
6. Check the front end alignment and adjust it to the recommended speci
the
frame
2 attaching bolts
the
ers snug.
5. Connect the sway bar to the low
the
to
firmly
studs
the
spindle
to
bumper to the lower arm with the two bolts to attaching bolts. Torque the
er arm with
to
nut
to
tions.
shaft rebound
and
arm
speci washer.
two attaching bolts. 4. Secure the strut and the
bumper install the
the
arm. upper
torque
and
ball
7. Turn the tool until
tool
cross-
the
of
rear
the
in the spindle. Do not loosen the studs in the
upper arm.
with
ing
from
the
tension, and,
arm
Do
turns.
two
nuts
from loosen
stud nuts.
the
an
sembly (Fig. 4).
the seat.
engages
seat
both
of
10. Remove the lower
Install
should
joint
the
and
nuts,
between the upper joint studs (Fig. 3).
tool
floor
the
one
nuts
pins
cotter
stud
this time.
the lower arm.
9. Raise
re
and
spindle
rod
the
attempt
INSTALLATION on
the
to
shield
move the splash shield.
8. Remove the tool from between the ball joint studs and place a floor
to loosen the stud from
the
wheel
or
3. Remove the wheel and tire from hub. Remove 2 bolts and wash ers retaining the caliper and brake hose bracket to the spindle. Remove the caliper from the rotor and wire it
spindle with tool pressure only.
not
spindle.
a
the
the
Do
in the
stud
place
and
frame. the hub cap
5. Remove both ball joint
the
1. Position the spring arm so that the lower
floor,
cover.
the tool places the stud
Tap
the front
until
vehicle
the
support under the
splash
the adapt
turn
wrench,
until
loosen the
the
spring.
a
tension.
under
the
the
top
on
be
stud cotter pin.
7. With er
screw
should
against
not
and
be
lower ball joint
adapter
The tool against
studs
attach
bumper
rebound
to the
to the
the
and
the
clears
2. Remove
T57P-3006-A
tool
upper
a
arm.
7.
the
tween
2. Place
arm
Install
6.
jack
with
stands.
the
from the
pin
ball joint stud turns. Do not re
from
nut
I. Raise wheel
time.
the
REMOVAL
tire from
and
upper
two
or
the
move
1. Raise
FRONT WHEEL SPINDLE
wheel
or
the
5. Loosen the
FRONT SPRING
the
hub cap
the
the
of
cover.
(Sec
required
frame just back
the
sides
toe-
(Section
2,
to
the
the
steering
spindle
and
connecting install the
Torque the nut to specification. Continue to tighten the nut until the cotter pin hole is in line with the nut.
3-15
PART 3-2-Suspension
in
slots
the
Then,
nut.
install
the
cotter pin.
5. Install the
splash
shield
on
the
spindle and torque the
attaching bolts to specification (Part 3-5). Install the hub and rotor on the spindle. Posi tion
the
caliper
the
over
rotor
and
install the attaching bolts. Be sure to insert the upper bolt through the brake hose bracket. Torque the bolts to
(Part
specification
the
wheel
3-5). Install hub and bearings as outlined
tire
and
adjust the wheel
the
on
in Part 3-4). 6. Install stand and
hub
the
Then,
cover.
lower the
or
cap the
remove
wheel
support
vehicle.
7. Check caster, camber, and toein (Part 3-1) and adjust as necessary.
SHOCK
SHOCK
ABSORBER
ABSORBER
REAR SPRING
MOUNTING BRACKET
MOUNTING BRACKET COIL SPRING
F1247-C
REMOVAL
FIG. 5 1. Raise the vehicle on a hoist with the hoist under the rear axle hous ing. Place jack stands under the frame side rails. 2. Disconnect the lower studs of
Removing
or
FRONT PIVOT BOLT
Installing
Rear
Spring
LOWER ARM
REAR PIVOT BOLT NUT
the two
rear shock absorbers from the mounting brackets on axle housing. 3. Lower the hoist and axle hous
ing
the
until
coil
leased (Fig. 5). 4. Remove the insulators from the
springs
springs
are
re
the
and
vehicle.
INSTALLATION 1. Position the spring in the
upper
lower seats with an insulator between each seat and the spring. Position lower end of spring pig tail and
outboard,
on
the
right
on
the
pointing rearward hand spring; frontward
left spring. 2. Raise the hoist
ing
with
connect shock
the
spring the lower studs
absorbers
brackets
and
in
the
on
to
the axle
and
the
rear
the
mounting housing. Install torque
and
nuts,
mounting
FIG. 6
to
specifications.
shock absorbers
jack
stands
and
the
right
from the
4. Lower the axle lieve spring pressure.
left
and
enough
the
the
to
re
LOWER ARM
new
not
lower
arm
and
The the
and
frame
side rails.
2. Remove washer
from
the the
attaching axle
nut
track
mounting stud and disconnect bar from the stud (Fig. 2).
rear suspension
arms are
interchangeable. The lower arm for the left side can be identified by notches in the bushing flange (Fig.
axle
rear shock absorbers
4.
Install
to
arm a
the
bolt
new
not
6).
time.
tighten
axle
and
Then, pivot bolts (Part 3-5).
and
the
(Tool
spacers
C) between the frame (Fie. 3, Part
torque and
connect
or
the
nuts
to
lower
arm
specification
not
5. Connect
the
mounting stud, and attaching
2). The
bar
notches.
specification (Part
1. Position the lower arm in the bracket on the frame side rail. Install
and
right
arm
does
not
have the
6.
track install
and
the
this
at
to the axle.
alignment
-T65P-3000-B-
3-1).
lower
(Fig.
nut
nut
the lower bracket and install nut (Fig. 6). Do
3. Raise the
REMOVAL
hoist
and
the
the nut at this time.
rear
a
bolt
tighten
from
bracket.
INSTALLATION
1. Raise the vehicle on stands under place jack
pivot
2. Position axle
6. Remove the pivot bolt and nut from the frame bracket and remove the lower arm from the vehicle.
REAR SUSPENSION
a
Do
axle.
5. Remove the lower arm pivot bolt and nut from the axle bracket.
Then, disengage
3. Remove the lower the vehicle.
B
Rear Suspension Lower Arm Installed
3. Disconnect
hous
axle
position of
249-
nut.
and
bar the
to
the
washer
torque
to
3-5).
Remove the alignment jack stands and lower the
spacers
vehicle.
GROUP 3-Suspension, Steering, Wheels And Tires
3-16
REAR SUSPENSION UPPER ARM
SHOCK ABSORBERS
Passenger
REMOVAL
wagons
shock
1. Raise the vehicle and support the frame side rails with jack stands. 2. Support the
bar from the
absorbers
and
are
with
hydraulic
direct-acting
the
of
station
and
equipped
nonadjustable
non-
and
refillable, and cannot be repaired.
dis
then
rear axle,
the track
connect
type
vehicles
are
SHOCK ABSORBER TESTS
axle
housing. 3. Lower
the
far
axle
enough
it. 4. Remove
bolt
nut,
the
attach
housing. from the housing.
the
arm
the
that
washers
to
On Vehicle Tests
to
the shock absorbers to support
allow
two
and
upper
arm
Disconnect the
axle
1. Check the shock absorber to be it is securely and properly instal led. Check the shock absorber insula
sure
for damage and wear. Replace any defective insulators
tors
tighten
5. Remove the
secures
the
nut
upper
bolt that
and
to
arm
the
1. Hold the
the
upper
crossmember
arm and
new
washer.
in place install the
lock-
attaching bolt, ntit and Do not tighten the nut at this
2. Inspect the shock absorber for ev idence of fluid leakage. A light film of fluid is permissible. Be sure any fluid observed is not from sources other than the shock absorber. absorber if shock the Replace leakage is severe. 3. Disconnect one end of the shock absorber. Extend and compress the shock absorber as fast as possible,
using tion
3. Adjust the pinion angle as de tailed in Part 3-1. 4* Remove jack stands and lower
form throughout
the vehicle.
become
should
on
resistance
is
pression
smooth
normal
and
stroke.
each
extension
a
F 1277- A
FIG. 7
Removing
Upper Arm
Bushings
travel as possible. Ac
much
as
time.
uni
Higher
T65P Tool A3 3044
Tool
-
-
3044
T65P
A2
than on com
condition.
Faint
swish noises are also normal.
Remove the shock absorber for a bench test if action is erratic. If the action is smooth, but the shock absor
BAR
TRACK
replace
the shock absorber).
attaching new bolt and a new nut. Do not tighten the nut at this time. 2. Secure the upper arm to the axle housing with the flat washers and
and
specified
integral insulators,
corporates
INSTALLATION
on
the
torque (on a shock absorber which in
cross-
member and remove the arm.
to
attachments
bers
are
suspected
of
being
weak
fol
low step 4.
Raise the hoist.
1.
vehicle
on
axle
an
2. Remove
the track
bracket
at
axle
and
nut
bar to the
washer
re
upper arm
disengage the track bar
and
from the mounting 4. Remove the
stud nut
(Fig. 5). bolt and
at
frame bar. 5. Position the track bar to the frame side rail and install a new at bar to
track
the
taching
the
side rail and remove the track
taching bolt arm
the
track
bracket
bar
the
on
install the washer and a new taching nut. Torque the track bar
rubber
and
the
nut.
cover
large flat
vehicle.
track
over
Secure the
absorbers.
Replace the shock absorber having lower resistance. Ensure that the
the
part number of
the replacement is the
same as that of the original shock ab sorber.
ber
The
replacement
stud
rubber cover onto
washer.
to be higher due to initial fric
Then, lower
J276
the
A
Bench Test
FIG. 8
at
Position
bar
shock absor
resistance will appear
tion of the rod seal.
at
taching bolt and nuts to specification (Part 3-5). Apply lubrication (syn thetic rubber lubricant) to the inside of the rubber cover.
results of
is similar, it is unlikely that either shock absorber is Reconnect both defective. shock action
stud
mounting
and
diameter
and compare
than either original
and nut.
Position
6. upper
of the vehicle,
both tests. If the
bar.
track
3. Remove the
taining
cover
rubber
attachment of
4. Repeat step 3 on the mating shock installed on the opposite side
absorber
contact
and
With the
shock
absorber
up (as installed in vehicle), fully. Then turn the shock
right
times
to
ensure
has been
that
expelled.
any Now
it
absorber
entrapped place
Upper Arm Shaft
side
extend
up side down and fully compress it. Repeat this procedure at least three air
Installing
Bushings
the
right side up in a hand stroke the shock absor ber as described on On Vehicle Tests, step 3. If action is not now smooth
shock
absorber
vise, and
and
uniform,
absorber.
install
a
new
shock
3-17
PART 3-2-Suspension FRONT SHOCK ABSORBER
the shock
REPLACEMENT
stall
top
absorber
the
stud
attaching
and
Torque
nut.
in to
4. Expel step 3
by
air
all
performing
On Vehicle Tests
under
.
specifications.
1. Remove the nut, washer, and from the shock absorber
bushing
upper end.
2. Raise the vehicle install safety stands. 3. Remove 2 bolts shock absorber to the
on
hoist
a
and
the
attaching lower arm
and
remove the shock absorber.
the the
a
shock
position
front
1. Raise the 2. Remove from
washer
and
absorber
the
top
shock
spring.
attaching bolts
bushing stud
absorber
press
inside
Install the 2 lower
and
torque
them
to
specifications.
5. Remove the lower the vehicle. 6. Place
a
safety
bushing
and
stands
and
the
shock
washer
stud
upper
and at
insulator the
upper
the spring upper seat. Com the shock absorber to clear the
hole in the spring seat, the inner insulator and the
absorber
upper
remove
from
stud.
mounting
3. Remove
and
washer
the
self-locking
re
disconnect the shock lower stud from the mount ing bracket on the rear axle housing (Fig. 2).
taining
nut, and
absorber
washer
on
on
the
and
position
that
the
the
in
and
washer
mounting stud,
upper
upper
absorber
shock
so
enters
stud
mounting
hole in the spring upper seat. While holding the shock absorber in this position, install the outer insula the
tor
upper
stud
the
and
washer
and
of
on
and
the
sulator
hoist.
vehicle on a
nut,
mounting side
4. Place
5. Place the inner
REAR SHOCK ABSORBER REPLACEMENT
from
the
the
on
nut
side
upper
the spring upper seat. Torque the to specifications.
of nut
6. Extend the shock absorber and locate the lower stud in the hole in mounting bracket on the rear axle housing. Install a new self-locking attaching fications.
nut
the
shaft
from
the
bushing
torque
and
to
speci
MAJOR REPAIR OPERATIONS FRONT SUSPENSION UPPER BUSHINGS ARM REMOVED
ARM
3. Position arbor
(Fig.
ing 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 Tool place T65P-3044-A3 inside the upper arm around the inner shaft (Fig. 7).
press
7),
out of
the on
and
the
arm in an T65P-3044-A4 the lower bush
upper
Tool
press
upper arm.
4. Remove the bushing from the inner shaft; turn the assembly over and remove the bushing from the other side of the arm. It may be nec essary to remove Tool T65P-3044Al from the inner shaft and remove
install the tool move
the
the
from
other
on
the
bushings
upper
remove
shaft
Then, and
re
bushings install the
and
and
shaft
in the
upper
in Fig. 8.
arm as shown
6. Install
the
shaft
arm
inner
and
to
shaft.
bushing.
5. Position the to
arm
the
a
on each end of
washer
and
the inner shaft.
new
nut
3-18
3-3-
PART Section 1 Description
Steering
S tee ring Gear
Power
Power
3.
3-20
Vehicles Without Air Conditioner Vehicles With Air Conditioners
3-20
Power
3-20 3-21
Power
Repairs Valve Spool Centering Check Steering Gear Adjustments Pump Belt Tension Adjustment Power Steering Pump Drive Belt Replacement 3 Removal and Installation
Steering
3-22
3-18
Steering Pump
2 In-Vehicle Adjustments
Page
Section
Page
Operation
and
and
1g
Steering Pump
3-22 3-22
3-22
Steering Pump Pulley Steering Pump Reservoir
3-23 3-23
4 Major Repair Operations
3-23
Gear
3-21 3-21
Steering Centering Shim Replacement Steering Gear Disassembly
3-21
Parts Repair
3-21
Steering
3-23
Valve
Gear
3-26
Replacement
or
Gear
3-25 3-27
Assembly
DESCRIPTION AND OPERATION
STEERING GEAR
OUTLET PORT INPUT SHAFT INLET PORT
DESCRIPTION The is
(Fig. 1) hydraulic as This system furnishes
power
unit
steering
torsion-bar type of
a
sisted
system.
power
to
ing
effort
It
wheel.
required
the
at
steering
road shock and
reduces
also
SECTOR SHAFT COVER
the amount of turn
reduce
vibrations.
The torsion bar power steering includes a worm and one-piece piston, which is meshed to the unit
gear
includes a hydraulic valve, input shaft and tor
also
actuator,
bar assembly
sion
CONTROL VALVE HOUSING
the steering sector shaft. The
teeth on
valve
unit
rack
mounted
are
which
the end of the worm shaft and op erated by the twisting action of the on
bar.
torsion
The
type
torsion-bar
is designed
gear
steering
rack-piston,
in
one
housing
spool
in
an
attaching
makes
inder, lines and
thus
valve
(Fig. internal fluid and
valve all
external
the
pressure
the
part
of
the
is double sure
gear
acting,
may be
integral
an
housing. The piston in that fluid pres
applied
to
either
side of
the piston.
A
metal
selective
housing
the
valve
the
purpose
efforts. cations
If
of
located in
shim,
of
the
gear
is for
tailoring steering
gear
efforts are not within specifi
they
creasing or follows:
be
can
changed
decreasing
shim
by in
thickness
as
Efforts
heavy
to the
left
-Increase
light
shim thickness.
A
change
to
the
left
Decrease
Steering
of one
shim
Shims
ing
are
available
Gear
will
in
efforts
ap
size
decrease steering proximately 1 1/2 in-lbs. or
crease
outside
tvnsting
diameter for identification.
1 2
notch
inch
0.0117-0.0123
inch
3
notches
valve
0.0137-0.0143
inch-
4
notches
of
operation
trol
valve
of
spool
the
is
notches
governed
side
con
sist
by
Any
assembly
resistance to
the
spool
actuated
by
the
twisting
bar, directs fluid to piston where hydraulic
the torsion
shim.
hydraulic
piston.
turning of the front wheels, results in twisting of the bar. The twisting of the bar increases as the front wheel turning effort increases. The control
inch
The
effort
the
0.0097-0.0103
one
All
wheel
integral
0.0077-0.0083
than
bar.
is trans through the input shaft
steering
and
notch
more
directly
torsion
torsion bar to the worm
inch 0
use
a
and
0.0057-0.0063
not
of
applied to the mitted
in the follow
thicknesses and are notched on the
Do
shim thickness.
Efforts
Power
FIG. 1 is
cylinder
power
G1276-A
pump
and gear assembly.
The
MOUNTING PADS
cyl SECTOR SHAFT
except
hoses between
return
the
housing
eliminating
hoses,
and
the
sector
and
and
possible
between
passages
power
the one
worm
piece shaft
1). This
of with
of
is
the
the as
required.
The
upper
end
of
the
torsion
bar
9KJ09MNtf
ns
SERVICE PUBLICATIONS
FORM 7750-67
LITHO IN U.S.A.
